Bacharach Fyrite Tech 50 Operation and maintenance manual

Fyrite®Tech
Model 50 & 60
Combustion Gas Analyzer
Instruction 24-9428
Operation & Maintenance
Rev. 4 – August 2005
Product Leadership • Training • Service • Reliability

WARRANTY
Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in material
and manufature and will onform substantially to Baharah In.’s aliable seiations. Baharah’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 uon Baharah, In. unless in writing, signed by a duly authorized ofer of Baharah.
AInstruction 24-9428
Register Your Warranty by Visiting
www.bacharach-inc.com
Notice:
Produt imrovements and enhanements are ontinuous, therefore the seiations and information on-
tained in this document may change without notice.
Bacharach, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in con-
nection 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 © 2002–2005, 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.
Declaration of Conformity
Manufacturer’s name: Bacharach, Inc.
Manufacturer’ address: 621 Hunt Valley Circle
New Kensington, PA 15068
European Operations: Bacharach Europe
Sovereign House, Queensway
Leamington Spa
Warwickshire CV31 3JR
United Kingdom
Product name: Fyrite Tech
onforms to the following seiations:
European Directive 89/336/EEC
EN50082-1: 1997 (Electrostatic Discharge)
EN50082-1: 1997 (Immunity)
EN55022; Group 1, Class B (Emmission)

Fyrite Tech
Instruction 24-9428 i
Contents
Ordering Information...............................................................................iii
1.0 INTRODUCTION ..................................................................................1
1.1 The Fyrite Tech ................................................................................1
1.2 Operational Overview ......................................................................2
2.0 TECHNICAL CHARACTERISTICS...................................................3
3.0 SETTING UP THE ANALYZER .........................................................5
3.1 Scope .................................................................................................5
3.2 Checking & Replacing the Batteries............................................... 5
3.3 Connecting the Probe.......................................................................6
3.4 Front Panel Pushbuttons.................................................................8
3.5 Setup Mode ....................................................................................... 9
3.5.1 Entering Setup ...................................................................... 9
3.5.2 Selecting Temperature Units................................................ 9
3.5.3 CO Channel Setup (Model 60 only) .................................... 10
3.5.4 Time Setup (Model 60 only) ................................................ 10
3.5.5 Date Setup (Model 60 only) ................................................ 11
3.5.6 Year Setup (Model 60 only)................................................. 11
3.5.7 Selecting Printer Protocol (Model 60 only) ........................ 12
3.5.8 Exiting Setup.......................................................................12
4.0 OPERATION ........................................................................................13
4.1 Performing a Test...........................................................................13
4.1.1 Analyzer Turn On and Warm Up.......................................13
4.1.2 Selecting a Fuel ...................................................................13
4.1.3 Manual Zero of the CO Channel (Model 60 only) .............. 13
4.1.4 Sampling Point ....................................................................14
4.1.5 Performing a Combustion Efciency Test.......................... 16
4.1.6 Printing Test Results (Model 60 only)................................16
4.1.7 Ending a Combustion Test..................................................18
4.1.8 Turning OFF the Analyzer .................................................18
4.2 CO Purge During Turn OFF (Model 60 only)...............................18
4.3 Operating Tips................................................................................19
4.4 Using the Backlight .......................................................................20
4.5 Using the Probe..............................................................................20
4.6 Resetting the Microprocessor ........................................................20
4.7 Run Mode Screens..........................................................................21

Fyrite Tech
Instruction 24-9428
ii
4.8 Screen Descriptions........................................................................22
4.8.1 Warm-Up Screens................................................................22
4.8.2 Fuel Screen ..........................................................................22
4.8.3 O2Screen (Model 50 only)...................................................23
4.8.4 CO & O2Screen (Model 60 only).........................................23
4.8.5 CO Air Free Screen (Model 60 only)...................................24
4.8.6 Ambient Air Temperature Screen ......................................24
4.8.7 Stack Temperature & Efciency Screen ............................25
4.8.8 CO2& Excess Air Screen ....................................................25
5.0 CALIBRATION & MAINTENANCE ................................................27
5.1 Entering the Calibration Mode and Testing the Display Segments ...27
5.2 Ambient Temperature Calibration................................................28
5.3 Stack Thermocouple Channel Calibration....................................28
5.4 O2Sensor Zero................................................................................29
5.5 CO Sensor Zero & Calibration (Model 60 only) ............................30
5.6 Water Trap / Filter Maintenance ..................................................32
5.7 O2Sensor Replacement..................................................................33
5.8 CO Sensor Replacement (Model 60 Only)..................................... 34
5.9 Pump Assembly Replacement .......................................................35
6.0 PARTS & SERVICE............................................................................38
6.1 Replacement Parts .........................................................................38
6.2 Accessories......................................................................................38
6.3 Service Centers...............................................................................39

