Super Systems CAT-100 User Manual
CAT-100
ATMOSPHERIC CARBON
POTENTIAL ANALYZER
OPERATIONS MANUAL
Super Systems Inc.
7205 Edington Drive
Cincinnati, OH 45249
513-772-0060
Fax: 513-772-9466
www.supersystems.com
CAT-100 Operations Manual
Super Systems Inc.
Page 2 of 51
Super Systems Inc.
USA Office
Corporate Headquarters
7205 Edington Drive
Cincinnati, OH 45249
Phone: (513) 772-0060
http://www.supersystems.com
uper Systems Mexico
S
Sistemas Superiores Integrales S de RL de CV
Calle 3 Int.: 11.
Zona Ind. Benito Juarez
Querétaro, Qro. Méx.
C.P.: 76120
Phone: +52 (442) 210 2459
http://www.supersystems.com.mx
Super Systems Europe
Units 3 & 4, 17 Reddicap Trading Estate,
Sutton Coldfield, West Midlands
B75 7BU
UNITED KINGDOM
Phone: +44 (0) 121 329 2627
http://www.supersystemseurope.com
uper Systems China
S
No. 335 XianXia Road
Phone: +86 21 5206 5701/2
http://www.supersystems.com
Room 308
Shanghai, CHINA
200336
CAT-100 Operations Manual
Super Systems Inc.
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Table of Contents
Introduction ........................................................................................................................................ 5
CAT-100 Specifications ...................................................................................................................... 6
Replacement Parts ............................................................................................................................ 6
Testing Procedure ............................................................................................................................. 8
Unpacking and Charging the CAT-100 .......................................................................................... 8
Entering the Coil Factor ................................................................................................................. 8
Preparing the Insertion Rod with Steel Wire Coil ....................................................................... 10
Using the Insertion Rod in the Testing Environment .................................................................. 12
Cooling Down and Removing the Insertion Rod .......................................................................... 14
Using the Emery Cloth on the Steel Wire Coil ............................................................................ 15
Attaching the Steel Wire Coil to the Binding Posts ..................................................................... 15
Storing Test Results ..................................................................................................................... 16
CAT-100 Menu Navigation ............................................................................................................... 19
Note about Battery Level Indicator .......................................................................................... 20
Main .............................................................................................................................................. 20
Detail............................................................................................................................................. 21
Coil Factor and Advanced Detail Display (Configuration Mode) ............................................. 21
Review Tests ................................................................................................................................. 22
About ............................................................................................................................................. 22
LOGIN ........................................................................................................................................... 23
Calibration .................................................................................................................................... 23
Coil TC Calibration ....................................................................................................................... 25
Comms Setup (Communications Setup) ..................................................................................... 25
Ethernet Setup ............................................................................................................................. 26
DHCP Button ............................................................................................................................. 27
Update .......................................................................................................................................... 28
View Updates ................................................................................................................................ 28
General Setups ............................................................................................................................. 29
Temperature Mode ................................................................................................................... 30
Date/Time Set ........................................................................................................................... 30
Display Theme .......................................................................................................................... 31
Factory Defaults ....................................................................................................................... 31
Clear Tests ................................................................................................................................ 31
Test Enables ................................................................................................................................. 31
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Super Systems Inc.
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Touch Cal (Touch Screen Calibration) ......................................................................................... 32
Pass Code ..................................................................................................................................... 33
Language ...................................................................................................................................... 33
CAT-100 PC Software (CAT-100 View) ............................................................................................ 34
Installation .................................................................................................................................... 34
CAT-100 USB Driver ................................................................................................................. 35
Main Screen .................................................................................................................................. 35
Sorting Data in the Main Screen View ..................................................................................... 37
File Menu ...................................................................................................................................... 37
Show Graph .............................................................................................................................. 37
Export Tests to CSV .................................................................................................................. 38
Print Selected Tests ................................................................................................................. 40
Options Menu................................................................................................................................ 40
Manage CAT100s ...................................................................................................................... 41
Temperature Scale ................................................................................................................... 43
Data Menu .................................................................................................................................... 43
Sort ............................................................................................................................................ 43
Filter.......................................................................................................................................... 43
Users Menu .................................................................................................................................. 44
Log In ........................................................................................................................................ 44
Log Out ...................................................................................................................................... 45
Manage Users ........................................................................................................................... 45
Help Menu .................................................................................................................................... 45
Check for Updates .................................................................................................................... 46
About ......................................................................................................................................... 46
Troubleshooting ............................................................................................................................... 47
Warranty ........................................................................................................................................... 50
Revision History ............................................................................................................................... 51
CAT-100 Operations Manual
Super Systems Inc.
