Bacharach Fyrite InTech Owner's Manual

Combustion Gas Analyzer
Configuration and Operation Manual

Instruction 0024-9486
Revision 2
December 27, 2012

Product Leadership • Training • Service • Reliability

Fyrite InTech



Manual

WARRANTY POLICY

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 CO sensor, and within one (1)
year after the date of delivery on the O

sensor.

2

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

ii 0024-9486 Rev 2

Fyrite InTech

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Manual

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 © 2012, Bacharach, Inc., all rights reserved.

BACHARACH, Fyrite, InTech, and B-SMART are registered trademarks of

Bacharach, Inc. All other trademarks, trade names, service marks and logos

referenced herein belong to their respective companies.

0024-9486 Rev 2 iii

Fyrite InTech

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Manual

iv 0024-9486 Rev 2

Fyrite InTech

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Manual Table of Contents

Table of Contents

Section 1. Overview .................................................................................... 1

1.1. Introduction ............................................................................................ 1

1.2. Conventions............................................................................................. 1

1.3. Safety ....................................................................................................... 1

1.4. Product Overview .................................................................................... 3

1.5. North American (NA) vs. Siegert (S) Combustion Equations ................... 3

1.6. Components ............................................................................................ 5

1.7. Features ................................................................................................... 7

1.8. Combustion Test Process Overview ........................................................ 8

1.9. Fyrite InTech Sales Combinations ...................................................... 9

1.10. Specifications....................................................................................... 11

Section 2. Setup ........................................................................................ 13

2.1. Connecting the Probe and Thermocouple ............................................ 13

2.2. Front Panel Buttons ............................................................................... 14

2.3. Power Options ....................................................................................... 15

2.4. Turning On the Fyrite InTech ............................................................ 16

Section 3. Configuration ........................................................................... 17

3.1. Menu Structure Overview ..................................................................... 17

3.2. The Warm-up Sequence ........................................................................ 17

3.3. Main Menu ............................................................................................ 18

3.4. Select Fuel Menu ................................................................................... 19

3.5. Ambient CO Menu (Siegert Only) .......................................................... 20

3.6. Memory Options Menu ......................................................................... 22

3.7. Setup Menu ........................................................................................... 24

3.8. Calibration Menu ................................................................................... 34

3.9. Diagnostics Menu .................................................................................. 35

3.10. Status Menu ........................................................................................ 37

Section 4. Operation ................................................................................. 38

4.1. Prerequisites ......................................................................................... 38

4.2. Sampling Point Examples ...................................................................... 38

4.3. Combustion Testing Process ................................................................. 41

4.4. The RUN Screen ..................................................................................... 42

4.5. Printing Using the Optional IrDA Printer ............................................... 43

4.6. Taking Ambient CO Measurements ...................................................... 46

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Table of Contents Fyrite InTech

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Manual

4.7. PC Interface and Fyrite User Software ................................................ 47

Section 5. Calibration and Maintenance .................................................. 48

5.1. Serviceability ......................................................................................... 48

5.2. Cleaning the Probe ................................................................................ 48

5.2.1. Equipment Required ................................................................. 49

5.2.2. Procedure ................................................................................. 49

5.3. Water Trap and Filter Replacement ...................................................... 50

5.4. O2 and/or CO Sensor Replacement ....................................................... 51

5.4.1. Accessing the Sensors ............................................................... 51

5.4.2. Material Required (As Needed) ................................................ 51

5.4.3. O2 Sensor Replacement Procedure ........................................... 52

5.4.4. CO Sensor Replacement Procedure .......................................... 52

5.4.5. B-SMART CO Sensor Replacement.......................................... 53

5.5. T-Stack Calibration ................................................................................ 54

5.5.1. Materials Required ................................................................... 54

5.5.2. T-Stack Calibration Procedure .................................................. 54

5.6. CO Sensor Calibration ............................................................................ 56

5.6.1. Materials Required ................................................................... 56

5.6.2. CO Manual Zero Procedure ...................................................... 56

5.6.3. CO Sensor Span Procedure ....................................................... 57

5.7. T-Ref Sensor Calibration ........................................................................ 58

Section 6. Troubleshooting ....................................................................... 59

