Bacharach Fyrite Classic Operating Manual

INSTRUCTION 11-9026

FYRITE® Gas Analyzer

CO2 and O2 Indicators

Operation/Maintenance

Rev. 8 – September 2005

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Bacharach, Inc.

621 Hunt Valley Circle, New Kensington, PA 15068

Phone: [phone] • Fax: [phone]

Web: www.bacharach-inc.com

Printed in U.S.A. ® Registered Trademarks

WARRANTY

Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will
be free from defects in material and manufacture and will conform substantially
to Bacharach Inc.’s applicable 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 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 one (1) year 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 warranty set forth in paragraph 1 does not apply to parts the Operating
Instructions designate as having a limited shelf-life or as being expended in
normal use.

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
WARANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE: AND (II) ANY OBLIGATION, LIABILITY, RIGHT, CLAIM OR
REMEDY IN CONTACT 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 limitation will be binding upon Bacharach, Inc. unless in writing, signed by
a duly authorized officer of Bacharach.

NOTE: Gaskets are considered consumable items and are excluded
from the terms of this warranty.

Register Your W arranty by Visiting

www.bacharach-inc.com

CAUTION

Corrosive fluid is contained inside this unit.
These instructions should be thoroughly read
before operation is attempted.

Copyright © 1998-2005 Bacharach, Inc., all rights reserved.

A

FYRITE SAFETY PRECAUTIONS

The operator (s) of this instrument should thoroughly familiarize themselves with the
applicable safety precautions before handling or using the FYRITE for gas analysis.

Review Figures 1a,1b, 1c and 1d on this page. Make certain to follow the steps
outlined below and read the fluid handling precautions for your personal safety.

1) Always use protective equipment such as safety goggles, gloves, and protective
clothing as illustrated in Figure 1a.

2) Read the instruction manual thoroughly. When filling the FYRITE with the
applicable fluid charge, use safety equipment and perform the operation in the
vicinity of running tap water (Figure 1b).

3) The FYRITE fluid should always be in the bottom reservoir before and during
sample introduction to the FYRITE. When venting the FYRITE to atmosphere,
hold the instrument in the vertical position and at a location away from your face
(Figure 1c).

4) NEVER vent FYRITE in the inverted position (with the plunger facing down­ward). This will cause fluid to spill, which is corrosive and contains harmful
elements (Figure 1d).

NOTE: In the event of fluid spill - refer to Section 2.2 (FYRITE Handling
Precautions). For Maintenance - refer to Section 6.0.

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Figure 1a. Protective equipment
required before attempting gas
analysis.

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Figure 1c. Venting FYRITE to
atomsphere at 45° angle.

Figure 1b. Preparing to fill FYRITE
using recommended protective
safety equipment.

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Figure 1d. NEVER vent FYRITE in
the inverted position, which will
cause fluid to spill.

i

TABLE OF CONTENTS

1.0 DESCRIPTION ............................................................................................................................................. 1

2.0 FYRITE INSPECTION BEFORE AND DURING TEST............................................................................ 1

2.1 Pre-Operational Check .................................................................................................................... 1

2.2 FYRITE FLUID HANDLING PRECAUTIONS ............................................................................ 2

3.0 BASIC FYRITE OPERATION PERCENT CO2 AND 02............................................................................ 3

3.1 Determining CO2 and O2 FYRITE Fluid Strength ......................................................................... 7

3.2 Operating Precautions to Ensure Maximum Accuracy..................................................................7

3.2.1 Draining Fluid Droplets .................................................................................................. 8

3.3 FYRITE Temperature ...................................................................................................................... 8

3.3.1 Temperature of Gas Sample............................................................................................ 8

4.0 PRINCIPLE OF OPERATION ...................................................................................................................... 9

5.0 APPLICATION INFORMATION ............................................................................................................... 10

5.1 FYRITE Absorbing Fluid .............................................................................................................. 10

5.1.1 FYRITE Refill Fluid (Storage Life, etc.) ..................................................................... 10

5.2 FYRITE Operating Temperature Range ....................................................................................... 11

5.3 Typical FYRITE Applications....................................................................................................... 11

5.4 CO2 FYRITE Only Combustion Testing....................................................................................... 12

