TSI Incorporated 4040 Operation manual

GENERAL PURPOSE
THERMAL MASS FLOWMETER
MODEL 4040/4043/4045
OPERATION AND SERVICE MANUAL
P/N 1980339, REVISION J
FEBRUARY 2016
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ii
EXCLUSIVE REMEDY SHALL BE THE RETURN OF THE PURCHASE PRICE
DISCOUNTED FOR REASONABLE WEAR AND TEAR OR AT SELLER’S OPTION
REPLACEMENT OF THE GOODS WITH NON-INFRINGING GOODS.
TO THE EXTENT PERMITTED BY LAW, THE EXCLUSIVE REMEDY OF THE USER
OR BUYER, AND THE LIMIT OF SELLER'S LIABILITY FOR ANY AND ALL LOSSES,
INJURIES, OR DAMAGES CONCERNING THE GOODS (INCLUDING CLAIMS
BASED ON CONTRACT, NEGLIGENCE, TORT, STRICT LIABILITY OR OTHERWISE)
SHALL BE THE RETURN OF GOODS TO SELLER AND THE REFUND OF THE
PURCHASE PRICE, OR, AT THE OPTION OF SELLER, THE REPAIR OR
REPLACEMENT OF THE GOODS. IN THE CASE OF SOFTWARE, SELLER WILL
REPAIR OR REPLACE DEFECTIVE SOFTWARE OR IF UNABLE TO DO SO, WILL
REFUND THE PURCHASE PRICE OF THE SOFTWARE. IN NO EVENT SHALL
SELLER BE LIABLE FOR LOST PROFITS, BUSINESS INTERRUPTION, OR ANY
SPECIAL, INDIRECT, CONSEQUENTIAL OR INCIDENTAL DAMAGES. SELLER
SHALL NOT BE RESPONSIBLE FOR INSTALLATION, DISMANTLING OR
REINSTALLATION COSTS OR CHARGES. No Action, regardless of form, may be
brought against Seller more than 12 months after a cause of action has accrued. The
goods returned under warranty to Seller's factory shall be at Buyer's risk of loss, and will
be returned, if at all, at Seller's risk of loss.
Buyer and all users are deemed to have accepted this LIMITATION OF WARRANTY
AND LIABILITY, which contains the complete and exclusive limited warranty of Seller.
This LIMITATION OF WARRANTY AND LIABILITY may not be amended, modified or its
terms waived, except by writing signed by an Officer of Seller.
Service Policy
Knowing that inoperative or defective instruments are as detrimental to TSI attention to
any problems. If any malfunction is discovered, please contact your nearest sales office
or representative, or call TSI's Customer Service department at [phone] (USA)
or (001 651) 490-2811 (International) or visit www.tsi.com.
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iii
CONTENTS
CHAPTERS
1 UNPACKING AND PARTS IDENTIFICATION ............................. 1
2 SETTING-UP ................................................................................. 3
Supplying Power ............................................................................ 3
Connecting Filter and Flow Tubes ................................................. 4
RS232 Configuration and Operation ............................................. 4
Configuration Software .................................................................. 5
3 OPERATION ................................................................................. 7
Overview ........................................................................................ 7
ON/OFF Switch ............................................................................. 7
Warm-up Time ............................................................................... 7
Flow Rate Measurement ............................................................... 7
Temperature Measurement ........................................................... 8
Pressure Measurement ................................................................. 8
Volume Measurement ................................................................... 8
4 MAINTENANCE ............................................................................ 9
Flow Sensor ................................................................................... 9
Re-certification ............................................................................... 9
Cases ............................................................................................ 9
Storage .......................................................................................... 9
5 TROUBLESHOOTING ................................................................ 11
APPENDIXES
A SPECIFICATIONS* ..................................................................... 13
B STANDARD FLOW RATE VS. VOLUMETRIC FLOW RATE.... 17
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1
Chapter 1
Unpacking and Parts Identification
Carefully unpack the instrument and accessories from the shipping
container. Check the individual parts against the list of components in
Table 1. If any parts are missing or damaged, notify TSI immediately.
