www.actoolsupply.com Combustion Gas Analyzer Configuration and Operation Manual Instruction 0024-9486 Revision 0 August 15, 2012 Fyrite Intech 0024-8510 Combustion Analyzer with O2 Sensor Fyrite Intech 0024-8511 Combustion Analyzer with O2 and CO Sensor Fyrite Intech 0024-8512 Combustion Analyzer Reporting Kit O2 CO Fyrite Intech 0024-8523 Combustion Analyzer with O2 and CO Sensor Product Leadership • Training • Service • Reliability www.actoolsupply.
www.actoolsupply.com WARRANTY POLICY 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.
www.actoolsupply.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.
www.actoolsupply.com Table of Contents Section 1. Overview .................................................................................... 1 1.1. Introduction ............................................................................................ 1 1.2. Conventions............................................................................................. 1 1.3. Safety ....................................................................................................... 1 1.4.
www.actoolsupply.com Section 5. Calibration and Maintenance .................................................. 47 5.1. 5.2. 5.3. 5.4. Serviceability ......................................................................................... 47 Cleaning the Probe ................................................................................ 47 Water Trap and Filter Replacement ...................................................... 49 O2 and/or CO Sensor Replacement ........................................
www.actoolsupply.com Section 1. Overview 1.1. Introduction Thank you for investing in a Bacharach Fyrite InTech combustion analyzer. To assure proper use and operator safety, please read the contents of this manual for important information on the operation and maintenance of the analyzer. 1.2. Conventions WARNING: A warning statement denotes a potential hazard associated with the use of this equipment. Failure to follow this information could result in serious personal injury or death.
www.actoolsupply.com CAUTION: Do not store instrument or its sensors with solvents or products that contain solvents. CAUTION: Except for sensor and battery replacement, this analyzer should only be opened and/or serviced by authorized Bacharach personnel. Failure to comply may void the warranty. HAZARDOUS AREA WARNING: This instrument has not been designed to be intrinsically safe for use in areas classified as hazardous locations. For your safety, DO NOT use it in hazardous (classified) locations.
www.actoolsupply.com 1.4. Product Overview The Fyrite InTech is a portable hand-held combustion analyzer for use in residential and light commercial applications. It is intended to be used by: • • • • HVAC contractors home inspectors maintenance personnel energy auditors to conduct combustion efficiency analysis on residential and light commercial furnaces and appliances in the worldwide market.
www.actoolsupply.com Feature Countries North American (NA) versus Siegert (S) Configurations Typical North American (NA) Users Asia Australia Latin America North America South America Typical Siegert (S) Users Belgium Denmark France Germany Italy Netherlands Poland Spain United Kingdom Heating Values For combustion calculations, Siegert uses the fuel’s lower heating value; NA uses the higher value. Fuels Different fuel sets and composition (p 19) Different RUN Parameters EFF (NA) vs.
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www.actoolsupply.com 1.8. Combustion Test Process Overview FUNCTION PAGES Connect Probe ...................................................... 13 Turn On Instrument ................................... 14, 15, 16 Verify Power ......................................................... 15 Zero Instrument (Auto/Manual) ................ 17, 30, 55 Use Menu System ................................................. 17 Set System Parameters ....................................
www.actoolsupply.com NOTE: The North American (NA) configuration of Fyrite InTech computes and displays the calculations as long as the measured oxygen is not above 16% O2 and the stack temperature is not above 650° C (1200° F). The Siegert configuration of the Fyrite InTech computes and displays the calculations as long as the measured oxygen is not above 18.8% O2 and the stack temperature is not above 650° C (1200° F). 1.9.
