Bacharach Fyrite INSIGHT Operating & Maintenance Instructions
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Bacharach Fyrite INSIGHT Operating & Maintenance Instructions

Combustion gas analyzer
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Fyrite
INSIGHT
®
®
Combustion Gas Analyzer
Instruction 0024-9460
Operation & Maintenance
Rev. 5 – October 2011
Product Leadership • Training • Service • Reliability

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  • Page 1 Fyrite INSIGHT ® ® Combustion Gas Analyzer Instruction 0024-9460 Operation & Maintenance Rev. 5 – October 2011 Product Leadership • Training • Service • Reliability...
  • Page 2 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...

  • Page 3: Table Of Contents

    ® Fyrite INSIGHT TABLE OF 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...
  • Page 4 ® Fyrite INSIGHT 4.9 Ending a Combustion Test ............. 30 4.10 Emptying the Water Trap ............30 4.11 Powering OFF the Analyzer & Purging ........31 4.12 Low Battery Alarm ..............31 4.13 Memory ................... 31 4.14 Printing Test Data ..............32 4.15 Fyrite User Software ............

  • Page 5: Introduction

    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.

  • Page 6: Fyrite Insight Features & Benefits

    • Use only Bacharach AC Adapter (P/N 0024-1254). 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.
  • Page 7 ® Fyrite INSIGHT USER INFORMATION - The instrument will accept up to three lines of 20 characters of user information. This information will appear with the test records when they are printed or downloaded. CALIBRATION AND REMINDERS - Calibration can be performed by applying gas and entering calibration gas concentrations through software menu selections.
  • Page 8 ® Fyrite INSIGHT SENSOR ACCESS - Sensor replacement can be accomplished in the field. Easy access to the O2 and CO sensors is provided through the back of the instrument. POWER - The Fyrite INSIGHT is powered by 4 AA alkaline batteries. A ® new set of alkaline batteries will provide a minimum of 20 hours of con- tinuous operation with the pump running and the back light on.

  • Page 9: Operational Overview

    ® 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 press the RUN/HOLD button to place the analyzer into its Run Mode.

  • Page 10: Technical Characteristics

    ® Fyrite INSIGHT 2.0 TECHNICAL CHARACTERISTICS The Analyzer Measures & Displays: Primary/Ambient Air Temperature -4 to 600 °F (-20 to 316°C) Oxygen 0.1 to 20.9% O Stack Temperature -4 to 1202 °F (–20 to 650 °C) Carbon Monoxide 0 to 2000 ppm CO Differential Pressure/Draft ±...

  • Page 11: General Characteristics

    ® 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, &...

  • Page 12: Setting Up The Analyzer

    POWER jack located on the bot- tom of the unit. The batteries do not need to be removed when using the AC adapter. CAUTION: Use only the Bacharach AC Adapter (P/N 24-1254). Failure to do so could damage the unit and will void the war- ranty.

  • Page 13: Connecting The Probe Hose & Thermocouple

    ® Fyrite INSIGHT 3.3 Connecting the Probe Hose & Thermocouple A rigid stainless steel probe with handle is connected to a flexible hose with integral water-trap / filter used to draw a gas sample into the ana- lyzer from the room, grilles, diffusers, and furnace flues. Inspect the flue-gas hose for cracks.
  • Page 14 ® 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 Probe Handle...

  • Page 15: Front Panel Push Buttons

    ® Fyrite INSIGHT 3.4 Front Panel Push Buttons Note that a push button may perform several functions, depending on the analyzer’s model number and what screen is being displayed at the time. • Powers the analyzer ON and OFF. Hold this button down for at least 2 seconds to turn the power OFF.

  • Page 16: Setup Mode

    ® Fyrite INSIGHT Setup Mode The analyzer is preset at the factory for the parameters shown below, but can be changed as described in their corresponding sections. Function Parameter To Change Fuel Natural Gas Section 4.3 Temperature Unit °F Section 3.5.2 Pressure Unit InWC Section 3.5.3...

  • Page 17: Pressure Units

    ® Fyrite INSIGHT 3.5.3 Pressure Units Select to display pressure in inches of water column (inwc), millibar (mb), Pascals (Pa), hectoPascals (hPa), or millimeter of water column (mmwc) as follows: 1. Enter the Setup Menu per Section 3.5.1. If necessary, press ESC until MENU appears above F2.

  • Page 18: Reference

    ® Fyrite INSIGHT 3.5.5 O Reference The measured value of CO can be referenced to a specific O percentage of 0% to 15%. Set up the reference value as follows: 1. Enter the Setup Menu per Section 3.5.1. If necessary, press ESC until MENU appears above F2.

