Hoffer Flow Controls CAT1 Series User manual

Model: CAT1
Microprocessor Controlled Two-Wire
4-20mA Loop Powered Transmitter
USER’S MANUAL
HP-310
June 2018
107 Kitty Hawk Lane ●P.O. Box 2145 ●Elizabeth City, NC 27909
1-800-628-4584 ●[phone] ●Fax [phone]
www.hofferflow.com email: [email protected]

HFC 9708
NOTICE
HOFFER FLOW CONTROLS, INC. makes no warranty of any kind with regard to
this material, including, but not limited to, the implied warranties of merchantability
and fitness for a particular purpose.
This manual has been provided as an aid in installing, connecting, calibrating, operating,
and servicing this unit. Every precaution for accuracy has been taken in the
preparation of this manual; however, HOFFER FLOW CONTROLS, INC. neither
assumes responsibility for any omissions or errors that may appear nor assumes
liability for any damages that may result from the use of the products in accordance
with information contained in the manual.
HOFFER FLOW CONTROLS' policy is to provide a user manual for each item
supplied. Therefore, all applicable user manuals should be examined before
attempting to install or otherwise connect a number of related subsystems.
During installation, care must be taken to select the correct interconnecting wiring
drawing. The choice of an incorrect connection drawing may result in damage to the
system and/or one of the components.
Please review the complete model number of each item to be connected and locate the
appropriate manual(s) and/or drawing(s). Identify all model numbers exactly before
making any connections. A number of options and accessories may be added to the
main instrument, which are not shown on the basic user wiring. Consult the appropriate
option or accessory user manual before connecting it to the system. In many cases, a
system wiring drawing is available and may be requested from HOFFER FLOW
CONTROLS.
This document contains proprietary information, which is protected by copyright.
All rights are reserved. No part of this document may be photocopied, reproduced,
or translated to another language without the prior written consent of HOFFER
FLOW CONTROLS, INC.
HOFFER FLOW CONTROLS’ policy is to make running changes, not model
changes, whenever an improvement is possible. This affords our customers the
latest in technology and engineering. The information contained in this document is
subject to change without notice.
Return Requests / Inquiries
Direct all warranty and repair requests/inquiries to the Hoffer Flow Controls
Customer Service Department, telephone number [phone] or 1-800-628-
4584. BEFORE RETURNING ANY PRODUCT(S) TO HOFFER FLOW
CONTROLS, PURCHASER MUST OBTAIN A RETURNED MATERIAL
AUTHORIZATION (RMA) NUMBER FROM HOFFER FLOW CONTROLS’
CUSTOMER SERVICE DEPARTMENT (IN ORDER TO AVOID PROCESSING
DELAYS). The assigned RMA number should then be marked on the outside of the
return package and on any correspondence.
FOR WARRANTY RETURNS, please
have the following information available
BEFORE contacting HOFFER FLOW
CONTROLS:
1. P.O. number under which the product
was PURCHASED,
2. Model and serial number of the
product under warranty, and
3. Repair instructions and/or specific
problems relative to the product.
FOR NON-WARRANTY REPAIRS OR
CALIBRATIONS, consult HOFFER FLOW
CONTROLS for current repair/ calibration
charges. Have the following information
available BEFORE contacting HOFFER
FLOW CONTROLS:
1. P.O. number to cover the COST of the
repair/calibration,
2. Model and serial number of the product
and
3. Repair instructions and/or specific
problems relative to the product.

