Hoffer CAT3-DC-MIL User manual

Safety 1
www.hofferflow.com E-mail: [e-mail]
107 Kitty Hawk Lane, P.O. Box 2145, Elizabeth City, NC 27906-2145
800-628-4584 252-331-1997 FAX [phone]
Model: CAT3-DC-MIL
DC Powered Microprocessor
Controlled Transmitter
Style 5 Enclosure
USER’S MANUAL
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]
HP-324-5
January 2018

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.

i HP-324-5
FORWARD
The manual contains the information required to install, operate,
maintain, and repair a CAT3-DC-MIL Flow Rate Signal Converter.
The CAT3-DC-MIL unit is intended to provide ships personnel with
the ability to monitor flow of fuel and other liquids.

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iii HP-324-5
CONTENTS
FORWARD ------------------------------------------------------------------------ i
CONTENTS---------------------------------------------------------------------- iii
1. Safety ------------------------------------------------------------------------ 1
2. Compliance----------------------------------------------------------------- 3
3. Specifications--------------------------------------------------------------- 5
3-1 Model Number Designation----------------------------------------- 6
4. Operation ------------------------------------------------------------------- 7
4-1 Preamplifier ----------------------------------------------------------- 7
4-2 Microcontroller ------------------------------------------------------- 7
4-3 Analog Output -------------------------------------------------------- 8
4-4 Scaled Pulse Output-------------------------------------------------- 9
4-5 Communications Interface ------------------------------------------ 9
5. Installation-----------------------------------------------------------------11
5-1 Wiring-----------------------------------------------------------------11
6. Preventative Maintenance----------------------------------------------13
6-1 Introduction ----------------------------------------------------------13
6-2 Unit Removal --------------------------------------------------------13
7. Troubleshooting ----------------------------------------------------------15
7-1 Introduction ----------------------------------------------------------15
7-2 Flow Sensor Troubleshooting Procedures -----------------------15
Appendix A – Default Configuration --------------------------------------17
Appendix B - Communications----------------------------------------------19
Communications Interface --------------------------------------------------19
Appendix C – Drawings ------------------------------------------------------20

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Safety 1
HP-324-5
1. SAFETY
The CAT3-DC-MIL Fuel Metering unit is designed to satisfy the safety
requirements for shipboard use.
The safety precautions and warnings described here are to be observed
at all times. Additional precautionary messages appear throughout this
manual.

2 Safety
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Compliance 3
HP-324-5
2. COMPLIANCE
This instrument is designed to conform to the EMC-Directive of
the Council of European Communities 89/336/EEC. This
instrument has been certified to meet MIL-S-901D for shock and
vibration and MIL-STD-461F for EMI compliance.

4Compliance
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S p e c i f i c a t i o n s 5
HP-324-5
3. SPECIFICATIONS
Input Signal Type: Magnetic pick up
Input frequency range: 0.2 Hz to 4 KHz
Signal level: 10 mV rms to 30 Vdc
Power supply: 13-30 VDC
Analog Output: 4-20mA,
24mA overflow condition
Analog Output
Response Time: 1/8 sec.*
Load resistance: Max 650 Ohms at 24 Vdc
Accuracy: +/- 0.02% of full scale @ 20C
Temperature drift: 40ppm/deg C
Pulse output 0-5, 0-10V, Open Collector, AC square
Internal pull-up resistor 10k Ohms
Recommended load min. 50k Ohms
Maximum Pulse 1, 2, 4, 8, 100, 50% Duty Cycle
Frequency
Pulse Scaling Per flow unit of measure, divide by 1, 10, 100
100 Hz max frequency
Communications RS232 port for Configuration and
diagnostics
Operating temperature: -40 to 85 Co
Humidity: 0-90% Non-condensing
Enclosure: Extruded aluminum housed in Style 5
enclosure (NEMA 4)
Regulatory: CE compliant
Linearization: 20 point
*Limited by signal frequency and MST settings. Refer to Section 4-3.

