Tricon Technical Product Guide PDF

Emergency Shutdown Systems
Tricon
Technical Product Guide
Version 9.6 Systems
Turbine Control Systems
Burner Management Systems
Fire and Gas Protection Systems
An Invensys company
Technical Product Guide
Copyright 2000 Triconex Corporation. All Rights Reserved. Printed in the United States of America. Information in this document is subject to change without notice and does not represent a commitment on the part of Triconex Corporation.
Trademark Acknowledgments
Cause & Effect Matrix Programming Language Editor (CEMPLE), Tricon, Trident and TriStation 1131 are trademarks of Triconex Corporation in the USA and other countries Microsoft, Windows and Windows NT are registered trademarks of Microsoft Corporation. Modbus is a registered trademark of Modicon Corporation. Triconex is a registered trademark of Triconex Corporation in the USA and other countries. All other brands or product names may be trademarks or registered trademarks of their respective owners.
DISCLAIMER
Because of the variety of uses for this equipment and because of the differences between this faulttolerant 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, Triconex Corporation cannot assume responsibility or liability for actual use based upon the illustrative uses and applications. In no event will Triconex Corporation be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. TRICONEX CORPORATION DISCLAIMS ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Triconex 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 Triconex Corporation with respect to use of information, circuits, equipment or software described in this text. Reproduction of the content of this manual, in whole or part, without written permission of Triconex Corporation, is prohibited.
Table of Contents
Introduction ........................................................................................................................ 1 Theory of Operation ........................................................................................................... 3 System Configuration....................................................................................................... 11 Product Specifications...................................................................................................... 17 Field Termination Options ............................................................................................... 45 Communication Capabilities ............................................................................................ 57 TriStation 1131 Developers Workbench ........................................................................ 61 CEM Programming Language Editor .............................................................................. 67 Sequence of Events (SOE) Capability for NT ................................................................. 69 Appendix A. Hardware Requirements for TriStation and SOE ....................................... 73 Glossary............................................................................................................................. 74
Triconex Part No. 9791007-006, January 2001
Preface
The Tricon fault-tolerant control system is the industry choice for critical process applications requiring maximum safety and uninterrupted operation. Leading producers of chemical, oil and gas, pulp and paper, and electric power have successfully implemented Tricon fault-tolerant control to improve safety, increase productivity, and reduce downtime. This Tricon Technical Product Guide will familiarize you with theory and terminology for fault-tolerant control, reliability and availability. The guide covers configuration and specifications of the Tricon system, and discusses the capabilities of the TriStation Programming Systems and the Communication Modules which enable the Tricon to interface with external devices. The information in the Tricon Technical Product Guide applies to Version 9.6 Tricon systems. The Triconex sales and application staff is readily available to provide additional information or assistance as needed. Triconex also offers technical courses on configuration, programming and Tricon maintenance. Open enrollment courses are held at our headquarters in Irvine, California and at our regional business centers. If desired, on-site training can be arranged at your facility for your operation and maintenance personnel. Product, support and service information are available for users 24 hours a day through Internet connections. Administered by the Customer Satisfaction Group at Triconex Headquarters, customer reference documents can be downloaded or diagnostic files uploaded for analysis by Customer Satisfaction Engineers. For Tricon product information and support, please visit our website at http://www.triconex.com or call our Technical Support Group at 949885-0800, toll free 866-TMR-CALL (866-867-2255), or fax 949-7686601.
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 identifies and compensates for failed control system elements and allows repair while continuing an assigned task without process interruption. A highintegrity control system such as the Tricon is used in critical process applications that require a significant degree of safety and availability.
What is the Tricon?

The Tricon is a state-of-the art controller that provides fault tolerance by means of Triple-Modular Redundant (TMR) architecture. TMR integrates three isolated, parallel control systems and extensive diagnostics in one control system. The system uses twoout-of-three voting to provide highintegrity, error-free, uninterrupted process operation with no single point of failure. The Tricon controller uses three identical channels. Each channel independently executes the application program in parallel with the other two channels. Specialized hardware/software voting mechanisms qualify and verify all digital inputs and outputs from the field, while analog inputs are subject to a mid-value selection process. Because each channel is isolated from the others, no single-point failure in any channel can pass to another. If a hardware failure does occur on one channel, the other channels override it. Meanwhile the faulting module can easily be
The Tricon Fault-Tolerant Controller removed and replaced while the controller is online without interrupting the process. Setting up applications is simplified with the triplicated Tricon system, because it operates as a single control system from the users point of view. The user terminates sensors and actuators at a single wiring terminal and programs the Tricon with one set of application logic. The Tricon manages the rest! Extensive diagnostics on each channel, module, and functional circuit immediately detect and report operational faults by means of indicators or alarms.
Introduction
All diagnostic fault information is accessible by the application program and the operator. The program or the operator can use diagnostic data to modify control actions or direct maintenance procedures. Other key features of the Tricon controller that ensure the highest possible system integrity are: No single point of failure Ability to operate with 3, 2 or 1 Main Processor before shutdown Fully implemented and transparent triplication Comprehensive system diagnostics Complete range of I/O modules Dual and single I/O modules for safety-critical points with a limited need for availability Remote I/O up to 12 kilometers (7.5 cable miles) away Simple, on-line module repair Unsurpassed reliability and availability equalization and temperatureare monitored and shutdown actions taken if an upset condition occurs. Traditional shutdown systems implemented with mechanical or electronic relays provide shutdown protection but can also cause dangerous nuisance trips. The Tricon increases system integrity, providing automatic detection and verification of field sensor integrity, integrated shutdown and control functionality, and direct connection to the supervisory data highway for continuous monitoring of safety-critical functions. Boiler Flame Safety Process steam boilers function as a critical component in most refinery applications. Protection of the boiler from upset conditions, safety interlock for normal startup and shutdown, and flame-safety applications are combined by one integrated Tricon system. In traditional applications, these functions had to be provided by separate, nonintegrated components. But with the fault-tolerant, fail-safe Tricon controller, the boiler operations staff can use a critical resource more productively while maintaining safety at or above the level of electromechanical protection systems. Turbine Control Systems The control and protection of gas or steam turbines requires high integrity as well as safety. The continuous operation of the fault-tolerant Tricon controller provides the turbine operator with maximum availability while maintaining equivalent levels of safety. Speed control as well as start-up and shutdown sequencing are implemented in a single integrated system. Unscheduled outages are avoided by using hot spares for the I/O modules. If a fault occurs in a module, a replacement module is automatically activated without operator intervention. Offshore Fire & Gas Protection The protection of offshore platforms from fire and gas threats requires continuous availability as well as reliability. The Tricon provides this availability through on-line replacement of faulty modules. Faults in individual modules, field wiring and sensors are managed automatically by built-in diagnostics. Analog fire and gas detectors are connected directly to the Tricon, eliminating the need for trip amps. An operator interface monitors fire and gas systems as well as diagnostics for the Tricon controller and its attached sensors. Traditional fire and gas panels can be replaced with a single integrated system, saving costly floor space while maintaining high levels of safety and availability.
What is TriStation?
The TriStation 1131 Developer's Workbench is an integrated tool for developing, testing and documenting applications for the Tricon. TriStation complies with the IEC 1131 International Standard for Programmable Controllers and follows the Microsoft Windows guidelines for graphical user interfaces. See page 61 for more information.
What are Typical User Applications?

Each day the Tricon supplies increased safety, reliability and availability to a worldwide installed base. The following are a few typical applications. For details on the Tricons value to your applications, ask your sales representative for additional documentation and customer references. Emergency Safety Shutdown (ESD) The Tricon provides continuous protection for safety-critical units in refineries, petrochemical/chemical plants and other industrial processes. For example, in reactor and compressor units, plant trip signalsfor pressure, product feed rates, expander pressure 2
What about Communication Capabilities?

Optional modules enable the Tricon to communicate with other Tricons on a peer-to-peer network and with: Modbus masters and slaves Distributed Control Systems (DCS) Operator workstations Host computers accessed by means of TCP(UDP)/IP/802.3 protocol For more information, see Communication Capabilities on page 57.
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 by means of a Triple-Modular Redundant (TMR) architecture. The Tricon provides error-free, uninterrupted control in the presence of either hard failures of components, or transient faults from internal or external sources. which takes control if a fault is detected on the primary module during operation. The hot-spare position can also be used for on-line system repairs. memory for use in the hardware voting process. The individual input table in each Main Processor is transferred to its neighboring Main Processors over the proprietary TriBus. During this transfer, hardware voting takes place. The TriBus uses a Direct Memory Access programmable device to synchronize, transmit, vote and compare data among the three Main Processors.
Auto Spare Output Leg A TriBus
Main Processor Modules
A Tricon system contains three Main The Tricon is designed with a fully tripProcessor (MP) Modules to control licated architecture throughout, from three separate legs of the system. Each the input modules through the Main Main Processor operates in parallel Processors to the output modules. Every I/O module houses the circuitry for three independent legs. Auto Spare Each leg on the input modules reads the process data and passes that Input I/O Bus Main Leg information to its respective Main Processor A TriBus A Processor. The three Main ProcesMain sors communicate with each other Input Processor I/O Bus Leg using a proprietary high-speed bus B B Input system called the TriBus. Main Termination
TriBus
Output Leg B
Voter Output Termination
Once per scan, the three Main Processors synchronize and communicate with their two neighbors over the TriBus. The Tricon votes digital input data, compares output data, and sends copies of analog input data to each Main Processor. The Main Processors execute the userwritten application and send outputs generated by the application to the output modules. In addition to voting the input data, the TriBus votes the output data. This is done on the output modules as close to the field as possible, in order to detect and compensate for any errors that could occur between the Tricon voting and the final output driven to the field. For each I/O Module, the system can support an optional hot-spare module
Input Leg C
I/O Bus
Processor C
Output Leg C
Simplified Trident Architecture with the other two Main Processors, as a member of a triad. A dedicated I/O Processor (IOP) on each Main Processor manages the data exchanged between the Main Processors and the I/O modules. A triplicated I/O Bus is located on the chassis backplane and is extended from chassis to chassis by means of I/O Bus Cables. As each input module is polled, the new input data is transmitted to the Main Processor over the appropriate leg of the I/O Bus. The input data from each Input Module is assembled into a table in the Main Processor and stored in If a disagreement is discovered, the signal value found in two out of three tables prevails, and the third table is corrected accordingly. One-time differences which result from sample timing variations can be distinguished from a pattern of differing data. The three independent Main Processors each maintain data about necessary corrections in local memory. Any disparity is flagged and used at the end of the scan by the built-in Fault Analyzer routines to determine whether a fault exists on a particular module.
Theory of Operation
After the TriBus transfer and input data voting have corrected the input values, these corrected values are used by the Main Processors as input to the userwritten application. (The application is developed in the TriStation and downloaded to the Main Processors.) The 32bit main microprocessor and a math coprocessor execute the user-written application in parallel with the neighboring Main Processor Modules. The user-written application generates a table of output values based on the table of input values, according to the rules built into the application by the customer. The IOP on each Main Processor manages the transmission of output data to the output modules by means of the I/O Bus. Using the table of output values, the IOP generates smaller tables, each corresponding to an individual output module in the system. Each small table is transmitted to the appropriate leg of the corresponding Output Module over
Dual Power Rails
the I/O Bus. For example, Main Processor A transmits the appropriate table to Leg A of each Output Module over I/O Bus A. The transmittal of output data has priority over the routine scanning of all I/O modules. The IOP manages the data exchanged between the Main Processors and the communication modules using the communication bus, which supports a broadcast mechanism. The Model 3008 Main Processors provide 16 Megabytes DRAM each for V9 Tricon Systems. The RAM is used for the user-written application, sequence-of-events data, I/O data, diagnostics and communication buffers. In the event of an external power failure, the integrity of the user-written program and the retentive variables is protected for a minimum of six months. The Main Processor Modules receive power from dual Power Modules and power rails in the Main Chassis. A
failure on one Power Module or power rail will not affect the performance of the system.
Bus Systems and Power Distribution

Three triplicated bus systems are etched on the chassis backplane: the TriBus, the I/O Bus and the Communication Bus. The TriBus consists of three independent serial links operating at 25MBaud (with Model 3008 MPs). The TriBus synchronizes the Main Processors at the beginning of a scan. Then each Main Processor sends its data to its upstream and downstream neighbors. The TriBus performs one of two functions with the data: Transfer of data onlyfor I/O, diagnostic and communication data. Comparing data and flagging disagreementsfor previous scans output data and memory of user-written application. An important feature of the Tricons fault-tolerant architecture is the use of a single transmitter to send data to both the upstream and downstream Main Processors. This ensures receipt of the same data by the upstream processor and downstream processor. Each I/O module transfers signals to or from the field through its associated field termination assembly. Two positions in the chassis tie together as one logical slot. The first position holds the active I/O module and the second position holds the hot-spare I/O module. Termination cables are
Dual-Power Regulators
+3.3 Volts +5 Volts
DIAG Read (DB25) Up Stream Down Stream
802.3 Network (RJ-45) Modbus (DB9)
Reserved for future use
Diag Bus (to other MPS)
Main Processor MPC860A
Clock/ NVRAM 32 KB
I/O & COMM Processor MPC860A
Fault Tolerant I/O Bus 375Kb
I/O Modules
32 Bit bus
Shared Memory 128K
COMM Bus 2Mb 32-Bit Bus
Communication Modules
FLASH 6 MB
TriBus FPGA
DRAM 16 MB
DRAM 16 MB
Up Stream TriBus (to other MPS) Up Stream
Down Stream Down Stream
Main Processor (Model 3008) Architecture 4
connected to the top of the backplane. Each connection extends from the termination module to both active and hot-spare I/O modules. Therefore, both the active module and the hotspare module receive the same information from the field termination wiring. The 375 KBaud I/O Bus transfers data between the I/O Modules and the Main Processors. The triplicated I/O Bus is carried along the bottom of the backplane. Each leg of the I/O Bus runs between one of the three Main Processors and the corresponding legs on the I/O module. The I/O Bus can be extended between chassis using a set of three I/O Bus Cables. The 2 MBaud Communication (COMM) Bus runs between the Main Processors and the Communication Modules. Power for the chassis is distributed across two independent power rails down the center of the backplane. Every module in the chassis draws power from both power rails through dual power regulators. There are four sets of power regulators on each input and output module: one set for each of the legs A, B and C and one set for the status-indicating LEDs.
ELCO Connectors for I/O Termination

Pow er Term ina l Strip
Term inal Strip #1
Term inal Strip #2
TriBus
P ow er S upply #1
D ual P ow er R ails
P ow er S upply #2
Channel A Channel B Channel C
C om m B us
Channel A Channel B Channel C
I/O B us
M ain P rocessors A, B, & C
Right I/O Module * Left I/O Module * Communication Module
Typical Logical Slot
* Either the left module or right module functions as the active or hot-spare module.
Backplane of the Main Chassis cannot pass to another. In addition, each leg contains an 8-bit microprocessor called the I/O communication processor which handles communication with its corresponding Main Processor. Each of the three input legs asynchronously measures the input signals from each point on the input termination module, determines the respective states of the input signals, and places the values into input tables A, B and C respectively. Each input table is regularly interrogated over the I/O bus by the I/O communication processor located on the corresponding Main Processor module. For example, Main Processor A interrogates Input Table A over I/O Bus A. On TMR Digital Input Modules, all critical signal paths are 100% triplicated for guaranteed safety and maximum availability. Each leg conditions signals independently and provides optical isolation between the field and the Tricon. (The 64-point High-Density Digital Input Module is an exception it has no channel-to-channel isolation.) DC models of the TMR digital input modules can self-test to detect stuck ON conditions where the circuitry cannot tell whether a point has gone to the OFF state. Since most safety systems are set up with a de-energize-totrip capability, the ability to detect stuck ON points is an important feature. To test for stuck ON inputs, a switch within the input circuitry is closed to allow a zero input (OFF) to be read by the optical isolation circuitry. The last data reading is frozen in the I/O communication processor while the test is running.
Digital Input Modules

The Tricon supports two basic types of digital input modules: TMR and single. The following paragraphs describe digital input modules in general, followed by specifics for TMR and single modules. Every digital input module houses the circuitry for three identical legs (A, B and C). Although the legs reside on the same module, they are completely isolated from each other and operate independently. A fault on one leg
Theory of Operation
FIELD CIRCUITRY TYPICAL POINT (1 of 32) AC/DC Input Circuit +
Threshold Detect Opto-Isolator Input Mux OptoIsolator Proc Bus Xcvr A
INTELLIGENT I/O CONTROLLER(S) Intelligent I/O Controller(s)
TRIPLICATED I/O BUS
Individual Opto-Isolation
Dual Port RAM B
+
Threshold Detect Opto-Isolator Input Mux OptoIsolator Proc Bus Xcvr
Leg-to-Leg Isolation
Bridge Rectifier
AC
+ Smoothing
Optical Isolation Threshold Detect Opto-Isolator Input Mux OptoIsolator
Dual Port RAM
fault, force the measured input value to the safe state. Because the Tricon is optimized for de-energize-to-trip applications, detection of a fault in the input circuitry forces to OFF (the de-energized state) the value reported to the Main Processors by each leg.
There are four basic types of Digital Output Modules: dual, Architecture of TMR Digital Input Module with Self-Test (DC Model) supervised, DC voltage and AC On Single Digital Input Modules, only self-test circuitry detects all stuck-ON voltage. The following paragraphs those portions of the signal path which and stuck-OFF fault conditions within describe digital output modules in are required to ensure safe operation are the non-triplicated signal conditioners general, followed by specifics for the triplicated. Single modules are optiin less than half a second. This is a four types. mized for those safety-critical applicamandatory feature of a fail-safe system, Every digital output module houses the tions where low cost is more important which must detect all faults in a timely circuitry for three identical, isolated than maximum availability. Special manner and upon detection of an input legs. Each leg includes an I/O microprocessor which receives its output table from the I/O commuANALOG INPUT SIGNAL INDIVIDUAL ADC INTELLIGENT TRIPLICATED nication processor on its correCIRCUIT CONDITIONING FOR EACH LEG I/O CONTROLLER(S) I/O BUS TYPICAL POINT sponding Main Processor. All of the digital output modules, except A Bus ADC Amp the dual DC modules, use special Proc Xcvr quadruplicated output circuitry Mux which votes on the individual output signals just before they are applied to the load. This voter B Bus ADC Amp Proc Xcvr circuitry is based on parallelseries paths which pass power if Mux the drivers for Legs A and B, or Legs B and C, or Legs A and C C command them to closein other Bus ADC Proc Amp Xcvr words, 2-out-of-3 drivers voted ON. The quadruplicated voter Mux circuitry provides multiple redundancy for all critical signal paths,
Individual Point Field Terminations
Individual Point Field Termination
Proc
Bus Xcvr
Control Signal
Dual Port RAM
Digital Output Modules
Architecture of TMR Analog Input Module 6
guaranteeing safety and maximum availability. Each type of Digital Output Module executes a particular Output Voter Diagnostic (OVD) for every point. Loop-back on the module allows each microprocessor to read the output value for the point to determine whether a latent fault exists within the output circuit.
TRIPLICATED I/O BUS
INTELLIGENT I/O CONTROLLER(S) A
FIELD CIRCUITRY TYPICAL POINT (16)
Bus Xcvr
Proc
Point Register
Output Switch Drive Circuitry
+V
*
A and B
B B C
Loopback Detector
Bus Xcvr
Proc
Point Register
to other points
B
Analog Input Modules

