FRC FPA400 User manual

FPA400 Rev0708
1
FIRE RESEARCH CORPORATION
www.fireresearch.com
26 Southern Blvd., Nesconset, NY11767
TEL ( 631 ) 724-8888 FAX ( 631 ) 360-9727 TOLL FREE 1-800-645-0074
DIGITAL FLOWMETER
AND PRESSURE
INDICATOR
MODEL FPA400
Document Number:
XE-FPA4PM-R0A
OPTIONAL
BACKLIGHTING

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CONTENTS
Table of Contents
CONTENTS ................................................................................................................ 2
INTRODUCTION ...................................................................................................... 4
Overview ................................................................................................................ 4
Features .................................................................................................................. 4
Specifications ......................................................................................................... 5
GENERAL DESCRIPTION ....................................................................................... 6
Components ........................................................................................................... 6
Controls and Indicators .......................................................................................... 7
INSTALLATION ........................................................................................................ 8
Install Display Module .......................................................................................... 8
Install Pressure Sensor ........................................................................................... 9
Install Flow Sensor .............................................................................................. 10
OPERATION ............................................................................................................ 16
Datalink Interface ................................................................................................ 16
Program Features ................................................................................................. 17
External Totalizing Button (Optional) ................................................................. 17
PROGRAMMING .................................................................................................... 18
Inputs ................................................................................................................... 18
Display Module Identification Mode ................................................................... 18
Program Access Mode ......................................................................................... 19
Program Code Descriptions ................................................................................. 22
CALIRBRATION ..................................................................................................... 26
Flow Calibration, Single Point (Code 321) ......................................................... 26
Flow Calibration, Multiple Point (Code 322) ...................................................... 27
Pressure Calibration (Code 323) .......................................................................... 28
WIRING .................................................................................................................... 30
External Totalizing Button Option ....................................................................... 30
Display Module ................................................................................................... 30
Pressure and Flow Sensor .................................................................................... 31

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List of Tables
Table 1. Pressure Sensor Output Voltage ................................................................... 5
Table 2. Program Code Quick Reference ................................................................ 20
List of Figures
Figure 1. Controls and Indicators ............................................................................... 7
Figure 2. Display Module Mounting Dimensions ..................................................... 8
Figure 3. Pressure Sensor Dimensions ....................................................................... 9
Figure 4. Flow Sensor Location Guide ................................................................... 11
Figure 5. Saddle Clamp Installation ......................................................................... 13
Figure 6. Weldment Installation ............................................................................... 15
Figure 7. Display Module Wiring ............................................................................ 30
Figure 8. Pressure and Flow Sensor Wiring ............................................................. 31

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INTRODUCTION
Overview
The INSIGHT ULTIMATE digital flowmeter and pressure indicator combines a
digital LED flow display and a traditional style electronic pressure indicator into one
practical display module. The flowmeter/pressure indicator is able to communicate
with other display modules over the FRC datalink. This technology allows for remote
displays, the display of flow for multiple discharges (summing), and the totalization
of flow for multiple discharges (accumulation).
The digital flowmeter is a 4-digit LED display. During normal operation flow rate
information is provided from a paddlewheel flow sensor or the datalink interface. This
information is processed and and shown on the digital display as flow rate.
The pressure indicator is an electronically controlled analog display. During normal
operation pressure information is provided from a solid state pressure sensor or the
datalink interface. The pressure sensor provides an electrical signal to the input of the
display module. A microprocessor controls the needle movement to provide an accurate
and steady pressure display. Leakage and freeze-up problems common in mechanical
pressure gauges are eliminated.
There are two operator selectable modes; display module identification and
program access. The digital display is used to show stored data or operator inputs when
a selectable mode is accessed. In the display module identification mode the digital
display will show the module serial number, manufactured date, software revision,
module function, and ID number. In the program access mode the digital display will
show operator inputs, program options, and error codes. The operator selected modes
are accessed and inputs are made by using the three magnet sensors on the front of the
display module.
All controls and indicators are located on the front of the display module.
Features
Display Module Identification and Program Access Modes
Datalink Interface
Multiple Flow Rate Calibration Points
Pressure Scale Expands Between 100 and 250 PSI
High and Low Flow Warnings
Backlighting (Optional)
NFPA Color Coded Bezel (Optional)
External Totalizing Button (Optional)
Flow Conditioner (Optional)

