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Fyrite INSIGHT

4. The new thermocouple has been coiled for shipping purposes.

Straighten the thermocouple using your thumb and index finger.

5. If not already done, install supplied O-Rings onto thermocouple.

6. Insert thermocouple into probe body until it “bottoms out.”

7. Strip

inch of insulation from each of the probe’s thermocouple

connector wires.

IMPORTANT:

In Step 8, the thermocouple wires must first be twisted

together and then crimped.

Twist

both red thermocouple wires together; insert them into the

supplied wire-splice connector; and then crimp the connector using

a pair of pliers. Repeat this step for the yellow thermocouple wires.

9. Reassemble the probe handle, being careful not to pinch the ther-

mocouple wires between the handle pieces. In addition, ensure that

the end of the thermocouple is in front of the rib molded into the

bottom handle piece; otherwise, the handle pieces will not fit tightly

together.

6.5 Gas Pump Replacement

Ordering Replacement Parts:

Two replacement pumps are available based on the revision of the printed

circuit board (PCB) inside your Insight. Proper PCB version identification

ensures that you order and receive the correct replacement pump. Use the

serial number of your analyzer to determine which PCB revision it has.

1. Locate the serial number on the back of your Insight analyzer.

2. Compare your serial number with transition serial number RU1025. If

your serial number is RU1025 or newer, you have a Revision 1 PCB. If

your serial number is older than RU1025, you have a Revision 0 PCB.

NOTE:

Bacharach serial numbers contain a mix of alphabetic and nu-

meric characters. The first two most significant positions are represented

by sequential characters A-Z (where “A” is earlier than “Z”). The last four

least significant positions are each represented by digits 0-9 (where “0” is

earlier than “9”). For example, serial number AZ9999 is older (i.e., was

assigned earlier) than serial number ZA0000.

NOTE:

During certain Insight repairs (for example, the replacement

Содержание 0024-8252

Страница 1: ...Fyrite INSIGHT Combustion Gas Analyzer Siegert Version Instruction 0024 9461 Operation Maintenance Rev 4 October 2011 Product Leadership Training Service Reliability...

Страница 2: ...ON THE IM PLIED WARRANTIES OF MERCHAN TABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND II ANY OBLIGA TION LIABILITY RIGHT CLAIM OR REMEDY IN CONTRACT OR TORT WHETHER OR NOT ARIS ING FROM BACH A RACH...

Страница 3: ...3 7 Setup Menu 14 3 7 1 Temperature Units 14 3 7 2 Pressure Units 15 3 7 3 Smoke Number 15 3 7 4 Oil Derivative 16 3 7 5 Boiler Temperature 17 3 7 6 Clock 17 3 7 7 O2 Reference 18 3 7 8 Print Pressure...

Страница 4: ...re Sensor Calibration 47 5 5 T Stack Calibration 49 5 6 T Air Calibration 51 5 7 CO Sensor Calibration 53 6 0 Maintenance 55 6 1 Fyrite INSIGHT Disassembly 55 6 2 Water Trap Filter 57 6 2 1 Emptying t...

Страница 5: ...safe practices To assure operator safety and the proper use of the Fyrite INSIGHT please read the contents of this manual for important information on the operation and maintenance of the analyzer Thi...

Страница 6: ...mwc or Inches of Water Column inwc LANGUAGE The display options are English French Spanish German Italian Danish Polish and Dutch MEMORY The Fyrite INSIGHT has the ability to store recall to display a...

Страница 7: ...sor 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 applyin...

Страница 8: ...nds 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...

Страница 9: ...nd Decrement buttons The recommended time required to achieve a stable measurement is a minimum of 3 minutes Pressing the RUN hold button during a test will freeze all measured and calculated values a...

Страница 10: ...0 ETA 0 1 to 111 2 EFF 0 1 to 100 CO CO2 Ratio 0 0001 to a fuel dependent maximum value in Carbon Dioxide 0 1 to a fuel dependent maximum value in CO referenced to O2 0 to 9 999 ppm LAMBDA 1 to 9 95 F...

