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Kayden CLASSIC Series, Product Manual

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CLASSIC

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 800 Product Manual

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Summary of Contents for CLASSIC Series

Page 1: ...CRN Canadian Registration Number Product Manual CLASSIC Series Thermal Thermal Flow Level Interface Temperature Switches Transmitters CRN Canadian Registration Number...

Page 2: ...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 r...

Page 3: ...ace 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 Horizonta...

Page 4: ...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 Configuratio...

Page 5: ...ble 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...

Page 6: ...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 F...

Page 7: ...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 s...

Page 8: ...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 Ana...

Page 9: ...p 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...

Page 10: ...CLASSIC 800 Product Manual CLASSIC 800 viii kayden com Online Store Thermal Dispersion CLASSIC 800 1 Shop Online Notes...

Page 11: ...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...

Page 12: ...ault 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 i...

Page 13: ...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 micropr...

Page 14: ...erence 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 T...

Page 15: ...al 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...

Page 16: ...ses 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 1 2 CLASSIC High Level Set Po...

Page 17: ...ult 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...

Page 18: ...t run flow profile minimizes turbulence Recommended minimum of 5 pipe diameters from any disturbance preferably 15 pipe diamteres Undesirable Process Conditions Liquids Inconsistent process compositio...

Page 19: ...rocess Conditions Liquids Liquid to Liquid Consistent process composition temperature Non turbulent applications Large differential in thermal conductivities Air or Gas to Liquid Consistent process co...

Page 20: ...ve 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...

Page 21: ...ipe Side Mount Ideal As shown in Figure 10a ensure the sensing tip is inserted to a point between 5 and 75 of the inside diameter of the pipe Avoid locations where sediment may accumulate and isolate...

Page 22: ...ling the switch in vertical piping Kayden strongly recommends installing the switch transmitter at a point of UPWARD process flow to ensure continued total immersion of the sensing tip Vertical Pipe S...

Page 23: ...t seal on mating flanges mount and tighten flanges according to ANSI standards 2 Sensor Orientation To optimize the sensor s performance ensure the sensor is positioned as outlined below As shown in F...

Page 24: ...ity 3 Do not run the transient protection ground wire in the same conduit as the signal wiring as the ground wire may carry excessive current if a lightning strike occurs 2 Wiring Connections to the S...

Page 25: ...isolated 4 20 mA Analog Output which can be wired in a 3 Wire or 4 Wire configuration as shown in Figures 15 16 Wiring RS 485 Interface The RS 485 remote communications port is connected as follows 4...

Page 26: ...ctronics Module one full turn to put a twist in the sensor cable There is no surplus room in the enclosure for excessively long wires Use a quality data communications cable for all non power connecti...

Page 27: ...17 kayden com Online Store CLASSIC 800 Product Manual Installation Guidelines Figure 15 CLASSIC 800 Electronics Module Terminal Wiring Diagram VI LOCAL ENCLOSURE WIRING DIAGRAMS...

Page 28: ...fety of the operator a remote module should be used 2 Enclosed or Difficult to Reach Locations If the sensor is placed in a location that makes reading the electronics module difficult use a remote di...

Page 29: ...ncentric Class B tinned copper 020 PVC insulation individual and overall foil shield color number coded drain and Mylar separator PVC inner jacket aluminum interlock armor PVC outer jacket Voltage Rat...

Page 30: ...20 kayden com Online Store CLASSIC 800 Product Manual Installation Guidelines Figure 18 A06 XP Remote Cable and Connector Spec Drawing...

Page 31: ...21 kayden com Online Store CLASSIC 800 Product Manual Installation Guidelines Figure 19 CLASSIC 800 Wiring Diagram Remote...

Page 32: ...00 Product Manual Installation Guidelines Optional Wiring Methods for 4 20 mA Current Loop Figure 20 DC Powered CLASSIC 4 Wire External Loop Power Current Sinking Figure 21 DC Powered CLASSIC 3 Wire I...

