Kayden CLASSIC 800 Series User manual
Date: 0
3/22/201
6
Project:
Keystone Pipeline Project
Document Title INSTALLATION OPERATION MANUAL
Document Number
25472‐101‐V1A‐JF00‐W00
10
Purchase Order
25472‐101‐POA‐JF00‐W0001
Equipment Tag s)
Document Revision:
Comments
25472-101-V1A-JF00-W0010 Rev 02
view
pages 2 and 3
2
STATUS
NUMBER
1
Work may proceed.
2
3
4
Review
no required. Work may proceed.
Reviewed by: Dae:
Co‐Reviewed
(if
applicable)
by:
Dae:
Permission o proceed does no consiue accepance or approval of
design
deails, calculaions, analysis, es mehods or maerials
developed
or seleced by he supplier and does no relieve supplier from
full
compliance from conracual obligaions.
Keysone Pipeline Projec
25472
DOCUMENT REVIEW STATUS
Revise and resubmi. Work may proceed subjec o
incorporaion
of changes indicaed.
Revise
and resubmi. Work may no proceed.
25472-101-V 1A -JF 00-W 0010
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Bata_Diane
2016/03/2
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25472-101-V1A-JF00-W0010 Rev 02
25472-101-V1A-JF00-W0010 Rev 02
Thermal Flow, Level, Interface & Temperature
Switches & Transmitters
CLASSIC 800 Series
Prouct Manual
K
A
Y
D
E
N
I
N
S
T
R
U
M
E
N
T
S
A
N
N
I
V
E
R
S
A
R
Y
1994
th
1
6
2010
CRN
anadian
Registration
Number
25472-101-V1A-JF00-W0010 Rev 02
kayden
.com
The products described in this document are NOT designed for nuclear qualified
applications.
Read this manual before working with the product. For personal and system
safety, and for optimum product performance, make sure you thoroughly
understand the contents before installing, using or maintaining this product.
For equipment serice or support needs, please contact your local Kayden
representatie.
NOTICE
CAUTION
!
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Table of Contents
CLASSIC 800 Product Manual
1. INTRODUCTION
Technical Specs............................................................................................................. 1
Overview of Switch Transmitter Setup ............................................................................... 3
Models Described in This Manual ...................................................................................... 4
CASSIC 800 Electronics................................................................................................. 5
Typical Applications ....................................................................................................... 5
I. THE KAYDEN CASSIC 800 - DIGITA EECTRONICS FEATURES
........................................... 6
II. PRINCIPE OF OPERATION (Flow & evel)
...................................................................... 7
III. THERMA SIGNA..................................................................................................... 8
IV. 4-20 mA ANAOG OUTPUT .......................................................................................... 9
2. INSTALLATION GUIDELINES
I. GENERA
................................................................................................................. 10
II. APPICATION CONSIDERATIONS
Application Considerations - Flow
.............................................................................. 11
Application Principles - Flow, evel, Interface & Temperature.......................................... 11
Application Considerations - evel ............................................................................. 12
Application Considerations - Interface ........................................................................ 12
III. GUIDEINES FOR PIPE MOUNTING
Horizontal Pipe - Side Mount (Ideal) .......................................................................... 13
Horizontal Pipe - Top Mount ..................................................................................... 13
Horizontal Pipe - Bottom Mount................................................................................. 13
Vertical Pipe - Side Mount (Acceptable) ...................................................................... 14
Vertical Pipe - Side Mount - Downward Flow ................................................................ 14
Vertical Pipe - Top & Bottom Mount (ess Desirable) ..................................................... 14
IV. INSTA ING THE SENSOR .......................................................................................... 15
V. EECTRICA ............................................................................................................ 16
Wiring Connection Diagram ...................................................................................... 18
VI. TESTING THE INSTA ATION ..................................................................................... 19
3. SETUP & OPERATION
Display Panel Indicators .......................................................................................... 20
Display Panel Button Functions ................................................................................. 20
I. GENERA INFORMATION ............................................................................................. 21
II. CONTRO SETTINGS and SETUP PROCEDURES ............................................................... 21
1. View or Adjust Relay 1 & 2 Energized Mode .................................................................... 22
Fail-safe Relay Configuration .................................................................................... 23
2. View or Adjust the 4-20 mA Fault Mode Configuration....................................................... 24
3. View or Adjust Set Points 1 & 2.................................................................................... 25
4. View or Adjust the Start-up Bypass Timer ...................................................................... 26
5. View or Adjust the Heater Power .................................................................................. 27
6. View or Adjust the Node Address & View the Software Revision .......................................... 28