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Introduction
The Super Systems Inc. (SSi) CAT-100 is an Atmospheric Carbon Potential Analyzer that
provides a measurement of Carbon Potential in a positive pressure atmosphere. This
measurement is determined by measuring specific properties of a steel wire coil that has been
inserted into an atmosphere with a carbon-bearing gas for a predefined amount of time. The
CAT-100 system is designed to provide accurate results in a cost-effective manner.
Figure 1 - CAT-100 Carbon Potential Analyzer
The concept behind the CAT-100 is similar to the concept behind the SSi Shim Port with Shim
Stock. The CAT-100 is designed to provide an on-site carbon measurement. More information
on this process can be found in the Testing Procedure section on page 8.
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Super Systems Inc.
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CAT-100 Specifications
Carbon Potential Measurement Specifications
Range: 0.1% to 1.3% Carbon Potential
Read Time: 30 to 45 seconds per coil
Accuracy
Accurate to within ±0.03% Carbon Potential
Operating Temperature
50°F to 100°F (10°C to 377/9°C)
Power
Input Power Range: Universal, 85 – 264 VAC
Input Frequencies Supported: 50 Hz, 60 Hz
Batteries: NiMH (up to 6 hours of continuous operation)
Dimensions
Length of front and rear plates: 12.5 inches
Length of sides: 10.5 inches
Height: 5.5 inches
Weight
9.5 lbs. (approx. 4.31 kg)
Touch Screen
Type: Resistive, TFT LCD
Size: 4.3”
Insertion Rod
Maximum extension length: Approximately 41.4”. (NOTE: An extension to the rod is available
through SSi. The extension piece is approximately 24” in length.)
Replacement Parts
Contact SSi at (513) 772-0060 to order parts.
Figure 2 - Insertion rod
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Super Systems Inc.
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Part
Number
Item
Explanation
13569
CAT-100 Complete Unit
CAT-100 retail unit. Includes all
components in an assembled unit.
13497
Insertion Rod
The rod used to properly insert the
equipment.
20616
Cage Assembly for Insertion Rod
The piece that attaches to the
steel wire coil
20767
Calibration Bridge
The module used to perform a circuit
Calibration section (page 23).
20753
Bag of 100 Coils
Steel wire coils that are inserted into
NOTE:
printed on the bag.
30058
Emery Cloth (Fine Grade, 150 Grit)
A cloth containing coarse material
carbon analysis.
13564
Carrying Case Assembly
Carrying case used to transport and
unit
34601
Hinged Standoff
The long, thin metal standoffs on the
front of the unit that support it
34557
CAT-100 Handle
Handle attached to the top of the
polycarbonate enclosure
32016
Battery
Replacement battery for CAT-100
33018
Power Cord
Power cord used with CAT-100
20759
Custom Foam Packaging
Specially designed packaging
storage
20756
Enclosure
The enclosure that covers the CAT100 unit
steel wire coils into a carboncontaining atmosphere. Typically,
the rod is inserted into the
atmosphere through an access port
on the furnace or other piece of
insertion rod and surrounds the
calibration on the CAT-100. See
a carbon-containing atmosphere for
testing purposes
The % Carbon content of the
untested coils will be imprinted on
this bag. The Coil Factor will also be
used with the steel wire coil prior to
provide protection for the CAT-100
material used to protect the CAT-100
from damage during transport or
Table 1 - Replacement Parts List
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Super Systems Inc.
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First, note the recommended Coil Factor printed on the bag of coils that the coil you are using
Next, log in with Configuration Mode
Figure 3 – Entering Configuration pass code (default is ‘2’)
Open the Detail menu from the main
Figure 4 – Detail screen with Coil Factor box
Testing Procedure
Unpacking and Charging the CAT-100
Carefully remove the packing tape from the box in which the CAT-100 was shipped and remove
the CAT-100, right side up. Using proper lifting technique, place the CAT-100 on a level surface.
