Fieldpiece Fieldpiece CAT45K2 Manual

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Fieldpiece®
Combustion Analyzer
OPERATOR'S MANUAL
Model CAT45
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Contents
Test Equipment Depot - 800.517.8431 - 5 Commonwealth Ave, MA 01801
TestEquipmentDepot.com
ning and Caution
War
Description . . . . . . . . 6
eatures
F What’s Included
T45 Hardware
CA Common S
Operation. . . . . . . . . 12
SensorVault™ Technology Inline
ery Charging
Batt Powering ON
wering OFF
Po Storage
Job Menu . . . . . . . . . 14
Combustion Ambien Drafts Primary Air Smoke
ampling Points
Water Trap
t CO
Customer . . . . . . . . . 19
e
Not Report Save and Exit Job Archive
Settings
Main
General Dust Filter Replacement Sensor Replacement
alibration
C
Specications . . . . . . . 28
Sensors Test Parameters
Limited Warranty . . . . . . 32
Sensor W Obtaining Service
. . . . . . . . . 22
tenance.
. . . . . . . 24
arranty
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Safety Information
!
!
Only qualified personnel trained in service and installation of electric heaters, boilers, and furnaces shall use this combustion analyzer.
This devic parameters of combustion equipment including oxygen, carbon monoxide, temperature, carbon dioxide, eciency, and draft pressure
R
ead and understand this operator’s manual in its entirety before using to prevent injury or damage to you or the equipment. A any job, appropriate use of personal protective equipment (PPE) is required
e measures and analyzes key
.
s with
.
WARNING
Do not use the analyzer as a safety device.
Always be aware of and test for ambient CO levels.
Do not use unless in a well-ventilated location.
Do not use in areas classied as hazardous locations; not intrinsically safe.
Do not use unless a visual inspection ensures it’s safe to do so.
Ensure any connections to fuel sources are leak-free.
Do not touch or store probe until it cools to ambient temperature.
Condensate may be acidic.
Combustion gases may be toxic even in low concentrations.
Seal any equipment holes used during testing in order to prevent dangerous ue gas entering the space.
CAUTION
Do not use or store near solvents.
Do not clean with solvents.
Do not use on a continuous basis.
Refer to 3rd party smoke test documentation to verify if smoke in equipment is at a safe level (1 or less). Not verifying this prior to conducting other tests, such as combustion, can result in damage of the analyzer and produce incorrect measurements.
This device should only be opened and/or serviced by authorized personnel. Gas sensors may be replaced by user.
Do not disconnect combustion probe cable when powered on.
Use only within operating environment specication.
Do not use in the rain or wet environments.
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Description
The Fieldpiece CAT45 Combustion Analyzer provides a hassle-free solution for technicians to get the job done quickly, easily, and safely while improving system eciency
A
ccurate sensors of O2, CO, pressure, and temperature along with powerful trending, provide key insight into equipment performance S
ensorVault™ technology seals to prolong sensor
life.
.
Features
• 4 Year Gas Sensor Warranty Lar
ge Intuitive Touchscreen
• Powerful Trending
• SensorVault™ Technology
• Inline Water Trap
• Rechargeable Battery I
n-use USB-C Charging
.
• Field Replaceable Smart Sensors
• Job Link® System App Compatible
• Wireless Printer (CATPR) Compatible
• Durable Hard Lined Case
What’s Included
• Combustion Analyzer + Probe
• Hard Lined Carrying Case
• Extra Dust Filters and O-rings
• USB-C Charging Cable
• Operator’s Manual
• 1 Year Device Warranty
• 4 Year Sensor Warranty
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Sensing Point (Flue Gas Inlet, Temperature Sensor, Probe Pressure)
CAT45
(4) Magnetic
Mounts
Click Power Button
(SensorVault™ Technology)
Threaded Probe Cone Lock
Touchscreen LCD
Hardware
O-ring
Filter
Filter Cap (1/4 turn)
Gas Sensor Cover (2) 2.5mm Hex Sockets
USB-C Charging Port
Inline Water Tra p
Permanent Probe Connection
Flue Gas Exhaust
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SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
Common Sampling Points
The many types of combustion equipment vary in their design and therefore their ideal sampling points. However, there are commonalities that make for useful guidelines when analyzing performance.
Heed equipment manufacturer instructions above anything mentioned in this manual.
Before inserting the probe in the ue, it’s good
practice to test for excessive soot which may lead to carbon buildup within the analyzer or overexpose sensors.
Use the probe cone lock to hold the
probe tightly in place at the sampling point.