7. View or Adjust the 4-20 mA Output Configuration (Forward or Reverse) .............................. 29
8. View or Adjust the 0% & 100% Thermal Signal Scaled Bar Graph View ................................ 30
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Table of Contents CLASSIC 800 Product Manual
9. View or Adjust the 0% & 100% Thermal Signal EDs:....................................................... 31
Kayden RCM Software
............................................................................................. 32
RS-485 Remote Communications ............................................................................... 33
Kayden Converters/Adapters - USB to RS-232 & RS-232 to RS-485.................................. 33
Communications Cable ............................................................................................ 33
4. QUICK SETUP GUIDE ...................................................................................................... 34
Mechanical Installation ................................................................................................... 34
Sensor Orientation......................................................................................................... 34
Setup & Configuration Flow Chart
..................................................................................... 35
Display Panel Indicators ................................................................................................. 36
Display Panel Button Functions
........................................................................................ 36
Power AC/DC
................................................................................................................ 37
Relay Outputs ............................................................................................................... 37
Heater Power................................................................................................................ 37
5. MAINTENANCE
1. Spin Cover
............................................................................................................... 38
2. Process and Conduit Connections.................................................................................. 38
3. Sensing Elements ...................................................................................................... 38
4. Electronics Module
..................................................................................................... 38
5. Adjustment & Calibration
............................................................................................ 39
6. Preventative Maintenance Requirements......................................................................... 39
6. BINARY TABLE ............................................................................................................... 40
7. TROUBLESHOOTING
ED Fault Indicator
........................................................................................................ 41
How to Reset the Switch/Transmitter to Factory Settings ...................................................... 42
Resistance Values for Sensor Wiring.................................................................................. 43
Return of Material ......................................................................................................... 44
Hazardous Materials....................................................................................................... 44
Service, Technical Support & Contact Information................................................................ 44
8. GLOSSARY ..................................................................................................................... 45
APPENDIX A - OUTLINE DIMENSIONAL DRAWING
CASSIC 810 Threaded................................................................................................... 46
CASSIC 812 Flanged..................................................................................................... 46
CASSIC 828 Sanitary Flanged......................................................................................... 46
CASSIC 821 Threaded (Single Probe)............................................................................... 47
CASSIC 830 In-ine Threaded (Horizontal) ....................................................................... 47
CASSIC 830 In-ine Threaded (Vertical) ........................................................................... 47
CASSIC 832 In-ine Flanged (Horizontal) ......................................................................... 48
CASSIC 832 In-ine Flanged (Vertical) ............................................................................. 48
CASSIC 816 Retractable Packing Gland - 1" MNPT - to 50 psi ............................................... 48
CASSIC 816 Retractable Packing Gland - 1" MNPT - c/w Security Chain - to 125 psi ................. 49
CASSIC 816 Retractable Packing Gland - 1" MNPT - to 500 psi ............................................. 49
CASSIC 814 Retractable Packing Gland Flanged - to 50 psi .................................................. 49
CASSIC 814 Retractable Packing Gland Flanged - to 500 psi ................................................ 50
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Table of Contents CLASSIC 800 Product Manual
Remote Electronics Enclosure - Explosion-proof (CSA)
.......................................................... 50
Remote Electronics Enclosure - Flameproof (FM)
................................................................. 51
CASSIC 825 Flanged MultiPoint (2 & 3 Point) .................................................................... 52
CASSIC 825 Flanged MultiPoint (4 Point)
.......................................................................... 53
APPENDIX B - MODEL NUMBER LEGENDS
CASSIC 810 Threaded................................................................................................... 55
