Kayden CLASSIC Series User manual

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

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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.

!

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CLASSIC 800 Product Manual
Table of Contents
CLASSIC®800 Specifications ................................................................................................................... v
Overview of CLASSIC®Setup ................................................................................................................. vii
1. INTRODUCTION
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
Application Principles - Flow, Level, Interface & Temperature............................................................. 8
II. APPLICATION CONSIDERATIONS ..................................................................................................... 8
Application Considerations - Flow ..................................................................................................... 8
Application Considerations - Level .................................................................................................... 9
Application Considerations - Interface............................................................................................... 9
Application Considerations - Temperature ....................................................................................... 10
II. ELECTRONICS LOCATION CONSIDERATIONS ................................................................................ 10
III. GUIDELINES FOR PIPE MOUNTING ................................................................................................ 11
Horizontal Pipe - Side Mount (Ideal) ............................................................................................... 11
Horizontal Pipe - Top Mount............................................................................................................ 11
Horizontal Pipe - Bottom Mount ...................................................................................................... 11
Vertical Pipe - Side Mount (Acceptable) .......................................................................................... 12
Vertical Pipe - Side Mount - Downward Flow ................................................................................... 12
Vertical Pipe - Top & Bottom Mount (Less Desirable) ....................................................................... 12
IV. INSTALLING THE SENSOR .............................................................................................................. 13
V. ELECTRICAL ................................................................................................................................... 14
VI. LOCAL ENCLOSURE WIRING DIAGRAMS........................................................................................ 17
Wiring Connection Diagram - Local ................................................................................................. 17
VII. REMOTE ENCLOSURE WIRING DIAGRAMS & APPLICATIONS ....................................................... 18
Interconnecting Cables for Remote Electronics................................................................................ 19
General Purpose (Non-hazardous) Cable & Connector Assembly ..................................................... 19
Flameproof Cable & Connector Assembly........................................................................................ 19
Wiring Connection Diagram - Remote ............................................................................................. 20
Optional Wiring Methods for 4-20 mA Current Loop ......................................................................... 22
VIII. TESTING THE INSTALLATION ....................................................................................................... 24

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Table of Contents
3. QUICK SETUP GUIDE
Mechanical Installation ........................................................................................................................... 25
Sensor Orientation ................................................................................................................................. 25
Setup & Configuration Flow Chart ........................................................................................................... 26
Display Panel Indicators ......................................................................................................................... 27
Display Panel Button Functions .............................................................................................................. 27
Power AC/DC ......................................................................................................................................... 28
Relay Outputs ........................................................................................................................................ 28
Heater Power ......................................................................................................................................... 28
4. SETUP & OPERATION
Display Panel Indicators................................................................................................................. 29
Display Panel Button Functions ...................................................................................................... 29
I. GENERAL INFORMATION ................................................................................................................ 30
II. CONTROL SETTINGS and SETUP PROCEDURES ........................................................................... 30
1. View or Adjust Relay 1 & 2 Energized Mode ...................................................................................... 31
Failsafe Relay Configurations ......................................................................................................... 32
2. View or Adjust the 4-20 mA Fault Mode Configuration ........................................................................ 33
3. View or Adjust Set Points 1 & 2......................................................................................................... 34
4. View or Adjust the Start-up Bypass Timer.......................................................................................... 35
5. View or Adjust the Heater Power....................................................................................................... 36
6. View or Adjust the Node Address & View the Software Revision ......................................................... 37
7. View or Adjust the 4-20 mA Output Configuration (Forward or Reverse Acting) ................................... 38
8. View the Bar Graph Lower Range Value (0%) and Upper Range Value (100%) ................................... 39
9. Adjust the Bar Graph Lower Range Value (0%) and Upper Range Value (100%) ................................. 40
Additional Setup Features Using Kayden RCM Software via Modbus RTU ........................................ 41
Kayden Setting & Configuration Log Sheet...................................................................................... 42
5. MODBUS RTU INTERFACE
1. Modbus History ................................................................................................................................ 43
2. Modbus Implementation.................................................................................................................... 43
3. Node Address .................................................................................................................................. 43
4. Function Codes................................................................................................................................ 43
5. Coils................................................................................................................................................ 44
6. Holding Registers............................................................................................................................. 44
6. MAINTENANCE
1. Cover................................................................................................................................................. 48
2. Process and Conduit Connections....................................................................................................... 48
3. Sensing Elements............................................................................................................................... 49
4. Electronics Module ............................................................................................................................. 49
5. Adjustment & Calibration .................................................................................................................... 49
6. Preventative Maintenance w/ RCMS.................................................................................................... 49