6.1. Error and Warning Messages ................................................................ 59

6.2. Replacement Parts ................................................................................ 60

6.3. Accessories ............................................................................................ 61

6.4. Instrument Identification ...................................................................... 62

6.5. Service Centers ...................................................................................... 62

Declaration of Conformity ................................................................................. 63

∇ ∇ ∇

vi 0024-9486 Rev 2

A warning statement denotes a potential hazard

injury. Caution statements may also be used to alert against

feature, operation, etc. Failure to follow this

, result in improper

Fyrite InTech



Manual Overview

Section 1. Overview

1.1. Introduction

Thank you for investing in a Bacharach Fyrite InTech combustion analyzer.
To assure proper use and operator safety, please read the contents of this
manual for important information on the operation and maintenance of the
analyzer.

1.2. Conventions

WARNING:

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
important
information could void your warranty
operation, or cause equipment damage.

NOTE: A note statement provides emphasis of a feature,
operation, practice, etc.

1.3. Safety

WARNING: This analyzer is not intended to be used as a safety
device.

WARNING: When testing an appliance, a full visual inspection of
the appliance should be performed to ensure its safe operation.

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Overview Fyrite InTech

This analyzer is not intended to be used on a

, this

analyzer should only be opened and/or serviced by authorized

This instrument has not been

CAUTION:

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Manual

CAUTION:
continuous basis.

CAUTION: Do not store instrument or its sensors with solvents or
products that contain solvents.

CAUTION: Except for sensor and battery replacement

Bacharach personnel. Failure to comply may void the warranty.

HAZARDOUS AREA WARNING:

designed to be intrinsically safe for use in areas classified as
hazardous locations. For your safety,

DO NOT use it in hazardous

(classified) locations.

CAUTION: Do not use flammable or combustible substances (like
carburetor fluid used for cleaning the probe) near an open flame.

When the instrument is used in an inefficient oil-fueled
appliance where there is a high emission of soot, the probe’s
sample filter may become clogged. Before every use check the
filter to confirm it is clean or replace it with a new filter.

To prevent soot intake and a clogged filter, a smoke test should be
performed before operating under such conditions. This ensures
that the furnace or boiler is burning at a level appropriate for the
use of this instrument.

When the CO

level exceeds the allowable threshold, a warning

2

will prompt the user to consider performing a smoke test. This
screen is cleared by pressing the ENTER button. Once the warning
is cleared, it will not be displayed again for that particular test. If a
new test is started (by pressing the HOLD button), the warning will
be displayed again if the limit has been exceeded.

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Manual Overview

1.4. Product Overview

The Fyrite InTech is a portable hand-held combustion analyzer for use in
residential and light commercial applications. It is intended to be used by:

• HVAC contractors

• home inspectors

• maintenance personnel

• energy auditors

to conduct combustion efficiency analysis on residential and light commercial
furnaces and appliances in the worldwide market.

The instrument is supplied with all of the following components:

• probe and hose assembly

• four disposable “AA” alkaline batteries

• soft or hard carrying case (depending on model)

• factory-calibrated and installed sensor(s) as ordered

and, depending on the model and kit, some or all of the following:

• rubber boot

• spare filters

• Fyrite

• USB cable (type A to mini B)

• Infrared Data Association (IrDA) printer with four disposable “AA”

• printer paper



User Software (FUS)

alkaline batteries

1.5. North American (NA) vs. Siegert (S) Combustion Equations

Though the combustion process is fairly standardized across the globe, a
combustion analyzer intended for worldwide use demands a degree of
flexibility for a few regional preferences. The Fyrite
American configuration and a Siegert configuration (see page
these and other needs, which are contrasted below.

NOTE: Detailed differences between North American and Siegert
configurations are noted where appropriate in this manual.