CASSIC 812 Flanged..................................................................................................... 56
CASSIC 821 Threaded (Single Probe)............................................................................... 57
CASSIC 830 In-ine Threaded
........................................................................................ 58
CASSIC 832 In-ine Flanged .......................................................................................... 59
CASSIC 816 Threaded Retractable Packing Gland
............................................................... 60
CASSIC 814 Flanged Retractable Packing Gland
................................................................. 61
CASSIC 828 Sanitary Flanged......................................................................................... 62
CASSIC 825 MultiPoint Flanged....................................................................................... 63
APPENDIX C - kayen.com WEB SITE
.................................................................................. 64
Contact Us, Distributors an Orering Information.............................................................. 67
TABLE OF FIGURES
Figure 1 - CASSIC 800 Display Panel
............................................................................... 5
Figure 2 - How Thermal Conductivity is Displayed ............................................................... 8
Figure 3 - 4-20 mA Wiring ............................................................................................. 9
Figure 3a - Pump Flow Detection
..................................................................................... 10
Figure 4 - Threadolet
..................................................................................................... 13
Figure 5 - Insertion ‘U’ ength ......................................................................................... 13
Figure 6a - Horizontal Pipe, Side Mounting ......................................................................... 13
Figure 6b - Horizontal Pipe, Top/Bottom Mounting ............................................................... 13
Figure 7 - Horizontal Pipe, Sensor Positioning..................................................................... 14
Figure 8 - Flow Direction, Vertical Pipe.............................................................................. 14
Figure 9 - Sensor Orientation for Horizontal Flow & evel ..................................................... 15
Figure 10 - Disconnecting Sensor Connector from Electronics Module ...................................... 17
Figure 11 - CASSIC 800 Mounting Base Plate / Wiring Terminal
............................................ 17
Figure 12 - CASSIC 800 Wiring Connection Diagram
........................................................... 18
Figure 13 - CASSIC 800 Display Panel ............................................................................. 20
Figure 14 - Control Functions RUN/SET Mode...................................................................... 20
Figure 15 - Relay Energized Mode..................................................................................... 22
Figure 16 - 4-20 mA Fault Mode Configuration .................................................................... 24
Figure 17 - Set Point 1 & 2 Configuration........................................................................... 25
Figure 18 - Start-up Bypass Timer.................................................................................... 26
Figure 19 - Setting the Heater Power ................................................................................ 27
Figure 20 - Software Revision & Node (Unit) Number
........................................................... 28
Figure 21 - 4-20 mA Output Mode
.................................................................................... 29
Figure 22 - Scaled Bar Graph View vs. Baseline Bar Graph View............................................. 30
Figure 23 - Setting 0% & 100% Thermal Signal .................................................................. 31
Figure 24 - Factory Reset................................................................................................ 42
Figure 25 - Display Panel Indicators.................................................................................. 43
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Thermal Dispersion
CLASSIC
™
800
Applications:
• Flow, Level, Interface & Temperature
Process Connections:
•
1/2", 3/4", 1", 1 1/4", 1 1/2" & 2" MNT
•
1/4" MNT Single robe
• 3/4" FNT & Flanged In-Line
• Flanged & Sanitary 1" to 3.5" Tri-Clamp
®
• Threaded (1" MNT) & Flanged
Retractable acking Glands
Insertion ‘U’ Lengths: (Dual Prob e Sensors)
• Imperial:
1.2", 2", 3", 4", 6", 9", 12" & 18" standard
Model 828 (Sanitary) - 2", 3", 4" & 6" only
• etric:
3, 5, 7.5, 10,15, 23, 30 & 45 cm standard
Model 828 (Sanitary) - 5, 7.5, 10 & 15 cm only
• Custom Lengths:
vailable in 1/2" or 1 cm increments
Min. 1.2" - Max. 120" (6.0 - 305 cm)
Note: 1/2" & 3/4" MNT connections-Max.‘U’ Length=36"
Insertion ‘U’ Lengths: (Single Prob e odel 821)
• Imperial:
2", 3", 4" & 6" standard
• etric:
5, 7.5, 10 & 15 cm standard
Wetted aterials:
• 316L Stainless Steel standard
• Titanium Gr. 2, Hastelloy
®
C-276, Monel
®
400,
Inconel
®
600, lloy 20, Nickel 200
• 316L Stainless Steel c/w Nickel Braze
(830 & 832 In-Line Models)
• Highly Saturated Nitrile
(ressure Seal - 814 & 816 acking Gland Models)
Enclosure aterial:
• Copper-free aluminum
(does not exceed 0.4% copper)
• owder coated olyester TGIC
(polyester triglycidyl isocyanurate)
• NEM 4X / Type 4 / I55
• 1" FNT Conduit Connection
• Buna O-ring on cover
Temperature Range – Continuous Service:
• Sensors:
-67°F to +392°F (-55°C to +200°C)
(Models 814 & 816: -40°F to +320°F [-40°C to +160°C])
•
Electronics:
-67°F to +149°F (-55°C to +65°C)
Note: For temperatures above +167°F (+75°C)
electronics must be remotely mounted.
