Oriflow Rhino User manual

© Copyright 2015 ORIFLOW LLC
Operating Instructions for
Rhino
Duct Leakage Tester
(Metric)

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
1
Table of Contents
Introduction
Introduction ……………………………………….…….. 2
Safety Precautions
Safety Precautions ………………………………….…. 2
Prior to Testing
System Preparation …………………….………………. 3
Power Requirements …………………………………... 3
Extension Cord Requirements ………………………... 4
Flex-Duct Length ………………………………………... 4
Determining Maximum Allowable Leakage ….……... 4
Determining Which Orifice Plate to Use ……………... 5 - 7
Duct Leakage Test Setup and Procedure
Install Orifice Plate and Upper Tube Section………… 8 - 9
Connect Flexible Duct to Orifice Tube ……………….. 10
Connect Flexible Duct to Duct System ………………. 10
System Test Pressure Connection …………………… 11
Duct Leakage Test Setup (SUPPLY) ………………… 12
Duct Leakage Test Setup (RETURN/EXHAUST) ...….. 13
Inlet Transition Required for Return/Exhaust Testing . 14
Zeroing Pressure Gauges ……………………………… 15
Avoiding Over-Pressurization ………………………… 16
Obtaining System Test Pressure ……………………… 16 - 17
Determining Leakage Rate……………………………… 17 - 19
Troubleshooting
Zero reading on “DUCT SYSTEM” gauge ………….... 19
Zero reading on “ORIFICE PLATE” gauge …………….. 20
Can’t obtain system test pressure ……………………… 21
“ORIFICE PLATE” gauge reading maxed out………...... 21

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Introduction
These operating instructions are for ORIFLOW model RHINO air leakage tester.
Take pride in knowing that you have purchased the best air leakage tester on the
market. It is no secret that Oriflow manufactures the highest quality testers, and has
unparalleled customer service and technical support.
The orifice plates available for your duct leakage tester are constructed from laser-
cut 3.2 mm stainless steel and do not require recalibration for 10 years. Note the
authority having jurisdiction may override this requirement, and if so, Oriflow has very
reasonable rates for calibrating orifice plates manufactured by Oriflow.
Safety Precautions
Before operating your tester, read the following safety precautions:
DO NOT operate the tester in the rain,
DO NOT operate the tester while it is near or in water,
DO NOT operate the tester with a damaged electrical cord or plug,
DO NOT remove the inlet safety screen,
DO NOT touch the blower wheel when the unit is plugged in,
DO NOT look into the discharge end of the tester when the unit is plugged in,
DO NOT use the tester as a ladder or step stool,
DO NOT allow children near the tester,
DO use an extension cord of the proper gauge (see Table 2),
DO use the proper voltage and line frequency listed on the motor nameplate,
DO lock the caster when the tester is positioned horizontally,
DO use the tester on level ground,
DO secure the tester when transporting it,
DO wear proper hearing protection, safety glasses and work gloves,
DO seek assistance when lifting the tester (e.g., loading onto truck, going up
or down stairs).

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Prior to Testing
System Preparation
Cap off all ends of system using clear plastic and duct tape or sheetmetal duct end
caps. Make sure you test the part of the duct system that leakage testing is required.
Usually, this is from the system fan up to, but not including, the VAV boxes (terminal
units). Refer to the engineer's specifications and all applicable codes and test
standards.
Power Requirements
Do you have an adequate power supply for your tester (see Table 1)?
Table 1 – Tester Amp Draw
Tester
Model Voltage Flow
Control
Option Phase Full Load
Amps
Rhino
208 Slide Gate 3 13
208 VFD 3 14
230 VFD 1 21
230 Slide Gate 3 12
230 VFD 3 13
380 Slide Gate 3 7
380 VFD 3 8
460 Slide Gate 3 6
460 VFD 3 7

