TSI Instruments 4040 Operation manual

Model 4040/4043/4045
General Purpose
Thermal Mass Flowmeter
Operation and Service Manual
1980339, Revision E
November 2002
Mass Flowmeters

TSI Model 4040/4043/4045
General Purpose
Thermal Mass Flowmeter
Operation and Service
Manual
November 2002
P/N 1980339
Revision E
MAIL/SHIP TO: E-mail address:
TSI Incorporated [e-mail]
500 Cardigan Road
Shoreview, MN 55126-3996 Web site:
USA http://www.tsi.com
U.S. INTERNATIONAL
Sales and Customer Service: Sales and Customer Service:
800-874-2811 or 651-490-2811 (1) 651-490-2811
Fax: Fax:
651-490-3824 (1) 651-490-3824

Copyright
TSI Incorporated / November 2002 / All rights reserved.
Address
TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 USA
WARNING
!
These flowmeters employ a heated platinum sensor.
They should not be used with flammable or explosive
gases or mixtures.
Caution
!
TSI flowmeters 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 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 twelve (12) months, or 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:
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. 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.
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 malfunction
is discovered, please call TSI's Customer Service department at [phone].

i
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
Flowrate 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 FLOWRATE VS.
VOLUMETRIC FLOWRATE ............................................... 17

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
Qt
y
Item Descri
p
tion 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 Com
p
uter Cable 1303583
1 Analo
g
Cable 1303584
1 Filter
22 mm ISO-taper (for Model 4040)
3/8” Female NPT (for Model 4043/45)
1602292
1602300
1 AC Adapter
120 V, North America, ungrounded
100-240 V, NEMA 5-15 plug, grounded
100-240 V, Europlug, CEE 7/16, grounded
100-240 V, Great Britain, grounded, fused
100-240 V, Australia/NZ
2613033FLO
8918-NA
8918-EC
8918-GB
8918-AT
1 O
p
eration and Service Manual 1980339
1 RS232 Serial Command Set manual 1980340
1 Carr
y
in
g
Case
(
o
p
tional accessor
y)
1319176

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

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 Analo
g
Out
p
ut
(
+
)
Red
4 Analo
g
Ground
(
-
)
Brown
5 (no connection) Blue
6 RS232 Receive
(
in
)
White
7 RS232 Transmit
(
out
)
Yellow
8 Lo
g
ic Groun
d
Gra
y

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 inlet of 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 flowrate, 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 Ox
yg
en Concentration in Air
(
21% to 99%
)
SGM
Select Standard or Volumetric Flow Measuremen
t
SU
LCD Display Update Rate (controls averaging) SUR
Select Data U
p
date Rate for Analo
g
Out
p
u
t
SSR
Set Analo
g
Out
p
ut Full-Scale Flowrate Value SAS
Set Analo
g
Out
p
ut Zero Value SAZ

Operation
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:
http://flowmeters.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 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.”

Chapter 2
6
3. If you plan to develop a more sophisticated program for data collection
and control using LabVIEW, 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
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 flowrate,
temperature and absolute pressure of the gas inside the flow tube. All
measurements made by the Model 4040/4043/4045 are traceable to NIST.
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 flowrate, temperature and pressure.
Flowrate Measurement
Flowrate 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.
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.

Chapter 3
8
*TSI instruments defines standard conditions as 21.1°C (70° F) and
101.3 kPa (14.7 psia, 1 bar).
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 flowrate 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 flowrates, 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.

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’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.

11
Chapter 5
Troubleshooting
Table 4 lists the symptoms, possible causes, and recommended solutions for
common problems encountered with the flowmeter. If your symptom is not
listed, or if none of the solutions solves your problem, please contact TSI.
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.

13
Appendix A
Specifications
Specifications
Flow Measurement
Measurement Range
Accuracy
Resolution (Display)
Response
Models 4040/4045: 0 to 300 Std L/min.
Model 4043 only: 0 to 200 Std L/min.
Air, O2: 2% of reading or 0.05 Std L/min, whichever
is greater
N2, Air/O2mixtures: 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 1through 6below.
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
Measurement Range
Accuracy
Resolution (Display)
Response
Over Pressure
Measured inside flow tube near the exit
50 to 199 kPa Absolute
±1 kPa, See note 7below
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 999.999 Liters
2% of Reading at flows greater than 2.5 Std L/min
See notes 1through 6below.
Instrument Temp. Range
Operation, Ambient
Storage, Ambient
0 to 50°C
-20 to 60°C

14 Appendix A
Specifications
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 8 pin mini-DIN
Type RS232 Serial
Baud Rate 38.4 k
Data Bits 8
Parity None
Stop Bits 1
Flow Control None
Analog Output (Flow
Only)
Range
Resolution
Maximum Current
Flow Accuracy
0 to 10 V
13 bit
10 mA
See note 6below.
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 flowrate 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.