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Tricon Systems
Introduction .......................................................................... 1
Theory of Operation............................................................. 3
System Configuration ........................................................ 11
Product Specifications ....................................................... 17
Field Termination Options.................................................. 47
Communication Capabilities .............................................. 59
TriStation 1131 Developers Workbench ........................... 63
CEM Programming Language Editor................................. 67
Sequence of Events (SOE) Capability............................... 69
Part Number Cross-Reference .......................................... 71
Glossary............................................................................. 73
Information in this document is subject to change without notice. Companies, names and data used in
examples herein are fictitious unless otherwise noted. No part of this document may be reproduced or
transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express
written permission of Triconex.
2006 Invensys Systems, Inc. All Rights Reserved.
Triconex, Tricon, Trident, TriStation 1131, and CEMPLE are trademarks of Invensys plc, its subsidiaries and
affiliates. All other brands may be trademarks of their respective owners.
DISCLAIMER
Because of the variety of uses for this equipment and because of the differences between this fault-tolerant
equipment and traditional programmable logic and process controllers, the user of, and those responsible for
applying, this equipment must satisfy themselves as to the acceptability of each application and the use of the
equipment.
The illustrations, charts and layout examples shown in this manual are intended solely to illustrate the text of
this manual. Because of the many variables and requirements associated with any particular installation,
Invensys Systems, Inc. cannot assume responsibility or liability for actual use based upon the illustrative uses
and applications.
In no event will Invensys Systems, Inc. be responsible or liable for indirect or consequential damages
resulting from the use or application of this equipment.
INVENSYS SYSTEMS, INC. DISCLAIMS ANY IMPLIED WARRANTY OF FITNESS FOR A
PARTICULAR PURPOSE.
Invensys Systems, Inc. reserves the right to make changes at any time in order to improve design and to supply
the most reliable product. No patent or copyright liability is assumed by Invensys Systems, Inc. with respect
to use of information, circuits, equipment or software described in this text.
TECHNICAL SUPPORT
Customers in the U.S. and Canada can obtain technical support from the Customer Satisfaction Center (CSC)
at the numbers below. International customers should contact their regional support center.
Telephone: T oll-free number 866-746-6477
Toll number 508-549-2424 (outside U.S.)
Fax: Toll number 508-549-4999
E-mail: ips.csc@ips.invensys.com
The Tricon is a fault-tolerant controller based on a Triple-Modular
Redundant (TMR) architecture.
Introduction
What is Fault-Tolerant
Control?
A fault-tolerant control system identi-
fies and compensates for failed control
system elements and allows repair
while continuing an assigned task
without process interruption. A high-
integrity control system such as the
Tricon is used in critical process appli-
cations that require a significant degree
of safety and availability.
1
Introduction
All diagnostic fault information is product feed rates, expander pressure Offshore Fire and Gas
accessible by the control program and equalization and temperatureare Protection
the operator. The program or the oper- monitored and shutdown actions taken The protection of offshore platforms
ator can use diagnostic data to modify if an upset condition occurs. Traditional from fire and gas threats requires
control actions or direct maintenance shutdown systems implemented with continuous availability as well as reli-
procedures. mechanical or electronic relays provide ability. The Tricon provides this avail-
shutdown protection but can also cause ability through online replacement of
Other key features of the Tricon
dangerous nuisance trips. faulty modules. Faults in individual
controller that ensure the highest
possible system integrity are: The Tricon increases system integrity, modules, field wiring and sensors are
providing automatic detection and veri- managed automatically by built-in
No single point of failure diagnostics. Analog fire and gas detec-
fication of field sensor integrity, inte-
Ability to operate with 3, 2 or 1 grated shutdown and control tors are connected directly to the
Main Processor before shutdown functionality, and direct connection to Tricon, eliminating the need for trip
the supervisory data highway for amps. An operator interface monitors
Fully implemented and transparent fire and gas systems as well as diagnos-
continuous monitoring of safety-crit-
triplication tics for the Tricon controller and its
ical functions.
Comprehensive system diagnostics attached sensors. Traditional fire and
Boiler Flame Safety gas panels can bereplaced with a single
Complete range of I/O modules Process steam boilers function as a crit- integrated system, saving costly floor
Dual and single I/O modules for ical component in most refinery appli- space while maintaining high levels of
safety-critical points with a limited cations. Protection of the boiler from safety and availability.
need for availability upset conditions, safety interlock for
normal startup and shutdown, and
Remote I/O up to 7.5 miles flame-safety applications are combined What is TriStation?
(12 kilometers) away from MPs by one integrated Tricon system. In TriStation 1131 Developer's Work-
Simple, online module repair traditional applications, these functions bench is an integrated tool for devel-
had to be provided by separate, non- oping, testing and documenting control
Unsurpassed reliability and integrated components. But with the programs that execute in the Tricon
availability fault-tolerant, fail-safe Tricon controller. TriStation 1131 complies
controller, the boiler operations staff with the IEC 61131 International Stan-
can use a critical resource more produc- dard for Programmable Controllers and
What are Typical User tively while maintaining safety at or follows the Microsoft Windows guide-
Applications? above the level of electromechanical lines for graphical user interfaces.
Each day the Tricon supplies increased protection systems.
safety, reliability and availability to a
Turbine Control Systems
worldwide installed base. The What about Communication
following are a few typical applica- The control and protection of gas or
steam turbines requires high integrity
Capabilities?
tions. For more information on how a
as well as safety. The continuous oper- Optional modules enable the Tricon to
Tricon controller can add value to your
ation of the fault-tolerant Tricon communicate with other Triconex
applications, ask your sales representa-
controller provides the turbine operator controllers and with other hosts such as:
tive for additional documentation and
customer references. with maximum availability while main- Modbus masters and slaves
taining equivalent levels of safety.
Emergency Safety Shutdown Speed control as well as start-up and Distributed Control Systems (DCS)
(ESD) shutdown sequencing are implemented Operator workstations
The Tricon provides continuous protec- in a single integrated system. Unsched- Host computers using Ethernet
tion for safety-critical units in refin- uled outages are avoided by using hot- (802.3) protocol
eries, petrochemical/chemical plants spares for the I/O modules. If a fault
occurs in a module, a replacement For more information, see Communi-
and other industrial processes. For
module is automatically activated cation Capabilities on page 59.
example, in reactor and compressor
units, plant trip signalsfor pressure, without operator intervention.
2
The Tricon is designed with a fully triplicated architecture
throughout, from the input modules through the main processors
(MPs) to the output modules.
Theory of Operation
Fault tolerance in the Tricon is achieved which takes control if a fault is detected memory for use in the hardware voting
by means of a Triple-Modular Redun- on the primary module during opera- process.
dant (TMR) architecture. The Tricon tion. The hot-spare position can also be
The individual input table in each main
provides error-free, uninterrupted used for online system repairs.
processor is transferred to its neigh-
control in the presence of either hard
boring main processors over the propri-
failures of components, or transient
etary TriBus. During this transfer,
faults from internal or external sources. Main Processor Modules
hardware voting takes place. The
The Tricon is designed with a fully trip- A Tricon system contains three main TriBus uses a direct memory access
licated architecture throughout, from processor (MP) modules to control (DMA) programmable device to
the input modules through the main three separate channels of the system. synchronize, transmit, vote and
processors to the output modules. Each main processor operates in compare data among the three main
Every I/O module houses the circuitry parallel with the other two main proces- processors.
for three independent channels, sors, as a member of a triad.
which are also referred to as legs.
Each channel on the input modules Auto Spare Auto Spare
reads the process data and passes Input I/O Bus Output
that information to its respective Leg
A
Main
Processor
Leg
A
main processor. The three main TriBus A
3
Theory of Operation
After the TriBus transfer and input data priate channel of the corresponding The main processor modules receive
voting have corrected the input values, output module over the I/O bus. For power from dual power modules and
these corrected values are used by the example, Main Processor A transmits power rails in the main chassis. A
main processors as input to the user- the appropriate table to Channel A of failure on one power module or power
written control program. (The control each output module over I/O Bus A. rail will not affect the performance of
program is developed in the TriStation The transmittal of output data has the system.
software and downloaded to the main priority over the routine scanning of all
processors.) The 32-bit main micropro- I/O modules.
cessor executes the user-written control Bus Systems and
The I/O and COMM processor
program in parallel with the neigh- Power Distribution
manages the data exchanged between
boring main processor modules. Three triplicated bus systems are etched
the main processors and the communi-
The user-written control program cation modules using the communica- on the chassis backplane: the TriBus,
generates a table of output values based tion bus, which supports a broadcast the I/O bus and the communication bus.
on the table of input values, according mechanism. The TriBus consists of three indepen-
to the rules built into the control dent serial links which operate at 25
The model 3008 Main Processors
program by the customer. The I/O megabits per second. The TriBus
provide 16 megabytes of DRAM,
processor on each main processor synchronizes the main processors at the
which is used for the control program,
manages the transmission of output beginning of a scan. Then each main
sequence-of-events data, I/O data, diag-
data to the output modules by means of processor sends its data to its upstream
nostics and communication buffers.
the I/O bus. and downstream neighbors. The TriBus
In the event of an external power performs one of two functions with the
Using the table of output values, the I/O
failure, the integrity of the user-written data:
processor generates smaller tables,
program and the retentive variables is
each corresponding to an individual Transfer of data onlyfor I/O,
protected for a minimum of six months.
output module in the system. Each diagnostic and communication data.
small table is transmitted to the appro-
Comparing data and
flagging disagreements
Dual Power Rails
for the previous scans
output data and memory of
Dual-Power
Regulators
+3.3 Volts
user-written control
+5 Volts
802.3 Network program.
(RJ-45) Reserved for
4
I/O Bus ELCO Connectors for I/O Termination
TriBus
the bottom of the backplane. Each
channel of the I/O bus runs between
Power
one of the three main processors and Supply
#1
the corresponding channels on the I/O
module.
Dual
The I/O bus can be extended between Power
Rails
chassis using a set of three I/O bus
cables. Power Channel A
Supply
#2 Channel B Comm
Channel C Bus
Communication Bus
Channel A
The communication (COMM) bus Channel B
I/O
Bus
runs between the main processors and Channel C
down the center of the backplane. * Either the left module or right module functions as the active or hot-spare module.
Every module in the chassis draws Backplane of the Main Chassis
power from both power rails through
dual power regulators. There are four
sets of power regulators on each input Digital Input Modules tion module, determines the respective
and output module: one set for each of The Tricon supports two basic types of states of the input signals, and places
the channels A, B and C and one set for digital input modules: TMR and single. the values into input tables A, B and C
the status-indicating LED indicators. The following paragraphs describe respectively. Each input table is regu-
digital input modules in general, larly interrogated over the I/O bus by
followed by specifics for TMR and the I/O communication processor
Field Signals single modules. located on the corresponding main
processor module. For example, Main
Each I/O module transfers signals to or Every digital input module houses the Processor A interrogates Input Table A
from the field through its associated circuitry for three identical channels over I/O Bus A.
field termination assembly. Two posi- (A, B and C). Although the channels
tions in the chassis tie together as one reside on the same module, they are On TMR digital input modules, all crit-
logical slot. The first position holds the completely isolated from each other ical signal paths are 100 percent tripli-
active I/O module and the second posi- and operate independently. A fault on cated for guaranteed safety and
tion holds the hot-spare I/O module. one channel cannot pass to another. In maximum availability. Each channel
Termination cables are connected to the addition, each channel contains an 8-bit conditions signals independently and
top of the backplane. Each connection microprocessor called the I/O commu- provides isolation between the field and
extends from the termination module to nication processor, which handles the Tricon. (The 64-point high-density
both active and hot-spare I/O modules. communication with its corresponding digital input module is anexceptionit
Therefore, both the active module and main processor. has no channel-to-channel isolation.)
the hot-spare module receive the same
Each of the three input channels asyn- DC models of the TMR digital input
information from the field termination
chronously measures the input signals modules can self-test to detect stuck-
wiring.
from each point on the input termina- ON conditions where the circuitry
5
Theory of Operation
AC/DC Input Circuit Individual Opto-Isolation Intelligent I/O Controller(s) must detect all faults
in a timely manner and
- +
Threshold Detect Input Bus
A upon detection of an
Proc
Opto-Isolator Mux Xcvr input fault, force the
Individual Point Field Termination
Opto-
Isolator Dual processors by each
Control Signal Port
RAM channel.
