Hoffer Flow Controls CAT2 User manual

Model: CAT2
Versatile DC or AC Transmitter
(Can Be Interfaced With Any Hoffer Flow Sensor)
USER’S MANUAL
HP-311
January 2015
107 Kitty Hawk Lane • P.O. Box 2145 • Elizabeth City, NC 27906-
2145
1-800-4584 • 252-331-1997 • FAX: [phone]
www.hofferflow.com • E-mail: [e-mail]

HP-311

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 the
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 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 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-311
CONTENTS
1. Introduction---------------------------------------------------------1
1.1. Model Number Designation ----------------------------------2
2. Specifications--------------------------------------------------------5
3. Installation-----------------------------------------------------------7
3.1. Power Supply---------------------------------------------------7
3.2. Flowmeter Input------------------------------------------------7
3.3. Pulse Output ----------------------------------------------------7
3.4. Analog Output--------------------------------------------------7
3.5. Alarm Outputs--------------------------------------------------7
3.6. Wiring Note-----------------------------------------------------8

Introduction 1
HP-311
1. Introduction
The CAT2 is a versatile DC or AC powered transmitter, which
provides pulse output, analog output and High/Low flow
alarm options. Up to 3 circuit boards may be installed to
provide a variety of input/output options.
CAT2 Block Diagram
HIGH ALARM
OUT
P
CA181
F
REQUENCY
T
O CURRENT
C
ONVERTER
SCALED
SIGNAL
H
IGH
A
LARM
L
OW
A
LARM
P
CA184
C
ONVERTER
O
R
A
C/DC
LOW ALARM
OUT
P
CA182
ANALOG
OUT
P
CA180
ANALOG
OUT
L
A
D
ivide by N
(
2,4,8,16,32)
PULSE
OUT
H
A
FLOWMETER
INPUT
P
REAMP
Many enclosure options are available including the standard
extruded aluminum enclosure, an optional bracket for DIN rail
mounting or direct flowmeter mounting using an optional
NEMA 4X or EX enclosure.

Introduction 2
HP-311
1.1. Model Number Designation
MODEL CAT2-( A )- ( B )-( C )-( D )-( E )-( F )-( G )
PULSE INPUT
PULSE OUTPUT
ANALOG OUTPUT
POWER SUPPLY
ALARM OUTPUT
ENCLOSURE STYLE
SPECIAL FEATURES
PULSE INPUT
MODEL CAT2-( A )-( )-( )-( )-( )-( )-( )
OPTION ( A )
(1) MAG COIL, PULSE, DRY CONTACT
(2) MC3P
(3) ISOLATED PULSE, RPM, RPR COILS
PULSE OUTPUT
MODEL CAT2-( )-( B )-( )-( )-( )-( )-( )
OPTION ( B )
(1) 0-5V TTL / CMOS
(2) OPEN COLLECTOR
(3) OPEN COLLECTOR WITH PULL UP TO V+
(4) AC SQUARE WAVE
(5) 0-10V SQUARE WAVE
ANALOG OUTPUT
MODEL CAT2-( )-( )-( C )-( )-( )-( )-( )
OPTION ( C )
(1) 4-20 MA
(3) 0-5 VDC
(4) 0-10 VDC
(5) 1-5 VDC

