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.
Fyrite InTech 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.
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Fyrite InTech Manual Table of Contents Table of Contents Section 1. Overview .................................................................................... 1 1.1. Introduction ............................................................................................ 1 1.2. Conventions............................................................................................. 1 1.3. Safety .......................................................................................................
Fyrite InTech Manual Table of Contents 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 ............................
Fyrite InTech Manual Section 1. Overview 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: A warning statement denotes a potential hazard associated with the use of this equipment. Failure to follow this information could result in serious personal injury or death.
Overview Fyrite InTech 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 InTech 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.
Fyrite InTech Manual Overview Feature Countries North American (NA) versus Siegert (S) Configurations Typical North American (NA) Users Asia Australia Latin America North America South America 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.
Fyrite InTech Manual Overview 1.6.
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Fyrite InTech Manual Overview 1.7.
Fyrite InTech Manual Overview 1.8. Combustion Test Process Overview FUNCTION ............................................... PAGES Connect Probe ...................................................... 13 Turn On Instrument ................................... 14, 15, 16 Verify Power ......................................................... 15 Zero Instrument (Auto/Manual) ................ 17, 32, 56 Use Menu System ................................................. 17 Set System Parameters .............
Fyrite InTech Manual Overview NOTE: The North American (NA) configuration of Fyrite InTech 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 (1200° F). The Siegert configuration of the Fyrite InTech 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 (1200° F). 1.9.
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Fyrite InTech 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 8.0” x 3.6” x 2.3” (20.3 cm x 9.1 cm x 5.
Fyrite InTech Manual Overview Specification Description Power Supply Options Type: Disposable Alkaline (Included) Duration: 15 hours min, continuous max draw Batteries (4 AA) Type: Disposable Lithium Duration: 20 hours, continuous max draw Type: Rechargeable Duration: 8 hours, continuous max draw Measure -ment Range Resolution O2 0 to 20.9 % 0.1% O2 Response Time (T90) Accuracy ±0.
Fyrite InTech 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, grilles, diffusers, and furnace flues. 1. 2. 3. 4. 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 clean and dry.
Fyrite InTech Manual Setup 2.2. Front Panel Buttons Button Description • • • • • • • 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.
Fyrite InTech 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.
Fyrite InTech Manual Setup NOTE: A Set Clock error message will be displayed if the 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 warmup procedure which includes an auto-zero procedure for the sensors (see pages 17 and 32). For this reason, be sure to turn on the Fyrite InTech in a clean air environment.
Fyrite InTech Manual Section 3. Configuration Configuration 3.1. Menu Structure Overview NOTE: The Fyrite InTech may be configured to use either North American combustion equations or Siegert combustion equations (see page 32). 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.
Fyrite InTech Manual Configuration 3.3. Main Menu Display the Main Menu by pressing the F2 key. Note that features and items displayed in menus are model dependent. Your screens may vary. Main Menu Function Access the Select Fuel Menu (see page 19) • Select combustion fuel Access the Ambient CO Test Menu (Siegert Only) (see page 20) • • • Initiate a 15-minute CO test Get reading every minute and max CO reading Print/Save 16 readings and max CO Access the Memory Options Menu (see page 22).
Fyrite InTech Manual Configuration 3.4. Select Fuel Menu Select Fuel Function Select the combustion fuel from the fuel list. Use the UP () and DOWN () arrow keys to highlight the desired fuel and use the ENTER key to select.
Fyrite InTech Manual Configuration 3.5. 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). Press ENTER to initiate the Ambient CO test. This begins a 15-minute test cycle, during which a status screen is displayed.
Fyrite InTech Manual Ambient CO Configuration Function The test results can be printed by pressing F1 and saved to memory (with a time and date stamp) by pressing F3. Press F2 to return to the menu. NOTE: If the ambient CO results are saved to memory, they are not included as part of the Print Average feature. NOTE: Any over-range CO values (e.g., CO = 2000 ppm) are displayed as “xxx”.
Fyrite InTech Manual Configuration 3.6. Memory Options Menu Memory Options Function Access the Memory Directory. This directory contains a numbered list of saved combustion tests (starting at “1”). “NO DATA” is displayed if no tests were saved since the last time that memory was cleared. To view saved data, use the UP () and DOWN () arrow keys to highlight the desired test from the list. Press the ENTER button to display the saved data.
Fyrite InTech Manual Memory Options Configuration Function Print Average (Siegert Only) displays the memory directory with the first 3 samples highlighted. Use the UP () and DOWN () arrow buttons to move the scrolling window up and down to select which three contiguous samples are to be averaged, then press ENTER. The average is calculated, displayed, and available for printing (left). If fewer than 3 samples exist, the average is not calculated (right).