6Specifications
HP-324-5
3-1 Model Number Designation
MODEL CAT3-( A )-( B )-( C )-( D )-( E )-( F )-( G )
PULSE INPUT
LINEARIZED PULSE OUTPUT
LINEARIZED ANALOG OUTPUT
POWER SUPPLY
ALARM OUTPUT
ENCLOSURE STYLE
SPECIAL FEATURES
PULSE INPUT
MODEL CAT3-( A )-( )-( )-( )-( )-( )-( )
OPTION ( A )
(1) MAG COIL, PULSE, DRY CONTACT
LINEARIZED PULSE OUTPUT
MODEL CAT3-( )-( B )-( )-( )-( )-( )-( )
OPTION ( B )
(4) AC SQUARE WAVE
LINEARIZED ANALOG OUTPUT
MODEL CAT3-( )-( )-( C )-( )-( )-( )-( )
OPTION ( C )
(1) 4-20 MA
POWER SUPPLY
MODEL CAT3-( )-( )-( )-( D )-( )-( )-( )
OPTION ( D )
(DC) 13-30 VDC
ALARM OUTPUT
MODEL CAT3-( )-( )-( )-( )-( E )-( )-( )
OPTION ( E )
(X) NONE
ENCLOSURE STYLE
MODEL CAT3-( )-( )-( )-( )-( )-( F )-( )
OPTIONS ( F )
(5) STYLE 5 ENCLOSURE, NEMA 4
SPECIAL FEATURES
MODEL CAT3-( )-( )-( )-( )-( )-( )-( G )
OPTIONS ( G )
(MIL) DESIGNED TO MEET EMC STDS EN5011-1992 AND EN61326-1:1997

O p e r a t i o n 7
HP-324-5
Preamp Microcontroller
Communications
Interface
RS232
Scaled Pulse Out
4-20mA
Loop Driver
Flow Sensor
Pickup Coil 1
4. OPERATION
The CAT3-DC-MIL is a DC powered microprocessor-based
transmitter, which provides pulse and analog outputs. The flowmeter
input circuitry will accept a magnetic type pickup, pulse and contact
closure. Optional 20-point linearization is available to correct for
flowmeter non-linearity, improving overall system accuracy.
CAT3-DC-MIL Block Diagram
4-1 Preamplifier
The Preamplifier receives signals from the flow sensor pick up coil.
The signal is amplified, filtered, and converted into a logic level
square-wave before sending it to the Microcontroller.
4-2 Microcontroller
The Microcontroller performs all of the calculations that are required to
control the analog output and pulse output. The following equations
are used to calculate the flowrate and the analog output current.

8Operation
HP-324-5
Flowrate = frequency/K-factor x 60
Where:
K-factor = Is the flow meter calibration factor in
pulses/gal
Flowrate is in gal/min.
Frequency is in Hertz.
4-3 Analog Output
CAT3-DC-MIL provides an analog output current that is proportional to the
flow rate. The analog output is scaled as follows:
4 mA = 0 GPM
20mA = Max Flow Rate in GPM
If the calculated flowrate is greater than the 20mA setting, the current is set
to 24mA to indicate an “Over-range” condition. Microcontroller calculates
the current and sends data to the Loop Driver. The Loop Driver, located on
PCA183 controls the current of the loop. The Loop Driver also supplies
power to the Microcontroller.
The analog output is updated 8 times per second (8 Hz). When flow stops,
the time for the analog output to return to 4 mA is between 250 mS and 8
seconds, depending on the Maximum Sample Time (MST) setting. MST is
a value between 1 and 80, with each count equal to 1/10th of a second. The
MST setting adjusts the amount of time the electronics will wait for the next
input pulse before returning to zero. This will prevent the displayed flow
rate and/or analog output from going to 0 when the input frequency is less
than the update time of the electronics. Adjusting the MST is only
recommended for low flow applications where the minimum input
frequency is below 10 Hz. The default MST setting is 1.

O p e r a t i o n 9
HP-324-5
4-4 Scaled Pulse Output
CAT3-DC-MIL Pulse Output can be configured for turbine raw
frequency or for unit of measure scaled for the least significant digit of
the internal total. A scaling factor of 1, 10 or 100 is available to reduce
or increase the resolution of the pulse output. For example, if the Total
Decimal Point is set to 0000000.0, and the Pulse Scale is 1, then 1
pulse will be output for each tenth (0.1) of a unit of measure. Changing
the Pulse Scale to 10, would result in an output pulse for each 1.0 unit
of measure. The output must be scaled so that the pulse frequency does
not exceed the Pulse Frequency setting (100 Hz. Max) at the maximum
flow rate.
4-5 Communications Interface
An RS232 communications port located under the top plate allows
CAT3-DC-MIL to be remotely configured and trouble-shoot using a
Windows based program. Refer to the Appendix B section for
communication details.
The communication function is available only when CAT3-DC-MIL
device is powered.

10 Operation
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Installation 11
HP-324-5
5. INSTALLATION
5-1 Wiring
When installing CAT3-DC-MIL, it is a good practice to use shielded
cables for all input and output signals. The shield should be connected
to the earth ground lug on the CAT3-DC-MIL. The shield on the
opposite end of the cable should be left open.
This wiring practice is mandatory in order to comply with the
requirements for Electromagnetic Compatibility, as per EMC-Directive
89/336/EEC of the Council of European Community.

12 Installation
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