If you are going to use the CAT-100 without electrical outlet power, allow the unit to charge
overnight before use. Do this by simply plugging the unit into an AC electrical outlet and
allowing it to charge. Make sure that the unit is charging with the power turned OFF.
Entering the Coil Factor
The Coil Factor for the wire coil is used in calculating Carbon Potential and is based on
variations in coils in a batch. The recommended Coil Factor is printed on each bag of coils and is
the same for all coils in a batch. Before using the coil in the testing process, follow this
procedure for entering and verifying the Coil Factor.
It is essential that this procedure be
followed correctly.
came from. If you do not have the bag, assume a Coil Factor of 100.
on the CAT-100. This is done by
opening the “LOGIN” screen from the
main menu and entering the
Configuration pass code (which is ‘2’
by default).
menu. The Detail screen will be
shown, and the Coil Factor will be
displayed in a box labeled “Factor”.
Tap on that box.
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Super Systems Inc.
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A numeric entry screen will appear.
Figure 5 – Entering a new Coil Factor
The Detail screen will now show the
Figure 6 – Detail screen with new Coil Factor shown
Return to the CAT-100 main status screen.
Enter the Coil Factor that you noted
earlier for the wire coil.
Coil Factor that you entered.
Attach the wire coil to the binding posts as illustrated in Figure 7. Make sure to tighten the
binding posts by turning each screw clockwise; do not overtighten. Also, do not allow the coil to
make contact with the external thermistor.
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Super Systems Inc.
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Note location of
thermistor
Contact point
Contact point
external
Figure 7 - Attaching wire coil to binding posts
Once the coil is attached to the binding posts, note the %Carbon displayed on the CAT-100. The
% Carbon should be as close to
0.83 as possible, or within the range of .83 ±. 03. In order to
increase the %C, increase the Coil Factor. In order to decrease the %C, decrease the Coil
Factor.
Preparing the Insertion Rod with Steel Wire Coil
The wire coil is designed to be placed in the testing atmosphere with the use of a metal
insertion rod that can be purchased from SSi. The parts of the insertion rod, shown in Figure 8,
are as follows:
• Shaft. A long metal shaft supports the working end of the insertion rod (where the wire
coil is housed) and allows the rod to span the length of a typical furnace access conduit.
• Threaded port connector. The port connector is designed to attach to, and provide a tight
connection with, the access port on a furnace.
• Protective cage. The protective cage provides housing for the wire coil when the coil is
attached to the insertion rod.
• Rod screw. The rod screw, which screws into the shaft through the protective cage,
helps keep the protective cage in place on the insertion rod.
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Super Systems Inc.
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IMPORTANT!
Shaft
Protective cage
Rod screw
Threaded port connector
Figure 8 - Parts of metal insertion rod
NOTE: After repeated use, the insertion rod will gradually turn from its silver, “out of the box”
color to a charcoal black color. This is due to the rod’s placement in the furnace atmosphere
and does not affect its function.
To prepare the insertion rod for placement in a testing atmosphere, first slide the “wound”
portion of the wire coil over the rod screw (Figure 9).
Figure 9 - Wire coil placed on rod screw
The wire coil must be placed on the rod screw, not on the protective cage.
Next, slide the rod screw through the opening in the protective cage (Figure 10).
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Super Systems Inc.
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WARNING!
Use ANSI-approved eye protection at all times when working with the insertion rod in a plant or
other testing environment. Take any additional precautions necessary to lower the risk of injury
in the environment in which you are working.
IMPORTANT: Hand tighten rod screw until it
screws tightly in place on insertion rod.
Figure 10 – Rod screw inserted through opening in protective cage
Finally, insert the protective cage and rod screw into the insertion rod (Figure 11); hand tighten
the rod screw until it screws into place tightly on the insertion rod. Ensure that the “legs” of the
protective cage are inserted into the metal stopper on the insertion rod.
Figure 11 - Protective cage and rod screw attached to insertion rod
Using the Insertion Rod in the Testing Environment
The insertion rod is now ready to be placed in the testing atmosphere. Since the testing
atmosphere will be extremely hot, placement in the testing atmosphere is usually accomplished
by extending the insertion rod through an access port in the furnace.
