Hoffer Flow Controls CAT1 Operation & User’s Manual

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 252-331-2886 www.hofferflow.com E-mail: [email protected]

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 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 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 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 (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. 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.

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 (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 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 LIABILITY EMBRACES THE PURCHASER’S EXPENSES FOR DOWNTIME, DAMAGES FOR WHICH THE PURCHASER MAY BE LIABLE TO OTHER PERSONS, DAMAGES TO PROPERTY, AND INJURY TO OR DEATH OF ANY PERSON. 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 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. Disclaimer: Specifications are subject to change without notice. Some pages are left intentionally blank.

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

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.

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.

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.

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: -40o to 85o C Humidity: 0-90% Non-condensing Enclosure: Extruded aluminum DIN rail mount Explosion Proof Regulatory: CE compliant 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 flowrate mAx 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. 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. xCF x Kfactor frequency flowrate FM 60 

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.

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

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

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

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)

HP-310 Appendix B – Communications Message Format And Timeout Communication messages consist of a string of ASCII characters terminated by a carriage return character. The maximum message length received by CAT1 is 20 characters, including the carriage return. The CAT1 will transmit no more than 35 characters before transmitting a carriage return. If a message longer than A 20 characters command is sent, the instrument responds with “Command Sequence is Too Long!” If an unrecognized or invalid command is sent, the instrument responds with “Invalid Command! ” The sending unit RS232C serial port configuration must be configured as follows: Baud rate: 2400 Data bits: 8 Parity: none Stop bits: 1 Handshaking: none The CAT1 echoes all received messages and then transmits a response string terminated with a carriage return. If the sending unit takes longer than one minute to send a message, the CAT1 aborts the message by clearing the receive buffer. If the sending unit (PC or other such device) wishes to change a setting on the CAT1, the sending unit shall follow the command with an equal sign (“=”) with the data following immediately after the equal sign. The carriage return terminates the message. Any CAT1 response that sends data back to the sending unit shall have an equal sign (“=”) followed by the data. Space is allowed between the equal sign and the data on the return message, but the total message length is limited to 35 characters.

HP-310 READ Example: If the sending unit wishes to read the number of points that the CAT1 has in the K factor table, the sending unit shall send “NP” The CAT1 echoes the sent message, and responds with “NUM PTS = 2” WRITE Example: If the sending unit wishes to change the number of points to 20 in the K factor table, the sending unit shall send “NP=20” The CAT1 echoes the sent message and responds with “NUM PTS = 20”. The CAT1 checks the ranges for data and rejects writes that are not within the allowed range. If the sending unit sends data that is not within the allowed range, the CAT1 echoes the sent message and responds with the value that is currently stored in the CAT1. Example: If the sending unit wishes to change the max sample time to 2000 from the previous setting of 10, the sending unit shall send “NB=2000” The CAT1 echoes the sent message, and responds with “MAX M TIME= 10”.

HP-310 Messages Commands Supported By Communications Messages Command Description/Allowed Data/Response DN Tag Number “0” to “99999999” “TAG NUM = (DATA)” The first three digits are the units code for total. Changing these digits will change the TU settings. FC Linearization “0” = Average K factor “1” = Linearization table “F C METHOD = AVG” for Average K factor or “F C METHOD = LIN” for Linearization table KD K Factor Decimal Point Location “0” for 00000000. “1” for 0000000.0 and all K Factors are less than 9999999.9, otherwise not allowed “2” for 000000.00and all K Factors are less than 999999.99, otherwise not allowed “3” for 00000.000 and all K Factors are less than 99999.999, otherwise not allowed “K-FAC DECL=(DATA)” AK Average K Factor “0.001” to “99999.999” if KD = 3 “999999.99” if KD = 2 “9999999.9” if KD = 1 “ 99999999” if KD = 0 “AVG KFAC =(DATA)” NP Number Points in the Table “2” to “20” “NUM PTS =(DATA)”