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CLASSIC®800 Product Manual
Table of Contents
7. TROUBLESHOOTING
1. LED Fault Indicator............................................................................................................................. 51
2. LED Fault Codes ................................................................................................................................ 51
3. Fault Check List ................................................................................................................................. 57
4. Restore Operation after a Fault........................................................................................................... 57
Options for Clearing a Fault ............................................................................................................. 57
5. How to Perform a Factory Reset ......................................................................................................... 58
6. How to Check the Sensor ................................................................................................................... 58
7. Return of Material............................................................................................................................... 59
8. Hazardous Materials........................................................................................................................... 59
9. Service, Technical Support & Contact Information................................................................................ 59
8. GLOSSARY................................................................................................................................................ 60
APPENDIX A - OUTLINE DIMENSIONAL DRAWING
CLASSIC®810 Threaded ........................................................................................................................ 64
CLASSIC®812 Flanged .......................................................................................................................... 64
CLASSIC®814 Retractable Packing Gland Flanged - to 50 psi ................................................................. 65
CLASSIC®814 Retractable Packing Gland Threaded - to 125 psi ............................................................. 65
CLASSIC®816 Retractable Packing Gland Threaded - 1” MNPT - to 50 psi............................................... 66
CLASSIC®816 Retractable Packing Gland Threaded - 1” MNPT - c/w Chain - to 125 psi........................... 66
CLASSIC®816 Retractable Packing Gland Threaded - 1” MNPT - to 500 psi............................................. 66
CLASSIC®830 InLine Threaded (Horizontal) ........................................................................................... 67
CLASSIC®830 InLine Threaded (Vertical) ............................................................................................... 67
CLASSIC®832 InLine Flanged (Horizontal) ............................................................................................. 67
CLASSIC®832 InLine Flanged (Vertical) ................................................................................................. 68
Remote Electronics Enclosure - Flameproof (CSA) .................................................................................. 68
Remote Electronics Enclosure - Flameproof (FM) .................................................................................... 69
APPENDIX B - MODEL NUMBER LEGENDS
ORDER LEGENDS
CLASSIC®810 Threaded ................................................................................................................ 71
CLASSIC®812 Flanged .................................................................................................................. 72
CLASSIC®814 Flanged Retractable Packing Gland ......................................................................... 73
CLASSIC®816 Threaded Retractable Packing Gland....................................................................... 74
CLASSIC®830 In-Line Threaded..................................................................................................... 75
CLASSIC®832 In-Line Flanged....................................................................................................... 76
APPENDIX C - KAYDEN.COM WEB SITE ....................................................................................................... 77
APPENDIX E - RCM SOFTWARE INSTALLATION & USE................................................................................ 78
CONTACT US, DISTRIBUTORS AND ORDERING INFORMATION ................................................................... 93