• Storage:
-67°F to +167°F (-55°C to +75°C)
Operating Pressure - Sensor:
Threaded Style:
•
Maximum Working ressure:
24 Ma (3500 psig) at 70°F (21°C)
Derated with temperature
Flanged Style:
• Maximum Working ressure:
per flange rating
Sanitary Tri-Clamp
®
Style:
• Maximum Working ressure:
1723 ka (250 psig) at 70°F (21°C)
Switch / Transmitter Switch Point Range
(Insertion Style - 1/4" to 2"NPT, Flanged):
• Water-based Liquids:
0.01 to 3.0 ft./sec. (0.003 to 0.9 meters/sec.)
• Hydrocarbon-based Liquids:
0.01 to 5.0 ft./sec. (0.003 to 1.5 meters/sec.)
• Gases:
0.25 to 254 sfps (0.076 to 77 smps)
Standard conditions: 70°F (21°C) at 14.7 psi (1 atm)
Switch / Transmitter Switch Point Range
(In-Line Style):
• Water-based Liquids:
0.015 to 50 cc/sec.
• Hydrocarbon-based Liquids:
0.033 to 110 cc/sec.
• Gases:
0.6 to 20,000 cc/sec.
Standard conditions: 70°F (21°C) at 14.7 psi (1 atm)
Accuracy:
• Flow Service:
±1% set point velocity
over operating range of ±50°F (±28°C)
• Level Service:
±0.25 inches (±0.64 cm)
CLASSIC
™
800 Specifications
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CLASSIC
™
800 Thermal Dispersion
Response Time:
• pproximately 0.5 to 30 seconds
Remote Electronics Option:
•
Maximum recommended cable length - 200 feet (0 m)
•
Cable type - 24 WG minimum - twisted pairs
Heater Power:
• Field adjustable to optimize performance
Input Power:
• Universal Power standard
12-24 VDC and 115-230 V C, 50-0 Hz
• Consumption: Maximum: 4.8 watts (fully configured)
Outputs:
•
4-20 m current loop
• Two (2) SPDT sealed relay contacts
rated @ 5 amps resistive 230 V C or 30 VDC Max.;
individually adjustable
Start-Up Bypass Timer:
• djustable for 0 to 100 seconds
Communications:
• Modbus via RS-485
RCMS Remote Control & Monitoring Software)
Functions and Features:
• Display Panel Lock-Out
• Set Points configuration
1
• Relay ctuation Delay Timer (Classic series only)
• Independently configurable for both On and Off,
increasing or decreasing
• djustable from 0 - 5,000 seconds
• Start-up Bypass Timer
1
•
djustable from 0 - 100 seconds
• Relay Mode Configuration
1
• Energized above or below set point
• Relay Temperature Mode Configuration (Classic series only)
• Heater Power setting
1
•
Zero and Span settings
1
(Classic series only)
• nalog (4-20 m ) output configuration
1
• View and Print Graphing (Trend) function
• Configuring settings; write to device,
save to file and print
• Fault Event Log (Classic series only)
Note:
1 lso configurable from Display Panel
Diagnostics:
• Primary watchdog circuit monitors microprocessor
parameter anomalies
•
Secondary watchdog circuit monitors
microprocessor health
• Heater monitored for out-of-range conditions
• Fault Mode de-energizes relay(s) and halts power
to the heater
Agency Approvals:
• CSA - ANSI/UL
Class I, Div. 1, Groups B, C and D;
Ex d IIB + H
2
; Ex d IIB+H
2
(Class I, Zone 1, Group IIB + H
2
,)
T3; Enclosure Type 4 / IP55
Single Seal Approval
Per NSI/IS 12.27.01-2003
• CRN
(Canadian Registration Number): 0F09437.215
• FM
Class I, Div. 1, Groups B, C and D;
Class I, Zone 1, Ex d IIB+H
2
T2D (Ta=75°C); T3 (Ta=5°C);
Enclosure Type 4 / IP55
Weights and Dimensions:
•
810 Threaded: 2" U length - 7 lbs (3.18 kg)
• Carton Size - 15" x 5" x " (38 cm x 13 cm x 15 cm)
• Other models/sizes - consult Kayden
Warranty:
• Three (3) Years from shipment date from factory
(see Terms & Conditions on kayden.com for details)
CLASSIC
™
800 Specifications
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Introuction CLASSIC 800 Product Manual
Notes
.
Warm up
At initial start-up or restart allow approximately 90 seconds for the heater element to warm up and the
switch/transmitter to stabilize before making any adjustments.
