Bacharach Fyrite Operating Manual

Fyrite® Tech

Model 50 & 60

Combustion Gas Analyzer

Instruction 24-9428

Operation & Maintenance

Rev. 6 – August 2009

Product Leadership • Training • Service • Reliability

WARRANTY

Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in material

and manufature and will onform substantially to Baharah In.’s aliable seiations. Baharah’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 manufacture and shown to Bacharach Inc.’s
reasonable satisfaction to have been defective; provided that written notice of the defect shall have been given
by Buyer to Bacharach Inc. within two (2) years after the date of delivery of this Product by Bacharach, Inc.

Bacharach, Inc. warrants to Buyer that it will convey good title to this Product. Bacharach’s liability and Buyer’s
remedy under this warranty of title are limited to the removal of any title defects or, at the election of Bacharach,
to the replacement of this Product or parts thereof that are defective in title.

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF (I) ANY
AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IM­PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE: AND (II) ANY
OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOT ARIS­ING FROM BACHARACH’S NEGLIGENCE, ACTUAL OR IMPLIED. The remedies of the Buyer shall be limited
to those provided herein to the exclusion of any and all other remedies including, without limitation incidental or
consequential damages. No agreement varying or extending the foregoing warranties, remedies or this limita-

tion will be binding uon Baharah, In. unless in writing, signed by a duly authorized ofer of Baharah.

Register Your Warranty by Visiting

www.mybacharach.com

Declaration of Conformity

Manufacturer’s name: Bacharach, Inc.

Manufacturer’ address: 621 Hunt Valley Circle
New Kensington, PA 15068

Product name: Fyrite Tech

onforms to the following seiations:

European Directive 89/336/EEC
EN50082-1: 1997 (Electrostatic Discharge)
EN50082-1: 1997 (Immunity)
EN55022; Group 1, Class B (Emmission)

Notice:

Produt imrovements and enhanements are ontinuous, therefore the seiations and information on­tained in this document may change without notice.

Bacharach, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in con­nection with the furnishing, performance, or use of this material.

No part of this document may be photocopied, reproduced, or translated to another language without the prior
written consent of Bacharach, Inc.

Copyright © 2009, Bacharach, Inc., all rights reserved.
BACHARACH and Fyrite are registered trademarks of Bacharach, Inc. All other trademarks,
trade names, service marks and logos referenced herein belong to their respective companies.

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Instruction 24-9435

Fyrite Tech

Contents

Ordering Information ...............................................................................iii

1.0 INTRODUCTION .................................................................................. 1

1.1 The Fyrite Tech ................................................................................1

1.2 Operation Overview ......................................................................... 2

2.0 TECHNICAL CHARACTERISTICS...................................................3

3.0 SETTING UP THE ANALYZER .........................................................5

3.1 Scope ................................................................................................. 5

3.2 Checking & Replacing the Batteries ...............................................5

3.3 Connecting the Probe .......................................................................6

3.4 Front Panel Pushbuttons ................................................................. 8

3.5 Setup Mode .......................................................................................9

3.5.1 Entering Setup ......................................................................9

3.5.2 Selecting Temperature Units................................................9

3.5.3 CO Channel Setup (Model 60 only) ....................................10

3.5.4 Time Setup (Model 60 only) ................................................ 10

3.5.5 Date Setup (Model 60 only) ................................................ 11

3.5.6 Year Setup (Model 60 only) ................................................11

3.5.7 Selecting Printer Protocol (Model 60 only) ........................12

3.5.8 Exiting Setup .......................................................................12

4.0 OPERATION ........................................................................................13

4.1 Performing a Test ........................................................................... 13

4.1.1 Analyzer Turn On and Warm Up .......................................13

4.1.2 Selecting a Fuel ................................................................... 13

4.1.3 Manual Zero of the CO Channel (Model 60 only) ..............13

4.1.4 Sampling Point .................................................................... 14

4.1.5 Performing a Combustion Efciency Test ..........................16

4.1.6 Printing Test Results (Model 60 only) ............................... 16

4.1.7 Ending a Combustion Test ..................................................18

4.1.8 Turning OFF the Analyzer .................................................18

4.2 CO Purge During Turn OFF (Model 60 only) .............................. 18

4.3 Operating Tips ...............................................................................19

4.4 Using the Backlight .......................................................................20

4.5 Using the Probe ............................................................................. 20

4.6 Resetting the Microprocessor ........................................................20

4.7 Run Mode Screens .........................................................................21

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4.8 Screen Descriptions .......................................................................22

4.8.1 Warm-Up Screens................................................................22

4.8.2 Fuel Screen .......................................................................... 22

4.8.3 O2 Screen (Model 50 only) ...................................................23

4.8.4 CO & O2 Screen (Model 60 only) ......................................... 23

4.8.5 CO Air Free Screen (Model 60 only) ................................... 24

4.8.6 Ambient Air Temperature Screen ...................................... 24

4.8.7 Stack Temperature & Efciency Screen ............................ 25

4.8.8 CO2 & Excess Air Screen ....................................................25

5.0 CALIBRATION & MAINTENANCE ................................................27

5.1 Entering the Calibration Mode and Testing the Display Seg-

ments .....................................................................................................27

5.2 Ambient Temperature Calibration ................................................28

5.3 Stack Thermocouple Channel Calibration ...................................28

5.4 O2 Sensor Zero ...............................................................................29

5.5 CO Sensor Zero & Calibration (Model 60 only) ............................30

5.6 Water Trap / Filter Maintenance .................................................. 32

5.7 O2 Sensor Replacement .................................................................. 33

5.8 CO Sensor Replacement (Model 60 only) ...................................... 34

5.9 Pump Assembly Replacement .......................................................35

6.0 PARTS & SERVICE ............................................................................38

6.1 Replacement Parts .........................................................................38

6.2 Accessories ......................................................................................38

6.3 Service Centers ...............................................................................39

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Instruction 24-9435

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Ordering Information

Model No.
Part No.

