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Fyrite INSIGHT ® Combustion Gas Analyzer (Siegert Version) Instruction 0024-9461 Operation & Maintenance Rev. 4 – October 2011 Product Leadership • Training • Service • Reliability...
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WARRANTY Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in mater ial and manufac ture and will conform substan tially to Bacharach Inc.’s ap plicable specifications. Bacharach’s liability and Buyer’s remedy under this warranty are limited to the repair or replacement, at Bacharach’s option, of this Product or parts thereof returned to Seller at the factory of manufac ture and shown to Bacharach Inc.’s...
Contents 1.0 INTRODUCTION ................1 ® 1.1 The Fyrite INSIGHT .................1 ® 1.2 Fyrite INSIGHT Features & Benefits ..........2 1.3 Operational Overview ................5 2.0 TEChNICAl ChARACTERISTICS ..........6 3.0 SETTING UP ThE ANAlYZER ............8 3.1 Preliminary Steps ................8 3.2 Power ....................8 3.2.1 Installing or Replacing Batteries ............8 3.2.2 Using the AC Power Adapter ............
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4.7 Temperature Measurement ..............38 4.8 Saving Test Data ................38 4.9 Ending a Combustion Test ...............39 4.10 Emptying the Water Trap ..............39 4.11 Powering Off the Analyzer & Purging ..........40 4.12 Low Battery Alarm ................40 4.13 Memory ..................40 4.13.1 Averaging Stored Test Data ............41 4.14 Printing Test Data ................43 ®...
Caution statements may also be used to alert against unsafe practices. To assure operator safety and the proper use of the Fyrite INSIGHT, please read the contents of this manual for important information on the operation and maintenance of the analyzer. This manual contains infor- mation on all models of the Fyrite INSIGHT.
Fyrite INSIGHT CAUTIONS! • When the instrument is used in an inefficient furnace or boiler application where there is a high emission of soot, probe sample filter may become clogged. Check filter before every use to confirm that it is clean for use or replace with a new filter. To prevent this from occurring, a smoke test should be performed before operating under such conditions to ensure that the furnace is burning at a level appropriate for the use of this instrument. • Use only the Bacharach AC Adapter. Failure to do so could result in damage to the unit and void the warranty. • Do not store instrument or its sensors with solvents or products that contain solvents. ® 1.2 Fyrite INSIGHT Features & Benefits AUTO/MANUAL ZERO - In automatic mode, the instrument automati- cally zeroes all sensing channels on ambient air when it is powered on. If...
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Fyrite INSIGHT Temperatures. AVERAGING - The Fyrite INSIGHT can average 3 like records and ® print out the information. DOWNLOAD - Test records can be downloaded to a personal computer via the USB port. Saved records are transferred using PC based software and will be automatically loaded into an Excel spreadsheet.
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Fyrite INSIGHT KEYPAD SOUND - Keypad sounds can be enabled or disabled with soft- ware menu selections. LOW BATTERY - A tone will sound every 10 seconds when a low battery condition exists. A low battery message will also be displayed.
Fyrite INSIGHT 1.3 Operational Overview Pressing the PWR button turns the analyzer ON. Note that there is a warm-up period of 60 seconds that must elapse before the analyzer can be used. To perform a combustion test, choose a fuel code that corresponds to the fuel being burned by the appliance being tested (Section 4.3), and then...
Fyrite INSIGHT 2.0 Technical Characteristics The Analyzer Measures & Displays: Oxygen 0.1 to 20.9% O Carbon Monoxide 0 to 2000 ppm Stack Temperature -20 to 650 °C (-4 to 1202 °F) Primary/Ambient Air Temperature -20 to 316°C (-4 to 600 °F) CO Differential Pressure/Draft + 249 mB (±...
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Fyrite INSIGHT General Characteristics: Power Requirements Four disposable ‘AA’ Alkaline batteries (op- tional AC adapter is available) Operating Time Minimum of 20 hours continuous operation (pump running and backlight ON) Warm Up Time 60 seconds Memory Up to 100 complete sets of combustion, temperature, &...
Fyrite INSIGHT 3.0 SETTING UP ThE ANAlYZER 3.1 Preliminary Steps Before using the analyzer . . . • Check batteries (Section 3.2) • Connect probe to analyzer (Section 3.3) • Check setup (Section 3.6) 3.2 Power 3.2.1 Installing or Replacing Batteries Install fresh batteries as described below.
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Fyrite INSIGHT Inspect the flue-gas hose for cracks. If a hose is defective, replace the entire probe assembly. Before using the analyzer, check that the Water Trap / Filter is dry and not dirty. If necessary, dry out the trap and replace the filter element per Section 6.2.