On an Analog Input Module, each of the three legs asynchronously measures the input signals and places the results into a table of values. Each of the three input tables is passed to its associated Main Processor Module using the corresponding I/O Bus. The input table in each Main Processor Module is transferred to its neighbors across the Tricon. The middle value is selected by each Main Processor, and the input table in each Main Processor is corrected accordingly. In TMR mode, the mid-value data is used by the application program; in duplex mode, the average is used. Each Analog Input Module is automatically calibrated using multiple reference voltages read through the multiplexer. These voltages determine the gain and bias that are required to adjust readings of the analog-to-digital converter (ADC). Analog Input Modules and Termination Modules are available to support a wide variety of analog inputs, in both isolated and non-isolated versions: 0-5
Bus Xcvr
Proc
Point Register C
A and B
LD A B C
Loopback Detector RTN

to other points
* All output switches are opto-isolated.
Architecture of 16-point Supervised Digital Output Module VDC, 0-10 VDC, 4-20 ma, thermocouples (types K, J, T, E), and Resistive Thermal Devices (RTDs).
Termination Modules
Various termination options are available for field wiring of the Tricon High Density chassis, including external panels and direct cabling. A field termination module is an electrically passive circuit board to which field wiring is easily attached. A termination module merely passes input signals from the field to an input module or passes signals generated by an output module directly to field wiring, thereby permitting removal or replacement of the input or output module without disturbing field wiring. In addition, External Termination Assemblies are available for specialized applications. See Special Termination Panels on page 46 for more information.
Analog Output Module

The Analog Output Module receives three tables of output values, one for each leg from the corresponding Main Processor. Each leg has its own digitalto-analog converter (DAC). One of the three legs is selected to drive the analog outputs. The output is continuously checked for correctness by loop-back inputs on each point which are read by all three microprocessors. If a fault occurs in the driving leg, that leg is declared faulty and a new leg is selected to drive the field device. The designation of driving leg is rotated among the legs, so that all three legs are tested.
Theory of Operation
DCS Environment
Enhanced Intelligent Communication Module (EICM) Supports RS-232, RS-422 and RS-485 serial communication with external devices at speeds up to 19.2 Kbaud. The EICM provides four serial, optoisolated ports which can interface with Modbus masters, slaves, or both; or a TriStation. The module also provides a Centronicscompatible parallel port. Network Communication Module (NCM)
MPs
DCS Bus TRICON Chassis DCS Operator Workstation
TriStation
NCM
EICM
TS/TSAA Connection 802.3 Network Programming Workstation Modbus Master
Host Computer
* The module in this slot is a generic module representing any
Modbus Slave
alarm alarm alarm alarm alarm
Triconex module that can communicate with a DCS. For example, the ACM communicates with Foxboros I/A Series Nodebus; the SMM communicates with Honeywells UCN; the NCM can communicate with any DCS that uses TCP-IP protocol; and the EICM can communicate with any DCS that uses Modbus protocol.
This module supports 802.3 networking over a high-speed 10 Megabit/second data link for the use of Triconexproprietary protocols and applications (described in the section called Communication Capabilities later in this document). In addition, users can write their own applications using the TCPIP/TCP-UDP protocol see Protocols for Open Networks on page 59 for details. Hiway Interface Module (HIM)
Annunciator
Communication Capabilities of Tricon Modules
Communication Modules
By means of the communication modules described in this section, the Tricon can interface with Modbus masters and slaves, other Tricons in peer-to-peer networks, external hosts running applications over 802.3 networks, and Honeywell and Foxboro Distributed Control Systems (DCS). The Main Processors broadcast data to the communication modules across the communication bus. Data is typically refreshed every scan; it is never more than two scan-times old.
This module acts as an interface between a Tricon controller and Honeywells TDC 3000 Distributed Control System (DCS) by means of the Hiway Gateway and Local Control Network (LCN). The HIM enables higher-order devices, such as computers and operator workstations, to communicate with the Tricon.
Safety Manager Module (SMM) This module acts as an interface between a Tricon controller and Honeywells Universal Control Network (UCN), one of three principal networks of the TDC 3000 DCS. The SMM appears to the TDC 3000 as a safety node on the Universal Control Network (UCN), allowing the Tricon to manage process-critical points within the overall TDC 3000 environment. The SMM transmits all Tricon aliased data and diagnostic information to TDC 3000 operator workstations in display formats that are familiar to Honeywell operators.
Advanced Communication Module (ACM) This module acts as an interface between a Tricon controller and Foxboros Intelligent Automation (I/A) Series DCS. The ACM appears to the Foxboro system as a safety node on the I/A Series Nodebus, allowing the Tricon to manage process-critical points within the overall I/A DCS environment. The ACM transmits all Tricon aliased data and diagnostic information to I/A operator workstations in display formats that are familiar to Foxboro operators. See the section called Product Specifications for specifications of the EICM, NCM, SMM and ACM.
Power Supply Modules Each Tricon chassis houses two Power Modules arranged in a dual-redundant configuration. Each module derives power from the backplane and has independent power regulators for each leg. Each can support the power requirements for all the modules in the chassis in which it resides, and each feeds a separate power rail on the chassis backplane. The Power Modules have builtin diagnostic circuitry which checks for out-of-range voltages and over-temperature conditions. A short on a leg disables the power regulator rather than affecting the power bus.
Architecture of Power Subsystem 9
Theory of Operation
10
A Tricon system consists of one Main Chassis and up to fourteen additional chassis.
System Configuration
A Tricon system is composed of a Main Chassis and up to 14 Expansion or Remote Expansion (RXM) Chassis. The maximum system size is 15 chassis supporting a total of 118 I/O modules and communication modules that interface with Modbus devices, other Tricons, and external host applications over 802.3 networks, as well as Foxboro and Honeywell Distributed Control Systems (DCS). The following sections provide guidelines for chassis layout and system configuration.
E A B
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 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. 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. (The spaces used by the Main Processors and the COM slot in the Main Chassis are now available for other purposes.) The Main and Expansion Chassis are interconnected by means of triplicated I/O Bus Cables. The maximum I/O bus cable length between the Main Chassis
G
A. Memory backup battery B. Connectors for terminations C. I/O expansion ports D. Power terminals E. Keyswitch
F. Redundant Power Modules G. Three Main Processors H. COM slot1 with NCM I. AI module without spare J. DI module with hot spare
K. DI module without spare L. DO module with hot spare M. DO module without spare N. EICM
Sample Layout of a Tricon Chassis

1. The COM slot can be configured for the EICM or NCM only.
11
and the last Expansion Chassis is normally 30 meters (100 feet), but in restricted applications the length can be up to 300 meters (1000 feet). (Please consult your Triconex Customer Satisfaction representative for assistance when configuring a system that exceeds 30 meters of I/O bus cable length.) RXM Chassis are used for systems in which the total cable distance between the first chassis and the last chassis exceeds 30 meters (100 feet). Each RXM Chassis houses a set of three RXM modules in the same position as the Main Processors in the Main Chassis. Six remaining logical slots are available in an RXM Chassis and one blank (unused) slot. The primary module is active, and the other modulethe hot spareis powered but inactive. The Tricon cycles control between the two healthy I/O modules approximately every hour, so that each undergoes complete diagnostics on a regular basis. If a fault is detected on the primary module, the Tricon automatically switches control to the hot spare module, allowing the system to maintain three healthy legs continuously. The faulty module can then be removed and replaced. Alternatively, a module can be replaced on-line even when only one I/O module is normally installed in a logical slot. If a fault occurs, the FAULT indicator turns on, but the module remains active on two legs. A replacement module is then inserted into the unused space in the slot. The Tricon will grant control to this second I/O module after it passes a diagnostic test. Once the replacement I/O module becomes active, the faulty I/O module can be removed. This repair method demonstrates the Tricons ability to automatically transition from triplicated to dual control and back again without process interruption. A Tricon system should include at least one hot-spare module in place for each type of I/O module in the system. With this arrangement, the hot spare modules are tested regularly and can be used for on-line module replacement anywhere in the system.
I/O Bus Connections

As shown in the configuration drawing on page 12, each chassis has three sets of RS-485 I/O Bus Ports (IN & OUT). Additional chassis may branch out from the Main Chassis by means of the I/O Bus Ports, up to a maximum of 14. There are six portstwo sets of three for triplicated serial communication located on a panel in the upper left corner of the backplane. One set of three I/O Bus Cables is required for each Expansion Chassis, and for each RXM Chassis that houses a Primary RXM module set. (Remote RXM Chassis are connected to the Primary RXM Chassis with fiber-optic cables.) Communication across the I/O Bus Cables (and the RXM fiber-optic cables) proceeds at 375 kBaud, the same rate as the internal I/O bus on each chassiss backplane.
On-Line Module Repair

The logical slot arrangement of a Tricon chassis provides two ways to repair faulting modules on-line: the hot spare method and on-line module replacement. With the hot spare method, a logical slot contains two identical I/O modules.
I/O Bus Ports
Tricon Chassis, Front View
OUT A B C
IN
I/O Bus Connections

OUT A Leg A output port OUT B Leg B output port OUT C Leg C output port IN A Leg A input port IN B Leg B input port IN C Leg C input port
I/O Bus Ports
12
System Configuration Guidelines

A V9 Tricon system must have a Main Chassis and may have up to 14 Expansion or Remote Expansion (RXM) Chassis. The following configuration guidelines apply: For Main Chassis There is one Main Chassis with a chassis address of 1. The Main Chassis must contain three Model 3008 Main Processors. The Main Chassis must house two Power Modules. The Main Chassis provides six logical slots for user-selected modules and one COM slot. Expansion Chassis Expansion Chassis are used when the total I/O Bus cable length for the system is less than 30 meters (100 feet) for each leg. Each Expansion Chassis must have a unique address between 2 and 15. This address must not be used by any other Expansion Chassis or by an RXM Chassis. Each Expansion Chassis must house two Power Modules. One set of triplicated I/O Bus Cables is used to interconnect legs A, B and C between Expansion Chassis. Each Expansion Chassis provides eight logical slots. For RXM Chassis RXM Chassis must be used when the total I/O Bus cable length for the system is greater than 30 meters (100 feet) for each leg. Each RXM Chassis must have a unique address between 2 and 15. This address must not be used by any other RXM Chassis or by an Expansion Chassis.
A A B B C C A
RXM Chassis
Expansion Chassis
A B
Remote Location #1
B C C
Remote RXM Set
Jumper Cable
Junction Box Main Cable Junction Box
NOTES
Dotted lines represent six fiber-optic cables for remote location. Solid lines represent RS-485 I/O Bus Cables for local expansion. A Tricon system may contain a maximum of 15 chassis, including Main, Expansion and RXM Chassis.
Jumper Cable
Main Chassis
MPs
RXM Chassis
Expansion Chassis
A B
Primary RXM Set
to Remote Location #3 to Remote Location #2
System Configuration with Three Remote Locations One RXM Chassis must be located within 30 meters (100 cable-feet) of the Main Chassis. This RXM Chassis must house the Primary RXM Module Set. Up to 2 Primary RXM Module sets are normally supported. Contact Triconex regarding other configurations. Each Primary RXM Module Set can support up to 3 remote sites, each up to 12 kilometers (7.5 miles) away. One RXM Chassis must be located at each remote site. This RXM Chassis must house a Remote RXM Module Set. A Primary RXM Module Set and a Remote RXM Module Set are connected by 6 fiber-optic cables which transmit and receive signals for legs A, B and C. RXM Chassis can be connected to local Expansion Chassis using I/O Bus Cables. Each RXM Chassis must contain 2 Power Modules. Each RXM Chassis provides 6 logical slots for I/O modules and 1 blank (unused) slot.
13
Chassis & Terminations Mounted in an Enclosure
Communication Modules The following rules apply to EICM, NCM, HIM, SMM and ACM modules in a Tricon system: A TriStation PC can be connected to an EICM, NCM or ACM, so at least one of these modules must be included in each system. One logical slot is available for EICMs, NCMs and ACMs respectively. Matched pairs of these modules can be installed in both the left and right positions of one logical slot.
The COM slot can be configured for the EICM or NCM only. Up to two logical slots can be configured for SMM modules. A matched pair of SMMs can be installed in both the left and right positions of each logical slot. Up to two logical slots can be configured for HIM modules, and both slots must be in the Main Chassis. All types of communication modules must be housed in the Main Chassis or in Chassis #2.
If communication modules are housed in Chassis #2, this chassis must be connected directly to the Main Chassis using I/O COMM Cables (Model #9001) rather than standard I/O Bus Cables. Chassis #2 must be an I/O Expansion Chassis or a Primary RXM Chassis.
14
Chassis Power Limitations In order to maintain the safety and reliability of the Tricon, each system must be configured for operation under a worst-case scenario. These circumstances include operation with only one functional power supply at 60C (140F), ambient. (See Power Modules on page 24 for detailed specifications). Under these conditions, the power supply is rated to deliver 175 Watts. The table above lists the logic power consumption per module in Watts.
ACM
Module Type Analog Input Analog Input, Isolated Analog Input, High Density Analog Output Digital Input, High Density Digital Input, Single Digital Input, TMR Digital Output, AC Digital Output, DC Digital Output, Dual Digital Output, Supervised EICM HIM Main Processor, Model 3008 NCM Power Module SMM Thermocouple Input, Isolated Thermocouple Input, Non-Isolated Pulse Input Pulse Totalizer RXM Relay Output
Watts Consumed 15 10 15 10 15 10 10 10 10 10 10 15 10 10 10 20 n/a 20 15 10 20 10 5 15
15
16
The Tricon supports a comprehensive range of modules to meet customers needs.
Product Specifications
The Tricon product family includes a comprehensive range of modules to meet users needs. To familiarize you with the various options that Triconex offers, this section includes: A summary of the system components and their uses A table that lists standard products and their model numbers Summary specifications for each standard product in the Tricon family See the Tricon Planning and Installation Guide for complete information. See pages 22 and 23 for chassis mounting and enclosure specifications. Power Supply Modules Provide power to modules in the Main, Expansion or RXM Chassis. Available in 24 VDC, 115 VAC and 230 VAC versions. Each Power Supplys output rating is 175 W at 60C (140 F). Main Processors The Main Processors execute the system diagnostics and the userwritten application. Communication Modules Enhanced Intelligent Communication Module (EICM) supports RS-232, RS-422 and RS485 serial communication with Modbus devices and TriStation. Network Communication Module (NCM) supports a number of Triconex protocols and applications and user-written applications on 802.3 networks, including TriStation and TCP-IP/UDP-IP. Safety Manager Module (SMM) acts as an interface between a Tricon controller and Honeywells Universal Control Network (UCN), one of three principal networks of the TDC 3000 DCS. Hiway Interface Module (HIM) acts as an interface between a Tricon controller and Honeywells TDC 3000 Hiway Gateway and Local Control Network (LCN). Advanced Communication Module (ACM) allows the Tricon controller to interface with Foxboros Industrial Automation (I/A) Series DCS and TriStation. Fiber-Optic Remote Extender Modules (RXM) For operation of Expansion Chassis up to 12 kilometers (7.5 miles) away from the Main Chassis, with exceptional immunity against electro-static and electro-magnetic interference. I/O Modules Digital Input Modules receive discrete signals of these nominal voltages: 115 V AC/DC, 48 V AC/DC, 24 V AC/DC, Pulse Input and Pulse Totalizer. All voltages are available in TMR modules. NonTMR modules are available in 24 V DC and 48 V DC only. Supervised Digital Output Modules produce discrete output signals of these nominal voltages, with diagnostic coverage of the field circuit and load device: 115 VAC, 120 VDC, 48 VDC & 24 VDC. Digital Output Modules produce discrete output signals of these nominal voltages: 115 VAC, 120 VDC, 48 VAC, 48 VDC & 24 VDC. Dual output modules are also available. Analog Input Modules receive analog signals of these types: 0-5 VDC, 0-10 VDC and Thermocouple types J, K, T & E. Available in both isolated and DC-coupled versions. Analog Output Module drives eight 4-20 mA analog output signals. 17
Summary of Tricon Components

Chassis Main Chassishouses Main Processors, memory back-up batteries, communication modules and I/O modules. Expansion Chassisfor additional I/O modules up to 30 meters (100 feet) away from the Main Chassis. In restricted applications, operation up to 300 meters (1000 feet) is supported. RXM Chassisfor I/O modules up to 12 kilometers (7.5 miles) away from the Main Chassis. Mechanical KeyingEach slot in the Tricon is mechanically keyed to correspond with a certain type of module. This prevents the installation of modules into improper slots.
Standard Products of the Tricon Family
Description Chassis Assemblies Main Chassis, High Density Configuration Expansion Chassis, High Density Configuration Remote Expansion Chassis, High Density Configuration I/O Bus Expansion Cables (Set of 3) I/O-COMM Bus Expansion Cables (Set of 3) Blank I/O Slot Panel Power Modules 120 VAC/VDC 175-Watt Power Module 24 VDC 175-Watt Power Module 230 VAC 175-Watt Power Module Main Processor Modules Main Processor, 16 Megabytes DRAM Communication Hardware & Software Enhanced Intelligent Communication Module (EICM), Isolated Network Communication Module (NCM), 802.3 Port Safety Manager Module (SMM), Honeywell UCN Interface Hiway Interface Module (HIM), Honeywell Data Hiway Interface Advanced Communication Module (ACM), Foxboro I/A Series Nodebus Interface Network DDE Server Interface Software Network Accessory Kit (802.3 thin cable, connectors & terminators) Remote Extender Modules Primary RXM, Multi-mode Fiber Optics, Set of 3 Modules Remote RXM, Multi-mode Fiber Optics, Set of 3 Modules Primary SRXM, Single-mode Fiber Optics, Set of 3 Modules Remote SRXM, Single-mode Fiber Optics, Set of 3 Modules TriStation Software TriStation 1131 Software Package, Version 9 License (per system) TriStation 1131 Software Package, Workstation License (per station) Documentation Sets Tricon User Documentation (hardcopy) TriStation 1131 V3.1 User Documentation for Tricon Users (hardcopy) CEMPLE V3.1 User Documentation (hardcopy) SOE Recorder Users Guide (hardcopy) Triconex User Documentation Set (CD-ROM) 8700-2 8746-2 8745-2 8754-2 TBD n/a n/a n/a n/a n/a 7202 7202 page 61 page 61 4200-3 4201-3 4210-3 4211-3 page 31 page 31 page 31 page 31 4119A 4329 4409 4509 4609 7569-3 7600-3 page 26 page 27 page 28 page 29 page 30 page 59 n/a 3008 page 25 8310 8311 8312 page 24 page 24 page 24 8110 8111 8112 90001 9001 8105 page 13, page 21 page 13, page 21 page 13, page 21 page 12 page 12, page 21 page 22 Model No. For Details, See
1.I/O Bus Expansion Cables are available in custom lengths. Please contact Triconex for more information.
18
I/O Modules of the Tricon System

