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Summary of Contents for Kimray GEN 3
- Page 1 PNEUMATIC LEVEL CONTROLLER GEN 3...
- Page 2 And while efforts have been made to ensure their accuracy, they are not to be construed as warranties for guarantees, express or implied, regarding Kimray products or services described herein or their use or ap- plication. All sales are governed by our terms and conditions, which are available on request.
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Page 3: Table Of Contents
Paraffin clean out port ..........9 Repair kit replacements ........9 Other replacements ..........9 Pilot Assembly ............10 Mount Assembly ...........12 Spring Assembly ..........14 Filter ...............14 TROUBLESHOOTING Troubleshooting ...........16 If you have any questions about this manual, contact your Kimray applications support group before proceeding. www.kimray.com... -
Page 4: Introduction
A1 Scope This document contains information for the Gen 3 Liquid A4 Tools Needed for Installation, Level Controller & includes detailed installation, operation & repair/maintenance information for the product. Conversions & Repair This Kimray controller DOES NOT require special tools A2 Description for disassembly, inspection & assembly. The Gen 3 Liquid Level Controller is designed for use in single-phase & interface liquid control applications. The These are the standard tools required: pilot is capable of both Snap mode (on/off) & Throttle 1. Pipe Wrench or other Wrench to fit 2-1/2" Flats. mode (modulating). Pneumatic output can be set to 2. -
Page 5: Configuration
PNEUMATIC LEVEL CONTROLLER MODEL: GEN 3 Installation, Operation & Maintenance Guide Configuration Mount Orientation Left Hand / Right Hand Conversion The Gen 3 can be ordered in either Left Hand or Right Hand mount, but if you need to change the orientation 1. Remove Spring Adjustment Assembly (F) and 1/2" before installing, see “Left Hand and Right Hand NPT plug (E). Conversion” 2. Remove Pilot Lever Assembly (A). 3. Loosen Set Screw (D) at bottom of Torque Lever (B) and slide Torque Lever (B) off shaft. 4. Remove Cap Screws (C) and rotate the Mount (G) 180 degrees. Left Hand Right Hand 5. Reinstall Cap Screws (C) with thread locker, replace Torque Lever (B), and tighten Set Screw (D). -
Page 6: Installation
PNEUMATIC LEVEL CONTROLLER MODEL: GEN 3 Installation, Operation & Maintenance Guide Installation Install Onto Vessel NOTE: Always check fastener tightness prior to installation, WARNING: testing, and use, as fasteners have the potential to Before beginning installation, Block & Bleed valve. loosen in transit. This is recommended to ensure your Make sure all pressure is released from vessel, and safety and proper function of the unit. confirm no pressure remains in supply gas/instrument *Kimray assembly torque method below* air lines. Do not install in a location where Max Allowable Working Pressure could be exceeded. Read and follow... -
Page 7: Connections
PNEUMATIC LEVEL CONTROLLER MODEL: GEN 3 Installation, Operation & Maintenance Guide Installation Connections WARNING: Do not install or tighten any fittings, gauges, or any other connections while there is pressure on the line. Remove plastic plugs from 1/4” NPT openings. Use 1/4” or 3/8” tubing (not provided). Vent: Connect a Vent Line or Breather Plug to one of the Throttle Mode: Connect supply gas filter and pressure three Vent ports, and install plugs in remaining two ports. gauge to any of the three ports labeled “T” and plug the remaining “T” port. Connect supply line to filter. Use “S” Output: Connect pressure gauge to either port labeled ports for Vent. “OUT”, where it is easiest for operator to see. Connect output line to remaining “OUT” port. Snap Mode: Connect supply gas filter and pressure gauge to any of the three ports labeled “S” and plug the CAUTION: Ensure supply gas is clean and dry. remaining “S” port. Connect supply line to filter. Use “T” ports for Vent. Vent for Supply for... -
Page 8: Operation
PNEUMATIC LEVEL CONTROLLER MODEL: GEN 3 Installation, Operation & Maintenance Guide Operation Start-up Snap Mode: Direct Acting - Fail Closed (aka PO) valve: With the output at 0 psi, turn the set point adjustment knob counterclockwise to “snap on”, producing the full output WARNING: pressure. Then turn the knob clockwise until the output Verify all pressure connections are tight before pressure returns to 0 psi. pressurizing the system. Indirect Acting - Fail Open (aka PC) valve: At full output pressure, turn the set point adjustment knob counterclockwise to “snap off” the output pressure to WARNING: 0 psi. Then turn the knob clockwise until full output Never stand directly in front of or over a controller when pressure is reached. -
Page 9: Maintenance
PNEUMATIC LEVEL CONTROLLER MODEL: GEN 3 Installation, Operation & Maintenance Guide Maintenance Paraffin Cleanout Port WARNING: The Gen 3 is equipped with an access port to give the A leaking controller is an indication that service is ability to inspect and clean out the area inside the Mount, required. Failure to take controller out of service without having to remove the unit from the vessel. immediately may cause a hazardous condition. This can help if there are paraffins or other solids that build up over time inside the Mount, restricting movement of the Displacer Rod. WARNING: Before beginning repair, Block & Bleed valve. Make sure all pressure is released from vessel, and confirm no WARNING: Make sure all pressure is released pressure remains in supply gas/instrument air lines. -
Page 10: Pilot Assembly
PNEUMATIC LEVEL CONTROLLER MODEL: GEN 3 Installation, Operation & Maintenance Guide Maintenance - Pilot Assembly Pilot - Disassembly Pilot - Reassembly Step 1 – Remove 3 socket screws (1/8" hex key) holding Step 1 – Clean pilot cartridge and install pilot plug, small pilot to enclosure. Remove pilot by prying under flats and diameter first, into the side of the cartridge with the upper then pulling pilot out. seat. Step 2 – Remove and discard 4 O-rings around outside Step 2 – Place conical spring on upper diaphragm of pilot cartridge. assembly. Apply grease to assembly where spring rests. Step 3 – Place flats on lower pilot cartridge into vise or Step 3 – Place booster spring in top cap. Apply grease in hold in place with wrench. top cap where spring sets. Step 4– Unthread and carefully remove flanged top pilot Step 4 – Place diaphragm assembly in pilot block such... - Page 11 PNEUMATIC LEVEL CONTROLLER MODEL: GEN 3 Installation, Operation & Maintenance Guide Maintenance - Pilot Assembly Pilot Screw Top Cartridge Cap O-Ring Pilot Booster Spring Upper Diaphragm Assy. Booster Pilot Spring Pilot Plug Cartridge Body O-Ring O-Ring O-Ring Lower Spring Upper Seat Lower Diaphragm Assy.