2. Primary Settings
The following are the basic configurations for the CLASSIC 800 Series Electronics Modules:
1. Relay 1
2. Relay 2
3. Set Point 1
4. Set Point 2
5. Heater Power
6. 0% & 100% Thermal Signal
3.
Secondary Settings
The following are the additional configurations:
1. 4-20 mA Fault Configuration
2. Startup Bypass Timer
3. Node Address & Software Reision
4. 4-20 mA Configuration
Overview of Switch Transmitter Setup
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1
Section
Introuction
CLASSIC 800 Product Manual
Models Described in
this Manual This manual describes the following CLASSIC 800 Series Switches
and Transmitters:
CLASSIC 80 Threaded - Insertion Style - 1/2”, 3/4”, 1”, 1 1/4”, 1 1/2” & 2” MNPT.
CLASSIC 82 Flanged - Insertion Style - 1” ANSI 150 through 10” ANSI 2500
Flanges.
CLASSIC 84 Flanged Retractable Packing Gland -
Insertion Style - 1 1/2” ANSI
150 through 10” ANSI 2500 Flanges.
CLASSIC 86 Threaded Retractable Packing Gland - Insertion Style - 1” MNPT.
CLASSIC 82 Threaded (Single Probe) - Insertion Style - 1/4” MNPT.
CLASSIC 828 Sanitary Flanged - Insertion Style - 1”, 1.5”, 2”, 2.5” & 3” Tri-Clamp
®
Flanges.
CLASSIC 830 Threaded -
InLine Style - 3/4” FNPT.
CLASSIC 832 Flanged - InLine Style - 3/4” ANSI 150 through 10” ANSI 2500
Flanges.
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Introuction CLASSIC 800 Product Manual
Display Panel Indicators:
Relay On steady when Relay 1 is energized
Relay 2 On steady when Relay 2 is energized
Fault Indicates a self-test error or fault condition
Set Point On steady when iewing Set Point 1
Set Point 2 On steady when iewing Set Point 2
Run Mode Flashing when switch/transmitter is operating
Bypass Flashing when the Start-up Bypass Timer is actie
Thermal Signal Displays Thermal Signal
The Thermal Signal increases as:
Flow The flow rate increases
Level The sensor is submerged
Interface The sensor is submerged by the second liquid of
greater thermal conductiity
Display Panel & Intelligent User Interface
The Kayden CLASSIC 800 Electronics Module is designed to be easy to install and adjust while displaying
seeral control functions. All Kayden CLASSIC 800 Electronics Modules feature:
• Uniersal Power Input • 4-20 mA Analog Output
• Continuous Self-test diagnostics with Fault Indicator • Start-up Bypass Timer
• Easy setup; no jumpers or trim pots • True Temperature Compensation
• Incrementally adjustable heater power, range and
relay set points.
• All CLASSIC 800 series switches/transmitters use the same Electronics Module making it a uniersal
spare part. The Electronics Module is easily installed in the field without returning the entire
switch/transmitter to the factory.
Figure - CLASSIC 800
Display Panel
• Pump Protection – Dry Alarm
• Leak Detection
• Flow Monitoring & Verification
• Tank Oerflow Protection
• Flare Gas Monitoring
• Monitoring Purge Air Flow
• Drain Line Flow
• Interface Control in Separation Vessels
• High Pressure Flows
• Lube Oil Systems
• Vent Monitoring
• Natural Gas to Boilers
• Emergency Eye Wash Stations
• Tanker Loading & Unloading
• Relief Vale & Rupture Disk Flow Monitoring
• Remote Indication of Flow ia Analog Output
& Digital Communications
• Liquids, Air & Gases
• Slurries
• Interface Detection
• Corrosie Liquids
• Hazardous & General-Purpose Areas
• Interface Control & Leel Detection in Settling Vessels
• Chemical Injection/Additie Flow Monitoring
CLASSIC 800 Electronics
Typical Applications
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Introuction CLASSIC 800 Product Manual
I. THE KAYDEN CLASSIC 800 - DIGITAL ELECTRONICS FEATURES
The CLASSIC 800 is ersatile, rugged, cost effectie and easy to use. All setup and adjustments may be
performed using the Display Panel buttons. The CLASSIC 800’s Display Panel displays process condition
(flow, leel & interface) ia the Thermal Signal Bar Graph as well as Relay state, Timer functions and
operating conditions ia indiidual LEDs. The CLASSIC 800 may also be remotely controlled and/or
monitored ia RS-485 using the Kayden RCM (Remote Control & Monitoring) Software and the Serial
Communication Adapter (SCA) and communication cable.
