Hoffer Flow Controls CAT1 Series User manual

Microprocessor Controlled Two-Wire 4-20mA
Loop Powered Transmitter
Model: CAT1
HP-310
February 2008
USER’S MANUAL
HP-310
April 2009
107 Kitty Hawk Lane, P.O. Box 2145, Elizabeth City, NC 27906-2145
800-628-4584 252-331-1997 FAX [phone]
www.hofferflow.com E-mail: [e-mail]

HFC 9708
Notice HOFFER FLOW CONTROLS, INC. MAKES NO WARRANTY OF
ANYKINDWITHREGARDTOTHISMATERIAL,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 products in accordance with
information contained in the manual.
HOFFERFLOWCONTROLS’ policyistoprovideausermanualforeach
item supplied. Therefore, all applicable user manuals should be examined
before attempting to install or otherwise connect a number of related
subsystems.
Duringinstallation,care mustbetakentoselectthecorrectinterconnecting
wiringdrawing. Thechoiceofanincorrectconnection drawingmayresult
in damage to the system and/or one of the components.
Please review the complete model of each itemto 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 itto the system. In many cases, a systemwiring
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 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 warrantyand 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 (RMS) 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.
FORWARRANTYRETURNS,pleasehave
thefollowinginformationavailableBEFORE
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
currentrepair/calibrationcharges. 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
HOFFERFLOW CONTROLS,INC. (“HFC”)warrantsHFC’sproducts(“goods”)described in
the specifications incorporated in this manual to be free from defects in material and
workmanship undernormal useand service, but only if such goods have been properly selected
fortheserviceintended,properlyinstalledandproperlyoperatedandmaintained. Thiswarranty
shall extend for a period of (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’ssoleandexclusiveremedyistherepairand/orreplacementofnonconforminggoods
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 the continental United States) for inspection
by HFC. If HFC’s inspection determines that the workmanship or materials are defective, the
goodswillbe either repaired or replaced,atHFC’s sole determination,freeof additional charge,
and the goods will be returned, transportation paid by HFC, using the 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
selectedfor serviceintended, HFCwill notifythe purchaserin writingandwilldeliverthegoods
back to purchaser upon (i) receipt of Purchaser’s written instructions and (ii) the cost of
transportation. If Purchaser does not respond within 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 any 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 bee 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 WARRANTLY 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 OF LOSS OF USE OF THE GOODS. WITHOUT
LIMITING THE GENERALITY OF THE FOREGOING, THIS EXCLUSION FROM
LIABILITYEMBRACESTHEPURCHASER’SEXPENSESFORDOWNTIME,DAMAGES
FORWHICHTHEPURCHASERMAYBELIABLETOOTHERPERSONS,DAMAGESTO
PROPERTY,AND INJURY TOOR DEATHOF ANYPERSON. HFCNEITHERASSUMES
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
AGREEMENTS OR WARRANTIES COLLATERAL TO OR AFFECTING THE
AGREEMENT. PURCHASER’SSOLEANDEXCLUSIVEREMEDYISTHEREPAIRAND/OR
REPLACEMENT OF NONCONFORMING GOODS AS PROVIDED IN THE PRECEDING
PARAGRAPHS. HFCSHALLNOTBELIABLEFORANYOTHERDAMAGES WHATSOEVER
INCLUDING INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES.
Disclaimer:
Specifications are subject to change without notice.
Some pages are left intentionally blank.

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
3-1-4 Communications Interface --------------------------------- 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 – Communications-----------------------------------------15
Message Format And Timeout -----------------------------------------15
Messages ------------------------------------------------------------------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.
This instrument is designed to conform to the EMC-Directive of the
Council of European Communities 89/336/EEC and the following
standards:
Generic Emission Standard EN 50081-1
Residential, Commercial & Light Industry Environment.
Generic Emission Standard EN 50081-2
Industrial Environment.
Generic Immunity Standard EN 50082-1
Residential, Commercial & Light Industry Environment.
Generic Immunity Standard EN 50082-2
Industrial Environment.

2 Introduction
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.
(3/O) MEETS CLASS 1, DIV. 1 AND 2, GROUPS C, D
CLASS II, GROUPS E, F, G
CLASS III
NEMA 4X WITH ‘O’ RING
CERTIFIED CSA, UL
BODY KILARK #GECCT-3, STOCK #200-0945
FLAT COVER, STOCK #200-0533, KILARK #GECBC
(3B/O) MEETS CLASS I, DIV. 1 AND 2, GROUPS A, B, C, D
CLASS 1, ZONES 1 AND 2, GROUPS IIB + H2, IIA
CLASS II, DIV. 1 AND 2, GROUPS E, F, G
CLASS III
NEMA 3, 4, 7 (B, C, D), 9 (E, F, G)
CERTIFIED CENELEC, CSA, UL, FM
BODY KILARK #HKB, STOCK #200-0406
FLAT COVER , STOCK #200-0773, KILARK #HKB-B.
(3B/O-ATEX) EExd II C ENCLOSURE. ATEX-APPROVED 3/4" FNPT
CABLE ENTRIES.

Introduction 3
HP-310
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.
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.
NOTES: 1. INPUTS: ACCEPTS MAGNETIC COIL ONLY.
2. WINDOWS® BASED SETUP DISC AND 6 FOOT COMMUNICATION
CABLE. IF THREE OR MORE UNITS ARE ORDERED ON THE SAME
PURCHASE ORDER ONE SET IS SUPPLIED AT NO CHARGE.

4 Introduction
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
24 mA overflow condition
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: -40oto 85oC
Humidity: 0-90% Non-condensing
Enclosure: Extruded aluminum
DIN rail mount
Explosion Proof
Regulatory: CE compliant
Options
20 point linearization

6 Specifications
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.
3-1-4 Communications Interface
The Communications Interface, located on PCA183, provides an
RS232C port to the Microcontroller. The connector for the
communication interface may be accessed by removing the top
plate. The external terminal device provides power for the
Communication Interface. The Communications Interface is used
to configure and trouble-shoot the transmitter.
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) seconds. When flow stops, the time
for the analog output to return to 4 mA will be between 3 and 12
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

12 Installation
HP-310
4-2 Communications Connections
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.
In order to comply with the requirements for Electromagnetic
Compatibility, as per EMC-Directive 89/336/EEC 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
Factory default configuration:
FIELD Value
DN 10000000
FC 0 (Average)
KD 3
AK 1.00
NP 20
F01 4999.981
F02 4999.982
F03 4999.983
F04 4999.984
F05 4999.985
F06 4999.986
F07 4999.987
F08 4999.988
F09 4999.989
F10 4999.990
F11 4999.991
F12 4999.992
F13 4999.993
F14 4999.994
F15 4999.995
F16 4999.996
F17 4999.997
F18 4999.998
F19 4999.999
F20 5000.000
K01 1.00
K02 1.00
K03 1.00
K04 1.00
K05 1.00
K06 1.00
K07 1.00
K08 1.00
K09 1.00
K10 1.00
K11 1.00
K12 1.00
K13 1.00
K14 1.00
K15 1.00

14 Appendix A – Default Configuration
HP-310
FIELD Value
K16 1.00
K17 1.00
K18 1.00
K19 1.00
K20 1.00
TU 100 (GAL)
FM 1 (MIN)
NB 01
PA 1234
OC 0 (Rate)