FRC INSIGHT iPF-8 User manual

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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
PORTABLE
FLOWTESTER
MODEL: iPF - 8, -10, -12, -14, -16

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CONTENTS
Table of Contents
CONTENTS ............................................................................................................... 2
List of Tables ......................................................................................................... 3
List of Figures ....................................................................................................... 3
INTRODUCTION ...................................................................................................... 4
Overview ............................................................................................................... 4
Features ................................................................................................................. 4
Specifications ........................................................................................................ 5
GENERAL DESCRIPTION....................................................................................... 6
Components........................................................................................................... 6
TYPICAL APPLICATIONS....................................................................................... 8
Hydrant Total Flow Test........................................................................................8
Pump Test .............................................................................................................. 9
Nozzle Test ..........................................................................................................10
Training ............................................................................................................... 10
Calibrate a Vehicle Mounted Flowmeter.............................................................10
FLOW RATE MEASURING INFORMATION....................................................... 11
POWER ....................................................................................................................12
Internal Battery.................................................................................................... 12
Alternate Power Sources ..................................................................................... 12
OPERATION ............................................................................................................ 13
Program Features.................................................................................................13
Flow Test .............................................................................................................14
Totalized Flow..................................................................................................... 15
PROGRAMMING.................................................................................................... 16
Inputs ...................................................................................................................16
Program Access Mode......................................................................................... 17
Program Code Descriptions ................................................................................18
Enter Sensor/Tube Size ....................................................................................... 22
CALIBRATION........................................................................................................24
FLOW SENSOR MAINTENANCE ........................................................................ 26
PARTS LIST ............................................................................................................. 27

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List of Tables
Table 1. Values for K With a 2.5" Flow Tube ............................................................ 8
Table 2. Flowmeter Calibration Flow for Each Pipe Size....................................... 11
Table 3. Program Code Quick Reference................................................................ 18
List of Figures
Figure 1. Controls and Indicators.............................................................................. 7
Figure 2. Typical Programming Displays................................................................16
Figure 3. Sensor/Tube Size Program Displays........................................................ 23
Figure 4. Flow Sensor Maintenance........................................................................26
Figure 5. Parts List .................................................................................................. 27

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INTRODUCTION
Overview
The INSIGHT Portable Flow Tester is an instrument that will measure flow
rate directly without using charts or doing calculations. The tester is designed around
the FRC INSIGHT digital flowmeter and a paddlewheel type flow sensor mounted
ina flow tube.Theflowtesterprogram allows for upto six differentcalibration schemes
to be set in memory. This enables the operator to press a button and use the same
portable tester with different size flow tubes.
The PortableFlowTester consists of a Pelican case into which a panel is mounted
containing an INSIGHT digital flowmeter, a power switch, low battery indicator, and
cable connections. The Pelican case also contains a rechargeable battery and an AC
charger/power supply. Aslot cutout in the front panel allows for the storage of cables.
The INSIGHT digital flowmeter has a 4-digit LED flow display with daylight
bright digits 0.56 inch high. The flowmeter electronics are self contained and program
features are accessed via push buttons on the front of the module. Flow rate information
is provided from the paddlewheel flow sensor mounted in a flow tube. This information
is processed and shown on the digital display as flow rate.
The Portable Flow Tester is can be powered by its internal rechargeable 12 volt
battery, a 120 VAC source, or an external 12 VDC source (with optional cable). The
battery charging unit is mounted inside the box. To charge the internal battery plug
the cable into theAC CHARGER input on the front panel and connect the other end to
a standard 120 VAC electrical outlet.
All controls, indicators, and input connections are located on the front panel.
Features
Field Programmable
Multiple Flow Rate Calibration Points
Uses Multiple Diameter Flow Tubes
High and Low Flow Warnings
Totalizing Flow Function