Architecture of TMR Digital Input Module with Self-Test (DC Model) Digital Output
Modules
cannot tell whether a point has gone to stuck-OFF fault conditions within the There are four basic types of digital
the OFF state. Since most safety sys- non-triplicated signal conditioners in output modules: dual, supervised, DC
tems are set up with a de-energize-to- less than half a second. This is amanda- voltage and AC voltage. The following
trip capability, the ability to
detect stuck-ON points isan TRIPLICATED
important feature. To test I/O BUS INTELLIGENT I/O CONTROLLER(S) FIELD CIRCUITRY TYPICAL POINT (16)
Output
B
frozen in the I/O communi- Switch to
Drive C other
B Bus Point points
cation processor while the
Circuitry
Proc
Xcvr Register
test is running.
B
On single digital input Output
detects all stuck-ON and Architecture of 16-Point Supervised Digital Output Module
6
paragraphs describe digital output
modules in general, followed by ANALOG INPUT
CIRCUIT
SIGNAL
CONDITIONING
INDIVIDUAL ADC
FOR EACH LEG
INTELLIGENT
I/O CONTROLLER(S)
TRIPLICATED
I/O BUS
specifics for the four types. TYPICAL POINT
7
Theory of Operation
8
Safety Manager Module (SMM) Advanced Communication Power Supply Modules
The SMM acts as an interface between Module (ACM) Each Tricon chassis houses two power
a Tricon controller and a Honeywell The ACM acts as an interface between modules arranged in a dual-redundant
Universal Control Network (UCN), one a Tricon controller and a Foxboro Intel- configuration. Each module derives
of three principal networks of the TDC ligent Automation (I/A) Series DCS. power from the backplane and has inde-
3000 DCS. The SMM appears to the The ACM appears to the Foxboro pendent power regulators for each
TDC 3000 as a safety node on the system as a safety node on the I/A channel. Each can support the power
Universal Control Network (UCN), Series Nodebus, allowing the Tricon to requirements for all the modules in the
allowing the Tricon to manage process- manage process-critical points within chassis in which it resides, and each
critical points within the overall TDC the overall I/A DCS environment. The feeds a separate power rail on the
3000 environment. The SMM transmits ACM transmits all Tricon aliased data chassis backplane. The power modules
all Tricon aliased data and diagnostic and diagnostic information to I/A oper- have built-in diagnostic circuitry which
information to TDC 3000 operator ator workstations in display formats checks for out-of-range voltages and
workstations in display formats that are that are familiar to Foxboro operators. over-temperature conditions. A short
familiar to Honeywell operators. on a channel disables the power regu-
See Product Specifications on
page 17 for specifications of the TCM, lator rather than affecting the power
EICM, NCM, SMM, HIM, and ACM. bus.
9
Notes
A Tricon system consists of one main chassis and up
to fourteen additional chassis.
System Configuration
Chassis Layout
Two power supplies reside on the left
side of all chassis, one above the other.
In the main chassis, the three main
processors are immediately to the right.
The remainder of the chassis is divided
into six logical slots for I/O and F
communication modules and one COM
slot with no hot-spare position. Each
logical slot provides two physical
spaces for modules, one for the active
module and the other for its optional
hot-spare module.
The layout of an expansion chassis is
similar to that of the main chassis,
except that expansion chassis provide
eight logical slots for I/O modules. G H I J K L M
(The spaces used by the main proces-
sors and the COM slot in the main A. Memory backup battery F. Redundant Power Modules K. DO module with hot-spare
chassis are now available for other B. Connectors for terminations G. Three Main Processors L. AI module with hot-spare
purposes.) C. I/O expansion ports H. COM slot (empty) M. AO module without spare
D. Power terminals I. Two TCMs
The main and expansion chassis are
E. Keyswitch J. DI module without spare
interconnected by means of triplicated
I/O bus cables. The maximum I/O bus Sample Layout of a Tricon Chassis
cable length between the main chassis
11
System Configuration
and the last expansion chassis is With the hot-spare method, a logical control and back again without process
normally 100 feet (30 meters), but in slot contains two identical I/O modules. interruption.
restricted applications the length can be While one module is active, the other
A Tricon system should include at least
up to 1,000 feet (300 meters). (Please module is powered but inactive. The
one hot-spare module in place for each
consult your Triconex Customer Tricon cycles control between the two
type of I/O module in the system. With
Support representative for assistance healthy I/O modules approximately
this arrangement, hot-spare modules
when configuring a system that exceeds every hour, so that each undergoes
are tested regularly and can be used for
30 meters of I/O bus cable length.) complete diagnostics on a regular basis.
online module replacement anywhere
If a fault is detected on one module, the
RXM chassis are used for systems in in the system.
Tricon automatically switches control
which the total cable distance between
to the other module, allowing the
the first chassis and the last chassis
system to maintain three healthy chan-
exceeds the distance which can be I/O Bus Connections
nels continuously. The faulty module
supported by copper. Each RXM The figure on this page shows the three
can then be removed and replaced.
chassis houses a set of three RXM sets of RS-485 I/O bus ports (IN and
modules in the same position as the Alternatively, a module can be replaced OUT) on each chassis. Additional
main processors in the main chassis. online even when only one I/O module chassis may branch out from the main
Six remaining logical slots are vaailable is normally installed in a logical slot. If chassis by means of the I/O bus ports,
in an RXM chassis and one blank a fault occurs, the Fault indicator turns up to a maximum of 14. There are six
(unused) slot. on, but the module remains active on portstwo sets of three for triplicated
two channels. A replacement module is serial communication located on a
then inserted into the unused space in panel in the upper left corner of the
Online Module Repair the slot. The Tricon will grant control to backplane. One set of three I/O bus
The logical slot arrangement of a this second I/O module after it passes a cables is required for each expansion
Tricon chassis provides two approaches diagnostic test. Once the replacement chassis, and for each RXM chassis that
to the online repair of faulting modules: I/O module becomes active, the faulty houses a primary RXM module set.
the hot- spare method and online module can be removed. This repair (Remote RXM chassis are connected to
module replacement. method demonstrates the Tricon the primary RXM chassis with fiber-
controllers ability to automatically optic cables.) Communication across
transition from triplicated to dual the I/O bus cables (and the RXM fiber-
optic cables) is at 375 kilobits per
second, the same rate as the internalI/O
I/O Bus Ports Tricon Chassis,
bus on the backplane of each chassis.
Front View
OUT
A B C
IN
12
System Configuration
Guidelines RXM Chassis Expansion Chassis
A Tricon system must have a main
chassis and may have up to14 expan- A
A
guidelines apply.
Remote
RXM Set
Main Chassis
Jumper Cable
Configuration Guidelines
There is one main chassis with a NOTES
Junction
chassis address of 1. Box Dotted lines represent six fiber-optic cables
for remote location. Solid lines represent
Main RS-485 I/O Bus Cables for local expansion.
The main chassis must contain three
Cable
A Tricon system may contain a maximum of 15
Junction
model 3008 Main Processors for Box
chassis, including Main, Expansion and RXM Chassis.
A A
B
B
A v9 low-density configuration C C
13
System Configuration
RXM chassis can be connected to Communication Module Up to two logical slots can be
local expansion chassis using I/O Configuration Guidelines configured for NCMs. Matched
bus cables. The following rules apply to the TCM, pairs of NCMs can be installed in the
EICM, NCM, HIM, SMM, and ACM in left and right positions of each
Each RXM chassis must contain 2
a Tricon system: logical slot. If only one logical slot is
power modules.
used, the slot can be in the main
Each RXM chassis provides 6 A TriStation PC communicates with chassis or Chassis 2. If two logical
logical slots for I/O modules and 1 a Tricon controller through a TCM, slots are used, they must be Slot 6
blank (unused) slot. EICM, NCM or ACM, so at least and 7 in the main chassis, and peer-
one of these modules must be to-peer cannot be used.
installed in the main chassis or
Chassis 2. Up to two logical slots can be
configured for TCMs. Matched pairs
One logical slot is available for of TCMs can be installed in the left
EICMs or ACMs, respectively. and right positions of each logical
Matched pairs of these modules can slot, and they can be located in the
be installed in both the left and right main chassis or Chassis 2.
positions of one logical slot.
14
Up to three logical slots can be Module Type Watts Consumed
configured for SMMs. A matched
pair of SMMs can be installed in the ACM 15
left and right positions of each Analog Input 10
logical slot. All three slots must be Analog Input, Isolated 15
in the main chassis or Chassis 2. Analog Input, High Density 10
Up to two logical slots can be Analog Output 15
configured for HIMs. Both slots Digital Input, High Density 10
must be in the main chassis.
Digital Input, Single 10
The COM slot can be configured Digital Input, TMR 10
only for the EICM, TCM or NCM.
Digital Output, AC 10
You cannot install an NCM and a Digital Output, DC 10
TCM in the same Tricon system.
You also cannot install an EICM and Digital Output, Dual 10
a TCM in the same system. Digital Output, Supervised 15
15
Notes
The Tricon supports a comprehensive range of
modules to meet customers needs.
Product Specifications
The Triconex product family includes a Main Processors Fiber-Optic Remote
comprehensive range of modules. This The main processors execute the Extender Modules (RXM)
section includes: a summary of the system diagnostics and the user-written For operation of Expansion Chassis up
system components and their uses, a control program. to 7.5 miles (12 kilometers) away from
table that lists standard products and the Main Chassis, with exceptional
their model numbers, and a summary of Communication Modules
immunity against electro-static and
specifications for each standard product Tricon Communication Module electro-magnetic interference.
in the Tricon family (TCM) supports a number of
Triconex protocols and applications I/O Modules
See the Tricon Planning and Installa- Digital Input Modules receive
and user-written applications on
tion Guide for complete information. discrete signals of these nominal
Ethernet (802.3) networks,
including TriStation, Modbus TCP voltages: 115 VAC/VDC, 48
Summary of Tricon and OPC. It also supports RS-232 VAC/VDC, and 24 VAC/VDC. All
Components and RS-485 serial communication voltages are available in TMR
Chassis with Modbus devices, TriStation, modules. Non-TMR modules are
and GPS for time synchronization. available in 24 VDC and 48 VDC
Main Chassishouses main only. Speed input and totalization
processors, memory back-up Enhanced Intelligent
Communication Module (EICM) modules are also available.
batteries, communication modules
and I/O modules. supports RS-232, RS-422 and RS- Supervised Digital Output Modules
Expansion Chassisfor additional 485 serial communication with produce discrete output signals of
I/O modules up to 100 feet (30 Modbus devices and TriStation. these nominal voltages, with
meters) away from the main chassis. Network Communication Module diagnostic coverage of the field
In restricted applications, operation (NCM) supports a number of circuit and load device: 115 VAC,
up to 1,000 feet (300 meters) is Triconex protocols and applications 120 VDC, 48 VDC and 24 VDC.
supported. and user-written applications on Digital Output Modules produce
RXM Chassisfor I/O modules up Ethernet (802.3) networks, discrete output signals of these
to 7.5 miles (12 kilometers) away including TriStation. nominal voltages: 115 VAC, 120
from the main chassis. Safety Manager Module (SMM) acts VDC, 24 and 48 VDC. Dual output
Mechanical KeyingEach slot in as an interface between a Tricon modules are also available.
the Tricon is mechanically keyed to controller and a Honeywell
Analog Input Modules receive
correspond with a specific type of Universal Control Network (UCN),
analog signals of these types: 0-5
module. This prevents the one of three principal networks of
VDC, -5 to +5 VDC, 0-10 VDC and
installation of modules into the TDC 3000 DCS.
Thermocouple types J, K, T and E.
improper slots. Hiway Interface Module (HIM) acts Available in both isolated and DC-
For chassis mounting and enclosure as an interface between a Tricon coupled versions.
specifications, see page 23. controller and a Honeywell TDC
3000 Hiway Gateway and Local Analog Output Module drives eight
Power Supply Modules
Control Network (LCN). 4-20 mA analog output signals. The
Provide logic power to modules in high-current AO module includes 6
the main, expansion or RXM Advanced Communication Module points at 4-20 mA and 2 points at 20-
chassis. Available in 24 VDC, 115 (ACM) allows a Tricon controller to 320 mA.