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Fyrite INSIGHT ® Fyrite INSIGhT Connectors USB Cable AC Power Primary Ambient Adapter Jack Air Thermocouple (Power) (T-Air) (Optional) Differential Pressure Hose Sample Gas Draft (Optional) Hose Hose Sample Gas Thermocouple Connector (T-Stack) Probe Tube Probe Water Trap/ Stop Filter Assembly...
Fyrite INSIGHT Front Panel Push Buttons Note that a push button may perform several functions, depending on the analyzer’s model number and the screen that is displayed. • Pressing function keys accepts the corresponding function defined at the bottom of the display, including PRINT, SAVE, MENU, differential pressure ZERO, differential temperature ZERO, PAGE UP, PAGE DOWN and CLEAR data.
Fyrite INSIGHT Power-Up & Run/Hold Screen Overview Press the PWR button to power up the analyzer. Information about the device’s software version, model number and serial number will be dis- played briefly. Version: V2.00 8252 Model: 0024- Serial: NW1060 A warm up screen, displaying a 60 second count- down, will then appear.
Fyrite INSIGHT 3.6 Setup Mode The analyzer is preset at the factory with the parameters displayed below, but can be modified as described in their corresponding sections. Function Parameter To modify, refer to: Fuel Natural Gas Section 4.3 Temperature Unit °C...
Fyrite INSIGHT • Press ▲ ▼ buttons to scroll/highlight options. • Press (ENTER) to select or save. • Press ESC to go back. 3.7 The Setup Menu 1. Press the MENU (F2) button to access the Main Menu. 2. Scroll to Setup. Press ENTER.
5. Save and return to the Setup Menu or press ESC to cancel. 3.7.3 Smoke Number Three smoke numbers, as measured by the Bacharach True Spot Smoke tester, can be manually entered into the analyzer and their average auto- matically calculated. The average smoke number will be displayed on the combustion test Run/Hold screen.
Fyrite INSIGHT • Press ▲ ▼ buttons to scroll/highlight options. • Press (ENTER) to select or save. • Press ESC to go back. 3. Use the ◄► buttons to enter the desired smoke number for the op- tions in the list.
Fyrite INSIGHT • Press ▲ ▼ buttons to scroll/highlight options. • Press (ENTER) to select or save. • Press ESC to go back. 3.7.5 Boiler Temperature Use the Boiler Temperature screen to manually enter a boiler temperature as measured by an external thermocouple. Boiler temperature information will be displayed on the combustion test Run/Hold screen .
Fyrite INSIGHT • Press ▲ ▼ buttons to scroll/highlight options. • Press (ENTER) to select or save. • Press ESC to go back. 4. Save and return to the Setup Menu or press ESC to cancel. 3.7.7 O Reference The measured value of CO can be referenced to a specific O percentage of 0% to 15%.
Fyrite INSIGHT • Press ▲ ▼ buttons to scroll/highlight options. • Press (ENTER) to select or save. • Press ESC to go back. 3. Select Yes or No in regard to printing the pressure measurement. 4. Save and return to the Setup Menu or use ESC to cancel.
Fyrite INSIGHT • Press ▲ ▼ buttons to scroll/highlight options. • Press (ENTER) to select or save. • Press ESC to go back. 4. Save and return to the Setup Menu or use ESC to cancel. 3.7.10 Username The name of the user or owner (e.g. company name, address, phone num- ber) can be stored in system memory.
3.7.11 Run/hold Format Fyrite INSIGHT test data is displayed on the Run/Hold screen. The RUN/hOlD button is used to toggle between Run and Hold. Press the RUN/hOlD button to start the pump. While it is running, the word Run will appear in the upper-left corner of the display.
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Fyrite INSIGHT • Press ▲ ▼ buttons to scroll/highlight options. • Press (ENTER) to select or save. • Press ESC to go back. The default order in which data is displayed is listed below. Oxygen Carbon Monoxide LAMBDA Excess air...
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Fyrite INSIGHT • Press ▲ ▼ buttons to scroll/highlight options. • Press (ENTER) to select or save. • Press ESC to go back. 3. Select to display the current format. 4. Scroll to the item in the list to be modified and press the ENTER button.
Fyrite INSIGHT • Press ▲ ▼ buttons to scroll/highlight options. • Press (ENTER) to select or save. • Press ESC to go back. 3. Select Reset Format. 4. Select Yes. Press the ENTER button to reset the format and return to the Run/Hold format options.
Fyrite INSIGHT • Press ▲ ▼ buttons to scroll/highlight options. • Press (ENTER) to select or save. • Press ESC to go back. 4. Press ENTER to activate the selection and return to the Setup Menu or press ESC to cancel.