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Specifications
Display Module
Supply Voltage: 9 - 30 VDC
Supply Current: 0.5 Amp
Flow Tube
Material: Aluminum
Sizes Available:
iPF- 8 1.5" Tube w/2.5" Couplings (13 - 320 GPM)
iPF-10 2.0" Tube w/2.5" Couplings (21 - 520 GPM)
iPF-12 2.5" Tube w/2.5" Couplings (30 - 750 GPM)
iPF-14 3.0" Tube w/NPT Threads (40- 1400 GPM)
iPF-16 4.0" Tube w/NPT Threads (80 - 2000 GPM)
Note: GPM rating is at 0 PSI back pressure (no obstruction at end of tube).
Flow Sensor
Type: Paddlewheel with Brass Housing for Saddle Clamp
or Weldment Mount (Stainless Steel Housing
Optional)
Sensor Material: Acetal (Delrin) with Stainless Steel (316) Shaft
Excitation Voltage: 5 VDC
Cables
120 VAC Power Cable: Part # IPF-C120
Flow Sensor Cable: Part # IPF-C-12 (12 Feet)
12 VDC Power Cable: Part # IPF-C12V (Optional)

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GENERAL DESCRIPTION
Components
The INSIGHT Portable Flow Tester consists of the following components:
Case
Digital Flowmeter Display
Battery and Charger
Flow Tube(s)
Paddlewheel Flow Sensor and Sensor Housing Assembly
Cables
Case
Mounted inside the Pelican case is a panel that has a digital flowmeter display
module, power switch, low battery indicator, and input cable connectors installed.
The case also houses a rechargeable battery and an AC charger/power supply. A slot
cutout in the front panel allows for the storage of cables. All controls and indicators
are located on the front panel. (Refer to Controls and Indicators.)
Digital Flowmeter Display Module
The flowmeter display module contains a digital display, two buttons and an LED.
It also houses the electronics and programs that are used to operate the portable tester.
The programs are accessed and inputs are made by using two buttons on the front of
the display module.
Battery and Charger
The battery and charger used in the tester is a maintenance free, sealed lead acid
battery. If any problems occur with any of the charging circuits, or if it is found during
a test that the battery is not charged, it is possible to power the unit directly from either
a 120 VAC or a 12 VDC source. (Refer to Power section.)
Flow Tube(s)
The tester can store in memory calibration data for up to six flow tubes. Each
flow tube will have a mount for a paddlewheel flow sensor.
Paddlewheel Flow Sensor
The flow sensor provides an input signal to the display module that is proportional
to the flow rate through the tube. It is mounted in the discharge end of the tube. The
electrical connector is waterproof and molded into the flow sensor housing.

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Figure 1. Controls and Indicators
Mode Button Total ButtonTotalx100
LED
Digital
Display
Storage area for
all cables.
120 VAC Power
Cable Input
(For power or to charge
the internal battery.)
12V DC Power
Cable Input
(Requires optional
power cable.)
Low
Battery
Indicator
ON / OFF
Switch
Flow Sensor
Cable Input
Digital
Flowmeter

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TYPICAL APPLICATIONS
Hydrant Total Flow Test
A direct reading of flow in Gallons Per Minute (GPM) can be obtained by
connecting the portable flow tester to a discharge, flow water and record the flow
displayed. The tester can also be used (employing some simple math) to find the total
output of a hydrant. This can be accomplished by recording the differences in flow
out of one discharge as other ports on the hydrant are opened.
The hydrant test method described below assumes the use of a portable flow
testerwith a 2.5" flow tube. If adifferentsizetubeis used, the mathematicalcalculations
below would need to be adjusted.
The Portable Flow tester may be connected to the 2.5" hydrant port in order to
obtain individual hydrant flow measurements. Other ports may be opened as desired.
To conduct this test, proceed as follows:
1. Connect the flow tube to a 2.5" port. (Adapters are not supplied.)
2. Open the hydrant valve and record the flow reading.
3. Shut off the hydrant and remove the other 2.5" cap.
4. Open the hydrant valve and record the flow reading.
Note: This reading will be lower than the first reading as the water is now
being discharged from two ports.
5. If the hydrant has a steamer port, open that and record the flow as above.
If more than one port is opened, the total actual flow will be higher than the
displayed flow, but it will be in proportion to the opened port areas. The actual flow
can be determined by multiplying the displayed flow by a "K" factor such that:
Total Actual Flow = Displayed Flow x K
Use the values for "K" in Table 1 to determine actual estimated flow.
Table 1. Values for K With a 2.5" Flow Tube
PORTS OPENED K
One 2.5" port with 2.5" flowmeter attached 1.00
Two 2.5" ports, one with 2.5" flowmeter attached 2.00
One 2.5" with 2.5" flowmeter attached and one 4.5 “ steamer 4.24
Two 2.5", one with 2.5" flowmeter attached and one 4.5" steamer 5.24