VAC and 230 VAC versions. The interface with a Foxboro Industrial
power rating of each power supply is Automation (I/A) Series DCS and
175 watts at 140 F (60 C). TriStation.
17
Product Specifications
1. I/O Bus Expansion Cables are available in custom lengths. Please contact Triconex for more information.
18
Tricon I/O Modules
Voltage Description Type Model No. Points For Details, See
19
Product Specifications
General Environmental and EMC Specifications
Other than the optional conformal coating of all PCB assemblies, the Tricon is not explicitly protected against dust, corrosive atmospheres or
falling debris. Atmospheric and airborne-particle protection must be provided by housing the Tricon in an appropriate NEMA-rated enclosure.
Operating Temperature 32 to 140 F (0 to 60 C), ambient, as measured at the bottom of the chassis, per IEC 60080-2-1 Test Nb
Storage Temperature -40 to 167 F (-40 to 75 C), per IEC 60068-2-14, Test Na
Relative Humidity 5% to 95%, non-condensing, per IEC 60068-2-2, Test Bb, and IEC 60068-2-3 test Db
Sinusoidal Vibrations per Axis 2 G @ 10 to 150 Hz, per IEC 60068-2-6, Test Fc
Shock 15 G for 6-11 ms in each axis, per IEC 60068-2-27
Electrostatic Discharge IEC 61000-4-2, 4 kV air, 8kV contact
Conducted Susceptibility IEC 61000-4-4, Fast Transient/Burst, 2 kV power, 1kV signal lines and IEC 61000-4-5, Surge Withstand,
2 kV CM AC power lines, etc. IEC 61000-4-6, RFI, 0.15-80 MHz, 10V
Radiated Susceptibility IEC 61000-4-3, 26-1000 MHz, 10V/m and IEC 61000-4-8, 50-60 Hz, 30A/m
Conducted Emissions CISPR 16, Class A, 0.15-30MHz, 73-79db when installed per the guidelines of the P&I Guide.
Radiated Emissions CISPR 11, Class A, 30-1000 MHz @ 10m, 4-47 db when installed per the guidelines of P&I Guide.
International Approvals
The Tricon controller has been certified as complying with multiple internationally recognized standards by the following internationally recognized
certification agencies, these certifications have qualified the Tricon for use around the world in safety critical applications. Test reports from the various
certification agencies are available upon request.
TV Rheinland TV has certified that the Tricon v9 and v10 controllers are in full compliance with the internationally recognized standards
listed below, and thus are qualified for use in the following applications and jurisdictions.
Emergency safety shut-down or other critical control applications requiring SIL 1-3 certification per the functional safety requirements of
IEC 61508 9 (only Tricon v9.6 or later)
Emergency safety shut-down or other critical control applications requiring AK 1-AK6 certification per the functional safety requirements of
DIN V 19250 and DIN V VDE 0801 (only Tricon v9.x)
Fire and gas detection applications requiring certification per the requirements of EN 54
Fire and gas detection applications requiring certification per the requirements of NFPA 72 (only Tricon v9.6 or later)
Burner management applications requiring certification per the requirements of DIN VDE 0116
Burner management applications requiring certification per the requirements of NFPA 8501 or NFPA 8502 (only Tricon v9.6 or later)
All applications in the European Union or other jurisdictions requiring compliance with the EMC Directive No. 89/336/EEC and Low Voltage
Equipment Directive No. 72/23/EEC
All applications in the European Union or other jurisdictions requiring compliance with the ATEX Directive No. 94/9/EC for Zone 2, Group IIB
hazardous locations
Environmental, health, and safety applications in semiconductor manufacturing facilities per the requirements of SEMI S2
For hazardous location applications, see the Tricon Planning and Installation Guide for application-specific installation instructions.
Canadian Standards Association (CSA) CSA has certified that the Tricon v10 controller is in full compliance with the internationally recog-
nized electrical safety standards and is qualified for general use in North American and other jurisdictions requiring compliance with these standards.
Factory Mutual Research (FM) Factory Mutual has certified that the Tricon v10 controller is in full compliance with the international recog-
nized standards and is qualified for use in Class I, Division 2 Temperature T4, Groups A, B, C, and D hazardous indoor (or outdoor in a NEMA 4
cabinet) locations. For hazardous location applications, see the Tricon Planning and Installation Guide for application-specific installation instructions.
European Union CE Mark Based upon the independent TV evaluation and test results, Triconex has certified the Tricon controller is suitable
to use in the European Union and all other jurisdictions requiring compliance with the European Union EMC Directive No. 89/336/EEC and Low
Voltage Equipment Directive No. 72/23/EEC, see Certificate of Compliance for details. For hazardous location applications, see the Tricon Planning
and Installation Guide for application-specific installation instructions.
U.S. Nuclear Regulatory Commission (NRC) The NRC has certified that the Tricon controller is suitable for use in nuclear 1E
applications within the limitations and guidelines referenced in the NRC Safety Evaluation Report (SER) ML013470433, Review of Triconex
Corporation Topical Reports 7286-545, Qualification Summary Report and 7286-546, Amendment 1 To Qualification Summary Report,
Revision 1. This report is available from the NRC via the Agency Document Access and Management System (ADAMS) Web site. This
qualification was based upon EPRI TR-107330, Generic Requirements Specification for Qualifying a Commercially Available PLC for Safety-
Related Applications in Nuclear Power Plants. For details on models and revisions qualified for 1E applications, please contact Invensys
Nuclear by calling toll-free 866-703-6300, toll 949-885-0885, or visit the Invensys Nuclear Web site at http://www.invensysnuclear.com.
20
Chassis Options Keyswitch
A Tricon system is made up of one or LOCAL I/O Expansion Backplane
more chassis assemblies which contain REMOTE Bus Ports
21
Product Specifications
1/4 - 20 threaded
chassis ground 16.50"
41.9cm
Top View
of Chassis
3.00" R
7.6cm
Minimal clearance requirements
for communication cables
18.31"
46.5cm
Clearance for
#10 screw
(4 places) 22.75"
57.8cm
22
31.5" 31.5" 31.5"
(800 mm) (800 mm) (800 mm)
31.5"
Field Power Supply
(80.0cm)
DC Distribution
Panel
A/C Distribution
Panel Analog Input/
Digital Input
External
Termination
Panel
4.5" x 10"
(114 mm x 254 mm)
Tricon
Main
Wire Duct
Wire Duct
Chassis
86.0"
(2,200 mm)
1.75"
(44.5 mm)
Baffle minimum
Tricon
Expansion 16-point
Chassis Digital Output
Tricon External
Chassis Termination
(side view) Panel
4.5" x 5.0"
(114 mm x 127 mm)
Typical Dimensions and Clearances for Chassis Installation with External Terminations
NOTE
This drawing shows a typical set-up for external termination panelsother set-ups are possible.
Please contact the Triconex Customer Satisfaction Center for details.
* Other sizes are available. Please contact Triconex for more information.
23
Product Specifications
Power Modules The power module alarm contacts are
Front Panel of Power Module:
Each Tricon chassis is equipped with actuated when: (located on lower left side of chassis)
two power moduleseither one is fully A module is missing from the
capable of running the Tricon at full system 120 VAC/DC
load and rated temperature. Each power
The hardware configuration
module can be replaced online. The
conflicts with the control programs PASS
power modules, located on the left side
logical configuration FAULT
of the chassis, convert line power to DC ALARM
24
Main Processor Modules If multiple Tricon systems are Test all basic processor and floating-
Model 3008 Main Processors are avail- connected by means of NCMs, the time point instructions and operating
able for Tricon v9.6 and later systems. synchronization capability ensures a modes
For detailed specifications, see the consistent time base for effective SOE Validate user memory by means of
Planning and Installation Guide for time-stamping. See page 70 for more the TriBus hardware-voting circuitry
Tricon Systems. information.
Verify the shared memory interface
Three MPs must be installed in the Diagnostics with each I/O communication
main chassis of every Tricon system. Extensive diagnostics validate the processor and channel
Each MP independently communicates health of each MP, I/O module and Verify handshake and interrupt
with its I/O subsystem and executes the communication channel. Transient signals between the CPU, each I/O
user-written control program. faults are recorded and masked by the communication processor and
hardware majority-voting circuit. channel
Sequence of Events (SOE)
Persistent faults are diagnosed and the
and Time Synchronization Check each I/O communication
errant module is hot-replaced.
During each scan, the MPs inspect processor and channel
designated discrete variables for state MP diagnostics perform these tasks: microprocessor, ROM, shared
changes known as events. When an memory access and loopback of RS-
Verify fixed-program memory and
event occurs, the MPs save the current 485 transceivers
static RAM
variable state and time stamp in the Verify the TriClock and TriBus
buffer of an SOE block. interfaces
Feature Description
Microprocessor Motorola MPC860, 32 bit, 50 MHz
Memory 16 MB DRAM (non-battery backed-up)
32 KB SRAM, battery backed-up
6 MB Flash PROM
Tribus Communication Rate 25 megabits per second
32-bit CRC protected
32-bit DMA, fully isolated
I/O Bus and Communication Bus Motorola MPC860
Processors 32 bit
50 MHz
25
Product Specifications
TCM Specifications
SERIAL 4
TX RX
Model Number 4351A, 4352A, 4353, 4354
Serial Port #4 Serial ports 4, RS-232/RS-485 ports, DB-9 connectors
for TriStation or
Network ports 2, 10/100BaseT Ethernet ports, RJ-45 connectors (model 4351A and 4353)
Modbus interface 2, fiber-optic mode Ethernet ports, MTRJ connectors with 62.5/125 um fiber
cables (model 4352A and 4354)
Port isolation 500 VDC
Protocols TriStation, Modbus, TCP/IP, ICMP, SNTP, TSAA, Trimble GPS,
Peer-to-Peer, Peer-to-Peer Time Synchronization, Jet Direct (network printing)
DEBUG
Modbus functions 01 Read Coil Status 06 Modify Register Content
Debug Port supported
for Triconex use 02 Read Input Status 07 Read Exception Status
03 Read Holding Registers 08 Loopback Diagnostic Test
04 Read Input Registers 15 Force Multiple Coils
05 Modify Coil Status 16 Preset Multiple Registers
TCM
Communication speed Copper Ethernet ports: 10/100 Mbps
435x Fiber Ethernet ports: 100 Mbps
Serial ports: up to 115.2 Kbps per port
Status Indicators PASS, FAULT, ACTIVE, FIRM
LINK 1 per network port, TX (Transmit) 1 per port,
RX (Receive) 1 per port
26
Enhanced Intelligent Modbus or TriStation interface.
Communication Module Modbus communication can be
The model 4119A Enhanced Intelligent performed in either RTU or ASCII
Communication Module (EICM) mode. The parallel port provides a
allows the Tricon to communicate with Centronics interface to a printer.
Modbus masters and slaves, TriStation Each EICM supports an aggregate data
and printers. rate of 57.6 kilobits per second (for all
For Modbus connections, the EICM four serial ports).
user can select the RS-232 point-to- Programs for the Tricon use variable
point interface for one master and one names as identifiers but Modbus
slave, or the RS-485 interface for one devices use numeric addresses called
master and up to 32 slaves. The RS-485 aliases. Therefore an alias must be
network trunk can be one or two assigned to each Tricon variable name
twisted-pair wires up to a maximum of that will be read by or written to a
4,000 feet (1,200 meters). Modbus device. An alias is a five-digit
Each EICM contains four serial ports number which represents the Modbus
and one parallel port which can operate message type and the address of the
concurrently. Each serial port can be variable in the Tricon. An alias number
configured as a Modbus master with up is assigned in TriStation.
to seven Modbus masters per Tricon Any standard Modbus device can
chassis. A single Tricon system communicate with the Tricon through
supports a maximum of two EICMs, the EICM, provided that aliases are
which must reside in one logical slot. assigned to the Tricon variables. Alias
(The hot-spare feature is not available numbers must also be used when host
for the EICM, though you can replace a computers access the Tricon through
faulty EICM while the controller is other communication modules, such as
online.) Each serial port is uniquely the NCM. See Communication Capa-
addressed and supports either the bilities on page 59 for more informa-
tion.