Table 1. List of Components
Qty
Item Description
Part/Model
1
Mass Flowmeter, 22 mm ISO tapered inlet/outlet
Mass Flowmeter, 0.50 inch inlet/outlet
Mass Flowmeter, 0.75 inch inlet/outlet
4040
4043
4045
1
Computer Cable
1303583
1
Analog Cable
1303584
1
Filter
22 mm ISO-taper (for Model 4040)
3/8” Female NPT (for Model 4043/45)
1602292
1602300
1
AC Adapter
100 to 240 V, N. America NEMA 5-15 plug, grounded
100 to 240 V, Europlug, CEE 7/16, grounded
100 to 240 V, Great Britain, grounded, fused
100 to 240 V, Australia/NZ
8918-NA
8918-EC
8918-GB
8918-AT
1
Operation and Service Manual
1980339
1
RS232 Serial Command Set manual
1980340
1
Carrying Case (optional accessory)
1319176
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Chapter 1
2
Parts Identification
Figure 1-1 Model 4040/4043/4045 Mass Flowmeter
1. On/Off Switch
4. DC Power Input
2. Display
5. Flow Inlet
3. Mounting Inserts (2)
6. Computer Serial Interface and
Analog Output and Optional
Power Input Connector
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3
Chapter 2
Setting-Up
Supplying Power
The flowmeter can be powered in one of two ways: through the power
jack using the supplied AC adapter or through the mini-DIN
connector. The DC power input connector is shown below along with
the power requirements.
Power Supply: 7.5 VDC ± 1.5 V, 300 mA maximum
When supplying power through the TSI-supplied interface cable, line
up the arrow on the connector with the bottom side of the flowmeter.
Flowmeter connector pin-out designations are shown below.
Table 2. List of Connector Pin-outs and
Cable Color Code Designations
Pin
Function
Cable Color
Code
1
Power Input (+)
Black
2
Power Ground (-)
Green
3
Analog Output (+)
Red
4
Analog Ground (-)
Brown
5
(no connection)
Blue
6
RS232 Receive (in)
White
7
RS232 Transmit (out)
Yellow
8
Logic Ground
Gray
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Chapter 2
4
Connecting Filter and Flow Tubes
The Models 4040/4043/4045 have an exposed thermal flow sensor,
which must be protected from foreign matter and particles in the gas
flow. TSI has supplied a filter, which should be connected to the inlet
of the flowmeter; however, any filter will work as long as it has a
minimum efficiency of 99.9%.
Caution
Always use a filter on the inlet of the flowmeter.
Failure to filter the gas flow may change the
calibration and/or permanently damage the
sensor.
Note: Flow direction is identified by the large arrow printed on the
bottom side of the flowmeter.
After attaching the filter, connect the flow tube, to the inlet, of the
filter. Connecting a tube to the outlet of the flowmeter will create back
pressure. See Appendix A for flowmeter accuracy specifications when
operating at various pressures. In general, minimize back pressure on
the flowmeter to maintain higher accuracy.
RS232 Configuration and Operation
Many flowmeter operating parameters can be easily configured
through the RS232 serial port. Likewise, the flow rate, temperature,
pressure, and volume can be read through the serial port. Refer to
the Series 4000/4100 RS232 Serial Command Set manual for a
detailed description of the commands and command syntax.