Page 33: ...23 kayden com Online Store CLASSIC 800 Product Manual Installation Guidelines Figure 22 AC Powered CLASSIC 4 Wire External Loop Power Current Sinking...

Page 34: ...isplay As the heater element warms up the switch transmitter will respond to the process conditions and this LED indicator will move to the left Relay 1 and or Relay 2 LEDs may illuminate depending up...

Page 35: ...ds from binding 2 Extra caution should be taken not to over tighten the sensor threads while installing 3 Install the CLASSIC taking into account the orientation of the sensor as described below 4 Kee...

Page 36: ...t 75 Select a Heater Power setting This directly affects the sensitivity to flow Decrease Heater Power Increase Heater Power RELAY 1 Press x 7 Factory Default 1 Select a Node Address for Modbus Comms...

Page 37: ...ese operating instructions These operating instructions include all important information required for the installation and operation of this product They supplement the full Product Manual and the re...

Page 38: ...constant power heater 2 Watt maximum that can be set between 0 100 in 5 increments Since the energy added by the heater is used in determining the Thermal Signal altering the amount of heat changes th...

Page 39: ...of Set Mode Left Arrow Adjust selection as per Set Mode function Right Arrow Adjust selection as per Set Mode function 1 No function in Set Mode 2 No function in Set Mode Display Panel Button Function...

Page 40: ...er consumes typically 300 mA or 4 VA 4 Electronics The CLASSIC 800 Electronics Module is universal and may be installed for testing or operation in all CLASSIC 800 series switches transmitters regardl...

Page 41: ...ed Mode The Run Mode LED will be OFF 2 The Thermal Bar Graph will show the left 6 LEDs 0 to 25 ON to indicate the energized mode is lower than set point or the right 6 LEDs 75 to 100 ON to indicate th...

Page 42: ...ndition Thus in the event of a power failure cable break self test failure or other loss of electrical power the contact is opened the relay is de energized and an alarm will result A common Fail safe...

Page 43: ...f 2 The Thermal Signal Bar Graph shows the 4 20 Fault Mode For 3 0 mA the 0 25 LED s are on solid for 21 mA the 75 100 LED s are on solid 3 To adjust the Mode press and release the Left or Right Arrow...

Page 44: ...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 Set Point 1 LED is ON Set Point 2 LED is ON Single LED displays Set Point 1 Sing...

Page 45: ...LED in Bypass Mode equals 5 seconds therefore the maximum time in Bypass is 100 seconds Instead of measuring from 0 to 100 percent the Thermal Signal Bar Graph shows the delay from 0 to 100 seconds If...

Page 46: ...based liquids and suitable for many applications The CLASSIC 800 allows the Heater Power to be set between 0 and 100 in 5 steps RECOMMENDED HEATER POWER SETTINGS 30 60 heater power 7 13 LEDs Air or Ga...

Page 47: ...To View or Adjust the Node Unit Address 1 Press and release SET until the Relay 2 LED is flashing AND the Run Mode LED is off 2 The Thermal Signal Bar Graph now displays the value of the Software Revi...

Page 48: ...press and release RUN to return to Run Mode Figure 29 4 20 mA 20 4 mA Output Mode 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...

Page 49: ...ncerments the default value of LRV is 0 and URV is 100 as shown below in Figure 24 Adjust the LRV and URV according to Media type oil water or gas Best resolution to configure the Relay Set Points To...

Page 50: ...adjust the URV Single LED indicates LRV Single LED indicates URV Increase LRV Increase URV Decrease LRV Decrease URV 9 Adjust the Bar Graph Lower Range Value 0 and Upper Range Value 100 1 To set the L...

Page 51: ...ching RCM Software access the Unit Configuration view Configuration View 1 Displays CLASSIC unit information and LED status 2 Configure Relay 1 and 2 Actuation Level Thermal Signal or Temperature Cont...

Page 52: ...ING Heater Power Percentage 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Relay 2 FLASHING Modbus Address Appears to the Right can be multiple LEDs 0 5 10 15 20 25 30 35 40 45 50 55 60...