Measurements:

Oxygen
Stack Temperature
Ambient Temperature
Carbon Monoxide

Calculations:

Combustion Efieny

Excess Air
Carbon Dioxide
CO air free

Print Capability*

Fyrite Tech 50

24-8216

X
X
X

X
X
X

Fyrite Tech 60

24-8217

X
X
X
X

X
X
X
X

X

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Notes:

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1.0 INTRODUCTION

1.1 The Fyrite Tech

Available in two models, the Fyrite Tech 50 and 60 are hand-held ana-

lyzers that are designed to calculate the efciency of residential furnaces

and combustion appliances by measuring the stack temperature and the

percent oxygen level in the ue-gas stream.

While both analyzers are capable of combustion testing, the Fyrite Tech
60 has the added capability of measuring carbon monoxide and calculating
CO air-free, and also has the capability of sending combustion test data to
an optional printer via an infrared port using either HP or IrDA protocol.

Fyrite Tech 50 Fyrite Tech 60

Measures: Measures:

• Oxygen (O2)

• Stack Temperature • Stack temperature

• Ambient Temperature • Ambient Temperature

• Carbon Monoxide (CO)

Calculates: Calculates:

• Combustion Efciency • Combustion Efciency

• Carbon Dioxide (CO2) • Carbon Dioxide (CO2)

• Excess Air • Excess Air

• CO air-free

• Oxygen (O2)

WARNINGS!

This analyzer is not intended to be used on a continuous
basis.

The analyzer does not have an audible alarm, and is not
intended to be used as a safety device.

Except for battery replacement, this analyzer should only be
opened and serviced by authorized personnel.

When testing an appliance, a full visual inspection of the ap­pliance should be carried out to ensure its safe operation.

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1.2 Operation Overview

Pressing the I/O button turns the analyzer ON. Note that there is a 60 sec­ond warm-up period which must elapse before the analyzer can be used.

After warm-up is complete, choose the fuel code that corresponds to the
fuel being burned by the appliance being tested. Then press the ENTER
button to place the analyzer into its Run Mode and begin the combustion
testing process.

Begin testing by inserting the analyzer’s probe tube into the ug-gas

stream of the appliance under test. Each analyzer model will continuously

monitor the ue gas and display measured and calculated values that

are relative to the combustion process. These values are displayed on the
analyzer’s LCD, and are chosen for display by pressing the Increment ()
and Decrement () buttons.

The Fyrite Tech 60 has the capability of sending the current combustion
test to an optional printer by pressing the HOLD button twice.

Pressing the HOLD button during a test will freeze all measured and
calculated values at their current values. Pressing the ENTER button
resumes testing.

A backlight enables an operator to read the display in dimly-lit areas.
Pressing the LIGHT button turns the backlight ON and OFF. The backlight
will automatically turn OFF after 10 minutes of keyboard inactivity.

A power-saver function will shut the analyzer OFF after 20 minutes of
keyboard inactivity. Note, however, that the power-saver function is dis­abled if the detected O2 value is less than 17.9% or the CO value is more
than 50 ppm.

Press the I/O button to turn the analyzer OFF. Note, that there is a 5 sec­ond delay before the analyzer actually turns OFF, during which time the
unit can be kept ON by pressing the ENTER button.

If the analyzer is turned OFF while a high level of CO is still present
within the unit, the pump remains running and the unit will not turn OFF
until the detected CO level drops below 50 ppm.

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2.0 TECHNICAL CHARACTERISTICS

The Analyzer Directly Measures and Displays:

• Flue Gas O2 content ..................................... 0.0 to 20.9% O

2

• Stack Temperature ....................................... 0 to 999 °F (–18 to 537 °C)

• Ambient Temperature .................................. 32 to 212 °F (0 to 100 °C)

• Flue Gas CO content (Model 60) ................. 0 to 2,000 ppm CO

The Analyzer Computes and Displays:

(when the measured oxygen level is below 17.9 %)

• Combustion Efciency .................................. 0.1 to 99.9%

• Flue Gas CO2 content ................................... 0.0 to a fuel dependent

maximum value in %

• Flue Gas CO air-free content (Model 60) ..... 0 to 9,999 ppm

• Excess Air .................................................... 0 to 400%

Fuel Selection:
(F1 thru F4 denotes the fuel selected as displayed on the LCD)

• Natural Gas (F1)

• Oil #2 (F2)

• LPG (F3)

• Kerosene (F4)

Normal Operating Conditions:

Temperature:

• Analyzer ....................................................... 32 to 104 °F (0 to 40 °C)

• Probe ............................................................. 1,000 °F max (538 °C) at

5" insertion

Humidity ............................................................. 15 to 90% RH,

Non-Condensing

Power Requirements .................................... Four ‘AA’ Alkaline batteries

Operating Time ........................................up to 18 hours continuous

(pump running and backlight
off)

Warm Up Time ..........................................60 seconds

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Display ........................................................4 Digit, 2 Line, 7-segment

Liquid Crystal Display

Front Panel Controls ..............................Six pushbutton switches

(Refer to Section 3.4)

Accuracy:

• Oxygen....................................................±0.3% O2 w/typical ue gas

concentration of CO2

• Carbon Monoxide (Model 60) ................±5% of reading or ±10 ppm,

whichever is greater*

• Stack Temperature ................................±4 °F between 32 & 255 °F

(±2 °C between 0 & 124 °C)
±6 °F between 256 & 480 °F
(±3 °C between 125 & 249 °C)
±8 °F between 481 & 752 °F
(±4 °C between 250 & 400 °C)

• Ambient Temperature............................±4 °F between 32 & 104 °F

(±2 °C between 0 & 40 °C)

Size .............................................................. 7.5"H x 3.1"W x 2.1"D

(190.5 x 78.7 x 53.3 mm)

Weight .........................................................16 oz (0.454 kg) with batteries

Agency Approval ......................................CE Mark

* Tighter CO accuracy in the lower ranges, up to ±2 ppm, may be attained

if a lower range calibration gas (e.g. 100 ppm CO) is used.

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Remove battery cover
by pushing down here
and sliding cover outward

3.0 SETTING UP THE ANALYZER

3.1 Scope

Before using the analyzer. . .