  • Page 19: Username

    ® Fyrite INSIGHT lated data no matter what zoom level has been selected. Select the desired zoom level as follows: 1. Enter the Setup Menu per Section 3.5.1. If necessary, press ESC until MENU appears above F2. 2. From the SETUP MENU, use the ▲ ▼ buttons to select ZOOM. Press ENTER to display the Zoom Menu.

  • Page 20: Run/Hold Format

    3. Clear the information by selecting the CLEAR option (F3). 3.5.9 Run/Hold Format Fyrite INSIGHT test data is located in the Run/Hold screen. By press- ing the RUN/HOLD key, you should hear the pump running and see the word RUN at the upper-left hand corner of the display. The instrument is continuously measuring and calculating the data that is shown in the Run/Hold screen.
  • Page 21 ® Fyrite INSIGHT Change the order in which data is displayed as follows: 1. Enter the SETUP MENU per Section 3.5.1. If necessary, press ESC until MENU appears above F2. 2. Use the ▲ ▼ buttons to select RUN/HOLD FORMAT. Press ENTER to display the Run/Hold Format options. 3. Use the ▲...

  • Page 22: Language Selection

    ® Fyrite INSIGHT 3.5.10 Language Selection Information on the display screen can be shown in English, French, or Spanish. Select the desired language as follows: 1. Enter the SETUP MENU per Section 3.5.1. If necessary, press ESC until MENU appears above F2. 2. Use the ▲...

  • Page 23: Inactivity Timeout

    ® Fyrite INSIGHT NOTE: The default CAL Reminder period is set to NEVER. Set the calibration reminder period as follows: 1. Enter the SETUP MENU per Section 3.5.1. If necessary, press ESC until MENU appears above F2. 2. Use the ▲ ▼ buttons to select CAL RE- MINDER PERIOD. Press ENTER to dis- play the Cal Reminder Period Menu. 3. Use the ▲...

  • Page 24: Post-Purge Period

    ® Fyrite INSIGHT 3.5.14 Post-Purge Period The analyzer can be setup to purge the sensors following the combustion test. It can be programmed to purge for None, 5 seconds, 1, 5, or 10 min- utes. Set the Post-Purge Period as follows: 1.

  • Page 25: Auto/Manual Zero Feature

    ® Fyrite INSIGHT 3.5.16 Auto/Manual Zero Feature Manual Zero: When the CO channel is set to manual zero, the analyzer does not zero the CO sensor to ambient conditions during start up. In this mode, the “fresh air zero” established during manual mode setup is stored in memory and used during the measurement of CO.
  • Page 26 ® Fyrite INSIGHT Auto-Zero versus Manual Zero Instruction 0024-9460...

  • Page 27: Operation

    ® 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 condensate to form inside the case.

  • Page 28: Analyzer Power On & Warm Up

    ® Fyrite INSIGHT 4.2 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.

  • Page 29: Sampling Point

    ® Fyrite INSIGHT 4. Press ENTER to save the selection and re- turn to the Combustion Test HOLD screen or ESC to revert to the previous setting and return to the MAIN MENU. 4.4 Sampling Point Forced Air Furnace – When testing atmospheric burner or gravity vented, forced air heating equipment with a clamshell or sectional heat exchanger design, test each of the exhaust ports at the top of the heat ex- changer.
  • Page 30 ® Fyrite INSIGHT 1. Press the RUN/HOLD button to start the test. You should hear the pump start running and see the word RUN appear at the top of the Combustion Test screen. Sensor Indicators: The following indicators appear in the sensor's data field depending on certain conditions: ∗...
  • Page 31 ® Fyrite INSIGHT Undiluted Flue Gas Sample Taken Under Draft Diverter in Top of Fire Tube Hot Water Tank Atmospheric Burner or Gravity Vented Forced Air Atmospheric or Gravity Vented Boiler 80% Eff. Fan Assist or Power Vented Furnace/Boiler 90% Eff. Condensing Fig. 4.1 Furnace/Boiler Instruction 0024-9460...

  • Page 32: Making A Draft/Pressure Measurement

    ® Fyrite INSIGHT 4.6 Making a Draft / Pressure Measurement The difference in pressure (ΔP) between two areas can be measured by using the analyzer's two pressure ports and the PRESSURE screen. By using the -ΔP port as the reference, the pressure applied to the +ΔP port will be displayed on the PRESSURE screen as the differential pressure between the two ports. Perform a draft / pressure measurement as follows: 1.

  • Page 33: Temperature Measurement

    ® Fyrite INSIGHT sured. The differential pressure between the two areas is now displayed on the PRESSURE screen. If the pressure at the +ΔP port is higher than the -ΔP port, the pressure reading will be positive. If it is lower, the reading will be negative. 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.

