Tricon System Hardware IntroductionTricon

Tricon Hardware ArchitectureTricon

TriconTriple Modular SystemsTriconOver 6,300 TMR ESD/CPC Solutions Installed Worldwide 6300TMR ESD/CPCTV Certified for AK5/AK6 Safety Applications TUV AK5/AK6 TRICONEX Certified to U.S. and international standards - TUV, CSA, FM, IEC, UL, CE 1E Mark TRICONEX ---- TUV, CSA, FM, IEC, UL, CETRICONEX Headquarters and Manufacturing Facility is ISO 9000 certified TRICONEX ISO 9000

Definition of Tricon TMR Fault Tolerance Controler:Tricon - TMR :Identifies and compensates for failed control system elements and allows on-line repair while continuing its assigned task without process interruption. High Safety Integrity - High Safety Availability due to TMR architecture, diagnostics, and on-line repair TMR, High Availability - Eliminates spurious (false) trips -

Tricon TMR Fault-Tolerant ControlerTricon - TMR

Comprehensive diagnostics are embedded in the system, independent of user written application programming !Tricon 1. Diagnostics On - Line Repair 3. No single point of failure The difference between Long Term and Short Term Availability and Reliability - Diagnostics ! --- Tricon TMR vs. All Other PLC Technologies TriCON TMR PLC

1.Diagnostics - Catch problems before it become a threat to the process ! 2.On-Line Repair - A failed module can be pull out on-line (Hot Spare). 3.No Single Point of Failure - Isolation, so that a problem will not bleed over or affect or propagate to other legs. .

Tricon TMR Main PrinciplesTricon TMR

Tricon TMR ArchitectureTricon

Tricon TMR ArchitectureTriconConnect the Input and Output Module Circuitry to the ASICs and the Architecture is complete!

Tricon TMR TechnologyTricon TMR Redundancy => No single point of failure => Isolated architecture On-line repair possible Triplication - Fully implemented. Transparent to user -- Diagnostics - Transparent to user Direct communications to Supervisory Control Systems TV Class 6 certified (IEEE SIL 3) TV AK6 (IEEE SIL 3)TriStation allows off-line emulation TriStation Installation simplicity

Triple Modular Redundancy provides correct control in presence of any Single fault Ability to operate with 3, 2 or 1 0MP(s) before shutdown 3-2-10On-line repair provides replacement of faulty module without disrupting control Number of false shutdowns (trips) reduced Sequential and regulatory control capability TMR for High Availability TMR

No single point of failure Three Main Processors Process I/O modules with three independent legs I/ODual Power Supplies Dual Communication Modules

Redundancy

Three independent Main Processors Two independent Power Supplies in each rack No shared components on process I/O modules I/OMechanical and Electrical isolation of all processing elements Isolation

Replace faulty I/O module without disrupting operation I/O Replace faulty Main Processor without disrupting operation Automatic switch-over to Hot Spare when I/O module is faulty

Hot Replacement

Fault DetectionLoopback on DO and AO Modules DO AO Comparison of Triplicated Input Data Validation of each Main Processor Board CPU and Memory CPU Floating Point Unit TRIBUS Communication Communication MicroprocessorsFault indicator LED on all modules

Digital inputs voted by TRIBUS Digital outputs voted on DO Modules DO Analog outputs selected on AO Modules AO

Hardware Voting

Mid-value selection of analog inputs Diagnostic data on I/O modules I/O Software Voting

Tricon SYSTEM COMPONENTSTricon

Control System Structure Tricon Main System Tricon Engineer/SOE Station /SOE Operational Station Auxiliary Console Annunciator

Tricon High Density Main ChassisTricon

Tricon High Density Expansion ChassisTricon

Inter-connected I/O ChassisI/O

Remote Expansion Module (RXM)(RXM)

Inter-connection of Remote I/O ChassisI/O 1 Main Chassis 1 More than 14 Expansions 14 Remote Expansion Chassis most express 12Km 12Km

I/O Expansion Bus PortsI/O

Keyswitch on Tricon Main ChassisTricon

Backup Batteries on Tricon Main ChassisTricon

Tricon Chassis Power ModulesTricon

NO Normally OpenNC Normally ClosedC Common Dual Power Subsystem

Dual Power Supplies - Each capable of powering entire chassis load (175 Watts Each) 175Dual Voltage Regulators - Two per leg on each I/O module I/OFull noise isolation on inputs and outputs Over-temperature alarm at 60 degree C 60On-line replacement Batteries for memory back-up (Maintains memory for accumulated time of 6 months) Fault Tolerant Power Subsystem

