Fyrite Pro ® Combustion Gas Analyzer Instruction 24-9388 Operation & Maintenance Rev.
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.
Fyrite Pro Contents Ordering Information................................................................................iii 1.0 INTRODUCTION...................................................................................1 1.1 The Fyrite Pro..................................................................................1 1.2 Operational Overview......................................................................2 2.0 TECHNICAL CHARACTERISTICS...................................................3 3.
Fyrite Pro 4.9 Clearing Saved Test Data..............................................................24 4.10 Turning OFF the Analyzer & CO Purge...................................... 24 4.11 Resetting the Microprocessor.......................................................25 4.12 Run Mode Screens.........................................................................26 4.13 Screen Descriptions......................................................................28 4.13.
Fyrite Pro Ordering Information Model Part Number 122E 125E 24-7276 24-7220 Measurements Oxygen Stack Temperature Ambient Temperature Second Thermocouple Channel (Combustion Air Temperature) Carbon Monoxide (CO) qA (Stack Loss) Combustion Efficiency ETa Excess Air (LAMBDA ) Carbon Dioxide (CO2) Draft Calculations CO Air Free CO/CO2 Instruction 24-9388 iii
Fyrite Pro Notes: iv Instruction 24-9388
Fyrite Pro 1.0 INTRODUCTION 1.1 The Fyrite Pro The Fyrite Pro series of instruments are hand-held combustion efficiency analyzers that are designed for on-demand sampling of residential furnaces and appliances. This manual contains information on all models of the Fyrite Pro. Please disregard any information that does not pertain to your model. WARNINGS! This analyzer is not intended to be used on a continuous basis.
Fyrite Pro 1.2 Operational Overview Pressing the i/o button turns the analyzer ON. Note that there is a warmup period of 60 seconds before the unit can be used for testing. After completion of the warm-up period, choose a fuel code that corresponds to the fuel being burned by the appliance being tested, and then press the enter 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.
Fyrite Pro 2.0 TECHNICAL CHARACTERISTICS The Analyzer Directly Measures and Displays: • Combustion Air (TL).......................................0 to 100 °C (32 to 212 °F) • Flue Gas O2 content.........................................0.0 to 20.9% O2 • Flue Gas Temperature (TA)............................–18 to 537 °C (0 to 999 °F) • Flue Gas CO content (Model 125E only). ............0 to 2,000 ppm CO • Draft.................................................................–9.99 to 67 mb/HPa (–9.
Fyrite Pro Power Requirements......................... Four disposable ‘AA’ Alkaline batteries (an optional AC adapter is available that eliminates the need for batteries) Operating Time (using batteries) ... Up to 18 hours continuous (pump running and backlight off) Warm Up Time ................................... 60 seconds Memory ................................................ Up to 10 sets of readings can be saved in memory.
Fyrite Pro 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 Checking & Replacing the 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 lower right corner of the screen. To replace the batteries: 1. Remove battery cover from back of analyzer. 2.
Fyrite Pro 3.3 Connecting the Probe and Thermocouple Attach the probe and hose assembly to the analyzer as follows (Figure 3-2): 1. Push the yellow banded quick-connect Flue Gas Hose (giving a slight twist) onto the GAS inlet fitting. 2. Push the blue banded quick-connect Draft Hose (giving a slight twist) on the “+” pressure fitting. 3. Push the Flue Gas Thermocouple into the T-STACK jack Important: DO NOT force the thermocouple connector into its jack.
Fyrite Pro Figure 3-2.
Fyrite Pro 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. I/O • Toggles the analyzer ON and OFF. • Places the analyzer into either its Setup or Calibration Mode when used in conjunction with the ENTER or HOLD button. • Scrolls up through the display screens during a test.
Fyrite Pro 3.5 Setup Mode The analyzer is preset at the factory for the parameters shown below, but can be changed as described in their associated sections. Function Parameter To Change Fuel Temperature Unit CO Channel Draft (Pressure) Clock Printer Protocol Natural Gas (F1) °C Auto Zero (A2) mB Not Initialized IrDA Section 4.13.2 Section 3.5.2 Section 3.5.3 Section 3.5.4 Section 3.5.5 thru 3.5.7 Section 3.5.8 3.5.1 Entering Setup 1.