EICM Specifications
Model Number 4119A, Isolated
Serial ports 4 ports RS-232, RS-422 or RS-485
Parallel ports 1, Centronics, isolated
Port isolation 500 VDC
Protocol TriStation, Modbus
Modbus functions supported 01 Read Coil Status
02 Read Input Status
03 Read Holding Registers
04 Read Input Registers
05 Modify Coil Status
06 Modify Register Content
07 Read Exception Status
08 Loopback Diagnostic Test
15 Force Multiple Coils
16 Preset Multiple Registers
Communication speed 1200, 2400, 9600, or 19,200 Baud
Diagnostic Indicators PASS, FAULT, ACTIVE
TX (Transmit) 1 per port
RX (Receive) 1 per port
27
Product Specifications
SMM Specifications
28
Network Communication Communication Capabilities on
Module page 59 for more information about
With a model 4329 Network Communi- Triconex protocols and applications. PASS
cation Module (NCM) installed, the Two NCMs can reside in one logical
FAULT
Tricon can communicate with other slot of the Tricon chassis, but they func-
ACTIVE
Tricons and with external hosts over tion independently, not as hot- spare
Ethernet (802.3) networks. The NCM modules. External hosts can read or
supports a number of Triconex propri- write data only to Tricon variables to
etary protocols and applications as well which Alias numbers have been NET 1
(TCP(UDP)/IP/802.3) TX
Functions supported TRICON_DATA (Frame Type 1) RX
TRICON_DATA_REQ (Frame Type 2)
WRITE_TRICON_DATA (Frame Type 3) RS-232 Serial Port
WRITE_TRICON_DATA_RSP (Frame Type 4) Reserved for future use
READ_TRICON_CLOCK (Frame Type 5)
READ_TRICON_CLOCK_RSP (Frame Type 6)
SET_TRICON_CLOCK (Frame Type 7)
SET_TRICON_CLOCK_RSP (Frame Type 8)
READ_TRICON_DATA (Frame Type 11) NCM
READ_TRICON_RSP (Frame Type 12) 4329
Communication speed 10 megabits per second (for Ethernet ports)
Status indicators PASS, FAULT, ACTIVE
TX (Transmit) 1 per port
RX (Receive) 1 per port
29
Product Specifications
ACTIVE
I/A SERIES
Foxboro Intelligent Automation (I/A) Time synchronization from the I/A
Interface to NODEBUS Series system, appearing to the Series environment
I/A Series Nodebus ONLINE
Foxboro system as a safety node on the
SBRDY
I/A Series Nodebus. The ACM Reads Tricon diagnostics for display
TX RX
communicates process information at by the I/A Series workstation
full network data rates for use Write protection to lock out changes
BNC Connector
Reserved anywhere on the I/A Series system, to the Tricon safety system from all
NET1
transmitting all Tricon aliased data I/A Series sources
(including system variables and Hot-spare capability for
AUI Connector system aliases) and diagnostic infor- uninterrupted communication with
to DNBI Nodebus Data mation to operator workstations in the I/A Series Nodebus
display formats that are familiar to
The ACM also supports the following
Foxboro operators. The ACM makes
Triconex protocols and applications on
DNBI
TX RX the following functions available to the
external host PCs connected to a sepa-
I/A Series:
RS-423 Serial Port
rate BNC port (labeled NET 2):
Handles critical I/O points and
to DNBI Nodebus Control
Tristation protocol for the TriStation
passes results to the I/A Series
software
TriStation/TSAA Interface TS/TSAA using the Object Management
5 678
9 ABC
DEF
9 ABC
DEF
1. The address for this port is set by the TS/TSAA Node Addresses switches.
30
Hiway Interface Module The HIM allows redundant BNC
The model 4509 Hiway Interface connections directly to the Data Hiway
Module (HIM) acts as an interface and has the same functional capacity as
between a Tricon controller and a four extended Data Hiway Port (DHP)
Honeywell TDC 3000 control system addresses.
by means of the Hiway Gateway and The HIM provides eight Hiway
Local Control Network (LCN). The addresses, implements the same slot
HIM can also interface with Honey- structure as the DHP, and typically
wells older TDC 2000 control system refreshes all data in less than 0.5
by means of the Data Hiway. seconds. The hot-spare capability
The HIM enables higher-order devices allows online replacement of a faulty
on the LCN or Data Hiway, such as module.
computers and operator workstations,
to communicate with the Tricon.
HIM Specifications
31
Product Specifications
to be located several kilometers from FAULT FAULT FAULT FAULT FAULT FAULT
the main chassis. RXM sets, consisting ACTIVE ACTIVE ACTIVE ACTIVE ACTIVE ACTIVE
32
TMR Digital Input Modules All TMR digital input modules sustain de-energize-to-trip capability, the
Each TMR digital input (DI) module complete, ongoing diagnostics for each ability to detect OFF points is an impor-
has three isolated input channels which channel. Failure of any diagnostic on tant feature. To test for stuck-ON
independently process all data input to any channel activates the module Fault inputs, a switch within the input
the module. A microprocessor on each indicator which in turn activates the circuitry is closed to allow a zero input
channel scans each input point, chassis alarm signal. The module Fault (OFF) to be read by the optical isolation
compiles data, and transmits it to the indicator points to a channel fault, not a circuitry. The last data reading is frozen
main processors upon demand. Then module failure. The module is guaran- in the I/O communication processor
input data is voted at the main proces- teed to operate properly in the presence while the test is running.
sors just prior to processing to ensure of a single fault and may continue to
All TMR digital input modules support
the highest integrity. All critical signal operate properly with certain kinds of
hot-spare capability, and require a sepa-
paths are 100 percent triplicated for multiple faults.
rate external termination panel (ETP)
guaranteed safety and maximum avail- Models 3502E, 3503E, and 3505E can with a cable interface to the Tricon
ability. Each channel conditions signals self-test to detect stuck-ON conditions backplane. Each module is mechani-
independently and provides optical where the circuitry cannot tell whether cally keyed to prevent improper instal-
isolation between the field and the a point has gone to the OFF state. Since lation in a configured chassis.
Tricon. most safety systems are set up with a
1. For 3501T.
33
Product Specifications
64-Point Digital Input may operate properly with certain kinds The Single Digital Input Module
Modules of multiple faults. (model 3564) is optimized for safety-
Each 64-point digital input (DI) module critical applications where low cost is
All digital input modules support hot-
has three isolated channels which inde- more important than maximum avail-
spare modules and require a separate
pendently process all data input to the ability. On single modules, only those
external termination panel (ETP) with a
module. A microprocessor on each portions of the signal path which are
cable interface to the Tricon backplane.
channel scans each input point, required to ensure safe operation are
Each module is mechanically keyed to
compiles data and transmits it to the triplicated. Special self-test circuitry
prevent improper installation in a
main processors on demand. Then input detects all stuck-ON and stuck-OFF
chassis.
data is voted at the main processors just fault conditions in less than half a
The model 3504E High Density Digital second. If a single module detects an
prior to processing to ensure the highest
Input Module continuously verifies the input fault, it reports that point as OFF,
integrity.
ability of the Tricon to detect transitions which may cause a glitch during
All digital input modules sustain to the opposite state. On this TMR switch-over to a hot-spare module.
complete, ongoing diagnostics for each module, all critical signal paths are 100
channel. A failure on any channel acti- percent triplicated forguaranteed safety
vates the Fault indicator which in turn and maximum availability. Each
activates the chassis alarm. A TMR channel conditions signals indepen-
module is guaranteed to operate prop- dently between the field and the Tricon.
erly in the presence of a single fault and
34
Pulse Input Module Each module provides complete Relay Output Module
The pulse input (PI) module provides ongoing diagnostics on each channel. The model 3636R/T Relay Output (RO)
eight very sensitive, high-frequency Failure of any diagnostic on any Module is a non-triplicated module for
inputs. It is optimized for use with non- channel activates the Fault indicator, use on non-critical points which are not
amplified magnetic speed sensors which in turn activates the chassis compatible with high-side solid-state
common on rotating equipment such as alarm signal. The Fault indicator output switches. An example is inter-
turbines or compressors. The module merely indicates a channel fault, not a facing with annunciator panels. The
senses voltage transitions from module failure. The module is guaran- relay output module receives output
magnetic transducer input devices, teed to operate properly in the presence signals from the main processors on
accumulating them during a selected of a single fault and may continue to each of threechannels. The three sets of
window of time (rate measurement). operate properly with certain kinds of signals are then voted, and the voted
The resulting count is used to generate multiple faults. data is used to drive the 32 individual
a frequency or RPM which is trans- The pulse input module supports hot- relays.
mitted to the main processors. The spare modules. Each output has a loopback circuit
pulse count is measured to 1 micro-
WARNING: The PI module does not which verifies the operation of each
second resolution.
provide a totalization capabilityit is relay switch independently of the pres-
The PI module includes three isolated optimized for measuring the speed of ence of a load, while ongoing diagnos-
input channels. Each input channel rotation equipment. For pulse totaliza- tics test the operational status of the
independently processes all data input tion model 3515, see page 36. module. Failure of any diagnostic acti-
to the module and passes the data to the vates the Fault indicator, which in turn
main processors, which vote on the data activates the chassis alarm.
to ensure the highest integrity.
The relay output module comes with
normally open (NO) contacts. It
supports hot-spare modules and
requires a separate external termination
Model Number 3511
panel (ETP) with a cable interface to
Type TMR the Tricon backplane.
Input Signals 8, non-commoned
Resolution 16 bits Model Number 3636R/T
Accuracy 1000 Hz to 20,000 Hz, 0.01% Type Non-triplicated
Input Characteristics (AC coupled, balanced differential) Points 32, non-commoned
Update Rate 25 ms, typical Voltage Range 155 VAC/VDC,
Impedance (load) > 8 KW, 20 KW typical maximum
Common Mode Range -100 VDC to +100 VDC peak-to-peak Current Load 2A, maximum
Normal Mode Range 1.5 V to 200 V peak-to-peak Switching Power, 2000 V A, 150 watts
Resistive maximum
Overrange Protection 150 VDC, continuous
Point Isolation 1500 VDC
Hysteresis 150 millivolts, typical
2500 VDC1
Wave Shape Sine, square, pulse, etc.
Fuses 1 per output (2.5A
Duty Cycle 10% to 90% fast-acting)
Frequency 20 Hz to 20,000 Hz Diagnostic Indicators
Current Range 0-20 mA (250-ohm shunt) Output Status 1 per point
Diagnostic Indicators (ON=true) Module Status PASS, FAULT,
Input Status 1 per point ACTIVE
Module Status PASS, FAULT, ACTIVE Output Contact Normally Open
Color Code Light Purple Color Code Silver Blue
1. For 3636T.
35
Product Specifications
Pulse Totalizer Module passes it to the main processors, where The PTI module can operate with or
The model 3515 Pulse Totalizer Input it is voted before processing to ensure without a hot-spare module. If you use
(PTI) Module provides 32 individual the highest integrity. a hot-spare module, it re-educates all
31-bit counters that operate indepen- counter values from the active module.
Each PTI module provides complete
dently. The counters are used with ongoing diagnostics on each channel,
active-flow sensors or per-unit sensors including channel-to-channel count
to measure a quantity (count) which is comparison. Failure of any diagnostic
transmitted to the main processors. At on any channel activates the Fault indi-
the time specified by the TriStation cator, which in turn activates the chassis
control program, the main processors alarm. The Fault indicator points to a
clear a single counter or all counters. channel fault, not a module failure. The
The PTI module has three isolated input PTI module is guaranteed to operate
channels. Each input channel indepen- properly in the presence of a single
dently processes all input data and fault, and may continue to operate with
certain kinds of multiple faults.
36
TMR Digital Output Modules exist. Failure of the detected field All TMR digital output modules
A TMR digital output (DO) module voltage to match the commanded state support hot-spare capability, and
receives output signals from the main of the output point activates the require a separate external termination
processors on each of three channels. LOAD/FUSE alarm indicator. panel (ETP) with a cable interface to
Each set of three signals is then voted the Tricon backplane. Each module is
In addition, ongoing diagnostics are
by special quadruplicated output mechanically keyed to prevent
performed on each channel and circuit
circuitry on the module. The circuitry improper installation in a configured
of a TMR digital output module.
produces one voted output signal and chassis.