  • Page 34: Ending A Combustion Test

    ® Fyrite INSIGHT 2. Press the SAVE (F3) button to save the test data in the next available memory location. NOTE: When memory is full, the next read- ing will not be saved until space is made available by clearing previ- ously saved data.

  • Page 35: Powering Off The Analyzer & Purging

    ® 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, giving the operator an opportunity to keep the analyzer powered ON by pressing the RUN/HOLD button.

  • Page 36: Printing Test Data

    ® Fyrite INSIGHT 3. Use the ▲ ▼ buttons to select Memory Direc- tory. Press ENTER to display the saved data contained in the Memory Directory. TIP: When displaying the contents of the memory directory, the operator can quickly page through the screens by pressing the PAGE– (F1) and PAGE+ (F3) buttons. Or move to the first or last memory location by pressing the buttons, respectively.
  • Page 37 ® Fyrite INSIGHT BACHARACH, INC. Fyrite INSIGHT SN: 12345678 Time: 01:28:27 Date: 09/22/11 Fuel Nat Gas 4.0 % 12 ppm 82.6 % 9.5 % T-STK T-AIR 68.0 21.3 % CO (3) 13 ppm Comments: HOLD Fig. 4.2 1. Power up the printer. Refer to the printer’s instruction manual for detailed operating information.

  • Page 38: Fyrite ® User Software

    (provided in .PDF format) on the software disk. 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.

  • Page 39: Calibration & Maintenance

    ® INSIGHT. 5.1 B-Smart Sensors The Fyrite INSIGHT utilizes Bacharach’s new B-Smart Sensor technology for its CO sensor. The B-Smart sensor is marked with a 10-digit calibra- tion code that can be entered in the instrument's memory via the keypad, or with Fyrite user software.

  • Page 40: B-Smart Sensor Replacement & Calibration

    ® Fyrite INSIGHT • Oxygen sensor spanned to 20.9% • CO sensor zeroed • Pressure sensor zeroed. Any errors detected during warm-up will be listed on the dis- play immediately following warm-up. Correct any errors before proceeding. Refer to Section 6.8 for a list of error messages and their meaning.

  • Page 41: Pressure Sensor Calibration

    If problem persists, contact your nearest Bacharach Service Provider. Bacharach also offers a convenient Exchange Program that allows the cus- tomer to regularly send in old sensors and, as scheduled, receive new re- placements that are already calibrated and that include a code that can be entered into the analyzer for a quick convenient setup.
  • Page 42 ® Fyrite INSIGHT 1. Assemble the pressure sensor calibration equipment as shown in Figure 5.1, but DO NOT connect the analyzer to the calibration equipment at this time. 2. If not already done, power ON the analyzer and display the CALI- BRATION LIST per Section 5.2.

  • Page 43: T-Stack Calibration

    ® Fyrite INSIGHT 5.5 T-Stack Calibration This procedure first zeroes and then spans the stack-temperature channel to known temperature values. The use of an electronic thermocouple simulator is the preferred method of producing the desired calibration temperatures. Alternatively, ice and boiling water baths can be used.

  • Page 44: T-Air Calibration

    ® Fyrite INSIGHT Alternatively: Submerge probe tip into an ice-water bath with a ther- mometer, wait several minutes, and then use the buttons to enter an Applied value that exactly equals the thermometer read- ing. The calibration range is from 32 to 41 °F (0 to 5 °C). An attempt to calibrate outside this range will cause the message “Applied Value High" (or Low) to appear at the bottom of the screen. 5. Wait until the Measured reading stabilizes, and then press ENTER to calibrate the TS-Zero Measured value to that of the Applied value;...
  • Page 45 ® Fyrite INSIGHT Material Required: • Thermocouple simulator (K-type) - Range: 0 to 600 °F - Accuracy: ±0.5 °F • (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. Alternatively: Plug the probe’s thermocouple into the T-AIR connector located at the bot- tom of the analyzer.

  • Page 46: Co Sensor Calibration

    ® Fyrite INSIGHT TA-Span Procedure: 6. Set thermocouple simulator to 212 °F (100 °C), and then use the buttons to enter an Applied value that exactly equals the set- ting of the simulator. Alternatively: Submerge probe tip into a container of boiling water with a thermometer, wait several minutes, and then use the buttons to enter an Applied value that exactly equals the ther- mometer reading.
  • Page 47 ® Fyrite INSIGHT “Measured” is the current CO reading, while “Applied” is a known CO level that will be applied for calibration purposes. 3. Attach a 500 ppm CO cylinder to the regulator of the calibration fixture. 4. Use the buttons to enter an Applied value that exactly equals the concentration stamped on the CO cylinder. The calibration range is from 20 to 1,000 ppm. An attempt to calibrate outside this range will cause the message “Applied Value High” (or Low) to appear at the bottom of the screen.