Kayden’s CLASSIC 800 series uses an adanced microprocessor to perform continuous self-test
diagnostics
on the Electronics Module and the sensor elements.
•
Any open or shorted connection will result in an error indication that also opens all output contacts
and disables the heater circuitry.
• An internal watchdog circuit ensures that the microprocessor code is performing as expected and a
secondary external watchdog circuit ensures that the microprocessor itself is functioning. Both
circuits force the contacts open, illuminate the Fault LED and turn the heater off and de-energize
the relays in the eent of a malfunction. This preents the heater running out-of-control that would
result in excessie temperatures on the probe or a burnt-out heater.
• The microprocessor also monitors the heater for out-of-range conditions. For example in a leel
application when the sensor is “dry” for an extended period of time, the heater will cycle between
its current setting and a lower power rating until such time as the sensor is again submerged.
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Introuction CLASSIC 800 Product Manual
II. PRINCIPLE OF OPERATION
Kayden sensors incorporate two thin-film platinum Resistance Temperature Detectors (RTDs) and a
separate heater element. The Reference RTD senses the actual process condition (as temperature). Heat is
applied to the Actie RTD by the heater element which is controlled by the microprocessor.
The microprocessor makes continuous comparisons between the temperature readings from the Reference
RTD and the Actie RTD (alues stored as a result of setup programming). As process conditions change,
for example increased elocity in a flow application, the Reference RTD “senses” the change and the
microprocessor adjusts the heater and changes the relay state if required.
The CLASSIC 800 can be setup with a narrow range to detect ery low flows or ery small changes in the
process, or with a wider range to ignore small fluctuations. The CLASSIC 800 series switches and
transmitters are digital deices and will not require calibration. By design they cannot drift or change in any
way unless they suffer physical damage. After correct setup, the CLASSIC 800 will be stable and repeatable
under stable process conditions.
The CLASSIC 800 may be setup in the field by the user for flow, leel or interface with air, gases, liquids or
slurries. The CLASSIC 800 may be setup to display process temperature through the RCM Software while
functioning as a flow, leel or interface switch/transmitter.
Flow / No Flow – When the elocity of the process media is low or nonexistent, less thermal energy (heat)
is dissipated from the heated sensor. As the elocity increases the amount of energy
dissipated by the process media increases, thereby increasing the Thermal Signal.
The Thermal Signal is smallest (left-most LED illuminated) in a no-flow state and
increases (LED moves to the right) as flow increases (see Figure 2).
Liquid Level – Air and other gases do not dissipate heat as well as liquids. Therefore, the Thermal Signal
is smallest when in a process that does not dissipate heat well (air dissipates heat slower
than water).
The Thermal Signal is smallest (left-most LED illuminated) in a dry, motionless state
and increases as the fluid covers the sensor (see Figure 2).
Liquid Level / – The CLASSIC 800 can be setup to detect the difference between most liquids if there is
Interface ery little or no elocity and each material has a unique thermal property (for example oil
and water in a knockout tank).
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Introuction CLASSIC 800 Product Manual
III. THERMAL SIGNAL
The CLASSIC 800 senses changes to the temperature differential as changes occur in the process. The
“alue” being sensed and displayed as the Thermal Signal is the rate of thermal dispersion. Assuming the
added energy from the heater is a constant, the formula that determines the Thermal Signal has only two
ariables:
)
The thermal conductivity of the process media, and
2)
The velocity of the process media past the sensor.
The relationship between Thermal Signal and elocity is non-linear. When one of these ariables is constant
in a gien application, the alue of the other ariable can be monitored by the CLASSIC. The Thermal
Signal Bar Graph displays Flow & Leel as a percentage of the switch/transmitter’s full scale capability.
Figure 2 below illustrates the
Thermal Signal LED indicators moing to the right as process elocity
increases. Assuming a constant heater power and a consistent process media, as the elocity of the
process increases so does the
Thermal Signal, represented by moement of the illuminated LED to the
right.
For example, if the left-most LED is illuminated on the Thermal Signal Bar Graph, then a minimum amount
of heat is being carried away by the process based on the current settings. If the right-most LED is
illuminated on the
Thermal Signal Bar Graph this indicates the maximum amount of heat is being carried
away by the process based on the current settings.
