Bacharach Fyrite INSIGHT Installation and operation manual

Fyrite®INSIGHT
Combustion Gas Analyzer
Instruction 24-9460
Operation & Maintenance
Rev. 0 – Oct. 2008
Product Leadership • Training • Service • Reliability
F1 F2 F3
ESC
RUN
HOLD
PWR

Fyrite®INSIGHT
Instruction 24-9460 i
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 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 Bacharach,
to the replacement of this Product or parts thereof that are defective in title.
THE FOREGOING WARRANTIESARE EXCLUSIVE AND ARE GIVENAND ACCEPTED IN LIEU OF (I)ANY
AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IM-
PLIED WARRANTIES OF MERCHANTABILITYAND FITNESS FORA PARTICULAR PURPOSE:AND (II) ANY
OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOTARIS-
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 24-9460
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 © 2002–2008, 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.
TABLE OF CONTENTS
1.0 Introduction ................................................................................. 1
1.1 The Fyrite®INSIGHT...............................................................1
1.2 Fyrite®INSIGHT Features & Benefits....................................2
1.3 Operational Overview................................................................4
2.0 Technical Characteristics......................................................... 5
3.0 Setting Up the Analyzer ............................................................ 7
3.1 Preliminary Steps......................................................................7
3.2 Power..........................................................................................7
3.2.1 Installing or Replacing Batteries...........................................7
3.2.2 Using the AC Power Adapter .................................................7
3.3 Connecting the Probe Hose & Thermocouple...........................7
3.4 Front Panel Push Buttons.......................................................10
3.5 Setup Mode ..............................................................................11
3.5.1 Entering Setup......................................................................11
3.5.2 Temperature Units ...............................................................11
3.5.3 Pressure Units......................................................................11
3.5.4 Clock......................................................................................12
3.5.5 O2Reference..........................................................................13
3.5.6 Print Pressure ......................................................................13
3.5.7 Zoom ......................................................................................13
3.5.8 Username..............................................................................14
3.5.9 Run/Hold Format..................................................................15
3.5.10 Language Selection..............................................................17
3.5.11 Button Sound .......................................................................17
3.5.12 CAL Reminder Period .........................................................17
3.5.13 Inactivity Timeout ...............................................................18
3.5.14 Post-Purge Period ................................................................19
3.5.15 Date Format .........................................................................19
4.0 Operation .................................................................................... 20
4.1 Operating Tips ........................................................................ 20
4.2 Analyzer Power ON and Warm Up.........................................21
4.3 Fuel Selection...........................................................................21
4.4 Sampling Point ....................................................................... 22
4.5 Performing a Combustion Test .............................................. 23
4.6 Making a Draft/Pressure Measurement ............................... 25
4.7 Temperature Measurement .................................................... 26
4.8 Saving Test Data .....................................................................27
4.9 Ending a Combustion Test ......................................................27

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Instruction 24-9460
ii
1.0 INTRODUCTION
1.1 The Fyrite®INSIGHT
The Fyrite®INSIGHT is a hand-held residential and commercial grade
portable combustion analyzer that is designed for on-demand sampling of
light industrial combustion equipment, residential furnaces, and appli-
ances.
The Fyrite®INSIGHT is upgradeable from the Basic model to the Record-
ing model which includes additional features such as software compatible
for downloading data and the IrDA printer.
This manual contains information on all models of the Fyrite INSIGHT.
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 is not intended to be used as a safety device.
Except for sensor and battery replacement, this analyzer
should only be opened and serviced by authorized person-
nel.
When testing an appliance, a full visual inspection of the
appliance should be carried out to ensure its safe operation.
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
4.10 Emptying the Water Trap.......................................................27
4.11 Powering OFF the Analyzer & Purging ............................... 28
4.12 Low Battery Alarm................................................................ 28
4.13 Memory................................................................................... 28
4.14 Printing Test Data ................................................................. 30
4.15 Fyrite ®User Software Installation ..................................... 31
4.16 Fyrite®User Software Description....................................... 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 ......................... 37
5.4 Pressure Sensor Calibration ................................................... 37
5.5 T-Stack Calibration.................................................................. 39
5.6 T-Air Calibration ..................................................................... 41
5.7 CO Sensor Calibration............................................................. 43
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 ................................................................. 50
6.8 Error Messages....................................................................... 51
6.9 Diagnostics Screen ................................................................. 52
6.10 Status Screen ......................................................................... 53
7.0 Parts & Service ............................................................................ 54
7.1 Replacement Parts .................................................................. 54
7.2 Accessories .............................................................................. 54
7.3 Service Centers ....................................................................... 55