HP-310 Command Description/Allowed Data/Response F## Frequency 1-20 F01 has a range of “0.000” to the value of F02 minus 0.001; F20 has a range of the value from F19 plus 0.001 to “5000.000”; Frequencies F02 to F19 must be 0.001 greater than the previous frequency and 0.001 less than the next frequency. “FREQ ## =(DATA)” for F01 through F20. Data to fixed three decimal places. K## K-Factor 1-20 “K-FACT # =(DATA)” for K01 through K09. “K-FACT ## =(DATA)” for K10 through K20. DATA to decimal places as per KD command. TU Total Units “100” for gallons “140” for liters “110” for cubic feet “150” for cubic meters “180” for barrels All other integer values from 0 and less than 999 will map to custom units “TOT UNITS =(DATA)” (DATA) shall be: “GAL” for gallons “LIT” for liters “FT3” for cubic feet “M3 ” for cubic meters “BBL” for barrels “CUS” for custom These three numbers will be the same as the first three digits of the tag number. Changes to this menu shall cause the changes to the tag number.

HP-310 Command Description/Allowed Data/Response FM Rate Units “0” for seconds “1” for minutes “2” for hours “3” for days “FLOW UNITS=(DATA)” (DATA) shall be: “SEC” for seconds “MIN” for minutes “HR ” for hours “DAY” for days NB Max Sample Time “1” to “80” “MAX M TIME=(DATA)” LF Out Low “0.000” to a maximum value of the Out High setting “4mA FLOW =(DATA)” AF Out High Minimum is the Out Low Setting (LF) to a maximum of the following: “99999.999” if RD = 3 “999999.99” if RD = 2 “9999999.9” if RD = 1 “ 99999999” if RD = 0 “20mA FLOW =(DATA)” PA Password “0” to “9999” “PASS WORD =(DATA)” OC Current Out “0” - Current output follows rate. “1” - Current output set to 4mA. “2” - Current output set to 12mA. “3” - Current output set to 20mA. For “0”, response = “ Output equal to input.” For “1”, response = “ Output is 4mA.” For “2”, response = “ Output is 12mA.” For “3”, response = “ Output is 20mA.”

HP-310 System Commands Supported by Communications Messages System Command Description/Response/Comments OI Output 4mA “ Output is 4mA.” Current output set to 4mA. MO Output 12mA “ Output is 12mA.” Current output set to 12mA. OM Output 20mA “ Output is 20mA.” Current output set to 20mA. OF Output = Rate (Input) “ Output equal to input.” Current output follows rate. AA Auto Data “F (DATA) R (DATA) T (DATA)” The response, not the echo, is sent every two seconds until it receives another message from the master. The (DATA) following the F denotes the frequency of the pulses to a precision of three places past the decimal, the (DATA) following the R denotes the rate to a precision of three places past the decimal, and the (DATA) following the T denotes the total to a precision of three places past the decimal. DA Dump All All of the responses in previous table. The CAT1 gives all responses except for the CL command. UI Unit Identification “UNIT MODEL=HIT2A XX YY.ZZ” Model and software number for the unit. XX is the hardware revision number, YY.ZZ is the software revision where YY is the major software revision and ZZ is the minor software revision.

HP-310 System Command Description/Response/Comments RR Read Rate “FLOW = (DATA)” (DATA) = “0” to the following maximums: “99999.999” if RD = 3 “999999.99” if RD = 2 “9999999.9” if RD = 1 “ 99999999” if RD = 0 CN Adjust 4mA output point “CN=#(DATA)” (DATA) is the integer value that the HIT2A sends to the 4- 20mA converter to output 4mA This parameter is passed to the HIT2A to adjust the 4mA output point of the device. This value is used in production at the test step to calibrate the 4mA output point. “CN” will cause an Invalid Command response and absence of the # symbol will cause the HIT2A to ignore the data. CM Adjust 20mA output point “CM=#(DATA)” (DATA) is the integer value that the HIT2A sends to the 4- 20mA converter to output 20mA This parameter is passed to the HIT2A to adjust the 20mA output point of the device. This value is used in production at the test step to calibrate the 20mA output point. “CM” will cause an Invalid Command response and absence of the # symbol will cause the HIT2A to ignore the data.