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For different size flow tubes the value for K that is used to determine total flow
out of the hydrant will be different than those shown in Table 1. Use the following
formula to determine new value for K.
Total Flow Area
Constant K =
Area of Flow Tube Opening
Total Flow Area = Finding the sum of the areas of all open discharges.
(Area of a circle is
π r2)
"K" factor are used as multipliers to determine total flow out of a hydrant when
the portable flow tester is hooked up to only one port of the hydrant, but water is
flowing out of more than one.
Pump Test
The Portable Flow Tester can be used to test pumpers not only from draft but
also from the tank or from a hydrant. It is extremely valuable to know not only that
your pumper can pass the service test, but remember it is necessary to know your
capabilities on the fire ground.
Make sure your pump can supply your preconnected lines with enough water
from the tank, if that is the way you expect to use them. For in-line pump testing,
attach the portable flow tester to the hydrant and run a typical hose layout. Next,
extend your standard fire fighting lines and open them. Monitor the flow.
For the service type of test, connect three lines into a common manifold. On the
discharge of the manifold connect a short length of hose leading into the portable
flow tester. Attach another length of hose on the discharge side and connect this to a
deck gun or monitor. If the monitor incorporates a sufficient straight length, with an
integral stream straightener, then the tester may be attached on to the discharge end of
the monitor in lieu of the nozzle.
Test the pumper according to the certification pressure, RPM, and volume or
pressure pump settings. To do that, set the RPM and then adjust the pump pressure by
adjusting the discharge valves. Correct the RPM if it has changed and readjust the
pressure if that has changed. When you are at the correct pressure and RPM point,
note the flow. The flow should meet the pumper rating at that pressure and RPM.

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Nozzle Test
Attach a hose to the inlet of the flow tube and the nozzle to be tested on the
discharge of the flow tube. The nozzle may be either a smooth bore type or automatic.
Flow the nozzle at various pressures and note the flow and pressure displayed on the
readout.Thistestwillprovide a vividdepiction of the nozzlepressure/flow relationship.
Training
Use the Portable Flow Tester in training sessions to show firemen the effects of
pressure and flow on hose handling, reach of stream, the effects of kinked hose, etc. as
pumper pressure and nozzle sizes are changed.
Install the flow tube in the line behind the nozzle, preferably not directly on to the
discharge port of the pumper. Both the nozzleman and the pump operator vary their
valves. It is now possible to monitor the flow and thus determine the optimum flow
for various situations. This will be a graphic presentation of interaction of pressure,
flow, and nozzles. It will also demonstrate the desirability of Fire Research Flow and
PressureTesters, whichhavebeen specifically designed forthe fire industry, particularly
in the case where automatic nozzles are used.
Calibrate a Vehicle Mounted Flowmeter
1. Connect the portable flow tester flow tube to the pump suction port. (Refer to
Figure 2.)
2. Lay a 2 1/2" hose from the discharge to be tested to the flow tube making sure
there is no kink in the hose.
3. With the pump engaged open the discharge gate slowly all the way.
4. Control the flow with the suction port valve and by changing the RPM if
needed.
5. Read the displayed flow on the tester flowmeter.
Note: Referto the vehicle flowmetermanufacturer'sinstructions to determine
how to adjust the calibration of the vehicle mounted flowmeter.
6. Have an assistant calibrate the vehicle flowmeter to match the reading on the
tester flowmeter.