Combustion Gas Analyzer Instruction Manual Configuration • Operation • Maintenance P/N: 0024-9487 Revision 1 December 6, 2012 Product Leadership • Training • Service • Reliability
Fyrite INSIGHT Plus Manual 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.
Fyrite INSIGHT Plus 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.
Fyrite INSIGHT Plus Manual Table of Contents SECTION 1. OVERVIEW ................................................................................ 1 1.1. Introduction .......................................................................................... 1 1.2. Conventions .......................................................................................... 1 1.3. Safety .................................................................................................... 1 1.4.
Fyrite INSIGHT Plus Manual 4.3. 4.4. 4.5. 4.6. 4.7. Combustion Testing Process ............................................................... 59 The RUN Screen .................................................................................. 61 Making a Draft or Pressure Measurement ......................................... 63 Printing Using the Optional IrDA Printer ............................................. 64 Graphics Screens ...................................................................
Fyrite INSIGHT Plus Manual 6.1. 6.2. 6.3. 6.4. 6.5. Error and Warning Messages .............................................................. 92 Replacement Parts .............................................................................. 94 Accessories .......................................................................................... 95 Instrument Identification .................................................................... 96 Service Centers ........................................
Fyrite INSIGHT Plus Manual Section 1. Overview Overview 1.1. Introduction Thank you for investing in a Bacharach Fyrite INSIGHT Plus 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: A warning statement denotes a potential hazard associated with the use of this equipment.
Overview Fyrite INSIGHT Plus Manual CAUTION: This analyzer is not intended to be used on a continuous basis. CAUTION: Do not store instrument or its sensors with solvents or products that contain solvents. CAUTION: Except for sensor and battery replacement, this analyzer should only be opened and/or serviced by authorized Bacharach personnel. Failure to comply may void the warranty.
Fyrite INSIGHT Plus Manual Overview 1.4. Product Overview The Fyrite INSIGHT Plus 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.
Overview Fyrite INSIGHT Plus Manual Feature North American (NA) versus Siegert (S) Configurations Typical North American (NA) Users Asia Australia Latin America North America South America Countries Typical Siegert (S) Users Belgium Denmark France Germany Italy Netherlands Poland Spain United Kingdom Heating Values For combustion calculations, Siegert uses the fuel’s lower heating value; NA uses the higher value (see page 61).
Fyrite INSIGHT Plus Manual Overview 1.6.
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Fyrite INSIGHT Plus Manual Overview 1.7.
Overview • • 8 Fyrite INSIGHT Plus Manual o Temperature and pressure unit selection (p 32) Hardware o Probe/hose assembly for gas transport and temperature input (p 6) o Sample pump to provide gas sample delivery o Backlit color graphic LCD (p 5) o Hard carrying case (see below) o Time and date stamping of 100 test results o USB 2.
Fyrite INSIGHT Plus Manual Overview 1.8. Combustion Test Process Overview FUNCTION PAGES Connect Probe ................................................... 6, 15 Turn On Instrument ..................................... 5, 16, 19 Verify Power (Batteries or USB) ............................. 18 Zero Instrument (Auto/Manual) ................ 21, 48, 88 Use Menu System .................................................. 22 Set System Parameters ....................................
Overview Fyrite INSIGHT Plus Manual 1.9.
Fyrite INSIGHT Plus Manual Overview 1.10. Specifications Specification Temperature Description Storage: Operation: Reference: -20 to 50 C 0 to 20 C -5 to 45 C 20 ± 2 C ( -4 to 122 F) (32 to 68 F ) optimal (23 to 113 F) (68 ± 4 F) Humidity Storage: Operation: Reference: 15 to 90% RH, non-condensing 15 to 95% RH, non-condensing 45 ± 10% RH, non-condensing Pressure 1 atmosphere ± 10% Weight 16 ounces (454 g) with batteries Dimensions (HxWxD) 8.0” x 3.6” x 2.3” (20.3 cm x 9.1 cm x 5.
Overview Fyrite INSIGHT Plus Manual Specification Description IrDA Port Protocol: Baud Rate: Parity: IrDA-SIR 9600 None Data Bits: 8 Stop Bits: 1 Memory 100 locations for storing test results Type: Disposable Alkaline (Included) Duration: 15 hours min, continuous max draw Power Supply Options Batteries (4 AA) Type: Disposable Lithium Duration: 20 hours, continuous max draw Type: Rechargeable Duration: 8 hours, continuous max draw USB Cable (A to Mini B) Source: PC Source: AC source (vi
Fyrite INSIGHT Plus Manual Overview NOTE: The North American (NA) configuration of the Fyrite INSIGHT Plus computes and displays the calculations as long as the measured oxygen is not above 16% O2 and the stack temperature is not above 650° C (1202° F). The Siegert configuration of the Fyrite INSIGHT Plus computes and displays the calculations as long as the measured oxygen is not above 18.8% O2 and the stack temperature is not above 650° C (1202° F).