HFC 9708
Limited Warranty
HOFFER FLOW CONTROLS, INC. ("HFC") warrants HFC's products
("goods") described in the specifications incorporated in this manual to be
free from defects in material and workmanship under normal use and service,
but only if such goods have been properly selected for the service intended,
properly installed and properly operated and maintained. This warranty shall
extend for a period of one (1) year from the date of delivery to the original
purchaser (or eighteen (18) months if the delivery to the original purchaser
occurred outside the continental United States). This warranty is extended
only to the original purchaser ("Purchaser"). Purchaser's sole and exclusive
remedy is the repair and/or replacement of nonconforming goods as
provided in the following paragraphs.
In the event Purchaser believes the goods are defective, the goods must be
returned to HFC, transportation prepaid by Purchaser, within twelve (12)
months after delivery of goods (or eighteen (18) months for goods delivered
outside he continental United States) for inspection by HFC. If HFC's
inspection determines that the workmanship or materials are defective, the
goods will be either repaired or replaced, at HFC's sole determination, free of
additional charge, and the goods will be returned, transportation paid by
HFC, using he lowest cost transportation available.
Prior to returning the goods to HFC, Purchaser must obtain a Returned
Material Authorization (RMA) Number from HFC's Customer Service
Department within 30 days after discovery of a purported breach of
warranty, but no later than the warranty period; otherwise, such claims shall
be deemed waived. See the Return Requests/Inquiries Section of this manual.
If HFC's inspection reveals the goods are free of defects in material and
workmanship or such inspection reveals the goods were improperly used,
improperly installed, and/or improperly selected for service intended, HFC
will notify the purchaser in writing and will deliver the goods back to
Purchaser upon (i) receipt of Purchaser's written instructions and (ii) the cost
of transportation. If Purchaser does not respond within thirty (30) days after
notice from HFC, the goods will be disposed of in HFC's discretion.
HFC does not warrant these goods to meet the requirements of any safety
code of any state, municipality, or other jurisdiction, and Purchaser assumes
all risk and liability whatsoever resulting from the use thereof, whether used
singly or in combination with other machines or apparatus.
This warranty shall not apply to any HFC goods or parts thereof, which have
been repaired outside HFC's factory or altered in any way, or have been
subject to misuse, negligence, or accident, or have not been operated in
accordance with HFC's printed instructions or have been operated under
conditions more severe than, or otherwise exceeding, those set forth in the
specifications for such goods.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE. HFC SHALL NOT BE LIABLE FOR ANY LOSS OR DAMAGE RESULTING,
DIRECTLY OR INDIRECTLY,FROM THE USE OR LOSS OF USE OF THE GOODS.
WITHOUT LIMITING THE GENERALITY OF THE FOREGOING,THIS EXCLUSION
FROM LIABILITY EMBRACES THE PURCHASER'S EXPENSES FOR DOWNTIME OR
FOR MAKING UP DOWNTIME,DAMAGES FOR WHICH THE PURCHASER MAY BE
LIABLE TO OTHER PERSONS,DAMAGES TO PROPERTY,AND INJURY TO OR DEATH
OF ANY PERSONS.HFC NEITHER ASSUMES NOR AUTHORIZES ANY PERSON TO
ASSUME FOR IT ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OR USE OF
HFC'S GOODS,AND THERE ARE NO ORAL AGREEMENTS OR WARRANTIES
COLLATERAL TO OR AFFECTING THE AGREEMENT.PURCHASER'S SOLE AND
EXCLUSIVE REMEDY IS THE REPAIR AND/OR REPLACEMENT OF NONCONFORMING
GOODS AS PROVIDED IN THE PRECEDING PARAGRAPHS.HFC SHALL NOT BE LIABLE
FOR ANY OTHER DAMAGES WHATSOEVER INCLUDING INDIRECT,INCIDENTAL,OR
CONSEQUENTIAL DAMAGES.

HP-310
CONTENTS
1. INTRODUCTION ........................................................................ 1
1-1 Model Number Designation .................................................. 2
2. SPECIFICATIONS ...................................................................... 5
3. PRINCIPLE OF OPERATION................................................... 7
3-1 Functional Blocks.................................................................. 7
3-1-1 Preamplifier................................................................ 7
3-1-2 Microcontroller .......................................................... 8
3-1-3 Loop Driver................................................................ 8
3-2 System Response Time.......................................................... 9
4. INSTALLATION........................................................................ 11
4-1 Typical Connections............................................................ 11
4-2 Communications Connections............................................. 12
4-3 Wiring.................................................................................. 12
APPENDIX A – Default Configuration............................................ 13
APPENDIX B – Declaration of Conformity..................................... 15
APPENDIX C – Installation and Conditions for Safe Use Drawings
for Certified Systems.................................................................. 17

Introduction 1
HP-310
1. INTRODUCTION
The CAT1 is a microprocessor based loop powered transmitter. The
transmitter accepts a low-level frequency signal on the input and
provides a 4-20mA analog output proportional to the flow rate. CAT1
is compatible with all Hoffer turbine flowmeters as well as the H.O.G.
series positive displacement flowmeters.
The CAT1-L model provides for 20-point linearization of the flow
input signal and outputs a linearized analog current. CAT1 is fully
configurable via an RS232 communications port located under the top
plate. CAT configuration software is a Windows based application that
provides the interface for entering K-factors, frequencies, the timebase
for rate measurement, and calibration of the analog output.
Configuration and remote monitoring can also be performed using any
PC based communications program (e.g., HyperTerminal) or ASCII
terminal.
The standard unit is packaged in an extruded aluminum enclosure for
wall mounting or may be mounted directly on a flowmeter using an
optional NEMA 4X or EX enclosure. An optional bracket is also
available for mounting on standard DIN rail.
An RS232 communications port located under the top plate allows
CAT1 to be remotely configured using DevConfig 3.0, a PC
application program that is included with all units.

