TRICONEX 3624

Description

1. Product Description

2. Product Parameters

Parameter	Specification
Module Type	Digital Input Module (DIM) for safety-critical systems
Input Channels	32 isolated channels, 24 VDC nominal
Redundancy	Triple Modular Redundancy (TMR) with 2-out-of-3 voting logic
Voltage Range	16–30 VDC (input), 24 VDC (nominal)
Input Current	5 mA per channel (typical)
Isolation	1,500 VDC between channels and ground
Response Time	< 5 ms (typical for signal acquisition)
Operating Temperature	-40°C to +70°C (storage: -40°C to +85°C)
Humidity	5%–95% non-condensing
SIL Certification	SIL-3 (IEC 61508), suitable for safety-critical applications
Compatibility	TRICONEX Tricon CX, EX, and legacy systems; integrates with SCADA and DCS
Power Consumption	< 15 W (maximum under full load)

TRICONEX 3624

3. Advantages and Characteristics

• Triple Modular Redundancy (TMR): The TRICONEX 3624’s TMR architecture with 2-out-of-3 voting logic ensures that the module can continue operating even if one channel fails, achieving a mean time between failures (MTBF) exceeding 500,000 hours. This reduces the risk of erroneous signal acquisition by up to 90% compared to non-redundant modules.
• SIL-3 Safety Compliance: Certified to the highest safety integrity level, the module is ideal for applications where fault tolerance is critical, such as ESD systems in oil refineries or turbine protection systems in power plants.
• Hot-Swap Capability: Faulty modules can be replaced while the system is operational, minimizing downtime during maintenance. In a petrochemical plant case, this feature allowed technicians to replace a faulty channel in under 15 minutes without interrupting process control, safeguarding against potential production losses.
• Rugged Environmental Performance: Designed to operate in extreme temperatures and high-vibration environments, the TRICONEX 3624 has been proven reliable in offshore platforms and heavy manufacturing facilities, where it withstands conditions such as -40°C cold snaps and 5g vibration levels.

4. Application Areas and Application Cases

• Industry Applications:
  • Oil & Gas: Monitors emergency shutdown switches, valve position indicators, and fire detector signals in upstream and downstream facilities.
  • Chemical Processing: Acquires discrete signals from safety interlocks, batch process switches, and reactor status sensors.
  • Power Generation: Supports turbine overspeed protection, generator breaker status monitoring, and boiler safety switches.
• Case Study:
  A large chemical plant in Southeast Asia integrated the TRICONEX 3624 into its SIS to monitor over 200 discrete input signals from safety valves and interlocks. The module’s TMR technology and real-time diagnostics detected a faulty channel during normal operation, allowing the system to automatically bypass the faulty channel while maintaining full signal integrity. This prevented a potential safety incident and ensured continuous compliance with international safety standards.

5. Competitive Comparison

Compared to similar digital input modules, the TRICONEX 3624 stands out for its combination of SIL-3 certification, TMR redundancy, and high channel density. While some alternatives offer basic fault tolerance, few match its ability to handle safety-critical applications with 32 isolated channels in a compact form factor. Its advanced diagnostics and hot-swappable design also reduce maintenance complexity, making it a preferred choice for industries where signal accuracy and system availability are paramount.

TRICONEX 3624

6. Selection Recommendations

• System Compatibility: Ensure the module is compatible with your TRICONEX control system (e.g., Tricon CX, EX) and backplane configuration. Verify software versions and communication protocols to avoid integration issues.
• Signal Requirements: Confirm that the module’s input voltage (24 VDC nominal) and isolation specifications match the output of your field devices, such as proximity switches or limit switches.
• Environmental Needs: If installing in harsh environments (e.g., offshore, high-temperature zones), ensure the module’s temperature and vibration ratings align with your site conditions.
• Redundancy Strategy: For critical applications, pair the TRICONEX 3624 with redundant power supplies and communication networks to maximize system availability.

7. Precautions

• Installation: Power down the system and use anti-static wrist straps during installation to prevent electrostatic discharge (ESD) damage. Securely fasten cables to minimize electromagnetic interference (EMI) and ensure proper grounding.
• Configuration: Use TRICONEX’s approved software tools (e.g., Tristation 1131) to configure voting logic and channel parameters, ensuring alignment with your safety loop requirements.
• Maintenance: Regularly review the module’s diagnostic status via the control system interface to monitor channel health. Schedule firmware updates to incorporate the latest safety patches and performance optimizations.
• Troubleshooting: In the event of a channel fault, replace the module during a planned maintenance window or while the system is in hot-standby mode to avoid disrupting operations.