Bacharach Fyrite INSIGHT PLUS User manual

Combustion Gas Analyzer
Instruction Manual
Configuration •Operation •Maintenance
P/N: 0024-9487
Revision 1
December 6, 2012
Product Leadership •Training •Service •Reliability

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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 on Product, CO sensor, and LL O2sensor, and
within one (1) year after the date of delivery of the O2sensor.
Bacharach, Inc. warrants to buyer that it will convey good title to this product.
Bacharach’s liability and buyer’s remedy under this warranty of title are limited
to the removal of any title defects or, at the election of Bacharach, to the
replacement of this product or parts thereof that are defective in title.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED
IN LIEU OF (I) ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE: AND (II) ANY
OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT,
WHETHER OR NOT ARISING FROM BACHARACH’S NEGLIGENCE, ACTUAL OR
IMPLIED. The remedies of the buyer shall be limited to those provided herein
to the exclusion of any and all other remedies including, without limitation
incidental or consequential damages. No agreement varying or extending the
foregoing warranties, remedies or this limitation will be binding upon
Bacharach, Inc. unless in writing, signed by a duly authorized officer of
Bacharach.
Register your warranty by visiting
www.MyBacharach.com

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NOTICE
Product improvements and enhancements are continuous, therefore the
specifications and information contained in this document may change without
notice.
Bacharach, Inc. shall not be liable for errors contained herein or for incidental
or consequential damages in connection with the furnishing, performance, or
use of this material.
No part of this document may be photocopied, reproduced, or translated to
another language without the prior written consent of Bacharach, Inc.
Copyright © 2012, Bacharach, Inc., all rights reserved.
BACHARACH, Fyrite, INSIGHT, and B-SMART are registered trademarks of
Bacharach, Inc. All other trademarks, trade names, service marks and logos
referenced herein belong to their respective companies.

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Table of Contents
SECTION 1. OVERVIEW................................................................................1
1.1. Introduction .......................................................................................... 1
1.2. Conventions .......................................................................................... 1
1.3. Safety .................................................................................................... 1
1.4. Product Overview ................................................................................. 3
1.5. North American (NA) vs. Siegert (S) Combustion Equations................. 3
1.6. Components.......................................................................................... 5
1.7. Features ................................................................................................ 7
1.8. Combustion Test Process Overview...................................................... 9
1.9. FyriteINSIGHTPlus Sales Combinations ......................................... 10
1.10. Specifications .................................................................................... 11
SECTION 2. SETUP .....................................................................................15
2.1. Connecting the Probe and Thermocouple .......................................... 15
2.2. Front Panel Buttons ............................................................................ 16
2.3. Power Options .................................................................................... 18
2.4. Turning the FyriteINSIGHTPlus On/Off.......................................... 19
SECTION 3. CONFIGURATION ....................................................................21
3.1. Menu Structure Overview................................................................... 21
3.2. The Warm-up Sequence ..................................................................... 21
3.3. Main Menu.......................................................................................... 22
3.4. Select Fuel Menu ................................................................................ 24
3.5. Pressure Menu .................................................................................... 26
3.6. Temperature Menu............................................................................. 26
3.7. Leak Test Menu (Siegert Only)............................................................ 27
3.8. Ambient CO Menu (Siegert Only) ....................................................... 28
3.9. Memory Options Menu ...................................................................... 30
3.10. Setup Menu....................................................................................... 32
3.11. Calibration Menu .............................................................................. 51
3.12. Diagnostics Menu.............................................................................. 52
3.13. Status Menu...................................................................................... 55
SECTION 4. OPERATION ............................................................................56
4.1. Prerequisites ....................................................................................... 56
4.2. Sampling Point Examples .................................................................... 56

