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TRICONEX 4500 CPU module


4509—02


The TRICONEX 4500 CPU module is a core component of the Triconex Safety Instrumented System (SIS). It is designed based on the Triple Modular Redundancy (TMR) architecture and achieves high-reliability control through the collaborative work of hardware and software. The following is a detailed explanation of its working principle:


  1. Triple Modular Redundancy (TMR) Architecture
    The TRICONEX 4500 adopts a three-channel parallel processing mechanism:


  • Three independent CPUs: Each module contains three identical CPU channels (Channel A, B, and C), which execute the same control program in parallel.

  • Data synchronization: The three channels exchange data in real-time through a high-speed synchronization bus to ensure consistency in processing.

  • 2oo3 voting mechanism (two-out-of-three):

    • For digital I/O, the outputs of the three channels are compared through a hardware voting circuit, and a valid signal is output only when at least two channels are consistent.

    • For analog I/O, the median value of the three channels is taken as the final output to improve anti-interference capability.

  • Fault tolerance: When any channel fails, the system can still operate normally, and the faulty channel can be located through the diagnostic function, achieving a single-point fault-free design.


  1. Signal Processing Flow
    Input signal processing:


  • Signal acquisition: Signals from on-site sensors (such as pressure, temperature, and liquid level sensors) are input to the three CPU channels simultaneously.

  • Signal conditioning and digitization: Each channel independently filters, amplifies, and digitizes the input signal.

  • Data comparison and voting: The digitized data of the three channels are compared through the synchronization bus. If they are consistent, the result is output to the control logic through voting; if there is a discrepancy, the system triggers fault diagnosis.


Control logic execution:


  • Each CPU channel independently executes pre-programmed control logic (such as ladder diagrams, function block diagrams) to generate control instructions.

  • The control instructions also ensure reliability through the three-channel voting mechanism.

3503E (1)

Output signal processing:


  • Voting output: The control instructions of the three channels pass through hardware voting to generate the final output signal.

  • Execution drive: The output signal drives on-site actuators (such as valves, relays) to realize the control of industrial processes.


  1. Fault Detection and Fault-Tolerant Mechanism


  • Online self-diagnosis: The CPU module monitors its own hardware status (such as power supply, memory, processor) and software operation in real-time, and triggers an alarm when a fault is detected.

  • Inter-channel comparison: The data and operation results of the three channels are continuously compared through the synchronization bus. If a channel is inconsistent with the other two, it is judged as a faulty channel.

  • Fault isolation: When a faulty channel is detected, the system automatically isolates it, and the remaining two channels continue to work normally to ensure control continuity.

  • Hot-swap maintenance: Supports online replacement of faulty modules without shutdown, further reducing system downtime.


  1. Communication and Integration Capability


  • Internal communication: Data exchange and synchronization between the three CPU channels are realized through a high-speed synchronization bus.

  • External communication:

    • Supports multiple industrial protocols (such as Modbus, Profibus, Ethernet/IP) and integrates with systems such as DCS, PLC, and SCADA.

    • Connects with remote I/O modules (such as 4329, 4210) through redundant communication interfaces to expand the system scale.


  1. Safety Certifications and Standards
    The TRICONEX 4500 module complies with the following safety standards:


  • IEC 61508 SIL3: Applicable to applications with the highest safety integrity level.

  • ISA S84.01: Standard for industrial process safety systems.

  • API 556: Standard for safety instrumented systems in the refining industry.

3503E (4)

Typical Application Scenarios


  • Emergency Shutdown System (ESD): In the chemical and oil & gas industries, it quickly responds to dangerous situations and triggers safety interlocks.

  • Critical equipment protection: Such as compressor anti-surge control and steam turbine overspeed protection.

  • Fire and Gas Monitoring System (F&G): Real-time monitoring of fire and combustible gas leaks, and activation of alarm or fire-fighting measures.

  • Nuclear power auxiliary systems: Ensuring the reliable operation of non-nuclear safety-level systems in nuclear facilities.


Summary
The TRICONEX 4500 CPU module realizes high reliability and fault tolerance at the hardware level through the triple redundancy architecture and real-time voting mechanism, making it suitable for industrial scenarios with extremely high safety requirements. Its working principle core lies in "parallel processing, majority voting, and fault tolerance", ensuring that the system can still operate safely when a single channel fails, and minimizing unplanned downtime.


Product Tags: 4500 CPU module

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1Yr
Business Type
Trading Company
Year Established
2014
Factory Size
1,000-3,000 square meters
Product Certifications
SA8000