Fyrite Tech
Instruction 24-9428 iii
Model No.
Part No.
Fyrite Tech 50
24-8216
Fyrite Tech 60
24-8217
Measurements:
Oxygen
Stack Temperature
Ambient Temperature
Carbon Monoxide
Calculations:
Combustion Efieny
Excess Air
Carbon Dioxide
CO air free
Print Capability*
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
* The printer used with a Fyrite Tech 60 is an optional
accessory item that must be ordered separately. Refer to
Section 6.2 Accessories.
Ordering Information

Fyrite Tech
Instruction 24-9428iv
Notes:

Instruction 24-9428 1
Fyrite Tech
1.0 INTRODUCTION
1.1 The Fyrite Tech
Available in two models, the Fyrite Tech 50 and 60 are hand-held ana-
lyzers that are designed to calculate the efciency of residential furnaces
and combustion appliances by measuring the stack temperature and the
percent oxygen level in the ue-gas stream.
While both analyzers are capable of combustion testing, the Fyrite Tech 60
has the added capability of measuring carbon monoxide and calculating
CO air-free, and also has the capability of sending combustion test data to
an optional printer via an infrared port using either HP or IrDA protocol.
Fyrite Tech 50 Fyrite Tech 60
Measures: Measures:
• Oxygen (O2)• Oxygen (O2)
• Stack temperature • Stack temperature
• Ambient temperature • Ambient temperature
• Carbon Monoxide (CO)
Calculates: Calculates:
• Combustion Efciency • Combustion Efciency
• Carbon Dioxide (CO2) • Carbon Dioxide (CO2)
• Excess Air • Excess Air
• CO air-free
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 ap-
pliance should be carried out to ensure its safe operation.

Instruction 24-9428
2
Fyrite Tech
1.2 Operational Overview
Pressing the I/O button turns the analyzer ON. Note that there is a 60 sec-
ond warm-up period that must elapse before the analyzer can be used.
After warm-up is complete, choose the fuel code that corresponds to the
fuel being burned by the appliance being tested. Then press the ENTER
button to place the analyzer into its Run Mode and begin the combustion
testing process.
Begin testing by inserting the analyzer’s probe tube into the ue-gas
stream of the appliance under test. Each analyzer model will continuously
monitor the ue 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.
The Fyrite Tech 60 has the capability of sending the current combustion
test to an optional printer by pressing the HOLD button twice.
Pressing the HOLD button during a test will freeze all measured and
calculated values at their current values. Pressing the ENTER button
resumes testing.
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
keyboard inactivity. Note, however, that the power-saver function is dis-
abled 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.
If the analyzer is turned OFF while a high level of CO is still present
within the unit, the pump remains running and the unit will not turn OFF
until the detected CO level drops below 50 ppm.

Instruction 24-9428 3
Fyrite Tech
2.0 TECHNICAL CHARACTERISTICS
The Analyzer Directly Measures and Displays:
• Flue Gas O2content ..................................... 0.0 to 20.9% O2
• Stack Temperature....................................... 0 to 999 °F (–18 to 537 °C)
• Ambient Temperature.................................. 32 to 212 °F (0 to 100 °C)
• Flue Gas CO content (Model 60) ................. 0 to 2,000 ppm CO
The Analyzer Computes and Displays:
(when the measured oxygen level is below 17.9 %)
• Combustion Efciency.................................. 0.1 to 99.9%
• Flue Gas CO2content................................... 0.0 to a fuel dependent
maximum value in %
• Flue Gas CO Air-Free content (Model 60) ... 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 ‘AA’ Alkaline batteries
Operating Time .............................................. Up to 18 hours continuous
(pump running and back-
light off)
Warm Up Time ................................................ 60 seconds