Configuration Fyrite InTech Manual 3.7. Setup Menu Setup Menu Function Access Temperature Units (°C or °F) to be used by the instrument and for display and printing purposes. Use the UP () and DOWN () arrows buttons to highlight the desired choice. Press the ENTER button to use the selected temperature unit. Press ESC to quit without saving. 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.
Fyrite InTech Manual Setup Menu Configuration Function WARNING: DO NOT use the Fyrite InTech to sample gas from an oil-based combustion system without first doing a smoke test and adjusting your combustion process as needed. Smoke test results of greater than 1 indicate improper combustion, and demonstrate the need for process adjustment. Only use the Fyrite InTech to sample flue gas AFTER the combustion process is adjusted and the smoke test indicates a smoke level of 0 or 1.
Configuration Setup Menu Fyrite InTech Manual Function A boiler temperature (Siegert only) can be recorded manually. Enter the boiler temperature as measured by an external thermocouple. Use the LEFT () and RIGHT () arrow buttons to change position. Use the UP () and DOWN () arrow buttons to scroll through numerals 0-9 for the selected position. Press ENTER when finished. Select Position Change Value The Clock option provides access to the clock setup function to set date and time.
Fyrite InTech Manual Setup Menu Configuration Function NOTE: The presence of AM or PM after the time on the Set Clock display indicates 12-hour time format and MM/DD/YY date format. (This also indicates that the instrument must be in the North American configuration.) Similarly, the absence of AM or PM indicates 24-hour time format and the date is in DD/MM/YY format (either by default if Siegert configuration, or by choice through the Date Format parameter if North American configuration).
Configuration Setup Menu Fyrite InTech Manual Function Provides an interface for entering user identification Generally, the information used on printouts. 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.
Fyrite InTech Manual Configuration 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.
Configuration Setup Menu Fyrite InTech 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 InTech 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 InTech Manual Configuration Setup Menu Function Date format (North American Configuration only) Provides a list 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.
Fyrite InTech Manual Configuration Setup Menu Function Provides a list from which the user may select the desired method for zeroing the CO sensor. Auto-Zero happens automatically at warm-up. 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 InTech Manual Configuration Setup Menu Function IMPORTANT: Changing this setting resets several configuration parameters to their default values. Below is a list of affected parameters, and those unaffected.
Configuration Fyrite InTech Manual 3.8. 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.
Fyrite InTech Manual Configuration 3.9. Diagnostics Menu Diagnostics Menu Function Displays time metrics for pump use and total operation time. Displays information about the measurement sensors of the instrument. Displays the estimated oxygen (O2) sensor life based on: • 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 InTech Manual Configuration Diagnostics Menu Function 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. Resetting the Sensor Date Code Use the LEFT () and RIGHT () arrow buttons to move the cursor horizontally to select between the 2-digit month code (00-12) and the one digit year code (0-9 corresponding to the last digit of the manufacture year) that make up the 3-digit date code.
Fyrite InTech Manual Configuration Diagnostics Menu Function NOTE: 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 warm-up. After the warm-up countdown, any detected errors are displayed. Otherwise, a “Success” message is displayed. 3.10. Status Menu Status Menu Function This is the device status screen which displays information about the device.
Fyrite InTech Manual Section 4. Operation Operation 4.1.
Fyrite InTech 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.
Fyrite InTech Manual 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 InTech Manual Operation 4.3. Combustion Testing Process WARNING: The Fyrite InTech 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 InTech is properly configured for your region and desired combustion calculations. NOTE: The recommended time required to achieve a stable measurement is a minimum of 3 minutes.
Operation Step Fyrite InTech Manual Example Combustion Testing Procedure purge component that clears the sensors of combustion gases. 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 InTech, 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 InTech Manual Operation Combustion Test Parameters NA Siegert Oxygen O₂ O₂ Carbon Monoxide CO CO Excess Air EA Lambda Efficiency Using Higher Heating Value Eff Eff Carbon Dioxide CO₂ CO₂ Setting for Maximum Carbon Dioxide in Flue Gas CO₂ Max Stack Temperature T-STK T-STK Ambient Air Temperature T-AIR T-AIR Stack Loss qA Efficiency Using Lower Heating Value Eta Carbon Monoxide/Carbon Dioxide Ratio CO content referenced to an Oxygen percentage n CO/CO₂ CO(n) CO(n)
Operation Fyrite InTech Manual Combustion Equations are shown below. Fyrite InTech provides three lines of 20 characters for user information. This information will appear with test records when they are printed. User name and optional information are entered via software menu selections in the SETUP MENU or via the Fyrite User Software (FUS).