5.4.1 Percent CO2 Shows Volume of Excess Air................................................................... 12

5.4.2 Too Much Excess Air Means Inefficient Combustion .................................................13

5.4.3 What is Proper CO2 Value? ........................................................................................... 13

5.4.4 How To Calculate Combustion Efficiency .................................................................. 13

5.5 O2 FYRITE Only Combustion Testing ......................................................................................... 13

5.5.1 Percent O2 Shows Volume of Excess Combustion Air ................................................ 13

5.5.2 Too Much Excess Air Means Inefficient Combustion .................................................13

5.5.3 What is Proper O2 Value? .............................................................................................. 14

5.5.4 Measuring O2 in Addition to CO2................................................................................ 14

5.5.5 Where is Percent CO2 or O2 Measured? ....................................................................... 14

5.6 Background Gases Affecting FYRITE Readings ......................................................................... 16

5.7 General FYRITE Applications ...................................................................................................... 17

5.8 Altitude Correction Table .............................................................................................................. 18

6.0 FYRITE MAINTENANCE ........................................................................................................................ 18

6.1 Increasing FYRITE Fluid To Proper Level ...................................................................................18

6.1.1 Decreasing FYRITE Fluid to Proper Level ..................................................................19

6.2 Checking FYRITE Fluid Strength ................................................................................................ 19

6.2.1 CO2 FYRITE Fluid Only............................................................................................... 19

6.2.2 O2 FYRITE Fluid Only ................................................................................................. 21

6.3 Replacing FYRITE Fluid............................................................................................................... 21

6.4 Inspection of FYRITE for Fluid Leakage ..................................................................................... 22

6.5 Cleaning FYRITE .......................................................................................................................... 24

6.6 Replacing FYRITE Plastic and Rubber Parts............................................................................... 24

6.7 Aspirator Bulb - Sampling Assembly ........................................................................................... 26

6.8 Storing FYRITE and Refill Fluid.................................................................................................. 26

6.9 Replacing Saturator Filter Packing Part #11-0121 ...................................................................... 26

7.0 ILLUSTRATED PARTS LIST FYRITE CO2/O2........................................................................................ 29

7.1 FYRITE Illustrated Parts ............................................................................................................... 30

7.2 FYRITE Sampling Assemblies...................................................................................................... 31

ii

INSTRUCTIONS 11-9026

OPERATION/MAINTENANCE

BACHARACH FYRITE MODELS

CO2 and O2 INDICATORS

1.0 DESCRIPTION (Refer to Figure 1)

The FYRITE employs the well-known “Orsat” method of volumetric analysis involv­ing chemical absorption of a sample gas, such as carbon dioxide or oxygen. The
reagent used to absorb carbon dioxide (CO2) is potassium hydroxide (dyed red), and
chromous chloride (blue) is the absorbent for oxygen (O2). The unique feature of the
FYRITE is that the absorbing fluid is also used as the indicating fluid so that one
vessel takes the place of both measuring burette and absorption pipette.

The body of the FYRITE is molded of clear high-strength plastic, comprises top and
bottom reservoirs and a center tube connecting the two reservoirs. The bottom of the
lower reservoir is sealed off by a synthetic rubber diaphragm that rests on a perfo­rated metal plate. The upper reservoir is covered by a molded plastic cap that
contains a double-seated plunger valve. A spring holds this valve against a carefully
finished seat in the top cap providing a perfect seal which makes the instrument
spill-proof in any position. When the valve is partially depressed, the entire instru­ment is open to the atmosphere and the instrument is, of course, is no longer spill­proof.

The bottom reservoir is filled with the absorbing fluid, which extends about 1/4 inch
into the bore of the center tube when the instrument is held upright. The scale
position, mounted to one side of the center tube, is adjustable.

2.0 FYRITE INSPECTION BEFORE AND DURING TEST

CAUTION

Corrosive fluid is contained inside unit, instructions should be
thoroughly read before operation is attempted.

2.1 Pre-Operational Check

To ensure proper FYRITE operation and reliable results, check the following:

(a) With FYRITE vented and in a vertical position, it should be possible to adjust

scale zero to the top of the fluid column. Refer to FYRITE Operation for proper
setup (Section 3.0 Steps 1 through 5). If this is not possible, add or remove a
small amount of fluid per Section 6.1.