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Specifications
Display Module
SupplyVoltage: 9 to 30 VDC
Supply Current: 0.5 Amps Maximum (0.75 with Backlighting)
Dimensions:
Height 4.4"
Width 4.4"
Depth 3.4"
Flow Sensor
Model Number: XE-MF15P
Type: Paddlewheel
Sensor Material: Acetal (Delrin) with Stainless Steel (316) Shaft
Excitation Voltage: 5 VDC
Pressure Sensor
Model Number: XE-FP4000PT1
Pressure Range: 0 - 600 PSI
Proof Pressure: 1200 PSI
Excitation Voltage: 5 VDC
Output Voltage: 0.5 - 4.75 VDC (Refer to Table 1)
PRESSURE
(PSI)
VOLTAGE
(VDC)
0 0.5
100 1.21
150 1.56
200 1.92
250 2.27
300 2.625
600 4.75
Table 1. Pressure Sensor Output Voltage

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GENERAL DESCRIPTION
Components
The flowmeter/pressure indicator kit consists of the following components:
Display Module
Pressure Sensor
Paddlewheel Flow Sensor and Mounting Assembly
External Module Totalizing Button (Optional)
Cables
Display Module
The flowmeter/pressure indicator display module is waterproof and has dimensions
of 4.4 inches high by 4.4 inches wide by 3.4 inches deep. It is available with optional
backlighting and NFPA color coded bezels. (Both are an intricate part of the display
module and must be factory installed.) All controls and indicators are located on the
front of the display module. (Refer to Controls and Indicators.)
Pressure Sensor
The pressure sensor provides an input signal to the display module that is
proportional to the discharge pressure. It is mounted on the downstream side of the
discharge valve. The electrical connector is waterproof and molded into the pressure
sensor housing.
Paddlewheel Flow Sensor
The flow sensor provides an input signal to the display module that is proportional
to the discharge flow rate. It is mounted in the discharge piping. Placement of the
sensor in the piping is critical to obtaining accurate flow rate information, refer to the
installation procedures for detailed information on mounting locations. The electrical
connector is waterproof and molded into the flow sensor housing.
External Totalizing Button (Optional)
The totalizing button allows the operator to display the total flow for a discharge.
When the button is pressed the number shown in the digital display times 100 will be
the total flow.
Cables
Interconnecting cables are provided. Refer to Wiring Section.

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Figure 1. Controls and Indicators
Controls and Indicators
All controls and indicators are located on the front of the display module. It contains
the pressure scale and indicating needle, a digital display, and the three magnet sensors.
(Refer to Figure 1.)
Pressure Display
The pressure scale is non-linear and is expanded between 100 and 250 PSI. This
provides for better visibility and more accurate readings in the normal operating
range.
Digital Display
During normal operation this 4-digit LED display will indicate flow rate. When the
display module identification or program access modes are selected the digital display
shows module specific information, program codes, settings, and error codes. See the
Programming Section for more information.
Magnet Sensorson
The operator selected modes are accessed and inputs are made by using the three
magnet sensors M1, M2, and M3 located on the front of the display module. The M1 and
M2 sensors are used to input data when in the program access mode. The M3 sensor is
used to enter and exit these modes. See Programming Section for more information.
Magnet
The north pole of a small magnet is placed on the glass in close proximity to the
magnet sensor and then moved about 1 inch away to activate the sensor.
M1 M2
M3

