Hoffer Flow Controls CAT1 Operation & User’s Manual

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 ● (252) 331-1997 ● Fax (252) 331-2886 www.hofferflow.com email: [email protected]

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 (252) 331-1997 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.

("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.

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

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.

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.

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.

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 ≤ 85o C T6: -40o ≤ Ta ≤ 79o C 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

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.

HP-310       AF mAx flowrate mA current 16 4 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. xCF x Kfactor frequency flowrate 60FM 

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.

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 B A 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 1 1 1

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

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

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

HP-310 APPENDIX B – Declaration of Conformity

HP-310 APPENDIX C – Installation and Conditions for Safe Use Drawings for Certified Systems