Failure of any diagnostic on any
passes it to the field termination. The channel activates the Fault indicator, Digital outputs are designed to source
quadruplicated voter circuitry provides which in turn activates the chassis the current to field devices, so field
multiple redundancy for all critical alarm signal. The Fault indicator power must be wired to each output
signal paths, guaranteeing safety and merely indicates a channel fault, not a point on the field termination.
maximum availability. module failure. The module is guaran-
Each TMR digital output module has a teed to operate properly in the presence
voltage-loopback circuit which verifies of a single fault and may continue to
the operation of each output switch operate properly with certain kinds of
independently of the presence of a load multiple faults.
and determines whether latent faults
37
Product Specifications
16-Point Supervised and Each SDO module has voltage and A field short resulting in the load
32-Point Supervised/Non- current loopback circuitry coupled with being energized in error
Supervised Digital Output sophisticated online diagnostics that A shorted load in the de-energized
Modules verify the operation of each output state
switch, the field circuit and the pres-
Designed for the most critical control Failure to detect field voltage on any
ence of a load. This design provides
programs, supervised digital output output point energizes the power alarm
complete fault coverage without the
(SDO) modules meet the needs of indicator. Failure to detect the presence
need to influence the output signal.
systems whose outputs remain in a of a load energizes the load alarm indi-
single state for extended periods of time The modules are called supervised cator.
(in some applications, for years). An because fault coverage is extended to
include potential field problems. In All SDO modules support hot-spare
SDO module receives output signals
other words, the field circuit is super- modules and require a separate external
from the main processors on each of
vised by the SDO module so that the termination panel (ETP) with a cable
three channels. Each set of three signals
following field faults can be detected: interface to the Tricon backplane.
is then voted upon by a fully fault-
tolerant quadruplicated output switch Loss of power or blown fuse
whose elements are power transistors,
so that one voted output signal is passed Open or missing load
to the field termination.
1. CAUTION: Triconex highly recommends that you perform compatibility testing before selecting the model 3623T module for use in applications that have
field wiring lengths over 328 feet (100 meters), cable that is not twisted pair, or atypical loads such as smart devices, strobe lights, or klaxons.
2. For 3623T.
38
8-Point Supervised Digital sophisticated online diagnostics that A shorted load in the de-energized
Output Modules verify the operation of each output state
Designed for the most critical applica- switch, the field circuit and the pres- Failure to detect field voltage on any
tions, supervised digital output (SDO) ence of a load. This design provides output point energizes the power alarm
modules meet the needs of systems complete fault coverage without the indicator. Failure to detect the presence
whose outputs remain in a single state need to influence the output signal. of a load energizes the load alarm indi-
for extended periods of time (in some The modules are called supervised cator. When an optional secondary
applications, for years). An SDO because fault coverage is extended to power supply is used, shorted loads in
module receives output signals from the include potential field problems. In the OFF state can be detected. (This
main processors on each of three chan- other words, the field circuit is super- feature is not provided on model
nels. Each set of three signals is then vised by the SDO module so that the 3611E, an AC module.)
voted upon by a fully fault-tolerant following field faults can be detected: All SDO modules support hot-spare
quadruplicated output switch whose
Loss of power or blown fuse capability and require a separate
elements are mechanical power relays,
external termination panel (ETP) with a
so that one voted output signal is passed Open or missing load
cable interface to the Tricon backplane.
to the field termination. A field short resulting in the load
Each SDO module has voltage and being energized in error
current loopback circuitry coupled with
39
Product Specifications
Dual Digital Output Module the operation of each output switch glitch may occur during switch-over to
The dual digital output (DDO) modules independently of the presence of a load a hot-spare module.
receive output signals from the main and determines whether latent faults
The dual digital output modules
processors along a single parallel or exist. Failure of the detected field
support hot-spare capability which
series path, and applies a 2-out-of-3 voltage to match the commanded state
allows online replacement of a faulty
voting process individually to each of the output point activates the
module. Each module is mechanically
switch. The switches produce one LOAD/FUSE alarm indicator.
keyed to prevent improper installation
output signal which is then passed to In addition, ongoing diagnostics are in a configured chassis.
the field termination. While the quadru- performed on each channel and circuit
plicated output circuitry on TMR The dual digital output modules require
of a dual digital output module. Failure
modules provides multiple redundancy a separate external termination panel
of any diagnostic on any channel acti-
for all critical signal paths, dual (ETP) with a cable interface to the
vates the Fault indicator, which in turn
circuitry provides just enough redun- Tricon backplane. Digital outputs are
activates the chassis alarm signal. A
dancy to ensure safe operation. The designed to source the current to field
dual module operates properly in the
dual module is optimized for those devices, so field power must be wired to
presence of most single faults and may
safety-critical control programs where each output point on the field termina-
operate properly with some kinds of
low cost is more important than tion.
multiple faults, but stuck-OFF faults are
maximum availability. an exception. If one of the output
The dual digital output modules have a switches has a stuck-OFF fault, the
voltage-loopback circuit which verifies output goes to the OFF state and a
40
Analog Input Modules affecting another channel. Each analog The analog input module requires a
An analog input (AI) module includes input module sustains complete, separate external termination panel
three independent input channels. Each ongoing diagnostics for each channel. (ETP) with a cable interface to the
input channel receives variable voltage Failure of any diagnostic on any Tricon backplane. Each module is
signals from each point, converts them channel activates the Fault indicator for mechanically keyed for proper installa-
to digital values, and transmits the the module, which in turn activates the tion in a Tricon chassis.
values to the three main processor chassis alarm signal. The modules
modules on demand. In TMR mode, Fault indicator merely reports a channel
one value is then selected using a mid- fault, not a module failurethe module
value selection algorithm to ensure can operate properly with as many as
correct data for every scan. two faulty channels.
41
Product Specifications
42
Analog Output Modules are performed on each channel and output module requires up to 1 amp @
An analog output (AO) module receives circuit of the module. Failure of any 24-42.5 volts. A LOAD indicator acti-
output signals from the main processor diagnostic deactivates the faulty vates if an open loop is detected on one
module on each of three channels. Each channel and activates the Fault indi- or more output points. PWR1 and
set of data is then voted and a healthy cator, which in turn activates the chassis PWR2 are on if loop power is present.
channel is selected to drive the eight alarm. The module Fault indicator The 3806E High Current (AO) module
outputs. The module monitors its own merely indicates a channel fault, not a is optimized for turbomachinery appli-
current outputs (as input voltages) and module failure. The module continues cations.
maintains an internal voltage reference to operate properly with as many as two
Analog output modules support hot-
to provide self-calibration and module channels failed. Open loop detection is
spare capability which allows online
health information. provided by a LOAD indicator which
replacement of a faulty module.
activates if the module is unable to
Each channel on the module has a drive current to one or more outputs. The analog output module requires a
current loopback circuit which verifies separate external termination panel
the accuracy and presence of analog The module provides for redundant
(ETP) with a cable interface to the
signals independently of load presence loop power sources with individual
Tricon backplane. Each module is
or channel selection. The modules power and fuse indicators called PWR1
mechanically keyed to prevent
design prevents a non-selected channel and PWR2. External loop power
improper installation in a configured
from driving an analog signal to the supplies for analog outputs must be
chassis.
field. In addition, ongoing diagnostics provided by the user. Each analog
43
Product Specifications
Thermocouple Modules isolated thermocouple input modules. Failure of any diagnostic on any
A thermocouple input (TC) module The isolated module allows users to channel activates the Fault indicator,
includes three independent input chan- select upscale or downscale burnout which in turn activates the chassis
nels. Each input channel receives vari- detection with the TriStation software. alarm signal. The module Fault indi-
able voltage signals from each point, For non-isolated modules, upscale or cator merely reports a channel fault, not
performs thermocouple linearization downscale burnout detection depends a module failure. The module continues
and cold-junction compensation, and on the field termination selected. to operate properly with as many as two
converts the result to degrees Celsius or faulty channels.
Triplicated temperature transducers
Fahrenheit. Each channel then trans- residing on the field termination panel The thermocouple input module
mits 16-bit signed integers representing support cold-junction compensation. supports hot-spare capability which
0.125 degrees per count to the three Each channel of a thermocouple input allows online replacement of a faulty
main processors on demand. In TMR module performs auto-calibration using module.The thermocouple input
mode, a value is then selected using a internal precision voltage references. module requires a separate external
mid-value selection algorithm to ensure On the isolated module, a faulting cold- termination panel (ETP) with a cable
correct data for every scan. junction transducer is annunciated by a interface to the Tricon backplane.
Each thermocouple input module is cold-junction indicator on the front
Each module is mechanically keyed to
programmable to support one thermo- panel.
prevent improper installation in a
couple type, selected from J, K and T Each module performs complete configured chassis.
for standard thermocouple input ongoing diagnostics on each channel.
modules and from J, K, T and E for
44
Table A. Accuracy of Thermocouple Types for Model 3706A
Accuracy1
(TC Termination Module @ 32-140 F [0-60 C])
Accuracy1
(TC Termination Module @ 32-140 F [0-60 C])
1. Accuracy specifications account for errors related to reference-junction compensation, but do not account for errors caused by
temperature gradients between the temperature transducers and the TC terminations. The user is responsible for maintaining a
uniform temperature across the TC Termination Module.
45
Notes
A termination panel and associated cable pass signals to or from the field,
permitting replacement of I/O Modules without disturbing field wiring.
There are two general types of field products are the same as for a Tricon easily attached. A panel connector,
termination products available from chassis. (See General Environmental terminal blocks and various compo-
Triconex: and EMC Specifications on page 20 nents are mounted to the PCB and
for details.) enclosed in a plastic housing. A termi-
External termination panels
nation panel and associated cable pass
Cables input signals from the field directly to
External Termination Panels an input module, or pass output signals
All termination panels and cables are
An external termination panel (ETP) is from an output module directly to field
built to withstand harsh industrial envi-
an electrically-passive printed circuit wiring. This arrangement permits the
ronments. The environmental specifica-
board (PCB) to which field wiring is removal or replacement of I/O modules
tions for components used on these
Tricon Chassis with External Termination Panels and Standard 10' Cables
47
Field Termination Options
removal or replacement of I/O modules termination panel provides cold-junc- Termination panels with
without disturbing field wiring. tion temperature sensors and can be RTD/TC/AI input signal
ordered with upscale, downscale or conditioning
External termination panels allow you
programmable burnout detection. A
to marshal field signals in a separate Termination panels for 3603B
standard termination panel for analog
enclosure up to 99 feet (30 meters) from digital output modules
voltage inputs provides commoned
a Tricon.
signal returns, while the current-mode Termination panels for 3806E
Standard termination panels are bestfor version has a precision resistor at each analog output modules
remote marshaling of field wiring input point to convert current to
Basic Termination Panels
where maximum flexibility, high voltage.
density and simple maintenance is Basic termination panels are a low-cost
Each standard termination panel is means of connecting field wiring to a
desired.
packaged with a matched interface Tricon. However, basic termination
A standard termination panel consists cable that connects the panel to the panels do not provide any components
of a PCB with all necessary compo- backplane of a Tricon chassis. A female other than a 56-pin connector and
nentssuch as two-piece terminal connector at one end of the cable is terminal blocks. These two components
blocks, resistors, fuses and blown-fuse keyed to match the male connector on are mounted on a DIN rail-compatible
indicatorsmounted on a DIN rail- the Tricon backplane. A male connector plastic housing that snaps into
compatible plastic housing. The on the other end of the cable attaches to mounting rails in accordance with DIN
housing snaps into mounting rails in the standard termination panel. 50 022. The user must provide any
accordance with DIN 50 022. other components required by his appli-
In addition to standard termination
Compression terminals on the standard panels, there are other types of termina- cation.
panel are designed for use with 24- to tion panels, including: Other features of the basic termination
12-gauge (0.3 mm2 to 2.1 mm2) wiring. Basic termination panels panels are the same as for the standard
Some panels have an optional current- panels.
limiting series resistor, others have a Hazardous location (nonincendive)
termination panels Hazardous Location
fuse with a blown-fuse indicator, to
(Nonincendive) Termination
protect the field wiring and field device. Termination panels with interposing Panels
Standard termination panels are pre- relays
Hazardous location (nonincendive)
configured for specific applications. Bypass panels for digital inputs termination panels are suitable for use
For instance, the thermocouple input in Zone 2, and Class 1, Division 2 field
circuits. These panels contain extra
circuitry designed to limit power avail-
able to the field terminals and have been
examined and certified by TV Rhine-
land as being nonincendive. This guar-
antees that if the field wires are
accidentally opened, shorted, or
grounded, and the Tricon is operating
normally, the wiring and attached
devices will not release sufficient
energy to cause ignition in the specified
flammable atmosphere.