Fyrite INSIGHT • Press ▲ ▼ buttons to scroll/highlight options. • Press (ENTER) to select or save. • Press ESC to go back. Screen for normal operation. Regular calibration periods of 6 months to 1 year are recommended. NOTE: The default CAL Reminder period is Never.
Fyrite INSIGHT • Press ▲ ▼ buttons to scroll/highlight options. • Press (ENTER) to select or save. • Press ESC to go back. Set the Inactivity Timeout Period as follows: 1. Access the Setup Menu per Section 3.7. 2. Select Inactivity Timeout.
Fyrite INSIGHT • Press ▲ ▼ buttons to scroll/highlight options. • Press (ENTER) to select or save. • Press ESC to go back. 4. Save the selection and return to the Setup Menu or ESC to cancel. 3.7.17 Auto/Manual Zero Feature...
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Fyrite INSIGHT Both methods take the user through a 60-second count down to establish a new zero. The manual mode establishes a fresh air zero and stores it for use during instrument startup. Auto-Zero versus Manual Zero...
Fyrite INSIGHT 4.0 OPERATION 4.1 Operating Tips • When an analyzer is brought in from a cold vehicle, let it warm up slowly to minimize condensation. Temperatures below freezing will not damage the analyzer; however, bringing a cold analyzer into a warm, humid environment may cause condensation to form inside the case.
Fyrite INSIGHT Analyzer Power On & Warm Up 1. Connect the probe and make sure that the analyzer is properly set up per Section 3. IMPORTANT! DO NOT insert probe into stack before powering on the analyzer. 2. Place the probe in an area that contains fresh air. This ensures that the sensors will be properly zeroed during the warm-up cycle.
Fyrite INSIGHT If necessary, change the fuel as follows: 1. Press F2 to access the Setup Menu (per Section 3.7.) 2. Select FUEL. Press ENTER to display the Fuel Selection screen. 3. Select the desired fuel. 4. Press ENTER to view the default value; select Adjust to modify the default value.
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Fyrite INSIGHT Hot Water Tank – Domestic hot water tanks with the ‘bell’ shaped draft diverter on top can be accurately tested by inserting the probe tip directly into the top of the fire tube below the diverter. 80% Efficiency Fan Assist or Power Vented – Combustion testing of fan assist or power vented, furnaces/boilers should be done through a hole drilled in the vent approximately 12 inches above the inducer fan.
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Fyrite INSIGHT hot Water Tank Atmospheric Burner or Gravity Vented Forced Air Atmospheric or Gravity Vented Boiler 80% Eff. Fan Assist or Power Vented Furnace/Boiler Fig. 4.1 90% Eff. Condensing Furnace/Boiler...
Fyrite INSIGHT 4.5 Performing a Combustion Test Ensure that the following has been completed, and then proceed with the combustion test as described below: • Power on the analyzer and allow it to warm up (Section 4.2). • Select fuel being burned (Section 4.3).
Fyrite INSIGHT 4. Pressing the RUN/hOlD button freezes all readings, stops the pump and displays the Combustion-Test HOLD screen. Scroll to view all test values at the moment the RUN/hOlD button was pressed. Pressing RUN/hOlD again restarts the pump and resumes testing.
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Fyrite INSIGHT 4. Before taking a measurement, the pressure sensor may need to be re-zeroed if it is not already displaying zero with both pressure ports open to the atmosphere. If necessary, zero the pressure sensor as follows: • Press the ZERO (F2) button.
Fyrite INSIGHT 4.7 Temperature Measurement The difference in temperature between two areas can be measured by us- ing the analyzer’s two temperature channels and the Temperature Screen. By using the T-Air channel as a reference, the temperature applied to the T-Stack channel will be displayed on the Temperature Measurement screen as differential temperature between the two channels.
Fyrite INSIGHT NOTE: When memory is full, the next reading will not be saved until space is made available by clearing previously saved data. (Section 4.13) 4.9 Ending a Combustion Test WARNING! Burn Hazard. Do not touch the probe af- ter removing it from the stack. Allow the probe to cool before handling (about 5 minutes). 1. Remove probe from the flue-gas stream.
Fyrite INSIGHT 4.11 Powering Off the Analyzer & Purging Power off the analyzer by pressing the PWR button for at least 2 seconds, or until two beeps are heard. The unit will count down 5 seconds before shutting down. Pressing the RUN/hOlD button during this time will stop the countdown and the analyzer will remain pow- ered on.