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CLASSIC®800 Product Manual
Table of Figures & Tables
TABLE OF FIGURES
Figure 1 - CLASSIC 800 Display Panel...................................................................................................... 2
Figure 2 - CLASSIC 800 Probe & Outputs ................................................................................................. 4
Figure 3 - Thermal Signal vs Velocity in Glycol .......................................................................................... 5
Figure 4 - Thermal Signal Dry vs Submerged............................................................................................. 5
Figure 5 - Thermal Signal Submerged vs Dry............................................................................................. 6
Figure 6 - Thermal Signal in Alternate Fluids ............................................................................................. 6
Figure 7 - Pump Flow Detection ................................................................................................................ 7
Figure 8 - Insertion ‘U’ Length (Flanged) ................................................................................................. 11
Figure 9 - Insertion ‘U’ Length................................................................................................................. 11
Figure 10a - Horizontal Pipe, Side Mounting............................................................................................ 11
Figure 10b - Horizontal Pipe, Top / Bottom Mounting ............................................................................... 11
Figure 11 - Vertical Pipe, Flow Up & Down .............................................................................................. 12
Figure 12 - Horizontal Pipe, Sensor Positioning....................................................................................... 12
Figure 13 - Sensor Orientation for Horizontal Flow & Level ...................................................................... 13
Figure 14 - Disconnecting Sensor Connector from the Electronics Module................................................ 15
Figure 15 - CLASSIC 800 Electronics Module Terminal Wiring Diagram ................................................... 17
Figure 16 - CSA Remotely Mounted Electronics....................................................................................... 18
Figure 17 - FM Remotely Mounted Electronics......................................................................................... 18
Figure 18 - A06-XP Remote Cable and Connector Spec Drawing.............................................................. 20
Figure 19 - CLASSIC 800 Wiring Diagram (Remote) ................................................................................ 21
Figure 20 - DC Powered CLASSIC, 4-Wire External Loop Power (Current Sinking) ................................... 22
Figure 21 - DC Powered CLASSIC, 3-Wire Internal Loop Power (Current Sourcing) .................................. 22
Figure 22 - AC Powered CLASSIC, 4-Wire External Loop Power (Current Sinking).................................... 23
Figure 23 - Relay Energized Mode .......................................................................................................... 31
Figure 24 - 4-20 mA Fault Mode Configuration......................................................................................... 33
Figure 25 - Set Point 1 & 2 Configuration ................................................................................................ 34
Figure 26 - Start-up Bypass Timer........................................................................................................... 35
Figure 27 - Setting the Heater Power ...................................................................................................... 36
Figure 28 - Software Revision & Node (Unit) Number............................................................................... 37
Figure 29 - 4-20 mA & 20-4 mA Output Mode........................................................................................... 38
Figure 30 - Maximum Range of Lower Range Value (LRV) & Upper Range Value (URV)............................ 39
Figure 31 - Scaled Bar Graph View vs. Unscaled Bar Graph View ............................................................ 39
Figure 32 - Setting the Scaled Thermal Signal LRV.................................................................................. 40
Figure 33 - Setting the Scaled Thermal Signal URV ................................................................................. 40
Figure 34 - Kayden CLASSIC Exploded View .......................................................................................... 48
Figure 35 - Display Panel Indicators........................................................................................................ 50
Figure 36 - Fault Cycle Display Example ................................................................................................. 51
Figure 37 - Checking Sensor Resistances ............................................................................................... 58
TABLE OF TABLES
Table 1 - Modbus Address Binary Table ................................................................................................... 43
Table 2 - CLASSIC Modbus Function Codes ............................................................................................ 43
Table 3 - Coils........................................................................................................................................ 44
Table 4 - Low Holding Registers (Configuration and Status) ..................................................................... 45
Table 5 - High Holding Registers (Run-Time Variables) ............................................................................ 46

