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: [e-mail]

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.

HP-324-5 ii

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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

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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

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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.

4 Compliance

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S p e c i f i c a t io n s 5

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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 C

o

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.

6 Specifications

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 er 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.

8 Operation

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 1/10

th

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 er 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

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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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Preventative Maintenance 13

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6. PREVENTATIVE MAINTENANCE

6-1 Introduction

Observe any scheduled organizational level maintenance instructions
dictated by the requirements of the Planned Maintenance System (PMS)
established by the Naval Sea System Command for fuel system
components.

6-2 Unit Removal

1. Turn off the power supply.

2. Open the Style 5 enclosure and unplug the 10-pin terminal

from the header.

3. Remove the top plate screw from the blue enclosure to

disconnect ground wire.

4. Remove two mounting screws from the mounting plate on the

bottom of the blue enclosure.

5. Remove the unit and install new one.

6. Replace all mounting screws.

14 Preventative Maintenance

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Troubleshooting 15

HP-324-5

7. TROUBLESHOOTING

7-1 Introduction

The troubleshooting techniques in this chapter are designed to isolate and locate
the area of failure and to present the procedures for the replacement of
subassemblies to make the system operational.

7-2 Troubleshooting Procedures

The required test equipment for troubleshooting is as follows:
Digital Multimeter: Fluke Model 8060A or equal.
Identify one of the symptoms listed below and follow the procedure. In each case

proceed to the next step only if the defect is not found.

7-2-1 Symptom: No flow indication when flow is present

1. Visually examine the interconnecting signal cable for

broken or shorted leads.

2. With an established flowrate, configure the digital

multimeter to measure AC volts, using the two volt scale.
Measure voltage at the terminal, on Pin 3, SIG+ and Pin
4 SIG-. Depending on the flowrate, an approximate
voltage reading of 10 millivolts to 1 volt should be
measured. If voltage is present replace the electronic
unit. If no voltage go to step 3.

3. Disconnect the signal cable from the electronics unit and

from the flow sensor. Check the continuity of each lead
of the cable. If defective replace or repair.

4. With the signal cable disconnected from the flow sensor

measure the DC resistance of the pickup coil. The resistance
should read between 1500 and 2200 ohms between pin A and
pin B. A short or an open indicates a defective pickup coil
and the pickup coil must be replaced.

16 Troubleshooting

HP-324-5

5. With an established flowrate, configure the digital multimeter

to measure AC volts, using the two volt scale. Connect the
positive lead to pin A of pickup coil. And the negative lead to
pin B of pickup coil. Depending on the flowrate an
approximate voltage reading of 10 millivolts to 1 volt should
be measured.

6. If zero volts are measured, a stalled rotor condition is

indicated. Remove the flow sensor from the piping. Refer to
flow sensor manual.

7-2-2 Symptom: Flow indication with no flow present

This symptom indicates the presence of electrical noise

pickup.

1. Disconnect the signal cable from the electronics unit and from

the flow sensor. Check the continuity of each lead of the
cable. If defective replace or repair.

2. With the signal cable disconnected from the flow sensor

measure the DC resistance of the pickup coil. The resistance
should read between 1500 and 2200 ohms between pin A and
pin B. A short or an open indicates a defective pickup coil
and the pickup coil must be replaced.

3. Verify cable shield connection.

4. Verify electronics unit enclosure connection to ships ground.

Appendix A – Default Configuration 17

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Appendix A – Default Configuration

Factory default configuration:

FIELD Value

TAG NUMBER 10000000

LINEARIZATION Average

K FACTOR DECIMAL POINTS 3

AVERAGE K FACTOR 1.00

NUMBER OF LINEARIZATION POINTS 20

FREQUENCY 1 4999.981

FREQUENCY 2 4999.982
FREQUENCY 3 4999.983
FREQUENCY 4 4999.984
FREQUENCY 5 4999.985
FREQUENCY 6 4999.986
FREQUENCY 7 4999.987
FREQUENCY 8 4999.988

FREQUENCY 9 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 1 1.00

K FACTOR 2 1.00
K FACTOR 3 1.00
K FACTOR 4 1.00
K FACTOR 5 1.00
K FACTOR 6 1.00
K FACTOR 7 1.00
K FACTOR 8 1.00

K FACTOR 9 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

18 Appendix A – Default Configuration

HP-324-5

FIELD Value

K FACTOR 16 1.00
K FACTOR 17 1.00
K FACTOR 18 1.00
K FACTOR 19 1.00
K FACTOR 20 1.00

CORRECTION FACTOR 1.000

TOTAL UNITS GAL

RATE UNITS MIN

MAX SAMPLE TIME 01

4 MA SETTING 00000.000

20 MA SETTING 99.999

PULSE SCALE OFF

PULSE OUT FREQUENCY 8

ALARM FUNCTION OFF

ALARM SETPOINT 99999.981

CURRENT MODE RATE

TEST PULSE NO

ALARM TEST NO

Appendix B – Communications 19

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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 B - Communications

Communications Interface

CAT3-DC-MIL is equipped with a serial communication interface RS232
to allow changing flow sensor calibration parameters (k-factors). The
calibration parameters must be updated whenever the flow sensor is re­calibrated. The serial port may be accessed by removing the two screws
from the top plate of the blue enclosure. External power must be supplied
to the CAT3 in order to communicate.

Communications with the CAT3-DC-MIL also requires the use of the
HOFFER HIT2A-301 Communications Cable and the Hoffer Windows
Device Configuration Software. The computer serial port must be set to
the following:

Baud rate: 2400
Data bits: 8
Parity: none
Stop bits: 1
Handshaking: None

HIT2A-301 Communications Cable

20 Appendix C – Drawings

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Appendix C – Drawings

Appendix C – Drawings 21

HP-324-5