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InTech provides a North

32) to address

Overview Fyrite InTech

S

• • • • • • •

Feature North American (NA) versus Siegert (S) Configurations

Countries

Typical North American

(NA) Users

Asia Belgium

Australia Denmark

Latin America France

North America Germany

South America Italy

Netherlands

Poland

Spain

United Kingdom

Heating Values For combustion calculations, Siegert uses the fuel’s lower

heating value; NA uses the higher value.

Fuels Different fuel sets and composition (p 19)

Different RUN
Parameters

EFF (NA) vs. Stack loss and ETA (S)
Excess Air (NA) vs. Lambda (S)
(Lambda is similar to excess air)

Typical

Siegert (S) Users

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Manual

Extra Siegert
Parameters

CO/CO2 ratio, boiler temperature, smoke number, and oil
derivative are displayed for Siegert only.

CO2 Max Siegert users can set a CO2 max number for the fuel.

Print Average
Feature

There is a print average feature for Siegert.

NOx Filter A NOx filter is included in-line on the tubing of the gas sample

probe of Siegert units.

Languages 3 languages for North American (NA) configuration.

8 languages for Siegert (S) configuration.

English

French

Spanish

German

Italian

Danish

NA

• • •

•

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Polish

Dutch

Fyrite InTech

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Manual Overview

1.6. Components

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Manual

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Manual Overview

1.7. Features

• Sensors (pp 51, 60)

o Field-replaceable electrochemical sensors (O
o Flue gas temperature measurement using a Type K thermocouple

• Fuel codes (p 19)

o Six available fuels (in North American configuration)
o Ten available fuels (in Siegert configuration)

• Power (pp 12, 15)

o 4 AA alkaline batteries (included)
o 4 AA lithium batteries
o 4 AA rechargeable batteries (externally charged)
o Low battery warning

• Testing Features

o Complete test results (10 sets) can be stored, recalled, displayed,

and printed

(p 22).

o Time and date stamping of test results
o Secure calibration function (password protected) (p 34)
o Auto power-off feature with sensor purge feature (p 30)
o Status and diagnostic menus (p 35)
o Manual entry of values (Siegert only) (pp 25, 26)
o Ambient CO (Siegert Only) (p 46)

• User Customizations

o North American and Siegert combustion calculations (pp 32, 43)
o Multi-language interface (p 29)
o Auto/Manual zero functions for the CO sensor (p 32)
o Customized user information (3 lines of 20 characters) (p 44)
o Customized logo on printouts (192 x 384 pixels) (p 46)
o Temperature unit selection (p 24)

• Hardware (p 5)

o Probe/hose assembly for gas transport and temperature input
o Sample pump to provide gas sample delivery
o Backlit monochrome graphic LCD
o Hard or soft carrying case
o USB 2.0 (mini-B connection) for PC interface and communications

• PC Interface (p 47)

o USB cable (Type A to Mini B)
o Fyrite



User Software (FUS) (Windows compatible)

o Updates and instrument configuration

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and B-SMART CO)

2

Overview Fyrite InTech

Turn On Instrument ................................... 14, 15, 16

56

Set System Parameters .................................... 19, 24

51

56

Filter Replacement ................................................ 50

Collect Data (RUN Button) .................................... 42

42

42

43

42

43

Review All Combustion Data ...................... 14, 42, 43

42

Disconnect Probe .................................................. 41

41

41

1.8. Combustion Test Process Overview

FUNCTION ............................................... PAGES

Connect Probe ...................................................... 13

Verify Power ......................................................... 15

Zero Instrument (Auto/Manual) ................ 17, 32,

Use Menu System ................................................. 17

Set Combustion Test Parameters .......................... 19

Replace Sensor(s) as Needed ........................... 35,

Calibrate as Needed ......................................... 34,

Replace Batteries as Needed................................. 15

Place Probe in Sampling Point ............................... 38

Save Data as Needed (F3) ................................ 14,

Stop Test (HOLD Button) .................................. 14,

Print Data as Needed (F1) .......................... 14, 42,

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Manual

8 0024-9486 Rev 2

Save Data (F3) .................................................. 14,

Print Data (F1) (Option) .............................. 14, 42,

Adjust Combustion Equipment As Needed

Save Data (F3) .................................................. 14,

Purge Instrument ............................................. 30,

Turn Off Instrument ......................................... 14,

Clean and Store ..................................................... 41

Fyrite InTech

computes and displays the calculations as long as the measured

computes and displays the calculations as long as the measured

NOTE: The North American (NA) configuration of Fyrite InTech



Manual Overview

oxygen is not above 16% O2 and the stack temperature is not above
650° C (1200° F). The Siegert configuration of the Fyrite