• Check batteries (Section 3.2)

• Connect probe to analyzer (Section 3.3)

• Check setup (Section 3.5)

3.2 Checking & Replacing the Batteries

Install fresh batteries as described below. Check the analyzer for sufcient

charge prior to each use. Replace the batteries if the low-battery symbol

appears in the lower right corner of the screen. To replace the bat-

teries:

1. Remove battery cover from back of analyzer.

2. If old batteries are installed, remove them and properly discard.

3. Observing the polarity markings inside the battery compartment,
install four ‘AA’ Alkaline batteries as shown in Figure 3-1.

4. Replace battery cover.

Figure 3-1. Battery Installation

Instruction 24-9435

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3.3 Connecting the Probe

Connect the probe assembly’s ue-gas hose and thermocouple connector to

the analyzer as follows (see Figure 3-2):

1. Push the ue gas hose onto the analyzer’s GAS inlet tting.

2. Push the ue gas thermocouple into the T-STACK jack

Important: DO NOT force thermocouple connector. The con-

nection tabs are different sizes, allowing the connector to t

in only one way.

Inspect the ue-gas hose for cracks. Replace the hose if it is defective.

Before using the analyzer, check that the Water Trap / Filter is dry and

not dirty. If necessary, dry out the trap and replace the lter element per

Section 5.6.

6

Instruction 24-9435

T-STACK

GAS

THERMOCOUPLE

PROBE STOP
(Optional)

WATER TRAP /
FILTER ASSEMBLY

Fyrite Tech

Instruction 24-9435

Figure 3-2. Connecting the Probe

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3.4 Front Panel Pushbuttons

Note that a pushbutton may perform several functions, depending on what
screen is being displayed at the time.

I/O • Turns analyzer ON/OFF. There is a 60 second warm-up and

a 5 second turn-off-delay period.

• Places the analyzer into either its Setup or Calibration Mode
when used in conjunction with the ENTER or HOLD button.

• Aborts the CO purge function during turn-off.

 • Scrolls up through the display screens during a test.

• Causes the displayed value to increase or change while in
the Calibration or Setup Mode.

 • Scrolls down through the display screens during a test.

• Causes the displayed value to decrease or change while in
the Calibration or Setup Mode.

ENTER • Enters the Run Mode (starts a combustion test) from the

Fuel Select Screen.

• Displays the Fuel Select Screen when held down for 2 sec­onds while in the Run Mode.

• Sets up the analyzer to be placed into its Calibration Mode
when held down with the analyzer OFF. (Used in conjunc­tion with the I/O button.)

• Stores the displayed value and automatically steps to the
next screen when pressed during calibration or setup.

• Places the unit into its Run Mode when held down for 2 sec­onds while in the Calibration Mode.

• Aborts turn-off and keeps the analyzer turned ON when
pressed during the 5 second turn-off-delay period.

HOLD • Places the analyzer on hold and freezes the values in all

Run Mode Screens during a test, allowing the operator to
scroll through the displays and view all test values at that
point in time. Pressing ENTER resumes testing.

• Sets up the analyzer to be placed into its Setup Mode when

held down with the analyzer OFF. (Used in conjunction with

the I/O button.)

• Sends combustion test data to a printer when pressed twice
with the pump running (Fyrite Tech 60 only).

LIGHT Toggles the backlight ON and OFF.

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3.5 Setup Mode

The analyzer is preset at the factory for the parameters shown below, but
can be changed as described in their associated sections.

Function Parameter To Change

Fuel Natural Gas (F1) Section 4.1.2
Temperature Unit °F Section 3.5.2
CO Channel Auto Zero (A2) Section 3.5.3
Clock Not initialized Section 3.5.4 thru 3.5.6
Printer Protocol IrDA Section 3.5.7

3.5.1 Entering Setup

1. With the analyzer turned OFF, press and hold down the HOLD
button.

2. Press the I/O button.

3. Release both buttons.

4. The analyzer is now in its Setup Mode. Refer to Sections 3.5.2 thru

3.5.7 for information on how to set up the analyzer.

3.5.2 Selecting Temperature Units

The Temperature Setup Screen is labeled “Unit.”

1. Enter the Setup Mode per Section 3.5.1. If necessary, repeatedly
press the ENTER button until “Unit” is displayed.

2. Press the  or  button until the desired temperature unit (°F or
°C) is displayed.

3. Press ENTER to move to the next Setup Screen, or press I/O to exit
setup.

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3.5.3 CO Channel Setup (Model 60 only)

The CO Channel Setup Screen is labeled “CO.”

1. If not already done, enter Setup per Section 3.5.1. Repeatedly press
ENTER until CO Channel Setup Screen is displayed.

2. Press the  or  button until the desired parameter is displayed.

- no Sensor disabled. Use this function to turn off the CO chan-

nel if the sensor is missing or known to be bad to avoid
inaccurate CO readings from appearing.

- 2Ero 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.

- A2 Auto Zero. With the CO channel set to auto zero, the CO

sensor is zeroed to the ambient CO level during start up.

Important: When using this mode the analyzer must be
turned ON in fresh air; otherwise, incorrect CO read­ings will occur.

3. Press ENTER to move to the next Setup Screen, or press I/O to exit
setup.

3.5.4 Time Setup (Model 60 only)

There are two Time Setup Screens, one for hours and the other for min­utes. Two bars appear above the segments being changed. The clock value
is displayed in a 24 hour format for setup purposes, but will appear as
AM/PM on the printout.

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1. If not already done, enter Setup per Section 3.5.1. Repeatedly press

ENTER until the rst Time Setup Screen is displayed - the one with

two bars over the hour digits.

2. Press the  or  button until the correct hour value is displayed.

3. Press ENTER to move the selection bars over the minute digits.

4. Press the  or  button until the correct minute value is displayed.

5. Press ENTER to move to next Setup Screen, or press I/O to exit
setup.

3.5.5 Date Setup (Model 60 only)

There are two Date Setup Screens, each labeled, "DAtE". The rst screen

sets the month while the second sets the day.

1. If not already done, enter Setup per Section 3.5.1. Repeatedly press

ENTER until the rst Date Setup Screen is displayed.

2. Press the  or  button until the correct month is displayed.

3. Press ENTER to change the 'Day' value.

4. Press the  or  button until the correct day is displayed.

5. Press ENTER to move to next Setup Screen, or press I/O to exit
setup.

3.5.4 Year Setup (Model 60 only)

The Year Setup Screen is labeled "YEAr".

