Category: Triconex

Fault Tolerance

Fault tolerance, the most important capability of the Tricon controller, is the ability to detect

transient and steady-state error conditions and to take appropriate corrective action online.

With fault tolerance, there is an increase in safety and an increase in the availability of the

controller and the process being controlled.

The Tricon controller provides fault tolerance through Triple Modular Redundant (TMR)

architecture. The controller consists of three identical system channels, except for the Power

Modules which are dual-redundant. Each channel independently executes the control program

(also referred to as the TriStation application) in parallel with the other two channels. Hardware

voting mechanisms qualify and verify all digital inputs and outputs from the field; 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 occurs in one channel, the faulty channel is overridden by the

other channels. Repairs consist of removing and replacing the failed module in the faulty

channel while the Tricon controller is online and without process interruption. The controller

then reconfigures itself to full TMR operation.

Extensive diagnostics on each channel, module, and functional circuit immediately detect and

report operational faults by means of indicators or alarms. The diagnostics also store

information about faults in system variables. If faults are detected, the operator can use the

diagnostic information to modify control actions or direct maintenance procedures.

Because the triplicated system operates as one control system, the Tricon controller can be

programmed with one control program that terminates sensors and actuators at a single wiring

terminal.

Controller Features

The Tricon controller is a state-of-the-art programmable logic and process controller that

provides a high level of system fault tolerance. To ensure the highest possible system integrity

at all times, the Tricon controller includes these features:

• Provides Triple Modular Redundant (TMR) architecture whereby each of three

identical system channels independently executes the control program, and specialized

hardware/software mechanisms “vote” all inputs and outputs.

• Withstands harsh industrial environments.

• Enables field installation and repair to be done at the module level while the controller

remains online. Replacing an I/O module does not disturb field wiring.

• Supports up to 118 I/O modules (analog and digital) and optional communication

modules that interface with Modbus masters and slaves, Foxboro® and Honeywell™

Distributed Control Systems (DCS), other Triconex controllers in Peer-to-Peer

networks, and external host applications on Ethernet networks.

• Provides integral support for remote I/O modules located as far away as 7.5 miles

(12 kilometers) from the Main Chassis, using SRXM modules.

• Executes control programs developed and debugged with TriStation™ 1131

Developer’s Workbench Software or TriStation MSW software.

• Provides intelligence in the input and output modules to reduce the workload of the

Main Processors. Each I/O module has three microprocessors. Input module

microprocessors filter and debounce the inputs and diagnose hardware faults on the

module. Output module microprocessors supply information for the voting of output

data, check loopback data from the output terminal for final validation of the output

state, and diagnose field-wiring problems.

• Provides integral online diagnostics with adaptive-repair capabilities.

• Allows normal maintenance while the Tricon controller is operating, without

disturbing the controlled process.

• Supports transition to a hot-spare I/O module for critical applications where prompt

service may not be possible.

Architecture Overview

The TCMI is part of the TPS/TPN product lines as shown in Figure 1.  TCMI is connected to the EUCN and

provides interface with the supplied by Schneider Electric Tricon Safety System. TCMI doesn’t required CF9

switch for FTE network connection and can be directly connect with level 2 switch, firewall features is in-built

into TCMI.

Functional Overview

The TCMI performs the same functions as the Honeywell Safety Manager Module (SMM) in the Tricon, but

across the EUCN.

The TCMI converts Triconex data to EUCN data types (Tag. Parameter), performing engineering unit

conversion, alarm handling, annunciation, diagnostic status reporting, and EUCN communication functions.

The standard TCMI scan cycle is 0.5 second.

Operator and application access to TCMI is executed by use of the Local Control Network (LCN) and the

Enhance Network Interface Module (ENIM).

The TCMI Module database is configured from the TPN Native Window environment using the TPN Data

Entity Builder. Once loaded into the TCMI node, this TCMI configuration data can be saved on the History

Module, and downloaded over the EUCN to the TCMI. The ladder logic program for the Triconex TRICON™

is developed using the Triconex TRISTATION workstation. Once loaded in the memory of the TRICON™

Enhanced main processors, the control programs are saved in the TRISTATION database, which can save

multiple ladder logic programs under separate file names. In addition to integration of Triconex system data

points into standard TPN/TPS operating/engineering environment, some additional maintenance displays

have been created to provide TRICON™ diagnostic information.

The TCMI connects directly to an Ethernet port of the Tricon Communication Module (TCM) in the Tricon

Safety Manager. The TCM implements the TSAA communication protocol on Ethernet networks for

communication with the Tricon controller. TSAA Protocol is a messaging protocol used in application programs

that read and write data to the Triconex controllers and is utilized by the TCMI.

The TCMI requires the use of a pair (two; one-part number 4351A and one part number 4351B) of TCMs in

the Triconex system. The TCMs connecting to the TCMI must reside in a single Triconex System logical slot

and shall occupy the left and right module physical slots (which comprise a single logical slot). At least 1 port

on each of the TCMs is required to configure a redundant TCMI pair. If empty ports are not available in existing

installed TCMs, then new TCMs must be installed.

Note: Up to four logical slots can be configured for TCMs. Matched pairs of TCMs can be installed in the left

and right positions of each logical slot.

For detailed specifications and technical data on the Triconex TRICON™ version 10.3 and version 11.x system

and TCM interface hardware, please refer to Triconex documentation.

Product Introduction

Triconex Communication Interface Module (TCMI)

The TCMI is a standard Honeywell product that provides interface between the Fault Tolerant Ethernet (FTE)

based Enhanced Universal Control Network (EUCN) and Triconex TRICON Safety Manager System.

The TCMI is a redundant device capable of:

• Bi-directional communication with Triconex systems 10.3 and above.