Fyrite InTech Manual Operation IR Communications Settings: Baud Rate: Data Bits: Stop Bits: Parity: Protocol: Distance: Angle: 0024-9486 Rev 2 9600 8 1 None IRDA-SIR 8-16 in (20-41 cm) 60° maximum 45
Fyrite InTech Manual Operation Fyrite InTech 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 one of the following formats: .BMP, .JPG, .PNG, or .TIFF. For best results, the logo should be saved in black and white. 4.6.
Fyrite InTech Manual Operation 4.7. PC Interface and Fyrite User Software A PC with Fyrite User Software (FUS) installed can set, edit, and transfer the following: • • • • • • • • • instrument time and date calibration password time meters B-SMART code user name instrument settings customer logo firmware updates language.
Fyrite InTech 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. Additionally, a technician, with the use of readily available hand tools and factory-provided instructions, can: • • • perform basic diagnostics replace sensors confirm proper operation before putting the unit back into service.
Fyrite InTech 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 InTech Manual 5.3.
Fyrite InTech Manual Calibration and Maintenance 5.4. O2 and/or CO Sensor Replacement NOTE: The O2 sensor life is approximately 2 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 (P/N 0024-0788) CO Sensor (P/N 0024-7265) or B-Smart sensor (P/N 0024-1467).
Calibration and Maintenance Fyrite InTech Manual 5.4.3. O2 Sensor Replacement Procedure Follow the procedure below for O2 sensors. Step O2 Sensor Replacement 1 Remove battery door and connector tubing from both sensors. 2 Pull O2 sensor from its socket. 3 Remove the O2 cap. 4 Properly dispose of the old sensor. 5 Note 3-digit date code on new sensor. 6 Engage the nub on the new sensor within the slot on the cap's side and twist to secure the cap and sensor together.
Fyrite InTech Manual Step Calibration and Maintenance CO Sensor Replacement Procedure 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 either the standard calibration procedure or the BSMART procedure 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 34).
Calibration and Maintenance Fyrite InTech Manual NOTE: Bacharach offers a convenient Exchange Program (where available) that allows the customer to regularly receive pre-calibrated replacement sensors that include a code that can be entered into the analyzer for a quick convenient setup. Contact Bacharach customer service for more details about this program. 5.5. T-Stack Calibration This procedure first zeroes and then spans stack temperature to known temperature values.
Fyrite InTech Manual Step Calibration and Maintenance T-STACK Calibration Procedure "Measured" is the current temperature reading. "Applied" is a known temperature that will be applied for calibration purposes. 4 Set thermocouple simulator to 32° F (0° 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.
Calibration and Maintenance Fyrite InTech Manual Step T-STACK Calibration Procedure 7 Wait until the Measured reading stabilizes, and then press ENTER to calibrate the TS-Span Measured value to that of the “Applied” value, after which the message “Good Calibration” should briefly appear followed by the CALIBRATION menu being re-displayed. 5.6. CO Sensor Calibration 5.6.1. Materials Required • • Calibration kit, P/N 0024-7059 Gas cylinder: 500 ppm CO in air, P/N 0024-0492 5.6.2.
Fyrite InTech Manual Step Calibration and Maintenance Manual CO Zero Procedure 5.6.3. CO Sensor Span Procedure Step CO Span Procedure 1 From the Calibration Menu (see page 34), 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 34). “Measured” is the current CO reading, while “Applied” is a known CO level that will be applied for calibration purposes.
Fyrite InTech Manual Calibration and Maintenance 5.7. 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.
Fyrite InTech Manual Section 6. Troubleshooting Troubleshooting 6.1. Error and Warning Messages Message Description T-STK 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 InTech Manual Troubleshooting Message Description instrument. • Messages will indicate which sensors are in error. Set Clock Time and date values need to be set in the instrument. NOTE: If a “set clock” message occurs, then the instrument ignores all O2–related messages except “Bad Sensor.” XXX Occurs in the number fields of sensors that have achieved overrange condition. *** Occurs in the number fields of sensors.
Fyrite InTech Manual Troubleshooting Part Number Description 0024-1484 CO Sensor Cap 0024-1458 CO Sensor Base 0024-9486 Instruction manual 0019-3265 Water trap 6.3.
Fyrite InTech Manual Troubleshooting 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 InTech 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 InTech 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 InTech Manual 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.