Page 53: ...IC 2 Modbus Implementation Physical Layer RS 485 half duplex 9600 baud 8 bits no parity 1 stop bit Data Link Layer Modbus RTU Node Address 1 to 239 Factory Default 1 3 Node Address The CLASSIC display...

Page 54: ...iguration finish by writing 00F5h to Register 40517 to cause a restart This will ensure the new configuration takes effect Coil Number Address Hex Coil Function 1 0000 Relay 1 2 0001 Relay 2 3 0002 Ru...

Page 55: ...point FF On Higher than set point 40028 001B 40029 001C 4 20 Forward Reverse Mode 0000 4 to 20mA 00FF 20 to 4mA 40030 001D Relay Flow Temperature Mode Upper byte for Relay 1 Lower for Relay 2 00 Flow...

Page 56: ...Address Hex Register Name Description 40513 0200 AD0 Thermal Delta 16 bit unsigned word Inverse of Thermal Signal Thermal Delta of zero 0000h 100 Thermal Signal Thermal Delta of 60 000 EA60h 0 Therma...

Page 57: ...rietary 40520 0207 Proprietary 40521 0208 Proprietary 40522 0209 Proprietary 40523 020A Proprietary 40524 020B Proprietary 40525 020C Proprietary 40526 020D Proprietary 40527 020E Proprietary 40528 02...

Page 58: ...or an approved jacketed cable Ensure that the electrical connection made at the enclosure of the CLASSIC 800 meets all codes and requirements As described in detail in Section 2 Installation Guidelin...

Page 59: ...erface and temperature switch transmitter and is built to require minimal maintenance and no calibration beyond proper installation and setup The Kayden Electronics Modules are completely digital and...

Page 60: ...rate of Thermal Dispersion by default which represents the process condition Flow Level as determined by the setup Other values may be displayed depending on mode 7 RUN In RUN Mode pushing the RUN but...

Page 61: ...turn intermittently Time delay is adjustable through the Kayden RCM software The 4 20 mA output can be programmed to revert to a value of either 3 0 mA or 21 mA to indicate FAULT mode For more informa...

Page 62: ...List Description 0 0 40 45 Thermal Signal 0 100 Thermal Signal 0 100 Thermal Signal 0 100 Heater is Shorted Heater is Open Heater resistance below specification Heater resistance above specification C...

Page 63: ...rse of Action Course of Action Fault Code 5 Fault Code 6 Fault Code List Description 0 0 60 65 Thermal Signal 0 100 Thermal Signal 0 100 RTD 1 is Shorted RTD 1 is Open RTD 1 resistance is below specif...

Page 64: ...gnal 0 100 Thermal Signal 0 100 No Fault Code in Kayden RCMS No Fault Code in Kayden RCMS Security Checksum Error Eeprom memory fault Electronics Module Failure special case with all bargraph LEDs ill...

Page 65: ...de List Description 0 40 75 40 75 Thermal Signal 0 100 Thermal Signal 0 100 No Fault code in Kayden RCMS No Fault code in Kayden RCMS Electronics Module malfunctioning to start Electronics Module powe...

Page 66: ...If within spec investigate sensor plug wiring Confirm correct sensor resistance measurement at sensor plug to Electronics Module If within spec investigate sensor plug wiring RCMS Fault Code RCMS Faul...

Page 67: ...ftware Clicking the reboot button in RCM Software is equivalent to performing a power cycle This does not affect the stored configuration settings 4 Perform a Factory Reset Performing a Factory Reset...

Page 68: ...ress the following 3 buttons LEFT ARROW RIGHT ARROW RUN simultaneously until all LEDs flash or run back and forth A successful reset will be indicated by five consecutives flashes of all LEDs followed...

Page 69: ...f Products that are contaminated with any hazardous material It is solely the Customers responsibility to ensure any and all items returned to Kayden have been thoroughly and completely decontaminated...

