Bacharach Fyrite Insight Operating Manual
Fyrite® INSIGHT
F1
F2
F3
ESC
RUN
HOLD
PWR
Combustion Gas Analyzer
Instruction 24-9460
Operation & Maintenance
Rev. 1 – July 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 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 two (2) years after the date of delivery on Product and all gas sensors except
the O2 sensor which has a one (1) year warranty 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 limitation will be binding upon Bacharach, Inc. unless in writing, signed by a duly authorized officer of Bacharach.
Register your warranty by visiting
www.mybacharach.com
Notice:
Product improvements and enhancements are continuous, therefore the specifications and information
contained 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 © 2002–2008, Bacharach, Inc., all rights reserved.
BACHARACH, Fyrite, INSIGHT & B-SMART 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 24-9460
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 ................................................................4
2.0 Technical Characteristics ......................................................... 5
3.0 Setting Up the Analyzer ............................................................ 7
3.1 Preliminary Steps ......................................................................7
3.2 Power ..........................................................................................7
3.2.1 Installing or Replacing Batteries...........................................7
3.2.2 Using the AC Power Adapter .................................................7
3.3 Connecting the Probe Hose & Thermocouple ...........................7
3.4 Front Panel Push Buttons .......................................................10
3.5 Setup Mode ..............................................................................11
3.5.1 Entering Setup ......................................................................11
3.5.2 Temperature Units ...............................................................11
3.5.3 Pressure Units ......................................................................11
3.5.4 Clock ......................................................................................12
3.5.5 O2 Reference ..........................................................................13
3.5.6 Print Pressure ......................................................................13
3.5.7 Zoom ......................................................................................13
3.5.8 Username ..............................................................................14
3.5.9 Run/Hold Format ..................................................................15
3.5.10 Language Selection ..............................................................17
3.5.11 Button Sound .......................................................................17
3.5.12 CAL Reminder Period .........................................................17
3.5.13 Inactivity Timeout ...............................................................18
3.5.14 Post-Purge Period ................................................................19
3.5.15 Date Format .........................................................................19
4.0 Operation .................................................................................... 20
4.1 Operating Tips ........................................................................ 20
4.2 Analyzer Power ON and Warm Up .........................................21
4.3 Fuel Selection...........................................................................21
4.4 Sampling Point ....................................................................... 22
4.5 Performing a Combustion Test .............................................. 23
4.6 Making a Draft/Pressure Measurement ............................... 25
4.7 Temperature Measurement .................................................... 26
4.8 Saving Test Data .....................................................................27
4.9 Ending a Combustion Test ......................................................27
Instruction 24-9460
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Fyrite® INSIGHT
4.10 Emptying the Water Trap.......................................................27
4.11 Powering OFF the Analyzer & Purging ............................... 28
4.12 Low Battery Alarm ................................................................ 28
4.13 Memory ...................................................................................28
4.14 Printing Test Data ................................................................. 30
4.15 Fyrite ® User Software Installation ..................................... 31
4.16 Fyrite® User Software Description ....................................... 34
5.0 Calibration & Maintenance ......................................................35
5.1 B-Smart Sensors ...................................................................... 35
5.2 Starting a Calibration ............................................................. 35
5.3 B-Smart Sensor Replacement & Calibration ......................... 37
5.4 Pressure Sensor Calibration ................................................... 37
5.5 T-Stack Calibration.................................................................. 39
5.6 T-Air Calibration ..................................................................... 41
5.7 CO Sensor Calibration .............................................................43
6.0 Maintenance ................................................................................. 44
6.1 Fyrite® INSIGHT Disassembly ............................................. 44
6.2 Water Trap / Filter ................................................................. 46
6.2.1 Emptying the Water Trap Chamber .................................... 46
6.2.2 Replacing the Filter Element ............................................... 46
6.3 O2 Sensor Replacement .......................................................... 47
6.4 CO Sensor Replacement ......................................................... 48
6.5 Thermocouple Replacement .................................................... 49
6.6 Gas Pump Replacement .......................................................... 50
6.7 Cleaning the Probe ................................................................. 50
6.8 Error Messages ....................................................................... 51
6.9 Diagnostics Screen ................................................................. 52
6.10 Status Screen ......................................................................... 53
7.0 Parts & Service ............................................................................54
7.1 Replacement Parts .................................................................. 54
7.2 Accessories .............................................................................. 54
7.3 Service Centers ....................................................................... 55
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Instruction 24-9460
Fyrite® INSIGHT
1.0 INTRODUCTION
1.1 The Fyrite® INSIGHT
The Fyrite® INSIGHT is a hand-held residential and commercial grade
portable combustion analyzer that is designed for on-demand sampling of
light industrial combustion equipment, residential furnaces, and appliances.