Tricon High Density Chassis BackplaneTricon

Tricon I/O MODULESTricon I/O

Main Processor Module #3008

Main Processor Module #3008 #300832 Bit Central Processor, MPC860, at 50 MHz 32 ,MPC860, 50 MHz16 MB DRAM (with battery backup) 16 Mb DRAM(Fault Tolerant inter-processor Bus (TRIBUS) at 25 MHz, 32 bit CRC-protected, DMA fully isolated (TRIBUS)25MHZ,32CRC,DMA,32 Bit Communication processor MPC860, at 50 MHz 32 MPC860,50MHZHardware voting and comparison circuits Supports (SOE) and time-stamping SOE Extensive background diagnostics

Main Processor #3008 Architecture #3008

TMR Digital Input ModuleTMR

TMR Digital Input ModuleTMR Independent triplicated signal conditioning, power sources and communications paths No single point of failure Tests for stuck "ON" circuits Stuck-OnFull isolation between channels Input data voting is performed by the Main Processors All the 32 points can be scanned within 1 ms 321msFull noise immunity On-line replacement

TMR Digital Output ModuleTMR

Independent triplicated signal conditioning, power sources and communications paths Per point series/parallel Fault Tolerant Quad Voter hardware circuitry / Field Loopback Sensing Diagnostics No single point of failure Opto isolation between channels Full noise immunity On-line replacementTMR Digital Output ModuleTMR

TMR Analog Input ModuleTMR

Independent triplicated leg signal conditioning, power sources, and communication paths Triplicated A/D converters A/DAutomatic calibration using built-in reference voltages 0.15% full scale range accuracy, 12-bit resolution 0.15% 12Available with +6% over-range measurement +6% No single point of failure On-line replacement TMR Analog Input ModuleTMR

TMR Analog Output ModuleTMR

Triplicated 12-bit D/A converters for each of the 8 analog output points 12D/A2oo3 selection circuit selects correctly operating DAC for each point and periodically selects each DAC to check its correct operation 32Loopback checking of all analog output channels Automatic calibration using built-in reference voltages No single point of failure On-line replacement

TMR Analog Output ModuleTMR

TMR Pulse Input ModuleTMR

Independent triplicated leg signal conditioning, power sources, and communication paths Triplicated pulse counter for each of the 8 input points Accurate timers are used on each point to determine time required to accumulate the required number of pulses (1 microsecond accuracy) 1 Measures speed (RPM) to an accuracy of 0.01% at Normal operating speeds (RPM) 0.01% No single point of failure On-line replacement TMR Pulse Input ModuleTMR

ProcBus XcvrProcBus XcvrProcBus XcvrABCADCADCADCIndividual Point Field TerminationsINTELLIGENT I/O CONTROLLER(S)TRIPLICATED I/O BUSSIGNAL CONDITIONINGTHERMOCUPLE INPUT CIRCUIT -- TYPICAL POINTCJ SensorCJ SensorCJ SensorINDIVIDUAL ADC FOR EACH LEGAmpMuxAmpMuxAmpMuxTMR Thermocouple Input ModuleTMR

Triplicated A/D converters A/D Automatic calibration using built-in reference voltages Supports thermocouple types J, K, and T JKT Cold Junction compensation is performed > 0.5% Standard Deviation from mid-value for 256 samples - Leg is faulted 0.5% No single point of failure On-line replacement TMR Thermocouple Input ModuleTMR

Tricon Communication ModuleTricon Tricon Communication Module (TCM) Tricon TCMTCM 4351--RJ-45 network ports TCM 4351RJ-45 TCM 4352--multi-mode fiber-optic network ports TCM 4351Four RS-232/RS-485 serial ports, each of which are TriStation-configurable for Modbus master or slave, Trimble GPS, and TriStation RS-232/RS-485GPSModbus/Two 10/100 Mbps Ethernet ports (model 4351) or two 10/100 Mbps fiber-optic MTRJ Ethernet ports (model 4352) 210/100 Mbps(4351)210/100 Mbps MTRJ(4352)One RS-232 debug port (for Triconex use only) 1RS-232

Tricon Network Configuration Tricon

External Termination Panel (ETP)

Connection for the ETP and I/O moduleI/O

Keyed Connectors

TriStation 1131 SoftwareTriStation 1131

Currency Support Flat Roof for TRICONEX TMR Controller TRICONEX TMR

Support Tricon/Trident each Edition Controller TRICON/TRIDENT Engineering and Maintenance Workstation Runs on 100% Compatible IBM PC, Windows NT/2000/XP IBM PC 100%TriStation 1131 SoftwareTriStation 1131