Страница 11: ...rinter USB connectivity Accuracy Oxygen 0 3 O2 with 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 Temperatu...

Страница 12: ...artment 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...

Страница 13: ...orm 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...

Страница 14: ...bly 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 Pres...

Страница 15: ...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...

Страница 16: ...e Run Hold screen will appear in Hold mode This screen displays a list of information relative to the combustion pro cess The up down arrow keys permit scrolling through the list as displayed in the i...

Страница 17: ...meter To modify refer to Fuel Natural Gas Section 4 3 Temperature Unit C Section 3 7 1 Pressure Unit mB Section 3 7 2 Clock Not Initialized Section 3 7 6 O2 Reference 0 Section 3 7 7 Zoom Standard Sec...

Страница 18: ...3 7 1 Temperature Units Use this menu to display temperature in C or F 1 Access the Setup Menu per Section 3 7 2 Select Temperature Units 3 Press Enter to access the Temperature Units menu Select the...

Страница 19: ...nit from the list 5 Save and return to the Setup Menu or press ESC to cancel 3 7 3 Smoke Number Three smoke numbers as measured by the Bacharach True Spot Smoke tester can be manually entered into the...

Страница 20: ...er Yes or No in response to if oil derivatives were present during the smoke test Oil derivatives will be displayed on the combustion test Run Hold screen Enter an oil derivative as follows 1 Access t...

Страница 21: ...p Menu per Section 3 7 2 Select Boiler Temperature 4 Use the buttons to move the cursor Use the buttons to increment and decrement the number value 5 Save and return to the Setup Menu or press ESC to...

Страница 22: ...tup Menu per Section 3 7 2 Select O2 Reference 3 Select the O2 reference value Range 0 15 4 Save and return to the Setup Menu or use ESC to cancel 3 7 8 Print Pressure Select whether to print or not p...

Страница 23: ...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 sc...

Страница 24: ...e The Edit Username screen will display with the first line highlighted 3 Press ENTER Only the first character space will be highlighted Use the buttons to make selections for each character space Whe...

Страница 25: ...Run Hold screen The Run Hold button is used to toggle between Run and Hold Press the Run Hold button to start the pump While it is running the word Run will appear in the upper left corner of the dis...

Страница 26: ...higher heating value CO CO2 Carbon Monoxide Carbon Dioxide CO n Carbon Monoxide content referenced to O2 AVG SMOKE Average of 3 manually entered smoke numbers OIL DERIVE Manually entered Yes or No BO...

Страница 27: ...e selection The cursor will stop flashing 7 Change the data displayed at other locations by repeating steps 4 through 6 8 When finished scroll to the bottom of the list to select Edit Com plete 9 Pres...

Страница 28: ...isplay screen text can be in English French Spanish German Ital ian Danish Polish or Dutch Select the desired language as follows 1 Access the Setup Menu per Section 3 7 2 Select Language Selection A...

Страница 29: ...u or ESC to cancel 3 7 14 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...

Страница 30: ...tings must be correct to get ac curate calibration reminders 3 7 15 Inactivity Timeout This is the selected amount of time that will elapse before the analyzer automatically powers down due to inactiv...

Страница 31: ...or ESC to cancel 3 7 16 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...

Страница 32: ...turned ON in fresh air otherwise incorrect CO readings will occur Auto Zero determines the zero reading of the CO channel in fresh air and provides an offset for the CO measurements Manual zero is us...

Страница 33: ...GHT 29 Both methods take the user through a 60 second count down to establish a new zero The manual mode establishes a fresh air zero and stores it for use during instrument startup Auto Zero versus M...

Страница 34: ...ack 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 w...

Страница 35: ...the analyzer s firmware version model and serial numbers are briefly displayed followed by the Warm Up screen Version V2 00 Model 24 8252 Serial NW1060 4 After the 60 second warm up period is complete...