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Extension Cord Requirements
If you need an extension cord, is it the proper gauge? See Table 2 below for
extension cord requirements.
Table 2 – Required Extension Cord Wire Gauge
Rhino Model
Flow
Control
Option Voltage Phase
Extension
Cord Length
(meters)
Wire
Gauge
VFD 230 1 3 to 15 10
15 to 30 10
Slide Gate 230 3 3 to 15 14
15 to 30 14
VFD 230 3 3 to 15 14
15 to 30 14
Slide Gate 380 3 3 to 15 14
15 to 30 14
VFD 380 3 3 to 15 14
15 to 30 14
Slide Gate 460 3 3 to 15 14
15 to 30 14
VFD 460 3 3 to 15 14
15 to 30 14
Flex-Duct Length
Make sure you have enough flexible-duct with your tester for the job. Each tester
includes 3.8 m, which is enough for most applications. Extra lengths of flexible-duct
are available at www.oriflow.com/products.
Determining Maximum Allowable Leakage
To determine the maximum allowable leakage for the project, use ORIFLOW’s free
online programs to make these calculations (www.oriflow.com/programs).
Calculations are done for either of the two typical specifications: percentage of
system flow, or leakage class. If the specification uses leakage class, you will need
to calculate the total duct system surface area. Oriflow has a free Adobe form
available to our customers that will calculate duct surface area given the duct shape,
dimensions and length.

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Determining Which Orifice Plate to Use
After determining the allowable leakage at the system test pressure, refer to the
following tables for the capacities of each orifice plate available for the RHINO model
tester. Make sure you have an orifice plate that can measure the maximum allowable
leakage. The proper plate is the one where the maximum allowable leakage falls
between the minimum and maximum leakage at the system static pressure. For
example, if you are testing a system at 2500 Pa pressure and the maximum
allowable leakage is 283 L/s, you will need a 125 mm orifice plate since the 125 mm
plate can be used for up to 380 L/s of leakage (see Table 7).
It is a good idea to have the next larger orifice plate size since it is common for duct
systems to leak more than the maximum allowable. Smaller diameter plates are use
when leakage is relatively low.
Table 3 – Tester Capacities using the 25 mm Orifice Plate
System Static
Pressure
(Pa)
Minimum
Leakage*
(L/s)
Maximum
Leakage
(L/s)
500 4 21
1000 4 19
1500 4 18
2000 4 17
2500 4 14
3000 4 12
3500 4 9
4000 4 6

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Determining Which Orifice Plate to Use (continued)
Table 4 – Tester Capacities using the 50 mm Orifice Plate
System Static
Pressure
(Pa)
Minimum
Leakage*
(L/s)
Maximum
Leakage
(L/s)
500 17 87
1000 17 78
1500 17 73
2000 17 66
2500 17 57
3000 17 47
3500 17 35
4000 17 26
Table 5 – Tester Capacities using the 75 mm Orifice Plate
System Static
Pressure
(Pa)
Minimum
Leakage*
(L/s)
Maximum
Leakage
(L/s)
500 40 195
1000 40 180
1500 40 165
2000 40 145
2500 40 130
3000 40 105
3500 40 80
4000 40 60
Table 6 – Tester Capacities using the 100 mm Orifice Plate
System Static
Pressure
(Pa)
Minimum
Leakage*
(L/s)
Maximum
Leakage
(L/s)
500 75 370
1000 75 340
1500 75 310
2000 75 280
2500 75 245
3000 75 195
3500 75 155
4000 75 105

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Determining Which Orifice Plate to Use (continued)
Table 7 – Tester Capacities using the 125 mm Orifice Plate
System Static
Pressure
(Pa)
Minimum
Leakage*
(L/s)
Maximum
Leakage
(L/s)
500 125 560
1000 125 520
1500 125 480
2000 125 430
2500 125 380
3000 125 310
3500 125 240
4000 125 175
Table 8 – Tester Capacities using the 159 mm Orifice Plate
System Static
Pressure
(Pa)
Minimum
Leakage*
(L/s)
Maximum
Leakage
(L/s)
500 215 730
1000 215 670
1500 215 630
2000 215 560
2500 215 510
3000 215 425
3500 215 310
4000 215 230