Engineering and Maintenance Workstation Runs on 100% Compatible IBM PC IBM PC 100%Complete Documentation Package Off-Line Program Emulation and Monitoring On-Line Program Monitoring Supports On-Line Program Changes Detailed Diagnostics of Each Module in System TriStation 1131 SoftwareTriStation 1131

System Support Software Accorded with IEC 1131 Standard IEC 1131 Empolder according to IEC 1131 standard IEC1131 IEC 1131-3 Languages: FLD, Ladder Logic, Structured Text IEC 1131-3 : FLD, , Supports up to 256 Programs in a Single Project 256 Provides Identifiers (Global Variable Names) with up to 31 Characters 31 () Perfect logic function module TriStation 1131 SoftwareTriStation 1131

Function Block Diagram (FBD) Language

Ladder Diagram (LD) Language

Structured Text (ST) Language

System Support Software Obtained TV Attestation TV Supply detailed diagnose to all modules (I/O and communication module) I/O Supply safety On-Line Program Changes and load down function TriStation 1131 SoftwareTriStation 1131

Convenience complete programme elementStandard programme function Type conversion functions Numerical functions Arithmetic functions Bit-wise Boolean functions Bit-string functions Selection functions Comparison functions Character string functions Standard function block Bi-stable function blocks Edge detection function blocks Counter function blocks Timer function blocks

Wide-open Programme CircumstanceEximious opening character Consumer can entirety realize and attach the control project Enlarge various control function blocks User-defined various control function blocks

Multilevel Safety Manage can be definedDifferent user can set different access, and set password respectively Access can be enactment by grade

TriStation 1131 Four primary FunctionTriStation 1131Off-Line Configuration and Programme Off-Line Program Emulation and Monitoring On-Line Program Monitoring Supports On-Line Program Changes and Download

Function Block Diagram Instance

Panel Monitor Screen

Why Cause and Effect Matrix ? CEMs are used by Many Process Engineers to Define Their Safety Shutdown Strategy CEMUsers Have Had Successful Experiences Using CEMs and Tend to Standardize on Their Use. CEMCEMs are Understood by Plant Operators and Maintenance Personnel CEM

Cause Effect Matrix Editor with Function Display

CAUSE EFFECT MATRIX FBD Network Execution Order Cause FunctionsEffect FunctionsIntersection Functions

Cause Effect Matrix Instance Monitor Screen

TRICONTUVDINAK6CSAFM CETRICONIOSOECPUTRIBUSCPU TMR:.:., IOI6RS485IO375K1214 OUT IO375K4RUN PROGRAM STOP REMOTE ,6IO120V 24V 230VPASSFAULTALARMTEMP836065BATTLOWTRICON TRIBUS 4MIOCPUIO375COMCPU2M SOERTDESDESDFunction Block Diagram - FBDA code body programmed in the graphical language FBD is composed of functions and function blocks which are connected with each other or with variables using lines. These lines can also be connected with each other. In FBD networks it is not possible to connect outputs with outputs.

The set of connected objects is called FBD network.

Connectors can be used in case of large networks for better structuring the elements in the worksheet. Connectors replace connection lines.

Jumps can be used to jump to a label in the current worksheet.

Returns can be inserted to go back to the calling POU. Ladder Diagram - LDA code body programmed in the graphic language LD is composed of contacts and coils. According to IEC 1131-3 different types of contacts and coils can be used. The contacts lead according to their type the power from the left to the right. Coils store the incoming value to Boolean variables.

These contacts and coils are connected with lines and are bounded on the left and on the right with power rails. The state of the left power rail is considered ON all the time. The right rail is optional.

In addition to the serial connections of contacts and coils parallel branches can be created. Parallel branches are also called wired-ORs.

The set of connected objects is called LD network. Every LD network shall at least contain one coil and a left power rail.

Connectors can be used in case of large networks for better structuring the elements in the worksheet. Connectors replace connection lines.

Jumps can be used to jump to a label in the current worksheet.

Returns can be inserted to go back to the calling POU.

Variables in LD code bodies are always Boolean variables. While inserting contacts or coils the variable name can be entered. The variable name is displayed above the contact or coil in the worksheet.

Structured Text - STA code body programmed in the textual language ST consists of statements and expressions.

Different types of statements can be used while editing. All statements have to finish with a semicolon.

An expression is a construct which returns one value for the execution of statements. Expressions consist of operators and operands. The operators have to be applied to the operands in the way that the operator with the highest precedence is followed by the operators with the next lower precedence.

In ST code bodies comments can be inserted using asterisks and parentheses.