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4.3. Combustion Testing Process ............................................................... 59
4.4. The RUN Screen .................................................................................. 61
4.5. Making a Draft or Pressure Measurement ......................................... 63
4.6. Printing Using the Optional IrDA Printer............................................. 64
4.7. Graphics Screens................................................................................. 67
4.7.1. Overview................................................................................... 67
4.7.2. Graphical Line Graph Trend Screen .......................................... 68
4.7.3. Bar Graph Screen ...................................................................... 69
4.7.4. Stack Temperature Hot Spot Screen......................................... 72
4.8. Taking Ambient CO Measurements (Siegert Only) ............................. 72
4.9. PC Interface and FyriteUser Software.............................................. 73
SECTION 5. CALIBRATION AND MAINTENANCE .........................................74
5.1. Serviceability....................................................................................... 74
5.2. Cleaning the Probe.............................................................................. 74
5.2.1. Equipment Required ................................................................. 75
5.2.2. Procedure ................................................................................. 75
5.3. Water Trap and Filter Replacement.................................................... 76
5.4. O2and/or CO Sensor Replacement..................................................... 77
5.4.1. Accessing the Sensors............................................................... 77
5.4.2. Material Required (As Needed) ................................................ 77
5.4.3. O2Sensor Replacement Procedure........................................... 77
5.4.4. CO Sensor Replacement Procedure.......................................... 78
5.4.5. B-SMARTCO Sensor Replacement.......................................... 80
5.5. Pressure Sensor Calibration ................................................................ 81
5.5.1. Materials Required ................................................................... 81
5.5.2. Procedure ................................................................................. 81
5.6. T-Stack Calibration .............................................................................. 83
5.6.1. Materials Required ................................................................... 83
5.6.2. T-Stack Calibration Procedure .................................................. 83
5.7. T-Air Calibration .................................................................................. 85
5.7.1. Materials Required ................................................................... 85
5.7.2. T-Air Calibration Procedure ...................................................... 86
5.8. CO Sensor Calibration ......................................................................... 88
5.8.1. Materials Required ................................................................... 88
5.8.2. CO Manual Zero Procedure ...................................................... 88
5.8.3. CO Sensor Span Procedure ....................................................... 89
5.9. T-Ref Sensor Calibration ..................................................................... 90
SECTION 6. TROUBLESHOOTING ...............................................................92

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6.1. Error and Warning Messages.............................................................. 92
6.2. Replacement Parts .............................................................................. 94
6.3. Accessories.......................................................................................... 95
6.4. Instrument Identification.................................................................... 96
6.5. Service Centers ................................................................................... 96
CE Declaration of Conformity ............................................................................ 97
Index .................................................................................................................. 99
∇∇∇

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Section 1. 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. Failure to follow this
information could result in serious personal injury or death.
CAUTION: A caution statement indicates a potentially hazardous
situation which, if not avoided, may result in minor or moderate
injury. Caution statements may also be used to alert against
unsafe practices.
IMPORTANT: An important statement provides emphasis of an
important feat
ure, operation, etc. Failure to follow this
information could void your warranty
, result in improper
operation, or cause equipment damage.
NOTE: A note statement provides emphasis of a feature,
operation, practice, etc.
1.3. Safety
WARNING: This analyzer is not intended to be used as a safety
device.
WARNING: When testing an appliance, a full visual inspection of
the appliance should be performed to ensure its safe operation.

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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.
HAZARDOUS AREA WARNING:
This instrument has not been
designed to be intrinsically safe for use in areas classified as
hazardous locations. For your safety, DO NOT
use it in hazardous
(classified) locations.
CAUTION: Do not use flammable or combustible substances (like
carburetor fluid used for cleaning the probe) near an open flame.
CAUTION: When the instrument is used in an inefficient oil-fueled
appliance where there is a high emission of soot, the probe’s
sample filter may become clogged. Before every use check the
filter to confirm it is clean or replace it with a new filter.
To prevent soot intake and a clogged filter, a smoke test should be
performed before operating under such conditions. This ensures
that the furnace or boiler is burning at a level appropriate for the
use of this instrument.
When the CO2level exceeds the allowable threshold, a warning
will prompt the user to consider performing a smoke test.This
screen is cleared by pressing the ENTER button. Once the warning
is cleared, it will not be displayed again for that particular test. If a
new test is started (by pressing the HOLD button), the warning will
be displayed again if the limit has been exceeded.

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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.
The instrument is supplied with all of the following components:
•probe and hose assembly
•four disposable “AA” alkaline batteries
•hard carrying case
•rubber boot
•spare filters
•factory-calibrated and installed sensors as ordered
and, depending on the model and kit, some or all of the following:
•FyriteUser Software (FUS)
•USB cable (type A to Mini B)
•Infrared Data Association (IrDA) printer with four disposable “AA”
alkaline batteries
•printer paper.
1.5. North American (NA) vs. Siegert (S) Combustion Equations
Though the combustion process is fairly standardized across the globe, a
combustion analyzer intended for worldwide use demands a degree of
flexibility for a few regional preferences. The FyriteINSIGHTPlus provides a
North American (NA) configuration and a Siegert (S) configuration (see page 50)
to address these and other needs, which are contrasted below.
NOTE: Detailed differences between North American and Siegert
configurations are noted where appropriate in this manual.