Voltage Digital Input Modules 15 VAC/VDC 48 VAC/VDC 24 VAC/VDC 24/48 VDC 24 VDC 24 VDC Pulse Input Pulse Totalizer Digital Output Modules 115 VAC 120 VDC 24 VDC 48 VDC 115 VAC 48 VDC 120 VDC 24 VDC 24 VDC 24 VDC Relay Output Opto-Isolated, Non-commoned Opto-Isolated, Commoned Opto-Isolated, Non-commoned Opto-Isolated, Non-commoned Galvanically Isolated, Commoned., Supv. Galvanically Isolated, Commoned, Supv. Opto-Isolated, Commoned, Supervised Opto-Isolated, Commoned, Supervised Opto-Isolated, Commoned Opto-Isolated, Commoned Non-triplicated, Normally Open TMR TMR TMR TMR TMR TMR TMR TMR Dual Dual 3601E/3601T 3603E/3603T 3604E 3607E 3611E 3617E 3623/3623T 3624 3664 3674 16 16 16 16 8 8 16 16 32 32 32 page 36 page 36 page 36 page 36 page 38 page 38 page 37 page 37 page 39 page 39 page 34 Opto-Isolated, Non-Commoned Commoned in Groups of 8, Self-Test Commoned in Groups of 8, Self-Test High Density, DC Coupled Low Threshold with Self-test, Commoned Single, Opto-Isolated, Commoned Differential, AC Coupled Opto-isolated, Non-commoned TMR TMR TMR TMR TMR Single TMR TMR 3501E/3501T 3502E 3503E 3504E 3505E 3564 3511 3515 32 32 32 64 32 64 8 32 page 32 page 32 page 32 page 33 page 32 page 33 page 34 page 35 Description Type Model No. Points For Details, See
Non3636R triplicated
Analog Input Modules 0-5 VDC 0-10 VDC 0-5, 0-10 VDC 0-5, 0-10 VDC Thermocouple Thermocouple Analog Output Modules 4-20 mA 4-20 mA & 8-320 mA Current Loop, DC Coupled Current Loop, DC Coupled TMR TMR 3805E 3806 8 6&2 page 41 page 41 Differential, DC Coupled Differential, DC Coupled Differential, Isolated High-Density, Differential, DC Coupled Differential, DC Coupled Differential, Isolated TMR TMR TMR TMR TMR TMR 3700A 3701 3703E 3704E 3706A 3708E 32 32 16 64 32 16 page 40 page 40 page 40 page 40 page 42 page 42
19
Environmental Specifications
Operating Temperature Storage Temperature with Battery Storage Temperature without Battery Relative Humidity Sinusoidal Vibrations per Axis Shock Electrostatic Discharge Conducted Susceptibility Radiated Susceptibility Radiated Emissions
2
0 to 60C (32 to 140F), ambient1 -40 to 75C (-40 to 167F) -40 to 85C (-40 to 185F) 5% to 95%, non-condensing 2 G @ 10 to 500 Hz 15 G for 6-11 ms in each axis IEC 801-2, Level 3 (8KV) IEC 801-4, Class 3, Fast Transient/Burst & IEC 801-5, Level 3, Surge Withstand IEC 801-3, Level 3 Measured per CISPR 11
NOTE Other than the optional conformal coating of all PCB assemblies, the Tricon is not explicitly protected against dust, corrosive atmospheres or falling debris. The user must provide atmospheric and airborne-particle protection by housing the Tricon in an appropriate NEMA-rated enclosure.
1. Ambient refers to the air temperature measured at the bottom of the chassis. 2. Please contact Triconex for emission levels.
International Approvals
The Tricon system is regularly evaluated by third-party agencies and certified to meet the following standards. For additional details, contact Triconex regarding the appropriate TV Report and CSA File.
TV Rheinland TV certification ensures, per DIN standards, the functionality of Tricon systems for critical-process applications requiring maximum safety and uninterrupted operation. The Tricon fulfills the requirements for Class 5 and Class 6 safety equipment as defined in the following documents:
DIN V VDE 0801/01.90 DIN V VOE 0801/A1 10/94 DIN V 19250 06/94 DIN VDE 0116/10.89 EN 54 Part 2 EN 61131-2:1995 (Overvoltage Category II) IEC 61508, Parts 1-7
Canadian Standards Association (CSA) CSA/NRTL/C certification verifies the Tricons safety when it is attached to a power distribution system (primary line) and when it operates within specific temperature ranges. The Tricon does not constitute a fire hazard, and operator and maintenance persons are protected from electric shock when touching or replacing modules. CSA has certified that the Tricon fulfills the following standards: CAN/CSA Standard C22.2 No.0-M91 General Requirements - Canadian Electrical Code, Part II CSA Standard C22.2 No. 0.4-M1982 Bonding and Grounding of Electrical Equipment/Protective Grounding CSA Standard C22.2 No.142-M1987 Process Control Equipment UL Standard No. 508 Industrial Control Equipment Factory Mutual Research (FM) Factory Mutual has certified the V9 Tricon System for use in hazardous environments that meet Class I, Division 2 requirements. European Union CE Mark The CE Mark ensures the electro-magnetic compatibility (EMC) of the Tricon with other pieces of electrical/electronic equipment. When properly installed, the Tricon fulfills the requirements of the European Union EMC Directive No.89/336/EEC as defined by the document called IEC 61131-2, Programmable Controllers Part 2: Equipment Requirements and Test. Overvoltage Category II is assumed.
20
Chassis Options
A Tricon system is made up of one or more chassis assemblies which contain I/O and communication modules. The first chassis of a system is called the Main Chassis (Model 8110). To enlarge a system, Expansion Chassis (Model 8111) and/or RXM Chassis (Model 8112) can be added. (See System Configuration on page 11 for details.) I/O Expansion Bus Each chassis has six RS-485 I/O expansion bus ports at the top left corner of the backplane. There are two sets of ports for Legs A, B, and C, providing for two triplicated serial communications paths between chassis. One set of drop-line cables is required for each Expansion Chassis and for the RXM Chassis which houses the Primary RXM Module set. The standard length of a cable set (Model 9000) is 6 feet longer cables are available if needed. A 375 Kbaud triplicated I/O bus transfers data between the I/O modules and the Main Processors. A 2 MBaud communication bus runs between the Main Processors and the communication modules.
REMOTE
Keyswitch
LOCAL RUN PROGRAM STOP
I/O Expansion Bus Ports
Backplane
Power Supply Module #1
Power Supply Module #2
MPs
Logical Slots for I/O & Communication Modules
Keyswitch for System Control The Main Chassis has a four-position keyswitch which controls all the chassis in the system. The keyswitch setting is readable by Tricon and TriStation system software, and by application programs. Switch settings are: RUNNormal operation with readonly capability. The Main Processors
execute the previously-loaded application program. Attempts to modify program variables by TriStation, Modbus masters or external hosts are rejected. However, an application may call gated access functions to enable external host writes during a designated window of time. PROGRAMFor program loading and checkout. Allows control of the Tricon system from the TriStation software, including Download All and Download Change. Also allows writes to program variables by Modbus masters and external hosts. STOPStops reading inputs, forces non-retentive digital and analog outputs to 0, and halts the application. (Retentive outputs retain the value they had before the keyswitch was turned to STOP.) The STOP setting is recommended for installation and service of process-related equipment, but is not required for service of the Tricon. REMOTEAllows writes to program variables by TriStation, Modbus masters and external hosts. (Download All and Download Change by TriStation are not allowed.)
Mechanical Specifications
These specifications apply to Main, Expansion and RXM Chassis; Power Supply Modules; and other modules where indicated.
Overall Dimensions Chassis Fabrication Approximate Weights Main or Expansion Chassis Power Module Main Processor I/O Module Communication Module 16-point Termination Panel 32-point Termination Panel 24.5 kg. (54.0 lbs.) 3.3 kg. (7.2 lbs.) 2.1 kg. (4.7 lbs.) 2.1 kg. to 2.7 kg (4.7 to 6.0 lbs.) 2.3 kg. (5.0 lbs.) .04 kg. (.09 lbs.) .95 kg. (2.1 lbs.) 48.3 cm x 57.8 cm x 45.1 cm (19" W x 22.75" H x 17.75" D) Black zinc-plated & welded cold-rolled steel
21
Chassis & Mounting Specifications
The Tricon system can be rackmounted or panel-mounted in an industry-standard NEMA enclosure as described on the next page. Cabinets can optionally be equipped with base and casters. Multiple cabinets can be bolted together on the sides, but sufficient clearance must be allowed to fully open their front and rear doors. (Triconex does not recommend shipment of the Tricon system installed in a cabinet unless special provisions are made. Please contact the factory for assistance if shipping in this manner is necessary.)
Slot Covers
All unused slots in a chassis should be filled with Blank I/O Slot Panels (Model 8105) to minimize exposure to dust and other particulate matter.
Heat Management
When mounting Tricon chassis into vented or non-vented enclosures, the integration engineer must make provisions for sufficient heat management. Triconex recommends the installation of baffles (Triconex part number 2000361-001), as shown on page 23. For temperatures above 50C, other heat management provisions must be implemented, such as: Louvers and pagoda top
19.00" 48.3cm Optional location of mounting bracket for rear-rack or panel mounting of unit (2 places) 17.40" 44.2cm
1/4 - 20 threaded chassis ground
Top View of Chassis

Standard location of mounting bracket for front rack mounting of unit (2 places)
16.50" 41.9cm
(use for Rack or Panel Mounting)

21.00" 53.3cm
Enlarged front and rear louvers with raised pagoda top Lower density filters
3.00" R 7.6cm Minimal clearance requirements for communication cables
Redundant fans (running all the time) with appropriate louvers and pagoda top Failure detection circuitry
18.31" 46.5cm
NOTE: Bolt hole spacing on chassis fits standard 19" (48.3cm) rack hole spacing.
Top of Backplane
Top of Backplane
Slotted Clearance for 1/4" Screw (2 places)
Clearance for #10 screw (4 places)
22.75" 57.8cm
14.25" 36.2cm 10.25" 26.0cm 5.50" 14.0cm
Front View for Rack Mounting
Front View for Panel Mounting

13.12" 33.3cm 2.62" 6.7cm
1.50" 3.8cm
Minimum clearance 5.25" (13.3cm), to other equipment & cabinet floor
Minimum clearance 5.25" (13.3cm), to other equipment & cabinet floor
Dimensions and Clearances for Rack and Panel Mounting
22
31.5" (800 mm)
31.5" (800 mm)
31.5" (800 mm)
Field Power Supply
31.5" (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)
Wire Duct
Wire Duct
86.0" (2,200 mm)
Tricon Main Chassis
Baffle
1.75" (44.5 mm) minimum
Tricon Expansion Chassis Tricon Chassis (side view)
16-point Digital Output External Termination Panel 4.5" x 5.0" (114 mm x 127 mm)
3.5" minimum (89 mm minimum)
4.0" minimum (102 mm minimum)
FRONT VIEW
SIDE VIEW
REAR VIEW
Typical Dimensions & 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 Triconex for details.
Mounting Tricon Chassis in Enclosures

Triconex will mount Tricon chassis in any of the industry-standard enclosures listed below. (Please contact Triconex regarding other enclosures, available for additional engineering and documentation charges.) See page 14 for a photograph of Tricon chassis and terminations mounted in a sample enclosure.
Enclosures Typically Supported by Triconex:*

Width Rittal NEMA 12 MarkHon NEMA 1 800 mm (31.5") 800 mm (31.5") 800 mm (31.5") Depth 800 mm (31.5") 800 mm (31.5") 800 mm (31.5") Height 2,200 mm (86.0") 2,000 mm (78.0") 2,160 mm (85.0")
* Other sizes are available. Please contact Triconex for more information.
23
Terminal Strip for Power Module:
(located on backplane above the Power Module)
L N
1
Power Modules
Each Tricon Chassis is equipped with two Power Moduleseither one is fully capable of running the Tricon at full load and rated temperature. Each Power Module can be replaced on-line while the active module acts as a hot spare. The Power Modules, located on the lower left side of the chassis, convert line power to DC power appropriate for all Tricon modules. Terminal strips for system grounding, incoming power and hard-wired alarms are located on the lower left corner of the backplane. Incoming power should be rated for a minimum of 240 watts per power supply.
The Power Module alarm contacts are actuated when: The hardware configuration conflicts with the applications logical configuration A module is missing from the system A module fails A Main Processor detects a system fault Primary power to a Power Module fails A Power Module has a Low Battery or Over Temperature warning
NO C NC L N NO C NC
2
RC
Front Panel of Power Module:

(located on lower left side of chassis)
120 VAC/DC
PASS FAULT ALARM TEMP BATT LOW
Power Module Specifications

Isolation Input Terminations >1000 VAC or 1500 VDC, Input to Output Protected by safety cover Accepts three 12-gauge wires (3.310mm2): neutral, hot, and protective earth (chassis ground) Temperature warning monitortrips when internal temp. is greater than 83C (this typically occurs at ambient temp. 60C or higher) Normally open, normally closed & common Each contact supports 120 VAC @ 1 amp Accepts 12-gauge (3.310mm2) wire Protected by safety cover 240 Watts minimum per Power Module 175 Watts at 60C 6.5 VDC, 1% under all operating conditions 27 amperes maximum at 60C ambient
Over-Temp. Sensor
POWER MODULE MODEL 8310
Alarm Contacts
Input Power Required Output Power Output Voltage Output Current
Power Module Model Chassis Type Nominal Voltage Input VAC @ 47-63 Hz Input VDC Fuse Rating & Type Output Hold Time (nominal to 0 volts) Diagnostic Indicators
8310 Main/Expansion/RXM 120 VAC/VDC 85-140 95-180 5 amperes, time-delay 20 ms minimum PASS, FAULT, ALARM, TEMP, BAT LOW
8311 Main/Expansion/RXM 24 VDC n/a 22-31 15 amperes, time-delay 2.8 ms minimum PASS, FAULT, ALARM, TEMP, BAT LOW
8312 Main/Expansion/RXM 230 VAC 185-285 n/a 2.5 amperes, time-delay 20 ms minimum PASS, FAULT, ALARM, TEMP, BAT LOW
24
Main Processor Modules

Model 3008 Main Processor (MP) modules offer improved performance and greater application memory size compared to earlier Tricon MPs. Three MPs must be installed in the Main Chassis of every Tricon system. Each MP independently communicates with its I/O subsystem and executes the user-written application. Sequence of Events (SOE) and Time Synchronization During each scan, the MPs inspect designated discrete variables for state changes known as events. When an event occurs, the MPs save the variables current state and time stamp in the buffer of an SOE block. If multiple Tricon systems are connected by means of NCMs, the Time Synchronization capability ensures a consistent time base for effective SOE time-stamping. See page 70 for more information. Diagnostics Extensive diagnostics validate the health of each MP, I/O module and communication channel. Transient faults are recorded and masked by the hardware majority-voting circuit. Persistent faults are diagnosed and the errant module is hot-replaced.
Physical DescriptionModel 3008 Main Processor

Feature Main Microprocessor Main Processor Clock Rate Memory MP 3008 Motorola MPC860, 32 bit 50Mhz 16 MB DRAM (non-battery backed-up) 32 KB SRAM, battery backed-up 6 MB Flash PROM Tribus for Voting and Interprocessor Communication 25 Mb/sec 32 bit CRC protected 32 bit DMA, fully isolated Processors on I/O Bus and Communication Bus Motorola MPC860 32 bit 50Mhz for both I/O and Communication bus
MP diagnostics perform these tasks: Verify fixed-program memory and static RAM Test all basic processor and floatingpoint instructions and operating modes Validate user memory by means of the TriBus hardware-voting circuitry Verify the shared memory interface with each I/O communication processor and leg
Verify handshake and interrupt signals between the CPU, each I/O communication processor and leg Check each I/O communication processor and leg microprocessor, ROM, shared memory access and loopback of RS-485 transceivers Verify the TriClock and TriBus interfaces An RS-232 port at the bottom of each MP is used by Triconex personnel for diagnostic analysis.
Indicators on Main ProcessorsModel 3008

PASS FAULT ACTIVE MAINT1 MAINT2 COM TX COM RX I/O TX I/O RX Module has passed self-diagnostic tests Module has a fault and should be replaced Module is executing the user-written application Maintenance indicator 1 Maintenance indicator 2 Transmitting data across COMM bus Receiving data from COMM bus Transmitting data across I/O bus Receiving data from I/O bus
25
Enhanced Intelligent Communication Module
PASS FAULT ACTIVE
ASCII mode. The parallel port provides a Centronics interface to a printer. Each EICM supports an aggregate data rate of 57.6 Kbaud (for all four serial ports). Programs for the Tricon use variable names as identifiers but Modbus devices use numeric addresses called aliases. Therefore an alias must be assigned to each Tricon variable name that will be read by or written to a Modbus device. An alias is a five-digit number which represents the Modbus message type and the address of the variable in the Tricon. An alias is assigned using the Tricon Point Connections window in TriStation. Any standard Modbus device can communicate with the Tricon through the EICM, provided that aliases are assigned to the Tricon variables. Alias numbers must also be used when host computers access the Tricon through other communication modules, such as the NCM. See Communication Capabilities on page 57 for more information.
1TX 1RX
The Model 4119A Enhanced Intelligent Communication Module (EICM) allows the Tricon to communicate with Modbus masters and slaves, TriStation and printers. For Modbus connections, the EICM user can select the RS-232 point-topoint interface for one master and one slave, or the RS-485 interface for one master and up to 32 slaves. The RS-485 network trunk can be one or two twisted-pair wires up to a maximum of 4,000 feet (1,200 meters). Each EICM contains four serial ports and one parallel port which can operate concurrently. Each serial port can be configured as a Modbus master with up to seven Modbus masters per Tricon. A single Tricon system supports a maximum of two EICMs, which must reside in one logical slot. (Hot sparing is not available for the EICM.) Each serial port is uniquely addressed and supports either the Modbus or TriStation interface. Modbus communication can be performed in either RTU or EICM Specifications Model Number
Serial ports Parallel ports Port isolation Protocol Modbus functions supported
Serial Port #1 for Modbus interface
2TX 2RX
3TX 3RX
4TX 4RX
Serial Port #4 for TriStation or Modbus
4119A, Isolated
4 RS-232, RS-422 or RS-485 1, Centronics, isolated 500 VDC TriStation, Modbus 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 1200, 2400, 9600, or 19,200 Baud PASS, FAULT, ACTIVE TX (Transmit) 1 per port RX (Receive) 1 per port
PRT
Parallel Port #5 for Centronicscompatible printer
EICM 4119A
Communication speed Diagnostic Indicators
26
Network Communication Module

