TRICONEX 3005

Description

1. Product Description

2. Product Parameters

Parameter	Specification
Processor Architecture	Triple Modular Redundancy (TMR) with three independent 32-bit microprocessors
Memory	256 MB RAM, 512 MB Flash (expandable for application code)
Communication Interfaces	Ethernet (10/100 Mbps), RS-485, Serial (for programming and diagnostics)
Clock Speed	200 MHz per processor core
Redundancy Support	Built-in self-diagnosis and automatic failover between processors
Operating Temperature	-40°C to +70°C
Safety Certifications	IEC 61508 (SIL 3), IEC 61511 (SIS), API 615, CE, UL
Dimensions	8.5” (H) x 5.2” (W) x 10.8” (D)
Power Supply	24V DC (±10%) from TRICONEX power modules

TRICONEX 3005

3. Advantages and Characteristics

• Triple Modular Redundancy (TMR): The 3005’s unique TMR design ensures high availability by voting on results from three independent processors, eliminating single points of failure. This architecture achieves a hardware fault tolerance (HFT) of 1, making it suitable for SIL 3 applications.
• Real-Time Performance: With a deterministic execution cycle as low as 10 ms, the module handles time-critical control tasks, such as emergency shutdown systems (ESD) and turbine control.
• Advanced Diagnostics: Built-in self-test (BIST) functions continuously monitor processor health, memory integrity, and communication links, providing diagnostic coverage (DC) exceeding 99%. This reduces mean time to detect (MTTD) faults and enables predictive maintenance.
• Scalability: Supports up to [X] I/O modules per rack, allowing flexible system expansion for small to large-scale applications.
• Cyber-Security Features: Includes secure boot and encrypted firmware updates to protect against unauthorized access and ensure system integrity.

4. Application Areas and Cases

• Application Areas:
  • Safety Instrumented Systems (SIS) in oil refineries and LNG plants.
  • Power plant boiler control and turbine protection systems.
  • High-reliability manufacturing lines in automotive and pharmaceutical industries.
• Application Case: A major chemical plant integrated the TRICONEX 3005 into its SIS to manage critical reactor safety interlocks. The module’s TMR architecture prevented production downtime during a single processor fault, as the system automatically switched to the redundant processors without interrupting operations. Additionally, its real-time diagnostics identified a potential memory issue before it escalated, allowing scheduled maintenance and avoiding an estimated $1.2 million in unplanned downtime costs.

5. Competitor Comparison

Compared to single-processor or dual-redundant controllers, the TRICONEX 3005 offers superior fault tolerance and safety integrity due to its TMR architecture. Unlike non-SIL-certified alternatives, it guarantees compliance with the highest functional safety standards, making it a preferred choice for applications where system failure risks severe safety or environmental consequences. Its seamless integration with TRICONEX’s ecosystem of I/O modules and software tools also provides a more cohesive and optimized solution compared to mixed-vendor systems.

TRICONEX 3005

6. Selection Recommendations

• Safety Requirements: Confirm that the module’s SIL 3 certification aligns with your application’s safety integrity level (SIL) and risk assessment.
• Processing Needs: Evaluate the complexity of control logic and required cycle times. The 3005 is suitable for medium to high complexity applications; consider higher-end TRICONEX models for ultra-complex systems.
• System Compatibility: Ensure compatibility with existing TRICONEX racks, power supplies, and I/O modules. Verify communication protocols (e.g., Modbus, OPC UA) for integration with supervisory control and data acquisition (SCADA) systems.
• Future-Proofing: Account for potential system upgrades, such as adding remote I/O or expanding control loops, by selecting a module with adequate memory and scalability.

7. Precautions

• Installation:
  • Install the module in a grounded TRICONEX rack with proper electrostatic discharge (ESD) protection.
  • Avoid exposing the module to direct sunlight, moisture, or extreme vibrations; use anti-vibration mounts if necessary.
• Firmware Management:
  • Use only TRICONEX-approved firmware versions and follow the manufacturer’s update procedures to prevent compatibility issues.
  • Back up configuration files before firmware updates to restore functionality in case of interruptions.
• Maintenance:
  • Regularly review diagnostic reports via the TRICONEX software to monitor processor health and identify early signs of degradation.
  • Schedule annual inspections to clean dust from the module’s heatsinks and verify secure connections in the rack.
  • When replacing the module, ensure all power sources are disconnected and follow hot-swap procedures if applicable (consult TRICONEX documentation for specifics).