SP
SP
Power Burner
(Induced Draft)
Tankless Water Heater
SP
High Eciency
(Condensing) Furnace
The center of the ue is often a
good place to locate the sensing point of the probe, but locating at the highest point of CO is best.
SP
Sample Point
Flue Gas Direction
Power Burner
(Induced Draft)
Furnace
Atmospheric
(Natural Draft)
Water Heater
SP
SP
(Natural Draft) Furnace
Atmospheric
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Operation
The CAT45 workow is streamlined to quickly get into your job, complete your testing, send your report, and get onto your next job.
SensorVault™ Technology
The SensorVault™ technology of the power button unseals sensors when powering on and and seals the sensors when powering o. This requires a bit more force than most other buttons so be sure to press fully. You’ll hear a “click”.
Inline Water Trap
Condensate of the hot ue gas must be emptied as the water trap lls else airow to the sensors eventually stops. Rotate 1/4 turn to open and dispose condensate.
Battery Charging
Charge the batteries with the USB-C cable connected to any USB charging port/adapter rated at 5V/2A DC. CAT45 can be operated while charging. If you have diculty charging or using when connected, try a shorter cable or a USB port/adapter with higher rated amps.
Powering ON
Read “Safety Information” section.
1. Ensure inline water trap is sealed.
2. Move probe to fresh ambient air for accurate sensor zeroing.
This step should be executed outside of the test room and away from any vehicle exhaust where traces of CO could be lingering.
Do not rely on the analyzer alone to check for unsafe CO levels.
3. Fully press the power button down until you feel and hear the “click” of the SensorVault™ technology UNSEAL the sensors.
Press deeper if it displays “SEALED”.
4. Wait for start countdown to complete.
5. Start testing. See “Job Menu” section.
Powering OFF
Read “Safety Information” section.
1. Complete your testing and reporting.
2. Empty inline water trap.
3. Move probe to fresh ambient air to clear CAT45 of hot ue gas.
4. Fully press the power button down until you feel and hear the “click” of the SensorVault™ technology seal the sensors.
The unit powers o when SEALED and purging is complete. Press deeper if it displays “UNSEALED.”
5. Store safely. See “Storage” section below.
Allow the timer
to count down before turning ON/OFF again.
Storage
Read “Safety Information” section.
Ensure the probe has cooled to ambient temperature before inserting into its protective sleeve of the carrying case.
Insert the CAT45 body upside down into the padded pocket so the display is fully covered and the cable is free to move.
Do not stack objects on top of the case.
Warmup is extended if freezing temperatures are detected, but it’s best to store at room temperature.
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Job Menu
The JOB MENU is the heart of CAT45. Each job has its own list of saved tests. After saving your tests, view directly in the Job Link® mobile app or send your report to a model CATPR wireless thermal printer. SAVE AND EXIT when you’re ready for your next job. Jobs are automatically numbered sequentially to view, continue, or delete jobs
Combustion
By default, the COMBUSTION test starts automatically after startup is complete. This test analyzes ue gas from various heating equipment. Use this test to setup, test, and document equipment performance.
Read “Safety Information” section.
1. Ensure startup is complete. See “Powering On” section.
2. Mount the CAT45 onto a secure, cool, magnetic surface near the
sampling point.
3. Twist probe cone lock into the ue port at the sampling point and
secure the probe. See “Common Sampling Points” section.
4. Select COMBUSTION from the JOB MENU.
5. Select the fuel and equipment type.
6. View live measurements.
For best results, test for at least 5 minutes near the center of the ue, where you nd the highest level of CO.
7. SAVE ALL measurements displayed.
8. Remove the probe and cone from the ue when nished.
Be careful not to let the metal touch anything until it cools.
Open the JOB ARCHIVE
.
.
Reference Ranges
When selecting equipment, the reference range icon shows when available. Temperature, O2, CO, and CO air free all have reference ranges. These ranges show the generally accepted ranges for the chosen equipment type. The arrow is GREEN if within the reference range and YELLOW if not. These ranges are for reference only.
ZERO PROBE
ZERO PROBE sets the pressure sensor to 0 and resets the oxygen zero point. Always remove the probe from the ue before using ZERO PROBE. For the very best O2 measurements, start the pump and keep the probe in ambient air for 2 minutes before using ZERO PROBE.
CO Sensor Overexposure
Do not power o if you see this warning. It appears if the CO sensor detects a potentially damaging level of CO. Remove the probe from the ue so fresh ambient air can pump through the device.
Trending
Use trending to check how combustion parameters change over time. See “Settings” section for TRENDING SETUP.
