Section 4 Quick Setup Guide

Mechanical Installation

NOTE: Observe the following safety guidelines before installing or removing your CLASSIC switch/transmitter:

  • Use proper eye protection and any other safety equipment as required by your installation site.
  • Check electrical power to ensure that all power has been disconnected and “locked out.”
  • Ensure the process tank or line pressures are “zero.”
  • Protect yourself against accidental release of steam, hot water, acids and other potentially hazardous media.
  • Follow all safety precautions as specified for your installation site and local codes.
  1. Before installing your CLASSIC, coat the sensor threads with plant-approved lubricant or sealant to prevent threads 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. Keep in mind the need for easy access, safety of personnel and a suitable environment for the CLASSIC. In general, install the CLASSIC so as to minimize its exposure to vibration, shock, and extreme temperature fluctuations.

Sensor Orientation

The CLASSIC sensor is marked with the universal symbol Arrows. this surface should be flat up and level in a horizontal flow application only. refer to Figures 1 and 2 for flow and level applications; this surface of the hex should be parallel to the direction of change in the process.

Figure 1 - Sensor Orientation for Horizontal Flow
Figure 9 - Sensor Orientation For Horizontal Flow and Level
Figure 2 - Sensor Orientation for Vertical Flow
Figure 9 - Sensor Orientation For Vertical Flow and Level
Figure 6a - Horizontal Pipe, Side Mounting
Horizontal Pipe: Side Mount
Figure 6b - Horizontal Pipe, Top / Bottom Mounting
Top/Bottom Mount
Figure 7 - Horizontal Pipe, Sensor Positioning
Sensor Positioning, Horizontal Pipe

To configure or adjust the CLASSIC, perform the steps in the order indicated by 1 - 4

  • Perform steps 1 & 2.
  • Push RUN and verify Thermal Signal in your Flow/Level operating condition.
  • Push SET and perform steps 3 & 4.

- After each step Press SET to continue or RUN to exit

* If Relay 2 is not being used it is useful to confiure the settings for Relay 2 exactly the same as Relay 1.

START
Relay 1 3

Relay 1 LED illuminated

Use LEFT or RIGHT ARROWS to set Relay Action

LEFT ARROW - Relay on when
lower than set point
(Six far left LEDs illuminated)

RIGHT ARROW - Relay on
when higher than set point
(Six far right LEDs illuminated)

Relay 2 3 *

Relay 2 LED illuminated

Use LEFT or RIGHT
ARROWS
to set
Relay Action

LEFT ARROW - Relay on when lower than set point

RIGHT ARROW - Relay on when higher than set point

4-20 mA Fault
Configuration

Fault LED illuminated

Use LEFT or RIGHT
ARROWS
to set
4-20 mA Fault Action

LEFT ARROW - 3.0 mA

RIGHT ARROW - 21.0 mA

Set Point 1 4

Set Point 1 LED illuminated

Use LEFT or RIGHT
ARROWS
to choose
desired Alarm Action

LEFT ARROW - decrease
set point value

RIGHT ARROW - increase
set point value

Set Point 2 4 *

Set Point 2 LED illuminated

Use LEFT or RIGHT
ARROWS
to choose
desired Alarm Action

LEFT ARROW - decrease
set point value

RIGHT ARROW - increase
set point value

Startup
Bypass Timer

Bypass LED illuminated

Use LEFT or RIGHT
ARROWS
to start a
Bypass Delay for both relays

LEFT ARROW
- decreases delay

RIGHT ARROW
- increases delay

0 to 100 seconds; each LED
incidated 5 seconds

Heater Power 1

Relay 1 LED flashing

Use LEFT or RIGHT ARROWS
to adjust Heater

Power from 0 to 100%

Factory Default is 75%

Click to see a more detailed explanation

Node Address &
Software Revision

Relay 2 LED flashing

Shows software revision.
First 50% of Thermal
Signal Scale

Last 50% indicates the NODE address

Use LEFT or RIGHT ARROWS
to change
NODE Address

4-20 mA
Polarity

Fault LED flashing to setup the 4-20 mA representation

If 0-25% LEDs are
on then 0% = 3.0 mA

If 75 - 100% LEDs are on then
100% = 21 mA

Use LEFT or RIGHT ARROWS
to set 4-20 mA Fault Action

0% Thermal
Signal
2

Set Point 1 LED flashing.
Adjust the Thermal
Signal
LED

Change the 0%
LED Pointer

Use LEFT or RIGHT
ARROWS
to
increase/decrease value

100% Thermal
Signal
2

Set Point 2 LED flashing.
Adjust the Thermal
Signal
LED

Change the 100%
LED Pointer

Use LEFT or RIGHT
ARROWS
to
increase/decrease value

 

You have now completed the
setup for the Kayden
CLASSIc switch.