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1. If not already done, enter Setup per Section 3.5.1. Repeatedly press
ENTER until the Year Setup Screen is displayed.

2. Press the  or  button until the correct year is displayed.

3. Press ENTER to move to next Setup Screen, or press I/O to exit
setup.

3.5.7 Selecting Printer Protocol (Model 60 only)

The analyzer can be set up for either an HP or IrDA type printer.

1. If not already done, enter Setup per Section 3.5.1. Repeatedly press
ENTER until one of the following screens is displayed.

2. Press the  or  button to select the desired printer protocol.

3. Press ENTER to move to next Setup Screen, or press I/O to exit
setup.

3.5.8 Exiting the Setup Mode

Press the I/O button at any time to exit the Setup Mode and turn OFF the
analyzer.

Note that the last displayed parameter is automatically saved in memory.

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Instruction 24-9435

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4.0 OPERATION

4.1 Performing a Test

4.1.1 Analyzer Turn On and Warm Up

Important: The probe must be at room temperature before
performing the following steps. The temperature measured
by the probe during warm up is the combustion-air tempera-

ture used by the analyzer for efciency calculation purposes.

1. Make sure that the analyzer is properly set up per Section 3.0.

2. During warm-up, the analyzer’s probe must be located in the area
containing the burner’s combustion-air supply. If the burner is us­ing room air, simply place the probe within the room. In the case

of a high-efciency furnace where combustion air is drawn in from

an outside source, place the probe within that area with the burner
operating. After the probe is properly positioned, turn ON the ana­lyzer by pressing its I/O button.

3. Wait for the analyzer to complete its 60 second warm-up period;
after which, the Fuel Screen is displayed. If errors were detected
during warm-up, the Sensor Error Screen will be displayed. If this
occurs, refer to Section 4.8.9 to correct the cause of the error.

4.1.2 Selecting a Fuel

1. With Fuel Screen displayed, use the  or  button to step through
the fuel codes until the proper fuel is selected. The analyzer de­faults to the most recently selected fuel.

F1 = Natural Gas F3 = LPG
F2 = Oil #2 F4 = Kerosene

2. Press the ENTER button to select the displayed fuel code;after
which, the analyzer enters the Run Mode.

4.1.3 Manual Zero of the CO Channel (Model 60 only)

If the CO channel is set up for manual calibration (refer to Section 3.5.3),
and if the CO reading shows a value other than zero in fresh air, then be­fore proceeding with a test manually zero the CO channel per Section 5.5.

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4.1.4 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 ex­changer. The probe should be inserted back into each of the exhaust ports

to obtain a ue gas sample, before any dilution air is mixed in.

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 re tube below the diverter.

80% Efciency 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 immediately above the inducer fan.

90% Efciency Condensing – Condensing furnaces/boilers can be tested
through a hole drilled in the plastic vent pipe (when allowed by the manufac-

turer or local authority of jurisdiction) or taken from the exhaust termination.

Atmospheric or Gravity Vented Boiler – Boilers, which have a ‘bell’
shaped draft diverter directly on top, should be tested directly below the
diverter through a hole drilled in the vent connector.

Atmospheric Burner or

Gravity Vented Forced Air

14

Hot Water Tank

Instruction 24-9435

Fyrite Tech

80% Eff. Fan Assist

or Power Vented

Furnace/Boiler

Atmospheric or

Gravity Vented Boiler

Instruction 24-9435

90% Eff. Condensing

Furnace/Boiler

15

Fyrite Tech

4.1.5 Performing a Combustion Efciency Test

1. After turning ON the analyzer and selecting the appropriate fuel,
press the  and  button until the Stack Temperature & Efciency
Screen (refer to Section 4.8.7) is displayed.

2. Position the probe in the ue-gas stream to obtain the hottest

"STACK" reading. Locating the highest stack temperature is very

important for accurate efciency calculations.

3. You can now begin burner-service procedures. Use  and  but­tons during a test to scroll through the analyzer’s other display
screens (refer to Section 4.7). The analyzer readings will update
continuously showing changes in burner performance.

4. Pressing the HOLD button freezes all readings and stops the pump.
The  and  buttons can now be used to scroll through the dis­plays and view all test values at the moment the HOLD button was
pressed. Pressing ENTER restarts the pump and resumes testing.

4.1.6 Printing Test Results (Model 60 only)

During a combustion efciency test, the current test results can be sent to

a printer as follows:

1. Turn ON printer.

TIP: Refer to the printer's instruction manual for detailed operating

information. If not already done, set up the printer for 9600 baud,
DTR handshaking, and the same protocol as the analyzer (HP or
IrDA). Refer to Section 3.5.7 Selecting Printer Protocol.

2. Align the printer with the top of the analyzer as shown in Figure
4-1.

3. Begin printing by doing one of the following:

- If the pump is running, press the HOLD button twice.

- If the display has been previously frozen by pressing the HOLD
button, press the HOLD button only once.

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BA C HA R AC H, IN C .
F YR IT E T E CH A N AL Y ZE R
== = == == = == = == == = == = == = =

Instruction 24-9435

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4.1.7 Ending a Combustion Test

WARNING! Burn Hazard. Do not touch the probe after
removing it from the stack. Allow the probe to cool before
handling (about 5 minutes).

1. Remove probe from ue-gas stream.

2. Allow the pump to run until all combustion gases are ushed from

the analyzer as indicated by the O2 reading returning to 20.9%.

4.1.8 Turning OFF the Analyzer

After the analyzer has been purged with fresh air, turn it OFF by pressing
the I/O button. The unit will count down from 5 before turning OFF. Press­ing the ENTER button, however, will stop the count down and keep the
analyzer turned ON.

4.2 CO Purge During Turn OFF (Model 60 only)

If the detected CO level is above 50 ppm when the analyzer is turned OFF,
the unit will remain ON with its pump running and display "PurG CO."
The countdown from 5 will not begin until the CO level drops below 50
ppm.

Although not recommended for everyday use, the purging process can be
bypassed by pressing the I/O button a second time.

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4.3 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.