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DISPLAY ZOOM - 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 the
pump.
KEYPAD 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.
SENSOR ACCESS - Sensor replacement can be accomplished in the field.
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.
1.2 Fyrite®INSIGHT Features & Benefits
AUTOMATIC ZERO - The instrument will automatically zero all sensing
channels on ambient air when it is powered on. If a particular sensor is in
error during warm-up, the instrument will automatically display the error
and continue to operate with the sensor in error. However, all information
dependent on the sensor in error will not be presented.
TEMPERATURE UNITS - Temperatures can be displayed in Centigrade
or Fahrenheit.
PRESSURE UNITS - Pressures can be displayed in milliBar (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.
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 - Calibration can be performed by applying gas and enter-
ing calibration gas concentrations through software menu selections.
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.
CALIBRATION REMINDERS - Calibration reminders can be set for
Never, 6, 8, 10, 12, or 15 months.
DISPLAY FORMAT - The Run/Hold display format can be presented in
default or custom ordered for specific needs. Up to 8 lines can be custom-
ized in the Run/Hold screen.

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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
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 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.
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 %O20 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)

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General Characteristics:
Power Requirements Four disposable ‘AA’ Alkaline batteries (op-
tional AC adapter is available)
Operating Time Minimum of 20 hours continuous operation
(pump running and backlight ON)
Warm Up Time 60 seconds
Memory Up to 100 complete sets of
combustion, temperature, & pressure
tests can be saved in memory.
Display 128 x 64, LCD Graphic Display
Front Panel Controls Eleven front panel push buttons
(Refer to Section 3.4)
Interfaces IrDA printer & USB connectivity
Accuracy:
Oxygen ±0.3% O2with a typical flue gas
concentration of CO2
Carbon Monoxide ±5% of reading or ±10 ppm, whichever is
greater*, in the range of 0 to 1000 ppm.
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)
Ambient/Primary
Temperature ±2 °F between 32 & 212 °F (±1 °C between 0 & 100 °C
Draft ±2% of reading or ±0.02 InWC, whichever is
greater in the range of -10 to +10 InWC
± 3% in the range of -10 to -40 InWC
± 3% in the range of 10 to 40 InWC
* 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.
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 Power
3.2.1 Installing or Replacing 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 upper right corner of the screen. To replace the batteries:
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.
4. Replace battery cover.
3.2.2 Using the AC Power Adapter
The optional AC power adapter is capable of powering the analyzer on a
continuous basis. The adapter plugs into an appropriate 100-240 VAC wall
outlet and produces an output of +5 VDC. The adapter's output connector
plugs into the analyzer's POWER jack located on the bottom of the unit.
The batteries do not need to be removed when using the AC adapter.
3.3 Connecting the Probe Hose & Thermo-
couple
A rigid stainless steel probe with handle is connected to a flexible hose
with integral water-trap / filter used to draw a gas sample into the ana-
lyzer from the room, grilles, diffusers, and furnace flues.

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Inspect the flue-gas hose for cracks. If a hose is defective, replace the en-
tire 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 6.2.
Perform the following steps to connect the probe assembly to the Fyrite
INSIGHT:
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 ambient/primary-air thermocouple into the T-AIR
jack.
Probe
Tube
Water Trap/
Filter Assembly
USB Cable
Primary Ambient
Air Thermocouple
(T-Air) (Optional)
Sample Gas
Hose
Sample Gas
Thermocouple
Connector (T-Stack)
Draft
Hose
Probe
Stop
Probe
Handle
AC Power
Adapter Jack
(Power)
Differential
Pressure Hose
(Optional)
Fyrite®INSIGHT Connectors
Fig. 3.1

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3.5 Setup Mode
The analyzer is preset at the factory for the parameters shown below, but
can be changed as described in their corresponding sections.
Function Parameter To Change
Fuel Natural Gas Section 4.3
Temperature Unit °F Section 3.5.2
Pressure Unit InWC Section 3.5.3
Language English Section 3.5.10
CAL Reminder Never Section 3.5.12
Clock Not Initialized Section 3.5.4
3.5.1 Entering Setup
1. Display the MAIN MENU by pressing the
MENU (F2) button.
2. Use the ▲▼ buttons to highlight SETUP
and press ENTER to display the SETUP
MENU.
3.5.2 Temperature Units
Select to display temperature in either ºF or ºC as follows:
1. Enter the Setup Menu per Section 3.5.1. If necessary, press ESC
until MENU appears above F2.
2. From the SETUP MENU, use the ▲▼ but-
tons to select TEMPERATURE UNITS.
Press ENTER to display the Temperature
Units Menu.
3. Use the ▲▼ buttons to select the desired
temperature unit.
4. Press ENTER to save selection and return
to the SETUP MENU or ESC to revert the
previous setting.
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.
• Powers the analyzer ON and OFF. Hold this button down for
at least 2 seconds to turn the power OFF.
• Toggles the backlight ON and OFF while the analyzer is
turned ON.
• Scrolls up, down, left, and right through the display screen
options.
• Up and Down arrows cause the displayed value to in-
crease or decrease correspondingly.
• Acts as an ENTER button. Performs the action selected.
• While in the HOLD screen, turns the sample pump on, dis-
plays the RUN screen, and begins a combustion test.
• While in the RUN screen, turns the sample pump off, displays the
HOLD screen and the last set of combustion data.
• Displays the HOLD screen while pressing it from most menus.
• Return the display to the HOLD screen while pressing it during the
5 second power down sequence.
• Cancels most operations and displays the previous screen.
• Pressing function keys accepts the corresponding function
defined at the bottom of the display, including PRINT, SAVE,
MENU, differential pressure ZERO, differential temperature
ZERO, PAGE UP, PAGE DOWN and CLEAR data.