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CLASSIC®800 Technical Specifications
Thermal Dispersion
CLASSIC
®
800 Technical Specifications
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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
•Threaded (1” MNPT) & Flanged
Retractable Packing Glands
Insertion ‘U’ Lengths
•Imperial
1.2”, 2”, 3”, 4”, 6”, 9”, 12” & 18” standard
•Metric
3, 5, 7.5, 10,15, 23, 30 & 45 cm standard
•Custom Lengths
Available in 1/2” or 1 cm increments
Min. 2.5” - Max. 120” (6.0 - 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, 4X, 6P; IP65/67
•1” FNPT Conduit Connection
•Buna O-Ring on Cover
Temperature Range – Continuous Service
•Sensors
-55°C to +200°C (-58°F to +392°F)
(Models 814 & 816: -55°C to +160°C [-58°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. Refer to
Electronics Location Considerations Page 10.
•Storage
Product should be stored in a clean and dry
environment between -30° and +60° C (-34.5°
and 140° 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
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)
•Repeatability
±0.5% Thermal Signal
•Hysteresis (Dead Band)
±1% Thermal Signal
•Temperature
±1° C or ±2% of full-scale range, whichever is
greater.
CLASSIC®800 Specifications

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CLASSIC®800 Technical Specifications
Thermal Dispersion
CLASSIC
®
800 Technical Specifications
kayden.com Online Store
Doc. #: TSS-800-005-[001] July 2022
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
•DC input has reverse polarity protection
•AC & DC inputs have TVS diodes to protect against
transient voltages (390VAC, 39VDC)
•Internal 1A self-resettable non-user-replaceable
fuse
Outputs
•4-20 mA current loop (with reverse voltage
protection)
•Two (2) independent SPDT fully 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 RTU via RS-485
Additional Features (Configure Using Kayden
RCM Software or Modbus)
•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 Switch Configuration
•Heater Power setting1
•LRV and URV 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
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
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 kayden.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)
Factory Certifications
•Factory tested to NEMA 4, 4X, 6P; IP65/67.
Contact Technical Support for reports.
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 Kayden
Warranty
•One (1) Year from shipment date from factory
(see Terms & Conditions on kayden.com
for details)
Note: 1Also configurable from Display Panel
CRN
Canadian
Registration
Number

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CLASSIC®800 Product Manual
Introduction
Thermal Dispersion
CLASSIC™800
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Notes
Overview of CLASSIC 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. Start-up Bypass Timer
3. Node Address & Software Revision
4. 4-20 mA Configuration

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CLASSIC®800
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Thermal Dispersion
CLASSIC™800
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Notes

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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 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

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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
•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

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CLASSIC®800 Product Manual
Introduction
I. THE KAYDEN CLASSIC 800 - DIGITAL ELECTRONICS FEATURES
The CLASSIC 800 is versatile, rugged, cost effective and easy to use. All basic configurations can be performed
using the Display Panel buttons, although additional configurations may require using Kayden RCM Software (or
the Modbus interface).
The CLASSIC 800’s Display Panel displays process condition (flow, level & interface) via the Thermal Signal Bar
Graph as well as Relay state, Timer functions and operating conditions via individual LEDs.
The CLASSIC 800 may also be remotely controlled and/or monitored via RS-485 using Kayden RCM (Remote
Control & Monitoring) Software with a suitable RS-485 communication adapter and cable.
Kayden’s CLASSIC 800 series uses an advanced 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.
•A internal watchdog circuit in the microprocessor ensures the microprocessor program code is executing
correctly, and an external watchdog circuit ensures the microprocessor itself is functioning correctly.
Both circuits force the contacts open, turn the Fault LED ON, turn the heater off, and de-energize the
relays in the event of a malfunction. This prevents the heater from running out-of-control, which could
result in excessive probe temperatures or damage the heater.
•The microprocessor also monitors the heater for out-of-range conditions. For example in a level
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.
The CLASSIC 800 includes a number of circuit protection features:
•Reverse polarity protection on the 12-24 VDC power input and 4-20 mA analog output.
•Transient-voltage suppression on 12-24 VDC and 115-230 VAC power inputs to protect against voltage
spikes (TVS) diodes.
•Self-resettable non-user-replaceable fuse, to prevent external power supply current protection circuits
from tripping should the CLASSIC fail.