Страница 36: ...e Combustion Test HOLD screen or ESC to cancel and return to the select Fuel Menu From the Fuel Menu press ESC again to return to the Main Menu 4 4 Sampling Point See Fig 4 1 Forced Air Furnace When t...

Страница 37: ...y 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 authorit...

Страница 38: ...te INSIGHT 34 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 Fig...

Страница 39: ...ated data cannot be displayed because the measured data necessary to make the calculation is out of range i e oxygen level above 18 8 2 Scroll to the T STK reading Loosen the thumbscrew on probe stop...

Страница 40: ...CO CO2 Carbon Monoxide Carbon Dioxide ratio CO n Carbon Monoxide content referenced to of O2 concen tration AVG SMOKE Average of 3 manually entered smoke numbers OIL DERIVE Manually entered Yes or No...

Страница 41: ...t open to the atmosphere and connect the probe s draft hose to the P port 5 Do one of the following to measure draft or differential pressure To measure draft insert the probe into the stack and obser...

Страница 42: ...Press ENTER to dis play the Temperature Measurement screen 3 Install thermocouples in both temperature channel connectors 4 Before taking a measurement the temperature channels may need to be zeroed...

Страница 43: ...e 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...

Страница 44: ...h 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...

Страница 45: ...1 Press the MENU F2 button to access Main Menu 2 Use the buttons to scroll to Memory Press ENTER to display the Memory Menu 3 Select Clear Memory Select Yes and press ENTER A confirmation that the me...

Страница 46: ...ighlighted Select the 3 combustion tests to be averaged from the list by using the buttons 4 Press the ENT key The average test results will be displayed All 3 tests that are selected must be combusti...

Страница 47: ...he information shown in the DIAGNOSTIC screen can be printed 1 Power up the printer Refer to the printer s instruction manual for detailed operating information If not previously done select the follo...

Страница 48: ...loaded from the Fyrite Insight page of the Bacharach website www MyBacha rach com Refer to manual 0024 9465 Minimum computer requirements for installation and use of the Fyrite User Software are shown...

Страница 49: ...n 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 cal...

Страница 50: ...r a list of error messages and their meanings 3 Press the MENU F2 button to access the Main Menu 4 Use the buttons to select Calibration Press ENTER to dis play the Calibration Password screen 5 Befor...

Страница 51: ...rrect code was entered the screen will display Invalid Code Check to make sure the correct code has been entered If problem persists contact your nearest Bacharach Service Provider Bacharach also offe...

Страница 52: ...t DO NOT connect the analyzer to the calibration equip ment at this time 2 If not already done power on the analyzer and display the Calibra tion List per Section 5 2 3 Use the buttons to select Press...

Страница 53: ...ENTER to calibrate the pressure sensor s Measured value to that of the Ap plied value The message Good Calibration should briefly appear followed by the Calibration List screen 8 Remove calibration e...

Страница 54: ...Fyrite INSIGHT 50...

Страница 55: ...ss ENTER to display the CALIBRATE TS ZERO screen 1 Measured is the current temperature reading while Applied is a known temperature that will be applied for calibration purposes 4 Set thermocouple sim...

Страница 56: ...calibration range is from 80 to 330 C 175 to 625 F An at tempt to calibrate outside this range will cause the message Applied Value High or Low to appear at the bottom of the screen 7 Wait until the...

Страница 57: ...y the CALI BRATION LIST screen per Section 5 2 3 Use the buttons to highlight T Air and then press ENTER to display the Calibrate TA Zero screen 0 4 Measured is the current temperature reading while A...

Страница 58: ...pplied 100 o C Press ENT Alternatively Submerge probe tip into a container of boiling water with a thermometer wait several minutes and then use the and buttons to enter an Applied value that exactly...

Страница 59: ...zer and display the Calibra tion List screen per Section 5 2 2 Use the buttons to highlight CO and then press ENTER to dis play the Calibrate CO screen 4 Measured is the current CO reading while Appli...

