TSI/Alnor 4040 User manual

GENERAL PURPOSE

THERMAL MASS FLOWMETER

MODEL 4140/4143

OPERATION AND SERVICE MANUAL

P/N 1980383, REVISION E

SEPTEMBER 2013

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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

Pressure Measurement .........................................................................................8

Select Measurement Displayed ..........................................................................8

Display “Scroll” Mode .............................................................................................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

iii

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Qty

Item Description

Part/
Model

1

Mass Flowmeter, 0.25 inch inlet/outlet
(Air, Oxygen, Nitrogen)
Mass Flowmeter, 0.25 inch inlet/outlet
(Air, Oxygen, Nitrogen, Nitrous Oxide)*
Mass Flowmeter, 0.375 inch inlet/outlet
(Air, Oxygen, Nitrogen)
Mass Flowmeter, 0.375 inch inlet/outlet
(Air, Oxygen, Nitrogen, Nitrous Oxide)*

4140

41403

4143

41433

1

Filter

Model 4140: 60 mm ULPA filter with 0.25 inch barbed

fittings

Model 4143: 63 mm HEPA filter with 0.375 inch

barbed fittings

1602317

1602342

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 for Model 4140/4143

1980383

1

RS232 Serial Command Set Manual, 4000/4100

1980340

Item Description

Part/Mode

Computer Cable, mini-DIN to 9-pin RS-232

1303583

Analog Cable, mini-DIN to cable with tinned wires

1303584

Carrying Case for Model 4140/4143

1319201

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

*Other than the specifications in Appendix A, all references to 4140 and

4143 in this manual apply to the 41403 and 41433, respectively.

Table 2. Optional Accessories

1

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2

Parts Identification

1. On/Off Switch

4. DC Power Input

2. Display

5. Flow Inlet

3. Mounting Inserts (2)

6. Computer Serial Interface,
Analog Output, and Optional
Power Input Connection

Figure 1-1 Model 4140/4143 Mass Flowmeter

Chapter 1

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Table 3. Connector Pin-out and Color

Code for TSI Cable PN 1303584

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

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 optional TSI interface cable, line up
the arrow on the connector with the bottom side of the flowmeter.
Flowmeter connector pin-out designations are shown below.

3

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Connecting Filter and Flow Tubes

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.

Function

Command

Select Gas Calibration air, O2, N2, or N2O(if available)

SGn

Select Standard or Volumetric Flow Measurement

SUn

LCD Display Update Rate (controls averaging)

SURnnnn

Select Measurement Display Scroll Mode

SDMFTPn

Select Measurement Displayed on LCD Display

SDMm

Select Measurement Units on LCD Display

SDUn

Select Data Update Rate for Analog Output

SSRnnnn

Set Analog Output Full-Scale Flow Rate Value

SASnnn

Set Analog Output Zero Value

SAZnnn

The Model 4140/4143 has a thermal sensor exposed to the gas flow that
must be protected from foreign matter and particles. TSI supplies a filter
that 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%.

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

Table 4. Changeable Operating Parameters

Flow Control ........ None

4 Chapter 2

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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 4 (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. Setting up HyperTerminal to
communicate with your flowmeter can sometimes be confusing. 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.”

Setting Up 5

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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.

6 Chapter 2

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Caution

TSI flowmeters are not medical devices under FDA
510k and in no situation should they be utilized for
human respiration measurements.

Chapter 3

Operation

Overview

The Model 4140/4143 Flowmeter measures mass flow rate,
temperature and absolute pressure of the gas inside the flow tube. All
measurements made by the Models 4140/4143 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.

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 Model 4140/4143 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 20 Std
L/min. The analog output scaling is user selectable. Refer to the Series
4000/4100 RS232 Serial Command Set manual for instructions on
how to obtain flow data through the serial port.

Gas calibrations (air, 100% O2, 100% N
through the RS232 serial port. Refer to the Series 4000/4100 RS232
Serial Command Set manual. The LCD display will indicate the
calibration being utilized: air, O2, N2, or N2O.

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 of the two measurements. Selecting between the two
measurements is accomplished through the serial port. Refer to the

or 100% N

2

O) can be selected

2

*

TSI instruments defines standard conditions as 21.1°C (70° F) and 101.3 kPa (14.7 psia,

1 bar).

7

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Series 4000/4100 RS232 Serial Command Set manual for instructions
on how to select between flow units.

The Model 4140/4143 has an independent temperature sensor 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 can also be 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 4140/4143 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 can be displayed on the LCD and is
available through the RS232 serial port.

Select Measurement Displayed

By using RS232 commands the LCD display can be set up to
continuously display either flow rate, temperature, or pressure. See the
SDMm command in the Series 4000/4100 Serial Command Set
manual.

