Flow Computer Spares and Accessories

Flow Computer Spares and Accessories

At a metering point used for custody transfer, downtime means not only lost measurement but also invoicing and reconciliation problems. That is why spare part planning matters as much as device selection in these installations. The accessory and spare part group consists of modules that organise the in-panel connections, made-to-order cables, spare boards, logging hardware and mounting items.

On the wiring side, breakout modules split the multi-way connections at the device connectors out to screw terminals. Connecting, measuring and disconnecting the field cables during maintenance therefore becomes easier and the chance of error falls. On the communication side, separate modules cover multi-drop RS485 connections, RS232 links and Ethernet extension needs.

Among the spare parts, the power supply board and the auxiliary board stand out. The auxiliary board carries the mode and security switches, the backup battery and the SD card, and there is only one per flow computer. Small consumables such as fuses, SD cards and coin cells are more economical to order with the device or to source locally, because of the relative shipping cost.

What Accessories Do in Service

Flow computer spares and accessories answer three distinct needs:

1. Organising the wiring: Breakout modules and made-to-order cables standardise the transition between the device connector and the field terminal.

2. Standardising the mounting: Rack mounting options let the device sit tidily inside a panel or a rack.

3. Protecting continuity: Spare boards and consumables shorten downtime when a fault occurs.

In-panel wiring and terminal solutions

The I/O breakout module (3000-503) is used with the digital stream boards (3000-314 or 3000-319) through a 3000-054 cable, and with the analogue stream board (3000-316) through either a 3000-055 or a 3000-056 cable depending on the functionality required. The communication connection module (3000-502) supports 5-way RS485 multi-drop, RS232 with and without twist, and Ethernet extension. The communication breakout module (3000-506) converts up to four RJ45 cables to 5-way screw terminals.

Mounting and protection options

The 19 inch rack option allows up to two flow computers to be mounted in a single rack using the M2.5x10 cap head screws supplied with each unit; quarter panels are available where a single device is to be mounted. For harsh environments, the Certonal FC-742 coating option is a surface modifier fluorochemical polymer coating that can be applied to complete units and to all boards. It forms a very thin hydrophobic and oleophobic barrier, does not affect connectivity or measurement, and its organic nature means it can reform over small breaks.

Logging and security hardware

The spare auxiliary board (3000-303) carries the mode and security switches, the backup battery and the SD card, and only one is used per device. The 2 GB SD card is intended for storing extra logged data and is most effective in installations where the card can be removed and inserted into a PC for data retrieval. The spare PSU board (3000-302) is the replacement for the power supply board.

Input/output cables are made to order: they are supplied 36-way, with a back shell and a free end. The free ends are normally terminated with ferrule crimps, and unused wires can be supplied insulated with heat shrink tubing or removed. The back shell can be fitted the other way round for different cable routing.

Headline Items

·         I/O breakout module (3000-503): Splits the input and output connections of the digital and analogue stream boards out to screw terminals; used with a 3000-054, 3000-055 or 3000-056 cable depending on the board type.

·         Communication connection module (3000-502): Supports 5-way RS485 multi-drop, RS232 connections with and without twist, and Ethernet extension.

·         Communication breakout module (3000-506): Converts up to four RJ45 cables to 5-way screw terminals.

·         Spare PSU board (3000-302): The replacement for the power supply board; recommended as stock at critical stations.

·         Spare auxiliary board (3000-303): Carries the mode and security switches, the backup battery and the SD card; one per device.

·         2 GB SD card: For storing extra logged data; more effective in installations where the card can be removed and read in a PC.

·         Made-to-order I/O cables: 36-way free end cables with a back shell; the ends are terminated with ferrule crimps and the shell can be fitted the other way round.

·         19 inch rack option: Up to two devices in a single rack using the M2.5x10 screws supplied with the unit; a quarter panel is available for a single device.

·         Certonal FC-742 coating: A protective polymer coating that can be applied to complete units and all boards, repelling water and oil without affecting connectivity.

·         Consumables: Fuses, SD cards and coin cells; ordering them with the device or sourcing them locally is recommended because of shipping cost.

Accessory and Spare Part List

The list below summarises the published scope of flow computer spares and accessories.

Key Advantages

·         Short downtime: A stock of spare boards and consumables allows the measurement to be put back in service quickly after a fault.

·         Error-free wiring: Breakout modules and made-to-order cables reduce the chance of error on multi-way connector connections.

·         Tidy panel: Rack and panel options standardise the panel layout and make maintenance access easier.

·         Resistance to harsh environments: The protective coating option shields board surfaces in damp and dirty atmospheres.

·         Expandable logging: The SD card option increases the capacity available for alarm, audit and data logging.

·         Single point of supply: Supply by part code and support with the critical spares list shorten the purchasing process.