Figure 2 – How Thermal Conductivity is Displayed
Thermal Signal 100%
0
Relay 1
Relay 2
Fault
Set Point 1
Set Point 2
Run Mode
Bypass
RUN
SET 1 2
CLASSIC
™
Thermal Signal 100%
0
Relay 1
Relay 2
Fault
Set Point 1
Set Point 2
Run Mode
Bypass
RUN
SET 1 2
CLASSIC
™
Thermal Signal 100%
0
Relay 1
Relay 2
Fault
Set Point 1
Set Point 2
Run Mode
Bypass
RUN
SET 1 2
CLASSIC
™
No Flow or Dry (Level)
Maximum Flow or Wet (Level)
Increasing Flow
- no flow or flow is far below
Set Point - leel of process is below
sensor
- leel of process is aboe
sensor
- flow is increasing
- flow is at maximum elocity &
aboe Set Point
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Introuction CLASSIC 800 Product Manual
LOOP -
LOOP +
R2NC
R2NO
R2CM
R1NC
R1NO
R1CM
VAC-H
VAC-N
COM
+VDC
485 (T)
485 (-)
485 (+)
485 (C)
LOOP +
4-20 mA Switch Power Supply,
sitive 12/24 VDC
LOOP - PLC nipolar Voltage Input,
- 5 VDC
250 Ohm
Typical*
COM
Switch Power Supply,
gative (Common)
+VDC Switch Power Supply,
sitive 12/24 VDC
LOOP -
LOOP +
R2NC
R2NO
R2CM
R1NC
R1NO
R1CM
VAC-H
VAC-N
COM
+VDC
485 (T)
485 (-)
485 (+)
485 (C)
LOOP + 4-20 mA Switch Power Supply,
sitive 12/24 VDC
LOOP -
PLC nipolar Voltage Input,
- 5 VDC
Loop Power Supply,
Negative (Common)
GREEN GROUNDING SCREW Safety Ground
VAC-H 115 VAC, Hot
VAC-N
115 VAC, Neutral
250 Ohm
Typical*
IV. 4-20 mA ANALOG OUTPUT
The 4 to 20 mA analog output signal is relatie to the Thermal Signal displayed on the Thermal Signal Bar
Graph. The 0% to 100% of Thermal Signal corresponds to 4-20 mA or 20-4 mA.
Refer to View or Adjust
the 4-20 mA Output for programming this option.
•
The 4-20 mA output signal corresponds to the scaled Thermal Signal iew as determined by the
range (LED-0 and LED-100 pointers).
•
The 4-20 mA signal may be displayed either as forward-acting (ascending 4-20 mA) or reerse-
acting (descending 20-4 mA).
•
To iew or adjust the 4-20 mA output current configuration: (refer to the Section 3, “View or
Adjust the 4-20 mA Output Configuration (Forward or Reverse)” or the “CLASSIC 800 Series
Quick Setup Guide”
MOUNTING BASE PLATE
MOUNTING BASE PLATE
AC INPUT
Figure 3 – 4-20 mA Wiring
1. 4-20 mA output is passie (opto-isolated)
2. * 4-20 mA output current may be measured as a 1-5V oltage
across a 250 Ohm resistor.
1. 4-20 mA output is passie (opto-isolated)
2. * 4-20 mA output current may be measured as a 1-5V oltage
across a 250 Ohm resistor.
DC INPUT (3 or 4 Wire)
25472-101-V1A-JF00-W0010 Rev 02
kayden
.com 10
2
Section
Installation Guielines
CLASSIC 800 Product Manual
I. GENERAL
Kayden electronics are designed to be uniersal for flow, leel, interface and temperature applications and
with most liquids, gases and slurries. The user can take adantage of this flexibility through:
•
Correct setup of the electronics and
•
Proper physical installation of the sensor.
Location:
•
Consider the need for easy access in order to iew the operation and make any required field
adjustments.
•
Proide at least 12 inches (30 cm) clearance if possible to allow access for setup and iewing after
installation.
Shock and Vibration:
•
Install the switch/transmitter so as to minimize any effects due to ibration, shock and extreme
temperatures.
Temperature:
• The continuous operating temperature limits of the Electronics Module is -55°C to +65°C
(-67°F to +149°F). Ambient temperatures in excess of +65°C (+149°F) require the electronics to be
mounted remotely from the sensor. Consult kayden.com or the factory for more information.
•
The continuous operating temperature limits of the sensors are -55°C to +200°C (-67°F to +392°F).
