PNEUMATIC LEVEL CONTROLLER
PNEUMATIC LEVEL CONTROLLER
MODEL: GEN 3
Installation, Operation & Maintenance Guide
MODEL: GEN 3
Installation, Operation & Maintenance Guide
www.kimray.com
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TROUBLESHOOTING
Troubleshooting
Problem
Possible Cause and Solutions
Not sending signal or venting when it should
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)
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
out obstruction inside vessel.
Controller does not respond quickly enough
1. Improper calibration. Adjust sensitivity fulcrum per
Calibration section in this guide.
2. Improperly sized tubing. Ensure tubing diameter is at
least 1/4”. 3/8” diameter is preferable. Minimize length of
tubing between controller and valve.
3. Valve is inappropriately sized. Double check sizing of
valve to ensure adequate flow rate for process conditions.
Pilot bleeds continuously
1. Pilot plug and/or seat dirty. Clean pilot plug and seat,
and ensure filter is clean. Instrument gas may need up-
stream filtration or moisture removal.
2. Damaged seals. Isolate and bleed pressure from pilot.
Inspect pilot O-rings and diaphragms. Replace if neces-
sary.
Mount leaking around shaft or plugs
1. Damaged seals. Bleed pressure from vessel and
replace O-rings and backup rings on mount fittings.