• If the CO channel (Fyrite Tech 60) is set up for Auto Zero (refer to Sec­tion 3.5.3), ensure that the analyzer is sampling fresh air when turned

ON. Pulling a ue-gas sample through the analyzer during its warm-up

period will not damage the analyzer, but it will result in incorrect CO
readings. Also note that a CO sensor error will occur if the detected CO
level is above 50 ppm during warm-up.

• For analyzers that are used to measure ue-gas, note that ue-gas

condensate is acidic and very corrosive. It is important not to allow the
analyzer's internal components to become soaked in condensate for long
periods of time.

• Before each use, inspect the lter element of the water trap / lter assem­bly. Replace the lter if it looks dirty.

• When sampling ue-gas, keep the analyzer above the water-trap, and

keep the trap in a vertical position. This will maximize the effectiveness
of the trap and keep liquid condensate from being drawn directly into the
analyzer.

• When liquid condensate is seen inside the water trap, empty the trap
before it becomes full. Refer to Section 5.6.

• It is recommended that the analyzer be purged after taking a ue-gas

measurement before turning it OFF. Once the probe is removed from the
stack, disconnect the hose assembly from the bottom of the analyzer and
let the pump run for 10 minutes or so to completely remove any remain-

ing ue gases and dry any condensate from inside the sensor chamber.

• When storing the analyzer, it's a good idea to empty the water trap and
leave it open to further dry it out.

• Calibrate the analyzer every 6 months to ensure its accuracy.

Instruction 24-9435

19

Fyrite Tech

4.4 Using the Backlight

The LCD can be read in dimly-lit areas by pressing the LIGHT button.

The backlight automatically turns OFF after 10 minutes of keyboard
inactivity, but can be turned OFF at any time by again pressing the LIGHT
button.

4.5 Using the Probe

A rigid stainless steel probe with handle, connected to a exible hose with
integral water-trap / lter can be used to draw a gas sample into the ana­lyzer from the room, grilles, diffusers, and furnace ues.

The hose and probe assembly can be detached from the analyzer when the
operator desires to sample without the probe.

4.6 Resetting the Microprocessor

If the analyzer 'locks-up' and cannot be turned OFF, reset the microproces-

sor by removing one of the batteries for ve seconds.

20

Instruction 24-9435

Fyrite Tech

F1

E

L

U

F

251

92

CO

2

%

.

.

EXCESS AIR

F1

787

0

0

STACK F1

EFF

°F

%

5

.

5

2

AMBIENT F1

°F

7

.

46

9

F1

CO

O

2

ppm

%

.

12

CO

ppm

AIR

FREE

F1

ENTER

4.7 Run Mode Screens

The following diagrams show the order in which the screens are displayed
by pressing the  and  buttons while in the Run Mode.

Fyrite Tech 50

Fyrite Tech 60

Instruction 24-9435

21

Fyrite Tech

�

4.8 Screen Descriptions

4.8.1 Warm-Up Screens

As soon as the analyzer is turned ON, a series of Warm-Up Screens are
displayed. These screens show the analyzer’s model number (Tech 50 or

Tech 60), the unit’s software revision, and nally the remaining warm-up

time counted down from 60 seconds. At the end of warm-up, the analyzer
displays the Fuel Screen (refer to Section 4.8.2).

Note: If any errors were detected during warm-up, the Sen­sor Error Screen is displayed (refer to Section 4.8.9).

4.8.2 Fuel Screen

The Fuel Screen is displayed after warm-up, or can be accessed from any
Run Mode Screen by holding down the ENTER button for 2 seconds. The
Fuel Screen is where an operator chooses which fuel is to be used by the
analyzer to calculate combustion efciency. Use the  or  button to scroll
through the fuel codes until the desired fuel is displayed, and then press
ENTER to select the displayed fuel and place the analyzer into its Run
Mode. Note that the fuel code will be displayed in the top right corner of all
screens while in the Run Mode.

Fuel Codes: F1 = Natural Gas
F2 = Oil #2
F3 = LPG
F4 = Kerosene

Front Panel Button Functions:
 /  – Scroll through fuel codes

ENTER – Select fuel and enter Run Mode (refer to Section 4.7)
HOLD – No effect
LIGHT – Toggles backlight ON/OFF

I/O – Turns analyzer OFF (with a 5 second delay)

22

Instruction 24-9435

Fyrite Tech

4.8.3 O2 Screen (Model 50 only)

The O2 display is the measured percentage of oxygen present in the ue­gas stream.

Front Panel Button Functions:

 /  – Scrol through Run Mode Screens (refer to Section 4.7)

ENTER – Hold for 2 seconds to display Fuel Screen
HOLD – Freezes display (press ENTER to unfreeze)
LIGHT – Toggles backlight ON/OFF

I/O – Turns analyzer OFF (with a 5 second delay)

4.8.4 CO & O2 Screen (Model 60 only)

The CO display is the measured ppm amount of carbon monoxide pres­ent in the ue-gas stream. Note, however, that the amount of CO dis­played may be diluted by secondary air (refer to Section 4.8.5 CO Air Free
Screen).

The O2 display is the measured percentage of oxygen present in the ue­gas stream.

Front Panel Button Functions:

 /  – Scroll through Run Mode Screens (refer to Section 4.7)

ENTER – Hold for 2 seconds to display Fuel Screen
HOLD – Freezes display (press ENTER to unfreeze)
LIGHT – Toggles backlight ON/OFF

I/O – Turns analyzer OFF (with a 5 second delay)

Instruction 24-9435

23

Fyrite Tech

4.8.5 CO Air Free Screen (Model 60 only)

The CO AIR FREE reading is a calculation of the exact ppm concentration
of carbon monoxide if oxygen were 0.0% in accordance with ANSI standard
Z21.1.

CO

Air F ree

=

20.9 – O

CO x 20.9

2measured

Front Panel Button Functions:

 /  – Scroll through Run Mode Screens (refer to Section 4.7)

ENTER – Hold for 2 seconds to display Fuel Screen
HOLD – Freezes display (press ENTER to unfreeze)
LIGHT – Toggles backlight ON/OFF

I/O – Turns analyzer OFF (with a 5 second delay)

4.8.6 Ambient Air Temperature Screen

The AMBIENT reading is the room temperature in either °F or °C as mea­sured by a temperature sensor located inside the analyzer.