With a Model 4329 Network Communication Module (NCM) installed, the Tricon can communicate with other Tricons and with external hosts over 802.3 networks. The NCM supports a number of Triconex proprietary protocols and applications as well as userwritten applications, including those that use TCP-IP/UDP-IP protocol. The NCM provides two BNC connectors as ports: NET1 supports Peer-toPeer and Time Synchronization protocols for safety networks comprised of Tricons only. NET2 supports open networking to external systems using Triconex applications such as TriStation, SOE, SER and DDE Server or user-written applications. See Communication Capabilities on page 57 for more information about Triconex protocols and applications. NCM Specifications Model Number IEEE 802.3 ports
External Transceiver Ports Serial port Port Isolation Protocol Functions supported
Two NCMs can reside in one logical slot of the Tricon chassis, but they will function independently, not as hot spares. External hosts can read or write data only to Tricon variables to which Alias numbers have been assigned. (See Enhanced Intelligent Communication Module on page 26 for more information about Aliases.) The NCM is compatible with the IEEE 802.3 electrical interface and operates at communication speeds up to 10 Mbaud. The NCM connects with external host computers by means of coaxial cable (RG58) at typical distances up to 185 meters (607 feet). Distances up to 4,000 meters (2.5 miles) are possible using repeaters and standard (thick-net or fiber-optic) cabling. The Main Processors typically refresh data on the NCM once per scan.
PASS FAULT ACTIVE
NET 1
BNC Connector for Thin IEEE 802.3 Cable

TX RX
Port #1for Peer-to-Peer & Time Synchronization Only 15-Pin "D" Connector for Self-powered External Transceiver (reserved)
NET 2
BNC Connector for Thin IEEE 802.3 Cable

TX
4329
2, BNC connectors, RG58 50-ohm thin cable 2, 15-pin D connectors 1, RS-232 compatible 500 VDC Tricon System-Access Application Protocol (TCP(UDP)/IP/802.3) TRICON_DATA (Frame Type 1) TRICON_DATA_REQ (Frame Type 2) WRITE_TRICON_DATA (Frame Type 3) WRITE_TRICON_DATA_RSP (Frame Type 4) 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) READ_TRICON_RSP (Frame Type 12) 10 MBaud (for 802.3 ports) PASS, FAULT, ACTIVE TX (Transmit) 1 per port RX (Receive) 1 per port
RX
Port #2for TSAA, External Host Applications (including TRISTATION) & TCP-IP/UDP-IP 15-Pin "D" Connector for Self-powered External Transceiver (reserved)
COMM TX RX
RS-232 Serial Port Reserved for future use
Communication speed Status indicators
NCM 4329
27
Safety Manager Module
PASS FAULT ACTIVE
LOW BATT SPARE RDY UCN A UCN B XMIT
Four-character alphanumeric display for SMM diagnostic codes
A 0 7
STATUS
The Model 4409 SMM acts as an interface between a Tricon controller and Honeywells Universal Control Network (UCN), one of three principal networks of the TDC 3000 Distributed Control System. Appearing to the Honeywell system as a safety node on the UCN, the SMM communicates process information at full network data rates for use anywhere on the TDC 3000. The SMM transmits all Tricon aliased data (including system variables) and diagnostic information to operator workstations in display formats that are familiar to Honeywell operators. The SMM makes the following functions available to the TDC 3000: Handles critical I/O points and passes results to the DCS
Reads/writes aliased data to satisfy DCS requests Reads Tricon diagnostics for display by the DCS Write protection to lock out changes to the Tricon safety system from all TDC 3000 sources Time synchronization from the DCS master clock Peer-to-Peer communication for plants with many Tricon safety systems, each containing an SMM the DCS can use shared data to alert downstream Tricons of significant process changes Sequence of Eventstransmits Tricon event data to Universal Stations for display or History Modules for recording, to help determine the cause of plant trips and increase process up-time Hot spare capability for uninterrupted communication with Honeywell networks
UCN A
F-Connectors for Redundant UCN Ports

UCN B
Processes Tricon alarms and propagates them to user-defined DCS destinations (consoles, printers, etc.) SMM Specifications Model Number
UCN ports UCN data rate Status indicators
4409
2 isolated (AC coupled) 5 MBytes per second PASS (Module Status) FAULT (Module Status) ACTIVE (Module Status) LOW BATT (Low Battery) SPARE RDY (Hot Spare Ready) UCN A (UCN Port A Active) UCN B (UCN Port B Active) XMIT (SMM Transmitting)
DB-25P Connector for RS-232 Debug Port (for Triconex & Honeywell use only)
SMM 4409
STATUS (Module Node & Diagnostic Info.) Power Module load Isolation < 20 Watts 500 VDC
28
Hiway Interface Module

The Model 4509 Hiway Interface Module (HIM) acts as an interface between a Tricon controller and Honeywells TDC 3000 control system by means of the Hiway Gateway and Local Control Network (LCN). The HIM can also interface with Honeywells older TDC 2000 control system by means of the Data Hiway. The HIM enables higher-order devices on the LCN or Data Hiway, such as computers and operator workstations, to communicate with the Tricon. The
HIM allows redundant BNC connections directly to the Data Hiway and has the same functional capacity as four extended Data Hiway Port (DHP) addresses. The HIM provides eight Hiway addresses, implements the same slot structure as the DHP, and typically refreshes all data in less than 0.5 seconds. The hot spare feature allows on-line replacement of a faulty module or continuous backup to an active module.
STATUS LEDs
PASS FAULT ACTIVE
Self-test OK Module Fault Module Active HIM On-line Hiway Interface Call-up Received Channel A Active Channel B Active HIM Transmitting Standy-by Module Inserted Stand-by Module Ready
ON LN H I/F CAL UP CH A CH B XMIT STD BY IN STD BY READY
Data Hiway Channel A

A
HIM Specifications
O
POLL RESPONSE SWITCHES Channel A, Coarse Adjustments
Model Number
Data Hiway channels Poll response switches Baud rate Status indicators
4509
2 isolated (AC coupled) 2 per channel 250 Kbaud PASS (Module Status) FAULT (Module Status) ACTIVE (Module Status) ON LN (HIM On-line) H I/F (Hiway Interface) CAL UP (Call-up Received) CH A (Channel A Active) CH B (Channel B Active) XMIT (HIM Transmitting) STD BY IN (Standby Module Inserted) STD BY READY (Standby Module Ready)
Highway Interface 4509
B A/F O B/C O B/F A/C O
Channel A, Fine Adjustments
Channel B, Coarse Adjustments
Channel B, Fine Adjustments
DB-9P Connector for RS-232 Debug Port (for Triconex use only)
Data Hiway Channel B
Power Module load Isolation
< 10 watts 500 VDC
29
Advanced Communication Module (ACM)
PASS FAULT ACTIVE
Propagates Tricon alarms asI/A Series system messages Reads/writes aliased data to satisfy I/A Series requests Time synchronization from the I/A Series environment Reads Tricon diagnostics for display by the I/A Series workstation Write protection to lock out changes to the Tricon safety system from all I/A Series sources Hot spare capability for uninterrupted communication with the I/A Series Nodebus The ACM also supports the following Triconex protocols and applications on external host PCs connected to a separate BNC port (labeled NET2): Tristation protocol for the TriStation Programming System TSAA protocol for Triconex applications TSAA/TCP(UDP)IP for userwritten applications on external hosts
Interface to I/A Series Nodebus
I/A SERIES NODEBUS

ONLINE SBRDY
TX RX
BNC Connector Reserved

NET1
AUI Connector to DNBI Nodebus Data
DNBI TX RX
The Model 4609 ACM acts as an interface between a Tricon controller and Foxboros Intelligent Automation (I/A) Series system, appearing to the Foxboro system as a safety node on the I/A Series Nodebus. The ACM communicates process information at full network data rates for use anywhere on the I/A Series system, transmitting all Tricon aliased data (including system variables and system aliases) and diagnostic information to operator workstations in display formats that are familiar to Foxboro operators. The ACM makes the following functions available to the I/A Series: Handles critical I/O points and passes results to the I/A Series using the Object Management Database (OMDB) Processes Tricon alarms and propagates them to user-defined I/A Series destinations (consoles, printers, etc.) ACM Specifications Model Number
Nodebus Ports BNC connector 15-pin D connector 9-pin RS-423 connector NET2 port1 9-pin serial ports Port isolation Communication speeds BNC & 15-pin D connectors 9-pin Nodebus connector Status indicators Module status Nodebus/standby activity Port activity Power module load
RS-423 Serial Port to DNBI Nodebus Control
TriStation/TSAA Interface
Node Address Switches
TS/TSAA
0 1234 0 1234
5 678
9 ABC 9 ABC
TX RX
NET2 BNC Connector TriStation, SOE and and TSAA applications
2 TX RX
RS-232/422 Serial Port Reserved

1 TX RX
RS-232 Serial Port Reserved
ACM 4609
30
DEF DEF
NODE ADDRESS
5 678
NET2
4609 1 for RG58 50-ohm thin cable (reserved) 1 for AUI cable to DNBI 1 for Control Bus to DNBI 1 BNC connector for RG58 50-ohm Thin cable to 802.3 network RS-232/RS-485 protocol (reserved) 500 VDC (802.3 & RS-232 ports) 10 Mbaud 2400 baud PASS, FAULT, ACTIVE ONLINE & SBRDY TX & RX1 each per port 20 watts
1. The address for this port is set by the TS/TSAA Node Addresses switches.
RXM Modules
RXM modules and chassis allow I/O modules to be located several kilometers away from the Main Chassis. RXM module sets, consisting of three identical modules, serve as repeaters and extenders of the Tricon I/O bus and provide ground loop isolation. A Primary RXM Module Set supports three remote locations by connecting to three Remote RXM Module Sets housed in remote chassis. See System Configuration on page 11 regarding configurations that use RXMs. RXM sets are available for fiber-optic cables with a communication rate of 375KBaud. These sets provide maximum immunity against electrostatic and electro-magnetic interference, and support configurations with optical modems and fiber-optic pointto-point cabling. Remote sites can be located as far as 7.5 miles (12 kilometers) from the primary site. The figure at right shows uni-directional cabling for three legs of a remote location. For each leg, one cable carries data transmitted from the Primary RXM to the Remote RXM, and the other cable carries data received by the Primary RXM from the Remote RXM. A pair of modules must be wired for each of the three legs, amounting to a total of six cables for each remote location.
PASS PASS PASS PASS PASS PASS
FAULT
FAULT
FAULT
FAULT
FAULT
FAULT
ACTIVE
ACTIVE
ACTIVE
ACTIVE
ACTIVE
ACTIVE
TX
TX
TX
TX
TX
TX
(Receive) RX1 RX1 RX1 RX RX RX
(Receive)
To Remote Location #1
(Transmit)
C
(Transmit)
(Receive) RX2 RX2 RX2
(Transmit)
(Receive)
(Transmit)
RX3
RX3
RX3
RXM 42x0
RXM 42x0
RXM 42x0
RXM 42x1
RXM 42x1
RXM 42x1
Channel A
Channel B
Channel C
Channel A
Channel B
Channel C
Primary RXM Set Located Near Main Chassis
Remote RXM Set at Remote Location #1
Sample Wiring for One Remote Location

NOTE: The selection and installation of fiber-optic cabling requires specialized knowledge, training and tools. Triconex recommends hiring a fiber-optic specialist to handle these tasks.
Specifications for RXM Modules

RXM Model RXM Chassis Location Cable Type Cable Length Limit Connectors Remote Sites Supported Modem Ports Diagnostic Indicators 4200-3 Primary Multi-mode 2 kilometers (1.2 miles) 6/remote site 3 Fiber Optic with ST Connectors PASS, FAIL, ACTIVE, TX, RX1, RX2, RX3 4201-3 Remote Multi-mode 2 kilometers (1.2 miles) 6 n/a Fiber Optic with ST Connectors PASS, FAIL, ACTIVE, TX, RX1, RX2, RX3 4210-3 Primary Single-mode 6/remote site 3 Fiber Optic with ST Connectors PASS, FAIL, ACTIVE, TX, RX1, RX2, RX3 4211-3 Remote Single-mode 6 n/a Fiber Optic with ST Connectors PASS, FAIL, ACTIVE, TX, RX1, RX2, RX3
12 kilometers (7.5 miles) 12 kilometers (7.5 miles)
31
TMR Digital Input Modules
Each TMR Digital Input (DI) Module has three isolated input legs which independently process all data input to the module. A microprocessor on each leg scans each input point, compiles data, and transmits it to the Main Processors upon demand. Then input data is voted at the Main Processors just prior to processing to ensure the highest integrity. All critical signal paths are 100% triplicated for guaranteed safety and maximum availability. Each leg conditions signals independently and provides optical isolation between the field and the Tricon. All TMR Digital Input Modules sustain complete, ongoing diagnostics for each leg. Failure of any diagnostic on any leg activates the modules FAULT indicator which in turn activates the chassis alarm signal. The FAULT indicator points to a leg fault, not a module failure. The module is guaranteed to operate properly in the presence of a single fault and may continue to operate properly with certain kinds of multiple faults. Models 3502E and 3503E can self-test to detect stuck ON conditions where the circuitry cannot tell whether a point has gone to the OFF state. Since most safety systems are set up with a deenergize-to-trip capability, the ability to detect OFF points is an important feature. To test for stuck ON inputs, a switch within the input circuitry is closed to allow a zero input (OFF) to be read by the optical isolation circuitry. The last data reading is frozen in the I/O communication processor while the test is running. All TMR Digital Input Modules support hot spare functionality, and require a separate Field Termination Assembly with a cable interface to the Tricon backplane. Each module is mechanically keyed to prevent improper installation in a configured chassis.
Model Number Type Voltage Points AC Range/DC Range Maximum Voltage Switching Level OFF to ON ON to OFF Nominal Turn-On Typical Hysteresis Input Delay OFF to ON/ON to OFF Point Isolation Nominal Input Impedance Nominal Field Power Load Per ON point @ max. field voltage Diagnostic Indicators Input Status Module Status Stuck Test Color Code
1. For 3501T.
3501E/3501T TMR 115 VAC/VDC 32, non-commoned, isolated 90-155 VAC/VDC 155 VAC/VDC > 86 VAC/VDC < 28 VAC/VDC 6-9 mA 32 VAC/VDC < 8 ms/< 15 ms 1500 VDC/ 2500 > 8.5 K 1.5 Watts 2.9 Watts 1 per point PASS, FAULT, ACTIVE n/a Red VDC1
3502E TMR with Self-Test 48 VAC/VDC 32, commoned in groups of 8 35-95 VAC/VDC 95 VAC/VDC > 32 VAC/VDC < 11 VAC/VDC 6-9 mA 7 VAC/VDC < 8 ms/< 15 ms 1500 VDC > 2.9 K 1.0 Watt 3.2 Watts 1 per point ON Dark Red
3503E TMR with Self-Test 24 VAC/VDC 32, commoned in groups of 8 20-42.5 VAC/VDC 42.5 VAC/VDC > 18 VAC/VDC < 6 VAC/VDC 6-9 mA 4 VAC/VDC < 8 ms/< 15 ms 1500 VDC > 1.25 K 0.5 Watt 1.5 Watt 1 per point ON Dark Red
3505E TMR, Low Threshold 24 VDC 32, commoned in groups of 8 20-42.5 VDC 42.5 VDC > 12 VDC < 4 VDC 3 mA to 5 mA 2 VDC < 8 ms/< 15 ms 1500 VDC > 1.25 K 0.5 Watt 1.5 Watts 1 per point ON Dark Red
PASS, FAULT, ACTIVE PASS, FAULT, ACTIVE PASS, FAULT, ACTIVE
32
64-point Digital Input Modules

Each 64-point Digital Input (DI) Module has three isolated legs which independently process all data input to the module. A microprocessor on each leg scans each input point, compiles data and transmits it to the Main Processors on demand. Then input data is voted at the Main Processors just prior to processing to ensure the highest integrity. All Digital Input Modules sustain complete, ongoing diagnostics for each leg. A failure on any leg activates the modules FAULT indicator which in turn activates the chassis alarm. A TMR module is guaranteed to operate properly in the presence of a single fault and may operate properly with certain kinds of multiple faults. A single
module operates properly in the presence of most faults, but stuck-ON and stuck-OFF faults are exceptions. All Digital Input Modules support hot spares and require a separate Field Termination Assembly with a cable interface to the Tricon backplane. Each module is mechanically keyed to prevent improper installation in a chassis. The Model 3504E High Density Digital Input Module continuously verifies the ability of the Tricon to detect transitions to the opposite state. On this TMR module, all critical signal paths are 100% triplicated for guaranteed safety and maximum availability. Each leg conditions signals independently between the field and the Tricon.
The Single Digital Input Module (Model 3564) is optimized for safetycritical applications where low cost is more important than maximum availability. On single modules, only those portions of the signal path which are required to ensure safe operation are triplicated. Special self-test circuitry detects all stuck-ON and stuck-OFF fault conditions in less than half a second. If a single module detects an input fault, it reports that point as OFF, which may cause a glitch during switch-over to a hot spare.
Model Number Type Voltage Points DC Range Maximum Voltage Switching Level OFF to ON ON to OFF Nominal Turn-On Typical Hysteresis Input Delay OFF to ON/ON to OFF Minimum Point Isolation Nominal Input Impedance Nominal Field Power Load Per ON point @ maximum field voltage Diagnostic Indicators Input Status Module Status Stuck Test Color Code
3564 Single 24 VDC 64, commoned 15-30 VDC 36 VDC > 15 VDC < 6 VDC 2-3 mA 4 VDC < 2 ms/< 2 ms 1500 VDC > 3.0 K 0.2 Watt 0.5 Watts 1 per point PASS, FAULT, ACTIVE ON & OFF Dark Red
3504E TMR 24 or 48 VDC1 64, commoned, DC coupled 20-72 VDC 72 VDC 24 V 48 V >18 VDC >32 VDC < 6 VDC <11 VDC negligible 4 VDC/7 VDC < 10 ms/< 10 ms n/a > 30 K negligible negligible 1 per point PASS, FAULT, ACTIVE ON & OFF Dark Red
1.The voltage is selected using the TriStation software.
33
Pulse Input Module
The Pulse Input (PI) Module provides eight very sensitive, high-frequency inputs. It is optimized for use with nonamplified magnetic speed sensors common on rotating equipment such as turbines or compressors. The module senses voltage transitions from magnetic transducer input devices, accumulating them during a selected window of time (rate measurement). The resulting count is used to generate a frequency or RPM which is transmitted to the Main Processors. The pulse count is measured to 1 microsecond resolution. The PI Module includes three isolated input legs. Each input leg independently processes all data input to the module and passes the data to the Main Processors, which vote on the data to ensure the highest integrity. Each module provides complete ongoing diagnostics on each leg. Failure of any diagnostic on any leg activates the modules FAULT indicator, which in turn activates the chassis alarm signal. The modules FAULT indicator merely indicates a leg fault, not a module failure. The module is guaranteed to operate properly in the presence of a single fault and may continue to operate properly with certain kinds of multiple faults. The Pulse Input Module supports hot sparing, and like all I/O modules, requires a separate Field Termination Assembly with a cable interface to the Tricon backplane. WARNING: The PI Module does not provide a totalization capabilityit is optimized for measuring the speed of rotation equipment. For pulse totalization using model 3515, see page 35.
Relay Output Module