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CLASSIC®800 Product Manual
Introduction
II. PRINCIPLE OF OPERATION
The Kayden CLASSIC sensor probe incorporates two RTDs and a heating element.
•The Reference RTD senses the temperature of the
process.
•The Heating Element applies heat to the Active RTD.
The CLASSIC 800 Series uses a constant heater power
(configured by the operator).
•The electronics module calculates the thermal signal
based on the temperature difference between the two
RTDs.
•The difference in temperature between the two RTDs
varies according to the heat dissipated by the media.
•A change in process (Flow, Level, or Interface) results in a
change in Thermal Signal %.
The Thermal Signal depends primarily on:
1) The thermal conductivity of the process media.
2) The velocity of the process media past the sensor.
Active RTD
Heating Element
Reference RTD
4-20 mA Thermal Signal
Relays (2)
Modbus RTU
SENSOR (PROBE)
ELECTRONICS MODULE
OUTPUTS
Active RTD
Heating Element
Reference RTD
4-20 mA Thermal Signal
Relays (2)
Modbus RTU
SENSOR (PROBE)
ELECTRONICS MODULE
OUTPUTS
Figure 2 - CLASSIC 800 Probe & Outputs

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CLASSIC®800 Product Manual
Introduction
III. THERMAL SIGNAL
Thermal Signal as it Applies to Flow, Level, and Interface
The CLASSIC 800 may be setup in the field for flow, level or interface with air, gases, liquids, or slurries. The
CLASSIC 800 Local Thermal Signal Bar Graph display implies a range of flow detection from 0 to 100%.
If the LED bar graph indicates 0% then a minimum amount of heat is being carried away by the process.
If the LED bar graph indicates 100%, then a maximum amount of heat is being carried away by the process.
The Thermal Signal is continuously compared against the Relay Set Points and the relays are energized or de-
energized appropriately.
Flow / No Flow
The Thermal Signal increases as the FLOW increases.
When the velocity of the process media is low or nonexistent, less thermal energy (heat) is dissipated from the
heated sensor.
As the velocity 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.
The relationship between Thermal Signal and velocity is Non-Linear.
The following figure is a typical flow curve showing Thermal Signal (heat loss) vs Velocity in glycol.
Thermal Signal 100%
0
Relay 1
Relay 2
Fault
Set Point 1
Set Point 2
Run Mode
Bypass
RUN
SET
12
CLASSIC™
Thermal Signal (%)
Velocity (ft/sec)
Set Point
Max Flow
0
0 5
100
Set Point
Max Flow
Level
The Thermal Signal Increases when the sensor is submerged in a fluid.
Air and other gases have low thermal conductivity and do not dissipate heat as well as liquids.
Therefore the Thermal Signal is smallest when in air or gas. The Thermal Signal increases as the sensor is
submerged. The Thermal Signal is lower (left-most LED illuminated) in a dry motionless state and increases
once the sensor is submerged in fluid. (see Figure 4).
Thermal Signal 100%
0
Relay 1
Relay 2
Fault
Set Point 1
Set Point 2
Run Mode
Bypass
RUN
SET
12
CLASSIC™
Low Level Set Point
Thermal Signal (%)
Time
Set Point
Low Level
0
0
100
Figure 3 - Thermal Signal vs Velocity in Glycol
Figure 4 - Thermal Signal Dry vs Submerged
Low Level