Instruction 24-9428
4
Fyrite Tech
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% O2 w/typical ue gas
concentration of CO2
• Carbon Monoxide (Model 60) ................±5% of reading or ±10 ppm,
whichever is greater*
• Stack 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)
• Ambient Temperature............................±4 °F between 32 & 104 °F
(±2 °C between 0 & 40 °C)
Size...............................................................7.5"H x 3.1"W x 2.1"D
(190.5 x 78.7 x 53.3 mm)
Weight..........................................................16 oz (0.454 kg) with batteries
Agency Approval ......................................CE Mark
* 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 24-9428 5
Fyrite Tech
3.0 SETTING UP THE ANALYZER
3.1 Scope
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 sufcient
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. Remove old batteries and dispose of them properly.
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 24-9428
6
Fyrite Tech
3.3 Connecting the Probe
Connect the probe assembly’s ue-gas hose and thermocouple connector to
the analyzer as follows (see Figure 3-2):
1. Push the ue gas hose onto the analyzer’s GAS inlet tting.
2. Push the ue gas thermocouple into the T-STACK jack
Important: DO NOT force thermocouple connector. The con-
nection tabs are different sizes, allowing the connector to t
in only one way.
Inspect the ue-gas hose for cracks. Replace the hose if it is defective.
Before using the analyzer, check that the Water Trap / Filter is dry and
not dirty. If necessary, dry out the trap and replace the lter element per
Section 5.6.

Instruction 24-9428 7
Fyrite Tech
Figure 3-2. Connecting the Probe
T-STACK
GAS
THERMOCOUPLE
PROBE STOP
(Optional)
WATER TRAP /
FILTER ASSEMBLY

Instruction 24-9428
8
Fyrite Tech
3.4 Front Panel Pushbuttons
Note that a push button may perform several functions, depending on what
screen is being displayed at the time.
I/O • Turns analyzer ON/OFF. There is a 60 second warm-up
and a 5 second turn-off-delay period.
•Places the analyzer into either its Setup or Calibration Mode
when used in conjunction with the ENTER or HOLD button.
• Aborts the CO purge function during turn-off.
•Scrolls up through the display screens during a test.
•Causes the displayed value to increase or change while in
the Calibration or Setup Mode.
•Scrolls down through the display screens during a test.
•Causes the displayed value to decrease or change while in
the Calibration or Setup Mode.
ENTER •Enters the Run Mode (starts a combustion test) from the
Fuel Select Screen.
•Displays the Fuel Select Screen when held down for
2 seconds while in the Run Mode.
•Sets up the analyzer to be placed into its Calibration Mode
when held down with the analyzer OFF. (Used in conjunc-
tion with the I/O button.)
•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.
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.
• 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.)
•Sends combustion test data to a printer when pressed twice
with the pump running (Fyrite Tech 60 only).
LIGHT Toggles the backlight ON and OFF.

Instruction 24-9428 9
Fyrite Tech
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 4.1.2
Temperature Unit °F Section 3.5.2
CO Channel Auto Zero (A2) Section 3.5.3
Clock Not initialized Section 3.5.4 thru 3.5.6
Printer Protocol IrDA Section 3.5.7
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
3.5.7 for information on how to set up the analyzer.
3.5.2 Selecting Temperature Units
The Temperature Units Setup Screen is labeled “Unit.”
1. If not already done, enter Setup per Section 3.5.1. Repeatedly press
ENTER until the Temperature Units Setup Screen is displayed.
2. Press the or button until the desired temperature unit
(°F or °C) is displayed.
3. Press ENTER to move to next Setup Screen, or press I/O to exit setup.

Instruction 24-9428
10
Fyrite Tech
3.5.3 CO Channel Setup (Model 60 only)
The CO Channel Setup Screen is labeled “CO.”
1. If not already done, enter Setup per Section 3.5.1. Repeatedly press
ENTER until the CO Channel Setup Screen 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
inaccurate 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 next Setup Screen, or press I/O to exit setup.
3.5.4 Time Setup (Model 60 only)
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 value
is displayed in a 24 hour format for setup purposes, but will appear as
AM/PM on the printout.
1. If not already done, enter Setup per Section 3.5.1. Repeatedly press
ENTER until the rst Time Setup Screen is displayed—the one with
two bars over the hour digits.