The Model 3636R Relay Output (RO) Module is a non-triplicated module for use on non-critical points which are not compatible with high-side solid-state output switches. An example is interfacing with annunciator panels. The Relay Output Module receives output signals from the Main Processors on each of three legs. The three sets of signals are then voted, and the voted data is used to drive the 32 individual relays. Each output has a loopback circuit which verifies the operation of each relay switch independently of the presence of a load, while ongoing diagnostics test the operational status of the module. Failure of any diagnostic activates the FAULT indicator, which in turn activates the chassis alarm. The Relay Output Module comes with normally open (NO) contacts. It supports hot spare functionality and requires a separate Field Termination Assembly with a cable interface to the Tricon backplane.
Model Number Type Points Voltage Range Current Load Switching Power, Resistive Point Isolation Fuses 3636R Non-triplicated 32, non-commoned 155 VAC/VDC, maximum 2A, maximum Watts maximum 1500 VDC, minimum 1 per output (2.5A fast-acting)
Model Number
Type Input Signals Resolution Accuracy Update Rate Impedance (load) Common Mode Range Normal Mode Range Overrange Protection Hysteresis Wave Shape Duty Cycle Frequency Current Range Diagnostic Indicators (ON=true) Input Status Module Status Color Code
3511
TMR 8, non-commoned 16 bits 1000 Hz to 20,000 Hz, 0.01% 25 ms, typical
Input Characteristics (AC coupled, balanced differential)
> 8 KW, 20 KW typical

-100 VDC to +100 VDC peak-to-peak 1.5 V to 200 V peak-to-peak 150 VDC, continuous 150 millivolts, typical Sine, square, pulse, etc. 10% to 90% 20 Hz to 20,000 Hz 0-20 mA (250-ohm shunt) 1 per point PASS, FAULT, ACTIVE Light Purple
Diagnostic Indicators Output Status Module Status Output Contact Color Code 1 per point PASS, FAULT, ACTIVE Normally Open Silver Blue
34
Pulse Totalizer Module

The Model 3515 Pulse Totalizer Input (PTI) Module provides 32 individual 31-bit counters that each operate independently. The counters are used with active-flow sensors or per-unit sensors to measure a quantity (count) which is transmitted to the Main Processors. At the time specified by the TriStation application, the Main Processors clear a single counter or all counters. Typically, the PTI module is used for batch processes. To avoid counter overflow, the application should clear all counters before starting each batch.
The PTI module has three isolated input channels. Each input channel independently processes all input data and passes it to the Main Processors, where it is voted before processing to ensure the highest integrity. Each PTI module provides complete ongoing diagnostics on each channel, including channel-to-channel count comparison. Failure of any diagnostic on any channel activates the modules FAULT indicator, which in turn activates the chassis alarm. The FAULT indicator points to a channel fault, not a module failure. The PTI module is
guaranteed to operate properly in the presence of a single fault, and may continue to operate with certain kinds of multiple faults. The PTI module can operate with or without a hot-spare module. If you use a hot spare, it re-educates all counter values from the active module.
Model Number Type Number of Input Signals Input Frequency Range Minimum Input Pulse Width Accuracy Active Module Hot-spare module (maximum error counts during hot replacement) Maximum Count Counter Overflow (worst case @ 1 KHz) Count Overflow Indication Count Resets Recommended Input Voltage Range Count Up Switching Level Switching Voltages OFF to ON ON to OFF Typical Hysteresis Normal Turn-on Current Count Input Delay Point Isolation (opto-isolated) Diagnostic Indicators ON or OFF State Module Status Logic Power Nominal Field Power Load Color Code
3515 TMR 32, non-commoned 0 Hz to 1 KHz 300 microseconds 2 counts 110 >= 100 Hz 0-1 <= 100 Hz 2147483647 (231 - 1) 596 Hours (24 days) Count goes to negative integer Individual reset per counter 42.5 VDC absolute maximum Rising edge (OFF to ON) 15 VDC typical, 18 VDC worst case 8 VDC typical, 6 VDC worst case 4 VDC 6mA to 9mA < 15 ms 1500 VDC minimum 1 per point PASS, FAULT, ACTIVE < 10 Watts 0.5 Watts per ON point 1.5 Watts @ maximum field voltage Purple
35
TMR Digital Output Modules
A TMR Digital Output (DO) Module receives output signals from the Main Processors on each of three legs. Each set of three signals is then voted by special quadruplicated output circuitry on the module. The circuitry produces one voted output signal and passes it to the field termination. The quadruplicated voter circuitry provides multiple redundancy for all critical signal paths, guaranteeing safety and maximum availability. Each TMR Digital Output Module has a voltage-loopback circuit which verifies the operation of each output switch independently of the presence of a load and determines whether latent faults exist. Failure of the detected field voltage to match the commanded state of the output point activates the LOAD/FUSE alarm indicator. In addition, ongoing diagnostics are performed on each leg and circuit of a TMR Digital Output Module. Failure of any diagnostic on any leg activates the modules FAULT indicator, which in turn activates the chassis alarm signal. The modules FAULT indicator merely indicates a leg fault, not a module failure. The module is guaranteed to operate properly in the presence of a single fault and may continue to operate properly with certain kinds of multiple faults. All TMR Digital Output Modules support hot spare functionality, which allows on-line replacement of a faulty module or continuous backup to an active module. Each module is mechanically keyed to prevent improper installation in a configured chassis. Like every I/O module, each TMR Digital Output Module requires a separate Field Termination Assembly with a cable interface to the Tricon backplane. Digital outputs are designed to source the current to field devices, so field power must be wired to each output point on the field termination.
Model Number Nominal Voltage Type Output Signals Voltage Range Voltage Drop1 Current Ratings, Maximum Load Leakage Chassis Leakage Fuses (on Field Termination) Point Isolation Diagnostic Indicators ON or OFF state Module Status Field Alarm Color Code
3601E/3601T 115 VAC TMR 16, non-commoned 80-155 VAC < 3V, typical 2A per point 12A surge/cycle 2 mA maximum @ 60 Hz 4 mA maximum @ 60 Hz 1 per output, 3A fast-acting 1500 VDC/ 2500 VDC2
3603E/3603T 120 VDC TMR 16, commoned 90-150 VDC < 1.5V, typical 0.8A per point 4A surge/10 ms 2 mA maximum n/a 1 per output, 1.0A fast-acting 1500 VDC/ 2500 VDC3
3607E 48 VDC TMR 16, non-commoned 44-80 VDC < 3V, typical 1A per point 5A surge/10 ms 2 mA maximum n/a 1 per output, 1.25A fast-acting 1500 VDC
3604E 24 VDC TMR 16, non-commoned 22-45 VDC < 4V, typical 2A per point 10A surge/10 ms 2 mA maximum n/a 1 per output, 2.5A fast-acting 1500 VDC
1 per point PASS, FAULT, ACTIVE LOAD/FUSE Green
1 per point PASS, FAULT, ACTIVE LOAD/FUSE Blue
1 per point PASS, FAULT, ACTIVE LOAD/FUSE Light Blue
1 per point PASS, FAULT, ACTIVE LOAD/FUSE Dark Blue
1. WARNING: The voltage drop may be significantly higher in some applications. 2. For 3601T. 3. For 3603T.
36
16-point Supervised Digital Output Modules

Designed for the most critical applications, Supervised Digital Output (SDO) Modules meet the needs of systems whose outputs remain in a single state for extended periods of time (in some applications, for years). An SDO Module receives output signals from the Main Processors on each of three legs. Each set of three signals is then voted upon by a fully fault-tolerant quadruplicated output switch whose elements are power transistors, so that one voted output signal is passed to the field termination. Each SDO module has voltage and current loopback circuitry coupled with sophisticated on-line diagnostics that
verify the operation of each output switch, the field circuit and the presence of a load. This design provides complete fault coverage without the need to influence the output signal. The modules are called supervised because fault coverage is extended to include potential field problems. In other words, the field circuit is supervised by the SDO Module so that the following field faults can be detected: Loss of power or blown fuse Open or missing load A field short resulting in the load being energized in error A shorted load in the de-energized state
Failure to detect field voltage on any output point energizes the power alarm indicator. Failure to detect the presence of a load energizes the load alarm indicator. All SDO Modules support hot spares and require a separate Field Termination Assembly with a cable interface to the Tricon backplane.
Model Number Nominal Voltage Type Output Signals Voltage Range Maximum Voltage Voltage Drop Power Module Load Current Ratings, Maximum
3623/3623T 120 VDC TMR, Supervised 16, commoned 90-150 VDC 160 VDC < 1.5 VDC, typical < 10 Watts 0.8A per point 4A surge per 10 ms
3624 24 VDC TMR, Supervised 16, commoned 16-30 VDC 36 VDC < 1.5 VDC, typical < 10 Watts 0.7A per point 4.8A surge per 10 ms 30 mA 4 mA maximum n/aself-protecting VDC1 1500 VDC
Minimum Required Load Load Leakage Fuses (on Field Termination) Point Isolation Diagnostic Indicators ON or OFF State Module Status Field Alarm Color Code
1. For 3623T.
30 mA 4 mA maximum 1A fast-acting 1500 VDC/ 2500
1 per point PASS, FAULT, ACTIVE POWER, LOAD (1 per point) Steel Blue
1 per point PASS, FAULT, ACTIVE POWER, LOAD (1 per point) Turquoise Green
37
8-point Supervised Digital Output Modules
Designed for the most critical applications, Supervised Digital Output (SDO) Modules meet the needs of systems whose outputs remain in a single state for extended periods of time (in some applications, for years). An SDO Module receives output signals from the Main Processors on each of three legs. Each set of three signals is then voted upon by a fully fault-tolerant quadruplicated output switch whose elements are mechanical power relays, so that one voted output signal is passed to the field termination. Each SDO module has voltage and current loopback circuitry coupled with sophisticated on-line diagnostics that verify the operation of each output switch, the field circuit and the presence of a load. This design provides complete fault coverage without the need to influence the output signal. The modules are called supervised because fault coverage is extended to include potential field problems. In other words, the field circuit is supervised by the SDO Module so that the following field faults can be detected: Loss of power or blown fuse Open or missing load A field short resulting in the load being energized in error A shorted load in the de-energized state Failure to detect field voltage on any output point energizes the power alarm indicator. Failure to detect the presence of a load energizes the load alarm indicator. When an optional secondary power supply is used, shorted loads in the OFF state can be detected. (This feature is not provided on Model 3611E, an AC module.) All SDO Modules support hot spares and require a separate Field Termination Assembly with a cable interface to the Tricon backplane.
Model Number Nominal Voltage Type Points Voltage Range Maximum Switching Power ON State Voltage Drop1 Current Ratings, Maximum
3611E 115 VAC TMR, Supervised 8, commoned 90-155 VAC 2000 VA (resistive) < 2V, typical 2A per point 10A/AC cycle
3617E 48 VDC TMR, Supervised 8, commoned 36-72 VDC 150 W (resistive) < 2V, typical 1A per point 5A/10 ms 100 mA 5.00 VDC .25 VDC n/a 4 mA max. 1 per output (1.25A fast-acting) 1500 VDC, min.
Minimum Required Load Voltage Range of Secondary Power Supply Chassis Leakage Load Leakage Fuses (on Field Termination) Point Isolation Diagnostic Indicators Output Status Module Status Color Code
50 mA n/a 1mA max. @ 60 Hz 4 mA max. 1 per output (2.5A fast-acting) 1500 VDC, min.
POINT, PWR, LOAD, PASS, FAULT, ACTIVE Deep Green
POINT, PWR, LOAD, PASS, FAULT, ACTIVE Mint Green
1.WARNING: The voltage drop may be significantly higher in some applications.
38
Dual Digital Output Module

The Dual Digital Output (DDO) Modules receive output signals from the Main Processors along a single parallel or series path, and applies a 2out-of-3 voting process individually to each switch. The voting produces one output signal which is then passed to the field termination. While the quadruplicated output circuitry on TMR modules provides multiple redundancy for all critical signal paths, dual circuitry provides just enough redundancy to ensure safe operation. The dual module is optimized for those safety-critical applications where low cost is more important than maximum availability. The Dual Digital Output Modules have a voltage-loopback circuit which veri-
fies the operation of each output switch independently of the presence of a load and determines whether latent faults exist. Failure of the detected field voltage to match the commanded state of the output point activates the LOAD/FUSE alarm indicator. In addition, ongoing diagnostics are performed on each leg and circuit of a Dual Digital Output Module. Failure of any diagnostic on any leg activates the modules FAULT indicator, which in turn activates the chassis alarm signal. A dual module operates properly in the presence of most single faults and may operate properly with some kinds of multiple faults, but stuck-OFF faults are an exception. If one of the output switches has a stuck-OFF fault, the output goes to the OFF state and a
glitch may occur during switch-over to a hot spare. The Dual Digital Output Modules support hot spare functionality, which allows on-line replacement of a faulty module or continuous backup to an active module. Each module is mechanically keyed to prevent improper installation in a configured chassis. Like every I/O module, the Dual Digital Output Modules require a separate Field Termination Assembly with a cable interface to the Tricon backplane. Digital outputs are designed to source the current to field devices, so field power must be wired to each output point on the field termination.
Model Number Nominal Voltage Type Output Signals Voltage Range Maximum Voltage Voltage Drop Power Module Load Current Ratings, Maximum Load Leakage Fuses (on Field Termination) Point Isolation Diagnostic Indicators ON or OFF State Module Status Field Alarm Load Alarm, output stuck-ON Load Alarm, output stuck-OFF Color Code
3664/3674 24 VDC Dual, serial (recommended for de-energize-to-trip applications) 32, commoned 16-30 VDC 36 VDC < 1.5 VDC, typical < 10 Watts 2A per point 10A surge per 10 ms 2 mA maximum n/aself-protecting 1500 VDC minimum 1 per point PASS, FAULT, ACTIVE LOAD/FUSE 3664 Stuck-ON point, all others commanded state - ON or OFF 3674 Stuck-ON point, all others commanded OFF (de-energized) 3664 & 3674 Stuck-OFF point, all others commanded state ON or OFF Dark Blue
39
Analog Input Modules
An Analog Input (AI) Module includes three independent input legs. Each input leg receives variable voltage signals from each point, converts them to digital values, and transmits the values to the three Main Processor Modules on demand. One value is then selected using a mid-value selection algorithm to ensure correct data for every scan. Sensing of each input point is performed in a manner that prevents a single failure on one leg from affecting another leg. Each Analog Input Module sustains complete, ongoing diagnostics for each leg. Failure of any diagnostic on any leg activates the modules FAULT indicator which in turn activates the chassis alarm signal. The modules FAULT indicator merely reports a leg fault, not a module failurethe module can operate properly with as many as two faulty legs. Analog Input Modules support hot spare functionality, which allows online replacement of a faulty module or continuous backup to an active module. The Analog Input Module requires a separate Field Termination Assembly with a cable interface to the Tricon backplane. Each module is mechanically keyed for proper installation in a Tricon chassis.
Model Number Voltage Type No. of Input Points Isolated Points Input Update Rate Resolution Accuracy Input Resistance (load) Power-Off Resistance
3700A 0-5V, + 6% TMR 32, diff, DC coupled No 55 ms 12 bits < .15% of FSR, from 0 to 60C 30 M (DC), min. 30 K (DC), typical
3701 0-10V TMR 32, diff, DC coupled No 55 ms 12 bits < .15% of FSR, from 0 to 60C 30 M (DC), min. 30 K (DC), typical -80 dB (DC-100Hz), typical -12V to +12V peak 200 K, typical -3 dB -17 dB -23 dB 150 VDC/115 VAC continuous 0-20 mA, 500 shunt
3703E 0-5V or 0-10V , + 6% TMR 16, diff, isolated Yes 50 ms 12 bits < .15% of FSR, from 0 to 60C 30 M (DC), min. 30 M (DC), min. -90 dB @ 60Hz, min. -100 dB @ DC, min. +200V peak 20 K, typical -3 dB -17 dB -23 dB 150 VDC/115 VAC continuous 0-20 mA, 250 shunt for 5V 500 shunt for 10V PASS, FAULT, ACTIVE Mustard Yellow
1
3704E 0-5V or 0-10V1*, + 6% TMR 64, commoned No 75 ms 12 bits < .25% of FSR, from 0 to 60C 30 M (DC), min. 30 K (DC), typical n/a n/a 200 K, typical -3 dB -17 dB -23 dB 150 VDC/115 VAC continuous 0-20 mA, 250 shunt for 5V 500 shunt for 10V PASS, FAULT, ACTIVE Copper
Common Mode Rejection -80 dB (DC-100Hz), typical Common Mode Range Leg-to-Leg Isolation Normal Mode Rejection @ 8Hz @ 60Hz @ 120Hz Input Overrange Protection Current Range -3 dB -17 dB -23 dB 150 VDC/115 VAC continuous 0-20 mA, 250 shunt Diagnostic Indicators Module Status Color Code PASS, FAULT, ACTIVE Yellow -12V to +12V peak 200 K, typical
PASS, FAULT, ACTIVE Light Yellow
1.The voltage is selected using the TriStation software.
40
Analog Output Module

