Kayden CLASSIC 810 User manual

CRN
Canadian
Registration
Number
Product Manual
CLASSIC™Series
Thermal
Thermal Flow, Level, Interface &
Temperature Switches & Transmitters
CRN
Canadian
Registration
Number

Shop Online
NOTICE
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 service or support needs, please contact your local representative.
CAUTION
The products described in this document are NOT designed for nuclear qualied
applications.

!

i
Shop Online
CLASSIC 800 Product Manual
Table of Contents
1. INTRODUCTION
CLASSIC™800 Specifications.................................................................................................................. iv
Overview of Switch Transmitter Setup .................................................................................................... vi
Models Described in This Manual.............................................................................................................. 1
CLASSIC™800 Electronics ....................................................................................................................... 2
Typical Applications.................................................................................................................................. 2
I. THE KAYDEN CLASSIC 800 - DIGITAL ELECTRONICS FEATURES .................................................... 3
II. PRINCIPLE OF OPERATION .............................................................................................................. 4
III. THERMAL SIGNAL............................................................................................................................. 5
IV. 4-20 mA ANALOG OUTPUT ................................................................................................................ 6
2. INSTALLATION GUIDELINES
I. GENERAL.......................................................................................................................................... 7
II. APPLICATION CONSIDERATIONS ..................................................................................................... 8
Application Considerations - Flow ..................................................................................................... 8
Application Principles - Flow, Level, Interface & Temperature............................................................. 8
Application Considerations - Level .................................................................................................... 9
Application Considerations - Interface............................................................................................... 9
III. GUIDELINES FOR PIPE MOUNTING ................................................................................................ 10
Horizontal Pipe - Side Mount (Ideal) ............................................................................................... 10
Horizontal Pipe - Top Mount............................................................................................................ 10
Horizontal Pipe - Bottom Mount ...................................................................................................... 10
Vertical Pipe - Side Mount (Acceptable) .......................................................................................... 11
Vertical Pipe - Side Mount - Downward Flow ................................................................................... 11
Vertical Pipe - Top & Bottom Mount (Less Desirable) ....................................................................... 11
IV. INSTALLING THE SENSOR .............................................................................................................. 12
V. ELECTRICAL ................................................................................................................................... 13
Wiring Connection Diagram ............................................................................................................ 15
VI. TESTING THE INSTALLATION ......................................................................................................... 16
3. SETUP & OPERATION
Display Panel Indicators................................................................................................................. 17
Display Panel Button Functions ...................................................................................................... 17
I. GENERAL INFORMATION ................................................................................................................ 18
II. CONTROL SETTINGS and SETUP PROCEDURES ........................................................................... 18
1. View or Adjust Relay 1 & 2 Energized Mode ...................................................................................... 19
Failsafe Relay Configurations ......................................................................................................... 20
2. View or Adjust the 4–20 mA Fault Mode Configuration ....................................................................... 21
3. View or Adjust Set Points 1 & 2......................................................................................................... 22
4. View or Adjust the Start-up Bypass Timer.......................................................................................... 23
5. View or Adjust the Heater Power....................................................................................................... 24
6. View or Adjust the Node Address & View the Software Revision ......................................................... 25
7. View or Adjust the 4-20 mA Output Configuration (Forward or Reverse).............................................. 26
8. View or Adjust the 0% & 100% Thermal Signal Scaled Bar Graph View .............................................. 27

