Bacharach Fyrite INSIGHT Plus Operating Manual
Tune-Rite™ Software
Operation Manual
P/N: 0024-9504
Revision 0
July 2014
Product Leadership • Training • Service • Reliability
Tune-Rite
Table of Contents
SECTION 1. INTRODUCTION ........................................................................... 3
SECTION 2. SAFETY ........................................................................................ 4
2.1. Conventions ................................................................................................. 4
2.2. Safety Precautions ....................................................................................... 5
2.3. Data Ranges ................................................................................................. 6
SECTION 3. TUNE-RITE BASICS .................................................................... 7
3.1. Supported Appliances and Fuel Types ......................................................... 7
3.2. Typical Combustion Process Review ............................................................ 8
3.3. The Tune-Rite Integration ......................................................................... 9
SECTION 4. USING TUNE-RITE ................................................................... 12
4.1. Introduction ............................................................................................... 12
4.2. Selecting Fuel Type and Accessing Tune-Rite ......................................... 12
4.3. Furnace/Boiler Light-Off ............................................................................ 14
4.4. Sample Smoke Test (Oil-Fired Appliances Only) ........................................ 14
4.5. Tune-Rite Draft Analysis .......................................................................... 17
4.6. Tune-Rite Combustion Analysis .............................................................. 20
4.7. Custom Reporting ...................................................................................... 28
SECTION 5.
REFERENCE, SERVICE, AND SUPPORT ........................................ 31
List of Figures
Figure 1-1. Fyrite INSIGHT Plus Reporting Package Kit ................................... 3
Figure 3-1. Typical Combustion Analysis Flowchart ............................................ 8
Figure 3-2. Accessing Tune-Rite™ from the Main Menu ..................................... 9
Figure 3-3. Tune-Rite Process Map Integration ................................................ 10
Figure 4-1. Fuel Selection Screens for Supported Fuel ..................................... 13
Figure 4-2. Fuel Selection Screens for Unsupported Fuel ................................. 13
Figure 4-3. Cycling Through Tracking Options .................................................. 16
Figure 4-4. Sample Printout Showing Service Checklist .................................... 30
List of Tables
Table 2-1. Default “In Range” Data Ranges Used During Analysis ...................... 6
Table 4-1. Tune-Rite™ Menu Navigation Keys .................................................. 12
Table 5-1. Reference Material Part Numbers ................................................... 31
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© Bacharach, Inc. 2014. All rights reserved.
Section 1. Introduction
Thank you for purchasing a Bacharach Fyrite INSIGHT Plus. Your new
combustion analyzer provides a suite of features and functionality to simplify
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the combustion analysis process. These features and functions are detailed in
the Fyrite
INSIGHT Plus manual that is included with your instrument.
Figure 1-1. Fyrite INSIGHT Plus Reporting Package Kit
Fyrite INSIGHT Plus is a next-generation combustion analyzer that integrates
Bacharach’s new Tune-Rite combustion analysis assistant into the featurerich, state-of-the-art programming of the traditional Fyrite
Bacharach’s Fyrite
Tune-Rite help system provides:
• A “when-you-need-it” solution that is integrated with the Fyrite®
INSIGHT® Plus
• Guidance based on live data and typical characteristics of the
combustion appliance
• An additional layer of diagnostic thoroughness to the traditional
combustion analysis process
• Additional comfort and confidence for the service technician
• A detailed, customizable, and value-added service report for the
customer
Tune-Rite is a non-intrusive combustion analysis assistant offering as much
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INSIGHT Plus.
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warning statement denotes a potential hazard
injury. Caution statements may also be used to alert against
important feature, operation, etc. Failure to follow this
, result in improper
help as the technician chooses. It is integrated into the Fyrite INSIGHT Plus
interface and provides feedback and diagnoses throughout the entire
combustion analysis process if requested.
• It tells you when the combustion appliance is ready for analysis.
• It reviews combustion test results based on the appliance type,
fuel type, and various live readings.
• It identifies possible causes and recommends ways to correct
problems and improve overall combustion efficiency.
• It provides tools allowing you to track your progress through the
analysis and troubleshooting process.
• It includes a reporting feature enabling you to build then print a
customized summary report of your analysis, including “as found”,
“as left”, and service checklist data.
It is a help and training tool that’s as useful to the seasoned HVAC veteran as it
is to the novice technician.
Section 2. Safety
2.1. Conventions
WARNING: A
associated with the use of this equipment. Failure to follow this
information could result in serious personal injury or death.
CAUTION: A caution statement indicates a potentially hazardous
situation which, if not avoided, may result in minor or moderate
unsafe practices.
IMPORTANT: An important statement provides emphasis of an
information could void your warranty
operation, or cause equipment damage.
NOTE: A note statement provides emphasis of a feature,
operation, practice, etc.
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Only trained technicians should use a combustion
Failure to adjust the appliance to specifications
injury, death, or property
damage.
facturer’s instructions before servicing the
combustion analysis using the analyzer to confirm that the
2.2. Safety Precautions
For important information on proper operation and operator safety, read and
follow the contents of this manual. Failure to do so can result in serious injury,
death, or property damage.
WARNING:
analyzer.
recommended by the appliance manufacturer can cause it to
malfunction and result in serious
WARNING: Failure to prevent combustion by-products such as CO
gas from leaking into the living space can create hazardous
conditions that could result in serious injury, death, or property
damage.
