Section 3 Setup & Operation

Figure 1 - 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

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

Figure 14 - Control Functions RUN/SET Mode

GENERAL INFORMATION
- Warm-up
  
  At initial start-up or restart allow approximately 90 seconds for the heater element to warm-up and the switch/transmitter to stabilize before making any adjustments.
- Diagnostics
  
  As described in greater detail in Section 7 “Troubleshooting” an automatic diagnostic program runs continuously when power is connected.
  
  To prevent the possibility of intermittent failures the CLASSIC 800 will display a Fault condition in the event of improper electrical connection, loss of power and / or extensive physical damage.
- Universal Power
  
  The CLASSIC 800 will accept either 12-24 VDC or 115-230 VAC but must be wired accordingly.
  
  The CLASSIC 800 may not be loop powered. At a minimum the unit requires 4 wires: Hot and Neutral for AC/DC, R1COM and R1NO (see Figure 12 - CLASSIC 800 Wiring Connection Diagram).
  
  Power consumption for the CLASSIC 800 is rated at a maximum of 6 VA (watts). The maximum rating is based on the assumption that both relays are energized, the heater is at maximum power and several LEDs are illuminated.
  
  An application involving the relay energized and the heater at 80% power consumes typically 300 mA or 4 VA.
- Electronics
  
  The CLASSIC 800 Electronics Module is universal and may be installed for testing or operation in all CLASSIC 800 series switches/transmitters regardless of sensor configuration. Therefore, the Electronics Module may be considered a universal spare part and the most essential troubleshooting tool for all applications.
CONTROL SETTINGS and SETUP PROCEDURES
- Quick Setup Guide
  
  The CLASSIC 800 Quick Setup Guide, Section 4 “Quick Setup Guide”, contains the required information to facilitate setup and adjustments.
  
  The setup procedures contained in Section 3 of this manual are listed in the same order as the programming matrix in the Quick Setup Guide which is included in this manual as Section 4.
  
  Additional copies of the Quick Setup Guide may be obtained from Kayden.com.
1. View or Adjust Relay 1 & 2 Energized Mode
  
  Both relays on the CLASSIC 800 have Normally Open and Normally Closed contacts. The terms ‘Open’ and ‘Closed’ refer to the de-energized state of the relays. Normally Open or Normally Closed operation for Relay 1/ Relay 2 is determined by wiring the contacts accordingly (see Figures 11 & 12).
  Note:
  Low flow means less Thermal Signal as represented by the CLASSIC 800’s Thermal Signal Bar Graph. Some configurations may require one or both relays to be energized on high flow, i.e. higher than the set point.
  - RUN advances to Run Mode
    
    SET advances to next Setup step
    
    Run Mode LED is Off in Setup Mode
    Figure 15 - Relay Energized Mode
  - To View or Adjust the Relay 1 & 2 Energized Modes:
    1. Press SET until the Relay 1 or Relay 2 LED is on solid and the Run Mode LED is off.
    2. The Thermal Signal Bar Graph shows the Relay Mode. For Low Flow the first six (0-25% LED’s) are on solid; for High Flow the last six (75-100% LED’s) are on solid.
    3. To adjust the Mode, press and release the Left or Right Arrow keys.
    4. When satisfied with your configuration, press and release SET to continue to the next programmable variable OR press and release RUN to return to Run Mode.
  - Failsafe Relay Configurations
    - The term “Fail-safe” refers to a method of wiring and programming control instrumentation commonly used in hazardous locations/applications.
      - In a “Fail-safe” application the CLASSIC 800 switch/transmitter is wired and programmed so that the output relay is energized in normal process operating condition.
      - 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” setup for NO FLOW CONDITION, PUMP PROTECTION:
      - Connect the relay contact wires to Normally Open (R1NO, R1CM)
      - Program the relay(s) to energize above set point.
      - Depending on application and setup of the switch/transmitter, the relay contact(s) will OPEN (deenergize) when:
        
        The Thermal Signal decreases due to a decrease or loss of flow/level
        
        Power is lost to the switch/transmitter as described above.
2. View or Adjust the 4–20 mA Fault Mode Configuration
  
  The 4-20 mA output is used to monitor the analog data from the sensor, such as a self-test fault. The 4-20 mA output can be programmed for a value of 3.0 mA or 21 mA.
  