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www.actoolsupply.com 1.10. Specifications Specification Description Temperature Storage: -20° to 50° C ( -4° to 122° F) 0° to 20° C (32° to 68° F ) optimal Operation: -5° to 45° C (23° to 113° F) Reference: 20° ± 2° C (68° ± 4° F) Humidity Storage: Operation: Reference: 15 to 90% RH, non-condensing 15 to 95% RH, non-condensing 45 ± 10% RH, non-condensing Pressure 1 atmosphere ± 10% Weight 16 ounces (454 g) with batteries Dimensions 8.0” x 3.6” x 2.3” (20.3 cm x 9.1 cm x 5.
www.actoolsupply.com Specification Description Type: Disposable Alkaline (Included) Duration: 15 hours min, continuous max draw Power Supply Options Batteries (4 AA) Type: Disposable Lithium Duration: 20 hours, continuous max draw Type: Rechargeable Duration: 8 hours, continuous max draw Measure -ment Range Resolution O2 0 to 20.9 % 0.1% O2 CO 0 to 2000 ppm Stack Temp -20° to 650° C (-4° to 1202° F) Response Time (T90) Accuracy ±0.
www.actoolsupply.com Section 2. Setup 2.1. Connecting the Probe and Thermocouple A rigid stainless steel probe with handle is connected to a flexible hose with an integral water-trap/filter used to draw a gas sample into the analyzer from the room, grilles, diffusers, and furnace flues. 1. 2. 3. 4. Inspect the flue-gas hose for cracks. If a hose is defective, replace the entire probe assembly. Before using the analyzer, check that the water trap/filter is clean and dry.
www.actoolsupply.com 2.2. Front Panel Buttons Button Description • • • • • • • 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. UP (), DOWN (), LEFT (), and RIGHT () arrows are context-specific navigation buttons for the menus. UP () and DOWN () arrow buttons scroll to menu options that are hidden from view (when a side scroll bar is displayed indicating additional information).
www.actoolsupply.com 2.3. Power Options You use the PWR button to turn on the Fyrite InTech. Power options include: • Disposable AA alkaline batteries (included) • Disposable AA lithium (Li) batteries • Externally charged rechargeable NiMH batteries. Check the Fyrite InTech for sufficient power prior to each use. Replace the batteries if the low (or replace) battery symbol appears in the upper right corner of the Fyrite InTech screen.
www.actoolsupply.com NOTE: A Set Clock error message will be displayed if the instrument is without power for an extended period of time. 2.4. Turning On the Fyrite InTech To turn on the Fyrite InTech, press the PWR button. NOTE: After turning on the Fyrite InTech, it performs a warmup procedure which includes an auto-zero procedure for the sensors (see pages 17 and 30). For this reason, be sure to turn on the Fyrite InTech in a clean air environment. ∇ ∇ ∇ www.actoolsupply.
www.actoolsupply.com Section 3. Configuration 3.1. Menu Structure Overview NOTE: The Fyrite InTech may be configured to use either North American combustion equations or Siegert combustion equations (see page 30). As a result, several parameters are unique to each configuration. This section shows a mix of screens that have been configured for North American combustion equations as well as Siegert combustion equations.
www.actoolsupply.com Display the Main Menu by pressing the F2 key. Main Menu Function Access the Select Fuel Menu (see page 19) • Select combustion fuel Access the Memory Options Menu (see page 20). • • Access previously saved combustion results Delete all previously saved combustion results Access the Setup Menu (see page 22).
www.actoolsupply.com 3.4. Select Fuel Menu Select Fuel Function Select the combustion fuel from the fuel list. Use the UP () and DOWN () arrow keys to highlight the desired fuel and use the ENTER key to select. NA Fuel List Siegert Fuel List Natural Gas Natural Gas Oil 2 KOKS Oil 6 LEG Propane Propane Kerosene Oil 2 B5 Oil 6 Coal Biofuel LPG Butane www.actoolsupply.
www.actoolsupply.com 3.5. Memory Options Menu Memory Options Function Access the Memory Directory. This directory contains a numbered list of saved combustion tests (starting at “1”). “NO DATA” is displayed if no tests were saved since the last time that memory was cleared. To view saved data, use the UP () and DOWN () arrow keys to highlight the desired test from the list. Press the ENTER button to display the saved data. Prompts user before clearing all saved combustion tests from memory.
www.actoolsupply.com Memory Options Function The average is calculated, displayed, and available for printing (left). If fewer than 3 samples exist, the average is not calculated (right). www.actoolsupply.
www.actoolsupply.com 3.6. Setup Menu Setup Menu Function Access Temperature Units (°C or °F) to be used by the instrument and for display and printing purposes. Use the UP () and DOWN () arrows buttons to highlight the desired choice. Press the ENTER button to use the selected temperature unit. Press ESC to quit without saving. Smoke Number (Siegert only) is used to calculate and display an average smoke value based on 3 smoke test results that are entered by the user.