oxygen is not above 18.8% O2 and the stack temperature is not
above 650° C (1200° F).

1.9. Fyrite InTech Sales Combinations

Fuel Equations North American (NA) Siegert (S)

Final Assembly 0024-7340 0024-7341 0024-7342

Kit Type O2 Only Basic Reporting Basic Reporting

Sales Kit P/N 0024-8510 0024-8511 0024-8512 0024-8513 0024-8514

Probe X X X X X

Batteries X X X X X

T-Stack X X X X X

Manual X X X X X

O2 X X X X X

CO X X X X

Fuels 6 6 6 10 10

Soft Case X X X

Hard Case X X

Printer X X

Boot X X

PC Software X X

USB Cable X X

Spare Filters X X

NOx Filter X X



InTech

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Manual

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Manual Overview

1.10. Specifications

Specification Description

Temperature

Humidity Storage: 15 to 90% RH, non-condensing

Pressure 1 atmosphere ± 10%

Weight 16 ounces (454 g) with batteries

Dimensions 8.0” x 3.6” x 2.3” (20.3 cm x 9.1 cm x 5.8 cm) (H x W x D)

Warm-up Time Minimum = 30 seconds; Maximum = 60 seconds

Gas Sample Flow
Rate

Sensors O2 Electrochemical (P/N: 0024-0788)

Product Approvals
and Regulatory
Compliance

Case Construction High impact ABS plastic with co-molded rubber.

Display Monochrome with backlight

USB Connector Mini B (USB 2.0)

Memory 10 locations for storing test results

IrDA Port Protocol: IrDA-SIR Data Bits: 8 Stop Bits: 1

Storage: -20° to 50° C ( -4° to 122° F)
0° to 20° C (32° to 68° F ) optimal
Operation: -5° to 45° C (23° to 113° F)
Reference: 20° ± 2° C (68° ± 4° F)

Operation: 15 to 95% RH, non-condensing
Reference: 45 ± 10% RH, non-condensing

300 to 700 cc/min

CO Electrochemical (P/N: 0024-7265)
Temp (Stack) K-Type thermocouple

EN50270: (CE Mark) EMC tested in accordance with

European Directive 2004/108/EC .

EN50379: Standard for portable electrical apparatus

designed to measure combustion flue gas
parameters of heating appliances (Siegert only)
Parts 1 and 3.

RoHS Compliance

Protective rubber boot with molded-in magnets.

Baud Rate: 9600 Parity: None

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Overview Fyrite InTech



Specification Description

Power Supply
Options

Batteries

(4 AA)

Type: Disposable Alkaline (Included)
Duration: 15 hours min, continuous max draw

Type: Disposable Lithium
Duration: 20 hours, continuous max draw

Type: Rechargeable

Measure

-ment

Range Resolution Accuracy

O2 0 to 20.9 % 0.1% O2

CO 0 to 2000 ppm 1 ppm

Stack

Temp

-20° to 650° C

(-4° to 1202° F)

Calculation Calculation Range

Duration: 8 hours, continuous max draw

±0.3% O

(on flue gas)

2

±10 ppm (0 to 200)
±5% reading (201 to 2000)

1° C

(1° F)

±2° C (0° to 124° C)
±3° C (125° to 249° C)
±4° C (250° to 400° C)

