Bacharach 100 Troubleshooting guide

Fyrite®Pro
Combustion Gas Analyzer
Instruction 24-9395
Operation & Maintenance
Rev. 9 – July 2004
Product Leadership • Training • Service • Reliability
ENTER
HOLD
I/O
LIGHT
25
CO
O
%
PPM
2.
52
&

WARRANTY
Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in material
and manufacture and will conform substantially to Bacharach Inc.’s applicable specifications. Bacharach’s
liability and Buyer’s remedy under this warranty are limited to the repair or replacement, at Bacharach’s option,
of this Product or parts thereof returned to Seller at the factory of manufacture and shown to Bacharach Inc.’s
reasonable satisfaction to have been defective; provided that written notice of the defect shall have been given
by Buyer to Bacharach Inc. within two (2) years after the date of delivery of this Product by Bacharach, Inc.
Bacharach, Inc. warrants to Buyer that it will convey good title to this Product. Bacharach’s liability and Buyer’s
remedy under this warranty of title are limited to the removal of any title defects or, at the election of Bacharach,
to the replacement of this Product or parts thereof that are defective in title.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF (I) ANY
AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IM-
PLIED 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 ARIS-
ING 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 limita-
tion will be binding upon Bacharach, Inc. unless in writing, signed by a duly authorized officer of Bacharach.
AInstruction 24-9428
Register Your Warranty by Visiting
www.bacharach-inc.com
Notice:
Product improvements and enhancements are continuous, therefore the specifications and information
contained in this document may change without notice.
Bacharach, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in
connection with the furnishing, performance, or use of this material.
No part of this document may be photocopied, reproduced, or translated to another language without the prior
written consent of Bacharach, Inc.
Copyright © 2002–2004, Bacharach, Inc., all rights reserved.
BACHARACH and Fyrite are registered trademarks of Bacharach, Inc. All other trademarks,
trade names, service marks and logos referenced herein belong to their respective companies.

Fyrite Pro
Instruction 24-9395 i
Contents
Ordering Information.......................................................... iii
1.0 INTRODUCTION.............................................................. 1
1.1 The Fyrite Pro..................................................................................1
1.2 Operational Overview .....................................................................2
2.0 TECHNICAL CHARACTERISTICS .............................. 3
3.0 SETTING UP THE ANALYZER ..................................... 5
3.1 Preliminary Steps............................................................................5
3.2 Checking & Replacing the Batteries .............................................. 5
3.3 Connecting the Probe Hose and Thermocouple .............................6
3.4 Front Panel Push Buttons ............................................................11
3.5 Setup Mode ....................................................................................12
3.5.1 Entering Setup ................................................................12
3.5.2 Selecting Temperature Units..........................................12
3.5.3 CO Channel Setup...........................................................13
3.5.4 Draft Channel Setup .......................................................13
3.5.5 Time Setup.......................................................................14
3.5.6 Date Setup .......................................................................14
3.5.7 Year Setup .......................................................................15
3.5.8 Selecting Printer Protocol ...............................................15
3.5.9 Exiting the Setup Screen ................................................ 15
4.0 OPERATION.................................................................... 17
4.1 Performing CO and Draft Testing................................................17
4.1.1 Analyzer Turn On and Warm Up ...................................17
4.1.2 Measuring CO..................................................................18
4.1.3 Measuring Draft ..............................................................18
4.2 Performing a Combustion Test using the Model 110/120/125 ....19
4.2.1 Analyzer Turn On and Warm Up ...................................19
4.2.2 Selecting a Fuel ...............................................................19
4.2.3 Sampling Point ................................................................20
4.2.4 PerformingaCombustionEfciencyTest......................22
4.2.5 Ending a Combustion Test.............................................. 22
4.3 Operating Tips...............................................................................23
4.4 Using the Backlight.......................................................................24
4.5 Using the Probe .............................................................................24
4.6 Saving Test Data in Memory ........................................................24