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Feature North American (NA) versus Siegert (S) Configurations
Countries Typical North American
(NA) Users
Typical
Siegert (S) Users
Asia Belgium
Australia Denmark
Latin America France
North America Germany
South America Italy
Netherlands
Poland
Spain
United Kingdom
Heating Values For combustion calculations, Siegert uses the fuel’s lower
heating value; NA uses the higher value (see page 61).
Fuels Different fuel sets and composition (see page 24)
Different RUN
Parameters
EFF (NA) vs. Stack loss and ETA (S)
Excess Air (NA) vs. Lambda (S)
(Lambda is similar to excess air) (see page 61)
Extra Siegert
Parameters
CO/CO2ratio, boiler temperature, smoke number, and oil
derivative are displayed for Siegert only (see page 61).
CO2Max In the Siegert configuration, the user can set a CO2Max number
for the fuel (see page 24).
Print Average
Feature There is a print average feature for Siegert (see page 31).
Time and Date
Format
NA: MM/DD/YY w/ 12-hour time format with AM/PM or
DD/MM/YY w/ 24-hour time format (see page 47)
Siegert: DD/MM/YY w/ 24-hr time format only
Languages 3 for the North American (NA) configuration and 8 for the
Siegert (S) configuration (See language list on page 44)
NOTE: The Combustion Equations setting is used to configure the
instrument to use either North American combustion equations or
Siegert combustion equations (see page 50). Changing this setting
resets memory and the values of other settings. Refer to page 50
for a list of affected parameters.

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1.6. Components

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1.7. Features
•Sensors
oField-replaceable electrochemical sensors (O2and B-SMARTCO)
(pp 77-79)
oOptional long life O2sensor (pp 10, 77)
oPressure sensor (pp 6, 26)
oFlue gas (and optionally T-AIR) temperature measurement using a
Type K thermocouple (p 6)
•Fuel codes
oNine available fuels (in North American configuration) (p 24)
oTen available fuels (in Siegert configuration) (p 24)
oCustom fuel code entry (p 25)
•Power
oUSB cable (PC or wall adapter) (p 12)
o4 AA alkaline batteries (included) (p 12)
o4 AA lithium batteries (p 12)
o4 AA rechargeable batteries (externally charged) (p 12)
oLow battery warning (pp 12, 92)
•Testing Features
oComplete test results (100 sets) can be stored, recalled, displayed,
downloaded, and printed (pp 10, 30, 61)
oSecure calibration function (password protected) (p 51)
oAuto power-off feature with sensor purge feature (p 46)
oGraphic screens showing trending, bar, and hotspot graphic
functions (p 67)
oStatus and diagnostic menus (pp 52, 55)
oManual entry of values (Siegert only) (pp 24, 33, and 34)
oCalibration reminder function (p 45)
oCustom display formats (pp 41, 47, 64, and 66)
oZoom feature (p 37)
oPrint range feature (p 31)
oAmbient CO (Siegert Only) (pp 28, 72)
•User Customizations
oNorth American and Siegert combustion calculations (pp 50, 61)
oMulti-language interface (44)
oAuto/Manual zero functions for the CO sensor (pp 21, 48, 88)
oCustomized logo on printouts (192 x 384 pixels) (p 66)
oCustomized user information (3 lines of 20 characters) (pp 41, 64)
oTen sets of test IDs to customize printouts (p 38)

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oTemperature and pressure unit selection (p 32)
•Hardware
oProbe/hose assembly for gas transport and temperature input (p
6)
oSample pump to provide gas sample delivery
oBacklit color graphic LCD (p 5)
oHard carrying case (see below)
oTime and date stamping of 100 test results
oUSB 2.0 (mini-B connection) for PC interface and communications
(p 5)
•PC Interface (p 73)
oUSB cable (Type A to Mini B)
oFyriteUser Software (FUS) (Windows compatible)
oUpdates, instrument configuration, and downloading test results

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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.................................... 24,
32
Set Combustion Test Parameters ..........................
24
Replace Sensor(s) as Needed........................... 52,
77
Calibrate as Needed ........................................ 51, 74
Replace Batteries as Needed .................................
18
Filter Replacement ................................................
76
Place Probe in Sampling Point ......................... 56,
59
Collect Data (RUN Button) ....................16, 59, 61, 67
Save Data as Needed (F3) ...................... 5, 16, 59,
61
Stop Test (HOLD Button) ......................16, 59, 61,
67
Print Data as Needed (F1)......................................
64
Zero Pressure Sensor if Necessary................... 26,
81
Place Probe as Required .................................. 56,
63
Save Data as Needed (F3) ...................... 5, 16, 59, 61
Print Data as Needed (F1)......................................
64
Save Data (F3)........................................ 5, 16, 59, 61
Print Data (F1) (Option) ............................... 5, 16,
64
Review All Combustion Data ................30, 52, 55,
64
Adjust Combustion Equipment As Needed
Disconnect Probe .............................................. 6, 15
Purge Instrument...................................................
46
Turn Off Instrument........................................... 5,
16
Clean and Store .....................................................
74