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Fyrite INSIGHT Plus Manual Section 2. Setup 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, grills, diffusers, and furnace flues. Refer to page 6. 1. 2. 3. 4. 5. Inspect the sample gas hose for cracks. If a hose is defective, replace the entire probe assembly.
Setup Fyrite INSIGHT Plus Manual 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. • 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).
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Setup Fyrite INSIGHT Plus Manual 2.3. Power Options Power options include: • Disposable AA alkaline batteries (included) • Disposable AA lithium (Li) batteries • Externally charged rechargeable NiMH batteries • Power via USB cable (PC or wall adapter). Check the Fyrite INSIGHT Plus 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 INSIGHT Plus screen.
Fyrite INSIGHT Plus Manual Setup NOTE: The Fyrite INSIGHT Plus does NOT charge rechargeable batteries. NOTE: A Set Clock error message will be displayed if the instrument is without power for an extended period of time. 2.4. Turning the Fyrite INSIGHT Plus On/Off To turn on the Fyrite INSIGHT Plus, press the POWER button. Press and hold the power again button to begin the shutdown cycle.
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Fyrite INSIGHT Plus Manual Section 3. Configuration Configuration 3.1. Menu Structure Overview NOTE: The Fyrite INSIGHT Plus may be configured to use either North American combustion equations or Siegert combustion equations. As a result, several parameters are unique to each configuration. This section shows a mix of screens that have been configured for North American combustion equations as well as Siegert combustion equations.
Configuration Fyrite INSIGHT Plus Manual 3.3. Main Menu Main Menu Function Access the Select Fuel Menu (see page 24). • Select combustion fuel Access the Pressure Menu (see page 26). • • • View current pressure readings Gas pressure, Differential across heat exchanger, draft reading, and differential pressure Corresponding zero, save, and print functions Access the Temperature Menu (see page 26).
Fyrite INSIGHT Plus Manual Main Menu Configuration Function Access the Setup Menu (see page 32). • • • Edit/view instrument preferences Edit/view system parameters Edit/view combustion test parameters Access the Calibration Password Screen and the Calibration Menu (see page 51). • Calibrate sensors Access the Diagnostics Menu (see page 52). • • • • View “run” meters View system diagnostic values Check O2 sensor life Fresh air diagnostics Access the Device Status Menu (see page 55).
Configuration Fyrite INSIGHT Plus Manual 3.4. Select Fuel Menu Select Fuel Function Fuel List Select the combustion fuel from the fuel list. Use the UP () and DOWN () arrow buttons to highlight the desired fuel and use the ENTER button to select.
Fyrite INSIGHT Plus Manual Select Fuel Configuration Function Siegert configurations accept manually adjusted CO2 max values which are used for combustion calculations and represent corrections for fuel variations. Adjusted CO2 max values are stored with saved combustion records and displayed in the RUN/HOLD screen. CO2 max values are entered through software menu selections when a fuel type is selected.
Configuration Fyrite INSIGHT Plus Manual 3.5. Pressure Menu Pressure Function Displays the current pressure reading. Use F1 to print the current value (see page 64), F2 to zero the reading, and F3 to save the reading to memory. Use the LEFT () and RIGHT () arrow buttons to scroll through the following pressure readings: • Diff Acrs HtEx • Draft Reading • Diff Pressure To zero the pressure reading, press F2 and follow the instructions on the display.
Fyrite INSIGHT Plus Manual Temperature Menu Configuration Function 3.7. Leak Test Menu (Siegert Only) Let-by and Tightness are regional requirements for the UK market with very specific procedures. While they may be useful in other local jurisdictions to provide means to have safe readings for leak checks of gas and safe combustion processes, they are simply one way to test for these problems. Other procedures may be specified by local authorities.
Configuration Fyrite INSIGHT Plus Manual Leak Test Menu Function To perform the Tightness test, use the UP () and DOWN () arrow buttons to highlight the Tightness option and press ENTER. Follow the instructions on the screen. 3.8. Ambient CO Menu (Siegert Only) Ambient CO Function Access the Ambient CO Menu (Siegert only). When initiated, the Ambient CO feature monitors CO values continuously and captures a reading every minute for 15 minutes (a total of 16 readings from t0 to t15).
Fyrite INSIGHT Plus Manual Ambient CO Configuration Function NOTE: Press the F2 key to cancel a test in progress. After the test is complete, the Ambient CO Summary screen is displayed. This is a scrollable window that shows the 16 CO “snapshot” readings, as well as the maximum CO reading that was sampled during the entire test. NOTE: The Max CO Reading is the highest sampled CO reading – even if the reading was taken in between one of the sample “snapshot” readings.