Page 70: ...on for details Cycle Power The CLASSIC re starts operation the state e g Fault State is reset the CLASSIC performs a self test and enters RUN mode if no fault conditions are present Delay The CLASSIC...

Page 71: ...d Thermal Signal that the scaled Bar Graph and 4 20 Analog Output will indicate Mode of Operation A CLASSIC can be operating in one of four modes Run the normal operating condition the Run Mode LED is...

Page 72: ...Point 1 The Thermal Signal or Temperature value which determines the actuation of Relay 1 To view the value of Set Point 1 press and hold the 1 button while in Run mode or press the SET button suffici...

Page 73: ...ignal scaled according to the user configured LRV and URV Unit Data Refers to CLASSIC Model Tag Serial Number and Firmware version Also the Unit Data group in Kayden RCMS URV The URV Upper Range Value...

Page 74: ...roduct Manual Outline Dimensional Drawings Appendix A CLASSIC 810 812 CLASSIC 810 Threaded CLASSIC 812 Flanged OD RAD to H RAC 0 840 0 675 Inches cm 2 13 1 71 For dimensions on all process connections...

Page 75: ...65 CLASSIC 800 Product Manual Outline Dimensional Drawings CLASSIC 814 CLASSIC 814 Retractable Packing Gland Flanged to 50 psi Inches cm CLASSIC 814 Retractable Packing Gland Threaded 1 MNPT c w Reta...

Page 76: ...ne Dimensional Drawings CLASSIC 816 Retractable Packing Gland Threaded 1 MNPT c w Retaining Chain to 125 psi CLASSIC 816 Retractable Packing Gland Threaded 1 MNPT to 500 psi CLASSIC 816 CLASSIC 816 Re...

Page 77: ...Store 67 CLASSIC 800 Product Manual Outline Dimensional Drawings CLASSIC 830 832 CLASSIC 832 InLine Flanged Horizontal Inches cm as advised CLASSIC 830 InLine Threaded Horizontal CLASSIC 830 InLine T...

Page 78: ...L A C K 4 B L A C K 4 B L A C K 4 B L A C K 4 B L A C K 4 B L A C K 4 B L A C K 4 B L A C K 4 B L A C K 4 B L A C K 4 B L A C K 4 B L A C K 4 B L A C K 4 B L A C K 4 B L A C K 4 B L A C K 4 B L A C K...

Page 79: ...and Remote Enclosure Side View MOUNT SENSOR AND REMOTE ENCLOSURE USING FNPT ENTRY 1 FNPT ELECTRICAL ENTRY 1 FNPT ELECTRICAL ENTRY 1 FNPT ELECTRICAL ENTRY FIELD WIRING 5 5 5 3 3 3 3 7 7 7 7 8 8 8 8 1...

Page 80: ...SI 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 Flange...

Page 81: ...5 230 VAC 50 to 60 Hz Electronics Microprocessor Controlled with User Interface Two SPDT sealed relay contacts Modbus via RS 485 4 20 mA current loop CODE 1 Local Enclosure Flameproof Aluminum CODE B...

Page 82: ...increments Custom U Lengths Use 4 digits preceded by an I i e 3 5 U I0035 M cm CODE C Input Power 12 24 VDC and 115 230 VAC 50 to 60 Hz Electronics Microprocessor Controlled with User Interface Two SP...

Page 83: ...I0035 M cm CODE C Input Power 12 24 VDC and 115 230 VAC 50 to 60 Hz Electronics Microprocessor Controlled with User Interface Two SPDT fully sealed relay contacts Modbus via RS 485 4 20 mA current lo...

Page 84: ...t Power 12 24 VDC and 115 230 VAC 50 to 60 Hz Electronics Microprocessor Controlled with User Interface Two SPDT fully sealed relay contacts Modbus via RS 485 4 20 mA current loop CODE 1 Local Enclosu...

Page 85: ...and 115 230 VAC 50 to 60 Hz Electronics Microprocessor Controlled with User Interface Two SPDT fully sealed relay contacts Modbus via RS 485 4 20 mA current loop CODE 1 Local Enclosure Flameproof Alum...