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1.9. FyriteINSIGHTPlus Sales Combinations
Fuel Equations North American Siegert
Final Assembly 0024-
7343
0024-
7344
0024-
7345
0024-
7346
O2Sensor Type Standard Long Life Standard Long Life
Kit Type:
B=Basic
R=Reporting
B R B R B R B R
Sales Kit P/N 0024-
8515
0024-
8516
0024-
8517
0024-
8518
0024-
8519
0024-
8520
0024-
8521
0024-
8522
Hard Case X X X X X X X X
Sampling
Probe & Hose X X X X X X X X
Manual X X X X X X X X
Batteries X X X X X X X X
Boot X X X X X X X X
Spare filters X X X X X X X X
CO Sensor
w/NOxFilter X X X X X X X X
Pressure X X X X X X X X
T-Air X X X X X X X X
T-Stack X X X X X X X X
O2Sensor X X X X
LL O2Sensor X X X X
Fuels 9 9 9 9 10 10 10 10
Memory 100 100 100 100 100 100 100 100
FyriteUser
Software (FUS) X X X X
USB Cable X X X X
Printer X X X X

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1.10. Specifications
Specification Description
Temperature Storage: -20 to 50 C ( -4 to 122 F)
0 to 20 C (32 to 68 F ) optimal
Operation: -5 to 45 C (23 to 113 F)
Reference: 20 ± 2 C (68 ± 4 F)
Humidity Storage: 15 to 90% RH, non-condensing
Operation: 15 to 95% RH, non-condensing
Reference: 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 5.8 cm)
Warm-up Time Minimum = 30 seconds; Maximum = 60 seconds
Gas Sample
Flow Rate 300 to 700 cc/min
Sensors O2Electrochemical (P/N: 0024-0788)
CO w/ NOx Filter Electrochemical (P/N: 0024-1593)
LL O2(Optional) Electrochemical (P/N: 0024-1591)
Temp (Stack) K-Type thermocouple
Temp (Air) K-Type thermocouple
Pressure Piezo-resistive
Product
Approvals and
Regulatory
Compliance
EN50270: (CE Mark) EMC tested in accordance with European
Directive 2004/108/EC.
EN50379: Standard for portable electrical apparatus designed
to measure combustion flue gas parameters of
heating appliances (Siegert only) Parts 1 and 3.
ROHS Compliance
Case
Construction
High impact ABS plastic with rubber over mold
Protective rubber boot with molded-in magnets.
Display Color 3.0” graphics LCD
USB Connector Mini B (USB 2.0)

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Specification Description
IrDA Port Protocol: IrDA-SIR Data Bits: 8
Baud Rate: 9600 Stop Bits: 1
Parity: None
Memory 100 locations for storing test results
Power Supply
Options
Batteries
(4 AA)
Type: Disposable Alkaline (Included)
Duration: 15 hours min, continuous max draw
Type: Disposable Lithium
Duration: 20 hours, continuous max draw
Type: Rechargeable
Duration: 8 hours, continuous max draw
USB Cable
(A to Mini B)
Source: PC
Source: AC source (via Wall Adapter)
Measure-
ment Range Resolution Accuracy Response Time (T90)
O2and
LL O20 to 20.9 % 0.1% O2±0.3% O2< 20 sec
CO w/ NOx
filter
0 to
4000 ppm 1 ppm
±10 ppm (0 to 200 ppm)
±5% (201 to 4000 ppm) < 40 sec
Ambient
Temp
-20 to 316°C
(-4 to 600°F)
0.1°C
(0.1°F)
±1°C (0 to 100°C) < 70 sec
Stack Temp -20 to 650°C
(-4 to 1202°F)
1°C
(1°F)
±2°C (0 to 124°C)
±3°C (125 to 249°C)
±4°C (250 to 400°C)
< 50 sec
Differential
Temp
±600°C
(±1112°F)
0.1°C
(0.1°F) N/A N/A
Pressure /
Differential
Pressure
±100 mB
(±40 inwc)
0.01 mB
(0.01 inwc)
±0.03mB ( -1 to 1 mB)
±3% (-40 to -1 mB)
±3% (1 to 40 mB)
N/A

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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% O2and 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% O2and the stack temperature
is not above 650°C (1202°F).
Calculation Calculation Range Reso-
lution
Configuration
NA Siegert
Efficiency (HHV) 0.1 to 100 % 0.1% X X
ETA (LHV) 0 to 115% 0.1% X
Excess Air 1 to 250 % 1% X
Stack Loss 0.1 to 100 % 0.1 % X
Lambda 1 to 9.55 0.01 X
CO2(dry basis) 0.1 to a fuel-dependent max in % 0.1 % X X
CO Ref to O20 to 9999 ppm 1 ppm X X
CO/CO2Ratio 0.0001 to fuel-dependent max 0.0001 X
∇∇∇

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