Introduction 2
HP-310
1-1 Model Number Designation
MODEL CAT1-( A )-( B )-( C )-( D )
ENCLOSURE STYLE
LINEARIZED ANALOG OUTPUT
INPUT POWER
SPECIAL FEATURES
ENCLOSURE STYLE
MODEL CAT1-(A )-( )-( )-( )
OPTION ( A )
(1) GENERAL PURPOSE.
2.6"L X 2.6"H X 2.6"W MINIMUM MOUNTING SPACE.
(D) 2" LONG DIN RAIL MOUNT SINGLE UNIT.
UP TO 20 CAT1 UNITS CAN BE MOUNTED ON A SINGLE RAIL.
ADD 2" PER UNIT.
(E3) EXPLOSION-PROOF (ALL CONDUIT PORTS ARE ¾” FNPT)
(E3M) EXPLOSION-PROOF (CONDUIT PORTS D2 & D3 = M20 THR’D;
CONDUIT PORTS D1- ¾” FNPT)
(E6) EXPLOSION-PROOF STAINLESS STEEL
(ALL CONDUIT PORTS ARE ¾" FNPT)
(E6M) EXPLOSION-PROOF STAINLESS STEEL (M20 NOT AVAILABLE FOR CANADA)
(CONDUIT PORTS T2 = M20 THR’D; CONDUIT PORTS T1- ¾” FNPT)
NOTE: FOR UL LISTED EXPLOSION-PROOF APPLICATIONS CONTACT FACTORY.
LINEARIZED ANALOG OUTPUT
MODEL CAT1-( )-( B )-( )-( )
OPTION ( B )
(7) 4 TO 20 MA UP TO 20 POINTS.
ACCURACY +/-0.02% OF FULL SCALE.
INPUT POWER
MODEL CAT1-( )-( )-( C )-( )
OPTION ( C )
(D) 8 TO 24 VDC LOOP POWERED.

Introduction 3
HP-310
SPECIAL FEATURES
MODEL CAT1-( )-( )-( )-( D )
OPTION ( D )
(CE) MARK REQUIRED FOR EUROPE
(SP) ANY SPECIAL FEATURES THAT ARE NOT COVERED IN THE
MODEL NUMBER, USE A WRITTEN DESCRIPTION OF THE -SP.
(CFX) 6.75" LONG RISER AND UNION FOR EXPLOSION-PROOF SYSTEM
CERTIFIED ENCLOSURES MOUNTED ON TURBINE. USED WITH
“X” RISER TURBINE OPTION AND (EX) SPECIAL FEATURES
OPTION UNDER FLOWMETERS.
NOTE: IF PROCESS TEMP IS < -40°C AND > 79°C, EX-PROOF
ENCLOSURE MUST BE MOUNTED REMOTELY.
(C) REMOTED MOUNTED FOR EXPLOSION-PROOF SYSTEM
CERTIFIED ENCLOSURE
NOTE: “X” RISER, CERTIFIED UNION, REDUCER AND ENCLOSURE
(TO BE SPECIFIED) MOUNTED ON FLOWMETER.
(X) NO SPECIAL FEATURES
STYLE E3, E3M, E6 AND E6M SYSTEM CERTIFIED RATINGS
- CSA/FM: CLASS I, DIV. 1, GR. BCD; CLASS II, DIV. 1, GR. EFG;
CLASS III, TYPE 4X,
CLASS 1 ZONE 1 AEx db IIB + H2 T6/T5 Gb,
Ex d IIB+H2 T6/T5; Gb; Ex tb T80°C/T86°C IIIC Db; IP66
CLASS I, ZONE 21 AEx tb T80°C/T86°C IIIC Db; IP 66
- ATEX/IECEx: II 2 G Ex db IIB + H2, T6/T5 Gb
II 2 D Ex tb IIIC T80°C/T86°C Db; IP66
T6: -40°C ≤Ta ≤79°C; T5: -40°C ≤Ta ≤85°C
NOTES: 1. IF ENCLOSURE IS MOUNTED ON TURBINE FLOWMETER,
RISER MUST BE SPECIFIED ON METER.
2. INPUTS: ACCEPTS MAGNETIC COIL ONLY.
3. WINDOWS® BASED SETUP AND CABLE KIT CONSISTS OF:
1 EA. HIT2A-301
1EA. CABLE MODEL 26886
1 EA. WINDOWS® BASED SETUP DISC
IF THE CAT IS SHIPPED UN-CALIBRATED, THIS MUST BE
ORDERED TO CALIBRATE OR RE-CALIBRATE IN THE FIELD.

