Fieldpiece CAT45K2 User manual

Fieldpiece®
Combustion Analyzer
OPERATOR'S MANUAL
Model CAT45

32
Contents
Safety Information. . . . . . 4
Warning and Caution
Description . . . . . . . . 6
Features
What’s Included
CAT45 Hardware
Common Sampling Points
Operation. . . . . . . . . 12
SensorVault™ Technology
Inline Water Trap
Battery Charging
Powering ON
Powering OFF
Storage
Job Menu . . . . . . . . . 14
Combustion
Ambient CO
Drafts
Primary Air
Smoke
Customer . . . . . . . . . 19
Note
Report
Save and Exit
Job Archive
Settings . . . . . . . . . 22
Maintenance. . . . . . . . 24
General
Dust Filter Replacement
Sensor Replacement
Calibration
Specications . . . . . . . 28
Sensors
Test Parameters
Limited Warranty . . . . . . 32
Sensor Warranty
Obtaining Service

54
Safety Information
Only qualified personnel trained in service
and installation of electric heaters, boilers, and
furnaces shall use this combustion analyzer.
This device measures and analyzes key
parameters of combustion equipment including
oxygen, carbon monoxide, temperature, carbon
dioxide, eciency, and draft pressure.
Read and understand this operator’s manual
in its entirety before using to prevent injury
or damage to you or the equipment. As with
any job, appropriate use of personal protective
equipment (PPE) is required.
!
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.

76
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.
Accurate sensors of O2, CO, pressure, and
temperature along with powerful trending,
provide key insight into equipment performance.
SensorVault™ technology seals to prolong sensor
life.
Features
• 4 Year Gas Sensor Warranty
• Large Intuitive Touchscreen
• Powerful Trending
• SensorVault™ Technology
• Inline Water Trap
• Rechargeable Battery
• In-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

CAT45
Hardware
98
Flue Gas
Exhaust
USB-C
Charging
Port
Permanent Probe Connection
Touchscreen LCD
Inline
Water
Trap
Gas Sensor Cover
(2) 2.5mm Hex Sockets
(4) Magnetic
Mounts
Click Power Button
(SensorVault™Technology)
Threaded
Probe Cone
Lock
Filter Cap
(1/4 turn)
Sensing Point
(Flue Gas Inlet,Temperature Sensor, Probe Pressure)
Filter
O-ring

Atmospheric
(Natural Draft)
Water Heater
High Eciency
(Condensing) Furnace
Power Burner
(Induced Draft)
Furnace
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP SP
SP
SP
SP
SP
SP
SP SP
SP
SP
SP
SP
SP
SP SP
SP
SP
SP
SP
SP
Power Burner
(Induced Draft)
Tankless Water Heater
Flue Gas Direction
SP SP
SP
SP
SP
SP
SP
SP SP
SP
SP
SP
SP
SP
Sample Point
Atmospheric
(Natural Draft) Furnace
1110
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.
• 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.

1312
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.
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.
Allow the timer
to count down
before turning
ON/OFF again.

1514
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. Open the JOB ARCHIVE
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.
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 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.

1716
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.

1918
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.