Tricon™ v9–v11 Systems triconex

Tricon™ v9–v11 Systems triconex

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.

System Configuration

Physically, a basic Tricon controller consists of Main Processors and I/O modules, communication modules, the chassis enclosing the modules, field wiring connections, and a TriStation PC. This section briefly describes these components and provides general specifications. Tricon modules are field-replaceable units consisting of an electronic assembly housed in a metal spine. Each module has a protective cover that ensures no components or circuits are exposed even when a module is removed from the chassis. Offset backplane connectors make it impossible to plug a module in upside down, and keys on each module prevent the insertion of modules into incorrect slots. The Tricon controller supports digital and analog input and output points, as well as pulse and thermocouple inputs and multiple communication protocols

Tricon Controller Chassis

A Tricon controller can include a maximum of 15 chassis, housing any appropriate combination of input, output, communication, interface, and hot-spare modules. There are three types of chassis: Main, Expansion, and RXM. 

• The Main Chassis houses the Main Processor modules and I/O modules. The Model 8110 Main Chassis houses up to six slot sets of I/O modules and the Model 8120E Enhanced Performance Main Chassis houses up to five sets of I/O modules. The I/O modules in a chassis are connected via I/O expansion bus ports that are triplicated RS 485 bi-directional communication ports. 

• An Expansion Chassis (chassis 2 to 15) houses up to eight slot sets of I/O modules and HART™ Interface Modules. The Expansion Chassis connects to the Main Chassis by means of a triplicated RS-485 bi-directional communication port. Generally, the last Expansion Chassis must be located no more than 100 feet (30 meters) from the Main Chassis or an RXM Chassis. 

• An RXM Chassis houses a Primary or Remote RXM Module set and six slot sets of I/O modules. An RXM Chassis enables a system to extend to remote locations up to 7.5 miles (12 kilometers) from the Main Chassis, using SRXM modules

Main Processor Modules

A Tricon controller contains three Main Processor modules. Each Main Processor controls a separate channel of the system and operates in parallel with the other Main Processors. A dedicated I/O Processor on each Main Processor manages the data exchanged between the Main Processor and the I/O modules. A triplicated I/O bus, located on the chassis backplane, extends from chassis to chassis by means of I/O bus cables. 

As each input module is polled, the appropriate channel of the I/O bus transmits new input data to the Main Processor. The input data is assembled into a table in the Main Processor and is stored in memory for use in the voting process.

The individual input table in each Main Processor is transferred to its neighboring Main Processors over the TriBus. During this transfer, voting takes place. The TriBus uses a direct memory access programmable device to synchronize and transmit data among the three Main Processors. 

If a disagreement occurs, 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 are distinguished from a pattern of differing data. Each Main Processor maintains data about necessary corrections in local memory. The Tricon controller built-in fault analyzer routines flag any disparity in the data and use it at the end of the scan to determine whether a fault exists on a particular module. The Main Processors transmit the corrected data to the control program. The 32-bit main microprocessor executes the control program in parallel with the neighboring Main Processor modules. 

The control program generates a table of output values which are based on the table of input values according to customer-defined rules built into the control program. The I/O Processor 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 I/O Processor generates output messages, each corresponding to an individual output module in the system. Each output message is transmitted to the appropriate channel of the corresponding output module over the I/O bus. For example, Main Processor A transmits the appropriate table to Channel 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 I/O Processor manages the data exchanged between the Main Processors and the communication modules using the communication bus which supports a broadcast mechanism. 

Main Processors receive power from dual Power Modules and power rails in the Main Chassis. A failure on one Power Module or power rail does not affect the system performance

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