NOTE: The combustion-air temperature, which was measured
by the probe's thermocouple during warm-up, is stored by the

analyzer for efciency calculation purposes, but cannot be

displayed.

Front Panel Button Functions:

 /  – Scroll through Run Mode Screens (refer to Section 4.7)

ENTER – Hold for 2 seconds to display Fuel Screen
HOLD – Freezes display (press ENTER to unfreeze)
LIGHT – Toggles backlight ON/OFF

I/O – Turns analyzer OFF (with a 5 second delay)

24

Instruction 24-9435

Fyrite Tech

4.8.7 Stack Temperature & Efciency Screen

The STACK display is the temperature measured at the tip of the probe.

The EFF (Efciency) reading is a calculation of what percentage of energy

present in the fuel was converted into usable heat.

Front Panel Button Functions:

 /  – Scroll through Run Mode Screens (refer to Section 4.7)

ENTER – Hold for 2 seconds to display Fuel Screen
HOLD – Freezes display (press ENTER to unfreeze)
LIGHT – Toggles backlight ON/OFF

I/O – Turns analyzer OFF (with a 5 second delay)

4.9 CO2 & Excess Air Screen

The CO2 reading is a calculation of the percentage of carbon dioxide that is
being produced by the combustion process.

Excess Air is a calculation of the percentage of extra air that was avail­able in the combustion chamber above the theoretical amount needed for
perfect combustion.

Front Panel Button Functions:

 /  – Scroll through Run Mode Screens (refer to Section 4.7)

ENTER – Hold for 2 seconds to display Fuel Screen
HOLD – Freezes display (press ENTER to unfreeze)
LIGHT – Toggles backlight ON/OFF

I/O – Turns analyzer OFF (with a 5 second delay)

Instruction 24-9435

25

Fyrite Tech

4.8.9 Sensor Error Screen

An O2 sensor error is displayed if the analyzer determines during the
warm-up cycle that the oxygen sensor’s output is too low for it to be usable.
However, in the extreme condition when the O2 sensor has no output, a sen-
sor error will not occur. Instead, the O2 reading will be 0.0 as displayed in
the O2 Screen (Model 50) or the CO & O2 Screen (Model 60).

When the CO channel (Model 60 only) is set up for Auto Zero (refer to
Section 3.5.3), a CO sensor error will occur if the detected carbon monox­ide level is above 50 ppm during the warm-up cycle. Note that if the CO
channel is set up for manual calibration, the analyzer does not auto-zero
the CO sensor during warm-up, and thus does not generate a CO sensor
error when the analyzer is turned ON in an atmosphere containing a high
background level of CO.

Do the following before replacing a suspected spent or defective sensor:

1. Turn OFF the analyzer and turn it back ON in an area of fresh air
(containing 20.9% O2 and no CO).

2. Perform the Oxygen Sensor Zero procedure (Section 5.4) and, if ap­plicable, the CO Sensor Zero & Calibration procedure (Section 5.5).

3. If Steps 1 & 2 do not eliminate the error condition, replace sensor(s)
(refer to Sections 5.7 or 5.8).

26

Instruction 24-9435

Fyrite Tech

�

5.0 CALIBRATION & MAINTENANCE

Important: Fresh batteries should be installed, and the unit

allowed to stabilize at room temperature for at least two
hours before proceeding with calibration. To maintain ac­curacy as listed in the Technical Characteristics Section of
this manual, the standards used must be at least four times
as accurate as stated accuracy of the Fyrite Tech.

5.1 Entering the Calibration Mode and
Testing the Display Segments

1. With the analyzer turned OFF, place the unit in fresh, ambient air.

2. Press and hold down the ENTER button, and then press and release
the I/O button. Observe that all LCD segments are turned ON.

3. Release the ENTER button. Observe the unit’s model number and
software version are displayed. The word “CAL” is then displayed
while the unit counts down from 60 seconds.

At the end of 60 seconds, the rst calibration screen is automati-

cally displayed.

Note: During calibration: 1) The  and  buttons are used
to increase or decrease a displayed calibration value. 2)
Press ENTER to store the new value and move to the next
screen. 3) Press and hold down the ENTER button for 2 sec­onds to exit the Calibration Mode.

Instruction 24-9435

27

Fyrite Tech

5.2 Ambient Temperature Calibration

Material Required: Calibrated Thermometer

Procedure:

1. Enter the Calibration Mode as described in Section 5.1. Observe that
"AMBIENT" is displayed at the top of the display; if not, repeatedly
press ENTER until it appears.

2. Use the  and  buttons to set the displayed value to match the
reading of a calibrated thermometer at room temperature.

3. Press ENTER to store the displayed value and move to the next cali­bration screen, or hold down ENTER for 2 seconds to store the dis­played value and enter the Run Mode, or press the I/O button to exit
the Calibration Mode and turn OFF the analyzer without saving the
changes.

5.3 Stack Thermocouple Channel Calibration

Material Required: Thermocouple Simulator

Procedure:

1. Attach the thermocouple simulator to the Stack Thermocouple con­nector on the analyzer (T-STACK, see Figure 3-2).

2. Enter the Calibration Mode as described in Section 5.1. Then repeat­edly press the ENTER button until “STACK” appears in the top of
the display.

28

Instruction 24-9435

Fyrite Tech

3. Set the simulator to 32 °F (0 °C). Then use the  and  buttons to
set the displayed value to match the simulator’s value.

4. Set the simulator to 572 °F (300 °C). Then use the  and  but-

tons to adjust the displayed value to match simulator’s value.

5. Repeat Steps 3 and 4 as necessary until the analyzer is reading cor­rectly at both temperatures.

6. Press ENTER to store these calibration values and move to the next
calibration screen, or hold down ENTER for 2 seconds to store these
calibration values and enter the Run Mode, or press the I/O button
to exit the Calibration Mode and turn OFF the analyzer without
saving the changes.

7. Remove thermocouple simulator from analyzer.

5.4 O2 Sensor Zero

Material Required: • Cylinder of 100% Nitrogen, P/N 9550-0049

• Calibration Kit, P/N 24-7059

Procedure:

1. With the analyzer sampling fresh air, enter the Calibration Mode
as described in Section 5.1. Then repeatedly press the ENTER but­ton until “O2” appears in the lower left side of the display.

