TSI Instruments 4040 Operation manual

www.tsi.com
General Purpose
Thermal Mass
Flow Meter
Model 4040/4043/4045
Operation and Service Manual
P/N 1980339, Revision M
April 2022

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General Purpose
Thermal Mass
Flow Meter
Model 4040/4043/4045
Operation and Service Manual
P/N 1980339, Revision M
April 2022
U.S. & INTERNATIONAL TSI Instruments Ltd. (UK)
Sales and Customer Service: Sales and Customer Service:
[phone] / [phone] [phone]
Fax:
[phone]

i
Copyright
TSI Incorporated / 2002-2022 / All rights reserved.
Address
TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 USA
WARNING
TSI®Incorporated flow meters employ a heated
platinum sensor. They should not be used with
flammable or explosive gasses or mixtures.
C A U T I O N
TSI®Incorporated flow meters are not medical devices
under FDA 510k and in no situation should they be
utilized for human respiration measurements.
LIMITATION OF WARRANTY AND LIABILITY (effective February 2015)
(For country-specific terms and conditions outside of the USA, please visit www.tsi.com.)
Seller warrants the goods, excluding software, sold hereunder, under normal use and
service as described in the operator's manual, to be free from defects in workmanship
and material for 12 months, or if less, the length of time specified in the operator's
manual, 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 and
exceptions:
a. Hot-wire or hot-film sensors used with research anemometers, and certain other
components when indicated in specifications, are warranted for 90 days from the date
of shipment;
b. Pumps are warranted for hours of operation as set forth in product or operator’s
manuals;
c. 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;
d. 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;
e. This warranty does not cover calibration requirements, and seller warrants only that
the instrument or product is properly calibrated at the time of its manufacture.
Instruments returned for calibration are not covered by this warranty;
f. This warranty is VOID if the instrument is opened by anyone other than a factory
authorized service center with the one exception where requirements set forth in the
manual allow an operator to replace consumables or perform recommended cleaning;
g. This warranty is VOID if the product has been misused, neglected, subjected to
accidental or intentional damage, or is not properly installed, maintained, or cleaned
according to the requirements of the manual. 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.
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. WITH RESPECT TO
SELLER’S BREACH OF THE IMPLIED WARRANTY AGAINST INFRINGEMENT, SAID
WARRANTY IS LIMITED TO CLAIMS OF DIRECT INFRINGEMENT AND EXCLUDES
CLAIMS OF CONTRIBUTORY OR INDUCED INFRINGEMENTS. BUYER’S

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) 490-2860 (International) or visit www.tsi.com.
Trademarks
TSI and the TSI logo are registered trademarks of TSI Incorporated in the United
States and may be protected under other country’s trademark registrations.
HyperTerminal is a registered trademark of Hilgraeve, Incorporated.
Windows is a registered trademark of Microsoft Corporation.

iii
CONTENTS
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
A SPECIFICATIONS*....................................................................... 13
BSTANDARD FLOW RATE VS. VOLUMETRIC FLOW RATE ..... 19
C OPTIMAL USE OF THE 4000/4100 SERIES ANALOG
OUT CAPABILITY........................................................................ 21
Introduction.................................................................................. 21
Function of the Analog Out Feature............................................ 21
Considerations When Needing to Read Zero and Low
Flow Accurately........................................................................ 22
Considerations for Setting the Span Flow Voltage...................... 23
Process for Changing the Analog Zero and Span....................... 23

iv
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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®
Incorporated (TSI®) immediately.
Table 1. List of Components
Qty
Item Description
Part/Model
1
Mass Flow Meter, 22 mm ISO tapered inlet/outlet
Mass Flow Meter, 0.50 inch inlet/outlet
Mass Flow Meter, 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

Chapter 1
2
Parts Identification
Figure 1-1 Model 4040/4043/4045 Mass Flow Meter
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

3
Chapter 2
Setting-Up
Supplying Power
The flow meter 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 flow meter.
Flow Meter 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

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 flow meter; however, any filter will work as long as it has a
minimum efficiency of 99.9%.
C A U T I O N
Always use a filter on the inlet of the flow meter.
Failure to filter the gas flow may change the
calibration and/or permanently damage the sensor.
NO T ICE
Flow direction is identified by the large arrow printed on the bottom
side of the flow meter.
After attaching the filter, connect the flow tube, to the inlet, of the
filter. Connecting a tube to the outlet of the flow meter will create back
pressure. See Appendix A for flow meter accuracy specifications
when operating at various pressures. In general, minimize back
pressure on the flow meter to maintain higher accuracy.
RS232 Configuration and Operation
Many flow meter 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

Setting-Up
5
Configuration Software
TSI®has several software utilities to help you communicate with your
flow meter to change parameters and to obtain flow data. You can
download the latest versions of these at no charge from our web site:
https://tsi.com
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 flow meter’s memory.
2. If you want to communicate directly with the flow meter using the
basic RS232 commands shown in the Serial Command Set
Manual, you can use a terminal program. HyperTerminal®
program 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®program. Download the document called “Using
HyperTerminal to communicate with TSI Flow Meters.”

Chapter 2
6
3. If you plan to develop a more sophisticated program for data
collection and control using LabVIEW™ program, you can
download a demonstration program called “Real-time Demo
Program” and the source code “Source Code for Real-time
Demo Program.”This program is intended to be a basic
demonstration program and not a practical laboratory tool. It does,
however, have a convenient implementation of the VOLUME
measurement function that can be useful for basic tests.

7
Chapter 3
Operation
C A U T I O N
TSI®flow meters 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 Flow Meters 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 flow meter will begin
to simultaneously display flow rate, temperature and pressure.
Warm-up Time
The flow meter will provide readings immediately upon power-up.
Recommended warm-up time of the flow meter 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.

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).
NO T ICE
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 flow meter 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 flow
meter 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).

9
Chapter 4
Maintenance
Flow Sensor
Periodically inspect the flow sensor by looking into the outlet of the
flow meter. 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 flow meter and never touch the
sensor with a brush. Dust or other deposits on the flow sensor will
degrade the 4040/4043/4045 flow meter’s flow accuracy.
C A U T I O N
The flow meter 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 flow meter.
Storage
When storing the flow meter, always cover the ends of flow tubes with
the provided caps to prevent dust or other foreign matter from
entering the tube.

10 Chapter 4
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11
Chapter 5
Troubleshooting
Table 4 lists the symptoms, possible causes, and recommended
solutions for common problems encountered with the flow meter. If
the symptom is not listed, or if none of the solutions solves the
problem, please contact TSI®Customer Support at 1-800-680-1220
or 651-490-2860.
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 flow meter to
TSI®for service.

12 Chapter 5
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