Kimray GEN II Betriebsanleitung
GEN II
Repair Manual
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GEN II REPAIR MANUAL
INDEX
Introduction .................................................................................................... 1
Elastomer Materials ....................................................................................... 2
Terminal Arm Disassembly ........................................................................... 3
Terminal Arm Assembly ................................................................................ 7
Pilot Disassembly .......................................................................................... 9
Pilot Assembly ............................................................................................. 13
Pilot Installation ........................................................................................... 15
Settings ....................................................................................................... 17
NOTE: We reserve the right to modify or change, without prior
notice, any statement or information contained herein. If exact
dimensions or specifications are required by the customer
certified prints will be furnished for a minimum charge upon
request to KIMRAY, Inc.
® Copyright 2006, KIMRAY, Inc.
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GEN II REPAIR MANUAL
INTRODUCTION
SCOPE
This repair manual contains information for the GEN-II Liquid Level Controller. Included is detailed instruc-
tions in regard to its unique pilot.
DESCRIPTION
The GEN-II Liquid Level Controller uses a spring loaded float to operate a 3 way valve or pilot. This revolu-
tionary pilot can be set for snap mode or throttle mode with the simple turn of a knob. Controlling vessel liq-
uid level has been simplified with 1 control knob to adjust spring tension on float. The pilot assembly is easily
removed by taking out 2 screws. This gives you the choice of repairing the pilot or simply putting a new one
in and repairing the old one at your convenience. Replacement of the pilot assembly can be done in minutes
without taking the controller off line.
The GEN-II is NACE compliant out of the box and comes with a tapped vent hole to pipe bleed gas away.
Side and back npt connections are provided for ease of gas supply and output installation.
OPERATION
The GEN-II uses displacement of a float to control a vessel’s liquid level or it can be used as an interface
controller to maintain multiple liquids in a vessel. Simply mount controller to vessel, set pilot to snap or throt-
tle, and then set level with adjustment knob.
MAINTENANCE
Maintenance should be performed on a regular basis. An initial interval of 12 months is recommended.
Depending on the service conditions and the condition of the controller, the inspection interval may be
decreased or increased. The pilot can be repaired without removing the controller from the vessel, but the
controller will need to be removed for any float related repair.
WARNING
Before performing any service, make sure level controller is isolated from all gas sources. Be sure that all
operating or instrument gas lines have been disconnected.
Never tighten any fittings or the main connections to the level controller while there is pressure in the lines.
NOTE
Because of the how convenient the pilot assembly is to remove and replace, we suggest replacing the pilot
and rebuild old one on bench if a field repair is necessary.
• Use repair kit RMD
To get the long service you have come to expect from Kimray products, always use GENUINE KIMRAY
PARTS when doing repairs. Remember, parts made to less than Kimray specifications don’t save you
money!!!
ENG-002.6 Rev. 6 Issued 8-22-2017
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Page 2
GEN II REPAIR MANUAL
ELASTOMER MATERIALS
TEMPERATURE:
-10° to +350° F
-23° to +177° C
APPLICATION:
Crude Oil & Gas Production, Glycol Dehydrators,
Gasoline, Jet Fuel & Diesel Fuel Pumping, Water Disposal,
Methanol Injection Pumps. (Also Vacuum Service) (Gas
permeability is very low)
FLUID / GAS:
Crude Oil & Gas, Sour Gas (C02), Propane, Gasoline,
Diesel, Fuel Oil Systems
DO NOT USE WITH:
Hot Water, Not preferred for wet H2S, Methyl Alcohol,
Amines, Sodium hydroxide solutions
TEMPERATURE:
-65° to +300° F
-54° to +148° C
APPLICATION:
Steam Flood
FLUID / GAS:
Steam, Water, Alcohol
DO NOT USE WITH:
Crude Oil & Gas, Diester Lubricants (Lube Oils)
TEMPERATURE:
-40° to +220° F
-40° to +104° C
APPLICATION:
High abrasion resistance Seats, Diaphragms
FLUID / GAS:
Crude Oil gas and Water, Sour Gas (C02), propane,
butane, fuel, mineral oil and grease
TEMPERATURE:
±0° to +300° F
-17° to +149° C
APPLICATION:
Production Heaters, Thermostats
FLUID / GAS:
Crude Oil & Gas at High Temperature
DO NOT USE WITH:
Alcohol, Glycols
TEMPERATURE:
-25° to +500° F
-30° to +260° C
APPLICATION:
Crude Oil & Gas Production (High heat), Steam
Flood Production Chemicals (corrosion inhibitors) Amine
Sweetener Systems, Gasoline, Diesel, Fuel Oil Systems
FLUID / GAS:
Crude Oil & Gas Production, H2S, Steam, Petroleum
fluids, Sea Water
TEMPERATURE:
-15° to +300° F
-26° to +149° C
APPLICATION:
Crude Oil & Gas Production w/ H2S C02
FLUID / GAS:
Crude Oil & Gas H2S, C02, Sea Water
TEMPERATURE:
Buna-N:
-40° to +220° F
-40° to +105° C
Low-Temp:
-85° to +120° F
-65° to +49° C
APPLICATION:
Crude Oil & Gas Production Glycol Dehydrators,
Gasoline, Jet Fuel & Diesel Fuel Pumping, Water Disposal,
Methanol Injection Pumps, Water pump seals, hydraulic
pump seals
FLUID / GAS:
Crude Oil & Gas, Good to Poor in Sour Production (See
HSN), Water, Glycols, Hydraulic Oils, Resistance to crude
oil in the presence of hydrogen sulfide and amines, Diesel
fuel, fuel oils
DO NOT USE WITH:
Aromatic hydrocarbons, chlorinated hydrocarbons,
phosphate esters (hydraulic fluids)
TEMPERATURE:
-350° to +500° F
APPLICATION:
High heat, high chemical resistance, highly resistance
to gas permeation
AFLAS ® is a trade mark of Asahi Glass Co VITON ®is a trade mark of Dupont
ETHYLENE PROPYLENE
POLYURETHANE
GYLON
POLYACRYLATE
HSN (Highly Saturated Nitrile)
NITRILE
Screw 2213
Pivot Plate 5442
Mounting Piece 5528
Case 5444
Cover 5445
Gasket 5446
Lens 5447, 2 Req’d.