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Temperature in Testing Atmosphere
Soak Time
1575°F and higher
30 minutes
1574°F and below
40 minutes
With the wire coil in place on the insertion rod, place the insertion rod through an access port or
other designated conduit. Begin hand-tightening the threaded port connector by turning the
connector clockwise. See Figure 12.
Figure 12 - Placing insertion rod in access port and tightening threaded port connector
Using a wrench, turn the port connector clockwise to finish tightening it (Figure 13). Take care
not to overtighten the connector.
Figure 13 - Tightening port connector with wrench
Push the insertion rod until the wire coil is present in the testing atmosphere. The wire must
now soak in the atmosphere; the amount of time to soak the wire is based on the temperature
in the testing atmosphere. Table 2 shows the appropriate soak times.
Table 2 - Soak times based on temperature in testing atmosphere
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Super Systems Inc.
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NOTICE!
Exceeding indicated soak times by more than 5 minutes may result in adverse effects on carbon
potential readings when the wire coil is tested with the CAT-100.
WARNING!
Use ANSI-approved eye protection at all times when working with the insertion rod in a plant or
other testing environment. Use heat-resistant hand protection when removing the insertion rod
from the testing environment. Take any additional precautions necessary to lower the risk of
injury in the environment in which you are working.
NOTICE!
Do not immerse the insertion rod or wire coil in water or any other substance other than
ambient air or test environment air at any time. Doing so could damage equipment and will
invalidate the results of any carbon potential test.
Cooling Down and Removing the Insertion Rod
Put on heat-resistant full hand protection (such as welding gloves) before proceeding.
Once the appropriate soak time has been achieved, the insertion rod is ready to be removed.
Proper removal of the insertion rod is essential for achieving accurate carbon readings. Follow
these steps for proper removal.
Recommended:
Measuring tape; stopwatch or watch with seconds indication.
1. Retract the first 6” (six inches) of the insertion rod length from the access port.
2. Pause for one minute.
3. Retract another 3” (three inches) of the insertion rod length from the access port. Pause
for another minute.
4. Repeat Step 3 as many times as needed until the protective cage makes contact with the
ball valve (Figure 14).
Figure 14 - Removing insertion rod from access port
5. Once the insertion rod is fully retracted, leave it in place for a minimum of three
minutes.
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Super Systems Inc.
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NOTICE!
Do NOT quench in water; air cool only. If a method of cooling other than air cooling is utilized,
test results will be unreliable.
IMPORTANT!
IMPORTANT!
6. Close the access port valve.
7. Remove the insertion rod completely from the access port.
Using the Emery Cloth on the Steel Wire Coil
Before the wire coil is attached to the CAT-100 for analysis, the two ends of the wire should be
cleaned. An emery cloth is provided for this purpose. It is recommended that each wire end be
lightly cleaned with emery cloth, as pictured in Figure 15.
Figure 15 - Using emery cloth on wire coil
The correct type of emery cloth must be used for acceptable results. SSi sells a fine grade,
150 grit emery cloth for use in this process. See the Replacement Parts list (page 7) for more
information.
Attaching the Steel Wire Coil to the Binding Posts
Attach one of two wire coil leads to the hole on the right side of one of the two binding posts. Be
sure to insert the coil lead until it touches the back of the post (note the contact points in Figure
16). Then tighten the post to secure the lead. Repeat this procedure for the second lead.
Each lead must touch the back of the post to ensure the correct length of insertion. Note the red
arrows in Figure 16.
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Super Systems Inc.
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IMPORTANT!
Note location of
thermistor
Contact point
Contact point
external
Figure 16 - Attaching wire coil to binding posts
Once the wire coil is secured to the binding posts, close the protective cover on the CAT-100.
Ensure that the wire coil does not make contact with the external thermistor once the wire is
attached to the binding posts. The location of the external thermistor is noted in Figure 16
.
Storing Test Results
Leave the wire coil attached to the binding posts for 30 to 45 seconds. During this time, the %
Carbon reading will likely fluctuate. This is expected and is not an error. After 30 to 45 seconds,
press the button to save the setting to the CAT-100’s internal storage.
Depending on which options are enabled in the Test Enables menu (see page 31
), a series of
screens will appear. If one or more of these options are NOT enabled in the Test Enables menu,
that screen(s) will NOT appear.
• Test ID Entry (Figure 17). This screen gives you the ability to enter an identification
number for the test data that you are saving. When finished, press
↵ to continue.
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