The Fyrite® INSIGHT is upgradeable from the Basic model to the Recording model which includes additional features such as software compatible
for downloading data and the IrDA printer.
This manual contains information on all models of the Fyrite INSIGHT.
Please disregard any information that does not pertain to your model.
WARNINGS!
This analyzer is not intended to be used on a continuous
basis.
This analyzer is not intended to be used as a safety device.
Except for sensor and 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.
Instruction 24-9460
Basic
24-8250 24-8251
HARD CARRY CASE X X
PROBE ASSEMBLY X X
PRINTER IRDA X
BOOT X X
PC SOFTWARE X
USB CABLE X
BATTERIES X X
QUICK START GUIDE X X
Reporting
1
Fyrite® INSIGHT
1.2 Fyrite® INSIGHT Features & Benets
AUTOMATIC ZERO - The instrument will automatically zero all sensing
channels on ambient air when it is powered on. If a particular sensor is in
error during warm-up, the instrument will automatically display the error
and continue to operate with the sensor in error. However, all information
dependent on the sensor in error will not be presented.
TEMPERATURE UNITS - Temperatures can be displayed in Centigrade
or Fahrenheit.
PRESSURE UNITS - Pressures can be displayed in milliBar (mB),
Pascal (Pa), hectoPascal (hPa), Millimeters of Water Column (mmwc), or
Inches of Water Column (inwc).
LANGUAGE - The display options are English, French or Spanish.
MEMORY - The Fyrite® INSIGHT has the ability to store, recall to dis-
play, and print a minimum of 100 sets of time and date coded combustion,
differential pressure, or differential temperature test records.
DOWNLOAD - Test records can be downloaded to a personal computer via
the USB port. Saved records are transferred using PC based software and
will be automatically loaded into an Excel spreadsheet. PC based software
will also have the capability to update the instrument time and date and
upload custom fuels, username, customer logo, and future code updates.
The INSIGHT can also be set up from PC software.
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 - Calibration can be performed by applying gas and entering calibration gas concentrations through software menu selections.
SMART SENSORS - B-Smart sensor technology is employed for the CO
channel. CO sensors are calibrated prior to shipment and provide data that
can be entered through the software menu selections for easy calibration
without applying gas.
CALIBRATION REMINDERS - Calibration reminders can be set for
Never, 6, 8, 10, 12, or 15 months.
DISPLAY FORMAT - The Run/Hold display format can be presented in
default or custom ordered for specic needs. Up to 8 lines can be customized in the Run/Hold screen.
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Instruction 24-9460
Fyrite® INSIGHT
DISPLAY ZOOM - Combustion test data in the Run/Hold screens can be
shown with enlarged characters to make viewing easier. The complete
list of Run/Hold data can be scrolled through for all zoom levels. Available
zoom levels and information display are as follows:
• Standard - 4 lines of information
• 2X - 3 lines of enlarged characters
• 3X - 2 lines of enlarged characters
STATUS - A status menu displays the instrument software version, boot
version, model number, and serial number.
DIAGNOSTICS - The diagnostics menu displays the O2 sensor life, CO
sensor information, and hours of operation for the instrument and the
pump.
KEYPAD SOUND - Keypad sounds can be enabled or disabled with software menu selections.
LOW BATTERY - A tone will sound every 10 seconds when a low battery
condition exists. A low battery message will also be displayed.
AUTOMATIC POWER DOWN - The instrument can be set to automatically power off after a period of inactivity unless the user presses any button; the CO is greater than 50 ppm, or the O2 is less than 16.0%. Automatic power down can be set for None, 30, or 60 minutes.
PURGE - The sensors will be purged when the instrument is shutdown
until sensor outputs indicate that they have been exposed to fresh air.
Pressing the On/Off key a seconds time can defeat the purge routine. The
minimum purge time can be set to None, 5 seconds, 1 , 5, or 10 minutes.
SENSOR ACCESS - Sensor replacement can be accomplished in the eld.
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 continuous operation with the pump running and the back light on. Optionally, the analyzer can operate with a universal AC adapter. When the AC
adapter is plugged into the unit, batteries do not have to be removed.
Instruction 24-9460
3
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.
Begin testing by inserting the analyzer’s probe tube into the flue-gas
stream of the appliance under test. The analyzer will monitor the flue
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.
Pressing the RUN/HOLD button during a test will freeze all measured and
calculated values at their current levels. Pressing the RUN/HOLD button
again resumes testing.