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CLASSIC®800 Product Manual
Introduction
IV. 4-20 mA ANALOG OUTPUT
The 4-20 mA analog output signal corresponds to the Thermal Signal LED Bar Graph.
•The 4-20 mA signal may be displayed either as forward-acting (ascending 4-20 mA) or reverse-acting
(descending 20-4 mA).
• The 4-20 output can be configured to output either 3 mA (LOW) or 21 mA (HIGH) in a fault condition
(NAMUR NE 43).
•When the CLASSIC is in Set Mode, the 4-20 mA Output is disabled and will default to LOW or HIGH.
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.
The Thermal Signal is higher (right-most LED illuminated) when the sensor is submerged in a fluid and decreases
when the sensor is exposed to air or gas in a motionless state (see Figure 5).
Thermal Signal 100%
0
Relay 1
Relay 2
Fault
Set Point 1
Set Point 2
Run Mode
Bypass
RUN
SET 12
CLASSIC™
High Level
Set Point
Thermal Signal (%)
Time
Set Point
High Level
0
0
100
High Level
Interface
The Thermal Signal changes as the (interface) sensor is exposed to an alternate fluid which has a different rate
of thermal conductivity.
The CLASSIC 800 can be set up to detect the difference between most liquids when:
•The different rate of the thermo-conductivity of the two fluids is large enough to detect.
•There is little or no velocity, and the process media is in a stable motionless state.
Thermal Signal 100%
0
Relay 1
Relay 2
Fault
Set Point 1
Set Point 2
Run Mode
Bypass
RUN
SET 12
CLASSIC™
Oil Water
Set Point
Thermal Signal (%)
Time
Set Point
Water
Oil
100
0
Water
Oil
Figure 5 - Thermal Signal Submerged vs Dry
Figure 6 - Thermal Signal in Alternate Fluids
0

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CLASSIC®800 Product Manual
Installation Guidelines
Section
2
Figure 7 - Pump Flow Detection
DISCHARGE: Turbulent Flow INLET: Linear Flow
I. GENERAL
Kayden electronics are designed to be universal for flow, level, interface and temperature applications and with
most liquids, gases and slurries. Ensure:
•Correct setup of the electronics and,
•Proper physical installation of the sensor.
Location
•Consider the need for easy access in order to view the operation and make any required
field adjustments.
•Provide at least 12 inches (30 cm) clearance if possible to allow access for setup and viewing
after installation.
Shock and Vibration
•Install the switch/transmitter so as to minimize any effects due to vibration, 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 -45°C to +200°C (-50°F to +392°F).
Turbulence / Interference
•Pumps, fans, valves, or pipe bends of 90° or more will cause turbulence or significant variance 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 CLASSIC can be mounted on either the inlet or the discharge
side of the pump (the best linear response will be on the inlet side). If the CLASSIC must be mounted
on the discharge side, a straight run before the CLASSIC of at least 5 times the pipe bore diameter is
recommended.
•Keep the sensor away from any devices that may cause physical damage such as: agitators, valves,
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 have specific design
features that enable them to perform well even in difficult locations and applications. Please
consult your local representative or Kayden for questions or installation / setup recommendations.