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INSTALLATION
Note: Plumbing systems are always unique and may cause small deviations
in the factory calibration. It is recommended that the flowmeter/pressure
indicator is checked after installation for accuracy and calibrated when
necessary.
Install Display Module
Display modules are interchangeable. It is recommended to check display accuracy
if modules are swapped and calibrated when necessary.
1. Measure and mark mounting location for display module panel cutout and
mounting screw holes. Make sure there is clearance behind the panel for
the display and cables before cutting holes. Refer to Figure 2 for layout and
dimensions.
2. Cut out a 3 3/4 inch diameter hole and drill four holes (clearance or tapped)
for 10-32 mounting screws.
3. Place display module in position and secure with four screws.
Figure 2. Display Module Mounting Dimensions
Mounting holes are
clearance or tapped
for 10-32 screws.
Panel Cutout
3 3/4" Diameter
3.63"
1.25"
C
L
4 3/8"
4 3/8"
1/2"
3.5"
3 3/4"

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Install Pressure Sensor
The pressure sensor is mounted downstream of the discharge valve.
Pressure sensors are interchangeable. It is recommended to check display accuracy
if sensors are swapped and calibrated when necessary.
Note: Install the pressure sensor upright so water in the end of the sensor
drains back into the pipe.
1. Screw the sensor into a 1/4-18 NPT hole.
Caution: Do not use the main body that houses the electronics to tighten the
pressure snesor. Damage to the sensor may occur.
2. Tighten the sensor with a 3/4-inch wrench on the lower hex fitting.
3. Connect the pressure sensor cable from the control module to the sensor. (Refer
to Wiring Section.)
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Caution: Do not use the main
body that houses the electronics
to tighten the sensor. Damage to
the sensor may occur.
Figure 3. Pressure Sensor Dimensions

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Install Flow Sensor
There are several ways to install paddlewheel type flow sensors. Mounting options
include saddle clamps, weldments, pipe tees, and special adapters. Each mount meets
a particular plumbing requirement.
Flow sensors are interchangeable. It is recommended to check display accuracy if
sensors are swapped and calibrated when necessary.
The maximum flow sensor pressure is 600 PSI.
Flow Sensor Location
Locating the flow sensor in the plumbing system is critical. The flow of water
at and around the sensor must be laminar, or smooth, to ensure accurate flow rate
measurement. There must be enough straight pipe before the flow sensor for the water
stream to stabilize into a uniform flow. Guidelines for selecting flow sensor locations
are outlined in Figure 4.
Turbulent Water
When the sensor is mounted after an area in the plumbing that tends to increase
water stream turbulence (a valve, increase in pipe diameter, etc.), it is critical that steps
are taken to stabilize the flow. When a pipe is reduced in diameter the water stream
tends to be squeezed into a more uniform flow. This can help stabilize flow when there
is not sufficient straight pipe up stream.
Linearizer Feature
This meter features a Linearizer function in the calibration programming. This
function should be used when the flow sensor is installed in a plumbing location
where flow is not linear. It corrects for nonlinear flow by calibrating the display at
multiple flow rates (up to 9). This provides more accurate flow rate readings. (Refer
to Calibration Section.)

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Figure 4. Flow Sensor Location Guide
Before Valve or Elbow
L > 1 X PIPE DIA.
After Elbow
L > 6 X PIPE DIA.
After Valve
L > 14 X PIPE DIA.
After Reduction
L > 2 X PIPE DIA.
Best Orientation
is Vertical
L
L
L
L
Flow Sensor Location Guide
The preferred location for mounting
a flow sensor is on the top half of the
pipe. The best orientation is vertical. If
the sensor is mounted on the bottom of
the pipe, it may be susceptible to dirt
accumulation impacting operation.
When mounting a sensor after the pipe
diameter is reduced, length L must be at
least 2 times the pipe diameter.
When mounting a sensor after a valve,
length L must be at least 14 times the pipe
diameter.
When mounting a sensor after an elbow,
length L must be at least 6 times the pipe
diameter.
When mounting a sensor before a valve or
an elbow, length L must be at least equal
to the pipe diameter.