A backlight enables an operator to read the display in dimly-lit areas.
Pressing the PWR button turns the backlight ON and OFF.
An optional power saver function will shut the analyzer OFF after a set
time period of inactivity. This feature is disabled if the CO value is greater
than 50 ppm or the O2 value is less than 16.0%.
Press the PWR button for at least two seconds to power 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
RUN/HOLD button. There is a CO purge feature that keeps the analyzer’s
pump running until the measured CO level drops below 50 ppm.
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Instruction 24-9460
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 ± 100 inwc
The Analyzer computes & displays:
Combustion Efficiency 0.1 to 100%
Carbon Dioxide
0.1 to a fuel dependent
maximum value in %
CO referenced to %O2 0 to 9,999 ppm
Excess Air 0 to 250%
2
Fuel Selection
• Natural Gas
• Oil #2
• Oil #4
• Oil #6
• Propane
• Kerosene
• Wood
• Coal
Normal Operating Conditions:
Temperature
• Analyzer
• Probe
32 to 104 °F (0 to 40 °C)
1,000 °F max (538 °C) at
5" insertion
Humidity 15 to 90% RH, Non-Condensing
Dimensions Weight
7.9 in (20.1 cm) Height
1lb. (0.45 kg)
3.6 in (9.1 cm) Width
2.3 in (5.8 cm) Depth
Instruction 24-9460
5
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, & pressure
tests can be saved in memory.
Display 128 x 64, LCD Graphic Display
Front Panel Controls Eleven front panel push buttons
(Refer to Section 3.4)
Interfaces IrDA printer & USB connectivity
Accuracy:
Oxygen ±0.3% O2 with a typical flue gas
concentration of CO2
Carbon Monoxide ±5% of reading or ±10 ppm, whichever is
greater*, in the range of 0 to 1000 ppm.
Flue Gas 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/Primary
Temperature
±2 °F between 32 & 212 °F
(±1 °C between 0 & 100 °C
Draft ±2% of reading or ±0.02 InWC, whichever is
greater in the range of -10 to +10 InWC
± 3% in the range of -10 to -40 InWC
± 3% in the range of 10 to 40 InWC
* 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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Instruction 24-9460
Fyrite® INSIGHT
3.0 SETTING UP THE ANALYZER
3.1 Preliminary Steps
Before using the analyzer . . .
• Check batteries (Section 3.2)
• Connect probe to analyzer (Section 3.3)
• Check setup (Section 3.5)
3.2 Power
3.2.1 Installing or Replacing Batteries
Install fresh batteries as described below. Check the analyzer for sufficient
charge prior to each use. Replace the batteries if the low-battery symbol
appears in the upper right corner of the screen. To replace the batteries:
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.
4. Replace battery cover.
3.2.2 Using the AC Power Adapter
The optional AC power adapter is capable of powering the analyzer on a
continuous basis. The adapter plugs into an appropriate 100-240 VAC wall
outlet and produces an output of +5 VDC. The adapter's output connector
plugs into the analyzer's POWER jack located on the bottom of the unit.
The batteries do not need to be removed when using the AC adapter.
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 analyzer from the room, grilles, diffusers, and furnace flues.
Instruction 24-9460
7
Fyrite® INSIGHT
Inspect the flue-gas hose for cracks. If a hose is defective, replace the entire probe assembly.
Before using the analyzer, check that the Water Trap / Filter is dry and
not dirty. If necessary, dry out the trap and replace the filter element per
Section 6.2.
Perform the following steps to connect the probe assembly to the Fyrite
INSIGHT:
1. Push the probe’s sample-gas hose onto the GAS inlet fitting.
2. Push the probe’s draft hose onto the “+” pressure fitting.
3. Push the probe’s thermocouple into the T-STACK jack
Important: DO NOT force the thermocouple connector into
its jack. The connection tabs are different sizes, allowing the
connector to fit in only one way.
4. Push the optional ambient/primary-air thermocouple into the T-AIR
jack.
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Instruction 24-9460
Fyrite® INSIGHT
Fyrite® INSIGHT Connectors
USB Cable
AC Power
Adapter Jack
(Power)
Differential
Pressure Hose
(Optional)
Probe
Stop
Sample Gas
Thermocouple
Connector (T-Stack)
Probe
Tube
Draft
Hose
Primary Ambient
Air Thermocouple
(T-Air) (Optional)
Sample Gas
Hose
Water Trap/
Filter Assembly
Probe
Handle
Instruction 24-9460
Fig. 3.1
9
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.
• Toggles the backlight ON and OFF while the analyzer is
turned ON.
