Test Equipment Depot - 800.517.8431 - 5 Commonwealth Ave, MA 01801
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Safety Information. . . . . . 4
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
Specications . . . . . . . 28
Sensors
Test Parameters
Limited Warranty . . . . . . 32
Sensor W
Obtaining Service
. . . . . . . . . 22
tenance.
. . . . . . . 24
arranty
32
Page 3
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, eciency, 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 classied 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 specication.
• Do not use in the rain or wet environments.
54
Page 4
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 eciency
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
76
Page 5
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
98
Page 6
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 Eciency
(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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Page 7
Operation
The CAT45 workow 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 airow 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 diculty
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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Page 8
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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Page 9
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.
1716
Page 10
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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Page 11
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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Page 12
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. (Aects battery life.)
Brightness: HIGH, MEDIUM (default), LOW
(Aects 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
eectively zoom and shift each parameter independently for better
visibility.
Button Sound: ON (default), OFF
(Aects 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.
Eciency 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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Page 13
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)
2524
Page 14
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 notication 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.
2726
Page 15
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
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%
Eciency (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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Page 17
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 verication 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