Hoffer Flow Controls CAT2 User Manual

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Page 1

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: 252-331-2886

www.hofferflow.com

• E-mail: [email protected]

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HP-311

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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 interconn ecting 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) an d/or drawing(s). Ide ntify all model numbers exactly before making any connections. A number of options and accessories may be ad ded to the main ins tru ment, 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.

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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 LIMITIN G 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 P ROPERTY, 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 A FFECTING THE AGRE EMENT

PURCHASER'S SOLE AND EXCLUSIVE REMEDY IS THE REP AIR AND/OR REPLACEMENT

OF NONCONFORMING GOODS AS PROVIDED IN T HE PRECEDING PARAGRAPHS

. HFC

SHALL NOT BE LIABLE FOR ANY OTHER DAMAGES WHATSOEVER INCLUDING INDIRECT

INCIDENTAL

, OR CONSEQUENTIAL DAMAGES.

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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

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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

CA181

REQUENCY

O CURRENT

ONVERTER

SCALED

IGH

LARM

LOWA

LARM

CA184

ONVERTER

C/DC

LOW ALARM

CA182

ANALOG

CA180

ANALOG

LAD

ivide by N

(

2,4,8,16,32)

PULSE

FLOWMETER

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.

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Introduction 2

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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

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Introduction 3

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POWER SUPPLY MODEL CAT2-(

)-( )-( )-( D )-( )-( )-( )

OPTION

( D )

(DC) 13-30 VDC (AC) 100-240 VAC

NO TE: WHEN (AC) IS SELECTED, THE ALARM OPTION IS NOT AVAILA BLE. 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.

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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 II B + 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.

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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.

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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 C

Humidity: 0-90% Non-condensing

Enclosure: Extruded aluminum DIN rail mount Explosion Proof

Regulatory: CE compliant

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Installation 9

HP-311

3. INSTALLATION

3.1. Power Supply

DC Power (13-30 VDC)

N/C

POWER

PULSE-

N/C

ANLG

SUPPLY

SIG+

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

PULSE+

SIG+

ANLG

N/C

NEUTRAL HOT

L1 L2

PLUG AC MALE

PCA180

SW2

PCA180

SW2

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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

SIG+

ANLG

SIG-

DC+ DC-

PULSE+

MCP/RF Coil

A B

Modulated Carrier Pickup (RF)

N/C

PULSE-

N/C

SIG+

ANLG

SIG-

DC+ DC-

PULSE+

PCA180

SW1

PCA180

SW1

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Installation 11

HP-311

Redi-Pulse (TTL Pulse)

Redi-Pulse (TTL) Pickup Coil

N/C

PULSE-

N/C

ANLG

SIG+

SIG-

DC+ DC-

PULSE+

Redi-Pulse (Open Collector)

Redi-Pulse (Open Collector) Pickup Coil

N/C

PULSE-

N/C

SIG+

ANLG

SIG-

DC+ DC-

PULSE+

PCA180

SW1

PCA180

SW1

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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

SIG+

ANLG

SIG-

DC+ DC-

PULSE+

PCA180

SW2

TTL(0-5V), 0-10V, AC Square

PCA180

SW2

High Level Pulse, AC Square

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Installation 13

HP-311

Open Collector, Isolated Pulse

PULSE INPUT

USER DCS

N/C

PULSE-

N/C

ANLG

SIG+ SIG-

DC+ DC-

PULSE+

V+

2.7K

PCA180

SW2

Open Collector

PCA180

SW2

Isolated Pulse

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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

SUPPLY

SIG+

ANLG

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.

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Installation 15

HP-311

3.5. Alarm Outputs

CAT2 provides an optional High/Low Flow Alarm feature. The Alarms require an optional circuit board, PCA184. The Alarm option is not available when the AC Power option is equipped. The following drawings illustrate typical connections and switch settings for various alarm output options.

Hi/Lo Alarm Relay

N/C

PULSE-

N/C

ANLG

SIG+ SIG-

DC+ DC-

PULSE+

NC1

NO1

COM1

NO2

COM2

NC2

High Flow-Nomally Closed High Flow-COM High Flow-Nomally Open

Low Flow-Nomally Closed

Low Flow-Nomally Open

Low Flow-COM

Hi/Lo Alarm TTL(0-5V)

SIG+

COM

ALARM2

N/C

DC+

COM

DC-

ANLG

PULSE-

PULSE+

SIG-

N/C

ALARM1

N/C

USER DCS

Indicator

Alarm

Indicator

PCA184

SW1

PCA184

SW1

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Installation 16

HP-311

Hi/Lo Alarm Open Collector

USER DCS

Indicator

Alarm

Indicator

2.7K

V+

N/C N/C

N/C

SIG+

ALARM1

DC-

SIG-

COM

PULSE+

ANLG

PULSE-

DC+

ALARM2

3.6. Wiring Note

When installing CAT2, 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 CAT2. 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.

PCA184

SW1