Reso­lution

NA Siegert

Response

< 20 sec

< 40 sec

< 50 sec

Version

Efficiency (HHV) 0.1 to 100 % 0.1% X X

ETA (LHV) 0 to 115% 0.1% X

Excess Air 1 to 250 % 1% X

Stack Loss 0.1 to 100 % 0.1 % X

Lambda 1 to 9.55 0.01 X

CO2 (dry basis) 0.1 to a fuel-dependent max in % 0.1 % X X

CO Ref to O2 0 to 9999 ppm 1 ppm X X

CO/CO2 Ratio 0.0001 to fuel-dependent max 0.0001 X

∇ ∇ ∇

Manual

Time
(T90)

12 0024-9486 Rev 2

connector in only one orientation. DO NOT force the

Fyrite InTech



Manual Setup

Section 2. Setup

2.1. Connecting the Probe and Thermocouple

A rigid stainless steel probe with handle is connected to a flexible hose with an
integral water-trap/filter used to draw a gas sample into the analyzer from the
room, grilles, diffusers, and furnace flues.

1. Inspect the flue-gas hose for cracks. If a hose is defective, replace the

entire probe assembly.

2. Before using the analyzer, check that the water trap/filter is clean and dry.

If necessary, dry out the trap and replace the filter element.

3. Push the probe’s “sample gas” tubing onto the GAS inlet connector.

4. Push the probe’s thermocouple into the T-STACK connector on the

instrument noting the orientation.

IMPORTANT: The T-STACK connector tabs are keyed to fit into the

thermocouple connector tabs into the T-STACK connector.

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Setup Fyrite InTech

2.2. Front Panel Buttons

Button Description

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.



Manual

UP (

•

), DOWN (), LEFT (), and RIGHT () arrows



are context-specific navigation buttons for the menus.

UP (

•

) and DOWN () arrow buttons scroll to menu



options that are hidden from view (when a side scroll
bar is displayed indicating additional information).

UP (

•

) and DOWN () arrow buttons cause the



displayed value to increase or decrease accordingly.

LEFT (

•

) and RIGHT () arrow buttons jump to the



top and bottom of lists, respectively.

LEFT (

•

) and RIGHT () arrow buttons position the



active cursor on specific elements of a value to be
changed.

The ENTER button. Performs the action selected.

•

While in the HOLD screen, turns the sample pump on,

•

displays 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.

Returns the display to the HOLD screen while pressing it

•

during the shutdown sequence.

The ESC button cancels most operations and displays the

•

previous screen.

Pressing function keys accepts the corresponding function

•

defined above that key at the bottom of the display (for
example, PRINT, SAVE, MENU, etc.).

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Manual Setup

2.3. Power Options

You use the PWR button to turn on the Fyrite InTech. Power options
include:

• Disposable AA alkaline batteries (included)

• Disposable AA lithium (Li) batteries

• Externally charged rechargeable NiMH batteries.

Check the Fyrite InTech for sufficient power prior to each use. Replace the
batteries if the low (or replace) battery symbol appears in the upper right
corner of the Fyrite



InTech screen.

Batteries (4 AA, Fresh or Fully Charged)

Alkaline (disposable) 15 hours

Lithium (disposable) 20 hours

Rechargeable 8 hours

Estimated Life Span in Hours

(Continuous, Pump On)

Replace batteries as follows.

1. Remove the battery cover from the back of analyzer.

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

3. Observing the polarity markings inside the battery compartment,

install four ‘AA’ disposable (alkaline or lithium) batteries or four fully­charged (externally charged) AA rechargeable NiMH batteries.

4. Replace the battery cover.

NOTE: The Fyrite InTech does NOT charge rechargeable
batteries.

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Setup Fyrite InTech

will be displayed if the



Manual

NOTE: A Set Clock error message
instrument is without power for an extended period of time.

2.4. Turning On the Fyrite InTech

To turn on the Fyrite InTech, press the PWR button.

NOTE: After turning on the Fyrite InTech, it performs a warm-
up procedure which includes an auto-zero procedure for the
sensors (see pages
the Fyrite



InTech in a clean air environment.

17 and 32). For this reason, be sure to turn on

∇ ∇ ∇

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