RS232 Settings: Baud Rate ........ 38.4 k
Data Bits .......... 8
Parity ................ None
Stop Bits .......... 1
Flow Control ..... None
Table 3. Changeable Operating Parameters
Function
Command
Select Gas Calibration (air, oxygen, mixture)
SG
Select Oxygen Concentration in Air (21% to 99%)
SGM
Select Standard or Volumetric Flow Measurement
SU
LCD Display Update Rate (controls averaging)
SUR
Select Data Update Rate for Analog Output
SSR
Set Analog Output Full-Scale Flow Rate Value
SAS
Set Analog Output Zero Value
SAZ
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5
Configuration Software
TSI has several software utilities to help you communicate with your
flowmeter to change parameters and to obtain flow data. You can
download the latest versions of these at no charge from our web site:
1. If you only want to change one or more of the operating
parameters shown in Table 3 (above), the easiest way is to use
the software utility called “TSI setup.” This uses convenient drop-
down menus to help change these parameters. After you have
made your changes, be sure to click on “Send” to store the
changes in the flowmeter’s memory.
2. If you want to communicate directly with the flowmeter using the
basic RS232 commands shown in the Serial Command Set
Manual, you can use a terminal program. HyperTerminal is a
common terminal program that is included with most versions of
the Microsoft operating system. You can download a document
from our web site that helps you configure HyperTerminal.
Download the document called “Using HyperTerminal to
communicate with TSI Flowmeters.”
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7
Chapter 3
Operation
Caution
TSI flowmeters are not medical devices under
FDA 510k and in no situation should they be
utilized for human respiration measurements.
Overview
The Models 4040/4043/4045 Flowmeters measure mass flow rate,
temperature and absolute pressure of the gas inside the flow tube. All
measurements made by the Model 4040/4043/4045 are NIST
traceable.
ON/OFF Switch
Slide the switch to the ON position. The power switch is marked in the
international symbols '|' for on and 'O' for off. The flowmeter will begin
to simultaneously display flow rate, temperature and pressure.
Warm-up Time
The flowmeter will provide readings immediately upon power-up.
Recommended warm-up time of the flowmeter is 5 minutes.
Flow Rate Measurement
Flow rate data can be obtained from the Models 4040/4043/4045
through the LCD display, RS232 serial port or the linearized analog
output. The analog output is a 0 to 10 volt DC linear signal
representing 0 to 300 Std L/min (Model 4043: 200 Std. L/min) (analog
output scaling is user selectable). Refer to the RS232 Serial
Command Set manual for instructions on how to obtain flow data
through the serial port.
Gas calibrations (air, 100% nitrogen, 100% oxygen, or air/oxygen
mixtures) can be selected through the RS232 serial port. Refer to the
RS232 Serial Command Set manual for instructions on how to select
gas calibrations. The LCD display will indicate the calibration being
utilized, air or O2. When air/oxygen mixtures are being measured, the
LCD display will illuminate both the air and oxygen symbols. When
nitrogen is selected no gas type is displayed on the LCD.
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Chapter 3
8
Flow can be displayed in units of standard liters per minute
(Std L/min*) or in volumetric units of liters per minute (L/min). Refer to
Appendix B for a description between the two measurements.
Selecting between the two measurements is accomplished through
the serial port. Refer to the RS232 Serial Command Set manual for
instructions on how to select between flow units.
Temperature Measurement
The Models 4040/4043/4045 have an independent temperature
transducer in the flow tube to measure the gas temperature. The
temperature sensor is used for temperature compensation of flow rate
and for converting flow from standard to volumetric units.
Temperature is displayed on the LCD and is available through the
RS232 serial port in the units of degrees Celsius (°C).
Note: At low flow rates, the temperature inside of the flow tube will
increase because of the heat generated by the thermal flow
sensor. This effect is normal and the temperature of the
incoming gas will be measured once flow resumes.
Pressure Measurement
The Models 4040/4043/4045 measure absolute pressure near the
outlet of the flowmeter in the SI units of kilo-Pascals (kPa). Pressure
measurements are required when converting from standard to
volumetric flow. Absolute pressure measurements are displayed on
the LCD display and are available through the RS232 serial port.
Volume Measurement
The Models 4040/4043/4045 measure total volume by integrating flow
over time. This is a calculated measurement performed by the
flowmeter and is only available using the RS232 serial port. Volume is
not displayed on the LCD display. Refer to the Models
4040/4043/4045 RS232 Serial Command Set manual for instructions
on using the volume function.