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Ambient CO
CO is a very dangerous gas and it’s critical that living spaces are
clear of carbon monoxide.
Read “Safety Information” section.
1. Ensure startup is complete. See “Powering On” section.
2. Select AMBIENT CO from the JOB MENU.
3. View CO measurement while walking through the living space.
4. SAVE the measurement displayed.
“DELETE” temporarily deletes a single value so you can retest. “DELETE TEST” deletes the test.
Ambient CO Warning
Vacate the area immediatly if you see the Ambient CO warning. It appears if the CO sensor detects a harmful level of CO. The CO warning level can be adjusted from the warning screen.
Drafts
CAT45 does not measure draft pressure with the COMBUSTION test, but a saved FLUE DRAFT measurement shows during COMBUSTION. Draft pressure measurement is important for safety and performance.
Read “Safety Information” section.
1. Ensure startup is complete. See “Powering On” section.
2. Select DRAFTS from the JOB MENU.
3. Mount the CAT45 onto a secure, cool, magnetic surface near the
sampling point.
4. ZERO PROBE to zero the probe’s pressure sensor.
Always remove the probe from the ue before using ZERO PROBE.
5. Move probe to desired sampling point- DILUTED, FLUE, or
OVERFIRE.
6. View live measurement.
7. SAVE the measurement displayed.
“DELETE” temporarily deletes a single value so you can retest. “DELETE TEST” deletes the test.
8. Remove the probe from the sampling point when nished.
Be careful not to let the metal touch anything until it cools.
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Primary Air
Primary air temperature is measured during startup and is used for the COMBUSTION test. This is the temperature of the air going into the combustion equipment. It’s sometimes useful to set it after startup if the ambient temperature changes. You can enter it manually or use the probe’s temperature sensor.
Read “Safety Information” section.
1. Ensure startup is complete. See “Powering On” section.
2. Select PRIMARY AIR from the JOB MENU.
3. Move the probe to the entry point of air into the combustion
equipment.
4. View live measurement or use the keyboard onscreen to
manually enter a value.
5. SAVE the temperature.
“DELETE” temporarily deletes a single value so you can retest. “DELETE TEST” deletes the test.
Smoke
The smoke test is used to document the soot levels within the ue. This is good practice when “dirty” combustion is expected in order to extend the life of CAT45 and equipment. A third party smoke tester is needed.
Read “Safety Information” section.
1. Ensure startup is complete. See “Powering On” section.
2. Select SMOKE from the JOB MENU.
3. Use your smoke tester to nd the smoke level.
4. Select the corresponding level on screen.
5. SAVE the smoke level.
“DELETE” deletes the entry.
Customer
Each job has a customer entry. JOB ARCHIVE uses this entry for searching. You can use this eld for whatever you want. For example, it can be a serial number or a phone number. See “Settings” section for report contents.
1. Ensure startup is complete. See “Powering On” section.
2. Select CUSTOMER from the JOB MENU.
3. Use the keyboard to enter.
4. SAVE the customer.
“DELETE” deletes the entry.
Note
Each job has a note entry.
1. Ensure startup is complete. See “Powering On” section.
2. Select NOTE from the JOB MENU.
3. Use the keyboard to enter.
4. SAVE the note.
“DELETE” deletes the entry.
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Report
Each job has a report which is a collection of saved tests, your company info, reference O2, date, and time. Date and time is recorded at the time of sending the report. Edit report contents from settings.
1. Ensure startup is complete. See “Powering On” section.
2. Select REPORT from the JOB MENU.
At least one test must be saved to view the job report. Access the JOB MENU of saved jobs from JOB ARCHIVE.
3. Scroll through the report using the scroll bar.
4. PRINT to model CATPR wireless thermal printer.
PRINT button is active if CATPR is detected.
5. DELETE JOB deletes the job from memory.
Save and Exit
SAVE AND EXIT to save your job and start a new job, sequentially
numbered. You can return to saved jobs from JOB ARCHIVE.
Low Memory Notice
A notice appears when memory is too low to SAVE AND EXIT. Delete
jobs individually from JOB ARCHIVE or delete all jobs from SETTINGS.
Job Archive
Open JOB ARCHIVE from the JOB MENU.
Job Link® System Reporting
Turn Job Link System ON to view CAT45 in the Job Link system mobile app (see “Settings” section). The Fieldpiece Job Link system app is extremely powerful and ever evolving.
View live combustion and all saved tests of the current job directly in the app. Then email a report quick and easy directly from your mobile device!
Sort jobs by date.
Search jobs by customer.
Select a job to open it.