Configuration Fyrite INSIGHT Plus Manual 3.9. Memory Options Menu Memory Options Function Provides access to the Memory Directory. This directory contains a numbered list of up to 100 saved test records (combustion data, pressure data, temperature data, etc.). “NO DATA” is displayed if no tests were saved since the last time memory was cleared. To view saved data, use the UP () and DOWN () arrow buttons to highlight the desired test from the list.
Fyrite INSIGHT Plus Manual Memory Options Configuration Function Allows the user to select a range of test records to be printed. Use the UP () and DOWN () arrows to select the first record and then press ENTER. Use the UP () and DOWN () arrow buttons to select the last record and then press ENTER. Position IrDA printer (see page 64 for printing information). Press ENTER to print. Print Average (Siegert Only) displays the memory directory with the first 3 samples highlighted.
Configuration Fyrite INSIGHT Plus Manual 3.10. Setup Menu Setup Menu Function Set Temperature Unit (°C or °F) for display and printing purposes. Use the UP () and DOWN () arrow buttons to highlight the desired choice. Press the ENTER button to use the selected temperature unit. Press ESC to quit without saving. Set Pressure Unit for display and printing purposes.
Fyrite INSIGHT Plus Manual Setup Menu Configuration Function Smoke Number (Siegert only) is used to calculate and display an average smoke value based on 3 smoke test results that are entered by the user. A sample smoke scale is shown below. Perform 3 smoke tests then enter the results in the 3 smoke number parameters shown below. Use the UP () and DOWN () arrow buttons to highlight smoke number 1, 2, or 3, then press ENTER.
Configuration Setup Menu Fyrite INSIGHT Plus Manual Function Oil Derivative (Siegert only) specifies whether or not oil derivatives were present during the smoke tests (see page 33). For incomplete combustion, oil derivatives present in the sample can be precipitated onto the filter paper, causing a color change in the smoke spot. Use the UP () and DOWN () arrow buttons to select the YES option if oil derivatives were present during the smoke test. Otherwise select NO and press ENTER.
Fyrite INSIGHT Plus Manual Setup Menu Configuration Function The Clock option provides access to the clock setup function to set date and time. Use the LEFT () and RIGHT () arrow buttons to select the desired field to edit. Then use the UP () and DOWN () arrow buttons to change the value of the selected field. Press ENTER to save new date and time. Press ESC to quit without saving. NOTE: Siegert configurations display time and date information in DD/MM/YY and 24-hour time format only.
Configuration Fyrite INSIGHT Plus Manual Setup Menu Function The measured value of CO can be referenced to a specific O2 percentage (0% to 15%) as referenced in the equation below. 𝐶𝑂(𝑛) = 20.9 − 𝑂2 𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒 × 𝐶𝑂 20.9 − 𝑂2 𝑀𝑒𝑎𝑠𝑢𝑟𝑒𝑑 Use the UP () and DOWN () arrow buttons to enter the O2 reference value (n) from 0% to 15%. Press ENTER to save the selection or ESC to revert to the previous setting. NOTE: The O2 reference has a default value of 0%.
Fyrite INSIGHT Plus Manual Setup Menu Configuration Function 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 5 lines of combustion test data at one time. • 2X will display 4 lines of data with enlarged characters. • 3X will display 3 lines of data with enlarged characters. Select the desired zoom level using the UP () and DOWN () arrow buttons.
Configuration Setup Menu Fyrite INSIGHT Plus Manual Function TEST ID OVERVIEW Test records can be identified by manually entering up to three lines of text, with each line containing a maximum of 20 alphanumeric characters representing a customer’s name, burner number, location, etc. NOTE: This data can also be entered using the Fyrite User Software (FUS). From the Test ID screen, you can select, edit, and clear Test IDs.
Fyrite INSIGHT Plus Manual Configuration Setup Menu Function EDIT TEST ID NOTE: This data can also be entered using the Fyrite User Software (FUS). To Edit the contents of a Test ID record, use the UP () and DOWN () arrow buttons to highlight the Edit Test ID option and press ENTER. Use the UP () and DOWN () arrow buttons to highlight your desired choice from the list of 10 Test IDs (the first line of each Test ID is shown). Once highlighted, press ENTER to select that Test ID.
Configuration Setup Menu Fyrite INSIGHT Plus Manual Function CLEAR TEST ID To clear the contents of one or more Test IDs, use the UP () and DOWN () arrow buttons to highlight the Clear Test ID option and press ENTER. Use the UP () and DOWN () arrow buttons to highlight your desired choice: Individual Records • All Records. • Once highlighted, press ENTER. If “Individual Records” is selected, a list of the 10 Test IDs is displayed.