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Saddle Clamp Installation
Note: Ensure that the mounting location meets the requirements for uniform
water flow. (Refer to Flow Sensor Location.)
Note: Ensure that there is enough room for the saddle clamp, sensor, and connector
to fit. (Refer to Figure 5.)
1. Drill and deburr a 1-11/16" to 1-3/4" diameter hole at mounting location.
2. Clean pipe surface in area where saddle clamp gasket will seal.
Note: The sensor housing is epoxied in the saddle clamp with the alignment
tab in the correct position and is not meant to be removed.
3. Place saddle clamp over hole with sensor housing centered.
4. Tighten saddle clamp nuts until the gasket makes a good tight seal.
5. Insert flow sensor into sensor housing. Align flat spot on sensor rim with
alignment tab and make sure o-ring is in groove.
Note: The retainer cap is hand-tightened. There is an inside lip that stops
the cap from turning when it makes contact with the alignment tab. This
provides the correct pressure to make the seal at the o-ring. Make sure the
flow sensor engages the alignment tab and does not rotate.
6. Install retainer cap and hand tighten.
7. Connect cable from display module to flow sensor (cable is color coded blue).
(Refer to Wiring Section.)

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Figure 5. Saddle Clamp Installation
Note: Allow a minimum of
2 inches clearance above the
sensor for connector removal/
installation.
Note: When the retainer cap is
tightened make sure the flow
sensor engages the alignment
tab and does not rotate.
Note: Dimensions are typical and are an
aid to determine flow sensor mounting
locations.
Pipe Size Dimensions
(Sch 40) A B C
2 5.5 3.9 2.9
2.5 5.5 3.9 2.8
3 5.9 3.9 2.8
3.5 6.8 4.3 2.8
4 6.8 4.3 2.8
5 8 4.3 2.8
Measurements are in inches.
A
C
B
Retainer
Cap
O-Ring
Paddlewheel
Flow Sensor
Sensor
Housing
Saddle
Clamp
Alignment
Tab

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Weldment Installation
Note: Ensure that the mounting location meets the requirements for uniform
water flow. (Refer to Flow Sensor Location Guide.)
Note: Ensure that there is enough room for the weldment, sensor, and
connector to fit. (Refer to Figure 6.)
1. Drill and deburr a 1-11/16" to 1-3/4" diameter hole at mounting location.
2. Center weldment mount over hole and weld it to pipe. The weld must be
continuous around the fitting with no gaps or voids.
3. Screw sensor housing into weldment far enough to make sure it goes through
the pipe freely, then back it out.
Note: The paddlewheel sensor must be correctly aligned in the water stream.
The alignment tab is used to set the position of the sensor. Make sure that
the alignment tab is centered on the pipe centerline. (Refer to Figure 6.)
4. Set sensor housing to dimension A in Figure 6. Make sure the alignment tab is
centered on the pipe as shown (it can be on upstream or downstream side).
5. Install tru-seal locknut and tighten with 2" wrench using light to medium torque.
Make sure the sensor housing alignment tab remains centered and the sensor
housing does not rotate causing dimension A to change.
6. Insert flow sensor into sensor housing. Align flat spot on sensor rim with
alignment tab and make sure o-ring is in groove.
Note: The retainer cap is hand-tightened. There is an inside lip that stops
the cap from turning when it makes contact with the alignment tab. This
provides the correct pressure to make the seal at the o-ring. Make sure the
flow sensor engages the alignment tab and does not rotate.
7. Install retainer cap and hand tighten.
8. Connect cable from display module to flow sensor (cable is color coded blue).
(Refer to Wiring Section.)