  Note: For more general information on fault conditions, see Section 7 “Troubleshooting”.
  RUN advances to Run Mode
  
  SET advances to next Setup step
  
  Run Mode LED is Off in Setup Mode
  Figure 16 - 4-20mA Fault Mode Configuration
  To View or Adjust the Fault Current:
  1. Press and release SET until the Fault LED is on solid; the Run Mode LED will be off.
  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 keys.
  4. When satisfied with your configuration, press and release SET to continue to the next programmable variable OR press and release RUN to return to Run Mode.
3. View or Adjust Set Points 1 & 2
  Notes:
  1. Viewing either Set Point 1 or 2 from the Display Panel does not require entering the Manual Setup Mode. While still in RUN Mode, press and hold 1 or 2 to view the programmed Set Point.
  2. In this context “Set Point” refers to the point(s) within the user defined range at which Relay 1 and Relay 2 energize/de-energize.
  3. Set Point 1 always corresponds to Relay 1 and Set Point 2 always corresponds to Relay 2.
  Figure 17 - Set Point 1 & 2 Configuration
  
  To View or Adjust the Set Points
  1. Press and release SET until the Set Point 1 or Set Point 2 LED is on solid and the Run Mode LED is off.
  2. One LED on the Thermal Signal Bar Graph will illuminate, corresponding to the present setting of the selected set point.
  3. To adjust the selected Set Point, press and release the Left or Right Arrow keys.
  4. When satisfied with your configuration, press and release SET to continue to the next programmable variable OR press and release RUN to return to Run Mode.
4. View or Adjust the Start-up Bypass Timer
  
  The Start-up Bypass Timer provides a means to energize both relays when the switch/transmitter is initially powered on. This feature provides a means to automatically restart a pump that has been turned off by the switch/transmitter without the need for additional hardware.
  Notes:
  1. The Start-up Bypass Timer is commonly used to automatically re-start a pump after the specified (programmed) time delay.
  2. During the Bypass Delay, both relays are energized regardless of their Mode or the value of the Thermal Signal.
  3. When the Start-up Bypass Timer is in use, neither Setup Mode nor the Thermal Signal Bar Graph are available until the programmed delay time expires.
  The Thermal Signal Bar Graph displays the delay (each LED right of the zero 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 the Start-up Bypass Timer is set to zero then no Bypass Delay will occur. (The Factory Default setting is zero seconds.)
  
  Figure 18 - Start-up Bypass Timer
  
  To View or Adjust the Fault Current:
  1. Press and release SET until the Bypass LED is on solid and the Run Mode LED is off.
  2. One LED on the Thermal Signal Bar Graph will illuminate corresponding to the present setting of the Start-up Bypass Timer.
  3. To adjust the Start-up Bypass Timer, press and release the Left or Right Arrow keys.
  4. When satisfied with your configuration, press and release SET to continue to the next programmable variable OR press and release RUN to return to Run Mode.
5. View or Adjust the Heater Power
  - The correct heater setting is determined primarily by the process media and secondarily by the velocity of the process.
    
    The heater setting is a key factor in determining the sensitivity and reaction time of the switch/transmitter.
  - The Factory Default setting of 75% is optimal (70 - 80% depending on velocity) for Hydrocarbon-based liquids and suitable for many applications.
    
    The CLASSIC 800 allows the Heater Power to be set between 0% and 100% in 5% steps.
    - GUIDELINES FOR SETTING HEATER POWER:
      - 30 - 60% heater power (7-13 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’s sensor heater produces 2 watts at full power.
    - The main processor continuously and automatically monitors the heater element. This is the “Smart Heater” function.
      
      When the Thermal Signal decreases dramatically or goes to zero, the main processor will automatically reduce the output of the heater from the user setting to a lower power rating in order to prevent the creation of a “Thermal Offset”. This function will be automatically repeated until such time as the Thermal Signal increases
  Note: This function may be clearly observed in the graph function of the RCM software.
  - Figure 19 - Setting the Heater Power
6. View or Adjust the Node Address & View the Software Revision
  
  The Software Revision and Node Address are displayed on the Thermal Signal Bar Graph as two binary bytes. The Software Revision is not adjustable but can be useful should telephone support be required.
  
  The Factory Default for the Node Address is 1 (one).
  
  Adjusting the Node Address is only required if setting up a multi-point RS-485 network or adding the CLASSIC 800 to an existing RS-485 network.
  
  The Software Revision and Node Address can also be viewed while in Run Mode by pressing and holding the RUN key.
  - Figure 20 - Software Revision & Node (Unit) Number
  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 Revision and the setting of the Node Address.
  3. The Node Address is displayed in binary using the eight LED’s on the righthand side of the Bar Graph. Refer to Section 6 “Binary Table”, for a listing of Node Address to LED patterns.
  4. To adjust the Node Address, press and release the Left and Right Arrow keys.
  5. When satisfied with your configuration, press and release SET to continue to the next programmable variable or press and release RUN to return to Run Mode
7. View or Adjust the 4-20 mA Output Configuration (Forward or Reverse)
  
  The 4-20 mA output is used to monitor the analog data from the sensor. The current output is an analog signal representing the Scaled Thermal Signal Bar Graph View.
  
