HONEYWELL TK-PRR021 51309288-275 REDUNDANCY MODULE

The HONEYWELL TK-PRR021 (part number: 51309288-275) is a core redundancy module under Honeywell’s Experion PKS (Process Knowledge System). Specifically designed for the C200 controller, its core positioning is to "ensure the uninterrupted operation of industrial control systems under extreme working conditions through hardware redundancy and intelligent failover". It is designed in strict compliance with industrial-grade high-reliability standards and is widely used in critical process fields with "zero tolerance for system downtime" such as petrochemicals, oil and gas extraction, and thermal power generation. It serves as the core hardware carrier for Honeywell to achieve "fault-tolerant control".

• TK-PRR021: Product model, focusing on functions and adaptability

• "TK": A general prefix for modules in the C200 controller series of Honeywell’s Experion PKS system, distinguishing it from the Triconex safety system (prefix "TS");

• "PRR": Function code, where "P" = Process Control and "RR" = Redundancy Ready, clearly indicating that it is a dedicated module for redundancy control;

• "021": Hardware version number. Version 021 is the second-generation design, which has optimized synchronization speed and fault diagnosis accuracy compared to the first generation (Version 010) and is compatible with the latest C200 controller firmware (V4.0 and above).

• 51309288-275: Globally unique part number, used for production traceability and spare parts procurement

• The first 8 digits "51309288": Basic module code, identifying the "C200 controller redundancy unit";

• The last 3 digits "275": Configuration suffix, representing "with standard lithium battery backup + dual power input", distinguishing it from "270" (without battery backup) and "280" (adapted for explosion-proof environments).

• Dynamic Load Balancing: During normal operation, the active and standby processors are not in a state of "active busy, standby idle". Instead, through Honeywell’s patented "load sharing algorithm", the standby processor undertakes some non-real-time tasks (such as data log recording and alarm statistics), while the active processor focuses on real-time control (such as PID regulation and logic interlocking), improving the overall system processing efficiency;

• Fault Pre-diagnosis: Through the built-in "health monitoring algorithm", it collects real-time parameters of the active and standby processors (such as CPU load, memory usage, and power supply ripple). When the parameters approach the threshold (e.g., CPU load continuously > 90%), an "early warning signal" (non-emergency alarm) is sent to the upper computer in advance, facilitating maintenance personnel to intervene before a fault occurs;

• Disturbance-Free Switchover Design: During failover, after the standby processor takes over control, it continues to execute based on the last synchronized "control command snapshot", avoiding sudden changes in control output (such as valve opening jumps and motor start-stop misoperations) caused by switchover, and meeting the "disturbance-free switchover" requirement of industrial processes;

• Redundancy Status Visualization: Through the operator interface (HMI) of Experion PKS, real-time information such as the "active-standby status, synchronization progress, fault type, and battery power" of the redundancy module can be viewed, and a "redundancy switchover log" (including switchover time, trigger reason, and switchover duration) can be generated, facilitating post-event traceability.

• Dual-Power Isolation: The power circuits of the active and standby processors are completely independent and isolated by optocouplers (isolation voltage: 2500V AC), preventing a fault in one power circuit (e.g., short circuit) from affecting the other. At the same time, the power input terminal is connected in series with a PPTC self-recovering fuse (2A) to prevent circuit board damage due to overcurrent;

• Electromagnetic Shielding: The housing is made of aluminum alloy, and the internal circuit board is laid with grounding copper foil to form "double-layer electromagnetic shielding", which can resist radio frequency interference of 10V/m (80MHz-1GHz) (such as EMI generated by inverters and high-voltage motors) and ensure that data synchronization signals are not interfered with;

• Battery Leakage Protection: The built-in lithium battery adopts a sealed housing, and a "leakage prevention groove" is designed inside the module. Even if the battery leaks due to aging, it will not contaminate the circuit board or other modules. At the same time, the battery interface is equipped with an "overvoltage protection diode" to prevent damage caused by incorrect high-voltage connection during battery replacement;

• Hardware Latching Mechanism: When a "critical fault" (such as simultaneous failure of active and standby processors) is detected, the module triggers "hardware latching", freezes the control output (maintaining the last valid output state), and sends an "emergency shutdown signal" through the relay to prevent the system from entering an "uncontrollable state".

• Hot Swapping Function: Supports "live replacement". Maintenance personnel can remove the faulty module and install a new one while the system is running, without powering off the system (replacement time <5 minutes), avoiding system downtime caused by module replacement;

• Easy Battery Replacement: The lithium battery adopts a "snap-in drawer design". The battery can be replaced through the "battery drawer" on the rear panel without disassembling the module housing, with a replacement time <1 minute. After inserting a new battery, data synchronization is automatically performed (no reconfiguration required);

• Fault Code Self-Diagnosis: When the module malfunctions, the LED indicators on the front panel flash "fault codes" (e.g., "red-green-red" indicates "active processor CPU fault"). At the same time, the fault code is uploaded to the HMI via the Modbus protocol. With the help of Honeywell’s "Fault Diagnosis Manual", the fault point can be quickly located (e.g., "E03" corresponds to "synchronization bus fault", requiring inspection of RS-485 wiring);

• Online Firmware Upgrade: Supports online firmware upgrade of the module through Experion PKS’s "Firmware Management Tool" (no module disassembly required). During the upgrade process, the main and standby modules are upgraded alternately (first upgrade the standby module, then switch the active-standby state and upgrade the original active module), ensuring that the system is not interrupted during the upgrade.

• Controller Adaptability: Only compatible with Honeywell’s C200 controller (firmware version V4.0 and above), and not applicable to C300 or Triconex series controllers;

• Software Collaboration: Requires configuration with Experion PKS’s "Control Builder" software (e.g., setting redundancy switchover thresholds and synchronization cycles), monitors redundancy status through "Operator Station" software, and stores redundancy switchover logs through "Historian" software;

• I/O Module Collaboration: Achieves "redundancy linkage" with the C200’s I/O modules (such as AI module TK-AI161 and DO module TK-DO161). When the redundancy module switches, the I/O modules automatically synchronize the control commands of the new active processor to ensure consistent I/O point statuses;

• Third-Party System Connection: Supports uploading redundancy status data to third-party monitoring systems (such as SCADA) via the OPC UA protocol, meeting the user’s "cross-system monitoring" needs.