2. Allow pump to run and sample fresh air for at least 1 minute.

3. Use the  and  buttons to set the displayed value to 20.9%.

4. Set up the Calibration Kit with 100% N2 as described in the in­structions supplied with the kit.

5. Connect the tubing of the Calibration Kit to the inlet of the ana-

lyzer; then adjust the regulator for approximately 2 SCFH of excess
ow (see Figure 5-1).

Instruction 24-9435

29

Fyrite Tech

6. After the analyzer has stabilized (2 to 3 minutes), use the  and 
buttons to set the displayed value to 0.0%.

7. Disconnect tubing from analyzer and turn off gas ow.

8. Allow the pump to run until the O2 reading returns to 20.9. If
necessary, use the  and  buttons to readjust the reading to 20.9.

Repeat Steps 3 thru 7 to verify the zero adjustment.

9. Press ENTER to store the new calibration values and move to the
next calibration screen, or hold down ENTER for 2 seconds to store
the new calibration values and enter the Run Mode, or press the
I/O button to exit the Calibration Mode and turn OFF the analyzer
without saving the changes.

5.5 CO Sensor Zero & Calibration (Model 60 only)

Material Required: • Cylinder of 100 ppm (P/N 51-1994) or

500 ppm (P/N 24-0492) CO calibration gas

• Calibration Kit, P/N 24-7059

If the analyzer will be primarily used for ue gas testing, we suggest that

you calibrate your Fyrite Tech 60 with 500 ppm CO calibration gas. If the
analyzer will be primarily used for ambient CO testing, then you may wish
to consider using 100 ppm CO calibration gas.

Procedure:

1. With the analyzer sampling fresh air, enter the Calibration Mode
as described in Section 5.1. Then repeatedly press the ENTER but­ton until “CO” appears in the upper left side of the display.

2. Allow the pump to run and sample fresh air for at least 1 minute.

3. Use the  and  buttons to set the displayed value to 0 ppm.

30

Instruction 24-9435

Fyrite Tech

1

2 3 4 5

LEAVE TOP
PORT OPEN

Parts Shown:

1. Gas Cylinder

2. Regulator*

3. Tubing*

4. Tee*

5. Flowmeter*

6. Fitting, Gas
* Contained in Calibration Kit

3

6

ENTER

HOLD

I/O

LIGHT

Fyrite®

Analyzer

Tech

4. Do one of the following:

a. End this procedure and save the new zero value by holding down

the ENTER button for 2 seconds; after which, the analyzer enters
the Run Mode.

b. Continue with Step 5 to span the CO sensor to a known concen-

tration of carbon monoxide.

5. Set up the Calibration Kit with 100 or 500 ppm CO as described in
the instructions supplied with the kit.

6. Connect the tubing of the Calibration Kit to the inlet of the an-

alyzer. Then adjust the regulator for approximately 2 SCFH of
excess ow (see Figure 5.1).

7. After the analyzer has stabilized (2 to 3 minutes), use the  and 
buttons to set the displayed value to match the CO concentration
stamped on the gas cylinder.

8. Press ENTER to store the new calibration values and move to the
next calibration screen, or hold down ENTER for 2 seconds to store
the new calibration values and enter the Run Mode, or press the
I/O button to exit the Calibration Mode and turn OFF the analyzer
without saving the changes.

9. Turn off gas ow and disconnect tubing from analyzer.

Instruction 24-9435

Figure 5-1. Calibration Kit Hookup

31

Fyrite Tech

WATER TRAP
CHAMBER

Pull apart using a slight
twisting motion

FILTER
CHAMBER

FILTER ELEMENT

Pry apart filter chamber using
a small flat-blade screwdriver
inserted into notch

“A” “B”

When reassembling
the trap, make sure
that surfaces “A” and
“B” are in contact

5.6 Water Trap / Filter Maintenance

The Water Trap / Filter Assembly removes water condensate from the gas
sample, and also prevents soot from contaminating the internal compo­nents of the analyzer.

Drain the water condensate after every test.

Procedure:

1. Pull apart the Water Trap / Filter assembly (see Figure 5-2).

2. Pour out all water condensate. Then reassemble the trap.

Replace the Filter Element when dirty.

Material Required: • Filter Element, P/N 07-1644

• Small Flat Blade Screwdriver

Procedure:

32

1. Pull apart the Water Trap / Filter Assembly (see Figure 5-2).

2. Pry apart the Filter Chamber. Then remove and discard old lter.

3. Install new lter and reassemble trap, making sure that surfaces

"A" and "B" are in contact.

Figure 5-2. Water Trap / Filter Assembly

Instruction 24-9435

Fyrite Tech

O2 Sensor Replacement

Be sure to perform all of the hecks listed in Section 4.8.9 to ensure that
the O2 sensor needs to be replaced.

Procedure:

1. Disassemble the analyzer as follows:

a. Remove the battery cover and the batteries, uncovering one of the

cover hold-down screw.

b. Remove and set aside all four cover hold-down screws.

c. With the analyzer on its back, remove the front cover, laying it

face down to the left of the body.

d. Remove the battery connector from top of circuit board. Then

carefully remove the circuit board laying it face down in the top
cover.

2. Remove the O2 sensor's electrical connector from the circuit coard.
Then push down; twist counterclockwise; and then pull the O2 sen­sor out of its socket (see Figure 5-3).

Tip: To obtain a better grip on the O2 sensor, it may be necessary to
remove the screw that secures the sensor socket to the case.

3. Using the old sensor as a guide, remove the paper backing from the
new sensor gasket contained in the replacement kit, and adhere it to
the new sensor.

4. Dispose of the old O2 sensor in a proper manner (see the instruction
sheet that comes with the new sensor).

5. Mount the new O2 sensor in its socket. If the sensor socket was
removed in Step 2, re-attach it to the case.

6. Plug the O2 sensor's electrical connector into the printed circuit
board (observe polarity, see Figure 5-4), and then reassemble the
analyzer.

Note: A new O2 sensor may take several hours to stabilize after being

connected to the printed circuit board.