Introduction 3
HP-311
POWER SUPPLY
MODEL CAT2-( )-( )-( )-( D)-( )-( )-( )
OPTION ( D )
(DC) 13-30 VDC
(AC) 100-240 VAC
NOTE: WHEN (AC) IS SELECTED, THE ALARM OPTION IS NOT AVAILABLE.
USE REMOTE ACC39B POWER SUPPLY.
ALARM OUTPUT
MODEL CAT2-( )-( )-( )-( )-( E )-( )-( )
OPTION ( E )
(1) HIGH / LOW OPEN COLLECTOR
(2) HIGH / LOW TTL / CMOS
(3) HIGH / LOW RELAY TWO SPDT, CONTACT RATED @ 2A 30V
(4) HIGH OPEN COLLECTOR
(5) HIGH TTL / CMOS
(6) HIGH RELAY ONE SPDT, CONTACT RATED @ 2A 30V
(7) LOW OPEN COLLECTOR
(8) LOW TTL / CMOS
(9) LOW RELAY ONE SPDT, CONTACT RATED @ 2A 30V
NOTE: WHEN ALARM OPTION IS SELECTED, (AC) POWER IS NOT AVAILABLE.
USE REMOTE ACC39B POWER SUPPLY.
ENCLOSURE STYLE
MODEL CAT2-( )-( )-( )-( )-( )-( F )-( )
OPTIONS ( F )
(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 CAT2 UNITS CAN BE MOUNTED
ON A SINGLE RAIL. ADD 2" PER UNIT.
(E3) EXPLOSION-PROOF (ALL CONDUIT PORTS ARE ¾” FNPT)
- CSA/FM: CLASS I, DIV. 1, GR. BCD, CLASS II, DIV. 1, GR. EFG;
CLASS III, TYPE 4X, IP66;
CLASS 1 ZONE 1 AEx d IIB + H2, IP 66
- ATEX/IECEx: II 2 G Ex d IIB + H2, T1 – T6 Gb; IP66
T1-T5: -40°C ≤Ta ≤85°C; T6: -40°C ≤Ta ≤80°C
NOTE: FOR UL LISTED EXPLOSION-PROOF ENCLOSURES CONTACT FACTORY.

Introduction 4
HP-311
(E3M) EXPLOSION-PROOF (CONDUIT PORTS D2 & D3 = M20 THR’D;
CONDUIT PORTS D1- ¾" FNPT)
- CSA/FM: CLASS I, DIV. 1, GR. BCD; CLASS II, DIV. 1, GR. EFG;
CLASS III, TYPE 4X, IP66;
CLASS 1 ZONE 1 AEx d IIB + H2, IP 66
- ATEX/IECEx: II 2 G Ex d IIB + H2, T1 – T6 Gb; IP66
T1-T5: -40°C ≤Ta ≤85°C; T6: -40°C ≤Ta ≤80°C
NOTE: FOR UL LISTED EXPLOSION-PROOF ENCLOSURES CONTACT FACTORY.
(E4)* EXPLOSION-PROOF - FOR USE WITH AC POWERED CAT ONLY
(NOT Ex d SYSTEM CERTIFIED)
- FM: CLASS I, DIV. 1, GR. ABCD; CLASS II/III, DIV. 1,
GR. EFG, TYPE 4X
- CSA: CLASS I, DIV. 1, GR. ABCD; CLASS II, DIV. 1, GR. EFG;
CLASS III, TYPE 4X, Ex d IIC;
CLASS 1, ZONE 1, IP 66
- ATEX: Ex II 2GD, Ex d tD IIC, IP66/IP68
- IEC: Ex d IIC, IP68
NOTE: FOR UL LISTED EXPLOSION-PROOF ENCLOSURES CONTACT FACTORY.
*FOR Ex d CERTIFIED SYSTEM USE E6 OR E6M ENCLOSURE
(E6) EXPLOSION-PROOF STAINLESS STEEL
(ALL CONDUIT PORTS ARE ¾"FNPT)
- CSA/FM: CLASS I, DIV. 1, GR. BCD; CLASS II, DIV. 1, GR. EFG;
CLASS III, TYPE 4X, IP66;
CLASS 1 ZONE 1 AEx d IIB + H2, IP 66
- ATEX/IECEx: II 2 G Ex d IIB + H2, T1 – T6 Gb; IP66
T1-T5: -40°C ≤Ta ≤85°C; T6: -40°C ≤Ta ≤80°C
NOTE: FOR UL LISTED EXPLOSION-PROOF ENCLOSURES CONTACT FACTORY.
(E6M) EXPLOSION-PROOF STAINLESS STEEL (M20 NOT AVAILABLE FOR CANADA)
(CONDUIT PORTS T2 = M20 THR’D; CONDUIT PORTS T1- ¾"FNPT)
- CSA/FM: CLASS I, DIV. 1, GR. BCD; CLASS II, DIV. 1, GR. EFG;
CLASS III, TYPE 4X, IP66;
CLASS 1 ZONE 1 AEx d IIB + H2, IP 66
- ATEX/IECEx: II 2 G Ex d IIB + H2, T1 – T6 Gb; IP66
T1-T5: -40°C ≤Ta ≤85°C; T6: -40°C ≤Ta ≤80°C
NOTE: FOR UL LISTED EXPLOSION-PROOF ENCLOSURES CONTACT FACTORY.