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Page 12: Mount Assembly
PNEUMATIC LEVEL CONTROLLER MODEL: GEN 3 Installation, Operation & Maintenance Guide Maintenance - Mount Assembly Mount - Disassembly Mount - Reassembly Step 1 – Mount controller in vise or stand if available Step 1 – Install O-ring over threaded hubs & socket plug. To avoid seal damage, do not push O-ring over threads. Step 2 – Remove displacer arm and extensions from Roll O-ring over threads. Install socket plug. Tighten to mount. 30-35 ft·lbs. Step 3 – Open and remove cover. Inspect cover gasket Step 2 – Insert components into both hubs in the for rips or tears. following order: back-up ring, O-ring, flanged bearing. Step 4 – Relieve force on spring by rotating spring Step 3 – Install a bearing hub on one side of mount. adjuster knob clockwise. Remove spring and upper Insert shaft with flats facing side of mount that attaches spring plate. - Page 13 PNEUMATIC LEVEL CONTROLLER MODEL: GEN 3 Installation, Operation & Maintenance Guide Maintenance - Mount Assembly Bearing Hub O-Ring Back Up O-Ring Flanged Bearing O-Ring Socket Plug Torque Lever Mount Gasket Torque Shaft Displacer Arm Flanged Bearing O-Ring Back Up O-Ring...
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Page 14: Spring Assembly
PNEUMATIC LEVEL CONTROLLER MODEL: GEN 3 Installation, Operation & Maintenance Guide Maintenance - Spring Assembly Spring Assembly - Disassembly Spring Assembly - Reassembly Step 1 – Rotate spring adjusting knob clockwise to Step 1 – Install spring adjusting knob into ½” NPT relieve force on spring. bushing. Step 2 – Remove spring and upper spring plate. Step 2 – Install bushing and spring assembly into enclosure. Step 3 – Remove ½” NPT spring bushing. Unthread spring assembly from lower spring plate and remove Step 3 – Thread lower spring plate onto adjusting knob. from enclosure. Install spring and upper spring plate. Step 4 – Remove spring adjusting knob from bushing. Step 4 – Rotate spring adjusting knob to set controller Remove and replace PTFE washer and O-ring on spring level per Calibration instructions on pg. 8. -
Page 15: Filter
PNEUMATIC LEVEL CONTROLLER MODEL: GEN 3 Installation, Operation & Maintenance Guide Maintenance - Filter Filter - Disassembly Step 1 – Shutoff supply pressure to controller and bleed supply line Step 2 – Remove the supply line from the filter and remove the filter from the controller Step 3 – Clean out filter element. Using compressed air in the downstream (male) connection will help to ensure debris is dislodged. Step 4 – Reinstall filter. Direction of air flow to clean filter element www.kimray.com... -
Page 16: Troubleshooting
PNEUMATIC LEVEL CONTROLLER MODEL: GEN 3 Installation, Operation & Maintenance Guide TROUBLESHOOTING Troubleshooting Problem Possible Cause and Solutions 1. Insufficient supply gas pressure. Ensure that supply gas is flowing to controller and is between 15-45psi. 2. Blockage in controller passages. Inspect ports, filter, and vent plugs for any debris, clean if needed. Ensure that at least one vent port allows flow. Ensure supply gas is clean and dry. 3. Undersized displacer. If specific gravity differential is below 0.2, buoyant force from displacer may not be sufficient to activate pilot. A larger Kimray displacer may be necessary. When using a larger displacer (3x12 or 2x20) Not sending signal or venting when it should if specific gravity differential is below 0.1, differential must be increased to 0.1 or greater for controller to operate properly. 4. Damaged seals. Isolate and bleed pressure from pilot. Inspect pilot O-rings and diaphragms. Replace if necessary. 5. Displacer rod not able to move full range. Solids or other obstruction inside of vessel, restricting movement of displacer. Bleed all pressure from vessel and check/clean... - Page 17 PNEUMATIC LEVEL CONTROLLER MODEL: GEN 3 Installation, Operation & Maintenance Guide Page left blank www.kimray.com...
- Page 18 PNEUMATIC LEVEL CONTROLLER MODEL: GEN 3 Installation, Operation & Maintenance Guide Page left blank www.kimray.com...
- Page 19 Kimray is an ISO 9001- certified manufacturer. Kimray quality assurance process maintains strict controls of materials and the certification of parts used in the Kimray severe service control valve. Please visit our website for up to date product data www.Kimray.com For questions or comments, contact your local Kimray authorized distributor, or visit www.kimray.com.
- Page 20 Kimray.com © 2018 Kimray, Inc. RM:0021 Issued 3/21...
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