TSI Instruments 4000 Series Guide

Mass Flowmeters
TSI Series 4000/4100
High Performance
Linear OEM Mass Flowmeter
(TSI Models 4021, 4024,
4121, and 4122)
Design Guide
1980430, Revision H
August 2010

SHIP/MAIL TO:
TSI Incorporated
500 Cardigan Road
Shoreview, MN 55126-3996
USA
USA
Sales and Customer Service:
[phone]/[phone]
Fax:
[phone]
E-mail address:
[e-mail]
Website:
http://flowmeters.tsi.com
INTERNATIONAL
Sales and Customer Service:
([phone]
Fax:
([phone]

3
Copyright
TSI Incorporated / 2004-2010 / All rights reserved.
LIMITATION OF WARRANTY AND LIABILITY (effective July 2000)
Seller warrants the goods sold hereunder, under normal use and service as described in the
operator's manual, shall be free from defects in workmanship and material for 90 days for OEM
components, from the date of shipment to the customer. This warranty period is inclusive of any
statutory warranty. This limited warranty is subject to the following exclusions:
a. Batteries and certain other components when indicated in specifications are warranted for
a period of 90 days from the date of shipment to the customer.
b. Parts repaired or replaced as a result of repair services are warranted to be free from
defects in workmanship and material, under normal use, for 90 days from the date of
shipment.
c. Seller does not provide any warranty on finished goods manufactured by others or on any
fuses, batteries or other consumable materials. Only the original manufacturer's warranty
applies.
d. Unless specifically authorized in a separate writing by Seller, Seller makes no warranty
with respect to, and shall have no liability in connection with, goods which are
incorporated into other products or equipment, or which are modified by any person other
than Seller. All goods returned under warranty shall be at the Buyer’s risk of loss, Seller’s
factory prepaid, and will be returned at Seller’s risk of loss, Buyer’s factory prepaid.
The foregoing is IN LIEU OF all other warranties and is subject to the LIMITATIONS stated
herein. NO OTHER EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR
PARTICULAR PURPOSE OR MERCHANTABILITY IS MADE.

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 NO EVENT SHALL SELLER BE LIABLE FOR ANY SPECIAL,
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 as they are to our
customers, our service policy is designed to give prompt attention to any problems. If any mal-
function is discovered, please contact your nearest sales office or representative, or call TSI at
[phone] (USA) and (1) 651 490-2811.

i
CONTENTS
Chapter 1 - Models and Accessories..............................................1
Accessories..................................................................2
Model Designations .....................................................3
Chapter 2 - Measurements Available..............................................4
Flow Rate Measurement..............................................4
Temperature Measurement .........................................4
Volume Measurement..................................................5
Chapter 3 - Mechanical Interface.....................................................6
Overall Dimensions......................................................6
Inlet / Outlet Connections.............................................7
Inlet / Outlet Adapter Dimensions................................8
Chapter 4 - Design Considerations, Mechanical ...........................9
Important Safety Notes................................................9
Filtration Requirements................................................9
Inlet / Outlet Screens .................................................10
Inlet Flow Conditioning...............................................11
Liquids........................................................................11
Flow Reversal/Direction - Pumps...............................12
Mounting Orientation..................................................12
Pressure Drop............................................................12

ii
Chapter 5 - Design Considerations, Electrical............................ 13
Power Requirements................................................. 13
Grounding Scheme................................................... 13
Output Signal, Analog............................................... 13
Digital Interfaces........................................................ 14
Pin-out for Mini-DIN Connector................................. 16
Chapter 6 - I/O Signal Description................................................ 18
RS-232 Bi-Directional Interface................................. 18
Analog Output of Mass Flow Rate............................ 18
Optional User-Supplied Pressure Signal .................. 18
Chapter 7 - Specifications............................................................. 20
Appendix A - Back-Pressure and Barometric Pressure -
Effect on Accuracy................................................ 28
Appendix B - Standard Flow Rate vs. Volumetric Flow rate...... 32
Appendix C - Digital Serial Interface............................................ 34
Command Set Summary........................................... 34
Command Set ........................................................... 38
Error Codes............................................................... 62