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CLASSIC®800 Product Manual
Installation Guidelines
Thermal Dispersion
Installation Guidelines
1
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Ideal Process Conditions
Liquids
•Consistent process composition & temperature
•Sufficient straight run flow profile (minimizes
turbulence)
•Recommended minimum of 5 pipe diameters from
any disturbance, preferably 15 pipe diamteres.
Air & Gas
•Consistent process composition and temperature,
ideally clean and dry but not necessarily so long as
process is consistent.
•Sufficient straight run flow profile
(minimizes turbulence)
•Recommended minimum of 5 pipe diameters from
any disturbance, preferably 15 pipe diamteres.
Slurries
•Consistent process composition & temperature
•Sufficient straight run flow profile (minimizes
turbulence)
•Recommended minimum of 5 pipe diameters from
any disturbance, preferably 15 pipe diamteres.
Emulsion
•Consistent process composition & temperature
•Sufficient straight run flow profile (minimizes
turbulence)
•Recommended minimum of 5 pipe diameters from
any disturbance, preferably 15 pipe diamteres.
Undesirable Process Conditions
Liquids
•Inconsistent process composition or temperature
•Insufficient straight run
•Turbulence
Air & Gas
•Inconsistent process composition or temperature
•Wet or saturated air/gas
Slurries
•Inconsistent process composition or temperature
•Insufficient straight run
•Turbulence
Emulsion
•Inconsistent process composition & temperature
•Insufficient straight run
•Turbulence
Solids
•Dry granulated processes are NOT good
candidates for thermal switches
Application Considerations - Flow
GAS VENT
OVERFLOW
INLET
PROCESS TANK
INTERFACE
LEAK DETECTION
HIGH LEVEL
LOW LEVEL
PUMP
PROTECTION
LEAK
DETECTION
Side of Switch
Back of Switch
OVERFLOW
TANK
4Consistent process composition
4Consistent process temperature
4Clean or dirty process
4Liquids
4Dry air & gas
4Slurries
4Emulsion
4Aerated Fluids
8Large temperature swings
8Wet or saturated air/gas
8Solids
8Sediment covering sensing tip
Application Principles - Flow, Level, Interface & Temperature
Thermal Dispersion
Installation Guidelines
1
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Ideal Process Conditions
Liquids
•Consistent process composition & temperature
•Non-turbulent applications
Slurries
•Consistent process composition & temperature
Emulsion
•Consistent process composition & temperature
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
Ideal Process Conditions
Liquids
•Liquid to Liquid
•Consistent process composition & temperature
•Non-turbulent applications
•Large differential in thermal conductivities
Air or Gas to Liquid
•Consistent process composition & temperature
•Non-turbulent applications
•Dry gas
Emulsion
•Consistent process composition & temperature
•Large differential in thermal conductivities
Undesirable Process Conditions
Liquid to Liquid
•Inconsistent process composition or temperature
•High aeration
•High turbulence
•Small differential in thermal conductivities
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 conductivities
Solids
•Dry granulated processes are NOT good
candidates for thermal switches
Application Considerations - Level
Application Considerations - Interface

9
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CLASSIC®800 Product Manual
Installation Guidelines
Thermal Dispersion
Installation Guidelines
1
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Ideal Process Conditions
Liquids
•Consistent process composition & temperature
•Non-turbulent applications
Slurries
•Consistent process composition & temperature
Emulsion
•Consistent process composition & temperature
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
Ideal Process Conditions
Liquids
•Liquid to Liquid
•Consistent process composition & temperature
•Non-turbulent applications
•Large differential in thermal conductivities
Air or Gas to Liquid
•Consistent process composition & temperature
•Non-turbulent applications
•Dry gas
Emulsion
•Consistent process composition & temperature
•Large differential in thermal conductivities
Undesirable Process Conditions
Liquid to Liquid
•Inconsistent process composition or temperature
•High aeration
•High turbulence
•Small differential in thermal conductivities
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 conductivities
Solids
•Dry granulated processes are NOT good
candidates for thermal switches
Application Considerations - Level
Application Considerations - Interface

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CLASSIC®800 Product Manual
Installation Guidelines
II. ELECTRONICS LOCATION CONSIDERATIONS
A remote electronics enclosure is required when ambient temperatures near the sensor exceed 65°C (149°F)
where the electronics will be mounted. The combination of several factors relative to temperature should be
considered when mounting the switch/transmitter:
A. High temperatures of the process material, which may over time, become a convective heat source.
B. High ambient temperature, which may prevent the surrounding air from cooling or insulating the
electronics.
C. Radiant heat, if the switch/transmitter is installed in direct sun in a hot climate, or near a heat source.
D. Mechanical features of the installation such as pipe insulation, heat sinks, cooling fans, etc.
Thermal Dispersion
Installation Guidelines
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Ideal Process Conditions
•Consistent Processes
•Process Temperature -55°C to +200°C
Undesirable Process Conditions
•Process Temperature < -55°C or > +200°C
Note: See Additional Setup Features on Page 41 to configure relays to respond to temperature.
Application Considerations - Temperature