• Execution of data mapping of TRICON memory tables to EUCN format

• Data conversion to EUCN data types (Tag. Parameter), engineering unit and EUCN communication

functions.

• Execution of read and write function to TRICON memory tables

• Definition of signal alarm conditioning and messaging on the EUCN for alarm handling, annunciation

and diagnostic status reporting

• Direct peer-to-peer communication with other EUCN connected devices as Enhanced High

Performance Process Managers (EHPM), Enhanced Logic Managers (ELMM) or Honeywell Safety

Manager (SM)

• Communication with operators, engineers, and maintenance personnel at the Universal Stations, ES

T & ESVT via ENIM.

• Support of higher level strategies through communication with Application Modules and host

computers on the Local Control Network via ENIM.

• Database restoration of TCMI Module from the History Module via ENIM.

• Available in two hardware mounting form, front and rear cabinet access mounting (MC-ZTCMIR or

MC-TCMIR1), Front only cabinet access mounting (MC-ZTCMI2 or MC-TCMIR2)

Product Description

The Triconex CM3201S2 Communication Module is a highly reliable and efficient

component of the Triconex safety and control systems, specifically designed 

for industrial automation and critical processes.

It ensures seamless communication between the Triconex controllers and various field devices,

enabling high-speed data transfer and improved system integration.

This module adheres to rigorous safety and performance standards,

making it an ideal choice for industries requiring maximum uptime and precise control.

The Triconex CM3201S2 communication module is a workhorse for exchanging critical data within safety instrumented systems (SIS).

Function: Enables seamless communication between SIS components and external devices.

Applications: Ideal for process industries demanding high reliability and performance.

Key Features:

High-Density Digital I/O: Handles 32 digital channels for efficient data exchange.

Supports Industry Standards: Communicates via protocols like Ethernet, ControlNet, and DeviceNet.

Robust Design: Built for harsh industrial environments, operating from -40°C to 70°C.

Technical Specifications:

Form Factor: Compact design for easy integration into existing systems.

Power Supply: 24 VDC for compatibility with typical industrial control systems.

Networking Speeds: Supports Ethernet (100 Mbps), ControlNet (10 Mbps), and DeviceNet (5 Mbps).

Models 3502E, 3503E, and 3505E can perform a self-test to detect a “stuck-open” condition

in which the circuitry is unable to determine whether a point has entered a shutdown state.

The ability to detect the point of shutdown is an important feature

since most security systems have a power failure trip feature.

In order to detect the presence of a “stuck-open” input,

the switch within the input circuit needs to be turned off in order for the opto-isolated circuit to read a zero input (“off”).

The I/O communications processor will freeze the last reading while the test is running.

All TMR digital input modules support the hot standby feature and require a separate

external termination panel (ETP) with cable connections to the Tricon backplane.

Each module is mechanically keyed to prevent improper installation in the configured chassis.

PHYSICAL SPECIFICATIONS

Size

31.50 in (800 mm) width, 15.75 in (400 mm) depth,

47.24 in (1200 mm) height

Weight Range

300 to 350 lb. (136 to 159 kg) (depending on

configuration)

ENVIRONMENTAL SPECIFICATIONS

Operating Temperature

WITHOUT INTERNAL FANS–4° F to 113° F (–20° C to 45° C)

WITH INTERNAL FANS–4° F to 131° F (–20° C to 55° C)

Contaminant Severity Level

ELECTRONICS

ISA-71.04. G3 level

ENCLOSURE

UL 50E and ASTM B117

Relative Humidity

Certifications

FM (U.S. and Canada), ATEX, IECEx, CCCex, CE,

UKCA, RoHS 2. NEMA 4X/IP66

Hazardous Area Classification

Class I, Division 2. Groups A, B, C, D; T4

ATEX and IECEx Zone 2 and Zone 22

II 3 G Ex ec nC dc IIC T4 Gc

II 3 D Ex tc IIIC T80°C Dc

China Zone 2 and Zone 22

Ex dc ec nC IIC T4 Gc

Ex tc IIIC T80°C Dc

I/O BUS CONNECTION

The SIE supports a TMR I/O bus connection with

special interface modules:

 Triconex 4701X IMSS – Serial RS-485

Distances up to 100 ft (30 m)

 Triconex 4703X IMFF – Fiber

Distances up to 43.5 mi (70 km)

When using 4703X IMFFs, customers select and

procure small form-factor pluggables (SFPs) to meet

their specific needs. For more information, see “Small

Form-Factor Pluggable (SFP) Requirements” in the

Tricon CX Addendum to Tricon User Guides.

PHYSICAL SPECIFICATIONS

Size

31.50 in (800 mm) width, 15.75 in (400 mm) depth,

47.24 in (1200 mm) height

Weight Range

300 to 350 lb. (136 to 159 kg) (depending on

configuration)

FEATURES

 Protection against hazardous locations and harsh environments:

• Class I, Division 2 (U.S. and Canada)

• ATEX and IECEx Zone 2 and Zone 22

• China Zone 2 and Zone 22

• NEMA® 4X/IP66 rated

• Corrosion resistance:– Electronics: ISA-71.04. G3 level– Enclosure: UL 50E and ASTM B117

 Support for up to four Triconex 3902AX/3902X UIO Modules

 Input/output types that are software configurable

 Support for up to 64 TMR I/O points

 Wall-mounted

 Available in 24 VDC, and 120/240 VAC incoming power options

 Redundant power supplies

 Redundant fans (available with no fans)

 Supports star and daisy chain network topologies for the I/O bus

POWER DISTRIBUTION ARCHITECTURE

The SIE uses two independent 24 VDC power

sources to operate. One set of dual redundant power

supplies provides logic power to the I/O chassis and

another set of dual power supplies provides power to

the field instruments. This redundant power

architecture provides protection against a single power failure.