1
Chapter 1 - Models and Accessories
The TSI Series 4000/4100 High Performance Linear OEM Mass
Flowmeter is available in the following model numbers: 4021, 4024,
4121, and 4122.
Models 4121
4122

2
Models 4021
4024
Accessories
Interface Cable, mini-DIN -to- tinned wire: TSI Part Number 1303584

3
Model Designations
Model Gas Calibration Flow Range Inlet Adapter Outlet Adapter
40211 Air 0 to 300
standard L/min
22 mm ISO
tapered
Male
22 mm ISO
tapered
Male
40212 Oxygen
40241 Air 0 to 300
standard L/min
0.75 inch
(19.1 mm)
straight
0.75 inch
(19.1 mm)
straight
40242 Oxygen
40246 Nitrogen*
41211 Air 0.01 to 20
standard L/min
0.25 inch
(6.4 mm)
straight
0.25 inch
(6.4 mm)
straight
41212 Oxygen
41216 Nitrogen*
41221 Air 0.01 to 20
standard L/min
0.375 inch
(9.53 mm)
straight
0.375 inch
(9.53 mm)
straight
41222 Oxygen
41226 Nitrogen*
*Nitrogen models are calibrated in air and a nitrogen correction is applied by the meter.

4
Chapter 2 - Measurements Available
Flow Rate Measurement
Flow rate data can be obtained through the linearized analog output
or via the serial interfaces.
Flow rate can be output in units of standard liters per minute (Std
L/min*) or in volumetric units of liters per minute (L/min). Refer to
Appendix C for a description of the two measurements. Selecting
between the two measurements is accomplished through the serial
interfaces. Refer to the Command Set section for instructions.
*TSI instruments define standard conditions as 21.1°C (70° F) and
101.3 kPa (14.7 psia, 1 bar).
Temperature Measurement
These flowmeters have an independent sensor in the flow tube to
measure the gas temperature. The information is used for internal
temperature compensation of the flow sensor element and for
converting flow from standard to volumetric units. This flow

5
temperature is only available through the serial digital interface. See
the Command Set section.
At flows below 1 standard L/min, the temperature inside of the flow
tube will increase several degrees because of the heat generated by
the thermal flow sensor. This effect is normal and the temperature of
the incoming gas will be measured accurately once flow resumes.
Volume Measurement
These flowmeters can measure total volume by integrating flow over
time. This measurement is available only via the serial digital
interfaces. Refer to the Command Set section for instructions on
using the volume function.

6
Chapter 3 - Mechanical Interface
Overall Dimensions

7
Model A B C D E Mounting Screws
4021 -
4024 5.12 in
(130 mm) 2.52 in (64 mm) 1.50 in (38 mm) 2.60 in (66 mm) 0.63 in (16 mm) 8–32 UNF
4121 -
4122 3.67 in
(93 mm) 1.93 in (49 mm) 1.11 in (29 mm) 2.60 in (66 mm) 0.43 in (11 mm) 6–32 UNF
Inlet / Outlet Connections
Models equipped with male 22 mm ISO tapered, 0.25 inch,
0.375 inch, 0.75-inch straight inlet/outlet:
•Connections can be made with flexible tubing slipped over
the male ends of the inlet / outlet.
•Connections can also be made with an appropriate
compression fitting, such as those made by Swagelok®and
Parker Hannifin®. We recommend that you use nylon
compression fittings and not metal. Metal fittings put too
much stress on the flowmeter inlet / outlet stubs and can
crack them.

8
Models equipped with female 22 mm ISO tapered inlet/outlet:
•Connections can be made with appropriate 22 mm
ISO tapered male connectors.
Inlet / Outlet Adapter Dimensions
Inlet / Outlet Dimensions
Model L ID OD
4021 0.920 (23.37) 0.751 (19.08) 0.874 (22.20)
4024 0.795 (20.19) 0.621 (15.77) 0.749 (19.02)
4121 0.530 (13.46) 0.151 (3.84) 0.252 (6.40)
4122 0.530 (13.46) 0.276 (7.01) 0.377 (9.58)
Dimensions in inches (mm)