An Analog Output Module receives output signals from the Main Processor module on each of three legs. Each set of data is then voted and a healthy leg is selected to drive the eight outputs. The module monitors its own current outputs (as input voltages) and maintains an internal voltage reference to provide self-calibration and module health information. Each leg on the module has a current loopback circuit which verifies the accuracy and presence of analog signals independently of load presence or leg selection. The modules design prevents a non-selected leg from driving an analog signal to the field. In addition, ongoing diagnostics are
performed on each leg and circuit of the module. Failure of any diagnostic deactivates the faulty leg and activates the FAULT indicator, which in turn activates the chassis alarm. This modules FAULT indicator merely indicates a leg fault, not a module failure. The module continues to operate properly with as many as two legs failed. Open loop detection is provided by a LOAD indicator which activates if the module is unable to drive current to one or more outputs. The module provides for redundant loop power sources with individual power and fuse indicators called PWR1 and PWR2. External loop power supplies for analog outputs must be provided by the user. Each Analog
Output Module requires up to 1 ampere @ 24-42.5 Volts. A LOAD indicator activates if an open loop is detected on one or more output points. PWR1 and PWR2 are on if loop power is present. The 3806 High Current (AO) module is optimized for turbo-machinery applications. Analog Output Modules support hot spare functionality, which allows online replacement of a faulty module or continuous backup to an active module. The Analog Output Module requires a separate Field Termination Assembly with a cable interface to the Tricon backplane. Each module is mechanically keyed to prevent improper installation in a configured chassis.
Model Number Type Output current range Number of output points Isolated points Resolution Output Accuracy External loop power (reverse voltage protected) Output loop power requirements Load (Ohms) 250 500 750 1000 Over-range protection Switch time on leg failure Diagnostic Indicators Module status (one each per module) Color code
3805E TMR 4-20 mA output (+6% overrange) 8 No, commoned return, DC coupled 12 bits <0.25% (in range of 4-20mA) of FSR (0-22 mA), from 0 to 60 C +42.5 VDC, maximum +24 VDC, nominal
3806 TMR 4-20 mA & 16-320 mA 6 (4-20 mA); 2 (16-320 mA) No, commoned return, DC coupled 12 bits <0.25% (in range of 4-20mA) of FSR (0-22 mA & 0-352 mA), from 0 to 60 C +42.5 VDC, maximum +24 VDC, nominal Max. load Vx external loop voltage
Loop power required > 20 VDC (1 ampere minimum) > 25 VDC (1 ampere minimum) > 30 VDC (1 ampere minimum) > 35 VDC (1 ampere minimum) +42.5 VDC, continuous < 10 ms, typical 20 VDC 24 VDC 28 VDC 32 VDC
4-20 mA < 275 < 475 < 650 < 825
16-320 mA <15 <25 <40 <50
< +42.5 VDC < 10 ms, typical
PASS, FAULT, ACTIVE, LOAD, PWR1, PWR2 Pea Green
PASS, FAULT, ACTIVE, LOAD, PWR1, PWR2 Light Green
41
Thermocouple Modules
A Thermocouple Input (TC) Module includes three independent input legs. Each input leg receives variable voltage signals from each point, performs thermocouple linearization and cold-junction compensation, and converts the result to degrees Celsius or Fahrenheit. Each leg then transmits 16-bit signed integers representing 0.125 degrees per count to the three Main Processors on demand. A value is then selected using a mid-value selection algorithm to ensure correct data for every scan. Each Thermocouple Module is programmable to support one thermocouple type, selected from J, K and T for standard Thermocouple Modules and from J, K, T and E for Isolated Thermocouple Modules. The Isolated Thermocouple module allows users to select upscale or downscale burnout detection with the TriStation software. For Non-Isolated modules, upscale or downscale burnout detection depends on the Field Termination selected. Triplicated temperature transducers residing on the field termination panel support cold-junction compensation. Each leg of a Thermocouple Module performs auto-calibration using internal precision voltage references. On the Isolated Thermocouple Module, a faulting cold-junction transducer is annunciated by a cold-junction indicator on the front panel. Each module performs complete ongoing diagnostics on each leg. Failure of any diagnostic on any leg activates the modules FAULT indicator, which in turn activates the chassis alarm signal. The modules FAULT indicator merely reports a leg fault, not a module failure. The module continues to operate properly with as many as two faulty legs. The Thermocouple Module supports hot spare functionality for on-line replacement of faulty modules or continuous backup to active modules. Each module is mechanically keyed to prevent improper installation in a configured chassis and requires a separate Field Termination Assembly with a cable interface to the Tricon backplane.
Model Number Type Number of input signals Isolated points Input update rate Thermocouple types supported Accuracy/temp range Input resistance (load) Noise rejection Common mode Normal mode Common mode range Leg-to-leg isolation Input point protection Reference junction compensation range Diagnostic indicators Color code
2
3706A TMR 32 differential, DC coupled No 50 ms, J, K, T See Table A maximum1
3708E TMR 16 differential, isolated Yes 50 ms J, K, T, E See Table B
22 M (DC), typical
-85 dB @ 0-60 Hz, minimum -95 dB @ DC, typical -17 dB @ 60 Hz 10 VDC max. (channel-to-channel or channel-to-ground) 200 K, typical 110 VAC, continuous 0-60C (32-140F) PASS, FAULT, ACTIVE Tan
30 M (DC), minimum
-90 dB @ 0-60 Hz, minimum -100 dB @ DC, minimum -3 dB @ 8 Hz, typical -17 dB @ 60 Hz, typical 200 VDC, max (channel-to-channel or channel-to-ground) 20 K, typical 110 VAC, continuous 0-60C (32-140F) PASS, FAULT, ACTIVE, CJ FAULT Deep Yellow
1.Inputs frozen for 1 second upon insertion of spare module. 2.Must be selected with TriStation.
42
Table A. Accuracy of Thermocouple Types for Model #3706A

Accuracy1 (TC Termination Module @ 32-140F [0-60C]) TC Type J >32 to 2000F (0 to 1093C) -250 to 32F (-157 to 0C) K >32 to 2500F (0 to 1371C) -250 to 32F (-157 to 0C) T >32 to 752F (0 to 400C) 3.0F (1.7C) 5.0F (2.8C) 4.0F (2.3C) 5.0F (2.8C) 6.0F (3.4C) 9.0F (5.0C) 4.0F (2.3C) 6.0F (3.4C) 5.0F (2.8C) 9.0F (5.0C) Temperature Range -250 to 32F (-157 to 0C) Ta = 77F (25C) (Typical) 5.0F (2.8C) Ta = 32-140F (0-60C) (Maximum) 7.0F (3.9C)
Table B. Accuracy of Thermocouple Types for Model #3708E

Accuracy1 (TC Termination Module @ 32-140F [0-60C]) TC Type J >32 to 1400F (0 to 760C) -238 to 32F (-150 to 0C) K >32 to 2284F (0 to 1370C) -250 to 32F (-161 to 0C) T >32 to 752F (0 to 400C) E -328 to 32F (-200 to 0C) >32 to 1830F (0 to 999C) 3.0F (1.7C) 4.5F (2.5C) 8.0F (4.5C) 5.0F (2.8C) 3.0F (1.7C) 7.0F (3.9C) 8.5F (4.8C) 4.0F (2.3C) 5.5F (3.1C) 8.0F (4.5C) Temperature Range -238 to 32F (-150 to 0C) Ta = 77F (25C) (Typical) 3.0F (1.7C) Ta = 32-140F (0-60C) (Maximum) 9.0F (5.0C)
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.
43
44
A termination panel and associated cable pass signals to or from the field, permitting replacement of I/O Modules without disturbing field wiring.
Field Termination Options

There are two general types of field termination products available from Triconex: External termination panels Cables All termination panels and cables are built to withstand harsh industrial environments. The environmental specifications for components used on these products are the same as for a Tricon chassis. (See Environmental Specifications on page 17 for details.) terminal blocks and optional components are mounted to the PCB and enclosed in a plastic housing. A termination panel and associated cable pass input signals from the field directly to an input module, or pass output signals from an output module directly to field wiring. This arrangement permits the removal or replacement of I/O modules without disturbing field wiring.
External Termination Panels

An external termination panel is an electrically-passive printed circuit board (PCB) to which field wiring is easily attached. A panel connector,
Tricon Chassis with External Termination Panels & Standard 10' Cables
45

There are three types of external termination panels, all of which can connect to field signals in a separate enclosure up to 99 feet (30 meters) away from a Tricon: Standard Basic Special Standard Termination Panels Standard termination panels are best for remote marshaling of field wiring where maximum flexibility, high density and simple maintenance is desired. A standard termination panel consists of a PCB with all necessary componentssuch as two-piece terminal blocks, resistors, fuses and blown-fuse indicatorsmounted on a DIN railcompatible plastic housing. The housing snaps into mounting rails in accordance with DIN 50 022. Compression terminals on the standard panel are designed for use with 0.2 mm2 to 2.5 mm2 (24 4 AWG) wiring. Each point can have an optional currentlimiting series resistor, or a fuse with a blown-fuse indicator, to protect the field wiring and field device. Standard termination panels are preconfigured for specific applications. For instance, the thermocouple input termination panel provides cold-junction temperature sensors and can be ordered with upscale, downscale or programmable burnout detection. A standard termination panel for analog voltage inputs provides commoned signal returns, while the current-mode version has a 250-ohm precision resistor at each input point to convert current to voltage. Each standard termination panel is packaged with a matched interface cable that connects the panel to the backplane of a Tricon chassis. A female connector at one end of the cable is keyed to match the male connector on the Tricon backplane. A male connector on the other end of the cable attaches to the standard termination panel. Basic Termination Panels Basic termination panels are a low-cost means of connecting field wiring to a Tricon. However, basic termination panels do not provide any components other than a 56-pin connector and terminal blocks. These two components are mounted on a DIN rail-compatible plastic housing that snaps into mounting rails in accordance with DIN 50 022. The user must provide any other components required by his application. Other features of the basic termination panels are the same as for the standard panels. Special Termination Panels Special external termination panels are used for applications that require external relays, bypass switches, or analog signal conditioners. Special termination panels furnish all the necessary components for the specified application, including a matched cable for connecting to a Tricon chassis. Each special termination panel is designed for rack-mounting and complies with the RS-310-C EIA standard. The following special termination panels are available: External Relay Termination (ERT) panels with interposing relays Bypass panels for digital inputs Termination panels for use with industry-standard analog signal conditioners ERT Panels With Interposing Relays These panels can be used with all digital output modules. Interposing relays are recommended for applications that have load currents greater than 2 amperes, or field voltages greater than 115 VAC which require fieldcircuit conversion or compatibility with motor-starter circuits. Each interposing relay provides an auxiliary contact that can be connected to a Digital Input Module by means of an optional loopback cable to verify relay activation by the digital output module. The ERT panel uses compact general-purpose power relays for maximum reliability. Bypass Panels For Digital Inputs Bypass termination panels can be used to connect digital inputs using a bank of 32 pre-wired switches. The bypass panel has a master keyswitch and terminals for redundant +24 VDC power sources. Each input point contains an ON status indicator and a position for a user-defined label. Each bypass termination panel comes with one or two 10foot cables for connecting the termination panel to a Tricon backplane. Termination Panels For Use With Signal Conditioners Termination panels which use industrystandard analog signal conditioners provide a flexible, user-configurable interface to Resistive Thermal Devices (RTDs), thermocouples, and 4-20mA transmitters. Each termination panel supports 16 points and each Analog Module can support up to 2 panels. These termination panels are compatible with any signal conditioners in the 1V to 5V output range. For example, the 7B series of signal conditioners from Analog Devices are known to work well. These signal conditioners can be purchased from Triconex, or directly from Analog Devices at:
46
http://www.analog.com/IOS 1-800-426-2564 in the USA 781-461-3100 from anywhere in the world
PVC outer covering 56-pin panel connector at one end 50 stranded, stripped, tinned and labeled 22-gauge leads at the other end Special Cables Cables for special applications are not packaged with termination panels and must be ordered separately. For example, if the goal is to verify relay activation by a digital output module, a separate relay loopback cable must be used to connect the relay termination panel to a digital input module. Currently the only special cable available is the External Relay Termination (ERT) Loopback Cable (model #914xxx).
The Termination Options table (on the next two pages) shows the available termination choices for each I/O Module and gives the correct model number for each choice.
Triconex Termination Cables

Three types of separate termination cables are available from Triconex: Standard cables Fanned-out cables Special cables Although the normal length of all cables is 10 feet (3 meters), any length cable can be ordered up to 99 feet (30 meters) in 1-foot increments, using the last two digits of the termination panels model number to specify the length in feet. For example, the model number 9xxx-x50 specifies a 50-foot cable instead of the normal 10-foot cable. Standard Cables Standard cables are packaged with all standard and special termination panels. Each standard cable has a female connector on one end for connecting to the male connector on a Tricon backplane. Fanned-out Cables Fanned-out cables are a lower-cost alternative to using basic termination panels. A fanned-out cable has a female connector on one end that corresponds to a male connector on a Tricon backplane. The other end of the cable provides 50 fanned-out leads, each individually labeled with a pin number that matches the connector signals. Before a fanned-out cable can be installed, the female connector must be re-keyed to match its corresponding male connector on the Tricon chassis. Each fanned-out cable has the following characteristics:
Over-Current Protection
Standard and special termination panels offer over-current protection in various ways: Fuses for individual points and/or field power sources Series resistors Self-protection for Digital Output and Analog Output Modules If standard or special termination panels are not being used, the user must supply his own components for overcurrent protection.
Termination Configuration Options

Terminations are available in various factory configurations: Non-commoned Terminations can accommodate individual power supplies for each point. Commoned Terminations can support one power supply which is shared by multiple points. Points can be commoned in groups of 8 and 16. Analog signals can be read as 3-wire transmitter inputs, voltage inputs or current inputs. Thermocouple terminations provide cold-junction temperature sensors and are available for either upscale or downscale burnout detection. For the Model 3706A, upscale or downscale burnout detection depends on which termination panel is installed. For Model 3708E, upscale or downscale burnout detection is configured with TriStation.
Examples of External Termination Panels

See page 50 through page 52 for illustrations of the following types of External Termination Panels: Basic 16-point Digital Output without Fuses 16-point Digital Output with Fuses 8-point Supervised Digital Output 32-point Analog Input/Digital Input 16-point Analog Input/Digital Input 3-wire Transmitter Analog Input 16-point Thermocouple Input/Analog Input ERT Panel with Interposing Relays RTD/TC/AI Signal Conditioners External Bypass
47

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. The column labeled Points/Panel tells how many points are handled by each termination panel. As an example, a module may have 32 points, but the desired termination panel only handles 16 pointsin such a case, two termination panels are required for one I/O Module. Standard Terminations I/O Type Module DIGITAL INPUT 3501E/T 115 V AC/DC 3502E 48 V AC/DC 3503E 24 V AC/DC 3504E 24/48 VDC Non-Isol. Points/ Panel 16 16 16 32 16 8 32 32 16 16 16 16 16 16 8 8 16 16 16 16 16 16 32 16 8 8 Commoned 9561-810 9562-810 9563-810 9566-810, 24V 9565-810, 48V 9563-810 n/a n/a 9566-710 9661-610 9663-610 9661-910 9664-810 9662-810 9667-810 9661-510 9667-910 9661-910 9664-810 9662-610 n/a 9662-610 9662-610 Upscale 9766-210 9765-610 n/a n/a Non-Com 9561-110 n/a n/a n/a n/a n/a n/a n/a n/a 9661-110 9664-110 n/a n/a 9662-110 9667-110 n/a n/a n/a n/a n/a 9668-110 n/a n/a Downscale 9766-510 9765-610 Other Termination Options Basic Term Fanned-out Panels Cables 9551-110 9552-610 9553-610 9750-410, 24V 9750-310, 48V 9553-610 9753-110 9753-110 9553-610 9651-110 n/a 9651-110 n/a 9653-610 9652-610 n/a n/a 9651-110 n/a 9653-610 9651-110 9653-610 9653-610 n/a n/a 9101-010 9101-010 9101-010 n/a n/a 9101-010 n/a n/a 9101-010 9101-010 n/a 9101-010 n/a 9101-010 9101-010 n/a n/a 9101-010 n/a 9101-010 9101-010 9101-010 9101-010 n/a n/a Special Term. Panels Bypass ERT LoopPanels back Cable n/a n/a BP9228-010 BP9229-010 n/a BP9228-010 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 9141-010 9142-010 9143-010 n/a n/a 9143-010 n/a n/a n/a ERT Panel 9670-610 n/a 9673-810 9673-810 9671-810 9672-810 n/a n/a n/a n/a n/a n/a ERT Panel 9671-810 9671-810 n/a n/a
3505E 24 VDC Low Thresh. 3511 20-20 KHz, Pulse 3515 24 VDC Pulse Totalizer 3564 24 VDC Single DIGITAL OUTPUT 3601E 115 VAC 3601E/T 115 VAC 3603E 120 VDC 3603E/T 120 VDC 3604E 24 VDC 3607E 48 VDC 3611E 115 VAC 3617E 48 VDC 3623 120 VDC 3623T 120 VDC 3624 24 VDC 3636R Relay (Non-triplicated) Dual 3664 24 VDC, Self-Protect. 3674 24 VDC, Self-Protect. THERMOCOUPLE INPUT 3706A J, K, T Differential 3708E E, J, K, T Isolated ANALOG OUTPUT 3805E 4-20mA 3806 4-20mA, 8-320mA ANALOG INPUT 3700A 3701 3703E2 3704E2 0-5 VDC, Differential 0-10 VDC, Differential 0-5/0-10 VDC, Isolated 0-5/0-10 VDC, Non-Isolated
16 16 16 32
n/a 9853-610 n/a 9853-610 Standard Terminations 3-Wire 4-20mA Voltage 2-Wire 4-20mA 9761-210 n/a 9763-810 9771-210, 0-5V n/a 9763-810 9761-410 9762-210, 0-5V n/a 9763-810 9762-410, 0-10V 9771-210, 0-5V 9760-210, 0-5V 9765-210 n/a 9760-410, 0-10V
n/a n/a n/a n/a n/a n/a Other Term. Options Special Basic Termination Panels RTD/TC/AI 9753-110, 0-5V 9753-110, 0-10V 9753-110, 0-5/0-10V 9753-110, 0-5/0-10V 9750-210, 4-20mA 9750-810, 0-5/0-10V 9764-3101 n/a n/a n/a n/a n/a
1. Signal conditioners must be ordered separately. A total of 16 is required for each termination panel. 2. Must be configured with TriStation.
48
Dimensions of Termination Panels

Type of Panel Standard commoned termination (8-point or 16-point) Standard non-commoned termination (16-point) Voltage or 4-20 mA input termination (16-point) Upscale or downscale thermocouple termination (16-point) Standard commoned termination (32-point) 4-20 mA input termination (32-point) Basic termination Width (Across DIN Rail) 4.5 inches 4.5 inches 4.5 inches 4.5 inches 4.5 inches 4.5 inches 3.0 inches Length (Along DIN Rail) 5.0 inches 7.5 inches 5.0 inches 5.0 inches 10 inches 10 inches 5.0 inches
Standard Termination Panels in 16-point & 32-point Styles
49
R6 W3 R7
F7
F8
R8 W4
2 3 4 5 6 7 8 9
TM
CR1
R9 R10 W5
J1
R11 R13 R15 R16 W8 W9 W10