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3.5.3 Pressure Units
Select to display pressure in inches of water column (inwc), millibar (mb),
Pascals (Pa), hectoPascals (hPa), or millimeter of water column (mmwc) as
follows:
1. Enter the Setup Menu per Section 3.5.1. If necessary, press ESC
until MENU appears above F2.
2. From the SETUP MENU, use the ▲▼ but-
tons to select PRESSURE UNITS. Press
ENTER to display the Pressure Units Menu.
3. Use the ▲▼ buttons to selecte the desired
pressure unit.
4. Press ENTER to save selection and return
to the SETUP Menu or ESC to revert to the
previous setting.
3.5.4 Clock
The clock settings (12 hr. AM/PM or 24 hr.) and date format options (MM/
DD/YY or DD/MM/YY) are interdependent. (See DATE FORMAT, Section
3.5.15).
1. Enter the Setup Menu per Section 3.5.1. If necessary, press ESC
until MENU appears above F2.
2. From the SETUP MENU, use the▲▼ but-
tons to select CLOCK. Press ENTER to
display the Clock Setup Screen
3. Use the ▲▼ buttons to enter the current
date and time. Use the the ◄► buttons to
move the cursor across the screen.
4. Press ENTER to save the selection and re-
turn to the SETUP MENU or ESC to revert
to the previous setting.
3.5.5 O2Reference
The measured value of CO can be referenced to a specific O2 percentage of
0% to 15%. Set up the reference value as follows:
1. Enter the Setup Menu per Section 3.5.1. If
necessary, press ESC until MENU appears
above F2.
2. From the SETUP MENU, use the ▲▼
buttons to select O2 REFERENCE. Press
ENTER to display the O2 Reference Screen.
3. Use the ▲▼ buttons to enter the O2 refer-
ence value.
4. Press ENTER to save the selection and re-
turn to the SETUP MENU or ESC to revert
to the previous setting.
3.5.6 Print Pressure
Select whether to print or not print the pressure measurement on the com-
bustion test printout as follows:
1. Enter the Setup Menu per Section 3.5.1. If necessary, press ESC
until MENU appears above F2.
2. From the SETUP MENU, use the ▲▼ but-
tons to select PRINT PRESSURE. Press
ENTER to display the O2 Reference Screen.
3. Use the ▲▼ buttons to select YES or NO to
print the pressure measurement.
4. Press ENTER to save the selection and re-
turn to the SETUP MENU or ESC to revert
to the previous setting.
3.5.7 Zoom
Combustion test data in the Run/Hold screen can be shown with enlarged
characters to make viewing easier. The operator can set zoom levels to
Standard, 2X or 3X. The Standard zoom setting will display 4 lines of
combustion test data at one time; 2X will display 3 lines of data with en-
larged characters; 3X will display 2 lines of data with enlarged characters.
The operator can scroll through the complete list of measured and calcu-

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lated data no matter what zoom level has been selected. Select the desired
zoom level as follows:
1. Enter the Setup Menu per Section 3.5.1. If necessary, press ESC
until MENU appears above F2.
2. From the SETUP MENU, use the ▲▼
buttons to select ZOOM. Press ENTER to
display the Zoom Menu.
3. Use the ▲▼ buttons to select the desired
zoom level.
4. Press ENTER to save the selection and dis-
play the SETUP MENU or ESC to revert to
the previous setting.
3.5.8 Username
The name of the user or owner (e.g. company name, address, phone num-
ber) can be stored in memory by manually entering up to three lines of
text, with each line containing up to 20 alphanumeric characters. This
information will appear at the top of each printout, until it is cleared or
new information is entered.
Username Information can be entered as follows:
1. Enter the Setup Menu per Section 3.5.1. If necessary, press ESC
until MENU appears above F2.
2. Use the ▲▼ buttons to select USERNAME.
Press ENTER to display the most recently
saved information.
3. Use the ▲▼ buttons to select the line of in-
formation which you would like to edit and
press ENTER. A single cursor will appear
denoting the character you are changing.
4. Use the ▲▼ buttons to scroll the the list of
alphanumeric characters and the ◄► but-
tons to move across the screen.
5. Press ENTER to save the selection or ESC to
revert to the previous input.
6. Repeat Steps 3-5 to edit the remaining lines.
7. Once the input is complete, use the ▲▼ buttons to select EDIT
COMPLETE.
8. Press ENTER to accept the entered information or ESC to revert to
the previous information and display the SETUP MENU.
Helpful Hint: Use the Fyrite®user software to upload this informa-
tion from your computer.
To Clear a Username proceed as follows:
1. Enter the SETUP MENU per Section 3.5.1. If necessary, press ESC
until MENU appears above F2.
2. Use the ▲▼ buttons to select USERNAME. Press ENTER to dis-
play the most recently saved information.
3. Clear the information by selecting the CLEAR option (F3).
3.5.9 Run/Hold Format
Fyrite INSIGHT test data is located in the Run/Hold screen. By press-
ing the RUN/HOLD key, you should hear the pump running and see the
word RUN at the upper-left hand corner of the display. The instrument
is continuously measuring and calculating the data that is shown in the
Run/Hold screen. Press the RUN/HOLD key again. The pump should stop
running and the word HOLD should be shown at the upper-left hand cor-
ner of the display. The instrument will now show the last measured and
calculated data taken before the instrument was placed in HOLD. Use the
▲▼ buttons to scroll through the complete list of measured and calculated
values when the instrument is running or in the HOLD mode.
The order in which data appears in the RUN/HOLD screen is as follows:
O2 = Oxygen
CO = Carbon Monoxide
Eff = Combustion Efficiency
CO2= Carbon Dioxide
T-STK = Stack Temperature
T-AIR = Ambient/Primary Air Temperature
EA = Excess Air
CO(n) = Carbon Monoxide content referenced to an Oxygen
percentage
NOTE: (n) is the current O2Reference selected.