Use the X icon to delete a job
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Settings
Access SETTINGS from the top right corner of the Job Menu its options or to its own screen (blue arrow).
The DEFAULTS button in the top right corner of the settings reverts to default settings, but jobs are not deleted.
Job Link® System: OFF (default), ON
Select ON to view live combustion and saved tests on the Job Link
system mobile app. (Aects battery life.)
Brightness: HIGH, MEDIUM (default), LOW
(Aects battery life.)
. Ea
ch setting button cycles through
Startup Screen: COMBUSTION (default), JOB MENU, FUEL TYPE
Set which screen you want to see after start countdown is complete.
Auto Hold Display: PUMP STOP (default), NEVER
Select NEVER to continue viewing live measurements while the pump is stopped.
Combustion Setup: EDIT to select parameters and their slots on the
COMBUSTION screen. To hide a slot completely, assign a parameter to the slot you want to hide, then assign that parameter to another slot.
Trending Setup: EDIT to select parameters on the TRENDING screen.
SET LIMITS to adjust each parameter’s UPPER (maximum) and LOWER (minimum) values of the graph. Controlling these limits allows you to eectively zoom and shift each parameter independently for better visibility.
Button Sound: ON (default), OFF
(Aects battery life.)
Sensor Remaining (status): % O2 and % CO sensor life remaining.
New sensors show 100%. When life of either sensor is below 5%, a
notice appears at startup.
Memory % Free (status): % of memory remaining for saving jobs.
When memory is too low, a notice appears when trying to SAVE AND
EXIT a job. DELETE ALL is a quick way to delete all jobs and restart at
JOB #1. Delete single jobs from within the JOB ARCHIVE screen.
Date and Time: EDIT to adjust date and time. 24 hour time is always
used. Date format is always set to Year-Month-Day for easy sorting.
Company Information: EDIT to adjust Company Information shown
on reports.
Report Contents: EDIT to select what is shown on reports.
Language (status): English (default) This is not adjustable.
Temperature Unit: ° F (default), °C
Pressure Unit: inWC (default), torr, Pa
[%] Reference O2: 6.0% (default) EDIT to adjust the reference oxygen
% used for calculating CO Air Free.
Eciency Calculation: Standard (default), Siegert
Siegert’s formula is typically only used in parts of Europe.
Firmware [version]: UPDATE to install new rmware if it becomes
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Maintenance
Dust Filter Replacement
Replace the dust (particulate) lter if you notice
slow response times or when it’s visually darker.
Dust Filters: model RFC10
General
Wipe with damp cloth to clean the exterior. Do not use solvents.
1. Ensure the probe has cooled before opening to avoid contact with hot gas and liquid that may be within the probe.
2. Rotate the Filter Cap 1/4 turn counter-clockwise to release.
3. Pull out the old Probe Filter and replace if needed.
4. Pull out the O-ring and replace if needed.
5. Replace the Filter Cap.
O-ring
Filter
Filter Cap (1/4 turn)
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Carbon Monoxide Sensor (RSCOR)
Sensor Cover
Sensor Replacement
SensorVault™ technology prolongs the life of sensors, but they eventually need to be replaced. When a sensor’s life drops below 5%, a notication appears during startup to inform you it’s time to replace it. You can view estimated remaining life at any time in SETTINGS.
O2 sensor
CO sensor: model RSCOR
1. Double check which sensor needs to be replaced.
Leave a new sensor in its packaging until you’re ready to install it.
2. Power o CAT45.
3. Use a 2.5mm hex key to remove the two socket head screws on
the sensor cover labeled SENSOR ACCESS.
4. Lift up the bottom of the sensor cover to reveal the gas sensors.
5. Pull the old sensor straight out.
6. Check and remove the new sensor from its packaging.
7. Align and push the new sensor straight in.
The sensor cover won’t close if the sensor is inserted incorrectly.
8. Tilt the sensor cover lip back into place and fasten screws.
9. Power on CAT45 to check sensor life in SETTINGS.
Anything above 95% is normal.
: model RSO2L
Oxygen Sensor (RSO2L)
2.5mm Hex Sockets
Calibration
Replacement sensors have calibration data built-in and do not require calibration.