Maintenance and Operating Scenarios

The need for flow computer spares and accessories usually arises in the following situations during the operating period:

Rapid replacement after a board failure

If the power supply or auxiliary board fails, holding a spare in stock means the measurement can be back in service the same day. Because the auxiliary board carries the backup battery and the SD card, the logging and security settings should be reviewed during the swap.

Panel revision and adding a stream

When a new stream is added, the field terminal plan is renewed with a breakout module and a suitable cable, so the expansion can be made without disturbing the existing wiring.

Harsh ambient conditions

At coastal sites, in marine environments or in panels exposed to chemical vapour, the protective coating option helps to protect the board surfaces.

Extending the data log

When audit trail and data logging requirements grow, capacity is increased with the 2 GB SD card; the layout should be planned so that the card can be removed and read on site.

Spare Part Planning Criteria

A critical spares list for flow computer spares is set by the cost of downtime and by the lead time.

Criticality and the cost of downtime

·         The commercial consequence of the measurement and the cost per hour of downtime

·         Whether a standby metering stream is available

·         The effect of the site location on lead time

·         Expected response time in a shift-based operation

Board and cable compatibility

·         Installed stream board types and codes

·         The cable code to be used with the breakout module

·         Module selection to match the communication topology

·         The fact that only one spare auxiliary board applies per device

Supply and stocking approach

·         Consumables to be ordered together with the device

·         Items that can be sourced locally

·         Storage of configuration backups

·         Deciding on the coating option at the order stage

Options such as the protective coating have to be selected at the order stage; solutions intended for later application in the field should not be applied without consulting the manufacturer, for the sake of both the device warranty and measurement reliability.

Compatibility and Compliance Notes

Flow computer spares and accessories are used within the compliance scope of the device itself:

·         Board and cable compatibility: The cable code to be used with the breakout module is determined by the type of stream board being connected.

·         One auxiliary board per device: Because the auxiliary board carries the mode and security switches, the backup battery and the SD card, only one is fitted in each device.

·         Mounting hardware: The M2.5x10 screws supplied with the unit are used for 19 inch rack mounting.

·         Protective coating: The Certonal FC-742 coating is applied in a way that does not affect connectivity or measurement performance.

·         Unpublished data: Cable length, enclosure protection rating and power supply ratings are not given on the manufacturer's accessories page; project-by-project confirmation is required.

TLY Enerji Spare Part and Maintenance Support

TLY Enerji supports plants with an installed flow computer in drawing up the critical spares list. The installed board types, the communication topology and the panel layout are reviewed to determine which items should be held on site, which keeps the downtime risk to a minimum.

Flow computer spares and accessories are supplied by part code, and the breakout module and cable are selected to match the installed boards. After a replacement, field support is provided for the configuration check, the review of logging settings and communication verification.

On new installations, the protective coating, the rack mounting options and the consumables are planned at the order stage, which avoids delays at commissioning caused by a missing item.

·         Preparation of the critical spare part list

·         Module and cable selection according to the installed boards

·         Supply and quotation by part code

·         Configuration and communication checks after a replacement

·         Proposal for a periodic maintenance plan

Frequently Asked Questions

What does a breakout module do?

A breakout module splits the multi-way connector connections of the flow computer out to screw terminals, which makes the field cables easier to connect and easier to disconnect during maintenance. The I/O breakout module (3000-503) serves the inputs and outputs of the stream boards, while the communication breakout module (3000-506) converts up to four RJ45 cables to 5-way terminals.

Which cable is used with which board?

The I/O breakout module is used with the digital stream boards 3000-314 or 3000-319 through a 3000-054 cable. With the analogue stream board 3000-316, either a 3000-055 or a 3000-056 cable is chosen according to the functionality required. Because the cables are made to order, the board type and the intended function have to be stated when ordering.

Which flow computer spares should be held on site?

Depending on the level of criticality, the spare PSU board (3000-302), the spare auxiliary board (3000-303) and consumables such as fuses and coin cells are recommended, together with a spare stream board where the application calls for it. Small items such as fuses, SD cards and batteries are more economical to order with the device or to source locally because of shipping cost.

Why is there only one auxiliary board per device?

The auxiliary board carries the mode and security switches, the backup battery and the SD card. Because these functions exist once in the device, only one board is used. After a replacement, the security mode settings and the logging configuration should be checked.

What is the 2 GB SD card used for?

The SD card is used to hold alarm, audit and data logs with extended capacity. It is most effective in installations where the card can be removed and read in a PC, so the panel layout should make the card easy to reach.

How many devices can be mounted in one rack?

With the 19 inch rack option, up to two flow computers can be mounted in a single rack, using the M2.5x10 cap head screws supplied with the unit. Where a single device is to be mounted, quarter panels are used.

When is the protective coating the right choice?

The Certonal FC-742 coating is chosen to protect board and device surfaces in damp, salty or oily-vapour environments. It can be applied to complete units and to all boards; it forms a very thin barrier that repels water and oil, does not affect connectivity or measurement, and can reform over small surface breaks. The coating option has to be stated at the order stage.