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Figure 6. Weldment Installation
Pipe Size Dimension
(Sch 40) A
1.5 1.95 to 1.80
2 1.95 to 1.80
2.5 1.90 to 1.75
3 1.88 to 1.73
3.5 1.88 to 1.73
4 1.85 to 1.70
Measurements are in inches.
Note: When the retainer cap is
tightened make sure the flow
sensor engages the alignment
tab and does not rotate.
Note: Allow a minimum of 2 inches
clearance above the sensor for
connector removal/installation.
Make sure that the alignment tab
is centered on the pipe centerline.
Note: Dimensions are
typical and are an aid to
determine flow sensor
mounting locations.
2.5"
2.8"
Retainer
Cap
Sensor
Housing
Weldment
O-Ring
Paddlewheel
Flow Sensor
Alignment
Tab
Tru-Seal
Locknut
Alignment
Tab
A
C
L

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OPERATION
On power-up the flowmeter/pressure indicator will be in the normal operating
mode. Information from a pressure sensor, a paddlewheel type flow sensor, or from the
datalink interface is processed and displayed. Operator input is necessary only when
using the totalizing function or accessing program information.
Datalink Interface
The datalink interface provides a way of connecting multiple display modules on
a shared data bus. The DFA400 (digital flowmeter), FPA400 (pressure/flow indicator),
and FPA500 (pressure/flow indicator) series display modules can operate as independent
displays or interconnected to provide remote displays, the display of flow rate through
multiple discharges (summing), and the totalization of flow for multiple discharges
(accumulation).
Primary Display Module
Primary displays are programmed with the module function Pri. A primary display
receives input from the pressure sensor and flow sensor. When it is programmed with
Id 0, no information is output to the datalink. When it is programmed with Id 1 to Id
99, it provides information (via the datalink) to remote, summing, and accumulator
displays.
Remote Display Module
Remote displays are programmed with the module function SLA (slaved to a
primary). A remote display must be programmed with the same ID number as the
primary display. It receives flow rate from the primary display over the datalink. All
remote display features are programmed independently of the primary display. No
calibration is necessary on a remote display.

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Program Features
See Programming Section for more detailed information.
High and Low Flow Warning (Codes 315 and 316)
When the flow rate is above the programmed high flow value, a flashing -HI- is
shown in the digital display. When the flow rate is below the programmed low flow
value, a flashing -LO- is shown in the digital display.
Flow Cutoff (Codes 318 or 319)
The digital display indicates 0 when the flow rate is below the programmed flow
cutoff value.
External Totalizing Button (Optional)
The totalizing button performs two functions, display total flow for a discharge or
reset the totalized flow value to 0 (if totalizer reset function is set to YES).
Display Total Flow
When the total button is pressed and released the digital display shows the total
accumulated flow. (The flow will be x 100 the number shown in the display.)
Press and release the button again to show normal flow rate.
Reset Total Flow to 0
The totalizer reset (code 317) has two program settings, YES or no. (Refer to
Programming Section). To enable the reset function the program totalizer reset is set
to YES.
Total flow resets and starts from 0 when power is applied to the control module.
Flow total is reset to 0 during operations by displaying the total flow and then pressing
and holding the TOTAL button until the display shows 0.

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PROGRAMMING
The two operator selectable modes are display module identification and program
access. These modes are selected and inputs are made using the three magnet sensors
on the front of the display module. The digital display shows stored data and operator
inputs. (Refer to Figure 1.)
Note: When entering codes in the program access mode there is a time-out
feature that requires an operator input every three seconds. If an input is not
detected within five seconds the program returns to normal operation..
Inputs
The three magnet sensors M1, M2, and M3 located on the front of the display
module allow the operator to gain access to stored data and program functions. The
sensors are activated by placing the north pole of a small magnet on the glass in close
proximity to the sensor. (The sensor will not respond to the south pole of the magnet.)
The magnet is then moved about 1-inch away, this produces an electronic signal that
is similar to a button being released. If the digits in the display do not change move
the magnet further away from the sensor.
The M1 and M2 magnet sensors are used to input data when in the program access
mode.
The M3 sensor is used to enter and exit the operator selected modes.
Display Module Identification Mode
When in the module identification mode the digital display shows the module
serial number, manufactured date, software revision, function code, and ID number.
The module identification mode is a display-only mode and no changes can be made
to program information.
Note: There is a time-out feature that returns the program to normal operation
in five seconds if input is not detected.
Select Display Module Identification Mode
Turn on power. Touch a small magnet on the glass at the M3 sensor and remove it.
The program enters the display module identification mode and the display shows the
module serial number. Touch the magnet on the glass a second time at the M3 sensor
and remove it. The display shows the manufacturing date. Each time the magnet is
touched at the M3 sensor and removed, the display shows the next block of stored
identification data.
If the M3 sensor is activated for five seconds the module reverts to normal
operation.