A confirmation that the memory has been cleared will be briefly displayed. 4.13.1 Averaging Stored Test Data The Fyrite INSIGHT will provide data averages for 3 consecutive combus- tion records that are also printable. The combustion tests must first be stored in program memory (After running a test, press the F3 key to save the results).
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Fyrite INSIGHT 1. From the Main Menu, select Memory. The Memory Options screen will be displayed. 2. Select Print Average. 3. The saved tests will be displayed, with the first 3 tests highlighted. Select the 3 combustion tests to be averaged from the list by using the ▲...
Fyrite INSIGHT 4.14 Printing Test Data Combustion, pressure, smoke number or temperature data that is currently being displayed can be sent to a printer using IrDA protocol as described below. Data that is stored in memory can also be printed by first displaying the stored test data as described in Section 4.13.
The Fyrite User Software installation manual may also be downloaded ® from the Fyrite Insight page of the Bacharach website (www.MyBacha- ® rach.com). Refer to manual 0024-9465. Minimum computer requirements for installation and use of the Fyrite User Software are shown below.
Sensors can be moved from one analyzer to another. ™ The B-Smart sensors should be calibrated by an authorized Bacharach Service Center every 6 to 12 months to assure that the analyzer contin- ues to meet its published accuracy specifications. The B-Smart ™...
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Fyrite INSIGHT 2. Allow the analyzer to cycle through its 60 second warm-up period. During warm-up, the analyzer’s operation is checked and the sen- sors are set to the following ambient conditions: • Oxygen sensor spanned to 20.9% • CO sensor zeroed •...
Bacharach Service Provider. Bacharach also offers a convenient Exchange Program that allows the customer to regularly send in old sensors and, as scheduled, receive new replacements that are already calibrated and that include a code that can be entered into the analyzer for a quick, convenient setup.
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Fyrite INSIGHT Procedure: NOTE: The unit-of-measure for pressure is selected per Section 3.7.2. In the following procedure mB is selected, but note that any unit-of- measure can be used for calibration purposes. Figure 5-1 Pressure Sensor Calibration Equipment 1. Assemble the pressure sensor calibration equipment as shown in Fig- ure 5.1, but DO NOT connect the analyzer to the calibration equip- ment at this time. 2. If not already done, power on the analyzer and display the Calibra- tion List per Section 5.2.
8. Remove calibration equipment. Resetting the Calibration Pressure Gain NOTE: This feature resets the calibration to the default value and should be done under the direction of an authorized Bacharach service function. Reset is available in all calibration screens. 5.5 T-Stack Calibration This procedure first zeroes and then spans the stack-temperature channel to known temperature values.
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Fyrite INSIGHT - Range: 0 to 300 °C - Accuracy: ± 0.3 °C • (Alternatively) ice-water, boiling water, thermometer TS-Zero Procedure: 1. Set the thermocouple simulator to room temperature and plug its output into the T-STACK connector located at the bottom of the analyzer.
Fyrite INSIGHT value. The message “Good Calibration” should briefly appear, followed by the Calibrate TS-Span screen. TS-Span Procedure: 6. Set thermocouple simulator to 300 °C (572 °F), and then use the buttons to enter an Applied value that exactly equals the setting of the simulator.
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Fyrite INSIGHT ing water baths can be used. Material Required: • Thermocouple simulator (K-type) - Range: 0 to 300 °C - Accuracy: ±0.3 °C • (Alternatively) Ice-water, boiling water, thermometer TA-Zero Procedure: 1. Set thermocouple simulator to room temperature and plug its output into the T-AIR connector located at the bottom of the analyzer.
Fyrite INSIGHT 5. Wait until the Measured reading stabilizes, and then press ENTER to calibrate the TA-Zero Measured value to that of the Applied value. The message “Good Calibration” should briefly appear, fol- lowed by the Calibrate TA-Span screen. TA-Span Procedure: 6.
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Fyrite INSIGHT To improve the accuracy of the CO reading, we suggest that if the analyzer will be primarily used for flue gas testing, then calibrate using 500 ppm CO. If the analyzer, however, will be primarily used for ambient testing, then calibrate using 100 ppm CO.
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Fyrite INSIGHT ® Fyrite INSIGhT Components To gas fitting To O To O (Pump) sensor (Battery) To gas Front View Side View Fig. 6.1 1. O2 Sensor 4. Sample Pump 2. CO Sensor 5. LCD Screen 3. CO Sensor Base ®...
6. Turn off the gas and remove the CO cylinder. 6.0 MAINTENANCE 6.1 Fyrite INSIGHT Disassembly ® The following section describes how to disassemble the Fyrite INSIGHT to perform necessary periodic maintenance. (See Figure 6.1 for diagram.) Tools Required: • Medium Phillips screwdriver Procedure: 1.