Instruction 24-9435

33

Fyrite Tech

5.8 CO Sensor Replacement (Model 60 only)

Be sure to perform all of the checks listed in Section 4.8.9 to ensure that
the CO sensor needs to be replaced.

Material Required: • CO Sensor, P/N 24-7265

• CO Sensor Gasket, P/N 24-1112

• #1 Phillips Screwdriver

Procedure:

1. Disassemble the analyzer as follows:

a. Remove the battery cover and the batteries, uncovering one of the

cover hold-down screw.

b. Remove and set aside all four cover hold-down screws.

c. With the analyzer on its back, remove the front cover, laying it

face down to the left of the body.

d. Remove the battery connector from top of circuit board. Then

carefully remove the circuit board laying it face down in the top
cover.

2. Gently pull CO sensor out of its socket (see Figure 5-4).

3. Properly dispose of the old CO sensor (see the instruction sheet that
comes with the new sensor.

4. It is recommended that the CO sensor gasket be replaced at the
same time as the sensor. Remove the old gasket and discard. Re­move the paper backing from the new gasket and adhere it to the
case in the same position as the old one.

Important: Ensure that the new gasket does not restrict the inlet and
exhaust holes in the case.

5. Plug the new CO sensor into its socket.

6. Reassemble the analyzer.

34

Instruction 24-9435

Fyrite Tech

5.9 Pump Assembly Replacement

Material Required: • CO Sensor, P/N 24-7265

• #1 Phillips Screwdriver

Procedure:

1. Disassemble the analyzer as follows:

a. Remove the battery cover and the batteries, uncovering one of the

cover hold-down screw.

b. Remove and set aside all four cover hold-down screws.

c. With the analyzer on its back, remove the front cover, laying it

face down to the left of the body.

d. Remove the battery connector from top of circuit board. Then

carefully remove the circuit board laying it face down in the top
cover.

2. Remove the pump motot's electrical connector from the circuit board.

3. Unscrew the pump's hold down clamp and remove it from the pump
(see Figure 5-3). Make note of how the pump wiring is routed.

4. Make note of how the tubing connects to the pump, and then care­fully remove tubing from pump.

5. Remove the old pump and discard.

6. Mount the new pump using the hardware removed in Step 3.

7. Install tubing as was noted in Step 4, being careful not to pinch or
crimp the tubing.

8. Connect the pump's electrical connector to the circuit board, routing
the wiring as was noted in Step 3 (observe polarity, see Figure 5-4).

9. Reassemble the analyzer.

Instruction 24-9435

35

CO SENSOR
GASKET

PUMP

HOLD
DOWN
CLAMP

OXYGEN
SENSOR
& SOCKET

Fyrite Tech

36

Figure 5-3. Back Case Component Locations

Instruction 24-9435

CO
SENSOR

To
BATTERY

To
OXYGEN
SENSOR

T-STACK

To
PUMP

(RED
WIRE)

(RED
WIRE)

(RED
WIRE)

Fyrite Tech

Figure 5-4. CO Sensor Location

Instruction 24-9435

37

Fyrite Tech

6.0 PARTS & SERVICE

6.1 Replacement Parts

Description Part No.

Carbon Monoxide Sensor (Model 60 only) ...........................................24-7265

Carbon Monoxide Sensor Gasket (Model 60 only) ..............................24-1112

Oxygen Sensor w/ Gasket ................................................................... 24-8106

Oxygen Sensor Gasket ......................................................................... 24-1111

Pump Assembly ................................................................................... 24-3048

Probe, Hose, and Water Trap / Filter Assembly ................................. 19-7111

Tubing, Probe Assembly, 3/16" ID ...................................................... 03-6183

Water Trap / Filter Assembly ............................................................. 19-3265

Filter Element, for Water Trap / Filter Assembly, (pack of 3) ............07-1644

6.2 Accessories

STANDARD ACCESSORIES:

Battery, “AA” Alkaline ......................................................................204-0004

Instruction Manual ............................................................................. 24-9428

Soft Carrying Case ..............................................................................24-1267

Quick Start Guide ............................................................................... 24-9429

OPTIONAL ACCESSORIES:

Calibration Kit .....................................................................................24-7059

Gas Cylinder, 100 ppm CO ..................................................................51-1994

Gas Cylinder, 500 ppm CO ................................................................. 24-0492

Gas Cylinder, 100% Nitrogen .........................................................9550-0049

Hard Carrying Case ........................................................................... 24-0865

Printer:

IrDA w/rechargeable batteries (includes 120 VAC charger) ..........24-1229

IrDA w/disposable batteries ............................................................24-1400

Printer Paper:

1 Roll ............................................................................................... 06-8733

5 Roll Pack ....................................................................................... 24-1310

Protective Rubber Boot w/Magnets .....................................................24-1127

Probe Stop w/ Thumbscrew ................................................................ 19-3037

True Spot Smoke Test Set ...................................................................21-7006

Filter Paper, True Spot (40 strips) .................................................21-0019

38

Instruction 24-9435

Fyrite Tech

6.3 Service Centers

Replacement parts and service can be obtained by contacting one of the fol­lowing Bacharach Service Centers:

United States

Bacharach Inc.
621 Hunt Valley Circle
New Kensington, PA 15068
Phone: [phone]
Fax: [phone]
Email: [e-mail]

Canada

Bacharach of Canada, Inc.
250 Shields Court Unit #3
Markham, Ontario L3R 9W7
Canada
Phone: [phone]
Fax: [phone]
Email: [e-mail]

México

Bacharach de México
Playa Regatas No. 473 Tercer Piso
Col. Militar Marte
Delegación Iztacalco, 08830
México D.F.
México
Phones: [phone]
[phone]
Fax: [phone]
Email: bacharachservicio@
bacharach.com.mx
Website: www.bacharach-mexico.com

Instruction 24-9435

39

Fyrite Tech

Notes:

40

Instruction 24-9435

Printed in U.S.A.

621 Hunt Valley Circle, New Kensington, PA 15068

World Headquarters

Ph: 724-334-5000 • Fax: [phone] • Toll Free: 800-736-4666

Website: www.mybacharach.com • E-mail: [e-mail]