Fyrite Pro
Instruction 24-9395
ii
4.7 Opening and Viewing Saved Test Data .......................................25
4.8 Printing Test Data.........................................................................26
4.9 Clearing Saved Test Data .............................................................28
4.10 Turning OFF the Analyzer & CO Purge..................................... 28
4.11 Resetting the Microprocessor ......................................................29
4.12 Run Mode Screens........................................................................29
4.13 Screen Descriptions .....................................................................33
4.13.1 Warm-Up Screens.........................................................33
4.13.2 CO Screen .....................................................................33
4.13.3 CO & Draft Screen........................................................34
4.13.4 Draft Zero Screen .........................................................34
4.13.5 Fuel Screen ...................................................................35
4.13.6 O2Screen.......................................................................35
4.13.7 CO & O2Screen ............................................................36
4.13.8 CO2& Excess Air Screen .............................................36
4.13.9 Temperature Differential Screen................................. 37
4.13.10 StackTemperature&EfciencyScreen...................37
4.13.11 Ambient Air Temperature Screen ............................ 38
4.13.12 CO Air Free Screen ...................................................38
4.13.13 Sensor Error Screen ..................................................39
5.0 CALIBRATION & MAINTENANCE ............................ 41
5.1 Entering the Calibration Mode and Testing
the Display Segments....................................................................41
5.2 Ambient Temperature Calibration ..............................................42
5.3 Combustion Air Thermocouple Calibration ................................42
5.4 Stack Thermocouple Calibration ..................................................43
5.5 Oxygen Sensor Zero ......................................................................44
5.6 CO Sensor Zero & Calibration......................................................45
5.7 Draft Calibration ..........................................................................47
5.8 Water Trap / Filter Maintenance .................................................48
5.9 O2Sensor Replacement ................................................................. 49
5.10 CO Sensor Replacement ..............................................................50
5.11 Pump Assembly Replacement .....................................................51
6.0 PARTS & SERVICE........................................................ 55
6.1 Replacement Parts ........................................................................55
6.2 Accessories .....................................................................................55
6.2.1 Standard Accessories ......................................................55
6.2.2 Optional Accessories........................................................56
6.3 Service Centers..............................................................................57

Fyrite Pro
Instruction 24-9395 iii
Ordering Information
Model
100 100
Printer
Kit
105 110 120 125 125
Printer
Kit
125
Printer/
Oil Kit
Part Number 24-8200 24-8201 24-8202 24-8103 24-8104 24-8105 24-8205 24-8206
Measurements
Oxygen 
Stack Temperature 
Ambient Temperature 
Second Thermocouple
Channel (Combustion Air
Temperature)

Differential Temperature 
Carbon Monoxide (CO)  
Draft    
Differential Pressure*    
Calculations
Combustion Efficiency 
Excess Air 
Carbon Dioxide (CO2)
CO (Air Free) 
Supplied Accessories
Probe & Hose Assembly 19-7110 19-7110 24-3004 19-7111 19-7111 24-3004 24-3004 24-3004
Carrying Case (24-0865) 
Rubber Boot (24-1127) 
Tygon Tubing (03-6109)    
Barb Fitting (03-5251)    
Printer (24-1229)   
Smoke Test Kit (21-7006) 
* To measure differential pressure, use optional Pressure Kit 24-8214

Fyrite Pro
Instruction 24-9395iv
Notes:

