Bacharach Fyrite INSIGHT Installation and operation manual

Fyrite®INSIGHT
Combustion Gas Analyzer
Instruction 0024-9460
Operation & Maintenance
Rev. 5 – October 2011
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 mater ial
and manufac ture and will conform substan tially to Bacharach Inc.’s ap plicable 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 manufac ture 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 and all gas sensors except
the O2 sensor which has a one (1) year warranty 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 Bacha rach,
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 MERCHAN TABILITY AND FITNESS FOR A PARTICULAR PURPOSE: AND (II) ANY
OBLIGA TION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOT ARIS-
ING FROM BACH A RACH’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 includ ing, without limita tion incidental or
consequen tial damages. No agree ment 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 0024-9460
Register your warranty by visiting
www.MyBacharach.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 © 2002–2011, Bacharach, Inc., all rights reserved.
BACHARACH, Fyrite, INSIGHT & B-SMART are registered trademarks of Bacharach, Inc. All other trademarks,
trade names, service marks and logos referenced herein belong to their respective companies.

Fyrite®INSIGHT
Instruction 0024-9460 i
TABLE OF CONTENTS
1.0 Introduction ................................................................................. 1
1.1 The Fyrite®INSIGHT...............................................................1
1.2 Fyrite®INSIGHT Features & Benefits....................................2
1.3 Operational Overview................................................................5
2.0 Technical Characteristics......................................................... 6
3.0 Setting Up the Analyzer ............................................................ 8
3.1 Preliminary Steps......................................................................8
3.2 Power..........................................................................................8
3.2.1 Installing or Replacing Batteries...................................8
3.2.2 Using the AC Power Adapter .........................................8
3.3 Connecting the Probe Hose & Thermocouple...........................9
3.4 Front Panel Push Buttons.......................................................11
3.5 Setup Mode ..............................................................................12
3.5.1 Entering Setup..............................................................12
3.5.2 Temperature Units .......................................................12
3.5.3 Pressure Units..............................................................13
3.5.4 Clock..............................................................................13
3.5.5 O2Reference..................................................................14
3.5.6 Print Pressure ..............................................................14
3.5.7 Zoom ..............................................................................14
3.5.8 Username ......................................................................15
3.5.9 Run/Hold Format..........................................................16
3.5.10 Language Selection......................................................18
3.5.11 Button Sound ...............................................................18
3.5.12 CAL Reminder Period .................................................18
3.5.13 Inactivity Timeout .......................................................19
3.5.14 Post-Purge Period ....................................................... 20
3.5.15 Date Format ................................................................ 20
3.5.16 Auto/Manual Zero Feature..........................................21
4.0 Operation .................................................................................... 23
4.1 Operating Tips ........................................................................ 23
4.2 Analyzer Power ON & Warm Up ........................................... 24
4.3 Fuel Selection.......................................................................... 24
4.4 Sampling Point ....................................................................... 25
4.5 Performing a Combustion Test .............................................. 25
4.6 Making a Draft/Pressure Measurement ............................... 28
4.7 Temperature Measurement .................................................... 29
4.8 Saving Test Data .................................................................... 29

Fyrite®INSIGHT
Instruction 0024-9460ii
4.9 Ending a Combustion Test ..................................................... 30
4.10 Emptying the Water Trap...................................................... 30
4.11 Powering OFF the Analyzer & Purging ................................31
4.12 Low Battery Alarm.................................................................31
4.13 Memory................................................................................... 31
4.14 Printing Test Data ................................................................. 32
4.15 Fyrite®User Software........................................................... 34
5.0 Calibration & Maintenance ...................................................... 35
5.1 B-Smart Sensors...................................................................... 35
5.2 Starting a Calibration ............................................................. 35
5.3 B-Smart Sensor Replacement & Calibration ......................... 36
5.4 Pressure Sensor Calibration ................................................... 37
5.5 T-Stack Calibration.................................................................. 39
5.6 T-Air Calibration...................................................................... 40
5.7 CO Sensor Calibration............................................................. 42
6.0 Maintenance.................................................................................44
6.1 Fyrite®INSIGHT Disassembly ............................................. 44
6.2 Water Trap / Filter ................................................................. 46
6.2.1 Emptying the Water Trap Chamber ............................ 46
6.2.2 Replacing the Filter Element....................................... 46
6.3 O2Sensor Replacement........................................................... 47
6.4 CO Sensor Replacement ......................................................... 48
6.5 Thermocouple Replacement.................................................... 49
6.6 Gas Pump Replacement.......................................................... 50
6.7 Cleaning the Probe ................................................................. 52
6.8 Error Messages ....................................................................... 52
6.9 Diagnostics Screen ................................................................. 53
6.10 Status Screen ......................................................................... 54
7.0 Parts & Service ............................................................................ 55
7.1 Replacement Parts .................................................................. 55
7.2 Accessories .............................................................................. 55
7.3 Service Centers ....................................................................... 56
8.0 Declaration of Conformity ........................................................ 57