Terminal Arm 5452
Ext. Rod Assy. 5453V Coupling 5454
Ext. Housing 5455
Wire 5458
Retainer 5459
Pivot Rod 5460
Float 5461
5462 Gauge, 2 Req’d.
Latch 5463
Adj. Lever 5465
Tangent Arm 5466
Spring Assy 5467A
Screw 5468, 2 Req’d.
O Ring 855V (Not Shown)
Screw 5484, 4 Req’d.
Screw 5485
Filter 5486
Link Body 5489
Link Cap 5490
Yoke 5491
Screw 5494
Link Screw 5495
Spring 5496
O Ring 5500V *
Screw 5501
Filter Cap 5502
Arm Post 5504
Pivot Post 5505
Lens Gasket 5506, 2 Req’d.
Lens Retaining Ring 5509, 2 Req’d.
Snap Ring 941
Snap Ring 941
AVariable Link Knob Assy. 5493
Plug 699SS6, 3 Req’d.
Apply 15 ft./lbs.
Using manual torque wrench
when installing 699SS6 plugs
Nut 5531
Decal Left Hand 5521LH
Decal Right Hand 5521RH
Name Plate 5498
NOT SHOWN
Screw 4918, 2 Req’d.
Adjusting Screw 5481
STEP 1
Mount Controller in vise or stand if avail-
able (Fig 1.1).
STEP 2
Open case and inspect Gasket between
cases for rips or tears (Fig 1.2).
If the Gen II is not able to be put on a
stand now is a good time to separate case
by removing Hinge Screw (Fig 1.3).
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GEN II REPAIR MANUAL
Terminal Arm DISASSEMBLY
Figure 1.1
Figure 1.2 Figure 1.3
Bolt
STEP 3
Pull out on Variable Link Knob and slide
off of Tangent Arm (Fig 1.4).
Using a flat blade screwdriver pry off
lower end of Variable Link Knobs yoke.
Do not turn the Link Arm for it is set at
factory (Fig 1.5).
STEP 4
Remove retainer Snap Rings from Pivot
Post (Fig 1.6).
STEP 5
Remove Adjustment Lever and Leaf
Spring assembly by pulling out on spring
then slide Adjustment Lever off (Fig 1.7)
and (Fig 1.8).
1. Slide out
2. Slide back
STEP 6
Remove Pivot Plate Screws and pull Pivot
Rod out (Fig 1.9) and (Fig 1.10).
Remove Screws
STEP 7
Remove Coupling on end of Terminal Arm
(Fig 1.11).
This step is optional if you cannot get a
wrench around housing. Remove Arm
Post only to make clearance for wrenches
(Fig 1.12).
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GEN II REPAIR MANUAL
Terminal Arm DISASSEMBLY
Figure 1.4 Figure 1.5
Figure 1.6
Figure 1.7 Figure 1.8
Figure 1.9 Figure 1.10
Figure 1.12Figure 1.11
Knob Pry here
STEP 8
Remove terminal Retainer Nut, make sure
to use a wrench around housing.
(Fig 1.13).
Pull Terminal Arm out from mounting
housing
(Fig 1.14).
STEP 9
Remove Retaining Nut from Arm and dis-
card O ring and seal (Fig 1.15).
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GEN II REPAIR MANUAL
Terminal Arm DISASSEMBLY
Figure 1.14Figure 1.13
Figure 1.15
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Page 6
GEN II REPAIR MANUAL
NOTES
STEP 1
Install retaining nut, seal and O ring on
terminal arm. Do not push O ring over
threads or it may be cut by threads. Roll
O ring over threads (Fig 1.1).
Roll over threads
Very important
STEP 2
Apply Blue Loctite to housing threads
(Fig 1.2). Insert terminal arm and tighten
(Fig 1.3).
Loctite
STEP 3
Apply Blue Loctite to arm post and tighten
(Fig 1.4).
Loctite
STEP 4
Install adjustment assembly and spring
assembly. Put adjustment arm on first
then rotate back to align spring assembly
on post (Fig 1.5).
Install snap rings make sure they snap
into grooves on post (Fig 1.6).
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GEN II REPAIR MANUAL
Terminal Arm ASSEMBLY
Figure 1.1
Figure 1.2 Figure 1.3
Figure 1.4 Figure 1.5
Figure 1.6
Figure 1.7 Figure 1.8
STEP 5
Install Spring Clip. Insert back first then
use needle nose pliers to finish (Fig 1.9).
STEP 6
Insert Pivot Rod (Fig 1.10).
Make sure Pivot Rod moves freely & does
not bind Terminal Arm Assy.
Install Pivot Plate, be sure to use Loctite
on screws (Fig 1.11).
GEN II REPAIR MANUAL
Terminal Arm ASSEMBLY
Page 8 www.kimray.com
Figure 1.9
Figure 1.10 Figure 1.11
Loctite
Pivot Plate
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