Instruction 11-9026 Page 1

(b) FYRITE Fluid Strength

To check fluid strength.

NOTE: When repeating procedures as outlined in Section 3.0
Steps 7 through 9 (absorbing and reading percent O
absorbing and reading percent CO2) and before venting

and

2

FYRITE to atmosphere for next sample, if the reading in­creases by more than 1/2 percent for either CO2 or O2, replace
the fluid.

It is often desirable to check fluid strength before taking the FYRITE to a location
where it will be used. It can be tested on sample atmospheric air (which contains

20.9% O

maximum accuracy. (See Section 6.9)

O

2

samples containing 10% O2.

CO

approximately 350 samples containing 10% CO

). Be certain to wet Filter Saturator when checking atmospheric air for

2

(Oxygen) Fluid - Fresh FYRITE fluid will absorb all O2 from approximately 100

(Carbon Dioxide) Fluid - Fresh FYRITE Fluid will absorb all CO2 from

2

.

2

(c) FYRITE Sampling Assembly - Always check sampling assembly for proper

(leak-free) operation as outlined in Section 6.7 before proceeding with test.

(d) Make certain wool in Filter Saturator Tube is moistened with water if using

either O2 or CO2 FYRITE in a noncombustible application where the gas sample
is not fully saturated with water vapor. Examples where filter-saturator must
be wetted include measuring CO
samples. Refer to Section 6.9 when replacing or moistening saturator (wool)

or O2 in ambient air or from compressed gas

2

filter is required.

FYRITE OPERATION PRECAUTION: To prevent fluid
spill, never depress Plunger Valve to vent FYRITE when unit
is in the inverted or any other non-upright position. When
depressing Plunger Valve in the upright position to vent
FYRITE, hold at a slight angle away from the operator’s face.

2.2 FYRITE FLUID HANDLING PRECAUTIONS

CAUTION

FYRITE fluids used in the CO
and contain poisonous elements which must not be taken
internally. In the event of a spill or accidental body contact
with FYRITE fluid, read the following carefully.

Page 2 Instruction 11-9026

and O2 analyzers are corrosive

2

HAZARDS

Corrosive liquid causes burns. May cause blindness if splashed in eyes. Vapors are
irritating and may be harmful.

PRECAUTIONS

Prevent contact with eyes, skin and clothing. Wear eye protection and gloves. Do not
vent instrument until fluid has drained from top well. Do not vent instrument
(FYRITE) in inverted position.

FIRST AID

For contact with eyes: Immediately flush eyes with water 20 minutes. Get immedi­ate medical attention.

For contact with skin: Immediately flush skin with water 20 minutes. Get immedi­ate medical attention.

For inhalation overexposure: If irritation develops, move victim to fresh air.

For swallowing: Do not induce vomiting. Give two glasses of water or milk if con­scious and not convulsing. Get immediate medical attention.

Refer to the material safety data sheet for further information.

3.0 BASIC FYRITE OPERATION PERCENT CO2 AND 0

2

Four basic steps are required when making an analysis, many being common to both
the CO2 and O2 FYRITE.

FYRITE MODEL CO
(Red Fluid) (Blue Fluid)

2

FYRITE MODEL O

2

(a) Vent and adjust scale zero. (a) Vent and adjust scale zero.

(b) Pump sample into FYRITE. (b) Pump sample into FYRITE.

(c) Absorb CO2 from sample. (c) Absorb O2 from sample.

(d) Read % CO2 on scale. (d) Read % O2 on scale.

NOTE: To prevent warming of FYRITE fluid during analysis,
hold FYRITE by the fins only.

Instruction 11-9026 Page 3

CO2 FYRITE OPERATION O2 FYRITE OPERATION

(RED FLUID) (BLUE FLUID)

1. Hold upright (Fig. 1) and

away from face. Depress
Plunger Valve (momen­tarily) to vent FYRITE,
and release.

2. Invert FYRITE (Fig. 2).

Hold at slight angle to
drain fluid into top
reservoir.