9
Chapter 4 - Design Considerations,
Mechanical
Important Safety Notes
Hydrogen Safety
These models of TSI OEM flowmeters use a heated,
platinum-coated sensor element exposed to the flow stream.
For this reason do not use these flowmeters with hydrogen
or hydrogen mixtures.
Intrinsic Safety
These models of TSI OEM flowmeters are not designed to
be intrinsically safe.
Filtration Requirements
These flowmeters have an exposed thermal flow sensor, which must
be protected from foreign matter and suspended particles in the gas
flow. Failure to provide clean gas will change the calibration and may
permanently damage the sensor. We recommend that your system be

10
blown free of particles and metal shavings after manufacturing and
before the flowmeters are installed. We strongly recommend an
upstream filter with an efficiency of at least 99.9%. Do not use an oil-
impregnated filter. Consult factory for more information.
Inlet / Outlet Screens
The small screens on the inlet and outlet of the flowmeter trap dirt
and manufacturing debris. They are not a substitute for providing
clean, filtered gas. Do not operate the flowmeter without these
screens in place since the flowmeter was calibrated with them in
place.
These screens should be viewed as a “second” line of defense
against contamination. The “first” line of defense is designing the
system so that only clean gas goes to the flowmeter. Be especially
careful of assembly procedures that could introduce dirt, oil, filings,
fibers, sealants, etc., into the flow path.
There is no practical way for an end-user to clean the screens, since
it requires complete disassembly and recalibration. The instruments
must be returned to the factory for this service.

11
Inlet Flow Conditioning
The airflow going into the flowmeter’s measuring section normally has
a uniform flow profile. An upstream valve, regulator, or small diameter
tubing can create a non-uniform jet of gas through the flowmeter. For
best accuracy your design should avoid these devices immediately
upstream of the flowmeter. When these devices are used, they
should be at least 5 inside diameters upstream from the flowmeter
body. For Models 4021–4024: at least 5 inches (127 m). For Models
4120–4122: at least 1.5 inches (39 mm). Shorter diameters may work
depending on flow rate and change in size.
Same-size elbows and normal tubing bends do not create jetting
problems and they can be used close to the flowmeter body.
Devices on the outlet side of the flowmeter do not create jetting
problems, so anything can be used at that location.
Liquids
Never submerge the flowmeter in a liquid or allow liquid to enter the
flow tube. This may degrade accuracy or damage the internal sensor
element. Be sure that your system design does not allow condensate
or other liquids to enter the flowmeter.

12
Flow Reversal/Direction - Pumps
These flowmeters are designed and calibrated for unidirectional flow.
The arrow on the body of the flowmeter indicates the correct direction.
The flowmeter cannot detect flow direction, so the output signal is the
same regardless of flow direction. If your design presents the flowmeter
with momentary flow reversals, such as during valve switching, pump
operation, etc., you will see significant errors in the measured flow.
Rotary vane pumps frequently cause this condition. Contact TSI for
methods to identify and eliminate this problem.
Mounting Orientation
These flowmeters are calibrated in a horizontal position. For the
majority of uses these meters can be operated in any position. If you
are measuring flow rates near the very bottom end of the range, we
recommend a horizontal mounting position for best accuracy.
Pressure Drop
See the Specifications section for information about the pressure drop
across the instrument at various flow rates.

13
Chapter 5 - Design Considerations, Electrical
Power Requirements
5.0 VDC ±0.25 Volts, 300 mA maximum
The power is supplied through mini-DIN connector
Grounding Scheme
The following are connected together inside the flowmeter:
Power Ground
Logic Ground
Analog Ground (output signal return)
Output Signal, Analog
Model 4021-4024: 0-4 Volts = 0-300 Standard L/min (default)
Model 4121-4122: 0-4 Volts = 0-20 Standard L/min (default)

14
Important
Since the (-) side of the analog output is connected to the
common power/logic ground, you must use a differential
input on any device used to measure this analog output
signal. Failure to use a differential input will result in
measurement errors.
The zero intercept and the scaling factor can be changed via the
RS232 commands SAZnnn and SASnnn. See Appendix C for
complete information.
Digital Interfaces
The following data is available from the digital interfaces: flow rate,
temperature, and volume.
Device options can be changed via the digital interfaces. These
options include: flow units, sample rate, volume trigger levels, analog
output zero and full scale, standard/volumetric flow measurement.