  Operator may select:
  - 0% as 4 mA ascending to 20 mA
  - 100% as 4 mA descending to 20 mA
  - Figure 21 - 4-20 mA & 20-4 mA Output Mode
  To View or Adjust the 4-20 mA Output Current Mode:
  1. Press and release SET until the Fault LED is flashing AND the Run Mode LED is off.
  2. The Thermal Signal Bar Graph shows the 4-20 Output Mode.
    - For 0% equal to 4 mA the 0-25% LED’s are on solid.
      
      For 100% equal to 4 mA the 75-100% LED’s are on solid.
  3. To adjust the Mode, press and release the Left or Right Arrow keys.
  4. When satisfied with your configuration, press and release SET to continue to the next programmable variable OR press and release RUN to return to Run Mode.
8. View or Adjust the 0% & 100% Thermal Signal Scaled Bar Graph View
  
  There are two views of the Signal Data available for display on the Thermal Signal Bar Graph.
  1. The Baseline Bar Graph View shows the maximum possible span/complete thermal range that the CLASSIC 800 is capable of measuring.
  2. The Scaled Bar Graph View focuses only on the portion of the total thermal range required for each application (oil, water, gases).
    
    Once the 0% Thermal Signal and 100% Thermal Signal settings are defined, this range (Scaled Bar Graph View) will be displayed as 0% to 100% on the Thermal Signal Bar Graph at all times.
    
    The Scaled Bar Graph View can only be displayed by pressing and holding the Left Arrow while in Run Mode. When the zero (0%) and 100% LEDs illuminated, the switch is set for the widest range possible.
  To illustrate this principle refer to Figure 22.
  
  The LED-0 pointer is shown set to 50% of Baseline and the LED-100 pointer is shown set to 75% of Baseline. The result is that the Scaled View appears to zoom in on the area of the Baseline data that is framed by the LED- 0 and LED-100 Pointers.
  
  The data, indicated by the single illuminated LED, is at 55% of Baseline but on the Scaled View it is shown as 20%. This is because the data is at only 20% of the values framed by LED-0 and LED-100.
  - Figure 22 - Scaled Bar Graph View vs. Baseline Bar Graph View
9. View or Adjust the 0% & 100% Thermal Signal LEDs:
  
  There are two views of the Signal Data available for display on the Thermal Signal Bar Graph.
  1. Press and release SET until the Set Point 1 (LED-0) or Set Point 2 (LED-100) status LED is flashing and the Run Mode LED is off.
  2. The Thermal Signal Bar Graph now shows the setting of the LED Pointer.
  3. To adjust the LED Pointer, press and release the Left or Right Arrow keys.
  4. When satisfied with your configuration, press and release SET to continue to the next Programmable Variable OR press and release RUN to return to Run Mode.
  - Figure 23 - Setting the 0% & 100% Thermal Signal
  Kayden RCM Software
  - Kayden designed powerful software specifically for remote configuring and monitoring of Kayden thermal flow, level, interface and temperature switches/transmitters from a PC.
    
    Remote connectivity lets you operate and/or configure your CLASSIC 800 from a central location.
    
    The RCM Software provides the ability to view or adjust: Set Points, Relay Modes, Temperature Mode, Start-up Bypass Timer, Heater Setting and Lock or Unlock the Display Panel.
    
    The RCM Software includes a Thermal Graph screen which provides a graphical display of the process condition. The Thermal Graph displays the Thermal Signal and the Relay Set Point in either a line graph or chart recorder format. This feature may be useful for limited trending of the switch/transmitter.
    Notes:
    To communicate with your Kayden CLASSIC 800, you will require an RS-485 adapter such as the Kayden SCA.
    
    Additional copies or the latest revision of the RCM Software may be downloaded at our website, Kayden.com, or call Kayden at +1-403-253-1423.
  RS-485 Remote Communications
  - The RS-485 remote communications port is connected as follows:
    
    485 (C)
    
    The common ground reference used on some three wire half-duplex systems. While no current should pass through this conductor, it should not be used as a shield.
    
    If using a shield it should only be connected to ground at one point, usually at the PLC or computer.
    
    485 (A-)
    
    The A or negative data line.
    
    485 (B+)
    
    The B or positive data line
    
    485 (T)
    
    This pin provides an AC coupled terminator of 120 ohms when shorted to 485 (A-). This feature eliminates the need to add an external terminator.
    
    It is AC coupled to reduce power consumption when the 485 bus is idle. For more details on AC vs. DC termination of RS-485 networks, contact Kayden technical support at kayden.com.
    
    Notes:
    
    For more information see Figures 11 & 12