Fyrite INSIGHT 7. Lift printed circuit board from analyzer. 6.2 Water Trap / Filter 6.2.1 Emptying the Water Trap Chamber The water trap chamber should be emptied after every test, or when the water condensate approaches the tip of the riser tube.
Fyrite INSIGHT 6.3 O & CO Sensor Replacement Sensor Sensor Pry tab upward to remove the battery door from the unit. ® Fyrite Rear Panel Fig. 6.4 6.3.1 O Sensor Note: The O sensor life is approximately 2 years and the CO sensor life is greater than 3 years. Material Required: • O Sensor (P/N 0024-0788) Procedure: 1.
Fyrite INSIGHT Bayonet O2 Cap Sensor Fig. 6.5 4. Install the cap and sensor unit by • Aligning the ribs on the sides of the sensor with the corresponding shape in the base. • Inserting the pins into the connectors in the base.
Fyrite INSIGHT 3. Properly dispose of the old CO sensor. 4. Plug the new CO sensor into its socket. 5. Install the CO cap by aligning the arrow on the cap with the “OPEN” marker, then twisting to the “CLOSED” marker. Reattach tubing.
RU1025 or newer, you have a Revision 1 PCB. If your serial number is older than RU1025, you have a Revision 0 PCB. NOTE: Bacharach serial numbers contain a mix of alphabetic and nu- meric characters. The first two most significant positions are represented by sequential characters A-Z (where “A”...
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Fyrite INSIGHT of a battery wiring harness), service personnel may also need to replace the pump wiring harness. This is performed only by Bacharach service personnel. In such cases, wiring harness part numbers are listed in the following table for service personnel reference. For standard pump replace- ment orders, however, customers must use the combination pump/harness part number.
Fyrite INSIGHT 1. Gain access to the gas pump by removing the rear case. Refer to Sec- tion 6.1. 2. Disconnect J9 (pump) and J11 (Battery) connectors. 3. Lift the circuit board out of the unit. 4. Remove the screw that secures the pump to the board in order to separate the pump from the board.
Fyrite INSIGHT ing the gas hose and probe tube with alcohol. 4. Wipe off the surfaces of the probe and tubing with a clean rag. 5. Allow the parts to dry completely. If available, blow compressed air through the probe to expedite the drying process.
Fyrite INSIGHT • Message will indicate which channel is in error. XXXX - Occurs in the number fields of sensors that have achieved over- range condition. **** - Occurs in the number fields of sensors and the calculated values that depend on the sensors that were in error coming out or warmup.
Fyrite INSIGHT couple channels, Reference Temperature channel, Pressure channel, CO channel, O channel and Battery. O2 Sensor Life - Displays the approximate remaining life of the Oxygen sensor. Fresh Air Diagnostics - Fresh air diagnostics will cycle the instrument through the 60 second warm-up to check on the status of the sensors. The probe must be in fresh air to perform a valid check.
Fyrite INSIGHT 7.0 PARTS & SERVICE 7.1 Replacement Parts Description Part Number Battery / Sensor Cover 0024-1453 B-Smart CO Sensor 0024-1467 Carry Case 0024-0865 Connector Plate Assembly 0024-1483 CO Sensor 0024-7265 CO Sensor Cover Assembly 0024-1484 Draft Connector 0024-0878 Filter (pkg of 3), Water Trap...
Thermocouple, 2.5 cm 0104-1798 Thermocouple, 3.0 m 0104-1797 7.3 Service Centers Replacement parts and service can be obtained by contacting one of the fol- lowing Bacharach Service Centers: United States 621 Hunt Valley Circle New Kensington, PA 15068 Phone: 724-334-5051 Fax: 724-334-5723 Email: help@MyBacharach.com...
Combustible Gases, Toxic Gases, or Oxygen Directive(s): 2004/108/EC EMC Directive Signature: Name: Doug Keeports Title: VP of Product Development Date: 18 October 2010 The technical documentation file required by this directive is maintained at the corporate headquarters of Bacharach, Inc.
Fyrite INSIGHT Appendix A- Formulas & Tables max (20.9 – O 20.9 qA = (TA – TL) x ( 20.9 – O 20.9 λ (Excess Air) = 20.9 – O 2 Eta = (100% – qA) + [Kf, if TA < (T0 – 1.2 x O Efficiency = Eta –...
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World headquarters 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 • Toll Free: 800-736-4666 • Fax: 724-334-5001 Website: www.MyBacharach.com • E-mail: help@MyBacharach.com...
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