Press RUN to initiate Operation Mode

or

Press SET to return
to the beginning of
the Configuration Mode.

FINISH
Figure 1 - Class 800 Display Panel
CLASSIC 800 Display Panel

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

Mountain Base Plate Termainl Assembly

Mounting Base Plate /
Terminal Assembly

Mounting Base Plate
Wire Positions
LOOP - VAC-H
LOOP + VAC-N
R2NC COM
R2NO +VDC
R2CM 485-T
R1NC 485-A (-)
R1NO 485-B (+)
R1CM 485-C
RUN MODE – Run Mode LED is ‘Flashing’
RUN Press and hold to view the Software Revision and Node Address
SET Press and release to enter Set Mode (see table below)
Left Arrow Press and hold to view the LED-0 and LED-100 Pointers on Baseline graph
Right Arrow Press and hold to view Thermal Signal data on Baseline Graph
1 Press and hold to view Set Point 1 on Scaled Bar Graph View
2 Press and hold to view Set Point 2 on Scaled Bar Graph View
SET MODE – Run Mode LED is ‘Off’
RUN Press and release to exit Set Mode and return to Run Mode
SET Press and release to proceed to next step 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
CautionCaution

Installation, connection and maintenance must be carried out by expert technicians who have read these 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 relevant national regulations with respect to the equipment as well as with the maintenance activities.

POWER, AC/DC

Either AC or DC voltage can be used to power the CLASSIC:

  • For AC power, connect the HOT line to VAC-H, the NEUTRAL to VAC-N and the GROUND wire to the green grounding screw, also indicated by the ground symbol.
  • For DC Power, connect the positive voltage to +VDC and the common or negative to COM.
CautionCaution

Never power on the circuits in a potentially explosive area without first installing the enclosure cover.

Always lock the cover in place. This may be required by your local safety or electrical code.

RELAY OUTPUTS

The CLASSIC features two independent set points each with its own mechanical relay for output. The connections for the contacts of these relays are:
R1COM Common or pole contact for Relay 1
R1NC Normally closed contact for Relay 1 when the coil is not energized
R1NO Normally open contact for Relay 1 when the coil is not energized
R2COM Common or pole contact for Relay 2
R2NC Normally closed contact for Relay 2 when the coil is not energized
R2NO 485-A (-)Normally open contact for Relay 2 when the coil is not energized

NOTE: For fail-safe installations, the desirable relay is usually energized and the circuit closed. Use the normally open contacts for fail-safe installations since they are closed when the relay is energized.

 

MAINTENANCE

Your Kayden instrument requires very little maintenance as there are no moving parts.

Without detailed knowledge of the environment parameters of the application surroundings and process data media, Kayden cannot make specific recommendations for periodic inspection, cleaning, or testing procedures.

Kayden does however suggest general guidelines for maintenance (see the CLASSIC Product Manual). Use operating experience to establish the frequency of each type of maintenance.

 

CALIBRATION

The CLASSIC does not require any calibration for use as a switch/transmitter. Once properly setup, the CLASSIC will be as stable and repeatable as the process in which it is installed.

It may be necessary to check or repeat the setup procedure if the process changes dramatically over time.

 

HEATER POWER

The CLASSIC uses a 2-watt heater 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 the Thermal Signal.
  • If the heater power is changed more than 5% (1 LED) this may require the 0% & 100% Thermal Signal to be similarly adjusted in order not to lose sensitivity and reaction time.
  • The Factory Default Heater Power setting of 75% (1.5 watts) is suitable for most Flow applications with Hydro-carbons.
  • GUIDELINES FOR SETTING HEATER POWER:

    • 20 - 35% heater power (5-8 LEDs) - Air or Gas (Flow) (depending on velocity)
    • 60 - 75% heater power (13-16 LEDs) - Oil or Hydrocarbon based liquids (Flow, Level & Interface)
    • 80 - 100% heater power (17-21 LEDs) - Water or non-viscous liquids (Flow, Level & Interface)

The faster the flow rate (velocity) the more heat is required. In level applications the amount of heat, in part, determines the reaction time.

The CLASSIC 800 Series has a “Smart Heater” function (see the “Classic 800 Product Manual”). If a heater operates constantly in a no flow or dry condition, a “Thermal Offset” can occur. This means the heater may affect the reading from the reference RTD.

The microprocessor will automatically reduce the heater power setting to a lower power rating when the probe is “dry” or in a “no-flow” condition. When the process media touches the sensors, or flow begins again, the original heater power setting is restored.