Section 5 Maintenance

  1. General Information

    With proper installation the CLASSIC 800 will require very little maintenance, as there are no moving parts subject to wear. Following a few simple guidelines will ensure years of dependable service.

    1. Cover

      In accordance with CSA, FM, UL and local codes the cover must be properly installed at all times. The threads of the cover should be lightly coated with a lubricating compound to prevent seizing, freezing and corrosion. Spray lubricants are not recommended.

    2. Process & Conduit Connections
      • In accordance with CSA, FM and local codes all power and communication wiring should be enclosed either in conduit 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 Guidelines”, ensure that the sensor is installed with the proper orientation, to the proper depth and coat threads with a thin layer of thread tape or sealant/ lubricant.
      • Most Fault conditions and reported “failures” are actually caused by loose, broken or improper electrical connections. Ensure that the connections for the sensor, input power and relay output are correct and secure.
    3. Sensing Elements
      • The alloy (Stainless Steel, Titanium, Hastelloy, etc.) sensors require no periodic maintenance, but any deposits or scaling should be removed from the sensor tip as necessary.

        Use the appropriate cleaning device or material relative to your process (example: cloth, brush, wire brush, steel wool, sandpaper, water, detergent, compatible solvents to the sensor material, etc.).


      As described in detail in Section 2 “Installation Guidelines”, proper physical installation of the sensor is critical to the operation of the switch/transmitter in terms of sensitivity and response time.

      Because sediment will collect at the bottom of any vessel, and entrained gases will always collect at the top of any vessel, 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.

    4. Electronics Module
      • Proper ESD (electrostatic discharge) procedures should be observed when handling the Electronics Module.
      • A remote electronics enclosure system is required when ambient temperatures 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:

        1. High temperatures of the process material, which may over time, become a convective heat source.
        2. High ambient temperature, which may prevent the surrounding air from cooling or insulating the electronics.
        3. Radiant heat, if the switch/transmitter is installed in direct sun in a hot climate, or near a heat source.
        4. Mechanical features of the installation such as pipe insulation, heat sinks, cooling fans, etc.
    5. Adjustment & “Calibration”

      The CLASSIC 800 is a digital flow, level, interface 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 have no moving parts or mechanical trim pots that could be effected by vibration or high unit cycles.
      • True temperature compensation is programmed into the firmware and is continuously factored into the operation algorithms of the microprocessor.
      • The heater is a separate element from the sensors and is itself directly controlled by the microprocessor.

      Therefore, once properly setup, the CLASSIC 800 will be as stable and repeatable as the process in which it is installed. For instance should the application change from Flow to Level or the media change from Hydrocarbon to Water-based or the Flow Rate increase or decrease significantly it may be necessary to check and/or change the setup parameters (Range, Heater Power, Set Point).

    6. Using the Kayden RCM Software to Satisfy Preventative Maintenance Requirements

      One feature of the Kayden RCM Software* is the Configuration function which automatically stores all setup information and displays it on the Configuration screen within the software whenever the CLASSIC 800 is connected to a PC. This information may be named, stored and emailed as a file to preserve all operation setup parameters.

      Therefore, the user may construct “Maintenance Only Setup Parameters” with a slightly different heater setting and set point and save these as a file. This Maintenance Setup File could then be loaded in place of the normal operating setup which will cause the display and relay function to change accordingly. Once this change is observed the normal setup can be reloaded and the preventative maintenance requirement satisfied.

      * The Kayden RCM Software is available upon request, at no charge on CD, when a new CLASSIC 800 is purchased. Additional copies may be obtained at no charge from In addition to the software you will need the SCA Serial Communication Adapter, the USB to Serial converter and communication cable. These can be ordered online at