ii Shop Online
CLASSIC 800 Product Manual
Table of Contents
9. View or Adjust the 0% & 100% Thermal Signal LEDs: ........................................................................ 28
Kayden RCM Software ................................................................................................................... 29
RS-485 Remote Communications.................................................................................................... 30
Converters / Adapters - USB to RS-232 & RS-232 to RS-485 ........................................................... 30
Communication Cable .................................................................................................................... 30
4. QUICK SETUP GUIDE
Mechanical Installation ........................................................................................................................... 31
Sensor Orientation ................................................................................................................................. 31
Setup & Configuration Flow Chart ........................................................................................................... 31
Display Panel Indicators ......................................................................................................................... 31
Display Panel Button Functions .............................................................................................................. 31
Power AC/DC ......................................................................................................................................... 31
Relay Outputs ........................................................................................................................................ 31
Heater Power ......................................................................................................................................... 31
5. MAINTENANCE
1. Cover................................................................................................................................................. 35
2. Process and Conduit Connections....................................................................................................... 35
3. Sensing Elements............................................................................................................................... 35
4. Electronics Module ............................................................................................................................. 35
5. Adjustment & Calibration .................................................................................................................... 35
6. Preventative Maintenance Requirements............................................................................................. 35
6. BINARY TABLE.......................................................................................................................................... 38
LED Fault Indicator ................................................................................................................................ 39
7. TROUBLESHOOTING
How to Reset the CLASSIC Factory Settings ........................................................................................... 40
Resistance Values for Sensor Wiring....................................................................................................... 41
Return of Material .................................................................................................................................. 42
Hazardous Materials............................................................................................................................... 42
Service, Technical Support & Contact Information.................................................................................... 42
8. GLOSSARY................................................................................................................................................ 43
APPENDIX A - OUTLINE DIMENSIONAL DRAWING
CLASSIC™810 Threaded........................................................................................................................ 44
CLASSIC™812 Flanged.......................................................................................................................... 44
CLASSIC™828 Sanitary Flanged ............................................................................................................ 44
CLASSIC™830 InLine Threaded (Horizontal)........................................................................................... 45
CLASSIC™830 InLine Threaded (Vertical)............................................................................................... 45
CLASSIC™832 InLine Flanged (Horizontal) ............................................................................................. 46
CLASSIC™832 InLine Flanged (Vertical) ................................................................................................. 46
CLASSIC™816 Retractable Packing Gland Threaded - 1” MNPT – to 50 psi ............................................. 46
CLASSIC™816 Retractable Packing Gland Threaded - 1” MNPT – c/w Chain – to 125 psi ......................... 47
CLASSIC™816 Retractable Packing Gland Threaded - 1” MNPT – to 500 psi............................................ 47
CLASSIC™814 Retractable Packing Gland Flanged - to 50 psi................................................................. 47
CLASSIC™814 Retractable Packing Gland Threaded - to 125 psi............................................................ 48

iii
Shop Online
CLASSIC 800 Product Manual
Table of Contents
Remote Electronics Enclosure - Flameproof (CSA) .................................................................................. 48
Remote Electronics Enclosure - Flameproof (FM) .................................................................................... 49
APPENDIX B - MODEL NUMBER LEGENDS
ORDER LEGENDS
CLASSIC™810 Threaded................................................................................................................ 51
CLASSIC™812 Flanged.................................................................................................................. 52
CLASSIC™830 InLine Threaded ..................................................................................................... 53
CLASSIC™832 InLine Flanged ....................................................................................................... 54
CLASSIC™816 Threaded Retractable Packing Gland ...................................................................... 55
CLASSIC™814 Flanged Retractable Packing Gland......................................................................... 56
CLASSIC™828 Sanitary Flanged .................................................................................................... 57
APPENDIX C - TELEMATIC.COM WEB SITE .................................................................................................. 59
CONTACT US & ORDERING INFORMATION .................................................................................................. 63
TABLE OF FIGURES
Figure 1 - CLASSIC 800 Display Panel...................................................................................................... 2
Figure 2 - How Thermal Conductivity is Displayed ..................................................................................... 5
Figure 3 - 4-20 mA Wiring ........................................................................................................................ 6
Figure 3a - Pump Flow Detection .............................................................................................................. 7
Figure 4 - Threadolet.............................................................................................................................. 10
Figure 6a - Horizontal Pipe, Side Mounting.............................................................................................. 10
Figure 5 - Insertion ‘U’ Length................................................................................................................. 10
Figure 6b - Horizontal Pipe, Top / Bottom Mounting ................................................................................. 10
Figure 8 - Vertical Pipe, Flow Up & Down ............................................................................................... 11
Figure 7 - Horizontal Pipe, Sensor Positioning......................................................................................... 11
Figure 9 - Sensor Orientation for Horizontal Flow & Level ........................................................................ 12
Figure 10 - Disconnecting Sensor Connector from the Electronics Module................................................ 14
Figure 11 - CLASSIC 800 Mounting Base Plate / Wiring Terminal ............................................................. 14
Figure 12 - CLASSIC 800 Wiring Connection Diagram ............................................................................. 15
Figure 1 - CLASSIC 800 Display Panel.................................................................................................... 17
Figure 14 - Control Functions RUN/SET Mode......................................................................................... 17
Figure 15 - Relay Energized Mode .......................................................................................................... 19
Figure 16 - 4-20 mA Fault Mode Configuration......................................................................................... 21
Figure 17 - Set Point 1 & 2 Configuration ................................................................................................ 22
Figure 18 - Start-up Bypass Timer........................................................................................................... 23
Figure 19 - Setting the Heater Power ...................................................................................................... 24
Figure 20 - Software Revision & Node (Unit) Number............................................................................... 25
Figure 21 - 4-20 mA & 20-4 mA Output Mode........................................................................................... 26
Figure 22 - Scaled Bar Graph View vs. Baseline Bar Graph View ............................................................. 27
Figure 23 - Setting the 0% & 100% Thermal Signal.................................................................................. 28
Figure 24 - Factory Reset ....................................................................................................................... 40
Figure 25 - Display Panel Indicators........................................................................................................ 41