Fyrite Pro 3.5.3 CO Channel Setup (Model 125E only) The CO Channel Setup Screen is labeled “CO.” 1. Enter the Setup Mode per Section 3.5.1. If necessary, repeatedly press the ENTER button until “CO” is displayed. 2. Press either the or button until the desired parameter is displayed. - no Sensor disabled. Use this function to turn off the CO channel if the sensor is bad or not installed to avoid the CO sensor error message from appearing. - 2Ero Manual Zero.
Fyrite Pro 3.5.5 Time Setup There are two Time Setup Screens, one for hours and the other for minutes. Two bars appear above the segments being changed. Time is displayed in a 24 hour format. 1. Enter the Setup Mode per Section 3.5.1. If necessary, repeatedly press ENTER until the first Time Setup Screen is displayed—the one with two bars over the hour digits. 2. Press either the or button until the correct hour value is displayed. 3. Press ENTER to move the selection bars over the minute digits. 4.
Fyrite Pro 3.5.7 Year Setup The Year Setup Screen is labeled “yEAr”. 1. Enter the Setup Mode per Section 3.5.1. If necessary, repeatedly press ENTER until “yEAr” is displayed. 2. Press either the or button until the correct year is displayed. 3. Press ENTER to move to the next Setup Screen, or I/O to exit setup. 3.5.8 Selecting Printer Protocol The analyzer can be set up for either an HP or IrDA type printer. 1. Enter the Setup Mode per Section 3.5.1.
Fyrite Pro 4.0 OPERATION 4.1 Performing CO and Draft Testing 4.1.1 Analyzer Turn On and Warm Up 1. Connect the probe and make sure that the analyzer is properly set up per Section 3.0. 2. Turn ON the analyzer by pressing is i/o button and observe that the following Warm-Up Screens are displayed.
Fyrite Pro 4.1.2 Measuring CO (Model 125E only) 1. Turn ON the analyzer and allow it to warm-up per Section 4.1.1. Important: If the CO channel is set up for auto zero, then the analyzer must be turned ON in fresh air; otherwise, incorrect CO readings will occur. Refer to Section 3.5.3. When the CO channel is set up for manual zero, and if the CO reading is higher than zero when sampling fresh air, then manually zero the CO channel per Section 5.6, Steps 1 thru 4. 2.
Fyrite Pro 4.2 Performing a Combustion Test 4.2.1 Analyzer Turn On and Warm Up Important: The probe must be at room temperature before performing the following steps. 1. Connect the probe, and if used, the combustion-air thermocouple to the bottom of the analyzer per Section 3.3. 2.
Fyrite Pro 4.2.3 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 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.
Fyrite Pro 80% Eff. Fan Assist or Power Vented Furnace/Boiler 90% Eff.
Fyrite Pro 4.2.4 Performing a Combustion Efficiency Test 1. After turning ON the analyzer and selecting the appropriate fuel, the TA & Draft Screen (refer to Section 4.13.3) should be displayed. 2. Position the probe in the flue-gas stream to obtain the hottest TA (stack temperature) reading. Locating the highest stack temperature is very important for accurate calculations of qA, Eta, and efficiency. 3. Burner-service procedures can now begin.
Fyrite Pro 4.3 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. • If the CO channel (Model 125E only) is set up for Auto Zero (refer to Section 3.5.3), ensure that the analyzer is sampling fresh air when turned ON.
Fyrite Pro 4.4 Using the Backlight The LCD can be read in dimly-lit areas by pressing the LIGHT button. The backlight automatically turns OFF after 10 minutes of keyboard inactivity, but can be turned OFF at any time by again pressing the LIGHT button. 4.5 Using the Probe A rigid stainless steel probe with handle, connected to a flexible hose with integral water-trap / filter can be used to draw a gas sample into the analyzer from the room, grilles, diffusers, and furnace flues.