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Change the order in which data is displayed as follows:
1. Enter the SETUP MENU per Section 3.5.1. If necessary, press ESC
until MENU appears above F2.
2. Use the ▲▼ buttons to select RUN/HOLD
FORMAT. Press ENTER to display the
Run/Hold Format options.
3. Use the ▲▼ buttons to select EDIT FOR-
MAT. Press ENTER to display the current
format.
4. Change data for a particular location by
first using the ▲▼ buttons to select the loca-
tion. Press ENTER and the cursor will start
to flash.
5. Use the ▲▼ buttons to scroll through and
select the desired data to appear in that
location. Press ENTER to save the selection.
6. Change the data displayed at other locations
by repeating steps 4 and 5
7. When finished, use the ▲▼ buttons to select EDIT COMPLETE,
located at the bottom of the list. Press ENTER to save the new dis-
play format and return to the Run/Hold Format options.
Reset Display format back to factory default settings as follows:
1. Enter the SETUP MENU per Section 3.5.1.
If necessary, press ESC until MENU ap-
pears above F2.
2. Use the ▲▼ buttons to select RESET FOR-
MAT. Press ENTER to display the Reset
Format option.
3. Use the ▲▼ buttons to select YES. Press
ENTER to reset the format and return to the
Run/Hold format options.
3.5.10 Language Selection
Information on the display screen can be shown in English, French, or
Spanish.
Select the desired language as follows:
1. Enter the SETUP MENU per Section 3.5.1. If necessary, press ESC
until MENU appears above F2.
2. Use the ▲▼ buttons to select LANGUAGE
SELECTION. Press ENTER to display the
Language Selection Menu.
3. Use the ▲▼ buttons to select the desired
language. Press ENTER to activate the
selection and return to the SETUP MENU.
3.5.11 Button Sound
The audible sound used to signal when a button is pressed can be turned
OFF and ON as follows:
1. Enter the SETUP MENU per Section 3.5.1. If necessary, press ESC
until MENU appears above F2.
2. Use the ▲▼ buttons to select BUTTON
SOUND. Press ENTER to display the Button
Sound Menu.
3. Use the ▲▼ buttons to select YES or NO
button sound.
4. Press ENTER to save the selection and re-
turn to the SETUP MENU or ESC to revert
to the previous setting.
3.5.12 CAL Reminder Period
The analyzer can be set to indicate a calibration reminder during the 60
second warm-up. Calibration reminders can be preset to occur never, 6,
8, 10, 12, or 15 months after the last calibration. When the preset period
is exceeded the instrument will display the reminder, and how long since
the sensors were last calibrated. If a calibration reminder is displayed the
operator can press the RUN/HOLD key to move to the Run/Hold Screen for
normal operation. Regular calibration periods of 6 months to 1 year are
recommended.