3. Turn upright. Hold

FYRITE at 45° angle
(Fig. 3) momentarily to
allow fluid droplet
drainage into bottom
reservoir.

Figure 1

Figure 2

Figure 3

1. Hold upright (Fig. 1) and
away from face. Depress
Plunger Valve (momen­tarily) to vent FYRITE,
and release.

2. Invert FYRITE (Fig. 2) to
absorb O2 drawn into
FYRITE whenever
Plunger Valve is de­pressed). Hold at slight
angle to drain fluid into
top reservoir.

3. Turn upright. Hold
FYRITE at 45° angle to
drain fluid into bottom
reservoir. Turn upright.
Repeat sequence of Steps
1, 2, and 3 twice until
fluid level does not drop
more that 1/2% when
Plunger Valve is de­pressed. Turn upright.
Hold FYRITE at 45°
angle (Fig. 3) momen­tarily until excess fluid
droplets have been
drained from inside
surfaces.

4. Hold FYRITE in upright
(Fig. 4) position and away
from face. Depress
Plunger Valve (momen­tarily) and release.

4. Hold FYRITE in upright
(Fig. 4) position and away
from face. Note fluid level
in column. Depress
Plunger Valve (momen­tarily), and release.

Figure 4

Page 4 Instruction 11-9026

CO2 FYRITE OPERATION O2 FYRITE OPERATION

(RED FLUID) (BLUE FLUID)

5. Holding FYRITE upright
(Fig. 5), loosen locknut at
rear of scale. Slide scale
(Fig. 5a) until top of fluid
column lines up with zero
line on scale (Fig. 5b).
Tighten scale locknut.

NOTE: When setting
scale zero, hold FYRITE
vertically as shown and
level with eyes while
sighting across scale to
top of fluid column.

6. To pump gas sample into
FYRITE (Fig. 6), insert
open end of metal
sampling tube into area
bearing gas for analysis.
Hold FYRITE in upright
position and place
sampling assembly
rubber connector tip over
the Plunger Valve.

Depress Plunger Valve
firmly with connector tip.

Figure 5

Figure 5a

Figure 5b

5. Holding FYRITE upright
(Fig. 5), loosen locknut at
rear of scale. Slide scale
(Fig. 5a) until top of fluid
column lines up with zero
line on scale (Fig. 5b).
Tighten scale locknut.

NOTE: When setting
scale zero, hold FYRITE
vertically as shown and
level with eyes while
sighting across scale to
top of fluid column.

6. To pump gas sample into
FYRITE (Fig. 6), insert
open end of metal
sampling tube into area
bearing gas for analysis.
Hold FYRITE in upright
position and place
sampling assembly
rubber connector tip over
the Plunger Valve.

Depress Plunger Valve
firmly with connector tip.

Pump sample by squeez­ing and releasing
aspirator bulb 18 times.
During 18th bulb squeeze
(with bulb held deflated)
release connector tip and
Plunger Valve.

Pump sample by squeez­ing and releasing
aspirator bulb 18 times.
During 18th bulb squeeze
(with bulb held deflated)
release connector tip and
Plunger Valve.

Figure 6

Instruction 11-9026 Page 5

CO

FYRITE OPERATION O2 FYRITE OPERATION

2

(RED FLUID) (BLUE FLUID)

7. Absorb sample gas into
FYRITE by inverting
until fluid drains into top
reservoir (Fig. 7). Then
turn upright (Fig. 8) to
drain fluid into bottom
reservoir. Repeat this
step once.

8. Hold FYRITE at 45°
angle (Fig. 9) momen­tarily to allow fluid
droplets to drain into the
bottom reservoir.

9. With FYRITE held
upright (Fig. 10), permit
fluid in column to
stabilize a few seconds,
then immediately read %
carbon dioxide on scale at
the point corresponding
to top of the fluid column.

7. Absorb sample gas into
FYRITE by inverting
until fluid drains into top
reservoir (Fig. 7). Then
turn upright (Fig. 8) to
drain fluid into bottom
reservoir. Repeat this
step three (3) more times
(four complete inversions
total).