Fyrite Pro 2. Press the button once to display the Save Screen. The number shown in this screen represents the memory location (1 thru 10) to which the current test data will be saved. 3. Press enter to save the test data and return to the Hold Mode, or press hold to return to the Hold Mode without saving. 4.7 Opening and Viewing Saved Test Data Perform the following to open and view saved test data: Note: If no test data has been saved, the option to open the memory for viewing will not be available.
Fyrite Pro 4.8 Printing Test Data Turn ON the printer. Refer to the printer’s instruction manual for detailed operation and maintenance information. If not already done, set the printer parameters as follows: • Data: 8 bits • Baud: 9600 • Parity: None • Handshaking: X-on/X-off Align the printer with the top of the analyzer as shown in Figure 4-1.
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Fyrite Pro 4.9 Clearing Saved Test Data Clear all saved test data as follows: Note: If no test data has been saved, the option to clear memory will not be available. 1. With the analyzer in its Run Mode, press the hold button twice to display the Print Screen. 2. Press either the or button to scroll to the Clear Screen, and then press enter to display the Clear All Screen. 3.
Fyrite Pro 4.11 Resetting the Microprocessor If the analyzer ‘locks up’ and cannot be turned OFF, reset the microprocessor by removing one of the batteries for at least 5 seconds.
Fyrite Pro 4.12 Run Mode Screens Figures 4-2 and 4-3 show the order in which the screens are displayed by pressing the enter and buttons after the analyzer warms-up and enters its Run Mode. Refer to Section 4.13 for a detailed description of each screen. Fuel Select: F1 = Natural Gas F2 = Propane F3 = Light Oil F4 = City Gas � � � � � Stack Temperature & Draft Draft Zero Stack Temperature & Efficiency qA & Excess Air (LAMBDA) � TL & Eta CO2 & O2 Figure 4-2.
Fyrite Pro Fuel Select: F1 = Natural Gas F2 = Propane F3 = Light Oil F4 = City Gas � � � � � Stack Temperature & Draft Draft Zero Stack Temperature & Efficiency Ratio of CO to CO2 qA & Excess Air (LAMBDA) � TL & Eta CO & CO Air Free (Undilute) CO2 & O2 Figure 4-3.
Fyrite Pro 4.13 Screen Descriptions 4.13.1 Warm-Up Screens Including O2 Sensor Output As soon as the analyzer is turned ON, a series of Warm-Up Screens are displayed. These screens show the analyzer’s model number (Pro E 122 or Pro E 125), the unit’s software revision, and finally the remaining warmup time counted down from 60 seconds, including a measurement of the O2 sensor’s output level. At the end of warm-up, the Fuel Screen is displayed.
Fyrite Pro 4.13.3 TA (Stack Temperature) & Draft Screen The TA reading is the stack temperature measured at the probe tip. The draft reading is the pressure measured at the probe tip as referenced to the analyzer’s “–” pressure port. Front Panel Button Functions: – Displays next screen (refer to Section 4.12) – Displays previous screen (refer to Section 4.
Fyrite Pro 4.13.5 Stack & EFF Screen The STACK reading is the temperature measured at the probe tip. The EFF (Efficiency) reading is a calculation of what percentage of energy present in the fuel is being converted into usable heat based on the fuel’s high heating value. Front Panel Button Functions: – Displays next screen (refer to Section 4.12) – Displays previous screen (refer to Section 4.
Fyrite Pro 4.13.7 qA & Excess Air Screen � The qA reading is a calculation of stack loss in percent. The EXCESS AIR (LAMBDA) reading is the calculation of the percentage of extra air that is available in the combustion chamber above the theoretical amount needed for perfect combustion. Front Panel Button Functions: – Displays next screen (refer to Section 4.12) – Displays previous screen (refer to Section 4.