www.actoolsupply.com Setup Menu Function WARNING: DO NOT use the Fyrite InTech to sample gas from an oil-based combustion system without first doing a smoke test and adjusting your combustion process as needed. Smoke test results of greater than 1 indicate improper combustion, and demonstrate the need for process adjustment. Only use the Fyrite InTech to sample flue gas AFTER the combustion process is adjusted and the smoke test indicates a smoke level of 0 or 1.
www.actoolsupply.com Setup Menu Function A boiler temperature (Siegert only) can be recorded manually. Enter the boiler temperature as measured by an external thermocouple. Use the LEFT () and RIGHT () arrow buttons to change position. Use the UP () and DOWN () arrow buttons to scroll through numerals 0-9 for the selected position. Press ENTER when finished. Select Position Change Value The Clock option provides access to the clock setup function to set date and time.
www.actoolsupply.com Setup Menu Function NOTE: The presence of AM or PM after the time on the Set Clock display indicates 12-hour time format and MM/DD/YY date format. (This also indicates that the instrument must be in the North American configuration.) Similarly, the absence of AM or PM indicates 24-hour time format and the date is in DD/MM/YY format (either by default if Siegert configuration, or by choice through the Date Format parameter if North American configuration).
www.actoolsupply.com Setup Menu Function Provides an interface for entering user identification Generally, the information used on printouts. Username fields contain the HVAC company and related information. NOTE: This data can be entered using the Fyrite User Software (FUS). Use the UP () and DOWN () arrow buttons to choose a row and press ENTER to begin editing the selected row.
www.actoolsupply.com Setup Menu Function The Language Selection option allows the user to choose a language for all menus. Use the UP () and DOWN () arrow buttons to scroll through language options (varies based on instrument model). Use ENTER to enable the selected language. NOTE: The number of available languages may differ based on the combustion equation setting.
www.actoolsupply.com Setup Menu Function Provides a list from which to select an inactivity (key press) timeout for automatic shutdown. If no key presses occur for the time specified, the Fyrite InTech initiates an automatic shutdown. Use the UP () and DOWN () arrow buttons to scroll through Inactivity Timeout options (never [default], 20, 30, or 60 minutes). Use the ENTER key to enable the selected timeout.
www.actoolsupply.com Setup Menu Function Date format (North American Configuration only) Provides a list from which the user may select the desired date format used by the instrument: • • MM/DD/YY (default for NA configurations) DD/MM/YY (standard for Siegert) NOTE: The DD/MM/YY date format is the only format available in instruments configured with Siegert combustion This parameter is only equations. available in North American configurations.
www.actoolsupply.com Setup Menu Function Provides a list from which the user may select the desired method for zeroing the CO sensor. Auto-Zero happens automatically at warmup. Manual zero is used to initiate the zeroing process whenever desired. Use the UP () and DOWN () arrow buttons to highlight the desired zeroing method. Press ENTER to save. Press ESC to quit without saving.
www.actoolsupply.com Setup Menu Function IMPORTANT: Changing this setting resets several configuration parameters to their default values. Below is a list of affected parameters, and those unaffected. Reset to Default Values Unchanged Temperature units Manual/Auto zero O2 (Oxygen) reference Calibration data Fuel User name Memory erased Clock www.actoolsupply.
www.actoolsupply.com 3.7. Calibration Menu Calibration Menu Function Calibration is performed by applying known values and accessing the password-protected menu items. When the Calibration Menu is selected, the user must enter a 4-digit numeric security code in order to proceed to the calibration options. The default password is 1111. Use the UP () and DOWN () arrow buttons to scroll through numerals 0-9 until the desired numeral is reached. Press ENTER to advance to the next position of the password.
www.actoolsupply.com 3.8. Diagnostics Menu Diagnostics Menu Function Displays time metrics for pump use and total operation time. Displays information about the measurement sensors of the instrument. Displays the estimated oxygen (O2) sensor life based on: • the sensor’s 3-digit date code that you enter (from the label on the sensor) • the current date that you set • the typical O2 sensor life of approximately 24 months.