Fyrite INSIGHT Plus Manual Setup Menu Configuration Function Provides an interface for entering user identification information used on printouts. Generally, the Username fields contain the HVAC company and related information. NOTE: This data can be entered using the Fyrite User Software (FUS). Use the UP () and DOWN () arrow buttons to choose a row and press ENTER to begin editing the selected row.
Configuration Setup Menu Fyrite INSIGHT Plus Manual Function Changing the RUN/HOLD Format 1. Use the UP () and DOWN () arrow buttons to select EDIT FORMAT. Press ENTER to display the current format. 2. Change data for a particular location by first using the UP () and DOWN () arrow buttons to select the location in the list that you want to edit. Note that the entire line of each position is highlighted. Press ENTER when the desired row is highlighted.
Fyrite INSIGHT Plus Manual Setup Menu Configuration Function NOTE: Changing the RUN/HOLD format also can be done through the Fyrite User Software (FUS). Reset Format (Factory Default) Reset the display format back to the factory default settings as follows: 1. From the SETUP MENU, use the UP () and DOWN () arrow buttons to select RESET FORMAT. Press ENTER to display the Reset Format confirmation prompt. 2.
Configuration Fyrite INSIGHT Plus Manual Setup Menu Function The Language Selection option allows the user to choose a language for all menus. Use the UP () and DOWN () arrow buttons to scroll through language options (varies based on instrument model). Use ENTER to enable the selected language. NOTE: The number of available languages may differ based on the combustion equation setting.
Fyrite INSIGHT Plus Manual Setup Menu Configuration Function The analyzer can be set to indicate a calibration reminder during warmup. Calibration reminders can be set to occur never, 6, 8, 10, 12, or 15 months after the last calibration. When the preset period is exceeded the instrument will display the reminder, and how long since the sensors were last calibrated. If a calibration reminder is displayed, the operator can press the RUN/HOLD key to move to the RUN/HOLD Screen for normal operation.
Configuration Setup Menu Fyrite INSIGHT Plus Manual Function Provides a list from which to select an inactivity (key press) timeout for automatic shutdown. If no key presses occur for the time specified, the Fyrite INSIGHT Plus initiates an automatic shutdown. Use the UP () and DOWN () arrow buttons to scroll through Inactivity Timeout options (never [default], 20, 30, or 60 minutes). Use the ENTER key to enable the selected timeout.
Fyrite INSIGHT Plus Manual Setup Menu Configuration Function Provides a list (North American Configuration only) from which the user may select the desired date format used by the instrument: • • MM/DD/YY (default for NA configurations) DD/MM/YY (standard for Siegert) NOTE: The DD/MM/YY date format is the only format available in instruments configured with Siegert combustion equations. This parameter is only available in North American configurations.
Configuration Fyrite INSIGHT Plus Manual Setup Menu Function Provides a list from which the user may select the desired method for zeroing the CO sensor. Auto-Zero occurs automatically at warmup. Manual zero is used to initiate the zeroing process whenever desired. Use the UP () and DOWN () arrow buttons to highlight the desired zeroing method. Press ENTER to save. Press ESC to quit without saving.
Fyrite INSIGHT Plus Manual Setup Menu Configuration Function Provides a list from which the user may select the type of O2 sensor used in the instrument: • Standard O2 sensor (shown below) • Long-Life O2 sensor. Use UP () and DOWN () arrow buttons to highlight the installed O2 sensor option. Press ENTER to select.
Configuration Fyrite INSIGHT Plus Manual Setup Menu Function The COMBUSTION EQUATIONS menu allows the user to select either Siegert combustion equations or North American combustion equations. Use UP () and DOWN () arrow buttons to highlight the desired option. Press ENTER to select. IMPORTANT: Changing this setting resets several configuration parameters to their default values. Below is a list of affected parameters, and those unaffected.
Fyrite INSIGHT Plus Manual Configuration 3.11. Calibration Menu Calibration Menu Function Calibration is performed by applying known values and accessing the password-protected menu items. When the Calibration Menu is selected, the user must enter a 4-digit numeric security code in order to proceed to the calibration options. The default password is 1111. Use the UP () and DOWN () arrow buttons to scroll through numerals 0-9 until the desired numeral is reached.
Configuration Fyrite INSIGHT Plus Manual 3.12. Diagnostics Menu Diagnostics Menu Function Displays time metrics for pump use and total operation time. Displays information about the sensors of the instrument. Displays the estimated oxygen (O2) sensor life based on: • the sensor type (standard or long-life) that you enter • the sensor’s 3-digit date code that you enter (from the label on the sensor) • the current date that you set • the typical O2 sensor life of approximately 24 months.