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Program Access Mode
To gain access to the program features a three digit program code must be entered.
Review the Program Code Descriptions or refer to Table 2. Program Code Quick
Reference for the proper three digit code.
Note: There is a time out feature that returns the program to normal operation
in five seconds if input is not detected.
Select Program Access Mode
Turn on power. Touch and hold a small magnet on the glass at the M3 sensor until
the display shows four dashes. The program access mode is ready for a three digit
program code to be entered.
Enter Program Code
Note: There is a time out feature that returns the program to normal operation
in five seconds if input is not detected at the buttons.
1. Select the Program Access Mode (four dashes are shown in the display).
2. Touch the magnet at the M1 sensor and remove it. The number 100 shows in
the display with the first digit (1) flashing. Each time the magnet is touched at
the M3 sensor and removed, the number increments by 1. Set the first digit to
the number desired.
3. Touch the magnet at the M2 sensor and remove it. The second digit flashes.
Each time the magnet is touched at the M3 sensor and removed, the number
increments by 1. Set the second digit to the desired number.
4. Touch the magnet at the M1 sensor and remove it. The third digit flashes.
Each time the magnet is touched at the M3 sensor and removed, the number
increments by 1. Set the third digit to the desired number.
When a valid three-digit program code is entered, a program value or an option
shows in the display. If an invalid code is entered an error code shows in the display.
Note: When a valid code has been entered and a program value or an option
shows in the display, the time-out feature is disabled.
Change Values or Options
Touch the magnet at the M1 sensor and remove it to select the digit to be change.
The digit flashes. Touch the magnet at the M2 sensor and remove it to change the digit
or the option choice.
Exit Program Access Mode
Touch and hold the magnet at the M3 sensor until the display shows four dashes.
Enter a new code or after five seconds the program times out and returns to normal
operation.

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CODE FEATURE OPTION
311 Flow Rate Increment Set Point 0000 to 9999
312 ID Number 0 to 99
313 Module Function Pri, SLA
315 High Flow Warning 0001 to 9999
0 = Disabled
316 Low Flow Warning 0001 to 9999
0 = Disabled
317 Totalizer Reset Yes = Resets to 0 at Power On
No = Stores Total Flow at Power Off
318 Flow Cutoff (Frequency) 0 to 99.9 Hz
319 Flow Cutoff (Flow Rate) 0 to 999
321 Flow Calibration (Single Point) 1 Calibration Point
322 Flow Calibration (Multiple Point) 9 Calibration Points
323 Pressure Calibration 2 Calibration Points
340 CAN Terminator On, Off
E202 Invalid Program Code Entered Re-Enter Code
E204 No Flow Sensor Signal Check Water Flow and Wiring
E206 Invalid Calibration Point Select Different Calibration Point
E208 Memory Failure Contact Factory
E210 Exceeded Maximum Calibration
Points
Exit Calibration Procedure
Table 2. Program Code Quick Reference
Notes:
- Refer to Program Code Descriptions for detailed information.
- There is a timeout feature that will return the program to normal operation
in five seconds if input is not detected.
- When a valid code has been entered and a programed value or option is
shown in the display, the timeout feature is disabled.
- The three magnet sensors M1, M2, and M3 located on the front of the
display module allow the operator to gain access to stored data and program
functions. The sensors are activated by placing the north pole of a small
magnet on the glass in close proximity to the sensor. (The sensor will
not respond to the south pole of the magnet.) The magnet is then moved
about 1-inch away, this produces an electronic signal that is similar to a
button being released. If the digits in the display do not change move the
magnet further away from the sensor.