Turbulence / Interference:
• Pumps, fans, ales, or pipe bends of 90° or more will cause turbulence or significant ariance in
the flow which will affect the repeatability of the switch/transmitter. Care should be taken to
minimize this possibility.
• For Pump Flow/No-Flow detection the best/preferred installation point is on the inlet side of the
pump. The discharge side will hae turbulence, reerse flow and an undeeloped flow profile. These
factors will greatly reduce repeatability and accuracy.
• Keep the sensor away from any deices that may cause physical damage such as: agitators,
ales, injectors, etc.
Note: Many times, especially when replacing a different type of instrument, the installation point is
predetermined and is difficult to change. Kayden switches/transmitters hae specific design
features that allow them to perform well een in difficult locations and applications. Please
consult your local Kayden Representatie or Kayden for questions or installation / setup
recommendations.
DISCHARGE: Turbulent Flow
INLET: Linear Flow
Figure 3a - Pump Flow Detection
25472-101-V1A-JF00-W0010 Rev 02
Application Considerations - Flow
Flow
Ideal Process Conditions
Liquids:
•
Consistent process composition & temperature
•
Sufficient straight run flow profile (minimizes turbulence)
• Recommended minimum of 5 pipe diameters
from any disturbance
Air & Gas:
• Consistent process composition & temperature
•
Sufficient straight run flow profile
(minimizes turbulence)
• Clean and dry
Slurries:
•
Consistent process composition & temperature
•
Sufficient straight run flow profile (minimizes turbulence)
Emulsion:
• Consistent process composition & temperature
• Sufficient straight run flow profile (minimizes turbulence)
Undesirable Process Conditions
Liquids:
•
nconsistent process composition or temperature
•
nsufficient straight run
• Turbulence
•
erated fluids
Air & Gas:
• nconsistent process composition or temperature
• Wet or saturated air/gas
Slurries:
• nconsistent process composition or temperature
• nsufficient straight run
• Turbulence
• erated fluids
Emulsion:
•
nconsistent process composition & temperature
• nsufficient straight run
•
Turbulence
• erated fluids
Solids:
• Dry granulated processes are NOT good
candidates for thermal switches
kayden.com
11
Installation Guielines CLASSIC 800 Product Manual
Application Principles - Flow, Level, Interface & Temperature
4
Consistent process composition
4
Consistent process temperature
4
Clean or dirty process
4
Liquids
4
Dry air & gas
4
Slurries
4
Emulsion
8
Aerated fluids
8
Large temperature swings
8
Wet or saturated air/gas
8
Solids
8
Sediment coering sensing tip
GAS VENT
OVERFLOW
INLET
PROCESS TANK
INTERFACE
LEAK PROTECTION
HIGH LEVEL
LOW LEVEL
PUMP PROTECTION
Side of Switch
Bck of Switch
OVERFLOW
TANK
25472-101-V1A-JF00-W0010 Rev 02
Application Considerations - Level
Level
Ideal Process Conditions
Liquids:
• onsistent process composition
• Non-turbulent
Slurries:
•
onsistent process composition
Emulsion:
• onsistent process composition
Undesirable Process Conditions
Liquids:
• Inconsistent process composition
• Turbulence
• Large temperature swings
Slurries:
• Inconsistent process composition
•
Turbulence
• Large temperature swings
Emulsion:
• Inconsistent process composition
• Turbulence
•
Large temperature swings
Solids:
•
Dry granulated processes are NOT good
candidates for thermal switches
Application Considerations - Interface
Interface
Ideal Process Conditions
Liquid to Liquid:
• onsistent process composition & temperature
• Non-turbulent applications
•
Large differential in thermal conductiities
Air or Gas to Liquid:
• onsistent process composition & temperature
•
Non-turbulent applications
• Dry gas
Emulsion:
• onsistent process composition & temperature
• Large differential in thermal conductiities
Undesirable Process Conditions
Liquid to Liquid:
• Inconsistent process composition or temperature
• High aeration
•
High turbulence
• Small differential in thermal conductiities
Air or Gas to Liquid:
•
Inconsistent process composition or temperature
• High turbulence
Emulsion:
• Inconsistent process composition or temperature
• High aeration
• High turbulence
• Small differential in thermal conductiities
Solids:
• Dry granulated processes are NOT good
candidates for thermal switches
kayden
.com 12
Installation Guielines CLASSIC 800 Product Manual
25472-101-V1A-JF00-W0010 Rev 02
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