Fyrite INSIGHT Plus Manual Configuration Diagnostics Menu Function The Fyrite INSIGHT Plus will show that the O2 sensor needs to be replaced, and an error message is displayed (see below). In this case: • • • Note the 3-digit date code on the new sensor Replace the O2 sensor Press F3 to change and verify sensor date code.
Configuration Fyrite INSIGHT Plus Manual Diagnostics Menu Function NOTE: Use this feature as a reminder only. This status is based on: • • • • the date code on the sensor (that you enter) the current date (that you enter) the typical O2 life span (2 years) the output of the sensor If either of the entered values is incorrect, the status of your O2 sensor life will not be accurate. Actual sensor life may vary. Displays fresh air diagnostics similar to the display at warmup.
Fyrite INSIGHT Plus Manual Configuration 3.13. Status Menu Status Menu Function This is the device status screen which displays information about the device. Some of the information displayed on this screen includes serial number, firmware version, model number, etc.
Fyrite INSIGHT Plus Manual Section 4. Operation Operation 4.1.
Fyrite INSIGHT Plus Manual Operation Example Forced Air Furnace Example Hot Water Tank For atmospheric burner or gravity vented, forced air heating equipment with a clamshell or sectional heat exchanger design, test each of the exhaust ports at the top of the heat exchanger. The probe should be inserted back into each of the exhaust ports to obtain a flue gas sample, before any dilution air is mixed in.
Operation Example 90% Efficiency Condensing Furnace Condensing furnaces/ boilers can be tested through a hole drilled in the plastic vent pipe (when allowed by the manufacturer or local authority of jurisdiction) or taken from the exhaust termination.
Fyrite INSIGHT Plus Manual Operation 4.3. Combustion Testing Process WARNING: The Fyrite INSIGHT Plus calculates combustion parameters based on North American or Siegert combustion equations. NA or Siegert configuration is selected in the SETUP MENU. Be sure that your Fyrite INSIGHT Plus is properly configured for your region and desired combustion calculations. Step Example Combustion Testing Procedure 1 Confirm that testing prerequisites have been completed (see page 56).
Operation Fyrite INSIGHT Plus Manual Step Example Combustion Testing Procedure 11 Turn on the instrument to optionally print and/or evaluate saved test results (based on your local codes and practices for combustion data and CO levels). 12 To turn off the Fyrite INSIGHT Plus, press and hold the POWER button until you see the Shutdown timer. Wait for the purge function to complete (you will hear the pump stop and the display will shut off).
Fyrite INSIGHT Plus Manual Operation 4.4. The RUN Screen The Fyrite INSIGHT Plus test data is located in the Run screen. By pressing the RUN/HOLD button, you should hear the pump running and see the word RUN at the upper-left hand corner of the display. The instrument is continuously measuring and calculating the data that is shown in the Run screen. Press the RUN/HOLD button again. The pump should stop running and the word HOLD should be shown at the upper-left hand corner of the display.
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Fyrite INSIGHT Plus Manual Operation 4.5. Making a Draft or Pressure Measurement The difference in pressure (ΔP) between two areas can be measured by using the analyzer's two pressure ports and the PRESSURE screen. By using the -ΔP port as the reference, the pressure applied to the +ΔP port will be displayed on the PRESSURE screen as the differential pressure between the two ports. Perform a draft/pressure measurement as follows.
Operation Fyrite INSIGHT Plus Manual 4.6. Printing Using the Optional IrDA Printer The instrument has the ability to store, recall (to the display), and print sets of time- and date-coded test records. The time and date are set through software menu selections (see page 35). • • Displaying stored records is done through the MEMORY DIRECTORY MENU (see page 30). Press F1 to print displayed test records.
Fyrite INSIGHT Plus Manual Operation NOTE: The printout order of parameters matches any RUN/HOLD format changes that have been made (see page 41).
Operation Fyrite INSIGHT Plus Manual IR Communications Settings: Baud Rate: Data Bits: Stop Bits: Parity: Protocol: Distance: Angle: 9600 8 1 None IRDA-SIR 8-16 in (20-41 cm) 60° maximum Fyrite INSIGHT Plus can be setup to include a custom logo on printouts. Logos are loaded into the instrument using the Fyrite User Software (FUS). Logo size is limited to 192 x 384 pixels (height x width) and must be in .BMP, .JPG, .PNG, or .TIFF format.
Fyrite INSIGHT Plus Manual Operation 4.7. Graphics Screens 4.7.1. Overview Dynamic graphics screens provide an alternative way of viewing key combustion data and parameters in real time. The Fyrite INSIGHT Plus displays three graphics screens which provide continuous updates and are described in the table that follows. The screens are accessed from the RUN/HOLD screen by using the LEFT () and RIGHT () arrow buttons. See the figure below.