*TSI instruments defines standard conditions as 21.1°C (70° F) and 101.3 kPa (14.7
psia, 1 bar).
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9
Chapter 4
Maintenance
Flow Sensor
Periodically inspect the flow sensor by looking into the outlet of the
flowmeter. Remove dust, particles and fibers from the sensor, with
clean, dry compressed air. The flow sensor will break if touched.
Never run liquids through the flowmeter and never touch the
sensor with a brush. Dust or other deposits on the flow sensor will
degrade the 4040/4043/4045 flowmeter’s flow accuracy.
Caution
The flowmeter must be switched off for cleaning.
Only use clean, dry, compressed air when
attempting to remove contamination from the
sensor.
Re-certification
To maintain a high degree of confidence in the measurements made
by the Models 4040/4043/4045, TSI recommends that you return the
instrument to TSI every 12 months for re-certification. For a nominal
fee, we will recalibrate the unit and return it to you with a certificate of
calibration and US National Institute of Standards Technology (NIST)
traceability. This “annual checkup” assures you of consistently
accurate readings; it is especially important in applications where
strict calibration records must be maintained.
Cases
If the instrument case or storage case needs cleaning, wipe it off with
a soft cloth dipped in isopropyl alcohol or mild detergent. Never
submerge the flowmeter.
Storage
When storing the flowmeter, always cover the ends of flow tubes with
the provided caps to prevent dust or other foreign matter from
entering the tube.
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11
Chapter 5
Troubleshooting
Table 4 lists the symptoms, possible causes, and recommended
solutions for common problems encountered with the flowmeter. If the
symptom is not listed, or if none of the solutions solves the problem,
please contact TSI Customer Support at 1-800-874-2811 or
651-490-2811.
Table 4. Troubleshooting
Symptom
Possible Causes
Corrective Action
No display.
Unit not switched on.
Switch on the unit.
No power to
instrument.
Plug in AC adapter or
check power source on
mini-DIN connector.
Temperature
reads high at
low or zero
flows.
Temperature sensor is
being heated from the
flow sensor.
This is normal. Once
flow exceeds 1 Std
L/min, the temperature
will track the flowing gas
temperature.
Flow readings
fluctuate badly.
The flow is fluctuating.
Improve inlet conditions
or increase display
averaging time.
Display shows
flows over-range
with no flow
passing through
flow tube.
The sensor may be
damaged or broken.
Return flowmeter to TSI
for service.
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Specifications 13
Appendix A
Specifications*
Flow Measurement
Measurement Range
Models 4040/4045 .........
Model 4043 only ............
Accuracy
Air, O2 ...........................
N2, Air/O2 mixtures ........
Resolution (Display) ..........
Response .........................
0 to 300 Std L/min.
0 to 200 Std L/min.
2% of reading or 0.05 Std L/min, whichever is
greater
3% of reading or 0.1 Std L/min, whichever is
greater
Accuracy stated at standard conditions: 21.1°C
and 101.3 kPa)
See notes 1 through 6 below.
0.01 Std L/min between 0 and 90 Std L/min
0.1 Std L/min between 90 and 300 Std L/min
Less than 4 msec, 63% of final value at full
scale flow
Temperature Measurement
Measurement Range ........
Accuracy ...........................
Resolution (Display) ..........
Response .........................
0 to 50°C
±1°C, at flows greater than 1 L/min. See note 2
below.
0.1°C
Less than 75 msec, 63% of final value for 20°C
step change in temperature at full scale flow
Static Pressure Measurement (Measured inside flow tube near the exit)
Measurement Range ........
Accuracy ...........................
Resolution (Display) ..........
Response .........................
Over Pressure ..................
50 to 199 kPa Absolute
±1 kPa, See note 7 below
0.1 kPa
Less than 4 msec.