www.actoolsupply.com Diagnostics Menu Function • • • Note the 3-digit date code on the new sensor Replace the O2 sensor Press F3 to change and verify sensor date code. Resetting the Sensor Date Code Use the LEFT () and RIGHT () arrow buttons to move the cursor horizontally to select between the 2-digit month code (00-12) and the one digit year code (0-9 corresponding to the last digit of the manufacture year) that make up the 3-digit date code.
www.actoolsupply.com Diagnostics Menu Function NOTE: If either of the entered values is incorrect, the status of your O2 sensor life will not be accurate. Actual sensor life may vary. Displays fresh air diagnostics similar to the display at warmup. After the warmup countdown, any detected errors are displayed. Otherwise, a “Success” message is displayed. 3.9. Status Menu Status Menu Function This is the device status screen which displays information about the device.
www.actoolsupply.com Section 4. Operation 4.1.
www.actoolsupply.com Example Forced Air Furnace Example Hot Water Tank For 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 exchanger. 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.
www.actoolsupply.com Example 90% Efficiency Condensing Furnace Condensing furnaces/ boilers can be tested through a hole drilled in the plastic vent pipe (when allowed by the manufacturer or local authority of jurisdiction) or taken from the exhaust termination.
www.actoolsupply.com 4.3. Combustion Testing Process WARNING: The Fyrite InTech calculates combustion parameters based on North American or Siegert combustion equations. NA or Siegert configuration is selected in the SETUP MENU. Be sure that your Fyrite InTech is properly configured for your region and desired combustion calculations. NOTE: The recommended time required to achieve a stable measurement is a minimum of 3 minutes.
www.actoolsupply.com Step Example Combustion Testing Procedure 11 Turn on the instrument to optionally print and/or evaluate saved test results (based on your local codes and practices for combustion data and CO levels). 12 To turn off the Fyrite InTech, press and hold the POWER button until you see the Shutdown timer. Wait for the purge function to complete (you will hear the pump stop and the display will shut off).
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www.actoolsupply.com Combustion Equations are shown below. Fyrite InTech provides three lines of 20 characters for user information. This information will appear with test records when they are printed. User name and optional information are entered via software menu selections in the SETUP MENU or via the Fyrite User Software (FUS). www.actoolsupply.
www.actoolsupply.com IR Communications Settings: Baud Rate: Data Bits: Stop Bits: Parity: Protocol: Distance: Angle: 9600 8 1 None IRDA-SIR 8-16 in (20-41 cm) 60° maximum www.actoolsupply.
www.actoolsupply.com Fyrite InTech can be setup to include a custom logo on printouts. Logos are loaded into the instrument using the Fyrite User Software (FUS). Logo size is limited to 192 x 384 pixels (height x width) and must be in one of the following formats. • • • • .BMP .JPG .PNG .TIFF For best results, the logo should be saved in black and white. 4.6.
www.actoolsupply.com Section 5. Calibration and Maintenance 5.1. Serviceability The instrument operator is able to easily replace the following components without the use of tools: • • • • probe assembly probe filters batteries printer paper. Additionally, a technician, with the use of readily available hand tools and factory-provided instructions, can: • • • perform basic diagnostics replace sensors confirm proper operation before putting the unit back into service.
www.actoolsupply.com 5.2.1. Equipment Required • • • • Alcohol Aerosol Can of Automotive Carburetor Cleaner Clean Rag Source of Compressed Air (optional) CAUTION: Do not use flammable or combustible substances (like carburetor fluid used for cleaning the probe) near an open flame. 5.2.2. Procedure Step 1 Cleaning the Probe Remove gas sample hose from the top of the water trap. CAUTION: Carburetor cleaner damages plastic components. Take precautions not to spray cleaner onto the probe handle or analyzer.