Operation Fyrite INSIGHT Plus Manual Screen Description Graphical “Line Graph” Trend Screen • • User-selectable combustion parameter User-selectable time period Bar Graph Screen • • • 1, 2, or 3 bar graphs User-selectable combustion parameter for each bar User-selectable limits for each parameter Stack Temperature Hot Spot Screen • • • Used to dynamically locate “hot spot” in flue Based on stack temperature readings Use probe stop to maintain optimal probe position 4.7.2.
Fyrite INSIGHT Plus Manual Trend Screen Options (F3) Operation Description • • Press the F3 button to define options for the trend screen. The LINE GRAPH PARAMETER option is used to select the combustion parameter (from a list) to be graphed over time. • The LINE GRAPH TIME option defines the full-scale X-axis sample time over which the graph is plotted. 4.7.3.
Operation Fyrite INSIGHT Plus Manual Bar Graph Component Description • Color of “current value” pointer is based on limit status: Green: Between upper and lower limit Red: Outside upper or lower limit • • User-defined limits shown on bar graph in red and green. Display range adjusts to real-time values. Left Arrow • Press the LEFT () arrow to go to the Line Graph Trend screen. Right Arrow • Press the RIGHT () arrow to go to the Stack Temperature Hot Spot Screen.
Fyrite INSIGHT Plus Manual Bar Graph Component Format (F3) Operation Description • • Press F3 to display the Bar Graph format screen. It contains three bar graph options–-each of which defines the combustion parameter associated with that graph. A fourth option is selected when editing is complete. Use the UP () and DOWN () arrow buttons to highlight one of the rows corresponding to the three bar graphs (top, middle, or bottom) (see left, below).
Operation Fyrite INSIGHT Plus Manual 4.7.4. Stack Temperature Hot Spot Screen Hot Spot Component Hot Spot Graph Description • • • Press RUN/HOLD to start/stop the hot spot function. T-STACK parameter name shown in graph. Limits are determined automatically. • • Dynamic “current value” pointer indicates real-time value.
Fyrite INSIGHT Plus Manual Operation Step Example Procedure for Taking Ambient CO Measurements 3 If using battery power, check battery status. If battery life is questionable, replace the batteries, as the Ambient CO test takes approximately 15 minutes to complete. 4 Move instrument to target location to be tested. 5 Press F2 to display the Main Menu. 6 Use the down arrow to highlight Ambient CO Test and press the ENTER button. 7 Follow the on-screen instructions to initiate the test.
Fyrite INSIGHT Plus Manual Section 5. Calibration and Maintenance Calibration and Maintenance 5.1. Serviceability The instrument operator is able to easily replace the following components without the use of tools: • • • • probe assembly probe filters batteries printer paper.
Fyrite INSIGHT Plus Manual Calibration and Maintenance 5.2.1. Equipment Required • • • • Alcohol Aerosol Can of Automotive Carburetor Cleaner Clean Rag Source of Compressed Air (optional) CAUTION: Do not use flammable or combustible substances (like carburetor fluid used for cleaning the probe) near an open flame. 5.2.2. Procedure Step 1 Cleaning the Probe Remove gas sample hose from the top of the water trap. CAUTION: Carburetor cleaner damages plastic components.
Calibration and Maintenance Fyrite INSIGHT Plus Manual 5.3.
Fyrite INSIGHT Plus Manual Calibration and Maintenance 5.4. O2 and/or CO Sensor Replacement NOTE: The O2 sensor life is approximately 2 years. The LL O2 (long life) sensor life is approximately 3 years. The CO sensor life is greater than 3 years. 5.4.1. Accessing the Sensors 5.4.2. Material Required (As Needed) • • O2 Sensor (2 year) (P/N 0024-0788) or LL O2 Sensor (3 year) (0024-1591) CO Sensor (P/N 0024-1593) or B-SMART pre-calibrated sensor (P/N 0024-1616). 5.4.3.
Calibration and Maintenance Fyrite INSIGHT Plus Manual Step O2 Sensor Replacement LL O2 Sensor Replacement 1 Remove battery door and connector tubing from both sensors. Remove battery door and connector tubing from both sensors. 2 Pull O2 sensor from its socket. Remove LL O2 cap by twisting counter clockwise. 3 Remove the O2 cap. Gently pull LL O2 sensor out of its socket. 4 Properly dispose of the old sensor. Properly dispose of the old LL O2 sensor.
Fyrite INSIGHT Plus Manual Step Calibration and Maintenance CO Sensor Replacement Procedure 5 Plug new CO sensor into its socket. 6 Install the CO cap by aligning it toward the “open” position (12 o’clock) as shown in the diagram below, then twisting the cap clockwise approximately 40° to the "closed" position (2 o’clock). 7 Reattach tubing. 8 Calibrate the CO sensor (using the calibration procedure on page 88, or using the B-SMART procedure on page 80).