Figure 7

8. Hold FYRITE at 45°
angle (Fig. 9) momen­tarily to allow fluid
droplets to drain into the
bottom reservoir.

Figure 8

9. With FYRITE held
upright (Fig. 10), permit
fluid in column to
stabilize a few seconds,
then immediately read %
oxygen on scale at the
point corresponding to
top of the fluid column.

Figure 9

Page 6 Instruction 11-9026

Figure 10

10. This step completes CO2 or O2 FYRITE gas sample analysis. A few points to
remember when reading the FYRITE:

(a) FYRITE accuracy is within ±1/2% CO

or O2 compared to actual value.

2

(b) Always handle FYRITE by fins to ensure body heat is not absorbed by fluid.

(c) A delay in reading of 5 or 10 seconds may decrease accuracy of reading

slightly but longer delays may cause substantial error.

(d) The FYRITE is calibrated to indicate on a “dry” basis for flue gas samples,

which are normally fully saturated with moisture. Failure to artificially
moisten wool packing in Filter Saturator Tube when actual sample is not
fully saturated will cause FYRITE to read slightly low.

Therefore, make certain wool packing in Filter Saturator Tube is suffi­ciently moistened with water for accurate results on non-flue gases. Avoid
excessive moisture which can be drawn into the Aspirator Bulb and forced
into the FYRITE during sampling.

CAUTION

Never depress plunger valve to vent FYRITE in the inverted
position. This will cause fluid to spill, which is corrosive and
contains poisonous elements. In the event of a spill, read Instruc­tions in Section 2.2 FYRITE fluid handling precautions.

3.1 Determining CO2 and O2 FYRITE Fluid Strength

FYRITE Fluid strength can be conveniently checked immediately after the first
sample reading. Without venting, repeat the absorbing operations (Steps 7 through

9) by inverting FYRITE again and positioning upright until all fluid drains to the

bottom reservoir. Observe scale reading. An increase of more than 1/2% CO
the second reading as compared to the first indicates a need for fluid replacement.

or O2 in

2

3.2 Operating Precautions to Ensure Maximum Accuracy

Locate top of fluid column (refer to Fig. 11). The surface at the top of the fluid
column (meniscus) in the small, center bore will be dish-shaped as shown in Fig­ure 11. Either the high or low point of this dish-shaped surface may be used to
locate top of fluid column providing the same point is always used both for setting
scale zero and reading percent CO
operation and low point for the other will cause an error.

Best practice is to use high point of this fluid surface just at the small center bore
wall. In setting scale zero or reading percent CO
level with eyes and sight across scale to top of fluid column.

Instruction 11-9026 Page 7

or O2. Obviously, using high point for one

2

or 02, hold FYRITE vertically and

2

3.2.1 Draining Fluid Droplets

For maximum accuracy, it is important to form the habit of following a standard
procedure in this operation and to use the same procedure both before adjusting
scale zero and before reading percent CO2 or O2 .

3.3 FYRITE Temperature

The FYRITE temperature should be at or close to the temperature of the working
environment where the analysis is being made and should not be subject to sudden
temperature changes. If FYRITE is carried from cooler to warmer location or vice
versa, expose FYRITE to new temperature condition to permit uniform temperature
stabilization. Usually 15 or 20 minutes will suffice, except when extreme tempera­ture variations are involved. Temperature stabilization can also be accelerated by
inverting FYRITE frequently.

3.3.1 Temperature of Gas Sample

The gas sample as it enters FYRITE should be cooled (or warmed if sampling cool
gases) to same (ambient) temperature as the FYRITE.

Capacity of Standard Aspirator Bulb and Sampling Assembly (Part # 11-7029) to
cool the gas sample is sufficient if the temperature of gas being sampled does not
exceed 850°F (454°C), even where a large number of consecutive samples are
required if there is an interval of not less than 5 minutes between samples.

FYRITE indicators operate over a wide temperature range. They may be exposed to
ambient temperatures from –30° to 150°F (–34° to 66° C). Gases up to 850° F
(454° C) may be tested with Standard Aspirator Sampling Assembly (11-7029).
Special sampling equipment for high temperatures and unsaturated gas samples are
listed in Section 7.2. FYRITE Sampling Assemblies.

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Top of
Fluid
Column

Figure 11. Locating Top of Fluid Column.

Page 8 Instruction 11-9026