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www.actoolsupply.com 5.4. O2 and/or CO Sensor Replacement NOTE: The O2 sensor life is approximately 2 years. The CO sensor life is greater than 3 years. 5.4.1. Accessing the Sensors 5.4.2. Material Required (As Needed) • • O2 Sensor (P/N 0024-0788) CO Sensor (P/N 0024-7265) or B-Smart sensor (P/N 0024-1467). www.actoolsupply.
www.actoolsupply.com 5.4.3. O2 Sensor Replacement Procedure Follow the procedure below for O2 sensors. Step O2 Sensor Replacement 1 Remove battery door and connector tubing from both sensors. 2 Pull O2 sensor from its socket. 3 Remove the O2 cap. 4 Properly dispose of the old sensor. 5 Engage the nub on the new sensor within the slot on the cap's side and twist to secure the cap and sensor together.
www.actoolsupply.com Step CO Sensor Replacement Procedure below, then twisting the cap clockwise approximately 40° to the "closed" position (2 o’clock). 7 Reattach tubing. 8 Calibrate the CO sensor using either the standard calibration procedure or the B-SMART procedure 5.4.5. B-SMART CO Sensor Replacement Step B-SMART CO Sensor Replacement 1 Enter the CALIBRATION MENU. Note that this requires password validation (see page 32). 2 Use the UP () and DOWN () arrow buttons to select B-Smart.
www.actoolsupply.com NOTE: Bacharach offers a convenient Exchange Program (where available) that allows the customer to regularly receive pre-calibrated replacement sensors that include a code that can be entered into the analyzer for a quick convenient setup. Contact Bacharach customer service for more details about this program. 5.5. T-Stack Calibration This procedure first zeroes and then spans stack temperature to known temperature values.
www.actoolsupply.com Step T-STACK Calibration Procedure "Measured" is the current temperature reading. "Applied" is a known temperature that will be applied for calibration purposes. 4 Set thermocouple simulator to 32° F (0° C), and then use the UP (), DOWN (), LEFT (), and RIGHT () arrow buttons to enter an Applied value that exactly equals the setting of the simulator.
www.actoolsupply.com Step T-STACK Calibration Procedure 7 Wait until the Measured reading stabilizes, and then press ENTER to calibrate the TS-Span Measured value to that of the “Applied” value, after which the message “Good Calibration” should briefly appear followed by the CALIBRATION menu being re-displayed. 5.6. CO Sensor Calibration 5.6.1. Materials Required • • Calibration kit, P/N 0024-7059 Gas cylinder: 500 ppm CO in air, P/N 0024-0492 5.6.2.
www.actoolsupply.com Step Manual CO Zero Procedure 5.6.3. CO Sensor Span Procedure Step CO Span Procedure 1 From the Calibration Menu (see page 32), use the UP () and DOWN () arrow buttons to highlight CO, and then press ENTER to display the CALIBRATE CO screen. Note that this requires password validation (see page 32). “Measured” is the current CO reading, while “Applied” is a known CO level that will be applied for calibration purposes.
www.actoolsupply.com Step 5 CO Span Procedure Close the regulator and remove the CO cylinder. 5.7. T-Ref Sensor Calibration The T-Ref sensor is located inside the instrument. Calibration is done at the factory and should not need to be done in the field. ∇ ∇ ∇ www.actoolsupply.
www.actoolsupply.com Section 6. Troubleshooting 6.1. Error and Warning Messages Message Description T-STK Disconnected The probe thermocouple is not connected to the analyzers T-Stack connector. Plug the probe thermocouple plug into the T-Stack connector at the bottom of the instrument. Check Sensor O2 O2 sensor output is low, but still usable. Sensor may need to be replaced in the near future. The arrow on the O2 Sensor Life screen is in the “replace” segment.
www.actoolsupply.com Message Description XXX Occurs in the number fields of sensors that have achieved overrange condition. *** Occurs in the number fields of sensors. Replaces in-error sensor values and any calculated values that depend on those sensor values. --- Occurs in the number fields of sensors and indicates that values were not calculated. If a particular sensor is in error during warmup, the instrument automatically displays the error.
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www.actoolsupply.com 6.4. Instrument Identification A label on the back of the instrument provides the following information that is useful for service and troubleshooting. • • • • • manufacturer country of origin certification(s) part number serial number North American Label Siegert Label ∇ ∇ ∇ www.actoolsupply.
www.actoolsupply.com Declaration of Conformity The manufacturer of the products covered by this declaration: Bacharach, Inc. 621 Hunt Valley Circle New Kensington, PA 15068 Year conformity is declared: 2012 Product(s): Combustion Analyzer Model(s): Fyrite InTech The undersigned hereby declares that the above referenced product is in conformity with the provisions of the following standards and is in accordance with the following directive.