Calibration and Maintenance Fyrite INSIGHT Plus Manual 5.4.5. B-SMART CO Sensor Replacement Step B-SMART CO Sensor Replacement 1 Enter the CALIBRATION MENU. Note that this requires password validation (see page 51). 2 Use the UP () and DOWN () arrow buttons to select B-Smart. Press ENTER to display the B-Smart code screen. 3 Use the UP () and DOWN () arrow buttons to enter the 10-digit alphanumeric code supplied with the pre-calibrated B-SMART sensor.
Fyrite INSIGHT Plus Manual Calibration and Maintenance 5.5. Pressure Sensor Calibration This procedure calibrates the pressure sensor to a known pressure value. 5.5.1. Materials Required • • Bellows Manometer Range: Accuracy: ± 8 in. of water column (± 20 mB) ± 0.01 in. of water column (± 0.025 mB) 5.5.2. Procedure NOTE: The unit-of-measure for pressure is selected from the Pressure Units parameter in the Setup Menu.
Calibration and Maintenance Fyrite INSIGHT Plus Manual Step Pressure Sensor Calibration Procedure 1 Assemble the pressure sensor calibration equipment as shown above, but DO NOT connect the analyzer to the calibration equipment at this time. 2 If not already done, power ON the analyzer and display the CALIBRATION menu. Note that this requires password validation (see page 51).
Fyrite INSIGHT Plus Manual Calibration and Maintenance Step Pressure Sensor Calibration Procedure 7 Wait until the Measured reading stabilizes, and then press ENTER to calibrate the pressure sensor's Measured value to that of the Applied value. The message, "Good Calibration" should briefly appear, followed by the CALIBRATION menu. 8 Remove calibration equipment. 5.6. T-Stack Calibration This procedure first zeroes and then spans stack temperature to known temperature values.
Calibration and Maintenance Fyrite INSIGHT Plus Manual Step T-STACK Calibration Procedure 2 If not already done, turn ON the analyzer and display the CALIBRATION Menu. Note that this requires password validation (see page 51). 3 Use the UP () and DOWN () arrow buttons to highlight T-Stack, and then press ENTER to display the CALIBRATE TS-ZERO screen. "Measured" is the current temperature reading. "Applied" is a known temperature that will be applied for calibration purposes.
Fyrite INSIGHT Plus Manual Calibration and Maintenance Step T-STACK Calibration Procedure 6 Set thermocouple simulator to 572° F (300° C), and then use the UP (), DOWN (), LEFT (), and RIGHT () arrow buttons to enter an Applied value that exactly equals the setting of the simulator. Alternatively: Submerge probe tip into a container of boiling water with a thermometer, wait several minutes, and then use the and buttons to enter an Applied value that exactly equals the thermometer reading.
Calibration and Maintenance Fyrite INSIGHT Plus Manual 5.7.2. T-Air Calibration Procedure Step T-Air Calibration Procedure 1 Plug the simulator into the T-AIR connector located at the bottom of the analyzer. Alternatively: Plug the probe’s thermocouple into the T-AIR connector located at the bottom of the instrument.
Fyrite INSIGHT Plus Manual Step Calibration and Maintenance T-Air Calibration Procedure NOTE: The calibration range is from 32 to 41° F (0 to 5° C). An attempt to calibrate outside this range will cause the message “Applied Value High” (or Low) to appear at the bottom of the screen.
Calibration and Maintenance Fyrite INSIGHT Plus Manual 5.8. CO Sensor Calibration 5.8.1. Materials Required • • Calibration kit, P/N 0024-7059 Gas cylinder: 500 ppm CO in air, P/N 0024-0492 5.8.2. CO Manual Zero Procedure The CO zeroing process is done automatically during warmup or manually using the manual zero feature. To perform a manual zero, follow the steps below.
Fyrite INSIGHT Plus Manual Calibration and Maintenance 5.8.3. CO Sensor Span Procedure Step CO Span Procedure 1 From the Calibration Menu, use the UP () and DOWN () arrow buttons to highlight CO, and then press ENTER to display the CALIBRATE CO screen. Note that this requires password validation (see page 51). “Measured” is the current CO reading, while “Applied” is a known CO level that will be applied for calibration purposes.
Calibration and Maintenance Fyrite INSIGHT Plus Manual 5.9. T-Ref Sensor Calibration The T-Ref sensor is located inside the instrument. Calibration is done at the factory and should not need to be done in the field.
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Fyrite INSIGHT Plus Manual Section 6. Troubleshooting Troubleshooting 6.1. Error and Warning Messages Message Description T-STK Disconnected The probe thermocouple is not connected to the analyzers T-Stack connector. Plug the probe thermocouple plug into the T-Stack connector at the bottom of the instrument. Check Sensor O2 O2 sensor output is low, but still usable. Sensor may need to be replaced in the near future. The arrow on the O2 Sensor Life screen is in the “replace” segment.