Instruction 0024-9460
1
Fyrite®INSIGHT
1.0 INTRODUCTION
1.1 The Fyrite®INSIGHT
The Fyrite®INSIGHT is a hand-held residential- and commercial-grade
portable combustion analyzer designed for on-demand sampling of light
industrial combustion equipment, residential furnaces, and appliances.
The Fyrite®INSIGHT is upgradable from the Basic model to the Record-
ing model which includes additional features such as software compatible
for downloading data and the IrDA printer.
The following conventions are used in this manual:
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 in-
jury. Caution statements may also be used to alert against unsafe
practices.
To assure operator safety and the proper use of the Fyrite INSIGHT,
please read the contents of this manual for important information on the
operation and maintenance of the analyzer. This manual contains infor-
mation on all models of the Fyrite INSIGHT. Please disregard any infor-
mation that does not pertain to your model.
WARNINGS!
• This analyzer should not be used on a continuous basis.
• This analyzer should not be used as a safety device.
• Except for sensor and battery replacement, this analyzer should
only be opened and serviced by authorized personnel.
• When testing an appliance, a full visual inspection of the appli-
ance should be carried out to ensure its safe operation.
• HAZARDOUS AREA WARNING: This instrument has not
been designed to be intrinsically safe for use in areas classi-
fied as hazardous locations. For your safety, DO NOT use it in
hazardous (classified) locations.
• HAZARDOUSAREAWARNING:Thisinstrumenthasnot
been designed to be intrinsically safe for use in areas classi-
fied as hazardous locations. For your safety, DO NOT use it in
hazardous (classified) locations.

Instruction 0024-9460 2
Fyrite®INSIGHT
CAUTIONS!
• Whentheinstrumentisusedinaninefcientfurnaceorboiler
application where there is a high emission of soot, the probe
sampleltermaybecomeclogged.Checkthelterbeforeevery
usetoconrmthatitiscleanforuseorreplacewithanewlter.
Topreventthisfromoccurring,asmoketestshouldbeperformed
before operating under such conditions to ensure that the furnace
is burning at a level appropriate for the use of this instrument.
• UseonlyBacharachACAdapter(P/N0024-1254).Failuretodo
so could result in damage to the unit and void the warranty.
• Do not store instrument or its sensors with solvents or products
that contain solvents.
1.2 Fyrite® INSIGHT Features & Benets
AUTO/MANUAL ZERO - In automatic mode, the instrument automati-
cally zeroes all sensing channels on ambient air when it is powered on. If
a particular sensor is in error during warm-up, the instrument automati-
cally displays the error and continues to operate with the sensor in er-
ror. However, all information dependent on the sensor in error will not
be presented. When the CO channel is set to manual zero, the analyzer
does not zero the CO sensor to ambient conditions during start up. In this
mode, the “fresh air zero” established during manual mode setup is stored
in memory and used during the measurement of CO.
TEMPERATURE AND PRESSURE UNITS - Temperatures can be
displayed in Centigrade or Fahrenheit. Pressures can be displayed in mil-
liBar (mB), Pascal (Pa), hectoPascal (hPa), Millimeters of Water Column
(mmwc), or Inches of Water Column (inwc).
LANGUAGE - The display options are English, French or Spanish.
MEMORY - The Fyrite®INSIGHT has the ability to store, recall to dis-
play, and print a minimum of 100 sets of time and date coded combustion,
differential pressure, or differential temperature test records.
DOWNLOAD - Test records can be downloaded to a personal computer via
the USB port. Saved records are transferred using PC based software and
will be automatically loaded into an Excel spreadsheet. PC based software
will also have the capability to update the instrument time and date and
upload custom fuels, username, customer logo, and future code updates.
The INSIGHT can also be set up from PC software.