Страница 60: ...Jack Power 7 Sample Gas Thermocouple Connector T Stack 8 Primary Air Thermocouple T Air 9 USB Connector 10 Differential Pressure Hose Optional 11 Draft Hose 12 Sample Gas Hose Fyrite INSIGHT Component...

Страница 61: ...ntry Not Saved will appear The sensor will now be marked as BAD in the Diagnostics screen 6 Turn off the gas and remove the CO cylinder 6 0 Maintenance 6 1 Fyrite INSIGHT Disassembly The following sec...

Страница 62: ...satu rated with water Material Required Filter element P N 0007 1644 Small flat blade screwdriver 1 Remove water trap chamber per Figure 6 3 2 Pry apart filter chamber using a small flat blade screw...

Страница 63: ...mately 2 years and the CO sensor life is greater than 3 years Material Required O2 Sensor P N 0024 0788 Procedure 1 After battery door is removed remove connector tubing from both sen sors 2 Pull O2 s...

Страница 64: ...serting the pins into the connectors in the base 5 Reattach tubing 6 3 2 CO Sensor Material Required CO Sensor P N 0024 7265 or B Smart sensor P N 0024 1467 Procedure 1 After battery door is removed r...

Страница 65: ...contains a thermocouple assembly two O rings and two wire splice connectors Tools Required Small flat blade screwdriver Wire cutter Wire stripper Slip joint pliers Procedure 1 Gain access to the therm...

Страница 66: ...ill not fit tightly together 6 5 Gas Pump Replacement Ordering Replacement Parts Two replacement pumps are available based on the revision of the printed circuit board PCB inside your Insight Proper P...

Страница 67: ...he combination pump harness part number Refer to the table below Item PCB Rev 0 PCB Rev 1 Serial Back of Instrument PCB Label To Confirm Rev Pump Harness Part Number Connector Style on Pump Wiring Har...

Страница 68: ...ed and restrict the flow of gas into the analyzer resulting in incorrect combustion test readings and calculations NOTE An analyzer that is used to test natural gas furnaces normally requires less fre...

Страница 69: ...STK Disconnected The probe thermocouple is not connected to the analyzer s T Stack connector Plug the probe thermocouple plug into the T Stack connector at the bottom of the instrument Warmup Sensor E...

Страница 70: ...on the sensors that were in error coming out or warmup Occurs in the number fields of calculated values when Oxygen is above 18 8 6 8 Diagnostics Screen The DIAGNOSTICS menu provides information regar...

Страница 71: ...pears above F2 2 Use the buttons to highlight Diagnostics and then press ENT to display the Diagnostic Menu 3 Use the buttons to highlight the desired diagnostic topic and then press ENT to display th...

Страница 72: ...Trap 0007 1644 Gas Connector 0024 0877 O Ring Kit 2 sets 0024 1471 O2 Sensor 0024 0788 O2 Sensor Cover 0024 1421 PC Software 0024 1470 Probe Hose Assembly 0024 3053 Probe Stop 0019 3037 Replacement P...

Страница 73: ...798 Thermocouple 3 0 m 0104 1797 7 3 Service Centers Replacement parts and service can be obtained by contacting one of the fol lowing Bacharach Service Centers United States 621 Hunt Valley Circle Ne...

Страница 74: ...1 Part 1 General Requirements and Test Methods Speci cations for Portable Electrical Apparatus Designed to Measure Combustion Flue Gas Parameters of Heating Appliances EN 50379 3 Part 3 Performance Re...

Страница 75: ...Oxygen in percent TA Measured stack temperature in o C TL Measured combustion air temperature in o C CO Measured carbon monoxide level in ppm CO2 Calculated carbon dioxide level in percent qA Calculat...

Страница 76: ...World Headquarters 621 Hunt Valley Circle New Kensington PA 15068 Ph 724 334 5000 Toll Free 800 736 4666 Fax 724 334 5001 Website www MyBacharach com E mail help MyBacharach com...

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