Fyrite INSIGHT Plus Manual Message Set Clock Troubleshooting Description Time and date values need to be set in the instrument. NOTE: If a “set clock” message occurs, then the instrument ignores CO calibration reminder messages and all O2–related messages except “Bad Sensor.” Cal Reminder ## months The calibration reminder occurs during warmup and is based on the CO calibration reminder setting (see page 45), the current date setting (see 35), and the date of the last calibration of the CO sensor.
Troubleshooting Fyrite INSIGHT Plus Manual 6.2. Replacement Parts Part Number 94 Description 0204-0004 Battery, AA Alkaline 0024-1453 Battery door/sensor cover 0024-1461 Boot , rubber 0024-1616 B-SMART CO sensor w/ NOx filter 0024-0865 Carry case (hard) 0024-1587 CO sensor cap (includes gasket) 0024-1593 CO sensor w/ NOx filter 0024-1585 End plate (includes O rings) 0007-1644 Filters, pkg.
Fyrite INSIGHT Plus Manual Troubleshooting 6.3.
Troubleshooting Fyrite INSIGHT Plus Manual 6.4. Instrument Identification A label on the back of the instrument provides the following information that is useful for service and troubleshooting. • • • • • manufacturer country of origin certification(s) part number serial number North American Label Siegert Label 6.5. Service Centers Replacement parts and service can be obtained by contacting one of the following Bacharach Service Centers. United States Bacharach, Inc.
Fyrite INSIGHT Plus Manual Declaration of Conformity Declaration of Conformity The manufacturer of the products covered by this declaration: Bacharach, Inc. 621 Hunt Valley Circle New Kensington, PA 15068 Year conformity is declared: 2012 Product(s): Combustion Analyzer Model(s): Fyrite INSIGHT Plus The undersigned hereby declares that the above referenced product is in conformity with the provisions of the following standards and is in accordance with the following directive.
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Fyrite INSIGHT Plus Manual Index INDEX Symbols - - - display...................................... 92 * * * display ...................................... 92 X X X display ...................................... 92 ΔP ................................... 11, 62, 76, 81 ∆T .................................................... 21 Numbers 100 ppm CO ...................................... 94 12-hour time format ..................... 4, 34 24-hour time format ..................... 4, 34 500 ppm CO .........
Index Fyrite INSIGHT Plus Manual password screen.......................... 23 pressure sensor ........................... 80 range ................................ 81, 83-86 reminder................................ 44, 92 default .................................... 44 options ................................... 44 removing equipment ................... 82 T-Air ............................................. 84 T-Stack ......................................... 82 carbon dioxide ...............
Fyrite INSIGHT Plus Manual Index connector ...................................... 6 hose ............................................. 15 reading .............................22, 26, 62 F3 button ........... 5, 9, 26, 52, 58, 66, 68, 69, 70 Fyrite User Software (FUS) .......... 3, 8, 10, 24, 37, 38, 40, 41, 50, 63, 65, 72, 79, 94 E edit test ID ........................................ 38 efficiency ..................... 3, 13, 55, 57, 60 Email .................................................
Index Fyrite INSIGHT Plus Manual L O label ............................................ 51, 95 lambda .....................................4, 13, 60 languages ...................................4, 7, 43 Leak Test menu ........................... 22, 27 LEG fuel............................................. 24 let-by test ................................... 22, 27 life safety .......................................... 59 line graph parameters ...................... 68 long-life (LL) O2 sensor ....
Fyrite INSIGHT Plus Manual Index positioning to print ...................... 63 power switch ............................... 63 printing ............ 4, 22, 26, 29, 35, 58, 63 printouts ............................ 7, 32, 33, 40 custom logo on ............................ 65 probe ... 2, 3, 6, 8-10, 15, 55, 56, 58, 62, 67, 71, 73, 74, 82-86, 91, 93 cleaning ....................................... 73 handle ................................6, 15, 74 hose .
Index Fyrite INSIGHT Plus Manual status screen..................................... 54 stop bits ...................................... 12, 65 system parameters ........................... 22 connector ................................ 6, 12 user identification ............................. 40 user information ........................... 7, 63 username .........................40, 49, 63, 72 available characters ..................... 40 T T-AIR calibration ...............................
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Fyrite INSIGHT Plus Manual Index World Headquarters 621 Hunt Valley Circle, New Kensington, Pennsylvania 15068 Phone: 724-334-5000 • Toll Free: 1-800-736-4666 • Fax: 724-334-5001 Website: www.MyBacharach.com • E-mail: help@MyBacharach.