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Specifications
Display: Touchscreen TFT LCD (5.5 in diagonal) Probe Size: 10.7 in (272 mm) length, 0.32 in (8.0 mm) diameter Accuracy: Stated accuracies at 23°C ±5°C, <75% R.H. Battery Type: 3.7 VDC (nominal), 6400mAh, non-replaceable Battery Life: 7 hours typical (pump running 80% of the time) Charge Time: < 7 hours typical @ 5V/2A DC power
(USB power adapter not included)
Charging Port: USB-C (Usable when connected to power.) Memory: 1000 jobs (approx.) Warm Up Time: Operating Environment: 14°F to 104°F (-10°C to 40°C); < 75% RH (non-condensing) S
torage Temperature: -4°F to 140°F (-20°C to 60°C); < 80% RH
Weight: 39.5 oz (1120 g) with probe
Wireless Range: 1000 feet (305 meters) Fuel Types: Natural Gas, Propane (LPG), Oil #2 (Light), Oil #6 (Heavy),
Biofuel, Coal, Coal Town Gas, Coking Oven Gas, KOKS, Custom (x3)
Warranty: Job Link® System Minimum:
BLE 4.0 devices running iOS 7.1 or Android™ Kitkat 4.4
Printer: Fieldpiece Wireless Thermal Printer (model CATPR)
ertications:
C
45 seconds (90 seconds near freezing)
1 year (4 years sensors only)
Sensors
Temperature
Sensor Type: Type K rod thermocouple (xed)
Response Time: < 30 seconds (T90)
Oxygen %
Sensor Type: Electrochemical (replaceable)
Response Time: < 30 seconds (T90)
Max Overload: 30% Oxygen
Carbon Monoxide PPM
Sensor Type: Electrochemical (replaceable)
Response Time: < 90 seconds (T90)
Max Overload: 10000 ppm Carbon Monoxide
Pressure (Probe)
Sensor Type: MEMS pressure sensor
Response Time: < 10 seconds (T90)
Max Pressure: 4.0 inWC will cause damage
Units: inWC, torr, Pa
FCC ID: 2ALHRCATX5
IC: Industry Canada
IC: 22518-CATX5
Waste Electrical and Electronic Equipment
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Test Parameters
Stack Temperature
Range: 32 to 752°F; 0 to 400°C Best resolution: 0.1°F; 0.1°C Accuracy:
±2.5°F [32°F to 212°F], ±(3.6°F or 1.5%rdg) [213°F to 752°F]; ±1.4°C [0°C to 100°C], ±(2.0°C or 1.5%rdg) [101°C to 400°C]
O2
Range: 0 to 21 vol.% Best resolution: 0.1 vol.% Accuracy: ±0.3 vol.%
CO
Range: 0 to 4000 ppm Best resolution: 1 ppm Accuracy: ±20 ppm [0 to 400 ppm], ±5%rdg [401 to 2000 ppm],
±10%rdg [2001 to 4000 ppm]
Draft Pressure
Range: 0 to ±0.8 inWC Best resolution: 0.01 inWC Accuracy: ±0.02 inWC
CO Air Free (Calculated)
Range: 0 to 4000 ppm Best resolution: 1 ppm
CO2 (Calculated)
Range: 0 to CO2max vol.% Best resolution: 0.1 vol.%
Excess Air (Calculated)
Range: 0 to 999% Best resolution: 0.1%
Eciency (Calculated)
Range: 0 to 100% Best resolution: 0.1%
qA (Calculated)
Range: 0 to 25% Best resolution: 0.1%
Dew Point (Calculated)
Range: 32 to 212°F; 0 to 100°C Best resolution: 0.1°F; 0.1°C
Primary Air Temp
Range: 32 to 212°F; 0 to 100°C Best resolution: 0.1°F; 0.1°C
Accuracy: ±2.5°F [32°F to 212°F]; ±1.4°C [0°C to 100°C]
Ambient CO
Range: 0 to 200 ppm Best resolution: 1 ppm Accuracy: ±20 ppm
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Limited Warranty
This device is warranted against defects in material or workmanship for one year from date of purchase from an authorized Fieldpiece dealer.
The O2 and CO sensors are warranted against defects in material or workmanship for four years from date of purchase from an authorized Fieldpiece dealer
F
ieldpiece will replace or repair the defective unit, at its option, subject to verication of the defect.
Th
is warranty does not apply to defects resulting from abuse, neglect, accident, unauthorized repair, alteration, or unreasonable use of the analyzer.
Any implied warranties arising from the sale of a Fieldpiece product, including but not limited to implied warranties of merchantability and tness for a particular purpose, are limited to the above. Fieldpiece shall not be liable for loss of use of the analyzer or other incidental or consequential damages, expenses, or economic loss, or for any claim of such damage, expenses, or economic
.
loss
S
tate laws vary. The above limitations or
exclusions may not apply to you
.
.
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(Intentionally Blank) (Intentionally Blank)
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CAT45
© Fieldpiece Instruments, Inc 2022; v01
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