Fyrite Pro 4.13.9 CO & CO Air Free Screen (Model 125E only) The CO reading is the measurement of how much carbon monoxide in ppm is present in the flue-gas stream. The CO AIR FREE (undilute) reading is a calculation of the exact ppm concentration of carbon monoxide if oxygen were 0.0% in accordance with ANSI standard Z21.1. CO Air Free = CO x 20.9 20.9 – O2 measured Front Panel Button Functions: – Displays next screen (refer to Section 4.12) – Displays previous screen (refer to Section 4.
Fyrite Pro 4.13.11 Sensor Error Screen An O2 sensor error is displayed if the analyzer determines during the warm-up cycle that the oxygen sensor’s output is too low for it to be usable. However, in the extreme condition when the O2 sensor has no output, a sensor error will not occur. Instead, the O2 reading will be 0.0 as displayed in the CO2 & O2 Screen.
Fyrite Pro Notes: 34 Instruction 24-9388
Fyrite Pro 5.0 CALIBRATION & MAINTENANCE Important: Fresh batteries should be installed, or use the optional AC adapter to power the analyzer during calibration. The unit should be allowed to stabilize at room temperature for at least 2 hours before proceeding with calibration. To maintain accuracy as listed in the Technical Characteristics Section of this manual, the standards used must be at least four times as accurate as the stated accuracy of the Fyrite Pro. 5.
Fyrite Pro 5.2 Ambient Temperature Calibration Material Required: Calibrated Thermometer Procedure: 1. Enter the Calibration Mode as described in Section 5.1. Then repeatedly press the ENTER button until “AMBIENT” appears at the top of the display. 2. Use the and buttons to set the displayed value to match the reading of a calibrated thermometer at room temperature. 3.
Fyrite Pro 5. Repeat Steps 3 and 4 as necessary until the unit is reading correctly at both temperatures. 6. Press ENTER to store these calibration values and move to the next calibration screen, or hold down ENTER for 2 seconds to store these calibration values and enter the Run Mode, or press the I/O button to exit the Calibration Mode and turn OFF the analyzer without saving the changes. 7. Remove thermocouple simulator from analyzer. 5.
Fyrite Pro 5.5 Oxygen Sensor Zero Material Required: Procedure: • Cylinder of 100% Nitrogen, P/N 9550-0049 • Calibration Kit, P/N 24-7059 1. With the analyzer sampling fresh air, enter the Calibration Mode as described in Section 5.1. Then repeatedly press the ENTER button until “O2 ” appears in the lower-left side of the display. 2. Allow pump to run and sample fresh air for at least 1 minute. 3. Use the and buttons to set the display to 20.9%. 4.
Fyrite Pro 5.6 CO Sensor Zero & Calibration (Model 125E only) Material Required: • Cylinder of 100 ppm (P/N 51-1994) or 500 ppm (P/N 24-0492) CO calibration gas • Calibration Kit, P/N 24-7059 To improve the accuracy of the CO reading, we suggest that if the analyzer will be primarily used for flue gas testing, then calibrate using 500 ppm CO. If the analyzer, however, will be primarily used for ambient testing, then calibrate using 100 ppm CO. Procedure: 1.
Fyrite Pro 8. Press ENTER to store the new calibration values and move to the next calibration screen, or hold down ENTER for 2 seconds to store the new calibration values and enter the Run Mode, or press the I/O button to exit the Calibration Mode and turn OFF the analyzer without saving the changes. 9. Disconnect tubing from analyzer and turn off gas flow. LEAVE TOP PORT OPEN 2 3 4 3 5 1 Parts Shown: 1. Gas Cylinder 2. Regulator* 3. Tubing* 4. Tee* 5. Flowmeter* 6.
Fyrite Pro 5.7 Draft Calibration Material Required: Procedure: • Bellows • Micromanometer Range: ±20 mb (±8 in. H2O column) Accuracy: ±0.025 mB (±0.01 in. H2O column) 1. Set the draft units to “mB” per Section 3.5.4. 2. Enter the Calibrate Mode per Section 5.1, and then press the enter button until “mB” appears on the right-hand side of the display. 3. If necessary, zero the draft channel by using the and buttons to adjust the reading to 0.00 ±0.02. 4.