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18
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NOTE: The default CAL Reminder period is set to NEVER.
Set the calibration reminder period as follows:
1. Enter the SETUP MENU per Section 3.5.1. If necessary, press ESC
until MENU appears above F2.
2. Use the ▲▼ buttons to select CAL RE-
MINDER PERIOD. Press ENTER to dis-
play the Cal Reminder Period Menu.
3. Use the ▲▼ buttons to select the desired
time period.
4. Press ENTER to save selection and return to
the SETUP MENU or ESC to revert to the
previous setting.
NOTE: The date and time settings must be correct to get ac-
curate cal reminders.
3.5.13 Inactivity Timeout
The analyzer can be placed in an inactivity timeout period of None, 30 or
60 minutes. With this time period set the analyzer will automatically shut
off if there have been no button pushes made in the set period of time. The
analyzer will not turn off if the CO value is greater than 50 ppm or the O2
value is less than 16%.
NOTE: The default set time is NONE which will not allow the ana-
lyzer to automatically turn off.
Set the Inactivity Timeout Period as follows:
1. Enter the SETUP MENU per Section 3.5.1. If necessary, press ESC
until MENU appears above F2.
2. Use the ▲▼ buttons to select INACTIVITY
TIMEOUT. Press ENTER to display the
Inactivity Timeout Menu.
3. Use the ▲▼ buttons to select the desired
timeout period.
4. Press ENTER to save the selection and re-
turn to the SETUP MENU or ESC to revert
to the previous setting.
3.5.14 Post-Purge Period
The analyzer can be setup to purge the sensors following the combustion
test. It can be programmed to purge for None, 5 seconds, 1, 5, or 10 min-
utes.
Set the Post-Purge Period as follows:
1. Enter the SETUP MENU per Section 3.5.1.
If necessary, press ESC until MENU ap-
pears above F2.
2. Use the ▲▼ buttons to select POST-PURGE
PERIOD. Press ENTER to display the Post-
Purge Period Menu.
3. Use the ▲▼ buttons to select the desired
time period.
4. Press ENTER to save the selection and re-
turn to the SETUP MENU or ESC to revert
to the previous setting.
3.5.15 Date Format
The date format options and the clock settings are interdependent.
MM/DD/YY format - Used with a 12 hour time clock. This set up menu
includes an AM/PM option.
DD/MM/YY format - Used with a 24 hour time clock.
Change the date format as follows:
1. Enter the SETUP MENU per Section 3.5.1.
If necessary, press ESC until MENU ap-
pears above F2.
2. Use the ▲▼ buttons to select DATE FOR-
MAT. Press ENTER to display the Date
Format Menu.
3. Use the ▲▼ buttons to select the desired
date format.
4. Press ENTER to save the selection and re-
turn to the SETUP MENU or ESC to revert
to the previous setting.

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20
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4.0 OPERATION
4.1 Operating Tips
When an analyzer is brought in from a cold vehicle, let it warm up
slowly to minimize condensation. Temperatures below freezing will
not damage the analyzer; however, bringing a cold analyzer into a
warm, humid environment may cause condensate to form inside the
case.
Caution: Although the analyzer itself is not damaged by an ex-
tremely cold environment, the electrochemical sensors may be
damaged. The O2 sensor's electrolyte will freeze at approximately
-20 °F and the CO sensor's at approximately -90 °F. If the analyzer
is exposed to an extremely cold condition, it is strongly suggested
that the sensor housings be examined for hairline cracks. Be aware
that a leaking sensor can cause chemical burns to the skin and
possibly damage the PCB assemblies.
Ensure that the analyzer is sampling fresh air when turned ON. Pulling
a stack-gas sample through the analyzer during its warm-up period will
not damage the analyzer, but it will result in incorrect sensor readings,
and may result in sensor error messages appearing after the warm-up
cycle completes.
Note that f lue-gas condensate is acidic and very corrosive. It is important
not to allow the analyzer's internal components to come in contact with
condensate for long periods of time.
Before each use, inspect the filter element of the water-trap / filter as-
sembly. Replace the filter if it looks dirty.
When sampling flue-gas, keep the analyzer above the water-trap, and keep
the trap in a vertical position. This will maximize the effectiveness of the
trap and keep liquid from being drawn directly into the analyzer.
When liquid condensate is seen inside the water trap, empty the trap
before it becomes full.
When storing the analyzer, it's a good idea to empty the water trap and
leave it open to further dry it out.
Calibrate the analyzer every 6 months - 1 year to assure its accuracy.
•
•
•
•
•
•
•
•
4.2 Analyzer Power On & Warm Up
1. Connect the probe and make sure that the analyzer is properly set
up per Section 3.
IMPORTANT! DO NOT insert probe into stack before powering ON
the analyzer.
2. Place the probe in an area that contains fresh air. This ensures
that the sensors will be properly zeroed during the warm-up cycle.
3. Power ON the analyzer by pressing the
PWR button for at least 1 second, or until
a single beep is heard. Observe that the
analyzer's firmware version, model and se-
rial numbers are briefly displayed followed
by the Warm Up screen.
4. Wait for the analyzer to count down its 60
second warm-up period; after which, the in-
strument will display the Combustion Test
HOLD screen.
If, however, any errors were detected during
warm-up, the message "ERRORS DETECT-
ED" is displayed along with a list of those
errors. In this example, the O2 sensor is
missing and the T-Stack thermocouple is not
connected. Refer to Section 6.8 for a listing
and possible remedy for the errors displayed.
4.3 Fuel Selection
The top line of Combustion Test HOLD screen shows the fuel currently
selected. If necessary, change the fuel as follows:
1. Display the MAIN MENU by pressing the
MENU (F2) button. If necessary, press ESC
until MENU appears above F2
2. Use the ▲▼ buttons to select FUEL. Press
ENTER to display the Fuel Selection screen.
3. Use the ▲▼ buttons to select the desired fuel.
24-8250
V1.00