Instruction 24-9395 1
Fyrite Pro
1.0 INTRODUCTION
1.1 The Fyrite Pro
The Fyrite Pro series of instruments are hand-held analyzers that are
designed for on-demand sampling of residential furnaces and appliances.
The more advanced models can also to used to check combustion efficiency
by measuring the stack temperature and the percent oxygen level in the
flue-gas stream.
The Fyrite Pro is completely upgradeable from the very simple Model 100
that measures only carbon monoxide, to the Model 125 that measures
carbon monoxide (CO), oxygen (O2), draft, differential pressure, ambient
air temperature, stack temperature, and combustion air temperature, as
well as calculating combustion efficiency, excess air, carbon dioxide (CO2),
differential temperature, and CO air free.
This manual contains information on all models of the Fyrite Pro. Please
disregard any information that does not pertain to your model.
WARNINGS!
This analyzer is not intended to be used on a continuous
basis.
This analyzer does not have an audible alarm, and is not
intended to be used as a safety device.
Except for battery replacement, this analyzer should only be
opened and serviced by authorized personnel.
When testing an appliance, a full visual inspection of the
appliance should be carried out to ensure its safe operation.

Instruction 24-9395
2
Fyrite Pro
1.2 Operational Overview
Pressing the I/O button turns the analyzer ON. Note that there is a warm-
up period of either 10 or 60 seconds, dependent on the analyzer’s model and
setup, that must elapse before the analyzer can be used.
When using the analyzer to just measure CO or draft, insert the analyz-
er’s probe into the flue-gas stream of the appliance under test and begin
testing. The measured values of draft and/or CO will appear on the ana-
lyzer’s LCD.
For models that calculate combustion efficiency, choose a fuel code that cor-
responds to the fuel being burned by the appliance being tested, and then
press the ENTER button to place the analyzer into its Run Mode. Begin
testing by inserting the analyzer’s probe tube into the flue-gas stream
of the appliance under test. The analyzer will monitor the flue gas and
display measured and calculated values that are relative to the combustion
process. These values are displayed on the analyzer’s LCD, and are chosen
for display by pressing the Increment ()and Decrement ()buttons.
Pressing the HOLD button during a test will freeze all measured and calculat-
ed values at their current levels. Pressing the ENTER button resumes testing.
For analyzers with memory, pressing the HOLD button twice during a
test will display the Print/Memory Menu Screen. Using the  and
ENTER buttons the operator can choose to print the current readings,
save the current readings in memory, recall and view saved readings from
memory, clear all the memory, or print all saved readings.
A backlight enables an operator to read the display in dimly-lit areas.
Pressing the LIGHT button turns the backlight ON and OFF. The backlight
will automatically turn OFF after 10 minutes of keyboard inactivity.
A power saver function will shut the analyzer OFF after 20 minutes of key-
board inactivity. For models with an O2and CO sensor, however, the power
saver function is disabled if the detected O2value is less than 17.9% or the
CO value is more than 50 ppm.
Press the I/O button to turn the analyzer OFF. Note that there is a 5 sec-
ond delay before the analyzer actually turns OFF, during which time the
unit can be kept ON by pressing the ENTER button. For analyzers that
contain a CO sensor, there is a CO purge feature that keeps the analyzer’s
pump running until the measured CO level drops below 50 ppm.

Instruction 24-9395 3
Fyrite Pro
2.0 TECHNICAL CHARACTERISTICS
The Analyzer Directly Measures and Displays:
• Ambient Temperature ............................32 to 212 °F (0 to 100 °C)
• Flue Gas O2content................................0.0 to 20.9% O2
• Flue Gas Temperature ...........................0 to 999 °F (–18 to 537 °C)
• Flue Gas CO content ..............................0 to 2,000 ppm CO
• Draft........................................................–9.99 to 27 inWC
(–9.99 to 67 mb/HPa)
The Analyzer Computes and Displays:
(when the measured oxygen level is below 17.9%)
• Combustion Efficiency............................0.1 to 99.9%
• Flue Gas CO2content .............................0.1 to a fuel dependent
maximum value in %
• Flue Gas CO Air-Free content ...............0 to 9,999 ppm
• Excess Air ...............................................0 to 400%
Fuel Selection:
(F1 thru F4 denotes the fuel selected as displayed on the LCD)
• Natural Gas (F1)
• Oil #2 (F2)
• LPG (F3)
• Kerosene (F4)
Normal Operating Conditions:
Temperature:
• Analyzer .................................................32 to 104 °F (0 to 40 °C)
• Probe.......................................................1,000 °F max (538 °C) at
5" insertion
Humidity.......................................................15 to 90% RH,
Non-Condensing
Power Requirements ....................................Four disposable ‘AA’ Alkaline
batteries (an optional AC adapt-
er is available that eliminates
the need for batteries)