R2
CR2
R14
W7
PS2
R17 R18 R19 R20
R1
SN
REV A
PS1
R12 W6
SN
REV A
R26 W13
SN
R31 R32 W16
7400195-
16
7400166-
REV A
1 2 3 4 5 6 7 A 8 9 10 11 12 13 14 15 16
R24 W12
7400150-
CR3
SN
2 3 4 5 6
R19
R20
Basic Termination Panel for Various Types of I/O Modules
R21
R22
8-point and 16-point Digital Output Termination Panels with Fuses
7 8
Sample Drawings of External Termination Panels
R27
R28
R29
R30
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
F9
R24
R31
R32
7300167-
16-point and 32-point Analog Input/Digital Input Termination Panels
R23
L
R26
L+
R25
SPWR
REV A
50
CR3 W17
J1
CR1
CR2
CR5
CR4
PS1
CR 2
CR 1
PS2
PS1
F1 F2
A
PS2
F3 F4
R1 R2 R3 R4 W1 W2
TL
F5 F6
1
T+
L+
R5
TRICONEX
C E A
DIDO PANEL
F9
F10
R3
R4
R21 R22 W11 R23
10 11 12
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 J1
F11
F12
R5
R6
R25
13 14
R27 R28 W14
F13
F14
R7
R8
R29 R30 W15
15
F15
F16
R9
TR12
T+
R10
L+
R11
R13
R14
CR9
R15
R16
PS1
F1 F2
PS2
F3 F4 CR7 CR8 F5 F6
CR6
J1
SN 7400143REV A
F7
F8
CR2
L
1
L+
J1
R17
R18
F10
F11 CR1 F13 F15
F12 F14 F16
F1
F5
PWR
LOAD
1
2 3
F2 F6
5 6
F4 F8
7 8
9 10 11 12 13 14 15 16
F12 F16 F11 F15 F10 F14 F9 F13
PS1
CR2
PS2
RTN
T+
SN
Standard Non-commoned Termination Panel for Digital Input/Output & Relay Modules
REV A
J1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
RTN J1
T+
RTN
T T+
5 J1
10
11
3-wire Transmitter Analog Input Termination Panel

7400153REV A
12
13
14
15
16
7400171-
REV A
SN
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 RTN T T+
7400172-
CR1
SN
4
F3 F7
16-point Thermocouple Input/Analog Input Termination Panel
51

1
7B14
KK
ANALOG DEVICES
NN
2
7B14
ANALOG DEVICES
3
7B14
ANALOG DEVICES
4
7B14
ANALOG DEVICES
5
7B14
ANALOG DEVICES
6
7B14
ANALOG DEVICES
7
7B14
ANALOG DEVICES
8
7B14
ANALOG DEVICES
9
7B14
ANALOG DEVICES
10
7B14
ANALOG DEVICES
11
7B14
ANALOG DEVICES
12
7B14
ANALOG DEVICES
13
7B14
ANALOG DEVICES
14
7B14
ANALOG DEVICES
15
7B14
ANALOG DEVICES
16
7400225
7B14
ANALOG DEVICES
J1
CR1 C20 CR14
NON-ISOLATED RTD INPUT
S/N
D A
P1 P2 +
U1
J3
U2
U3
U4
J5
U5
U6
U7
U8
J7
U9
U10
U11
U12
J9
U13
U14
U15
U16
REV
J2
C21 C19
J4
J6
J8
J10
RTD/TC/AI External Termination Panel
2 AMP 250V
BLOWN FUSE
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
External Bypass Termination Panel
+ POWER
+ PW1
+ PW2
+ 10
+ 11
+ 12
+ 13
+ 14
+ 15
+ 16 POWER
CR1 CR2
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10 R25 R26 R27 R28 R29 R30 R31 R32
F11
F12
F13
F14
F15
F16
R17 R18 R19 R20 R21 R22 R23 R24 K1 K2 K3 K4

MODEL NUMBER ISOLATED COMMON RACK/CHASSIS/SLOT VOLTAGE REDUNDANT
TRICONEX CORP. ASSY. NO. 7400121-
REV
RELAY EXTERNAL TERMINATOR 1990 SERIAL NO. MADE IN U.S.A. DIGITAL INPUT
DIGITAL OUTPUT
K5
K6
K7
K8
K9
K10
K11
K12
K13
K14
K15
K16
CONTACT
CONTACT
1 NO
2 NO
3 NO
4 NO
5 NO
6 NO
7 NO
8 NO
9 NO
10 NO
11 NO
12 NO
13 NO
14 NO
15 NO
16 NO
External Relay Termination with 16 Interposing Relay Contacts
52
The Tricon controller can interface with Modbus masters and slaves, Distributed Control Systems (DCS), external host computers on 802.3 networks, other Tricons on a peer-to-peer network, and TriStation.
Communication Capabilities
In most process-control applications, there are two systems which monitor and manage the process. One is a Distributed Control System (DCS) and the other is a safety system such as the Tricon controller. These two systems are usually isolated, but share a common operator interface. Distributed Control Systems are designed to allow highly effective communication with the process operator, who must be informed of the state of the process at all times. This is desirable for safety systems as well, but was not feasible in the past because of the type of technology used to implement these systems. Today, the state-of-the-art, microprocessor-based architecture of the Tricon controller supports several modes of communication. Depending on application requirements, the Tricon can interface with: Any Modbus master, including DCS from ABB, Bailey, FisherRosemount and Yokogawa Modbus slave devices Foxboro's Intelligent Automation (I/A) Series Nodebus Honeywells Universal Control Network (UCN) Honeywells Data Hiway and Local Control Network (LCN) External host computers on IEEE 802.3 (Ethernet) networks Other Tricons in a peer-to-peer, TV-certified network A TriStation programming workstation
Networking with Modbus

The Enhanced Intelligent Communication Module (EICM) supports the industry-standard Modbus protocol over a serial link. Most suppliers of operator workstation software (PCbased or mini-computer-based) support Modbus RTU and ASCII protocol, as
Proprietary Network
Redundant Proprietary Network
Tricon 1
M M M P P P A B C N C M 1 N C M 2 M M M P P P A B C N C M 1 N C M 2
Tricon 2
M M M P P P A B C N C M 1 N C M 2
Tricon 3
Redundant Open Network Open Network Redundant PC for Host Application, SOE or TriStation
Host Application
SOE PC
TriStation
Communication with Modbus Master and TriStation 57
do most DCS vendors, by means of a network-bridging device. Because the EICM can operate as a Modbus master, slave or both, the productivity of the Tricon can be expanded in a low-cost manner for noncritical I/O. When the EICM operates as the master, it can control slave devices such as annunciators, bypass switches on non-critical PLCs, or other Tricons. When the EICM operates as a slave, a computer on the network is the masterthis can be a DCS, an operator workstation, or any general-purpose computer programmed to support Modbus devices. EICM users can select the RS-232 point-to-point interface for one master and one slave, or the RS-485 interface for one master and up to 32 slaves. The RS-485 network trunk can be one or two twisted-pair wires up to a maximum of 1,200 meters (4,000 feet). While the EICM is appropriate for many applications, Triconex offers alternate communication methods when fast response time or a large amount of data throughput is required.
Triconex Protocols Peer-to-Peer Time Synchronization TriStation Tricon System Access Application (TSAA) Protocols for User-written Applications Modbus RTU and ASCII TCP-IP/TCP-UDP Triconex Applications Sequence of Events Network DDE Server TriStation Programming Systems X X X X X X X X X X NCM X X X X ACM X X EICM X
Protocols and Applications for Networking NOTE

See page 26, page 27, and page 30 for network port usage on the EICM, NCM and ACM.
Networking with Ethernet

The Tricon system supports IEEE 802.3 networking by means of NET2 on both the Network Communication Module (NCM) and the Advanced Communication Module (ACM). Both of these modules support Triconex applications, user-written applications, and open networking with external systems by means of TCP-IP/UDP-IP protocol. In addition, the NCM supports the Triconex Peer-to-Peer and Time Synchronization protocols on its NET1 port. The table above lists the protocols and applications that can be used with the NCM, ACM and EICM respectively.
1
To maximize safety, the Tricon system offers module, media and workstation redundancy. Module/media redundancy is achieved by installing two NCMs (or ACMs) in the same logical slot and connecting their network nodes with two sets of cables. This arrangement permits continuous operation in case of broken cables, intermittent cable connections, port failures or NCM/ACM failures. External host redundancy is obtained by connecting a spare external host machine to the network. If the primary host fails, it can be shut down and the application restarted on the spare host. All Triconex applications use IBMcompatible PCs as external hosts, so all of the applications could be loaded on the primary and spare hosts without requiring any other PCs. Triconex Protocols A protocol is a set of rules for exchanging data between two or more devices. In a peer-to-peer protocol, any device on the network can initiate a data transfer operation. In a master/slave protocol, only the master can initiate a
data exchange. Triconex has developed one Peer-to-Peer protocol and three master/slave protocols (Time Synchronization, TriStation, and TSAA) to support different types of applications. All of the following Triconex protocols support a maximum of ten Tricons on a proprietary network. Peer-to-Peer Peer-to-Peer protocol allows Tricons to exchange small amounts of safety and process information on the proprietary network. For information about using the Peer-to-Peer SEND and RECV functions in applications, see the TriStation 1131 Developers Guide. Time Synchronization Time Synchronization is a master/slave protocol used to maintain a consistent time base for all Tricons connected to each other by means of NCMs. TriStation The TriStation protocol is a master/slave protocol in which the master (the TriStation PC) communicates with the slave (Tricon) over an 802.3 network. Although the TriStation
58
protocol supports a maximum of ten Tricons, the master can communicate with only one slave at a time. TSAA The Tricon System Access Application (TSAA) protocol is a master/slave protocol in which the master (the external host) communicates with one or more slaves (Tricons) over an open network. TSAA specifies the interfaces, commands and data structures used to develop application programs that send and receive data to and from Tricon systems. Protocols for Open Networks Customers who write their own applications using TSAA can use any of these transport, data link and physical layers depending on performance and reliability requirements: TCP/IP/802.3 UDP/IP/802.3 802.2/802.3 TSAA, along with the lower-level protocols, can be used to develop the following types of applications for open networks: Control (read/write) applications such as an operator interface that requires access to Tricon status and the ability to write data to the Tricon
Monitor (read only) applications such as a Sequential Events Recorder, Event Logger or status display that retrieves data from the Tricon Triconex Applications Triconex offers several applications for 802.3 networks, all of which use an IBM PC-compatible system as the external host. These applications are briefly described in the table below. The Tricon controller offers considerable flexibility and functionality in the area of data communication, and can readily be configured to match application requirements. Triconex is continually striving to advance the state of the art in safety systems. High-speed, redundant network communication is another example of that commitment.
formats that are familiar to Foxboro operators. The ACM makes the following functions available to the I/A Series: Handles critical I/O points and passes results to the I/A Series Processes Tricon alarms and propagates them to user-defined I/A Series destinations (consoles, printers, etc.) Propagates Tricon alarms as I/A Series system messages Reads/writes aliased data to satisfy I/A Series requests Enables time synchronization from the I/A Series environment Reads Tricon diagnostics for display by the I/A Series workstation Provides write protection to lock out changes to the Tricon safety system from all I/A Series sources Provides hot spare capability for uninterrupted communication with the I/A Series Nodebus The ACM also supports these Triconex protocols and applications on external host PCs connected to a separate BNC port (that is, NET2): TriStation protocol for the TriStation Programming System TSAA protocol for Triconex applications
Foxboro's Intelligent Automation Series System

Triconex offers the Advanced Communication Module (ACM) for tightlyintegrated interfacing with Foxboro's Intelligent Automation (I/A) Series Nodebus. The ACM communicates process information at full network data rates for use anywhere on the I/A Series system, transmitting all Tricon aliased data and diagnostic information to operator workstations in display
Name of Application Sequence of Events (SOE)
Brief Description Retrieves events (state changes of discrete variables) from up to ten Tricons on a network. For system maintenance and shutdown analysis. Allows Windows DDE client applications like Excel, InTouch, etc. to read and write Tricon aliased data. (Runs under Windows NT.) Allow the user to write and download applications for the Tricon, display system status, monitor program execution, and perform maintenance operations.
TSAA/TCP(UDP)IP for userwritten applications on external hosts
Network DDE Server Interface
TriStation Programming Systems
Triconex Applications 59
Honeywells TDC 3000 DCS
Triconex offers the Safety Manager Module (SMM) and the Hiway Interface Module (HIM) for tightly-integrated interfacing with various networks of the TDC 3000 DCS. The SMM is used solely for communication with the Universal Control Network (UCN), one of three principal networks of the TDC 3000. Appearing to the Honeywell system as a safety node, the SMM communicates process information at full network data rates for use anywhere on the TDC 3000. The SMM transmits all Tricon aliased data and diagnostic information to operator workstations in display formats that are familiar to Honeywell operators. The SMM makes the following functions 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 The HIM interfaces with the TDC 3000 by means of the Hiway Gateway and Local Control Network (LCN). The HIM can also interface with Honeywell's older TDC 2000 control system by means of the Data Hiway. Using the HIM, higher-order devices on the LCN or Data Hiway (such as computers and operator workstations) can communicate with the Tricon. Both the SMM and the HIM offer the hot spare capability for uninterrupted communication with Honeywell networks.
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Easy-to-use developer's workbench allow users to develop, test and document process-control applications for the Tricon.
TriStation 1131 Developer s Workbench

The TriStation 1131 Developer's Workbench is an integrated tool for developing, testing and documenting safety and critical-process control applications for the Tricon programmable logic controller. The programming methodology, user interface and selfdocumentation capabilities make the system superior to traditional and competing engineering tools. TriStation is compliant with Part 3 of the IEC 1131 International Standard for Programmable Controllers with defines programming languages. The TriStation software runs under Microsofts Windows NT operating system and follows the Microsoft Windows graphical user interface guidelines. Any PC that is compatible with the NT operating system can be used for TriStation. The pages that follow describe key TriStation features and the basic elements of TriStation projects. (CEM) methodology. Throughout the process control industry, CEMs are often used to define alarms, emergency shutdown, and mitigation actions. To support the Tricon controller, TriStation supplies the following editors and tools: Tricon Configuration Editor Emulator Control Panel Tricon Control Panel Tricon Diagnostic Panel Using these editors and tools, the user can: Create programs, function blocks and functions Define the I/O module configuration Declare tagnames for input/output points Declare program instances Connect program instance inputs & outputs to tagnames
Functional Overview
TriStation provides three editors to support the following IEC 1131-3 languages: Function Block Diagram Ladder Diagram Structured Text The Workbench also provides the Cause & Effect Matrix Programming Language Editor (CEMPLE) that Triconex developed to support the widely used Cause & Effect Matrix
Overview of TriStation 1131 Components
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Test and monitor program execution with the emulator Download and monitor program execution in the Tricon Monitor the Tricon system status and diagnose faults
Elements of a TriStation Project

A TriStation project contains all the elements required to implement a safety or control application in a Tricon controller. Some of these elements are automatically included in every project by TriStation, while others are created by the user. Programs A program is the highest-level executable logic element within a TriStation project. It is an assembly of programming language elements (function blocks, functions, data variables) that work together to allow a programmable control system to achieve control of a machine or process. Each program is uniquely identified by a user-defined type name. One TriStation project supports multiple programs. Function Blocks A function block is a logic element which yields one or more results and is uniquely identified by a user-defined type name. To use a function block in a program, an instance of the function block type must first be declared. Each instance is identified by a user-defined instance name. All the data associated with a specific instance of a function block is retained from one evaluation of the function block to the next. Functions A function is a logic element which yields exactly one result and is uniquely identified by a user-defined type name. Unlike the function block, the data associated with a function is not Sample Logic in FBD, ST and LD Languages
retained from one evaluation of the function to the next. Functions do not have to be instanced. Data Types A data type defines the size and characteristics of variables declared in a program, function or function block. Examples of data types are BOOL, DINT and REAL. Shared Libraries Shared libraries contain predefined function blocks and functions that can be used to develop programs as well as other function blocks and functions. TriStation provides three shared libraries to every project: IEC 1131-3 Standard Library the standard set of function blocks and functions defined by the IEC 1131-3 Standard Triconex Library a set of Triconex function blocks and function that can
be used with any Triconex programmable controller Tricon Library A set of function blocks and functions that are specifically implemented for use with the Tricon controller Users may also develop their own shared libraries and import them to other TriStation projects. Configuration The configuration defines which program elements will be instanced for downloading to the controller as well as which Tricon points (tagnames) each instance will access.
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Programming Languages
Function Block Diagram (FBD) A graphical language that corresponds to circuit diagrams. FBD elements appear as blocks that are wired together, to form circuits. The wires transfer binary and other types of data between elements. Structured Text (ST) A high-level, textual programming language, that is similar to PASCAL. ST allows users to create Boolean and arithmetic expressions, as well as programming structures such as conditional (IFTHENELSE) statements. Functions and function blocks may be invoked in ST. Ladder Diagram (LD) 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.
Sample CEM from a TriStation Project Cause & Effect Matrix Programming Language Editor (CEMPLE) A high-level graphical language that provides a two-dimensional matrix in which the user can easily associate a problem in a process with one or more corrective actions. The problem is known as the cause and the action as the effect. The matrix associates a cause with an effect in the intersection of the cause row and the effect column. CEMPLE is the worlds first automated implementation of CEM, a methodology that is commonly used throughout the process-control industry and readily understood by a broad range of plant personnel. CEM diagrams are automatically translated into IEC 11313 compliant Function Block Diagrams, thereby eliminating the risks associated with manual translation from handdrawn CEMs.
Tricon Configuration Editor

The Tricon Configuration editor is used to define which programs will be instanced for downloading to the Tricon controller as well as which Tricon points (tagnames) each instance will access. In addition, the editor allows the user to configure the chassis and I/O modules required by the application. The editor features a split-view window whose left view contains a hierarchical configuration tree. The right view displays information about the item that is currently selected in the
Declaring Tagnames with the Tricon Configuration Editor
63
Emulator Control Panel with Instance View of FBD Logic tree. Four major editing functions are used to define the configuration of a Tricon system: Hardware Configuration Through a graphical interface, the user configures the chassis and I/O modules to be used in the application. TriStation automatically allocates any memory required by the module. Tagname Definition Allows the user to manually or automatically declare tagnames and other properties for I/O points and aliased or non-aliased memory points. Program Instance Declaration Allows the user to instance each program that will be downloaded to the Tricon controller and assign a unique identifier to each instance. A program may be instanced more than once. 64 Program Instance Variable Connections Allows the user to connect (associate) each input variable and output variable in a program instance with a Tricon I/O or memory point. Commands may be selected to run, single-step, or halt program execution. Another control panel feature is a splitscreen instance view (shown above) which displays the values of annotated variables while the project is running. Tricon Control Panel The Tricon Control Panel provides the same features as the Emulator Control Panel except that it allows connection to the Tricon controller for real-time execution. Tricon Diagnostic Panel The Diagnostic Panel allows a user to monitor the status of chassis and modules in the Tricon system and diagnose faults. The panel also provides system performance information including the project name & version,
Tools for the Tricon Controller

Emulator Control Panel The Emulator Control Panel allows a user to connect to the emulator and download the project for testing and debugging. The panel features a data tree that lists the variables for all program instances. Testing and monitoring is achieved by dragging the desired variables from the tree on the left to the monitor sheet on the right and changing the variable values as desired.
memory size, scan time and current execution state.
Password Security TriStation provides a security system that defines users and their privileges with regard to editing, library changes, Tricon state changes and other operations. Project History An audit trail function is provided to document the history of a project and its program version changes. This detailed log keeps track of user actions and comments by automatically timestamping critical events within a session and manually logging user comments on demand.
Help System TriStation features an easy-to-use online help system which provides detailed information about developing and managing applications in TriStation. Extensive help is provided on using the various editors, libraries and control panels. The help system also includes information about the Tricon platform, IEC 1131-3 language reference, a how-to section describing common tasks, a question-and-answer section, and a list of error messages along with cause-and-solution explanations.
Other Key Features