Termination Panels with
Interposing Relays
Interposing relays are recommended
for applications that have load currents
greater than 2 amps, or field voltages
Standard Termination Panels in 16-Point and 32-Point Styles greater than 115 VAC which require
48
field-circuit conversion or compati- Fanned-Out Cables shared by multiple points. Points can
bility with motor-starter circuits. Fanned-out cables are a low-cost alter- be commoned in groups of 8 and
native to using external termination groups of 16.
Each interposing relay provides an
auxiliary contact that can be connected panels. Fanned-out cables allow you to Analog signals can be read as3-wire
to a digital input module by means of an marshal field signals in a separate transmitter inputs, voltage inputs or
optional loopback cable to verify relay enclosure up to 99 feet(30 meters) from current inputs.
activation by the digital output module. a Tricon. One end of a fanned-out cable
has a female connector that connects to Thermocouple terminations provide
Interposing relay panels use compact
a Tricon chassis backplane. The other cold-junction temperature sensors
general-purpose power relays for
end of the cable contains 50 fanned-out and are available for either upscale
maximum reliability and can be used
leads, each individually labeled with its or downscale burnout detection. For
with most digital output modules.
corresponding connector pin number. the model 3706A, upscale or
Bypass Panels for Digital Inputs downscale burnout detection
Bypass termination panels can be used Each fanned-out cable has the depends on which termination panel
to connect digital inputs using a bank of following characteristics: is installed. For model 3708E,
32 pre-wired switches. The bypass PVC outer covering upscale or downscale burnout
panel has a master keyswitch and termi- detection is configured with
56-pin connector at one end TriStation.
nals for redundant +24 VDC power
sources. Each input point contains an 50 stranded, stripped, tinned and The Termination Options table (on
ON status indicator and a position for a labeled 22-gauge leads at opposite the next two pages) shows the available
user-defined label. Each bypass termi- end termination choices for each I/O
nation panel comes with one or two 10- module and gives the correct model
Fanned-out cables should only be used
foot cables for connecting the termina- number for each choice.
with digital input and digital output
tion panel to a Tricon backplane.
modules. They are not certified for use
Termination Panels for Use with analog signals. Contact the
with Signal Conditioners Triconex Customer Support Center if Over-Current Protection
Termination panels which use industry- you need a fanned-out cable for Non-basic termination panels offer
standard analog signal conditioners handling analog signals. over-current protection in various
provide a flexible, user-configurable ways:
Although the normal length of all
interface to resistive thermal devices cables is 10 feet (3 meters), any length Fuses for individual points and/or
(RTDs), thermocouples, and 4-20 mA cable can be ordered up to 99 feet (30 field power sources
transmitters. Each termination panel meters) in 1-foot increments, using the
supports 16 points and each analog Series resistors
last two digits of the cable model
module can support up to 2 panels. number to specify the length in feet. For Self-protection for digital output and
These termination panels are compat- example, the model number 9101-050 analog output modules
ible with any signal conditioners in the specifies a 50-foot cable instead of the If basic termination panels are being
1 to 5 volt output range. For example, normal 10-foot cable. used, the user must supply his own
the 7B series of signal conditioners components for over-current protec-
from Analog Devices are known to tion.
work well. Termination Configuration
Options
These signal conditioners can be
purchased from Triconex, or directly Terminations are available in various
from Analog Devices at: factory configurations:
49
Field Termination Options
Match your I/O module number in the first column with termination options on the right. An I/O module can be wired to a
maximum of two termination panels, which may be of two different typesfor example, commoned and non-commoned.
ERT Loop-
Module Commoned Non-Common. Basic Nonincendive Fanned-out Bypass
Module Description Back
Part # Term Panels Term Panels Term Panels Term Panels Cables Panels Cables/Panels
3501E DI, 115 VAC/VDC, 32 pts. 9561-810 9561-110 9551-110 n/a 9101-010 n/a 9141-010
3501T
3502E DI, 48 VAC/VDC, 32 pts. 9562-810 n/a 9552-610 n/a 9101-010 n/a 9142-010
3503E DI, 24 VAC/VDC, 32 pts. 9563-810 n/a 9553-610 9572-610 9101-010 BP9228-010 9143-010
3504E DI, 24/48 VDC, 9566-810, 24V n/a 9750-310, 24V 9570-610, 24V n/a BP9229-010 n/a
non-isolated, 64 pts. 9565-810, 48V n/a 9750-410, 48V n/a n/a n/a n/a
3505E DI, 24 VDC, low threshold, 9563-810 n/a 9553-610 9572-610 9101-010 BP9228-010 9143-010
32 pts.
3510 PI, 20-20,000 Hz, 8 pts. n/a n/a 9753-110 n/a n/a n/a n/a
3511 PI, 20-20,000 Hz, 8 pts. n/a n/a 9753-110 9793-110 n/a n/a n/a
3515 Pulse totalizer, 24 VDC, n/a n/a 9753-110 9572-610 n/a n/a n/a
32 pts.
3564 DI, 24 VDC, single, 64 pts. 9566-710 n/a 9553-610 9571-610 9101-010 n/a n/a
3601E DO, 115 VAC, 16 pts. 9661-610 9661-110 9651-110 n/a 9101-010 n/a 9670-110
9663-610 9664-110 9670-610
3601T DO, 115 VAC, 16 pts. 9663-610 9664-110 n/a n/a n/a n/a n/a
3603B DO, 120 VDC, 16 pts. n/a 9251210 n/a n/a n/a n/a n/a
3603E DO, 120 VDC, 16 pts. 9661-910 n/a 9651-110 n/a 9101-010 n/a 9673-810
9664-810
3603T DO, 120 VDC, 16 pts. 9664-810 n/a n/a n/a n/a n/a 9673-810
3604E DO, 24 VDC, 16 pts. 9662-810 9662-110 9653-610 9671-610 9101-010 n/a 9671-810
3607E DO, 48 VDC, 16 pts. 9667-810 9667-110 9652-610 n/a 9101-010 n/a 9672-810
3611E DO, 115 VAC, 8 pts. 9661-510 n/a n/a n/a n/a n/a n/a
3613E DO, 120 VDC, 8 pts. 9661-810 n/a n/a n/a n/a n/a n/a
3614E DO, 24 VDC, 8 pts. 9662-910 n/a n/a n/a n/a n/a n/a
3615E DO, 24 VDC, low power, 9662-710 n/a n/a n/a n/a n/a n/a
8 pts.
3617E DO, 48 VDC, 8 pts. 9667-910 n/a n/a n/a n/a n/a n/a
3623 DO, 120 VDC, 16 pts. 9661-910 n/a 9651-110 n/a 9101-010 n/a n/a
3623T DO, 120 VDC, 16 pts. 9664-810 n/a n/a n/a n/a n/a n/a
3624 DO, 24 VDC, 16 pts. 9662-610 n/a 9653-610 9671-610 9101-010 n/a n/a
3625 DO, 24 VDC, 32 pts. 9662-610 n/a 9653-610 9671-610 9101-010 n/a n/a
3636R Relay output n/a 9668-110 9651-110 n/a 9101-010 n/a n/a
3636T (non-triplicated), 32 pts.
3664 Dual DO, 24 VDC, self- 9662-610 n/a 9653-610 9671-610 9101-010 n/a 9671-810
protected, 32 pts.
3674 Dual DO, 24 VDC, self- 9662-610 n/a 9653-610 9671-610 9101-010 n/a 9671-810
protected, 32 pts.
3805E AO, 420 mA, 8 pts. n/a n/a 9853-610 9861-610 n/a n/a n/a
3806E AO, 6 420 mA outputs, n/a n/a 9863-710 n/a n/a n/a n/a
2 20320 mA outputs (special panel)
50
Module Basic Term Nonincendive Fanned-out Bypass ERT Loop-
Module Description Upscale Downscale Back
Part # Panels Term Panels Cables Panels
Cables/Panels
3706A Thermocouple input, type J, K, T, 9766-210 9766-510 n/a 9784-610, n/a n/a n/a
differential, 32 pts. upscale
9785-610,
downscale
3708E Thermocouple input, type E, J, K, 9765-610 9765-610 n/a 9786-110 n/a n/a n/a
T, isolated, 16 pts.