Display “Scroll” Mode

By using RS232 commands the LCD display can be set up to
continuously scroll between flow rate, temperature, and pressure. The
scroll rate is adjustable and the user can specify the parameters to be
displayed. See the SDMFTPn command in the Series 4000/4100 Serial
Command Set manual.

Volume Measurement

These flowmeters 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 Series 4000/4100 RS232 Serial
Command Set manual for instructions on using the volume function.

8 Chapter 3

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Caution

The flowmeter must be switched off for cleaning.
Only use clean, dry, compressed air when
attempting to remove contamination from the
sensor.

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

4140/4143 flowmeter’s flow accuracy.

Re-certification

To maintain a high degree of confidence in the measurements made by
the Model 4140/4143, TSI recommends that the instrument be returned
to TSI every 12 months for re-certification. The flowmeter will be
recalibrated and returned with a certificate of calibration to US National
Institute of Standards Technology (NIST) traceable standards. 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 or allow liquids to enter the flow tube.

Storage

When storing the flowmeter, always cover the ends of flow tubes with
the caps provided to prevent dust or other foreign matter from entering
the tube.

9

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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.

The temperature value
will track the actual gas
temperature once the
flow rate through the
flowmeter exceeds
1 Std L/min.

Flow readings
fluctuate greatly.

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.

Chapter 5

Troubleshooting

Table 4 lists the symptoms, possible causes, and recommended
solutions for common problems encountered with Series 4100
flowmeters. If the symptom is not listed, or if none of the solutions
solves the problem,

Table 4. Troubleshooting

11

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Flow Measurement

Measurement Range .............

Accuracy
Air and 100% O

2.........................

100% N2 ...............................

100% N2O ............................

(41403 and 41433 only)

Resolution (Display) .............

Response ...................................

0.01 to 20 Std L/min.

2% of reading or .005 Std L/min, whichever is
greater,
3% of reading or .010 Std L/min, whichever is
greater,
3% of reading or .010 Std L/min, whichever is
greater,
Accuracy stated at standard conditions (21.1°C
and 101.3 kPa)
See notes 1 through 6 below.

0.001 Std L/min between 0.01 and 9 Std L/min

0.01 Std L/min between 9 and 20 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.

Appendix A

Specifications*

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Volume

Measurement Range .............

Accuracy

Air and 100% O2 ..............

100% N2 ...............................

100% N2O ...........................

(41403 and 41433 only)

0.001 to 99.99 Liters

2% of Reading at flows greater than

2.5 Std L/min
3% of Reading at flows greater than

2.5 Std L/min
3% of Reading at flows greater than

2.5 Std L/min
See notes 1 through 5 below.

Instrument Temp. Range

Operation, Ambient .............

Storage, Ambient ..................

0 to 50°C

-20 to 60°C

Gas Calibrations

Air, O2, N

2, N2

O (41403 and 41433 only), User selectable through serial port

Physical Dimensions

External Dimensions ...........

Tube Adapters .......................

(Inlet & Outlet)

Weight .......................................

Flow Body Material ..............

See Diagram
Model 4140/41403: 0.25 inch O.D. straight
Model 4143/41433: 0.375 inch O.D. straight
86 grams
Polycarbonate

Computer Interface

Connector .................................

Type ............................................

Baud Rate .................................

Data Bits ...................................

Parity .........................................

Stop Bits ....................................

Flow Control ...........................

8 pin mini-DIN
RS232 Serial
38,400
8
None
1
None

Analog Output (Flow Only)

Range .........................................

Resolution ................................

Maximum Current ................

Flow Accuracy ........................

0 to 10 V
13 bit
10 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 0.0003 Std L/min or 0.075% of reading, whichever is

greater, 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 101.3 kPa.

2 Accuracy stated with gas temperature and flow body temperature within

±10°C of one another.

14 Appendix A

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3 Accuracy stated measuring dry gas (less than 10% R.H.).

4140/4143 Pressure Drop

0

10

20

30

40

50

60

70

80

90

0 5 10 15 20 25

Flow (SLPM)

Pressure Drop (cm H20)

4140
4140 with filter
4143
4143 with filter

Mounts use 6-32 UNF Screws

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 0.005 to .02 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.

Figure A-1 Pressure Drop

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Specifications 15

Figure A-2 Model 4140/4143 Dimensions

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m

m

P

T

owStandardFlFlowVolumetric

3.101

11.2115.273

15.273

)(

















min/478.8

117

3.101

11.2115.273

1515.273

)10( LFlowVolumetric 

















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 Model
4140/4143 will multiply the standard flow measurement by the
following density correction factor:

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 10 Std L/min at 15C and 117kPa. The
volumetric flow as calculated by the Model 4140/4143 would be as
follows.

17

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