  • Page 48: Maintenance

    INSIGHT 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. Unplug all thermocouples from bottom of analyzer.
  • Page 49 ® 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 ®...

  • Page 50: Water Trap / Filter

    ® Fyrite INSIGHT 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. 1. Remove water trap chamber per Figure 6.3. 2.

  • Page 51: Sensor Replacement

    ® Fyrite INSIGHT 6.3 O Sensor Replacement Note: The O sensor life is approximately 2 years. Material Required: • O Sensor (P/N 0024-0788) Sensor Sensor Pry tab upward to remove the battery door from the unit. ® Fyrite Rear Panel Fig. 6.4 Procedure: 1.

  • Page 52: Co Sensor Replacement

    ® Fyrite INSIGHT 6.4 CO Sensor Replacement Note: The CO sensor life is greater than 3 years. Material Required: • CO Sensor (P/N 0024-7265) or B-Smart sensor (P/N 0024-1467). Sensor Sensor Pry tab upward to remove the battery door from the unit. ® Fyrite Rear Panel Fig. 6.6 Procedure: CO Cap 1. After battery door is removed, remove the connector tubing from the CO sensor.

  • Page 53: Thermocouple Replacement

    ® Fyrite INSIGHT 6.5 Thermocouple Replacement Using the appropriate thermocouple replacement kit listed below, replace the probe’s thermocouple as follows: Each kit contains a thermocouple assembly, two O-rings, and two wire- splice connectors. Tools Required: • Small flat blade screwdriver • Wire cutter • Wire stripper • Slip joint pliers Procedure: 1.

  • Page 54: Gas Pump Replacement

    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”...
  • Page 55 ® Fyrite INSIGHT Item PCB Rev 0 PCB Rev 1 ≥ RU1025 Serial # (Back of < RU1025 (= Rev 1) Instrument) (= Rev 0) 0024-1450 0024-1450 PCB Label (To 0 xxxxxxxx 1 xxxxxxxx Con rm Rev #) Order P/N: 0024-3049 Order P/N: 0024-3073 Pump/Harness Part Number...

  • Page 56: Cleaning The Probe

    ® Fyrite INSIGHT 6.7 Cleaning the Probe The probe tube and gas-sample hose will become dirty under normal use. Note that the water trap’s filter element should prevent soot from reaching the analyzer’s internal components. If the probe is not kept clean, it could become clogged and restrict the flow of gas into the analyzer, resulting in incorrect combustion test readings and calculations.

  • Page 57: Diagnostics Screen

    ® Fyrite INSIGHT Bad Sensor - O sensor is too low and can not be calibrated in the instru- ment and needs replaced. Low Sensor- O or CO sensor outputs were low but still usable. Sensor(s) may need to be replaced in the near future. Message will indicate which sensor(s) were in warning.

  • Page 58: Status Screen

    ® Fyrite INSIGHT 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. Access the DIAGNOSTIC menu as follows: 1.

  • Page 59: Parts & Service

    ® Fyrite INSIGHT 7.0 PARTS & SERVICE 7.1 Replacement Parts Description Part No. Sensor ..................0024-0788 CO Sensor ..................0024-7265 B-Smart CO Sensor .................0024-1467 Sensor Cover ................0024-1421 CO Sensor Cover Assembly..............0024-1484 Probe and Hose Assembly ............... 0024-3004 Water Trap ..................0019-3265 Filter (pkg of 3) .................0007-1644 Thermocouple Replacement (12 in.) ..........0024-8414 Probe Stop ..................0019-3037 Gas Connector .................

  • Page 60: Service Centers

    ® Fyrite INSIGHT 7.3 Service Centers Replacement parts and service can be obtained by contacting one of the fol- lowing Bacharach Service Centers. United States Pennsylvania 621 Hunt Valley Circle New Kensington, PA 15068 Phone: 724-334-5051 Fax: 724-334-5723 Email: help@mybacharach.com Canada Bacharach of Canada, Inc.

  • Page 61: Declaration Of Conformity

    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. Instruction 0024-9460...
  • Page 62 ® Fyrite INSIGHT Instruction 0024-9460...
  • Page 63 ® Fyrite INSIGHT Instruction 0024-9460...
  • Page 64 Headquarters: 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 • Fax: 724-334-5001 • Toll Free: 800-736-4666 Website: www.MyBacharach.com • E-mail: help@MyBacharach.com Printed in U.S.A.

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