Introduction 5
HP-311
SPECIAL FEATURES
MODEL CAT2-( )-( )-( )-( )-( )-( )-( G )
OPTIONS ( G )
(CE) MARK REQUIRED FOR EUROPE
(CFX) 6.75" LONG RISER AND UNION FOR EXPLOSION-PROOF SYSTEM
CERTIFIED ENCLOSURES MOUNTED ON TURBINE. USED WITH
“X” RISER TURBINE OPTION.
NOTE: IF PROCESS TEMP IS < -40°C AND > 85°C, EX-PROOF
ENCLOSURE MUST BE MOUNTED REMOTELY.
(SP) ANY SPECIAL FEATURES THAT ARE NOT COVERED IN THE
MODEL NUMBER, USE A WRITTEN DESCRIPTION OF THE –SP.
NOTES: 1. IF ENCLOSURE IS MOUNTED ON TURBINE FLOWMETER, RISER MUST
BE SPECIFIED ON METER.
2. PULSE SCALING IS SUPPLIED AS A STANDARD. THE PULSE OUTPUT
IS SCALED SO THAT THE MAX FLOW IS BETWEEN 75-150 HZ WHEN THE
ANALOG OPTION IS SELECTED.

Introduction 6
HP-311
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Specifications 7
HP-311
2. Specifications
General Specifications
Input Signal Type: Magnetic pick up, MCP pick up, Contact
Closure, Pulse
Input frequency range: 0.2 Hz to 4 KHz
Signal level: 10 mV rms to 30 Vdc
Power supply: 13-30 Vdc (Reverse polarity protected)
100-240 Vac (Fuse rating 0.5A, 250 Vac
Analog Output: 4-20mA, 1-5V, 0-5V, 0-10V
Load resistance: Max 550 Ohms at 24 Vdc
Accuracy: +/- 0.1% of full scale @ 20C
Temperature drift: 200ppm/deg C
Pulse output 0-5, 0-10V, Open Collector, AC square
Internal pull-up resistor 10k Ohms
Recommended load min. 50k Ohms
Pulse scaling Divide by 2, 4, 8, 16, 32
Hi/Lo Alarm Relay (2A, 30, Vdc), 0-5V,
Open Collector (0.5A, 30V)
Operating temperature: -40 to 85 Co
Humidity: 0-90% Non-condensing
Enclosure: Extruded aluminum
DIN rail mount
Explosion Proof
Regulatory: CE compliant

Specification 8
HP-311
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Installation 9
HP-311
3. INSTALLATION
3.1. Power Supply
DC Power (13-30 VDC)
N/C
N/C
POWER
PULSE-
N/C
ANLG
SUPPLY
SIG+
DC SIG-
+
DC+
DC-
-
PULSE+
AC Power (100-240 VAC)
AC power for CAT2 requires an optional circuit board, PCA182. The Alarm
option (PCA184) is not available when the AC Power option is equipped.
DC-
DC+
SIG-
PULSE-
N/C
N/C
PULSE+
SIG+
ANLG
N/C
NEUTRAL HOT
L1
L2
PLUG AC MALE
PCA180
SW2
1
PCA180
SW2
1