Instruction 24-9428 11
Fyrite Tech
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 next Setup Screen, or press I/O to exit setup.
3.5.5 Date Setup (Model 60 only)
There are two Date Setup Screens, each labeled “DAtE”. The rst screen
sets the month while the second sets the day.
1. If not already done, enter Setup per Section 3.5.1. Repeatedly press
ENTER until the rst 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 next Setup Screen, or press I/O to exit setup.
3.5.6 Year Setup (Model 60 only)
The Year Setup Screen is labeled “YEAr”.
1. If not already done, enter Setup per Section 3.5.1. Repeatedly press
ENTER until the Year Setup Screen is displayed.
2. Press the or button until the correct year is displayed.
3. Press ENTER to move to next Setup Screen, or press I/O to exit setup.

Instruction 24-9428
12
Fyrite Tech
3.5.7 Selecting Printer Protocol (Model 60 only)
The analyzer can be set up for either an HP or IrDA type printer.
1. If not already done, enter Setup per Section 3.5.1. Repeatedly press
ENTER until one of the following screens is displayed.
2. Press the or button to select the desired printer protocol.
3. Press ENTER to move to next Setup Screen, or press I/O to exit setup.
3.5.8 Exiting Setup
Press the I/O button at any time to exit the Setup Mode and turn OFF the
analyzer.
Note that the last displayed parameter is automatically saved in memory.

Instruction 24-9428 13
Fyrite Tech
4.0 OPERATION
4.1 Performing a Test
4.1.1 Analyzer Turn On and Warm Up
Important: The probe must be at room temperature before
performing the following steps. The temperature measured by
the probe during warm up is the combustion-air temperature
used by the analyzer for efciency calculations purposes.
1. Make sure that the analyzer is properly set up per Section 3.0.
2. During warm-up, the analyzer’s probe must be located in the area
containing the burner’s combustion-air supply. If the burner is using
room air, simply place the probe within the room. In the case of a
high-efciency furnace where combustion air is drawn in from an
outside source, place the probe within that area with the burner
operating. After the probe is properly positioned, turn ON the ana-
lyzer by pressing its I/O button.
3. Wait for the analyzer to complete its 60 second warm-up period;
after which, the Fuel Screen is displayed. If errors were detected
during warm-up, the Sensor Error Screen will be displayed. If this
occurs, refer to Section 4.8.9 to correct the cause of the error.
4.1.2 Selecting a Fuel
1. With the Fuel Screen displayed, use the or button to step
through the fuels codes until the proper fuel is displayed. The ana-
lyzer defaults to the most recently selected fuel.
F1 = Natural Gas F3 = LPG
F2 = Oil #2 F4 = Kerosene
2. Press the ENTER button to select the displayed fuel code; after
which, the analyzer enters the Run Mode.
4.1.3 Manual Zero of the CO Channel (Model 60 only)
If the CO channel is set up for manual calibration (refer to Section 3.5.3),
and if the CO reading shows a value other than zero in fresh air, then be-
fore proceeding with a test manually zero the CO channel per Section 5.5.

Instruction 24-9428
14
Fyrite Tech
4.1.4 Sampling Point
Forced Air Furnace – When testing 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 ex-
changer. The probe should be inserted back into each of the exhaust ports
to obtain a ue gas sample, before any dilution air is mixed in.
Hot Water Tank – Domestic hot water tanks with the ‘bell’ shaped draft
diverter on top can be accurately tested by inserting the probe tip directly
into the top of the re tube below the diverter.
80% Efciency Fan Assist or Power Vented – Combustion testing of
fan assist or power vented, furnaces/boilers should be done through a hole
drilled in the vent immediately above the inducer fan.
90% Efciency Condensing – Condensing furnaces/boilers can be tested
through a hole drilled in the plastic vent pipe (when allowed by the manufac-
turer or local authority of jurisdiction) or taken from the exhaust termination.
Atmospheric or Gravity Vented Boiler – Boilers, which have a ‘bell’
shaped draft diverter directly on top, should be tested directly below the
diverter through a hole drilled in the vent connector.
Atmospheric Burner or
Gravity Vented Forced Air Hot Water Tank