Fieldpiece CAT85K2 User manual

Fieldpiece®
Combustion Analyzer HC
OPERATOR'S MANUAL
Model CAT85

32
Contents
Safety Information. . . . . . 4
Warning and Caution
Description . . . . . . . . 6
Features
What’s Included
CAT85 Hardware
Common Sampling Points
Operation. . . . . . . . . 12
SensorVault™ Technology
HydroCycle™ Pump
Battery Charging
Powering ON
Powering OFF
Storage
Job Menu . . . . . . . . . 14
Combustion
Ambient CO
Drafts
Primary Air
Smoke
Fuel Pressures
Manometer . . . . . . . . 20
Customer
Note
Report
Save and Exit
Job Archive
Settings . . . . . . . . . 24
Maintenance. . . . . . . . 26
General
Dust Filter Replacement
Sensor Replacement
Calibration
Specications . . . . . . . 30
Sensors
Test Parameters
Limited Warranty . . . . . . 34
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 CAT85 Combustion Analyzer HC
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.
Live draft pressure measurement maintains
accuracy throughout your combustion test.
Dual manometer ports are also included for
convenience.
The combustion probe uses a patent pending
HydroCycle™ pump to return condensate back
into the ue - no more water trap hassles!
Features
• 4 Year Gas Sensor Warranty
• Large Intuitive Touchscreen
• Powerful Trending
• SensorVault™ Technology
• HydroCycle™ Pump
• Real-time Live Draft Pressure
• Dual Manometer Ports
• 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
• Combustion Probe + HydroCycle™ Pump
• 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

CAT85
Hardware
98
Flue Gas
Exhaust
USB-C
Charging
Port
P1 Pressure Port
Probe Connection
P2 Pressure Port
Touchscreen LCD
Gas Sensor Cover
(2) 2.5mm Hex Sockets
Probe Cable Connector
(Pull/Push at Arrows)
(4) Magnetic
Mounts
Click Power Button
(SensorVault™Technology)
Threaded
Probe Cone
Lock
HydroCycle™ Pump
Condenser Ventilation
Filter Cap
(1/4 turn)
HydroCycle™ Pump
Condensate Outlet
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 CAT85 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”.
HydroCycle™ Pump
The CAT85 does not have a water trap. Instead,
ue gas condensate is automatically pumped
back out of the front of the probe at a regular
interval. Point the probe downwards as you
remove it to empty any remaining condensate
before storing.
Battery Charging
Charge the batteries with the USB-C cable
connected to any USB charging port/adapter
rated at 5V/2A DC. CAT85 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. Push the probe cable connector into the bottom of CAT85.
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. Move probe to fresh ambient air to
clear CAT85 of hot ue gas.
3. 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.”
4. 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 CAT85 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 CAT85. 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 CAT85 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 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.

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
CAT85 saves live draft pressure with the COMBUSTION test, but a
saved FLUE DRAFT measurement overrides this value. Draft pressure
measurement is important for safety and performance.The probe
pressure sensor is used for all three drafts.
Read “Safety Information” section.
1. Ensure startup is complete. See “Powering On” section.
2. Select DRAFTS from the JOB MENU.
3. Mount the CAT85 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 CAT85 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.
Fuel Pressures
CAT85 has P1 and P2 pressure ports for connecting hoses (not
included) to gaseous fuel sources/regulators. Do not test liquid fuels.
This is very similar to the Manometer test, but uses fuel-centric labels
that aid in reporting.
Read “Safety Information” section.
1. Ensure startup is complete. See “Powering On” section.
2. Shut o main gas supply power to equipment.
3. Mount the CAT85 onto a secure, cool, magnetic surface near the
test point(s).
4. Connect a static pressure hose to P1 to measure INLET pressure.
Connect astatic pressure hose to P2 to measure OUTLET pressure.
An additional OUTLET pressure is available for two stage systems.
5. Select FUEL PRESSURES from the JOB MENU.
6. ZERO each pressure port sensor, P1 and P2 before connecting to
fuel source. Ensure there are no kinks in the hose.
7. Connect hose(s) to INLET and/or OUTLET.
8. View live measurements.
9. SAVE any measurement displayed.
“DELETE” temporarily deletes a single value so you can retest.
“DELETE TEST” deletes the test.
10. Follow manufacturer’s specication for target inlet and outlet
fuel pressures before operating equipment.