Introduction 4
HP-310
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Specifications 5
HP-310
2. SPECIFICATIONS
Specifications
Input Signal Type: Magnetic pick up, Contact Closure
Input frequency range: 0.2 Hz to 4 KHz
Signal level: 10 mV rms to 30 Vdc
Power supply: Loop Power 8-30 Vdc
Reverse polarity protection
Analog Output: 4-20 mA, 1-5V
Analog Output
Response Time: 1/8 sec.*
Load resistance: Max 650 Ohms at 24 Vdc
Accuracy: +/- 0.02% of full scale @ 20o C
Temperature drift: 40ppm/deg C
Communications RS232 port for Configuration and diagnostics
Operating temperature: T5 and STD: -40o ≤Ta ≤85oC
T6: -40o ≤Ta ≤79oC
Humidity: 0-90% Non-condensing
Enclosure: Extruded aluminum
DIN rail mount
Explosion Proof
Regulatory: CE compliant
*Limited by signal frequency and NST settings. Refer to Section 3.2.
Options
20 Point Linearization

Specifications 6
HP-310
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Principle of Operation 7
HP-310
3. PRINCIPLE OF OPERATION
The CAT1 consists of two printed circuit boards and four main functional
blocks: the Preamplifier, Microcontroller, Loop Driver, and
Communications Interface.
4-20 mA
4-20 mA
RS232
PCA180
FLOWMETER INPUT PREAMP MICROCONTROLLER
LOOP
DRIVER
CONDITIONED SIGNAL
COMMUNICATIONS
INTERFACE
PCA183
3-1 Functional Blocks
3-1-1 Preamplifier
The Preamplifier, located on PCA180, accepts the input from the
flowmeter. The Preamplifier applies amplification, low-pass filtering,
and wave-shaping to the input signal. The wave shaping function
converts the signal into a square-wave before sending it to the
Microcontroller.

8 Principle of Operation
HP-310






 AF
flowrate
mAxmAcurrent 164
3-1-2 Microcontroller
The Microcontroller, located on PCA183, accepts the square-wave
output of the preamplifier and performs all of the calculations that
are required to control the Loop Driver. After measuring the
frequency of the square-wave, the Microcontroller uses the
following equations to compute the flow rate and current.
Where:
Kfactor = Is dependent on the Flow Calculation Method setting and
is either the Average K-Factor or the Linearized K-Factor
from the Frequency / K-Factor table.
FM = Is the Flow rate Units setting of 0, 1, or 2. Where “0” is
for Seconds, “1” is for Minutes, and “2” is for Hours.
CF = Is the Correction Factor setting.
Where:
AF = Is the 20 mA maximum Flow rate value.
If the calculated flowrate is greater than the AF setting, the current
will be set to 24mA to indicate an “Over-range” condition. After
calculating the current, the Microcontroller digitally sends the
current information to the Loop Driver.
3-1-3 Loop Driver
The loop driver, located on PCA183, uses the digital information
sent to it by the Microcontroller to set the current of the loop. The
Loop Driver also supplies power to the Microcontroller.
xCFx
Kfactor
frequency
flowrate FM 60

Principle of Operation 9
HP-310
3-2 System Response Time
The analog output response time to reach steady state due to a change in
the flow rate is approximately 1/8 of a second. When flow stops, the
time for the analog output to return to 4 mA will be between .25 and 8
seconds, depending on the Maximum Sample Time (MST) setting.
MST is adjusted using the NB= (DATA) command, where NB is a value
between 1 and 80. The default MST setting is NB= 1. Adjusting the
MST is only recommended for low flow applications where the
minimum input frequency is below 1 Hz.

