TRICONEX 4500 CPU module

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):

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.

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.

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.

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.

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.

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

External communication:

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.

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.