Page 86: ...cm increments eg 16 0 0160 M cm 7 72 relative to ange size rating CODE A Bleed Port 1 4 Threaded Standard CODE H V Sensor Orientation Horizontal Vertical CODE 0 1 Pipe Schedule Schedule 40 Schedule 8...

Page 87: ...ermine those best suited to your application View and print Product Manuals View and print Outline Dimensional Drawings Wiring Diagrams Parts Lists View and print Quick Setup Guides View and print Pro...

Page 88: ...temperature set points RCMS can also save the configuration of a CLASSIC which can be saved as a record or used to identically configure other CLASSICs RCMS is only available for computers running Mic...

Page 89: ...S installed to a CLASSIC using a suitable RS 485 adapter the CLASSIC communicates using single duplex RS 485 at 9600 baud Kayden offers both USB to RS 485 adapters as well as RS 232 to RS 485 adapters...

Page 90: ...rt used by the RS 485 Adapter RCMS will connect immediately if the previous settings used are still valid The default Unit number is Unit 1 which is the CLASSIC factory default Node Address The COM po...

Page 91: ...es five views selected using the icons in the upper right Control Panel Shows operating status Graphs Shows thermal signal or temperature trend line Unit Configuration Configuration controls Fault Log...

Page 92: ...nt Panel LEDs Shows operating mode relay status and analog 4 20 mA loop status 6 4 20 mA Current Loop Active inactive if no loop current 7 Save Cancel Click Save Disk Icon to save the configuration ch...

Page 93: ...ntrol Panel View 2 Graph Selector Selector to graph Thermal Signal or Temperature plotting both the reference RTD and the active or heated RTD 3 Graph Region 4 Control Buttons Control buttons to Reboo...

Page 94: ...ter Power Lock Front Panel Analog 4 20 mA Output Direction and Analog 4 20 mA Error Condition 4 Delay Timers 5 Preferences Default unit and Unit of Measurement to show These settings apply ONLY to RCM...

Page 95: ...e CLASSIC configuration to a file by clicking the Save icon in RCMS The default filename will be SerialNumber_TAG_Date_Time kst but this can be edited if desired do not change the kst extension RCMS c...

Page 96: ...Installation Use IX Load CLASSIC Configuration 1 If the CLASSIC is a new device and you configure the Tag on your CLASSIC devices set the Tag first before loading a configuration Press to export conf...

Page 97: ...87 kayden com Online Store RCM Software Installation Use 2 Load the configuration into RCMS Enter the desired Tag text and click the Disk Icon to save to the CLASSIC Click the Load Icon to select a c...

Page 98: ...CLASSIC s current configuration the change warning and disk icon will appear Click the disk icon to save the configuration to the CLASSIC After saving the CLASSIC restarts with the new configuration S...

Page 99: ...t Errors Open or short circuit in the sensor circuitry or wiring or internal heater power supply failure e Communication Errors Modbus communication failure due to incorrect message construction incor...

Page 100: ...CLASSIC 800 Product Manual CLASSIC 800 90 kayden com Online Store Thermal Dispersion CLASSIC 800 1 Shop Online Notes...

Page 101: ...CLASSIC 800 Product Manual CLASSIC 800 91 kayden com Online Store Thermal Dispersion CLASSIC 800 1 Shop Online Notes...

Page 102: ...Weldolet are registered trademarks of Bonney Forge Corporation WFI International This catalog is for informational purposes only The information contained herein is believed to be reliable but no rep...

Page 103: ...chase up to 60 days from the date of invoice for a refund or credit of the product purchase price provided the quantity of Products does not exceed twenty five units nominal restocking fee apply to on...

Page 104: ...For more information about the CLASSIC Series or any of Kayden s other products please visit kayden com DOC PM 800 008 Effective November 2022 Supercedes October 2022 PM 800 008 017 This is a Controll...

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