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Install Orifice Plate and Upper Tube Section
The orifice plate that was determined from the previous section should now be
installed with the serial number facing upwards, so the corresponding calibration
certificate may be referenced after installation. Refer to Figures 1 through 4.
Figure 1 – Install Orifice Plate and then Rotate Clockwise
Figure 2 – Rotate Orifice Plate Clockwise until it Locks in Place

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Install Orifice Plate and Upper Tube Section (continued)
After the orifice plate is locked in place, place the upper tube section over the
bolt/wing nut set, rotate clockwise, and tighten wing nuts (Figures 3 and 4).
Figure 3 – Install Upper Tube Section and Rotate Clockwise
Figure 4 – Tighten Wing Nuts after Rotation

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Connect Flexible Duct to Orifice Tube
See the figures below for securing one end of the flexible duct to the orifice tube.
Note that the worm-gear clamp should be slid over the flex-duct before connecting it
to the orifice tube. Slide the flexible duct so that it overlaps the orifice tube 25 to 50
mm, and tighten clamp using a 8 mm nut driver.
Figure 5 – Installing Flex-Duct on Tube Figure 6 – Tightening Clamp
Connect Flex-Duct to Duct System
Find a convenient location in the duct system where the tester has easy access.
Make sure that the connection where you connect the flexible duct is a sturdy, sealed
tight connection. You don’t want to create a leaky connection where the tester is
supplying air into the system.
Figure 7 – Connection to Duct System

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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System Test Pressure Connection
So that you can monitor the system static pressure, you need to drill a hole at least 1
meter away from the flex-duct connection. Drill a 8 mm diameter hole and insert the
pressure tubing from the “DUCT SYSTEM” gauge so that 150 to 300 mm of tubing is
inside the duct system. Using putty or duct tape, seal the connection. If your
pressure tubing has a plastic static pressure tap at the end of the pressure tubing,
insert the tap in the hole and seal it to the duct wall using duct tape. See Figure 8
below.
Figure 8 - Static Pressure Tubing Connection
See Figure 9 showing the test setup for SUPPLY system testing. Refer to Figure 10
for the test setup required to measure air leakage of a RETURN/EXHAUST system.
Note you will need an inlet transition to attach to the blower inlet when performing a
return/exhaust test. The dimensions of the transition required depends on whether
you have a Rhino model with an inlet slide gate or VFD for flow control. See Figure
11 and 12 for inlet transition dimensions required.
DUCT SYSTEM pressure tubing
inserted into duct s
y
stem

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Figure 9 – Duct Leakage Test Setup for a SUPPLY System
Cap and seal
all outlets
Tap into existing
outlet if possible
1. Drill 9.5 mm hole
2. Insert tubing 150 to 300 mm
3. Seal penetration with putty

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Figure 10 – Duct Leakage Test Setup for a RETURN/EXHAUST System

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Fi
g
ure 11 - Inlet Transition Required for Rhino with Inlet Slide Gate
Fi
g
ure 12 - Inlet Transition Required for Rhino with VFD Speed Controller

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Zeroing Pressure Gauges
Before you run the tester, make sure both gauges have been zeroed.
Zeroing Analog Gauges
Using a very small screwdriver, turn the zero-adjustment screw on the gauge
until the needle is aligned with the zero reading. Turning the screw clockwise
increases the pressure reading; turning it counterclockwise, decreases the
reading. See Figure 13.
Figure 13 – Zeroing Analog Gauges
(zero BOTH gauges before testing)
Zeroing Digital Gauges
Use the following steps to zero each digital gauge:
1. Press MENU button once.
2. Press
▼arrow button until Adu shows on screen.
3. Press
Ebutton once to go into auto-zero mode
4. Press
Ebutton again and AUTO will be blinking on screen
5. Press
Ebutton a third time to complete the zeroing process.
6. Press MENU button two times to get back to the pressure reading.
7. Pressure should be reading zero or within +/- 5 Pa If not, repeat
steps.