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22
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4. Press ENTER to save the selection and re-
turn to the Combustion Test HOLD screen
or ESC to revert to the previous setting and
return to the MAIN MENU.
4.4 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 flue 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 fire tube below the diverter.
80% Efficiency 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 approximately 12 inches above the inducer fan.
90% Efficiency 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.
After testing, the hole should be sealed with high temperature silicon.
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.
NOTE: All drill holes should be sealed upon completion of combus-
tion testing.
4.5 Performing a Combustion Test
Ensure that the following has been completed, and then proceed with the
combustion test as described below:
• Power ON analyzer and allow it to warm up (Section 4.2).
• Select fuel being burned (Section 4.3).
• Inset probe into proper sample location (Section 4.4).
• If necessary, insert optional primary air thermocouple into combustion-
air stream of burners that use an outside source of combustion air.
1. Press the RUN/HOLD button to start the test. You should hear the
pump start running and see the word RUN appear at the top of the
Combustion Test screen.
Sensor Indicators: The following indicators appear in the sensor's data
field depending on certain conditions:
(
∗ ∗ ∗) Sensor that is not calibrated or installed.
(XXX) Sensor overrange
( - - - ) The calculated data cannot be displayed because the measured
data necessary to make the calculation is out of range (i.e., oxygen level
above 16%).
2. Use the up and down arrow keys to scroll to the T-STK reading.
Loosen the thumbscrew on probe stop and move probe in and out of
the stack until the stack’s core temperature (hot spot) is located as
indicated by the highest T-STK reading; then tighten thumbscrew to
prevent further probe movement. Locating the highest stack tempera-
ture is very important for accurate efficiency calculations.
3. You can now begin burner-service procedures. The analyzer readings
will change quickly to show changes in burner performance.
CAUTION: Position the Water Trap with its gas-flow
arrow pointing upward. Do not let water condensate go above
the tip of the riser tube. The sensors could be damaged if water
would enter the analyzer. Empty the Water Trap after every
combustion test (refer to Section 4.10)
4. Pressing the RUN/HOLD button freezes all readings, stops the pump and
displays the Combustion-Test HOLD screen. Use the ▲▼ buttons to view
all test values at the moment the RUN/HOLD button was pressed. Press-
ing RUN/HOLD again restarts the pump and resumes testing.
Display Name Description of Measurement or Calculation
O2% Oxygen
CO ppm Carbon Monoxide
Eff % Combustion Efficiency
CO2% Carbon Dioxide
T-STK Stack Temperature
T-AIR Primary/Ambient Air Temperature
EA % Excess Air
CO(O) Carbon Monoxide ppm level referenced to a % of oxygen

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Instruction 24-9460 25
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4.6 Making a Draft / Pressure Measurement
The difference in pressure (ΔP) between two areas can be measured by
using the analyzer's two pressure ports and the PRESSURE screen. By
using the -ΔP port as the reference, the pressure applied to the +ΔP port
will be displayed on the PRESSURE screen as the differential pressure
between the two ports. Perform a draft / pressure measurement as follows:
1. Turn ON the analyzer and allow it to complete its warm-up cycle.
2. Display the MAIN MENU by pressing the MENU (F2) button. If
necessary, press ESC until MENU appears
above F2.
3. Use the ▲▼ buttons to select PRESSURE.
Press ENTER to display the Pressure
screen.
4. Before taking a measurement, the pressure
sensor may need to be re-zeroed if it is not
already displaying zero with both pressure
ports open to the atmosphere. If necessary,
zero the pressure sensor as follows:
Press the ZERO (F2) button.
Disconnect any hoses connected to the
+ΔP and -ΔP ports, and then press EN-
TER to zero the pressure sensor.
Reconnect any hoses. When measuring
draft, leave the -ΔP port open to the at-
mosphere and connect the probe's draft
hose to the +ΔP port.
5. Do one of the following to measure draft or
differential pressure:
To measure draft, insert the probe into
the stack and observe the draft reading
on the PRESSURE screen.
To measure differential pressure, con-
nect two sampling hoses to the +ΔP
and -ΔP ports, and place the open end
of each hose into the areas being mea-
•
•
•
•
•
F1 F2 F3
Atmospheric Burner
or Gravity Vented
Forced Air
80% Eff. Fan Assist
or Power Vented
Furnace/Boiler
90% Eff. Condensing
Furnace/Boiler
Atmospheric or
Gravity Vented
Boiler
Hot Water Tank
Undiluted Flue
Gas Sample Taken
Under Draft
Diverter in Top
of Fire Tube
Fig. 4.1