10 Principle of Operation
HP-310
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Installation 11
HP-310
4. INSTALLATION
NOTE: CAT1 flow input interfaces with magnetic type pickup coils
and contact closure only. If another type of coil is required, refer to
CAT 2 and CAT3 models.
4-1 Typical Connections
Loop powered with MAG Coil Installation
BA
N/C
N/C
N/C
Mag Pickup Coil
DC+
N/C
POWER
N/C
N/C
SUPPLY
SIG+
ANLG
DC
SIG-
+
LOAD
-+
-
Dip Switch Settings
PCA183
SW1
PCA180
SW1 SW2
11 1

Appendix A – Default Configuration 12
HP-310
4-2 Communications Connections
CAT1 is equipped with RS232 serial communication port for changing
CAT1 configuration, diagnostics functions, and flow monitoring.
Hoffer communication program DevConfig 3.0 must be used to
communicate with CAT1.
The RS232 serial port connector is located under the top plate of CAT1
and may be accessed by removing the two screws from the top plate. A
matching connector is provided with HOFFER HIT2A-301
Communications Cable. CAT1 unit has to be powered from external
supply in order to be able to communicate. Additional power for CAT1
communication circuitry is supplied by the RS232 serial port of the
computer/terminal. COM port settings must be set as follows:
Baud Rate: 2400
Data Bits: 8
Parity: None
Stop bits: 1
Handshaking: None
HOFFER HIT2A-301 Communications Cable
4-3 Wiring
When installing the CAT1, it is good practice to use shielded cable.
The shield should be connected to earth ground near the instrument.
The other end of the shield should not be connected. Connections are
made to the CAT1 terminal blocks using wire gauges 16-28 AWG,
tightening Torque 0.22 to 0.25Nm.
In order to comply with the requirements for Electromagnetic
Compatibility, as per EMC-Directive 2014/30/EU of the Council of
European Community, this wiring practice is mandatory.
Tx 3
Rx 2
DTR 4
SIG COM 5
CD 1
6 DSR
7 RTS
8 CTS
9 NC
DB9
VDC1
VDC2
Pin 2
Pin 1
Molex
0511100660
or
Equivalent

Appendix A – Default Configuration 13
HP-310
APPENDIX A – Default Configuration
FIELD Value
FLOW CALC. METHOD 0 (Average)
K-FACTOR DECIMAL 3
AVERGAE K-FACTOR 1.00
NUMBER OF POINTS IN K-TABLE 10
FREQUENCY 01 4999.981
FREQUENCY 02 4999.982
FREQUENCY 03 4999.983
FREQUENCY 04 4999.984
FREQUENCY 05 4999.985
FREQUENCY 06 4999.986
FREQUENCY 07 4999.987
FREQUENCY 08 4999.988
FREQUENCY 09 4999.989
FREQUENCY 10 4999.990
FREQUENCY 11 4999.991
FREQUENCY 12 4999.992
FREQUENCY 13 4999.993
FREQUENCY 14 4999.994
FREQUENCY 15 4999.995
FREQUENCY 16 4999.996
FREQUENCY 17 4999.997
FREQUENCY 18 4999.998
FREQUENCY 19 4999.999
FREQUENCY 20 5000.000
K-FACTOR 01 1.00
K-FACTOR 02 1.00
K-FACTOR 03 1.00
K-FACTOR 04 1.00
K-FACTOR 05 1.00
K-FACTOR 06 1.00
K-FACTOR 07 1.00
K-FACTOR 08 1.00
K-FACTOR 09 1.00
K-FACTOR 10 1.00
K-FACTOR 11 1.00
K-FACTOR 12 1.00
K-FACTOR 13 1.00
K-FACTOR 14 1.00
K-FACTOR 15 1.00
K-FACTOR 16 1.00
K-FACTOR 17 1.00

Appendix A – Default Configuration 14
HP-310
FIELD Value
K-FACTOR 18 1.00
K-FACTOR 19 1.00
K-FACTOR 20 1.00
MEASURING UNITS GAL
FLOW RATE TIME UNITS MIN
MAX SAMPLE TIME 01
ANALOG OUTPUT LOW 0.000
ANALOG OUTPUT HIGH 100.000
PULSE SCALE OFF
PULSE FREQUENCY 100
ALARM FUNCTION Off
ALARM LEVEL 100.000