TRICONEX 3636R

Description

1. Product Description

2. Product Parameters

Parameter	Specification
Module Type	Relay Output Module (ROM) for safety-critical systems
Output Channels	16 isolated channels (SPDT relays)
Redundancy	Triple Modular Redundancy (TMR) with 2-out-of-3 voting logic
Switching Voltage	DC: 24 VDC (16–30 VDC); AC: 125 VAC (90–132 VAC)
Switching Current	2 A per channel (continuous), 5 A surge (10 ms)
Contact Rating	50 VA (DC), 125 VA (AC)
Isolation	1,500 VDC between channels and ground
Response Time	< 10 ms (switching on/off)
Operating Temperature	-40°C to +70°C (storage: -40°C to +85°C)
Humidity	5%–95% non-condensing
SIL Certification	SIL-3 (IEC 61508)
Compatibility	TRICONEX Tricon CX, EX, and legacy systems; integrates with SCADA and DCS
Power Consumption	< 20 W (maximum under full load)

TRICONEX 3636R

3. Advantages and Characteristics

• Triple Modular Redundancy (TMR): The TRICONEX 3636R’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 unplanned shutdowns caused by relay failures 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 chemical plant case, this feature allowed technicians to replace a faulty relay channel in under 15 minutes without interrupting production, safeguarding against potential losses of $100,000 per hour.
• Rugged Environmental Performance: Designed to operate in extreme temperatures and high-vibration environments, the TRICONEX 3636R has been proven reliable in offshore platforms and heavy manufacturing facilities, withstanding conditions such as -40°C cold snaps and 5g vibration levels.
• Enhanced Diagnostic Coverage: Real-time monitoring of relay contact wear, coil voltage, and channel status provides early warning of potential failures, reducing mean time to repair (MTTR) by 50%.

4. Application Areas and Application Cases

• Industry Applications:
  • Oil & Gas: Controls emergency shutdown valves, pump starters, and compressor interlocks in upstream wellheads and downstream refineries.
  • Chemical Processing: Manages reactor safety interlocks, batch process actuators, and safety-critical valve operations.
  • Power Generation: Supports turbine protection systems, generator circuit breakers, and boiler safety relays in thermal and nuclear power plants.
  • Manufacturing: Triggers safety interlocks, conveyor system controls, and quality control actuators in automated production lines.
• Case Study:
  A large LNG processing plant in Qatar integrated the TRICONEX 3636R into its ESD system to control 80+ critical valves. The module’s TMR technology and real-time diagnostics detected a relay contact degradation during a routine test, allowing the system to automatically switch to the redundant channel while maintaining full control. This prevented a potential shutdown that could have disrupted LNG production for hours, safeguarding an estimated $1.8 million in hourly output.

5. Competitive Comparison

Compared to similar relay output modules, the TRICONEX 3636R stands out for its combination of SIL-3 certification, TMR redundancy, and wide voltage compatibility. While some alternatives offer basic relay switching, few match its ability to handle safety-critical applications with 16 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 reliability and safety are non-negotiable. Unlike many competitors, the TRICONEX 3636R integrates seamlessly with TRICONEX’s broader TMR ecosystem, ensuring end-to-end redundancy and simplified system design.

TRICONEX 3636R

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.
• Load Requirements: Confirm that the module’s switching voltage (24 VDC/125 VAC) and current rating (2 A per channel) match the specifications of your field devices, such as solenoid valves or contactors.
• 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 3636R with redundant power supplies and communication networks to maximize system availability. Consider deploying multiple modules in a TMR configuration for the highest level of fault tolerance.

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, channel parameters, and relay response times, ensuring alignment with your safety loop requirements.
• Maintenance: Regularly review the module’s diagnostic status via the control system interface to monitor relay health and contact wear. Schedule firmware updates to incorporate the latest safety patches and performance optimizations, following the manufacturer’s guidelines.
• Troubleshooting: In the event of a relay channel fault, replace the module during a planned maintenance window or while the system is in hot-standby mode to avoid disrupting operations. Document all changes and perform system validation after module replacement to ensure proper functionality.