CLASSIC 800 Product Manual
CLASSIC™800
iv Shop Online
Thermal Dispersion
CLASSIC™800 Technical Specifications
Shop Online
Applications:
•Flow, Level, Interface & Temperature
Process Connections:
•1/2”, 3/4”, 1”, 1-1/4”, 1-1/2” & 2” MNPT
•3/4” FNPT & Flanged InLine
•Flanged & Sanitary 1” to 3.5” Tri-Clamp®
•Threaded (1” MNPT) & Flanged
Retractable Packing Glands
Insertion ‘U’ Lengths:
•Imperial:
1.2”, 2”, 3”, 4”, 6”, 9”, 12” & 18” standard
Model 828 (Sanitary) - 2”, 3”, 4” & 6” only
•Metric:
3, 5, 7.5, 10,15, 23, 30 & 45 cm standard
Model 828 (Sanitary) - 5, 7.5, 10 & 15 cm only
•Custom Lengths:
Available in 1/2” or 1 cm increments
Min. 1.2” - Max. 120” (3.0 - 305 cm) model
dependant
Wetted Materials:
•316/316L Stainless Steel - standard
•Titanium Gr. 2, Hastelloy®C-276
•316/316L Stainless Steel c/w Nickel Braze
(830 & 832 InLine Models)
•Highly Saturated Nitrile
(Pressure Seal - 814 & 816 Packing
Gland Models)
Enclosure Material:
•Copper-free Aluminum
(does not exceed 0.4% copper)
•Powder Coated Polyester TGIC
(polyester triglycidyl isocyanurate)
•NEMA 4 / Type 4 / IP55
•1” FNPT Conduit Connection
•Buna O-ring on Cover
Temperature Range – Continuous Service:
•Sensors:
-45°C to +200°C (-50°F to +392°F)
(Models 814 & 816: -45°C to +160°C [-50°F to
+320°F])
•Electronics:
-55°C to +65°C (-67°F to +149°F)
Note: For temperatures above +65°C (+149°F)
electronics must be remotely mounted.
•Storage:
-55°C to +75°C (-67°F to +167°F)
Operating Pressure - Sensor:
Threaded Style:
•Maximum Working Pressure:
24 MPa (3500 psig) dependent on
model and material of construction
Flanged Style:
•Maximum Working Pressure:
per flange rating
Sanitary Tri-Clamp®Style:
•Maximum Working Pressure:
per flange rating
Switch / Transmitter Switch Point Range
(Insertion Style - 1/2” to 2”MNPT, 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: 21°C (70°F) at 14.7 psi (1 atm)
Switch / Transmitter Switch Point Range
(InLine 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: 21°C (70°F) at 14.7 psi (1 atm)
Accuracy:
•Flow Service:
±1% set point velocity over operating range of
±28°C (±50°F)
•Level Service:
±0.25 inches (±0.64 cm)
CLASSIC™800 Specifications

