MesaLabs FlexCal Portable Gas Flow Calibrator

Overview

The MesaLabs FlexCal Portable Gas Flow Calibrator is an engineered solution for field and laboratory verification of gas flow measurement devices across environmental monitoring, industrial hygiene, emissions testing, and pharmaceutical process validation. Based on thermal mass flow sensing principles with real-time compensation for temperature and pressure variations, the FlexCal delivers traceable, high-reproducibility flow measurements in accordance with ISO/IEC 17025 requirements. Its compact, ruggedized design—housed in a Pelican™-certified transit case—enables reliable operation in mobile labs, stack testing sites, cleanroom HVAC audits, and regulatory inspection scenarios where portability and metrological integrity are equally critical.

Key Features

• Thermally compensated mass flow measurement with integrated Pt100 temperature and piezoresistive absolute pressure sensors for dynamic correction of volumetric-to-standardized flow conversion
• Three interchangeable calibrated ranges (FlexCal-L, -M, -H) covering 5 mL/min to 50 L/min, enabling optimized resolution and uncertainty across low-, mid-, and high-flow applications
• Standardized flow units (sL/min, smL/min, scf/min, scc/m) and volumetric units (mL/min, L/min, cc/min, cf/min) selectable via intuitive menu-driven interface
• Configurable measurement intervals (1–15 seconds) and readout modes—including single-cycle capture, continuous logging, and programmable averaging over 1–100 consecutive readings—to support both spot checks and time-series validation protocols
• USB 2.0 interface with native CDC-class driver compatibility for direct connection to Windows/macOS/Linux systems; no proprietary software installation required for basic data transfer
• Backlit graphical LCD with multi-line display supports simultaneous visualization of flow rate, temperature, pressure, unit selection, and battery status under variable ambient lighting conditions
• Sealed lead-acid battery system (6 V, 4.5 Ah) provides ≥8 hours of operation with backlight disabled—validated per IEC 62368-1 for safe use in Class I, Division 2 hazardous locations when operated within specified environmental limits

Sample Compatibility & Compliance

The FlexCal is validated for use with non-corrosive, dry or low-humidity (<70% RH, non-condensing) gases including air, nitrogen, oxygen, carbon dioxide, and helium. It is not rated for use with reactive, acidic, solvent-laden, or particulate-laden streams. Operation is limited to absolute pressures ≤15 PSI to maintain sensor linearity and prevent mechanical stress on the laminar flow element. All factory calibrations are performed against NIST-traceable primary standards and documented per ISO/IEC 17025:2017 clause 7.7, with certificate of calibration including measurement uncertainty budgets, environmental conditions, and as-found/as-left data. The device supports GLP-compliant audit trails when used with third-party data acquisition platforms that enforce 21 CFR Part 11 electronic signature and record retention policies.

Software & Data Management

Data export is supported via standard USB serial communication using ASCII-formatted, tab-delimited output. Each recorded sample includes timestamp (RTC-synchronized), flow value, temperature (°C/°F), absolute pressure (kPa/PSI/mmHg), selected unit, and measurement mode identifier. Users may import logs directly into Excel, MATLAB, LabVIEW, or LIMS environments without intermediate parsing. Firmware updates are delivered via signed .hex files and applied through the included USB utility—version history and cryptographic checksums are published in MesaLabs’ publicly accessible firmware repository. No cloud connectivity or telemetry is embedded; all data remains under user control at the instrument or host PC level.

Applications

• Field verification of fixed and portable gas analyzers (e.g., EPA Method TO-15, Method 18 samplers)
• Calibration of personal sampling pumps used in OSHA and NIOSH compliance monitoring
• Validation of fume hood face velocity and room air exchange rates per ANSI/AIHA Z9.5 and ASHRAE 110
• Performance testing of medical gas delivery systems (ISO 8573-1 purity verification, flow stability assessment)
• Verification of mass flow controllers (MFCs) and rotameters in semiconductor tool purge lines and bioreactor sparging systems
• Supporting ISO 50001 energy management audits through precise quantification of compressed air consumption

FAQ

Is the FlexCal suitable for calibrating wet or saturated gas streams?
No. The internal thermal sensor and laminar flow path are susceptible to condensation-induced drift and long-term corrosion. Use only with gases maintained below dew point at operating temperature and pressure.

Can the FlexCal be used in vacuum (negative pressure) applications?
Yes—its dual-mode flow path supports both pressurized supply and suction-side calibration, provided absolute inlet pressure remains ≥1 PSI to ensure laminar flow regime stability.

Does the device meet FDA 21 CFR Part 11 requirements for electronic records?
The FlexCal itself does not implement electronic signatures or audit trail functionality. However, its deterministic ASCII log format and UTC timestamps enable full compliance when integrated with validated third-party data acquisition software meeting Part 11 criteria.

What is the recommended recalibration interval?
Annual recalibration is advised under typical usage conditions. More frequent verification (e.g., pre- and post-campaign) is recommended for critical compliance applications or after exposure to mechanical shock, extreme temperatures, or contaminant ingress.

Are Swagelok® fittings included with the instrument?
Yes—each FlexCal ships with 1/4″ Swagelok® stainless steel compression fittings and compatible ferrules for immediate integration into standard gas handling manifolds.