Kayden electronics are designed to be universal for flow, level, interface and temperature applications and with most liquids, gases and slurries. The user can take advantage of this flexibility through:
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 allow them to perform well even in difficult locations and applications.
Please consult your local representative or Kayden for questions or installation / setup recommendations.
The CLASSIC 800 is a flow, point level, interface and temperature sensing device. The sensor tip must be inserted in the proper location and to the proper depth in order to accurately react to your process conditions.
The following information, including Figures 5 through 9, should be considered as text book examples for proper installation.
Most pipe connections for instrumentation are a variation of a butt-weld-type such as the weldolet or threadolet shown in Figure 4. The length of this connection must be added to the pipe diameter when determining the insertion length for the sensor. The Kayden literature refers to this “insertion length” dimension as the “U” length, Figure 5.
Horizontal Pipe – Side Mount (Ideal)
As shown in Figure 6a, ensure 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 the sensing tip from the process.
Horizontal Pipe – Top Mount
Gas will always collect at the top of any pipe, ensure sensing tip is inserted to a point where it will be constantly and fully exposed to the desired process media.
Horizontal Pipe – Bottom Mount
Because sediment will always collect at the bottom of any pipe, ensure sensing tip is inserted to a point where it will be constantly and fully exposed to the desired process media. Avoid locations where sediment may accumulate and eventually isolate the sensing tip from the process.
For vertical pipe mounting, Kayden strongly recommends installing the switch/transmitter at a point of UPWARD process flow to ensure continued total immersion of the sensing tip.
If there is no other option except to install the flow switch/transmitter in a vertical pipe with downward flow, the following information must be considered:
Vertical Pipe – Side Mount (Acceptable)
Vertical Pipe – Side Mount – Downward Flow:
Vertical Pipe – Side Mount – Top & Bottom Mount (Less Desirable)
Having followed the installation guidelines in Section 2, “Installation Guidelines”, Subheadings I through III, you may now proceed with installation.
Avoid locations where sediment may accumulate and eventually isolate the sensing tip from the process.
Sediment covering the sensor tip may prevent the switch/transmitter from being able to sense any changes in the process as the sediment will insulate the sensing tip.
Ensure all electrical installation is in accordance with all applicable local and national electrical code requirements. The CLASSIC 800 series standard configuration includes an explosion-proof enclosure.
The CLASSIC 800 Series is approved to Factory Mutual (FM), Canadian Standards Association (CSA) and Underwriters Laboratory (UL) standards and must be installed in accordance with these applicable codes and standards.
Power Supply: For applications using a DC power supply, ensure the power has less than 2% ripple.
Switch/Transmitter Enclosure: The switch/transmitter enclosure must be grounded in accordance with local and national electrical codes. The most effective grounding method is a direct internal connection to earth ground with minimal impedance.
The (green) Internal Ground Connection screw is located inside the electrical enclosure and is identified by the universal ground symbol.
To make the electrical connections to the CLASSIC 800, it is necessary to remove the Electronics Module as follows:
Turn the external stainless steel locking screw clockwise with a 5/32” (#10) Allen Key and turn the cover counter clockwise until it can be lifted off the enclosure.
To remove the Electronics Module, pull upward with an equal force on both stainless steel handles. Care should be taken to avoid damaging the sensor cable attached to the Electronics Module. Practice ESD (electrostatic discharge) procedures when handling the Electronics Module.
Electrostatic discharge may damage the electronics! Never place the Electronics Module on a surface or pass it to another person in a way that would allow an electrostatic discharge to pass through it.
Refer to Figure 10.
The Electronics Module must be removed from the enclosure before any wiring can be connected to the Mounting Base Plate.
Disconnect the sensor connector from the Electronics Module by disengaging the locking tab and pulling (with fingers) on the corners of the small black connector. Do not pull directly on the wires. The use of pliers may damage the connector.
The CLASSIC 800 will accept 12-24 VDC or 115-230 VAC input power via the universal power supply by wiring the Electronics Module according to input power available.
Repeat steps 2B and 2C in reverse order. The cable from the sensor to the Electronics Module should be gently positioned between the outside of the Mounting Base Plate with green & black connectors and the inside of the enclosure. If the excess length of the cable interferes with the mounting of the Electronics Module then gently rotate the Electronics Module one full turn to put a twist in the sensor cable.
At the conclusion of the self-test, if there is no fault condition present, the Run Mode LED will begin flashing and a single LED (in the Thermal Signal Bar Graph) will appear on the display.
As the heater element warms up, the switch/transmitter will respond to the process conditions and this LED indicator will move to the left.
When the sensor is alternated between wet and dry conditions (in and out of the media), the illuminated Thermal Signal LEDs should move and the relay set point LED(s) should change state (ON/OFF).
The degree and speed of the movement of the Thermal Signal LED depends completely on how well the current setup of the CLASSIC 800 corresponds to the process conditions of the test.*
* Because a complete setup may not have yet been performed allow at least 20 - 30 seconds for the sensor and relay to react when alternating between wet and dry conditions (in and out of the media).