Instruction 24-9395
4
Fyrite Pro
Operating Time ................................. Up to 18 hours continuous (pump
running and backlight off)
Warm Up Time ................................... 10 or 60 seconds, dependent on
analyzer’s model and setup (Refer
to Section 4.13.1)
Memory
(Model 105/110/120/125)..................... Up to 10 sets of readings can be
saved in memory. When memory
is full, the next reading saved will
overwrite the oldest reading.
Display ................................................. 4 Digit, 2 Line, 7-segment Liquid
Crystal Display
Front Panel Controls ....................... Six push button switches
(Refer to Section 3.4)
Accuracy:
• Oxygen............................................. ±0.3% O2with a typical flue gas
concentration of CO2
• Carbon Monoxide ............................ ±5% of reading or ±10 ppm, which-
ever is greater*
• Flue Gas Temperature.................... ±4 °F between 32 & 255 °F
(±2 °C between 0 & 124 °C)
±6 °F between 256 & 480 °F
(±3 °C between 125 & 249 °C)
±8 °F between 481 & 752 °F
(±4 °C between 250 & 400 °C)
• Second Thermocouple Channel ...... ±4 °F between 32 & 212 °F
(±2 °C between 0 & 100 °C)
• Ambient Temperature..................... ±4 °F between 32 & 104 °F
(±2 °C between 0 & 40 °C)
• Draft ................................................ ±1% of reading or ±0.02 inWC
(±0.05 mB), whichever is greater
* Tighter CO accuracy in the lower ranges, up to ±2 ppm, may be
attained if a lower range calibration gas (e.g. 100 ppm CO) is used.

Instruction 24-9395 5
Fyrite Pro
3.0 SETTING UP THE ANALYZER
3.1 Preliminary Steps
Before using the analyzer . . .
• Check batteries (Section 3.2)
• Connect probe to analyzer (Section 3.3)
• Check setup (Section 3.5)
3.2 Checking & Replacing the Batteries
Install fresh batteries as described below. Check the analyzer for sufficient
charge prior to each use. Replace the batteries if the low-battery symbol
appears in the lower right corner of the screen. To replace the bat-
teries:
1. Remove battery cover from back of analyzer.
2. If old batteries are installed, remove them and properly discard.
3. Observing the polarity markings inside the battery compartment,
install four ‘AA’ Alkaline batteries as shown in Figure 3-1.
4. Replace battery cover.
Figure 3-1. Battery Installation
Remove battery cover by
pushing down on cover
and sliding it outward

Instruction 24-9395
6
Fyrite Pro
3.3 Connecting the Probe Hose and
Thermocouple
The analyzer’s model number determines which hose and thermocouple
connections are made at the bottom of the unit. Perform the following steps
as required by your particular analyzer model (see Figures 3-2A thru D):
1. Push the probe’s sample-gas hose onto the GAS inlet fitting.
2. Push the probe’s draft hose onto the “+” pressure fitting.
3. Push the probe’s thermocouple into the T-STACK jack
Important: DO NOT force the thermocouple connector into
its jack. The connection tabs are different sizes, allowing the
connector to fit in only one way.
4. Push the optional room-air/primary-air thermocouple into the
T-AIR jack.
Inspect the flue-gas hose for cracks. If a hose is defective, replace the entire
probe assembly.
Before using the analyzer, check that the Water Trap / Filter is dry and
not dirty. If necessary, dry out the trap and replace the filter element per
Section 5.8.