Installation 10
HP-311
3.2. Flowmeter Input
The Preamp circuitry for conditioning the flow signal is located on PCA180.
The following drawings illustrate typical connections and switch settings on
PCA180 for various input signals.
Magnetic Pickup Coil
A B
Mag Pickup Coil
N/C
PULSE-
N/C
N/C
SIG+
ANLG
SIG-
DC+
DC-
PULSE+
MCP/RF Coil
A B
Modulated Carrier Pickup (RF)
N/C
PULSE-
N/C
N/C
SIG+
ANLG
SIG-
DC+
DC-
PULSE+
C
PCA180
SW1
1
PCA180
SW1
1

Installation 11
HP-311
Redi-Pulse (TTL Pulse)
BA
Redi-Pulse (TTL) Pickup Coil
N/C
N/C
PULSE-
N/C
ANLG
SIG+
SIG-
DC+
DC-
PULSE+
C
Redi-Pulse (Open Collector)
AB
Redi-Pulse (Open Collector)
Pickup Coil
N/C
PULSE-
N/C
N/C
SIG+
ANLG
SIG-
DC+
DC-
PULSE+
C
PCA180
SW1
1
PCA180
SW1
1

Installation 12
HP-311
3.3. Pulse Output
The pulse output circuitry for CAT2 is located on PCA180. The pulse
output is scalable by a factor of 1, 2, 4, 8, 16 and 32 of the input
frequency by selecting the proper switch on SW2. Scaling of the pulse
output may be limited if an analog output is used in conjunction with
the pulse output. The following drawings illustrate typical connections
and switch settings for various pulse output options.
Pulse Scaling
Scaling Factor
(Divide by N of
Input)
Switch Setting
(SW2, PCA180)
1 SW2-1 ON
2 SW2-2 ON
4 SW2-3 ON
8 SW2-4 ON
16 SW2-5 ON
32 SW2-6 ON
TTL(0-5V), 0-10V, High Level (DC In), AC Square
PULSE
INPUT -
+
USER DCS
N/C
PULSE-
N/C
N/C
SIG+
ANLG
SIG-
DC+
DC-
PULSE+
1 PCA180
SW2
TTL(0-5V), 0-10V, AC Square
1 PCA180
SW2
High Level Pulse, AC Square

Installation 13
HP-311
Open Collector, Isolated Pulse
PULSE
INPUT -
+
USER DCS
N/C
PULSE-
N/C
N/C
ANLG
SIG+
SIG-
DC+
DC-
PULSE+
V+
2.7K
1
PCA180
SW2
Open Collector
1
PCA180
SW2
Isolated Pulse

Installation 14
HP-311
3.4. Analog Output
CAT2 provides an Analog Output option that will output an analog
current or voltage that is proportional to the flow rate. The Analog
Output for CAT2 requires an optional circuit board, PCA181.
Analog Output
N/C
POWER
PULSE-
N/C
N/C
SUPPLY
SIG+
ANLG
DC
SIG-
+
DC+
LOAD
DC-
-+
-
PULSE+
The input frequency is scaled using SW2 on PCA180 so that the
preamp output frequency at max flow is between 75 and 150 Hz. For
example, if the max flow input signal is 1,000 Hz, SW2-4 should be in
the ON position to divide the preamp signal by 8 so that the max
frequency out of the preamp is 125 Hz. Refer to the table in the
previous section for the appropriate switch settings. If the Pulse Output
option is used in conjunction with the Analog Output, the Pulse Output
frequency will be limited by this scaling factor.
There are 3 potentiometers on PCA181 for ZERO and SPAN
adjustment. The ZERO pot adjusts the no flow output, while
COURSE SPAN and FINE SPAN adjusts the max flow output. All
pots are labeled accordingly on the circuit board and may be accessed
by removing the top plate from CAT2. The 0-20mA, 0-5V and 0-10V
options require no ZERO adjustment. Contact the factory for detailed
calibration instructions before making any adjustments.
Analog Output Response Time: The analog output response time to
reach steady state due to a change in the flow rate is approximately two
(2) seconds.