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26
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Instruction 24-9460 27
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sured. The differential pressure between the two areas is now
displayed on the PRESSURE screen. If the pressure at the +ΔP
port is higher than the -ΔP port, the pressure reading will be
positive. If it is lower, the reading will be negative.
4.7 Temperature Measurement
The difference in temperature between two areas can be measured by us-
ing the analyzer's two temperature channels and the Temperature Screen.
By using the T-Air channel as a reference, the temperature applied to
the T-Stack channel will be displayed on the Temperature Measurement
screen as differential temperature between the two channels.
Perform a differential temperature measurement as follows:
1. Display the MAIN MENU by pressing the MENU (F2) button. If
necessary, press ESC until MENU appears above F2.
2. Use the ▲▼ buttons to select TEMPERA-
TURE. Press ENTER to display the Tem-
perature Measurement screen.
3. Install thermocouples in both temperature
channel connectors.
4. Before taking a measurement, the tempera-
ture channels may need to be zeroed, if not
already displaying zero with both ther-
mocouples exposed to the same condition.
Press ZERO (F2) if necessary.
4.8 Saving Test Data
Up to 100 sets ("snap shots") of combustion test, pressure, or temperature
data can be saved in memory, which can later be recalled for viewing from
the Memory Directory.
1. First display the screen that contains the
data to be saved. In the example to the
right, all data associated with the Combus-
tion Test RUN screen will be saved.
2. Press the SAVE (F3) button to save the test
data in the next available memory location.
NOTE: When memory is full, the next read-
ing will not be saved until space is
made available by clearing previ-
ously saved data. (Section 4.13)
4.9 Ending a Combustion Test
WARNING! Burn Hazard. Do not touch the probe af-
ter removing it from the stack. Allow the probe to cool before
handling (about 5 minutes).
1. Remove probe from the flue-gas stream.
2. Allow the pump to run until all combustion gases are flushed from
the analyzer as indicated by the O2reading returning to 20.9%.
4.10 Emptying the Water Trap
The Water Trap / Filter Assembly removes stack-gas condensate, and also
prevents soot from contaminating the internal components of the analyzer.
IMPORTANT! Use the Water Trap / Filter Assembly in a vertical posi-
tion with the gas-flow arrow pointing up.
Empty the water trap chamber after each combustion test, or stop the test
and empty the chamber if the liquid condensate level approaches the tip of
the riser tube.
To empty the trap, first pull apart the two halves of the Water Trap using
a slight twisting motion; empty the water trap chamber, and then reas-
semble the trap.
After each combustion test, also check the Water Trap's filter element. If it
looks dirty, replace the filter per Section 6.2.
.1

Instruction 24-9460
28
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4.11 Powering OFF the Analyzer & Purging
Power OFF the analyzer by pressing the PWR button
for at least 2 seconds, or until two beeps are heard. The
unit will count down 5 seconds before shutting down,
giving the operator an opportunity to keep the analyzer
powered ON by pressing the RUN/HOLD button.
If the analyzer was not purged with fresh air then the analyzer may remain
ON with its pump running and display the message "PURGING SENSORS"
as the result of combustion gases still being present inside the analyzer. At
this time the operator should ensure that the probe is removed from the stack,
allowing the analyzer to purge itself with fresh air. The 5-second-shutdown
sequence will not begin until the gas levels inside the analyzer drop below
predeterminded levels.
TIP: Although not recommended, the purging process can be bypassed
by pressing the PWR button a second time.
4.12 Low Battery Alarm
When the batteries are nearly depleted, an empty battery icon appears in
the upper-right corner of the display, and a short beep is sounded every 10
seconds.
After a low battery alarm occurs, the analyzer will continue to operate for
only a few minutes. The amount of operating time that remains depends
on many factors (e.g. pump and backlight being ON or OFF and the type
and condition of the batteries).
4.13 Memory
All saved data can be retrieved for viewing through the MEMORY option.
To open and view saved test data:
1. Display the MAIN MENU by pressing the MENU (F2) button. If
necessary, press ESC until MENU appears above F2.
2. Use the ▲▼ buttons to select MEMORY.
Press ENTER to display the MEMORY
MENU.
3. Use the ▲▼ buttons to select Memory Direc-
tory. Press ENTER to display the saved data
contained in the Memory Directory.
TIP: When displaying the contents of the
memory directory, the operator can quickly
page through the screens by pressing the
PAGE– (F1) and PAGE+ (F3) buttons. Or
move to the first or last memory location by
pressing the buttons, respectively.
To Clear Test Data:
1. Display the MAIN MENU by pressing the
MENU (F2) button. If necessary, press ESC
until MENU appears above F2.
2. Use the ▲▼ buttons to select MEMORY.
Press ENTER to display the Memory Screen.
3. Use the ▲▼ buttons to select CLEAR
MEMORY. Press ENTER to display the
Clear Memory Options.
4. Use the ▲▼ buttons to select YES and press
ENTER. The screen will briefly display a
confirmation that the memory has been
cleared.