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Avoid Over-Pressurization
Prior to starting the blower, shut the inlet slide gate on models without the speed
controller option. For models with the VFD speed controller, rotate the speed control
knob completely counter-clockwise.
Figure 14 – Avoid Over-Pressurizing by Minimizing Air Delivery upon Startup
Obtaining System Test Pressure
Turn the blower on and slowly open the inlet slide gate for models without the
speed control option. If your tester has the VFD speed controller, rotate speed
control knob slowly clockwise to obtain system test pressure.
Figure 15 – Obtaining System Test Pressure

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Obtaining System Test Pressure (continued)
Regardless of tester model used, pay attention to the “DUCT SYSTEM” gauge while
increasing airflow. When you have reached the required system static pressure,
tighten the set-screw on the inlet damper (or STOP rotating speed control knob).
Figure 16 – Duct System Gauge Reading (analog on left, digital on right)
Determining the Leakage Rate
Now that you have obtained the system test pressure, note the pressure reading of
the ORIFICE PLATE gauge (Figure 17). Refer to your calibration certificate to
determine the leakage rate that corresponds to the gauge reading. An example of a
calibration certificate is shown in Figure 18; it is for informational purposes only and
used in the example shown on the next page. Always refer to the calibration
certificate(s) that came with your calibrated orifice plate(s).
Figure 17 –ORIFICE PLATE Gauge Reading (analog on left, digital on right)

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Determining the Leakage Rate (continued)
SAMPLE CALIBRATION CERTIFICATE
USE YOUR CERTIFICATE
Figure 18 – Example Calibration Certificate. Use the calibration certificate that came with your orifice
plate
Example (refer to Figures 17 and 18)
For an ORIFICE PLATE gauge reading of 725 Pa (Figure 16), the leakage
rate is approximately 194 L/s using the calibration certificate shown in
Figure 18 (see arrow).
For an exact value, use the equation that comes with every calibration
certificate. For the ORIFICE PLATE gauge reading shown in Figure 17:
Leakage = 7.206 x
203.2 mm

© Copyright 2018 ORIFLOW LLC Rev: 03-2018
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Determining the Leakage Rate (continued)
where the value of “7.206” is a constant and will be specific to the orifice
plate used (every plate has its own value; yours will be different).
Using a calculator, take the square root of the gauge reading first, and then
multiply by the constant for your orifice plate (for this example, the constant
is "7.206"). The exact leakage is 7.206 x (square root of 725) = 194.0 L/s.
Oriflow has FREE Adobe forms available that will calculate the leakage, leakage
factor, allowable leakage, Pass/Fail criteria and duct surface area among other
variables (www.oriflow.com/freeform).
Troubleshooting
Zero reading on “DUCT SYSTEM” gauge
If the gauge reading is zero, refer to the table below to fix this problem. Perform
troubleshooting steps in the order shown in the Table 9 below.
Table 9 –Troubleshooting steps when “DUCT SYSTEM” gauge is zero
Step Scenario What to do
1 Inlet damper was left shut,
cutting off air to the system. Open inlet damper slowly.
2 Pressure tubing connected
to gauge incorrectly
Look at the P1 and P2 stickers that are located on the
orifice tube and gauges. Make sure tubing from P1 tap
matches the P1 tap on the “ORIFICE PLATE” gauge.
3 Plugged fitting or
malfunctioning gauge.
Gently blow through other end of pressure tubing from
“DUCT SYSTEM” gauge, and watch needle increase
pressure reading.
4 System is leaking
too much air.
Check for these other sources of leakage:
Rectangular duct joints (check and seal corners),
Fire or smoke dampers,
Duct joints (pay particular attention to flex-duct
joints if they are part of the leak test),
VAV boxes (pay particular attention to parallel box
back draft dampers),
Built-up air handlers,
Plenums,
Uncured duct sealant blow-thru (follow
manufacturer instructions for cure time),
Improperly sealed or un-sealed joints,
Hot water coils and electric heaters,
Open duct end that was supposed to be
sealed/capped-off for the leak test.