• Scrolls up, down, left, and right through the display screen
options.
• Up and Down arrows cause the displayed value to in-
crease or decrease correspondingly.
• Acts as an ENTER button. Performs the action selected.
• While in the HOLD screen, turns the sample pump on, dis-
plays the RUN screen, and begins a combustion test.
• While in the RUN screen, turns the sample pump off, displays the
HOLD screen and the last set of combustion data.
• Displays the HOLD screen while pressing it from most menus.
10
• Return the display to the HOLD screen while pressing it during the
5 second power down sequence.
• Cancels most operations and displays the previous screen.
• Pressing function keys accepts the corresponding function
defined at the bottom of the display, including PRINT, SAVE,
MENU, differential pressure ZERO, differential temperature
ZERO, PAGE UP, PAGE DOWN and CLEAR data.
Instruction 24-9460
Fyrite® INSIGHT
3.5 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
Language English Section 3.5.10
CAL Reminder Never Section 3.5.12
Clock Not Initialized Section 3.5.4
3.5.1 Entering Setup
1. Display the MAIN MENU by pressing the
MENU (F2) button.
2. Use the ▲▼ buttons to highlight SETUP
and press ENTER to display the SETUP
MENU.
3.5.2 Temperature Units
Select to display temperature in either ºF or ºC 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 TEMPERATURE UNITS.
Press ENTER to display the Temperature
Units Menu.
3. Use the ▲▼ buttons to select the desired
temperature unit.
4. Press ENTER to save selection and return
to the SETUP MENU or ESC to revert the
previous setting.
Instruction 24-9460
11
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.
2. From the SETUP MENU, use the ▲▼ buttons to select PRESSURE UNITS. Press
ENTER to display the Pressure Units Menu.
3. Use the ▲▼ buttons to selecte the desired
pressure unit.
4. Press ENTER to save selection and return
to the SETUP Menu or ESC to revert to the
previous setting.
3.5.4 Clock
The clock settings (12 hr. AM/PM or 24 hr.) and date format options (MM/
DD/YY or DD/MM/Y Y ) are interdependent. (See DATE FORMAT, Section
3.5.15).
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 CLOCK. Press ENTER to
display the Clock Setup Screen
3. Use the ▲▼ buttons to enter the current
date and time. Use the the ◄► buttons to
move the cursor across the screen.
4. Press ENTER to save the selection and return to the SETUP MENU or ESC to revert
to the previous setting.
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Instruction 24-9460
Fyrite® INSIGHT
3.5.5 O2 Reference
The measured value of CO can be referenced to a specific O2 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.
2. From the SETUP MENU, use the ▲▼
buttons to select O2 REFERENCE. Press
ENTER to display the O2 Reference Screen.
3. Use the ▲▼ buttons to enter the O2 reference value.
4. Press ENTER to save the selection and return to the SETUP MENU or ESC to revert
to the previous setting.
3.5.6 Print Pressure
Select whether to print or not print the pressure measurement on the combustion test printout 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 PRINT PRESSURE. Press
ENTER to display the O2 Reference Screen.
3. Use the ▲▼ buttons to select YES or NO to
print the pressure measurement.
4. Press ENTER to save the selection and return to the SETUP MENU or ESC to revert
to the previous setting.
3.5.7 Zoom
Combustion test data in the Run/Hold screen can be shown with enlarged
characters to make viewing easier. The operator can set zoom levels to
Standard, 2X or 3X. The Standard zoom setting will display 4 lines of
combustion test data at one time; 2X will display 3 lines of data with enlarged characters; 3X will display 2 lines of data with enlarged characters.
The operator can scroll through the complete list of measured and calcu-
Instruction 24-9460
13
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.
3. Use the ▲▼ buttons to select the desired
zoom level.
4. Press ENTER to save the selection and display the SETUP MENU or ESC to revert to
the previous setting.
3.5.8 Username
The name of the user or owner (e.g. company name, address, phone number) can be stored in memory by manually entering up to three lines of
text, with each line containing up to 20 alphanumeric characters. This
information will appear at the top of each printout, until it is cleared or
new information is entered.
Username Information can be entered 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 USERNAME.
Press ENTER to display the most recently
saved information.
3. Use the ▲▼ buttons to select the line of information which you would like to edit and
press ENTER. A single cursor will appear
denoting the character you are changing.
4. Use the ▲▼ buttons to scroll the the list of
alphanumeric characters and the ◄► but-
tons to move across the screen.
5. Press ENTER to save the selection or ESC to
revert to the previous input.
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Instruction 24-9460
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