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Instruction 24-9460 31
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4.14 Printing Test Data
Combustion, pressure, or temperature data that is currently being dis-
played can be sent to a printer using IrDA protocol as described below.
Data that is stored in memory can also be printed by first displaying the
stored test data as described in Section 4.13.
In addition to printing combustion, pressure, and temperature data, the
contents of any screen that shows the label “PRINT” above the F1 button
can be printed. For example, the information shown in the DIAGNOSTIC
screen can be printed.
1. Power up the printer.
Refer to the printer’s
instruction manual for
detailed operating infor-
mation. If not previously
done, select the follow-
ing for the printer for:
• 8 bit
• No parity
• 9600 baud
• IrDA is set to
IrDA-SIR
• DTR
handshaking
2. Align the printer with
the top of the analyzer.
3. Press the PRINT (F1)
button to begin print-
ing.
4.15 Fyrite®User Software Installation
Windows XP Operating System
After the CD is loaded, the Setup window will be displayed. Click on OK.
(If applicable, wait for the Net 3.5 Framework set up to complete.)
Click "Next" on the “Welcome” screen to begin the installation.
Respond to the prompts on the screens that follow.
Click on: “Finish”...
“Next”...
“Close”...
“OK”...
After the installation,
• Open Fyrite®User Software via the desktop icon.
• Connect the instrument to the PC with a USB cable and power up the
unit.
F1 F2 F3
ESC
RUN
HOLD
PWR
BACHARACH, INC.
Fyrite Insight
SN: ENGR-CM03
Time: 01:28:27 PM
Date: 10/22/08
Fuel
Nat Gas
O
24.0 %
CO 12 ppm
Eff 82.6 %
CO2 9.5 %
T-STK 374 oF
T-AIR 68.0 oF
EA 21.3 %
CO (3) 13 ppm
Comments:
Fig. 4.2

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32
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Instruction 24-9460 33
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When first connected, a “Found New Hardware Wizard” screen will be
displayed. Again, respond to the prompts to completion.
Click on: "Next"...
"Continue anyway"...
"Finish"
Windows Vista Operating System
After loading the CD, the Security window will be displayed. Click on OK.
(If applicable, wait for the Net 3.5 Framework set up to complete.)
Click on: "Continue"...
"Next"...
"Install"...
"Install... software anyway"
Click on: “Finish”...
“Next”...
“Next”...
“Next”
The installation will progress...
Click on: "Continue..."
"OK"
"Close"...

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5.0 CALIBRATION & MAINTENANCE
IMPORTANT: Before performing any calibration procedure,
ensure that fresh batteries are installed or use the optional
AC power adapter. Also, ensure that the analyzer is at room
temperature and will be sampling fresh air when powered
ON.
IMPORTANT: To maintain accuracy as listed in the Techni-
cal Characteristics Section of this manual, the standards
used must be at least four times as accurate as the stated
accuracy of the Fyrite®INSIGHT.
5.1 B-Smart Sensors
The Fyrite®INSIGHT utilizes Bacharach’s new B-Smart Sensor tech-
nology for its CO sensor. The B-Smart sensor is marked with a 10-digit
calibration code that can be entered in the instrument's memory via the
keypad, or with Fyrite user software.
Benefits of B-Smart Sensors:
New sensors can be installed without applying gas for calibration.
Sensors can be pre-calibrated and installed when needed.
Sensors can be moved from one analyzer to another.
The B-Smart sensors should be calibrated by an authorized Bacharach
Service Center every 6 months to 1 year to assure that the analyzer contin-
ues to meet its published accuracy specifications. The B-Smart sensors,
however, can be calibrated in the field if your facility has the necessary
equipment and qualified personnel to perform the procedures described in
the following sections of this instruction manual.
5.2 Starting a Calibration
Start any calibration by performing the following:
1. With the analyzer power OFF, place the unit in fresh, ambient air;
then power on the analyzer.
•
•
•
After the installation,
• Open Fyrite®User Software via the desktop icon.
• Connect the instrument to the PC with a USB cable.
• Power up the unit.
• When first connected, a “Found New Hardware Wizard” screen will be
displayed.
Click on: "Next..."
"Next..."
"Continue anyway"
"Finish"
4.16 Fyrite®User Software Description
Fyrite®INSIGHT User Software
Set instrument time Sync instrument with computer's time
Calibration password Change 4 digit numeric code
Time meters Provides instrument & pump run time
B-Smart B-Smart calibration code entry
Saved measurements Downloads instrument memory to Excel
User/Customer ID User ID entry
Settings Change instrument set up parameter
Customer logo set up Load custom logos for print out. Limited to 384 x 192.
Custom fuel Bacharach can supply fuel codes for custom fuel. Consult
factory.
Update instrument software Remote upgrade of instrument software.