1. Signal conditioners must be ordered separately. A total of 16 is required for each termination panel.
2. Must be configured with TriStation.
51
Field Termination Options
52
Width Length Height
Panel Model
(across DIN rail) (along DIN rail) (out from DIN rail)
9750-810 3 in (7.62 cm) 5 in (12.7 cm) 4.25 in (10.795 cm)
9753-110 3 in (7.62 cm) 5 in (12.7 cm) 4.25 in (10.795 cm)
9760-210 4.5 in (11.43 cm) 10 in (25.4 cm) 4.25 in (10.795 cm)
9760-410 4.5 in (11.43 cm) 10 in (25.4 cm) 4.25 in (10.795 cm)
9761-210 4.5 in (11.43 cm) 5 in (12.7 cm) 4.25 in (10.795 cm)
9761-410 4.5 in (11.43 cm) 5 in (12.7 cm) 4.25 in (10.795 cm)
9762-210 4.5 in (11.43 cm) 5 in (12.7 cm) 4.25 in (10.795 cm)
9762-410 4.5 in (11.43 cm) 5 in (12.7 cm) 4.25 in (10.795 cm)
9763-810 4.5 in (11.43 cm) 5 in (12.7 cm) 4.25 in (10.795 cm)
9764-310 3.5 in (8.89 cm) 19 in (48.26 cm) 3 in (7.62 cm)
9765-210 4.5 in (11.43 cm) 10 in (25.4 cm) 4.25 in (10.795 cm)
9765-610 4.5 in (11.43 cm) 5 in (12.7 cm) 4.25 in (10.795 cm)
9766-210 4.5 in (11.43 cm) 5 in (12.7 cm) 4.25 in (10.795 cm)
9766-510 4.5 in (11.43 cm) 5 in (12.7 cm) 4.25 in (10.795 cm)
9771-210 4.5 in (11.43 cm) 5.729 in (14.552 cm) 4.25 in (10.795 cm)
9784-610 4.42 in (11.23 cm) 5.02 in (12.75 cm) 4.25 in (10.795 cm)
9785-610 4.42 in (11.23 cm) 5.02 in (12.75 cm) 4.25 in (10.795 cm)
9786-110 4.42 in (11.23 cm) 5.02 in (12.75 cm) 4.25 in (10.795 cm)
9787-110 4.42 in (11.23 cm) 5.02 in (12.75 cm) 4.25 in (10.795 cm)
9789-610 4.42 in (11.23 cm) 9.88 in (25.08 cm) 4.25 in (10.795 cm)
9791-610 4.42 in (11.23 cm) 5.02 in (12.75 cm) 4.25 in (10.795 cm)
9793-110 4.42 in (11.23 cm) 5.02 in (12.75 cm) 4.25 in (10.795 cm)
9853-610 3 in (7.62 cm) 5 in (12.7 cm) 4.25 in (10.795 cm)
9861-610 4.42 in (11.23 cm) 5.02 in (12.75 cm) 4.25 in (10.795 cm)
9863-710 3 in (7.62 cm) 6.66 in (16.9164 cm) 4.25 in (10.795 cm)
BP9228-010 3.5 in (8.89 cm) 19 in (48.26 cm) 8 in (20.32 cm)
BP9229-010 3.5 in (8.89 cm) 19 in (48.26 cm) 8 in (20.32 cm)
53
Field Termination Options
CR
1
F2 F4 F6 F8 F10 F12 F14 F16 F2 F4 F6 F8 F10 F12 F14 F16
J1
J1
CR
2
CR9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
L+
L+
L+
L+
L
L
L
PS1
PS1
PS2
PS2
SPWR
CR8
CR6
CR3
J1
SN REV A 7400171-
DIDO PANEL
REV A
SN
10
12
14
16
18
20
22
24
26
28
30
32
2
4
6
8
A A J1
TM
TRICONEX
7400143-
C C
E E
+
Types of I/O Modules
SN REV A 7400195-
W1
W2
W3
W4
W5
W6
W7
W8
W9
W10
W11
W12
W13
W14
W15
W16
W17
R10
R12
R14
R16
R18
R20
R22
R24
R26
R28
R30
R32
R2
R4
R6
R8
J1
R11
R13
R15
R17
R19
R21
R23
R25
R27
R29
R31
R1
R3
R5
R7
R9
CR3
T+
T+
CR2
CR4
PS1 PS2
T-
T-
A
A
CR1
CR5
54
CR1
PS1
CR2
PS2 R1 R2
R3 R4
1
2 R5 R6
SN
3
4 R7 R8
5
6
R9 R10
7
8
F1 F5
9 R11 R12
PWR LOAD
REV A
10
1 11 R13 R14
F2 F6
12
2 13 R15 R16
CR1 14
3 15
7400150-
PS1 CR2
16
4 F3 F7
SN
J1
PS2 5
RTN T T+ 6 F4 F8
1
7
2
SN
J1
REV A
3 8 R17 R18
4 17
5 18 R19 R20
6 19
7 9 20
8 R21 R22
21
9 22
REV A
10 F9 F13 7400172-
10 23 R23 R24
11 11 24
12 25 R25 R26
13 12 26
F10 F14
14 27
32-Point Analog Input and Digital Input Termination Panels
R27 R28
15 13 28
7400153-
16 29
30 R29 R30
RTN T T+ 14
J1 F11 F15
31
15 32 R31 R32
RTN T T+
17
18
19
20
21
22
23
24
55
Field Termination Options
NN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
7400225
7B14
7B14
7B14
7B14
7B14
7B14
7B14
7B14
7B14
7B14
7B14
7B14
7B14
7B14
7B14
7B14
KK
DEVICES
ANALOG
DEVICES
ANALOG
DEVICES
ANALOG
DEVICES
ANALOG
DEVICES
ANALOG
DEVICES
ANALOG
DEVICES
ANALOG
DEVICES
ANALOG
DEVICES
ANALOG
DEVICES
ANALOG
DEVICES
ANALOG
DEVICES
ANALOG
DEVICES
ANALOG
DEVICES
ANALOG
DEVICES
ANALOG
DEVICES
ANALOG
J1
NON-ISOLATED
NON-ISOLATED
NON-ISOLATED
NON-ISOLATED
NON-ISOLATED
NON-ISOLATED
NON-ISOLATED
NON-ISOLATED
NON-ISOLATED
NON-ISOLATED
NON-ISOLATED
NON-ISOLATED
NON-ISOLATED
NON-ISOLATED
NON-ISOLATED
NON-ISOLATED
CR1
RTD INPUT
RTD INPUT
RTD INPUT
RTD INPUT
RTD INPUT
RTD INPUT
RTD INPUT
RTD INPUT
RTD INPUT
RTD INPUT
RTD INPUT
RTD INPUT
RTD INPUT
RTD INPUT
RTD INPUT
RTD INPUT
C20
S/N
CR14
REV
J2
C21 C19
J4 J6 J8 J10
2 AMP
250V
BLOWN
FUSE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
ON
OFF
TRICONEX
+ 1 + 2 + 3 + 4 + 5 + 6 + 7 + 8 + PW1 + PW2 + 9 + 10 + 11 + 12 + 13 + 14 + 15 + 16
POWER POWER
CR1 CR2
CONTACT CONTACT
C 1 NO C 2 NO C 3 NO C 4 NO C 5 NO C 6 NO C 7 NO C 8 NO C 9 NO C 10 NO C 11 NO C 12 NO C 13 NO C 14 NO C 15 NO C 16 NO
56
Sample Drawings of Nonincendive External Termination Panels
57
Notes
The Tricon controller can interface with Modbus masters and slaves,
Distributed Control Systems (DCS), external host computers on
Ethernet networks, other Triconex Controllers on a Peer-to-Peer network,
and a TriStation PC.
Communication Capabilities
In most process-control applications, Today, the state-of-the-art, micropro- External host computers on Ethernet
there are two systems which monitor cessor-based architecture of the Tricon (802.3) networks
and manage the process. One is a controller supports several modes of
Other Triconex controllers in a Peer-
Distributed Control System (DCS) and communication. Depending on control
to-Peer, TV-certified network
the other is a safety system such as the program requirements, the Tricon can
Tricon controller. These two systems interface with: A TriStation PC
are usually isolated, but share a
Any Modbus master, including DCS OPC Server for Triconex
common operator interface. Distributed
from ABB, Bailey, Fisher-
Control Systems are designed to allow
Rosemount and Yokogawa
highly effective communication with
Networking with Modbus
the process operator, who must be Modbus slave devices
informed of the state of the process at The Tricon Communication Module
A Foxboro Intelligent Automation (TCM) supports the industry-standard
all times. This is desirable for safety
(I/A) Series Nodebus Modbus protocol over a serial link or a
systems as well, but was not feasible in
the past because of the type of tech- A Honeywell Universal Control TCP network. The Enhanced Intelli-
nology used to implement these Network (UCN) gent Communication Module (EICM)
systems. supports the Modbus protocol over a
A Honeywell Data Hiway and Local serial link. Most suppliers of operator
Control Network (LCN)
59
Communication Capabilities
60
nization, TriStation, and TSAA) to master/slave protocol in which the of the art in safetysystems. High-speed,
support different types of applications. master (the external host) communi- redundant network communication is
All of the following Triconex protocols cates with one or more slaves (Tricons) another example of that commitment.
support a maximum of 31 Tricons on a over an open network. TSAA specifies
network. Please contact Triconex for the interfaces, commands and data
application guidelines and potential structures used to develop applications Foxboro's Intelligent
performance limitations. that send and receive data to and from Automation Series System
Tricon controllers. Triconex offers the Advanced Commu-
Peer-to-Peer
TSAA can be used to develop the these nication Module (ACM) for tightly-
Peer-to-peer protocol allows Tricons to
types of applications: integrated interfacing with Foxboro's
exchange small amounts of safety and
Intelligent Automation (I/A) Series
process information on the proprietary Control (read/write) applications Nodebus. The ACM communicates
network. For information about using such as an operator interface that process information at full network data
the peer-to-peer SEND and RECV requires access to Tricon status and rates for use anywhere on the I/A Series
functions in applications, see the the ability to write data to the Tricon system, transmitting all Tricon aliased
TriStation Developers Guide.
Monitor (read only) applications data and diagnostic information to
Time Synchronization such as a Sequential Events operator workstations in display
Time Synchronization is a master/slave Recorder, Event Logger or status formats that are familiar to Foxboro
protocol used to maintain a consistent display that retrieves data from the operators.
time base for all Tricons connected to Tricon The ACM makes the following func-
each other by means of TCMs or tions available to the I/A Series:
For more information about TSAA, see
NCMs.
the Tricon Communication Guide. Handles critical I/O points and
TriStation passes results to the I/A Series
Triconex Applications
The TriStation protocol is a
Triconex offers several applications for Processes Tricon alarms and
master/slave protocol in which the
Ethernet (802.3) networks, all of which propagates them to user-defined I/A
master (the TriStation PC) communi-
use a PC as the external host. These Series destinations (consoles,
cates with the slave (Tricon) over an
applications are briefly described in the printers, etc.)
Ethernet network. Although the TriSta-
table below.
tion protocol supports a maximum of Propagates Tricon alarms as I/A
31 Tricons, the master can communi- The Tricon controller offers consider- Series system messages
cate with only one slave at a time. able flexibility and functionality in the
Reads/writes aliased data to satisfy
area of data communication, and can
TSAA I/A Series requests
readily be configured to match control
The Tricon System Access control program requirements. Triconex is Enables time synchronization from
program (TSAA) protocol is a continually striving to advance the state the I/A Series environment
61
Communication Capabilities
Reads Tricon diagnostics fordisplay Honeywells TDC 3000 DCS The HIM interfaces with the TDC 3000
by the I/A Series workstation Triconex offers the Safety Manager by means of the Hiway Gateway and
Module (SMM) and the Hiway Inter- Local Control Network (LCN). The
Provides write protection to lock out
face Module (HIM) for tightly-inte- HIM can also interface with Honey-
changes to the Tricon safety system
grated interfacing with various well's older TDC 2000 control system
from all I/A Series sources
networks of the TDC 3000 DCS. by means of the Data Hiway. Using the
Provides hot-spare capability for HIM, higher-order devices on the LCN
uninterrupted communication with The SMM is used solely for communi- or Data Hiway (such as computers and
the I/A Series Nodebus cation with the Universal Control operator workstations) can communi-
Network (UCN), one of three principal cate with the Tricon.
The ACM also supports these Triconex networks of the TDC 3000. Appearing
protocols and applications on external to the Honeywell system as a safety Both the SMM and the HIM offer the
host PCs connected to a separate BNC node, the SMM communicates process hot-spare capability for uninterrupted
port (that is, NET 2): information at full network data rates communication with Honeywell
for use anywhere on the TDC 3000. networks.
TriStation protocol for TriStation
1131 The SMM transmits all Tricon aliased
data and diagnostic information to
TSAA protocol for Triconex operator workstations in display
applications formats that are familiar to Honeywell
TSAA/TCP(UDP)IP for user- operators.
written applications on external The SMM makes the following func-
hosts tions available to the TDC 3000:
Handles critical I/O points and
passes results to the DCS
Processes Tricon alarms and
propagates them to user-defined
DCS destinations (consoles,
printers, etc.)
Reads/writes aliased data to satisfy
DCS requests
Reads Tricon diagnostics for display
by the DCS
Provides write protection to lock out
changes to the Tricon safety system
from all TDC 3000 sources
Enables time synchronization from
the DCS
Allows Peer-to-Peer communication
for plants with many Tricon safety
systems
Provides sequence of events to help
determine the cause of plant trips
and increase process uptime
Provides hot-spare capability for
uninterrupted communication with
Honeywell networks
62
Easy-to-use developer's workbench allow you to develop, test and
document process-control applications for the Tricon Controller.
Functional Overview
TriStation provides three editors which
support these IEC 61131-3 languages:
Function Block Diagram
Example of TriStation v4.1 Interface
63
TriStation 1131 Developers Workbench
Elements of a TriStation
Project
A TriStation project contains all of the
elements required to implement a
safety or control program in a Tricon
controller. Some of these elements are
automatically included in every
project by TriStation, while others are
user-created.
Programs
A program is the highest-level execut-
able logic element in a TriStation
project. It is an assembly of program-
ming language elements (functions,
function blocks, and data variables)
that work together to allow a program-
mable control system to achieve
control of a machine or a process.
Each program is uniquely identified
by a user-defined type name. A TriSta-
tion project can support hundreds of Sample Logic in FBD, ST and LD Languages
programs.
Functions
A function is a logic element which Libraries Programming Languages
yields exactly one result. Unlike a func- TriStation includes libraries of pre- TriStation includes these programming
tion block, the data associated with a defined functions, function blocks, and languages: Function Block Diagram,
function is not retained from one evalu- data types that can be used in a project. Structured Text, and Ladder Diagram.
ation of the function to the next. Func- An optional language, CEMPLE, can
tions do not have to be instanced. TriStation includes these libraries: be purchased separately.
Function Blocks IEC 61131-3 Standard Library a Function Block Diagram (FBD)
set of functions and function blocks
A function block is a logic element Function Block Diagram is a graphical
defined by the IEC 61131-3 Stan-
which yields one or more results. To use language that corresponds to circuit
dard
a function block in a program, an diagrams. FBD elements appear as
instance of the function block type must Triconex Library a set of Triconex blocks that are wired together to form
first be declared. Each instance is iden- functions and function blocks that circuits. The wires transfer binary and
tified by a user-defined instance name. can be used with any Triconex other types of data between elements.