63% of final value for 30 kPa step change
620 kPa
Burst Pressure
Tested to 690 kPa without rupture. Do not exceed 690 kPa.
Pressure Drop
See Chart.
Volume
Measurement Range ........
Accuracy ...........................
0.001 to 99.99 Liters
2% of Reading at flows greater than 2.5 Std
L/min
See notes 1 through 6 below.
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14 Appendix A
Instrument Temp. Range
Operation, Ambient ..........
Storage, Ambient ..............
0 to 50°C
-20 to 60°C
Physical Dimensions
External Dimensions ........
Tube Adapters ..................
(Inlet & Outlet)
Weight ..............................
Flow Body Material ...........
See Diagram
Model 4040: 22 mm male ISO Taper
Model 4043: ½ inch straight
Model 4045: ¾ inch straight
180 grams
PolyCarbonate
Computer Interface
Connector .........................
Type .................................
Baud Rate ........................
Data Bits ...........................
Parity ................................
Stop Bits ...........................
Flow Control .....................
8 pin mini-DIN
RS232 Serial
38.4 k
8
None
1
None
Analog Output (Flow Only)
Range ...............................
Resolution ........................
Maximum Current .............
Flow Accuracy ..................
0 to 10 V
13 bit
5 mA
See note 6 below.
Power
AC adapter or power supplied through mini-DIN
7.5 VDC ± 1.5 V, 300 mA maximum
Notes:
1 Accuracy stated at standard conditions of 21.1°C and 101.3 kPa.
 Add an additional 0.075% of reading per 1°C away from standard
conditions when operating within the range of 0°C to 50°C.
 Add an additional 0.015% of reading per 1 kPa above 101.3 kPa or
 Add an additional 0.022% of reading per 1 kPa below 101.3 kPa
when operating within the pressure range of 70 kPa to 170 kPa.
2 Accuracy stated with gas temperature and flow body temperature within
±10°C of one another.
3 Accuracy stated measuring dry gas (less than 10% R.H.).
4 Includes ±0.5% of reading repeatability.
5 Volumetric flow rate is calculated from the mass flow measurement. Add
an additional 0.25% of reading to the flow accuracy to account for the
uncertainty in measuring gas temperature and pressure.
6 For analog output, accuracy offset increases from 0.05 to 0.1 Std L/min.
7 Add uncertainty of 0.2 kPa for every 10°C away from 21.1°C.
*Specifications subject to change without notice.
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Specifications 15
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16 Appendix A
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17
Appendix B
Standard Flow Rate vs. Volumetric Flow Rate
Since thermal flow sensors are sensitive to changes in air density and
air velocity, all thermal flowmeters indicate flow rates with reference to
a set of standard conditions. For TSI instruments, standard conditions
are defined as 21.1° C (70° F) and 101.3 kPa (14.7 psia). Other
manufacturers may use different values.
Standard flow rate is the flow rate the air would be moving if the
temperature and pressure were at standard conditions. It is usually
the most useful measure of airflow because it defines the heat-
carrying capacity of the air.
Volumetric flow rate is the true volume flow of the gas exiting the
flowmeter.
In some instances, volumetric flow rate rather than standard flow rate
may be of interest. To display volumetric flow rate, the Models
4040/4043/4045 will multiply the standard flow measurement by the
following density correction factor:
m
mP3.101
11.2115.273 T15.273
)FlowStandard(FlowVolumetric 








Where
Tm = Gas temperature measured in flow tube in units of degrees
Celsius
Pm = Absolute pressure measured in flow tube in units of kPa
To demonstrate the difference in output, consider the following.
Measured flow displays 100 Std L/min at 15C and 117kPa. The
volumetric flow as calculated by the Models 4040/4043/4045 would
be as follows.
min/L78.84
117
3.101
11.2115.273 1515.273
)100(FlowVolumetric 









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