Instruction 24-9395 7
Fyrite Pro
Figure 3-2A. Connecting the 19-7110 Probe (Model 100)
GAS INLET
SAMPLE-GAS
HOSE
WATER TRAP /
FILTER ASSEMBLY
AC ADAPTER
JACK
PROBE TUBE
PROBE STOP
(Optional)

Instruction 24-9395
8
Fyrite Pro
Figure 3-2B. Connecting the 24-3004 Probe (Model 105)
DIFFERENTIAL
PRESSURE HOSE
(Optional)
WATER
TRAP / FILTER
ASSEMBLY
PROBE
HANDLE
GAS DRAFT
THERMOCOUPLE
CONNECTOR
(Not used on the
Model 105)
AC ADAPTER
JACK
DRAFT HOSE
SAMPLE-GAS
HOSE
PROBE TUBE
PROBE STOP

Instruction 24-9395 9
Fyrite Pro
Figure 3-2C. Connecting the 19-7111 Probe (Model 110/120)
T-STACK
GAS
INLET
SAMPLE-GAS
HOSE
THERMOCOUPLE
CONNECTOR
(T-STACK)
WATER TRAP /
FILTER ASSEMBLY
AC ADAPTER
JACK
PROBE TUBE
PROBE STOP
(Optional)

Instruction 24-9395
10
Fyrite Pro
Figure 3-2D. Connecting the 24-3004 Probe (Model 125)
T-STACK
T-AIR
ROOM AIR /
PRIMARY AIR
THERMOCOUPLE
CONNECTOR
(T-AIR)
DIFFERENTIAL
PRESSURE HOSE
(Optional)
GAS DRAFT
SAMPLE GAS
THERMOCOUPLE
CONNECTOR
(T-STACK)
AC ADAPTER
JACK
WATER
TRAP / FILTER
ASSEMBLY
PROBE
HANDLE
DRAFT HOSE
SAMPLE-GAS
HOSE
PROBE TUBE
PROBE STOP

Instruction 24-9395 11
Fyrite Pro
3.4 Front Panel Push Buttons
Note that a push button may perform several functions, depending on the
analyzer’s model number and what screen is being displayed at the time.
I/O • Toggles the analyzer ON and OFF.
•Places the analyzer into either its Setup or Calibration Mode
when used in conjunction with the ENTER or HOLD button.
•Scrolls up through the display screens during a test.
•Causes the displayed value to increase or change while in the
Calibration, Setup, or Print/Memory Menu Screen.
•Scrolls down through the display screens during a test.
•Causes the displayed value to decrease or change while in the
Calibration, Setup, or Print/Memory Menu Screen.
ENTER •Enters the Run Mode (starts a combustion test) from the Fuel
Select Screen.
•Unfreezes the display after pressing the HOLD button.
•Displays the Fuel Select Screen when held down for 2 seconds
while in the Run Mode.
•Performs the action selected in the Print/Memory Menu Screen.
•Stores the displayed value and automatically steps to the next
screen when pressed during calibration or setup.
•Places the unit into its Run Mode when held down for 2 seconds
while in the Calibration Mode.
•Aborts turn-off and keeps the analyzer turned ON when
pressed during the 5 second turn-off-delay period.
• Aborts the CO purge function at turn-off when the measured
CO level is above 50 ppm.
•Sets up the analyzer to be placed into its Calibration Mode
when held down with the analyzer OFF. (Used in conjunction
with the I/O button.)
HOLD •Places the analyzer on hold and freezes the values in all Run
Mode Screens during a test, allowing the operator to scroll
through the displays and view all test values at that point in
time. Pressing ENTER resumes testing.
•Model 100: Starts a printout when pressed twice from the Run Mode.
• Model 105/110/120/125: Displays the Print/Memory Menu
Screen when pressed twice from the Run Mode.
• Sets up the analyzer to be placed into its Setup Mode when held down
with the analyzer OFF. (Used in conjunction with the I/O button.)
LIGHT Toggles the backlight ON and OFF.