Reports & Documentation TriStation offers multiple methods of sorting data and documenting project elements, both during and after project development. Printouts of user-developed function blocks and programs can be obtained on a variety of userselected engineering drawing templates. A number of standard reports are available to document the project configuration data. Users can also create customized reports with Crystal Reports or any other dBASEcompatible report generator.
Sample TriStation 1131 Report
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CEMPLE is the Triconex automated implementation of the traditional CEM methodology that has been used by process control engineers for decades.
CEM Programming Language Editor

Cause and Effect Matrix (CEM) is a methodology that is commonly used in the process control industry to define alarms, emergency shutdown strategies, and mitigation actions. For decades, process control engineers have used manual methods such as graph paper and spreadsheet programs to identify problem conditions and corrective actions. Automatic conversion of matrix to Function Block Diagram language Customized view monitoring of active causes, intersections, and effects Multiple levels of undo and redo editing Matrix As the major component of the CEM Editor, the Matrix identifies the parts of associated with causes, effects, and intersections. The Matrix can also include functions or function blocks related to causes, effects, and intersections.
CEM Editor Automated CEM Called CEMPLE

The traditional CEM method is timeconsuming and subject to errors caused by misinterpretation of the matrix or inaccurate coding. Triconex has automated the CEM process with the Cause and Effect Matrix Programming Language Editor, referred to as CEMPLE. CEMPLE enables a cause and effect matrix to be used as the basis for a TriStation program.
Matrix
FBD Network
The FBD Network displays the Function Block Diagram (FBD) related to the cause, intersection, or effect that is selected in the matrix. It can also be used to specify properties and to invert values for variables. The FBD network uses internal boolean variables to save and move results to
The CEM Editor includes the following components as shown in the figure below: Matrix FBD Network Variable Detail Table
CEMPLE Features
CEMPLE includes the following features: Ability to specify up to 99 causes, 99 effects, and 1,000 intersections Ability to invoke functions and function blocks to evaluate cause, intersection, and effect states
FBD Network
Variable Detail Table
CEM Editor Components
67
CEM Programming Language Editor

variable values based on the state of an effect, and using time delays. User-created functions and function blocks, must be created and enabled for use before they can be included in a matrix.
Instance View
Active Areas Shown in Red
Testing and Monitoring

Like all TriStation programs, a matrix can be tested and debugged off-line using the Emulator Control Panel. After the project is downloaded, the Control Panel can be used to monitor the values of variables during real-time execution. In an instance view of a matrix, active causes, intersections, and effects can be viewed in a choice of colors. As with other types of executable elements, values and variables can be set for use during emulation and real-time execution.
Instance View of a Matrix associated cells so that causes and effects can be evaluated. For each cause, effect, and intersection, an internal variable is automatically created to store and move results between cells. sections between them. The state of a cause (true or false) determines the state of the related effect. If more than one cause is related to an effect, the state of the effect is based on how the matrix is evaluated. The effect state can be determined in either of two ways: by a logical AND operation or by a logical OR operation on the intersection. A logical AND is typically used for de-energize to trip systems; a logical OR is typically used for energize to trip systems.
CEMPLE Tools
A matrix can be developed and edited using a variety of graphical interface methods. Commands can be selected from a main menu, toolbar, and pop-up menu. Variables can be added or renamed by making changes in the Variable Detail Table. Where appropriate, drop-down lists provide variable names or function and function block names. For more information, see the CEMPLE Users Guide for Triconex Systems.
Variable Detail Table

The Variable Detail Table displays the inputs and outputs of the FBD Network that are generated when a cause, effect, or intersection is selected. The variable type and data type can also be specified from the Variable Detail Table.
Using Functions and Function Blocks

For more complex processes, CEMPLE enables functions and function blocks to be added to causes, effects, and intersections. This feature can be used for many purposes such as; evaluation of process input to determine the cause state, calculating one or more process
Developing a Matrix
A matrix created in CEMPLE can be as basic or complex as the situation requires. In a basic matrix, causes are identified as true or false inputs related to one or more effects through the inter68
During each scan of the TriStation project, the Main Processors examine selected discrete variables for state changes known as events.
Sequence of Events (SOE) Capability

(for TriStation 1131)
Understanding the sequence of events that leads to unsafe process conditions and possible shutdowns may be essential to a safety application. To help collect and analyze these events, Triconex control systems offer integrated SOE functionality using the TriStation 1131 Developers Workbench and SOE Recorder. SOE Recorder is a program that runs on a Windows NT Workstation. SOE Recorder allows the user to: Collect and analyze event data Print reports with event data Export event data to dBASE IV files Triconex SOE capability can be used with various communication modules to collect events. For systems using an ACM or NCM, SOE Recorder can be used. For systems using an ACM or SMM, a DCS application can be used. information about the event variable from the SOE definition file. The following tasks are completed in TriStation: Defining SOE blocks with buffer size and block types Assigning event variables to the SOE blocks Adding SOE function blocks to the program logic Types of Event Variables The types of discrete variables that can be designated as event variables are: BOOL input BOOL aliased memory variables Configuring SOE Blocks An SOE block is a data structure that resides in the memory of a controllers Main Processors. When SOE blocks are configured, the event variables to be detected by the controller are specified for each block. The maximum individual block size is 20,000 events, with 60,000 events for all blocks. The block size is the amount of memory that the Main Processors reserve for recording of events. When a block is collecting events, the Main Processors write an event entry which includes the values of event variables that changed during the current scan and a time stamp.
Preparing Your System for Event Collection

To enable the controller to detect events, event variables and SOE blocks are identified in the TriStation project. In addition, the project must include an SOE function block that starts the event collection. After an SOE-enabled project is downloaded to the controller, TriStation creates an SOE definition file that contains the SOE block definitions. When the SOE Recorder collects an event from the controller, it obtains the tagname, alias, state name, and other
M M M P P P A B C
Tricon 1
N C M 1 N C M 2 M M M P P P A B C N C M 1 N C M 2
Tricon 2
M M M P P P A B C N C M 1 N C M 2
Tricon nn
SOE Data Retrieval PC
TriStation 1131
Tricon Network with SOE Recorder 69
Sequence of Events (SOE) Capability (for TriStation 1131)

SOE Function Blocks SOE function blocks control and verify event collection for SOE blocks. The following function blocks are available: SOESTRT starts event collection SOESTOP stops event collection SOESTAT checks status of SOE blocks SOECLR clears status of SOE blocks The SOESTRT function block must be added to the TriStation program to identify the SOE blocks from which events are to be collected. The other SOE function blocks are optional.
SOE Events File
viewing the properties of individual events
SOE Recorder
SOE Recorder can simultaneously collect event data from as many as 32 networked controllers. It queries all the controllers on the network to determine which downloaded TriStation projects include SOE blocks. If a project includes one or more SOE blocks, then SOE Recorder opens the appropriate SOE definition file and begins collecting events from the associated controller. While the TriStation project is running, SOE Recorder can be used to analyze events online as it collects them from the controllers. Snapshots of events that cover specific periods of time before or after trips have occurred can also be saved. To analyze the event data, SOE Recorder includes tools for the following tasks: Finding events and copying them to other Windows applications Filtering and sorting saved event data Specifying the display of point properties for event data
SOE Recorder also allows event data to be exported to dBASEIV or ASCII text files, either manually or automatically. A report engine and standard report are included. Trip Processing A trip is a shutdown of the controlled process, or a portion of the controlled process. A TriStation project used for safety shutdown typically includes one trip variable, whose state change initiates the shutdown activities. If a project requires several variables related to trip conditions, these variables must be evaluated in combination to determine the final state of the trip variable. When a trip event occurs, SOE Recorder can automatically create a trip snapshot. This snapshot is a file of events that occurred x minutes before a trip and y minutes after a trip, based on TriStation settings. Time Synchronization and Time Stamps In a typical peer-to-peer network, the controllers synchronize their time with the master node (the controller with the
lowest node number) within 25 milliseconds. A controller recognizes events on a scan basis and time-stamps each event at the beginning of the scan. Because the scans of the various controllers on the network are not synchronized, the same event can be logged by two controllers with different time stamps. The worst-case difference is the longer scan time plus 25 milliseconds. Each day, SOE Recorder compares its clock with the clock of each controller from which event data is being collected. If a controllers clock is out of sync by more than five minutes, a message is displayed in the SOE message bar. For more information about SOE Recorder, see the SOE Recorder Users Guide.
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Appendix A Hardware Requirements for TriStation and SOE
The PC selected for use with the TriStation 1131 Developers Workbench or the SOE Data Retrieval Application must meet the following minimum requirements: Windows NT certified personal computer Pentium microprocessor, 233 MHz minimum Microsoft Windows NT Version 4.0 (Service Pack 5) 128 Mbyte RAM 125 Mbyte free hard disk space CD-ROM drive SVGA monitor (17-inch, 1024 x 768 resolution, 65535 colors recommended) NT-certified Ethernet adapter card
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Glossary
alias A five-digit number that the Tricon uses in place of a variable name when communicating with an external host. The alias is a convention of Modbus, an industry-standard protocol adopted by Triconex for use with its communication modules. Each alias contains a Modbus message type and the address of the variable in the Tricon. availability The probability that the control system is operational at some instant of time. bin An address range of aliased variables in the Tricon system, based on Class and Type combinations. For example, all Read Only Input Discrete variables are grouped into Bin 2, and all Read/Write Memory Integer variables are grouped into Bin 12. board See module. card See module. cause (CEMPLE) In CEM methodology, a cause is a problem to be solved by the matrix. CEM (CEMPLE) Acronym for Cause & Effect Matrix. CEM is a twodimensional matrix for the development of safety applications, where causes are represented by rows and effects are represented by columns. CE Mark A type of certification by the European Union which ensures the electro-magnetic compatibility of the Tricon with other pieces of electrical/electronic equipment. CEMPLE A language editor in the TriStation 1131 Developer's Workbench that allows you to develop CEMs for safety shutdown applications. communication modules Modules that enable the Tricon controller to communicate with host computers. Triconex offers communication modules which use IEEE 802.3, TCP/IP or Modbus protocol. configuration The arrangement of the programmable electronics within a Tricon and the combination of programmable and nonprogrammable equipment within the installation. control system The system which governs the operation of plant, machinery or other equipment by producing appropriate instructions in response to input signals. DDE Dynamic Data Exchange (DDE) is an interprocess communication mechanism provided by Microsoft Windows. Applications running under Windows can use DDE to send and receive data and instructions to and from each other. debug The act of locating and correcting faults: 1) one of the normal operations in software development such as editing, compiling, debugging, loading, and verifying; or 2) the identification and isolation of a faulty physical component, including its replacement or repair to return the PLC to operational status. effect (CEMPLE) In CEM methodology, an effect is an action that must be taken to solve a cause (problem) event A state change of a discrete aliased variable which has been designated for event logging. An event is said is to occur if such a variable changes from the normal state. If the variable later changes back to the normal state, another event is said to have occurred. event logger A utility that logs, displays and/or prints critical events in real time, based on state changes of discrete variables in the user-written application. Proper use of an event logger warns users about dangerous conditions and printouts of
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events can help identify the sequence of events that led to a trip. event variable A discrete memory variable or discrete input point that has been assigned to an SOE block. fault tolerance The ability to identify and compensate for failed control system elements and allow repair while continuing an assigned task without process interruption. Fault tolerance is achieved by incorporating redundancy and fault masking. host See external host. hot spare A unique feature of the Tricon which allows you to install spare I/O modules with automatic switchover to the spare in case the primary module fails. I/A Series DCS The acronym for Foxboros Intelligent Automation (I/A) Series Distributed Control System. The Tricons Advanced Communication Module (ACM) acts an interface between the Tricon and the IA DCS. IEEE The Institute of Electrical and Electronics Engineers (IEEE) is a professional society for engineers. input poll time The time required by the Tricon controller to collect input data from the controlled process. Input polling is asynchronous and overlaps execution of the user-written application. instance view (TriStation 1131) A feature of the Emulator Control Panel and Tricon Control Panel which displays the values of annotated variables while a TriStation 1131 project is running. In an instance view, the user can change the values of variables during emulation or real-time execution. intermittent fault A fault or error that is only occasionally present due to unstable hardware or varying software states.
intersection (CEMPLE) A cell in a matrix where a Cause Row intersects an Effect Column. intersection function (CEMPLE) A function or function block that may be selected from a drop-down list in the Intersection cell of a Cause Row and an Effect Row. ISO The International Organization for Standardization (ISO) is a worldwide federation of national standards bodies (ISO member bodies) that promulgates standards affecting international commerce and communications. logical slot In a Tricon chassis, a logical slot is a repository for a primary module, a hot spare module, and their associated field termination component. Markov model A generalized modeling technique which can be used to represent a system with an arbitrary number of modules, failure events, and repair events. A Markov model can be mathematically solved to produce a resultant probability. matrix (CEMPLE) 1. A CEM program 2. A traditional methodology for ESD applications which associates a problem (cause) in a process with one or more actions (effects) that must be taken to correct the problem. module An active field-replaceable unit consisting of an electronic circuit assembly housed in a metal spine. Also called board or card. MS-DOS Microsoft Disk Operating System (MS-DOS) is the operating system used by most IBM-compatible PCs. All Triconex-provided applications and utilities run on MSDOS. MTBF The acronym for Mean Time Between Failure. The expected average time between failures of a system, including the time taken to repair the system. Usually expressed in hours.
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MTTF The acronym for Mean Time To Failure. The expected average time to a system failure in a population of identical systems. Usually expressed in hours. MTTR The acronym for Mean Time To Repair. The expected time to repair a failed system or subsystem. Usually expressed in hours. node Any of the machines on a networkin this document, node usually means Tricon. node number The physical address of a node. open network A network to which an external host can be connected. output poll time The time required by the Tricon controller to implement the outputs generated by the user-written application in response to inputs from the controlled process. peer-to-peer A protocol that allow multiple Tricons on a proprietary network to exchange small amounts of process and safety information. program 1. The set of instructions, commands, and/or directions that define the Tricons output signals in terms of input signals. 2. The act of creating such a set of instructions using the relay ladder language of the TriStation programming system. protocol A set of rules describing the format used for data exchange between two entities. reliability The probability that no failure of the system will have occurred in a given period of time. scan time The period of the Tricon controllers cycle of required control functions. The scan time is composed of three elements: Input poll time (asynchronous with execution of the user-written application)
The time required to execute the user-written application Output poll time system Consists of a set of components which interact under the control of a design. TCP/IP Transmission Control Protocol/Internet Protocol (TCP/IP) are protocols for the Transport and Network layers of the OSI network model. TCP/IP provides reliable, sequenced data delivery. transient fault A fault or error resulting from a temporary environmental condition. TMR The acronym for Triple-Modular Redundant architecture, which allows the Tricon to achieve fault tolerance. The complete system is triplicated; each of the three identical systems is called a leg. Each leg independently executes the user-written application in parallel with the other legs. Tricon A state-of-the-art programmable logic and process controller that provides a high level of fault tolerance. trip A safety-related shutdown of the controlled process, or a portion of the controlled process. TriStation 1131 A Windows-NT based application for writing and downloading user-written applications and for performing maintenance and diagnostics on Version 9.1 and later Tricon systems. TriStation protocol A master/slave protocol used by a TriStation for communication with the Tricon. The Tristation protocol supports a maximum of 10 Tricons, but each master can communicate with only one slave at a time. TSAA Tricon System Access Application (TSAA) protocol is a master-slave protocol in which the master (an external host) communicates with one or more slaves (Tricons or TriconLites) over an open network. TSAA supports a maximum of 10 Tricons.
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TV Rheinland TV is the acronym for Technischer berwachungsVerein in German, which translates to Technical Supervisory Association. In Germany, TV Rheinland is an authorized technical inspection agency for a wide variety of products, processes, installations, plants and equipment. In addition, the agency is authorized to carry out statutory inspections and acceptance tests by more than 25 other countries. UCN The Universal Control Network (UCN) is one of three principal networks of Honeywells TDC 3000 Distributed Control System (DCS). The Tricon provides the Safety Manager Module (SMM) solely for communication with the UCN. UDP/IP User Datagram Protocol/Internet Protocol (UDP/IP) are protocols for the Transport and Network layers of the OSI network model. UDP/IP provides best-effort datagram delivery. voting A mechanism whereby each leg of a TMR system compares and corrects the data in each leg using a twoout-of-three majority voting scheme.
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Emergency Shutdown Systems

Burner Management Systems

Fire and Gas Protection Systems

Technical Product Guide

Triconex Part No. 9791007-006, January 2001

The Tricon is a fault-tolerant controller based on a Triple-Modular Redundant (TMR) architecture.

What is the Tricon?

What are Typical User Applications?

What about Communication Capabilities?

Main Processor Modules

Voter Output Termination

Bus Systems and Power Distribution

+3.3 Volts +5 Volts

DIAG Read (DB25) Up Stream Down Stream

802.3 Network (RJ-45) Modbus (DB9)

Reserved for future use

Diag Bus (to other MPS)

Main Processor MPC860A

I/O & COMM Processor MPC860A

Fault Tolerant I/O Bus 375Kb

Shared Memory 128K

COMM Bus 2Mb 32-Bit Bus

Up Stream TriBus (to other MPS) Up Stream

Down Stream Down Stream

Main Processor (Model 3008) Architecture 4

ELCO Connectors for I/O Termination

Term inal Strip #1

Term inal Strip #2

Channel A Channel B Channel C

Channel A Channel B Channel C

M ain P rocessors A, B, & C

Right I/O Module * Left I/O Module * Communication Module

Typical Logical Slot

Digital Input Modules

INTELLIGENT I/O CONTROLLER(S) Intelligent I/O Controller(s)

TRIPLICATED I/O BUS

Dual Port RAM B

Optical Isolation Threshold Detect Opto-Isolator Input Mux OptoIsolator

Dual Port RAM

Individual Point Field Termination

Dual Port RAM

Digital Output Modules

Architecture of TMR Analog Input Module 6

TRIPLICATED I/O BUS

INTELLIGENT I/O CONTROLLER(S) A

FIELD CIRCUITRY TYPICAL POINT (16)

Output Switch Drive Circuitry

Analog Input Modules

Loopback Detector RTN

* All output switches are opto-isolated.

Analog Output Module

DCS Bus TRICON Chassis DCS Operator Workstation

TS/TSAA Connection 802.3 Network Programming Workstation Modbus Master

* The module in this slot is a generic module representing any

alarm alarm alarm alarm alarm

alarm alarm alarm alarm alarm

Communication Capabilities of Tricon Modules

Architecture of Power Subsystem 9

Sample Layout of a Tricon Chassis

I/O Bus Connections

On-Line Module Repair

I/O Bus Ports

Tricon Chassis, Front View