Fyrite Pro 5.8 Water Trap / Filter Maintenance The Water Trap / Filter Assembly removes water condensate from the gas sample, and also prevents soot from contaminating the internal components of the analyzer. Drain the water condensate after every test. Procedure: 1. Pull off the Inlet End Cap using a slight twisting motion. 2. Pour out all water condensate; then reassemble trap. Replace the Filter Element when dirty. Material Required: • Filter Element, P/N 07-1644 Procedure: 1.
Fyrite Pro 5.9 O2 Sensor Replacement Be sure to perform all of the checks listed in Section 4.13.11 to ensure that the O2 sensor needs to be replaced. Material Required: • Oxygen Sensor, P/N 24-8106 • #1 Phillips Screwdriver Procedure: 1. Disassemble the analyzer as follows: a. Remove the battery cover and the batteries, uncovering one of the cover hold-down screws. b. Remove and set aside all four cover hold-down screws. c.
Fyrite Pro 5.10 CO Sensor Replacement (Model 125E only) Be sure to perform all of the checks listed in Section 4.13.11 to ensure that the CO sensor needs to be replaced. Material Required: Procedure: • CO Sensor, P/N 24-7265 • CO Sensor Gasket, P/N 24-1112 • #1 Phillips Screwdriver 1. Disassemble the analyzer as follows: a. Remove the battery cover and the batteries, uncovering one of the cover hold-down screws. b. Remove and set aside all four cover hold-down screws. c.
Fyrite Pro 5.11 Pump Assembly Replacement Material Required: Procedure: • Pump, P/N 24-3048 • #1 Phillips Screwdriver 1. Disassemble the analyzer as follows: a. Remove the battery cover and the batteries, uncovering one of the cover hold-down screws. b. Remove and set aside all four cover hold-down screws. c. With the analyzer on its back, remove the front cover, laying it face down to the left of the body. d.
Fyrite Pro CO SENSOR GASKET (Model 125E only) OXYGEN SENSOR & SOCKET PRESSURE SENSOR ON PCB PUMP HOLD DOWN CLAMP Figure 5-4.
Fyrite Pro To BATTERY (RED WIRE) CO SENSOR (Model 125E only) (RED WIRE) PRESSURE SENSOR To OXYGEN SENSOR To PUMP (RED WIRE) T-AIR T-STACK Figure 5-5.
Fyrite Pro Notes: 48 Instruction 24-9388
Fyrite Pro 6.0 PARTS & SERVICE 6.1 Replacement Parts Description Part No. Carbon Monoxide Sensor............................................................................ 24-7265 Carbon Monoxide Sensor Gasket................................................................24-1112 Oxygen Sensor w/ Gasket........................................................................... 24-8106 Oxygen Sensor Gasket.................................................................................
Fyrite Pro 6.3 Service Centers Replacement parts and service can be obtained by contacting one of the following Bacharach Service Centers: United States 621 Hunt Valley Circle New Kensington, PA 15068 Phone: 724-334-5051 Fax: 724-334-5723 Email: help@mybacharach.com Canada Bacharach of Canada, Inc. 250 Shields Court Unit #3 Markham, Ontario L3R 9W7 Canada Phone: 905-470-8985 Fax: 905-470-8963 Email: bachcan@idirect.com México Bacharach de México Playa Regatas No. 473 Tercer Piso Col.
Fyrite Pro Appendix A – Formulas and Tables CO2 = CO2 max (20.9 – O2%) 20.9 qA = (TA – TL) x ( λ (Excess Air) = A2 +B) 20.9 – O2 20.9 20.9 – O2 Eta = (100% – qA) + [Kf, if TA < (T0 – 1.
Fyrite Pro Notes: 52 Instruction 24-9388
Fyrite Pro Notes: Instruction 24-9388 53
Headquarters: 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 • Fax: 724-334-5001 • Toll Free: 800-736-4666 Website: www.mybacharach.com • E-mail: help@mybacharach.com Printed in U.S.A.