Instruction 24-9395
12
Fyrite Pro
3.5 Setup Mode
The analyzer is preset at the factory for the parameters shown below, but
can be changed as described in their associated sections.
Function Parameter To Change
Fuel Natural Gas (F1) Section 4.13.5
Temperature Unit °F Section 3.5.2
CO Channel Auto Zero (A2) Section 3.5.3
Draft (Pressure) WC Section 3.5.4
Clock Not Initialized Section 3.5.5 thru 3.5.7
Printer Protocol IrDA Section 3.5.8
3.5.1 Entering Setup
1. With the analyzer turned OFF, press and hold down the HOLD
button.
2. Press the I/O button.
3. Release both buttons.
4. The analyzer is now in its Setup Mode. Refer to Sections 3.5.2 thru
3.5.8 for information on how to set up each analyzer parameter.
3.5.2 Selecting Temperature Units
The Temperature Setup Screen is labeled “Unit.”
1. Enter the Setup Mode per Section 3.5.1. If necessary, repeatedly
press the ENTER button until “Unit” is displayed.
2. Press the or button until the desired temperature unit (°F or
°C) is displayed.
3. Press ENTER to move to the next Setup Screen, or I/O to exit setup.

Instruction 24-9395 13
Fyrite Pro
3.5.3 CO Channel Setup
The CO Channel Setup Screen is labeled “CO.”
1. Enter the Setup Mode per Section 3.5.1. If necessary, repeatedly
press the ENTER button until “CO” is displayed.
2. Press the or button until the desired parameter is displayed.
- no Sensor disabled. Use this function to turn off the CO chan-
nel if the sensor is missing or known to be bad to avoid inac-
curate CO readings from appearing.
- 2Ero Manual Zero. When the CO channel is set to manual zero,
the analyzer does not zero the CO sensor to ambient condi-
tions during start up.
- A2 Auto Zero. With the CO channel set to auto zero, the CO
sensor is zeroed to the ambient CO level during start up.
Important: When using this mode the analyzer must
be turned ON in fresh air; otherwise, incorrect CO
readings will occur.
3. Press ENTER to move to the next Setup Screen, or I/O to exit setup.
3.5.4 Draft Channel Setup
The Draft Setup Screen is labeled “PrES Unit”.
1. Enter the Setup Mode per Section 3.5.1. If necessary, repeatedly
press the ENTER button until “PrES” is displayed.
2. Press the or button until the desired parameter is displayed.
- no Pressure sensor disabled or not installed.
- WC inches of Water Column
- mB Millibars
- HPa Hecto Pascals
3. Press ENTER to move to the next Setup Screen, or I/O to exit setup.

Instruction 24-9395
14
Fyrite Pro
3.5.5 Time Setup
There are two Time Setup Screens, one for hours and the other for min-
utes. Two bars appear above the segments being changed. The clock is in a
24 hour format, but will appear as AM/PM on the printout.
1. Enter the Setup Mode per Section 3.5.1. If necessary, repeatedly
press ENTER until the first Time Setup Screen is displayed—the
one with two bars over the hour digits.
2. Press the or button until the correct hour value is displayed.
3. Press ENTER to move the selection bars over the minute digits.
4. Press the or button until the correct minute value is displayed.
5. Press ENTER to move to the next Setup Screen, or I/O to exit setup.
3.5.6 Date Setup
There are two Date Setup Screens, each labeled “DAtE”. The first screen
sets the month while the second sets the day.
1. Enter the Setup Mode per Section 3.5.1. If necessary, repeatedly
press ENTER until the first Date Setup Screen is displayed.
2. Press the or button until the correct month is displayed.
3. Press ENTER to change the ‘Day’ value.
4. Press the or key until the correct day is displayed.
5. Press ENTER to move to the next Setup Screen, or I/O to exit setup.