CLASSIC 800 Product Manual
CLASSIC™800
v
Shop Online
Thermal Dispersion
CLASSIC™800 Technical Specifications
Shop Online
Doc. #: TSS-800-004-[008] February 2016
Response Time:
•Approximately 0.5 to 30 seconds
Remote Electronics Option:
•Maximum recommended cable length -
200 feet (60 m)
•Cable type - 24 AWG minimum - twisted pairs
Heater Power:
•Field adjustable to optimize performance
Input Power:
•Universal Power standard
12-24 VDC and 115-230 VAC, 50-60 Hz
•Consumption: Maximum: 6.0 watts
(fully configured)
Outputs:
•4-20 mA current loop
•Two (2) independent SPDT sealed relay contacts
rated @ 4 amps resistive 230 VAC or 30 VDC Max.;
individually adjustable
Start-Up Bypass Timer:
•Adjustable for 0 to 100 seconds
Communications:
•Modbus via RS-485
RCMS (Remote Control & Monitoring
Software) Functions and Features:
•Display Panel Lock-Out
•Set Points configuration1
•Relay Actuation Delay Timer
•Independently configurable for both On and Off,
increasing or decreasing
•Adjustable from 0 - 5,000 seconds
•Start-up Bypass Timer1
•Adjustable from 0 - 100 seconds
•Relay Mode Configuration1
•Energized above or below set point
•Relay Temperature Mode Configuration
•Heater Power setting1
•Zero and Span settings1
•Analog (4-20 mA) output configuration1
•View and Print Graphing (Trend) function
•Configuring settings; write to device,
save to file and print
•Fault Event Log
Note:1Also 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 + H2; AEx d IIB+H2
(Class I, Zone 1, Group IIB + H2,)
T3; Enclosure Type 4 / IP55
•Single Seal Approval
Per ANSI/ISA 12.27.01-2003
•CRN
Canadian Registration Number
Note: CRN approvals available.
Visit telematic.com for CRN information
per model and jurisdiction.
•FM Approvals
Class I, Div. 1, Groups B, C and D;
Class I, Zone 1, AEx d IIB+H2
T2D (Ta=75°C); T3 (Ta=65°C);
Enclosure Type 4 / IP55
Weights and Dimensions:
•810 Threaded: 2” U length - 7 lbs (3.18 kg)
•Carton Size - 15” x 5” x 6” (38 cm x 13 cm x 15
cm)
•Other models/sizes - consult Telematic
Warranty:
•One (1) Year from shipment date from factory
(see Terms & Conditions on telematic.com
for details)
CRN
Canadian
Registration
Number
CLASSIC™800 Specifications

vi Shop Online
CLASSIC 800 Product Manual
Introduction
Thermal Dispersion
CLASSIC™800
1
Shop Online
Notes
Overview of Switch Setup
1. Warm-up
At initial start-up or restart allow approximately 90 seconds for the heater element to warm-up and the switch 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 Revision
4. 4-20 mA Configuration

1
Shop Online
CLASSIC 800 Product Manual
Introduction
Section
1
This manual describes the following CLASSIC 800 Series Switches
and Transmitters:
CLASSIC 810 Threaded
•Insertion Style - 1/2”, 3/4”, 1”, 1-1/4”, 1-1/2” & 2” MNPT
CLASSIC 812 Flanged
•Insertion Style - 1” ANSI 150 through 10” ANSI 900 Flanges
CLASSIC 814 Flanged Retractable Packing Gland
•Insertion Style - 1-1/2” through 10” ANSI 150 Flanges
CLASSIC 816 Threaded Retractable Packing Gland
•Insertion Style - 1” 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 900 Flanges
Models Described
In this Manual

2Shop Online
CLASSIC 800 Product Manual
Introduction
CLASSIC™800 Electronics
Display Panel & Intelligent User Interface
The Kayden CLASSIC 800 Electronics Module is designed to be easy to install and adjust while displaying
several control functions. All Kayden CLASSIC 800 Electronics Modules feature:
•Universal 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 universal spare
part. The Electronics Module is easily installed in the field without returning the entire switch/transmitter to
the factory.
Display Panel Indicators:
Relay 1 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 1 On steady when viewing Set Point 1
Set Point 2 On steady when viewing Set Point 2
Run Mode Flashing when switch is operating
Bypass Flashing when the Start-up Bypass Timer
is active
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 conductivity
Figure 1 - CLASSIC 800
Display Panel
Typical Applications
•Pump Protection - Dry Alarm
•Leak Detection
•Flow Monitoring &
Verification
•Tank Overflow 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 Valve & Rupture Disk
Flow Monitoring
•Remote Indication of Flow
via Analog Output & Digital
Communications
•Liquids, Air & Gases
•Slurries
•Interface Detection
•Corrosive Liquids
•Hazardous & General-
Purpose Areas
•Interface Control & Level
Detection in Settling Vessels
•Chemical Injection/Additive
Flow Monitoring