In this guide we’ll walk you through everything there is to know about float operated controllers.
From the basics of how it works to step-by-step repairs and troubleshooting, you’ll gain a solid foundation of knowledge on how to operate and maintain Kimray’s float operated controllers.
Use the table of contents to skip to different sections of the learning path.
The Kimray Gen 3 Liquid Level Controller is a simple, versatile solution that allows for quick adjustments, intuitive set up, and precise liquid level control.
In this video, Mike shows how to perform proper maintenance on a Gen 3 Liquid Level Controller.
The Gen 3 includes a 1/8" hex key for the pilot and lever fasteners, and it can be conveniently stored inside the enclosure as shown here.
In addition to this tool, you will also need the following:
Repair kits contain all seals and wear components recommended to be replaced during scheduled maintenance intervals for the entire unit.
We recommend an initial maintenance interval of 6 months. This interval can be increased or decreased based on the condition at the time of the first 6-month service.
Most of the following maintenance steps can be performed with the unit still connected to the vessel. But, as with any maintenance being performed, make sure all pressure has been released from the vessel, and confirm that no supply gas pressure remains in the lines or the pilot prior to beginning any maintenance.
A clean and well-maintained pilot is key to the performance of the Gen 3. Wet or dirty supply gas can introduce blockages in pilot communication holes or cause the pilot plug to stick. This can lead to the pilot not sending a signal or venting when it should, or continuously sending a signal.
You can purchase a new, preassembled, tested pilot as a drop-in replacement or follow these steps using a Kimray repair kit to disassemble and inspect your current pilot.
CAUTION: Do not allow grease to get into the communication holes, as this could cause the pilot to not operate properly.
For this portion of the maintenance, the unit should be removed from the vessel.
If any other components that were inspected need to be replaced, refer to the Gen 3’s Technical Specifications to determine which part number(s) are needed and contact your local Kimray store or authorized distributor to order.
A Pneumatic Level Switch can be used as either a high-level or low-level switch in a pressurized vessel. It sends a pneumatic signal, which can be used to actuate a control valve open or closed. It can also be used in place of a level controller for on/off service in tight spaces—for instance, in a 12” diameter vertical separator.
This switch is field-reversible from direct acting to indirect acting, so it can be used in conjunction with a fail-open or fail-closed control valve.
You can test the level switch by holding down the manual override. We recommend testing this at least every six months to confirm the level switch is working properly.
We also recommend using a repair kit at least once a year for preventative maintenance. While the body will last for many years, the internal components and soft goods can wear out more quickly.
A convenient feature of the switch is that it can be repaired without being removed from the piping. In this video, we use a controlled environment and a vise.
For this job, you will need the following tools, equipment and chemicals:
Repair Kit: RZX
If you are unthreading the switch from the vessel, place the switch in the vise but tighten only on the flats so that you do not damage the threads or housing.
Also note the orientation of the pilot body. If the vent is on the same side as the manual override, it is set up in direct acting mode. If you’re not changing applications, you’ll want to make sure to assemble this in the same orientation later.
You may need to inspect the float lever more closely or clean any solid buildup inside the level switch. This model (used in the video) was manufactured in 2013 and has more space for debris to accumulate. Newer models have a plug in this area, but the removal of the float is the same.
On this example level switch we used in our video, we found the internal threads were messed up and we were unable to thread the fitting back into the body. After trying a ¼" tap with no success, at this point we would need a new level switch because a replacement body would not be cost effective. For the purpose of this video, we’ll leave it partially unthreaded and continue showing the repair process.
If you’ve installed it correctly, you can hear a faint “click” sound when the float is moved, telling you that the shuttle can freely move.
Install the filter and nipple onto the pilot body using a 5/8” wrench. Orient the filter body in line with the other features on the housing.