WARNING: Tune-Rite screens help to optimize the combustion
efficiency of a heating appliance while reducing flue gas emissions
such as soot and CO. Before using the analyzer, read and follow
the INSIGHT® Plus instruction manual. ALWAYS refer to the
appliance manu
appliance. Where the appliance manufacturer’s recommendations
are in conflict with the analyzer’s screens, operating values, or
instructions, the appliance manufacturer’s recommendations take
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precedence and should always be followed.
WARNING: After making appliance adjustments, always rerun the
appliance is operating within the appliance manufacturer’s
recommendations.
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type and typical operating values. The operating
values programmed in the analyzer are typical but not
2.3. Data Ranges
WARNING: The probable causes in the help screens are based on
the appliance
comprehensive.
CO recommendations are based on 100 ppm CO. Local rules and
regulations always take precedence. Where applicable, smoke
tests (in fuel oil applications) and draft tests (for all fuels) should
be performed prior to combustion tests.
The operator should compare the appliance manufacturer’s
operating values to the analyzer’s default values to ensure that
analyzer results are applicable to the appliance under test. Review
Table 2-1 for a list of default values used during the analysis.
Table 2-1. Default “In Range” Data Ranges Used During Analysis
Default “In Range” Data Ranges
NG
NG
NG
Appliance Type
Fuel
Furnace
Atmospheric
Draft (70%)
Fan Induced
Draft (80%)
Condensing
(90%)
O2
(%)
6 to 9 375 to 550 < 100 -0.01 to -0.05
6 to 9 325 to 425 < 100 -0.01 to -0.05
5 to 9 < 125 < 100 n/a
T-Stack
(°F)
CO
(ppm)
Draft-Stack
(inwc)
NG Water Heater 5 to 9 380 to 580 < 100 -0.01 to -0.05
Oil 1
Oil 1
Flame
Retention
Non-Flame
Boiler
Retention
3 to 6 350 to 500 < 100 -0.02 to -0.05
5 to 9 400 to 600 < 100 -0.02 to -0.05
1 – Fuel type “Oil” includes Oil #2, Oil #4, Oil # 6, and B5.
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Section 3. Tune-Rite Basics
3.1. Supported Appliances and Fuel Types
The Fyrite INSIGHT Plus instrument is useful in analyzing the combustion
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process in a wide variety of applications. (For a complete list of features and
applications, refer to your Fyrite
Tune-Rite focuses exclusively on the gas-fired furnaces, gas-fired water
heaters, and oil-fired boilers listed below.
Supported Appliance Types are shown below.
• Natural gas (NG) 70% efficient atmospheric furnaces
• Natural gas (NG) 80% efficient induced furnaces
• Natural gas (NG) 90% high-efficiency/condensing furnaces
• Natural gas (NG) water heaters (standard and FVIR)
• Flame retention oil boilers (>80% efficient)
• Non-flame retention oil boilers (<75% efficient)
Supported Tune-Rite Fuel Types are shown below.
• Natural gas
• Oil #2
• Oil #4
• Oil #6
• B5
Refer to your Fyrite
INSIGHT Plus manual for the locations of sampling points
on your combustion appliance.
INSIGHT Plus combustion analyzer manual.)
IMPORTANT: Review the appliance manufacturer’s
recommendations for the combustion device being tested, and be
aware of accepted practices of the local jurisdiction before
introducing sampling holes into exhaust pipes or ducts.
WARNING: To prevent dangerous exhaust gases from leaking into
the space, be sure to completely and securely seal any sampling
holes made in the exhaust pipes or ducts.
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In a typical combustion process (see
), the following steps usually
may indicate hardware problems and
Additional adjustments may be made
3.2. Typical Combustion Process Review
Figure 3-1
take place:
• Initial light-off of the combustion
appliance
• The system warms up to the point
when a steady-state condition is
reached. If steady-state is not
reached, the combustion appliance
may require major tuning, major
repairs, or replacement.
• For oil-fired appliance, a smoke test
is performed.
• A draft test is performed to verify
proper draft in the system.
• Combustion variables (O
, CO, CO2,
2
ambient temperature, stack
temperature, etc.) are analyzed to
determine efficiency and proper
operation.
• Out-of-range values are indicative of
less-than-optimal combustion, and
even safety issues.
• Further investigation may occur and
adjustments may be made to the
combustion equipment.
• Combustion variables are re-
evaluated.
•
until the combustion appliance is
operating within the appliance
manufacturer’s recommended
guidelines. If this state is never
reached, major repairs may be
required, the appliance
manufacturer’s associated
documentation may need to be
referenced, or a full system
replacement may be warranted.
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Figure 3-1. Typical Combustion Analysis Flowchart
and fuel you are using (as well as combustion data).
Technology can be used to simplify this process. The Fyrite INSIGHT Plus
combustion analyzer provides precise live readings of critical combustion data
during this process. To determine if the combustion appliance is operating
properly and within the appliance manufacturer’s recommended specifications,
the HVAC technician must still refer to the following.
• Industry experience to evaluate the combustion data
• Familiarity with the combustion appliance
• Familiarity and understanding of the operation of the analyzer
3.3. The Tune-Rite Integration
Tune-Rite provides an integrated “when-you-need-it” solution that offers
guidance based on live data and typical characteristics of the combustion
appliance. It gives an additional layer of diagnostic thoroughness to the
traditional combustion analysis process, while offering additional confidence to
the service technician.
Tune-Rite
Figure 3-2. Accessing Tune-Rite™ from the Main Menu
WARNING: Be aware of operating limits associated with the
combustion appliance you are analyzing. Tune-Rite provides
general tuning and efficiency recommendations based on the type
of appliance
However, always follow the operating instructions and guidelines
from the appliance manufacturer for details on precise operating
limits.
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Figure 3-3. Tune-Rite Process Map Integration
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