TRICONEX 3002 Triple redundant controller

Each channel contains independent CPUs, memory, and I/O interfaces, which are isolated and completely identical.

Input signals are received and processed by the three channels simultaneously to generate respective output results.

Voting Mechanism: The output results of the three channels are compared in real-time (every 2–5 ms). In case of inconsistencies, the system uses the "2 out of 3" principle to select the correct result, ensuring that a single channel failure does not affect the system output.

Signal Acquisition: Signals from field sensors (such as temperature, pressure, liquid level, etc.) enter the system through redundant I/O modules (e.g., the 3700 series).

Signal Distribution: Each input signal is copied into three parts and sent to the three CPU channels respectively.

Parallel Processing: The three CPU channels independently process the input signals and execute control logic (such as PID algorithms and logical interlocks).

Intermediate Result Voting: At key calculation nodes (such as each scan cycle), the three channels compare intermediate results. If differences exist, the system marks the faulty channel and continues to use the majority-consistent result.

Output Voting: The final output signal is generated through a voting circuit to ensure that the output remains correct even if a channel fails.

Fault Handling: If a channel consistently produces inconsistent results, the system isolates it (without affecting the operation of other channels), triggers an alarm, and allows online replacement of the faulty module.

Built-in Self-Diagnosis: Each channel real-time monitors its own hardware status (such as CPU, memory, and communication links) and reports anomalies immediately.

Cross-Checking Between Channels: The three channels compare processing results with each other to identify potential software or hardware faults.

Redundant Power Supply and Communication: The system supports dual power inputs and redundant communication paths to further enhance reliability.

Emergency Shutdown System (ESD): Quickly shuts down equipment in hazardous situations.

Burner Management System (BMS): Monitors the combustion process of equipment such as boilers and reactors.

Fire & Gas Detection System (FGS): Responds in real-time to fire or gas leakage alarms.

Critical Process Control: Core production links in high-risk industries such as oil refining and chemical engineering.

Processor: Typically uses high-performance industrial-grade CPUs (such as Intel Xeon).

Scan Cycle: The typical value is 5–20 ms, supporting high-speed control requirements.

Safety Integrity Level: Complies with IEC 61508 SIL3 and ISA 84.01 standards.

Communication Interfaces: Supports multiple industrial protocols (such as Modbus, Profibus, Ethernet/IP).

Redundancy Mode: Triple redundancy (TMR), supporting online hot-swappable maintenance.