All of the data associated with a programmable controller
specific instance of a function block is Structured Text (ST)
Tricon Library a set of functions
retained from one evaluation of the and function blocks that are specifi- Structure Text is a high-level, textual
function block to the next. cally for use with the Tricon programming language that is similar
controller to PASCAL. Structured Text allows
Data Types Boolean and arithmetic expressions,
In addition to the pre-defined libraries,
A data type defines the size and charac- and programming structures such as
you can also develop your own libraries
teristics of variables declared in a conditional (IFTHENELSE) state-
of project elements. These libraries can
program, function or function block. ments. Functions and function blocks
include programs, functions, function
Data types used by TriStation include can be invoked in Structured Text.
blocks, and data types which can be
discrete (BOOL), analog (DINT), and
imported to other TriStation projects. In TriStation v4.0, these structures were
real (REAL).
added: arrays, structures, ForLoop and
64
Exit statements, CASE statement,
enumerated data types, var-external,
and var-temp variables.
Ladder Diagram (LD)
Ladder Diagram is a graphical
language that uses a standard set of
symbols for representing relay logic.
The basic elements are coils and
contacts which are connected by links.
Links are different from the wires in
FBD in that they transfer only binary
data between the elements.
Cause and Effect Matrix
Programming Language Editor
(CEMPLE) Sample CEM from a TriStation Project
CEMPLE is a high-level graphical
language that provides a two-dimen-
compliant Function Block Diagrams,
sional matrix in which you can asso-
thereby eliminating the risks associated Emulator Panel
ciate a problem in a process with one or
with manual translation from hand- The Emulator Panel allows you to
more corrective actions. The problem is
drawn CEMs. connect to an emulator, download the
referred to as the cause and the action as
the effect. The matrix associates a cause Controller Configuration control program, and test and debug the
with an effect in the intersection of the control program. The panel lists the
In TriStation, the controller configura-
cause row and the effect column. programs, variables, and tagnames in
tion identifies the modules in the
the control program. Testing can be
CEMPLE is the first automated imple- system, communication settings,
done by dragging variables and
mentation of CEM, a methodology that memory allocation for tagnames, and
tagnames from the list to the monitor
is commonly used throughout the operating parameters. These configura-
panel and changing the values as
process-control industry and readily tion settings are included in the control
desired. You can specify commands to
understood by a broad range of plant program that is downloaded to the
run the control program without inter-
personnel. CEM diagrams are automat- controller.
vention, to run in single-step, or to halt
ically translated into IEC 61131-3 the execution.
Controller Panel
The Controller Panel allows connection
to the controller for real-time execution
of the control program.
Diagnostic Panel
In TriStation versions prior to v4, the
Diagnostic Panel allows you to monitor
the status of MP, CM, and I/O modules
in the controller and to diagnose faults.
The panel also provides system perfor-
mance information including the
project name and version, memory size,
scan time and current execution state.
In TriStation v4.1, the Diagnostic
Declaring Tagnames in a Program Monitor is a separate interface that
65
TriStation 1131 Developers Workbench
enables monitoring of applications and elements, both during and after project comments by automatically time-
hardware status on multiple controllers. development. Printouts of user-devel- stamping critical events within a
oped function blocks and programs can session and manually logging user
Starting with TriStation v4.1.435, the
be obtained on a variety of user- comments on demand.
diagnostic functions from the Diag-
selected engineering drawing
nostic Panel and the Diagnostic Annotations
templates.
Monitor are included in the Enhanced Annotations can be added to constants,
Diagnostic Monitor, which is a separate Standard reports are available to docu- tagnames, and variables An annotation
application from TriStation. ment the project configuration data. can be used to display descriptive text,
You can also create customized reports including information specified in
TriStation Interface Options
with Crystal Reports. system and user-modifiable macros.
TriStation allows you to specify options
Password Security You can also display the value of a vari-
to be used in the interface. For example,
able during program execution.
you can specify the drawing colors used TriStation provides a security system
in the programming editors, and editor that defines users and their privileges Comments
options such as double-spacing with regard to editing, library changes, Comments can be added to programs,
between function block terminals. You state changes and other operations. functions, and function blocks to add
can also specify the directory location information about the operations.
Project History
for files.
An audit trail function is provided to Help Documentation
Reports and Documentation document the history of a project and its TriStation features an online Help
TriStation includes multiple methods of program version changes. This detailed system which provides detailed infor-
sorting data and documenting project log keeps track of user actions and mation about TriStation.
66
CEMPLE is the Triconex automated implementation of the
traditional CEM methodology that has been used by process
control engineers for decades.
CEMPLE Features
CEMPLE includes the following
features:
Ability to specify up to 99 FBD Network
causes, 99 effects, and 1,000
intersections
Ability to invoke functions
and function blocks to
evaluate cause, intersection,
and effect states Variable Detail Table
67
CEM Programming Language Editor
68
During each scan of the TriStation project, the Main Processors examine
selected discrete variables for state changes known as events.
Triconex controllers and software Preparing Your System Assigning event variables to the
include sequence of events capability for Event Collection SOE blocks
which provides the potential to track
To enable the controller to detect Adding SOE function blocks to the
events which lead to an unsafe process
events, event variables and SOE blocks program logic
or system shutdown. During each scan
are identified in the TriStation project.
of the control program, the Main Types of Event Variables
In addition, the project must include an
Processors examine specified discrete
SOE function block that startsthe event The types of discrete variables that can
variables for state changes known as
collection. be designated as event variables are:
events. Triconex software can be used
to retrieve the event data from the After an SOE-enabled project is down- BOOL input
controller. loaded to the controller, TriStation
BOOL aliased memory variables
creates an SOE definition file that
SOE for TriStation 1131 is compatible
contains the SOE block definitions. Configuring SOE Blocks
with Tricon v9.5 and later systems.
When the SOE software collects an An SOE block is a data structure that
The following host systems can be used resides in the memory of a controllers
event from the controller, it obtains the
to retrieve event data: Main Processors. When SOE blocks are
tagname, alias, state name, and other
SOE software from Triconex which information about the event variable configured, the event variables to be
runs on a PC from the SOE definition file. detected by the controller are specified
for each block.
Safety Manager Module (SMM) for These tasks are done in TriStation:
Honeywell DCS systems The maximum individual block size is
Defining SOE blocks with buffer 20,000 events, with 60,000 events for
Advanced Communication Module size and block types
(ACM) for Foxboro DCS systems
An OPC client control program
which has implemented the Alarm
and Events Handler as specified in
the OPC standard version 1.0
With SOE software you can: Tricon Tricon Tricon
1 2 nn
Collect and analyze event data M M M
P P P
T
C
M
T
C
M
M M M
P P P
T
C
M
T
C
M
M M M
P P P
T
C
M
T
C
M
A B C 1 2 A B C 1 2 A B C 1 2
69
Sequence of Events (SOE) Capability
70
Part Number Cross-Reference
This table identifies the ETA part number and cable part number for each termination panel model.
71
Part Number Cross-Reference
72
Glossary
cause
The symbol which represents ohm. In CEM methodology, a cause is a problem to be solved
by the matrix.
bin controller
An address range of aliased variables in Triconex A Triconex controller includes Main Processors, commu-
controllers, based on Class and Type combinations. nication and I/O modules, and field termination devices.
board DCS
See module. Stands for distributed control system, which is a system
that controls a process and provides status information to
card an operator.
See module.
73
Glossary
debug hot-spare
The act of locating and correcting faults: 1) one of the A unique feature of Triconex controllers which allows
normal operations in software development such as spare I/O modules to be installed with automatic switch
editing, compiling, debugging, loading, and verifying; or to the spare in case the primary module fails.
2) the identification and isolation of a faulty physical
component, including its replacement or repair to return IEEE
the PLC to operational status. Stands for the Institute of Electrical and Electronics Engi-
neers (IEEE) which is a professional society for engi-
effect neers.
In CEM methodology, an effect is an action that must be
taken to solve a cause (problem). IEC 61131-3
The part of the IEC 61131 standard for programmable
event controllers that specifies the syntax and semantics of a
A state change of a discrete aliased variable which has unified suite of programming languages for program-
been designated for event logging. An event occurs when mable controllers.
a variable changes from the normal state to another state.
input poll time
event logger The time required by the Triconex controller to collect
A utility that logs, displays and prints critical events in input data from the controlled process. Input polling is
real time, based on state changes of discrete variables in asynchronous and overlaps execution of the user-written
the user-written control program. Proper use of an event control program.
logger warns users about dangerous conditions and print-
outs of events can help identify the sequence of events instance view
that led to a trip. In TriStation 1131, the Emulator Control Panel and
Triconex Control Panel displays the values of annotated
event variable variables while a TriStation 1131 project is running. In an
A discrete memory variable or discrete input point that instance view, you can change the values of variables
has been assigned to an SOE block. during emulation or real-time execution.
74
Glossary
ISO MTTR
Stands for the International Organization for Standard- Stands for Mean Time To Repair which is the expected
ization (ISO) which is a worldwide federation of national time to repair a failed system or subsystem. Usually
standards bodies (ISO member bodies) that promulgates expressed in hours.
standards affecting international commerce and commu-
nications. node
Any of the machines on a network. In this document,
LD node usually means a Triconex controller.
Stands for Ladder Diagram, which is a graphical
programming language that uses a set of symbols to node number
represent relay logic. Modules are defined by their The physical address of a node.
connection to a left and right power rail.
nonincendive
logical slot Not capable of igniting a flammable gas or vapor under
In a Triconex chassis, a logical slot is a repository for a normal operating conditions.
primary module, a hot-spare module, and theirassociated
field termination component. open network
A network to which an external host can be connected.
m
Abbreviation for milli. output poll time
The time required by the Triconex controller to imple-
Markov model ment the outputs generated by the user-written control
A generalized modeling technique which can be used to program in response to inputs from the controlled
represent a system with an arbitrary number of modules, process.
failure events, and repair events. A Markov model can be
mathematically solved to produce a resultant probability. Peer-to-Peer
A protocol that allow multiple Triconex controllers on a
matrix proprietary network to exchange limited amounts of
1. A CEM program process and safety information.
2. A traditional methodology for ESD applications which
associates a problem (cause) in a process with one or program
more actions (effects) that must be taken to correct the 1. The set of instructions, commands, and/or directions
problem. that define the Triconex controllers output signals in
terms of input signals. 2.The act of creating such a set of
module instructions using the relay ladder language of the TriS-
An active field-replaceable unit consisting of an elec- tation programming system.
tronic circuit assembly housed in a metal spine. Also
called board or card. protocol
A set of rules describing the format used for data
MTBF exchange between two entities.
Stands for Mean Time Between Failure which is the
expected average time between failures of a system, reliability
including the time taken to repair the system. Usually The probability that no failure of the system will have
expressed in hours. occurred in a given period of time.
75
Glossary
The time required to execute the user-written control executes the user-written control program in parallel with
program the other legs.
Output poll time
trip
A safety-related shutdown of the controlled process or a
ST
portion of the controlled process.
Stands for Structured Text, which is a high-level
programming language used for complex arithmetic
TriStation 1131
calculations and procedures that are not easily expressed
An control program for developing and downloading
in graphical languages.
user-written control programs and for performing mainte-
nance and diagnostics. Runs on Windows 2000 or NT
system
operating systems.
Consists of a set of components which interact under the
control of a design.
TriStation protocol
A master/slave protocol used by a TriStation for commu-
TCP/IP
nication with the Triconex controllers.
Stands for Transmission Control Protocol/Internet
Protocol (TCP/IP) which are protocols for the Transport
TV Rheinland
and Network layers of the OSI network model. TCP/IP
TV stands for Technischer berwachungs-Verein
provides reliable, sequenced data delivery.
which translates to Technical Supervisory Association. In
Germany, TV Rheinland is an authorized technical
Time Synchronization
inspection agency for a wide variety of products,
A Triconex protocol used to establish and maintain a
processes, installations, plants and equipment.
synchronized, network-wide time basis. Time can be
synchronized with the master node in a network of Tricon
UDP/IP
or Tricon controllers, with a distributed control system
Stands for User Datagram Protocol/Internet Protocol
(DCS), or with an OPC client/server control program.
(UDP/IP) which are protocols for the Transport and
Network layers of the OSI network model. UDP/IP
transient fault
provides best-effort datagram delivery.
A fault or error resulting from a temporary environmental
condition.
voting
A mechanism whereby each leg of a TMR system
TMR
compares and corrects the data in each leg using a two-
Stands for Triple-Modular Redundant architecture, which
out-of-three majority voting scheme.
allows Triconex controllers to achieve fault tolerance.
The complete system is triplicated; each of the three iden-
tical systems is called a leg. Each leg independently
76