Instruction 0024-9460
3
Fyrite®INSIGHT
USER INFORMATION - The instrument will accept up to three lines of
20 characters of user information. This information will appear with the
test records when they are printed or downloaded.
CALIBRATION AND REMINDERS - Calibration can be performed by
applying gas and entering calibration gas concentrations through software
menu selections. Calibration reminders can be set for Never, 6, 8, 10, 12,
or 15 months.
SMART SENSORS - B-Smart sensor technology is employed for the CO
channel. CO sensors are calibrated prior to shipment and provide data that
can be entered through the software menu selections for easy calibration
without applying gas.
DISPLAY FORMAT AND ZOOM- The Run/Hold display format can be
presentedindefaultorcustomorderedforspecicneeds.Upto8lines
can be customized in the Run/Hold screen. Combustion test data in the
Run/Hold screens can be shown with enlarged characters to make viewing
easier. The complete list of Run/Hold data can be scrolled through for all
zoom levels. Available zoom levels and information display are as follows:
•Standard-4linesofinformation
•2X-3linesofenlargedcharacters
•3X-2linesofenlargedcharacters
STATUS - A status menu displays the instrument software version, boot
version, model number, and serial number.
DIAGNOSTICS - The diagnostics menu displays the O2 sensor life, CO
sensor information, and hours of operation (for the instrument and pump).
K EYPA D SOUND - Keypad sounds can be enabled or disabled with soft-
ware menu selections.
LOW BATTERY - A tone will sound every 10 seconds when a low battery
condition exists. A low battery message will also be displayed.
AUTOMATIC POWER DOWN - The instrument can be set to automati-
cally power off after a period of inactivity unless the user presses any but-
ton; the CO is greater than 50 ppm, or the O2 is less than 16.0%. Auto-
matic power down can be set for None, 30, or 60 minutes.
PURGE - The sensors will be purged when the instrument is shutdown
until sensor outputs indicate that they have been exposed to fresh air.
Pressing the On/Off key a seconds time can defeat the purge routine. The
minimum purge time can be set to None, 5 seconds, 1 , 5, or 10 minutes.

Instruction 0024-9460 4
Fyrite®INSIGHT
SENSOR ACCESS-Sensorreplacementcanbeaccomplishedintheeld.
Easy access to the O2 and CO sensors is provided through the back of the
instrument.
POWER - The Fyrite®INSIGHT is powered by 4 AA alkaline batteries. A
new set of alkaline batteries will provide a minimum of 20 hours of con-
tinuous operation with the pump running and the back light on. Option-
ally, the analyzer can operate with a universal AC adapter. When the AC
adapter is plugged into the unit, batteries do not have to be removed.
PRINT MEMORY RANGE FEATURE - The print memory function per-
mits the printing of a range of memory locations (versus printing the value
of a single memory location). To access this feature, press F2 then Memory
then Print Multiple.
Features Matrix for Basic and Reporting Models
Basic Reporting
24-8250 24-8251
HARD CARRY CASE X X
PROBE ASSEMBLY X X
PRINTER IRDA X
BOOT X X
PC SOFTWARE X
USB CABLE X
BATTERIES X X
QUICK START GUIDE X X

Instruction 0024-9460
5
Fyrite®INSIGHT
1.3 Operational Overview
Pressing the PWR button turns the analyzer ON. Note that there is a
warm-up period of 60 seconds that must elapse before the analyzer can be
used.
To perform a combustion test, choose a fuel code that corresponds to the
fuel being burned by the appliance being tested (Section 4.3), and then
press the RUN/HOLD 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 com-
bustion process. These values are displayed on the analyzer’s LCD, and
are chosen for display by pressing the Increment (▲)and Decrement (▼)
buttons. The recommended time required to achieve a stable measurement
is a minimum of 3 minutes.
Pressing the RUN/HOLD button during a test will freeze all measured and
calculated values at their current levels. Pressing the RUN/HOLD button
again resumes testing.
A backlight enables an operator to read the display in dimly-lit areas.
Pressing the PWR button turns the backlight ON and OFF.
An optional power saver function will shut the analyzer OFF after a set
time period of inactivity. This feature is disabled if the CO value is greater
than 50 ppm or the O2value is less than 16.0%.
Press the PWR button for at least two seconds to power the analyzer
OFF. Note that there is a 5 second delay before the analyzer actually
turns OFF, during which time the unit can be kept ON by pressing the
RUN/HOLD button. There is a CO purge feature that keeps the analyzer’s
pump running until the measured CO level drops below 50 ppm.

Instruction 0024-9460 6
Fyrite®INSIGHT
2.0 TECHNICAL CHARACTERISTICS
The Analyzer Measures & Displays:
Primary/Ambient Air Temperature -4 to 600 °F (-20 to 316°C)
Oxygen 0.1 to 20.9% O2
Stack Temperature -4 to 1202 °F (–20 to 650 °C)
Carbon Monoxide 0 to 2000 ppm CO
Differential Pressure/Draft ± 100 inwc
The Analyzer Computes & Displays:
Combustion Efficiency 0.1 to 100%
Carbon Dioxide 0.1 to a fuel dependent
maximum value in %
CO referenced to %O2 0 to 9,999 ppm
Excess Air 0 to 250%
Fuel Selection
• Natural Gas
• Oil #2
• Oil #4
• Oil #6
• Propane
• Kerosene
• Wood
• Coal
Normal Operating Conditions:
Temperature
• Analyzer
• Probe
32 to 104 °F (0 to 40 °C)
1,000 °F max (538 °C) at
5" insertion
Humidity 15 to 90% RH, Non-Condensing
Dimensions Weight
7.9 in (20.1 cm) Height
3.6 in (9.1 cm) Width
2.3 in (5.8 cm) Depth
1lb. (0.45 kg)