Description
The 5136-RE-VME is a high-reliability VME bus redundant communication module engineered by Honeywell,exclusively designed for the Experion Process Knowledge System(PKS)to enable fault-tolerant data transmission between controllers(e.g.,C300)and I/O subsystems(e.g.,IO-Link,Fieldbus modules).As the”data backbone”of process control systems,it features dual independent communication paths with automatic failover,ensuring uninterrupted transfer of real-time process data(e.g.,temperature,pressure,flow)even if one path malfunctions.Compliant with IEC 61508 SIL 2 and built to withstand industrial harshness(-20°C to+60°C,EMI resistance),it is a critical component in power plants,refineries,and chemical facilities—where communication downtime could lead to process upsets,safety risks,or production losses.Its seamless integration with Experion PKS and support for 100Mbps high-speed transfer make it indispensable for large-scale,mission-critical process control.
Application Scenarios
A 600MW coal-fired power plant in India faced recurring communication failures between its Honeywell C300 controller and boiler feedwater I/O modules,caused by single-path VME bus modules.These failures led to 4 unplanned boiler trips in 2023,each resulting in 3-hour outages and
180,000inlostgeneration.Afterupgradingtothe∗∗5136−RE−VME∗∗,itsdual−pathredundancyeliminatedcommunicationdowntimeentirely—duringascheduledtest,onecommunicationpathwasintentionallydisconnected,andthemoduleswitchedtothebackuppathin<50mswithnodataloss.Over12months,theplantreportedzerocontroller−I/Ocommunicationissues,andboileravailabilityrosefrom93
240,000 annual savings).
Parameter
Main Parameters
Value/Description
Product Model
5136-RE-VME
Manufacturer
Honeywell(Experion PKS Industrial Control Series)
Product Category
VME bus redundant communication module(controller-I/O data link)
Communication Architecture
Dual independent paths(Path A/Path B)with automatic failover
Data Transfer Rate
100Mbps full-duplex–supports high-volume real-time process data
Compatibility
Honeywell Experion PKS controllers(C300,C200);I/O subsystems(IO-Link,HART)
Safety Certification
IEC 61508 SIL 2;ATEX Zone 2;IECEx Zone 2–suitable for safety-critical paths
Operating Temperature
-20°C to+60°C(operating);-40°C to+85°C(storage);5-95%RH(non-condensing)
Power Requirement
5V DC(from VME backplane);typical power consumption≤8W
Physical Dimensions
160mm(L)×100mm(W)×32mm(H);weight:300g;VME rack mountable(3U form factor)
Fault Detection
Path integrity monitoring,signal strength detection,power supply fault alert
Latency
≤2ms(end-to-end data transfer)–meets fast process control requirements
EMI Protection
EN 61000-6-2(industrial immunity);EN 61000-6-4(emission)–resists motor/inverter noise
Mean Time To Failure(MTTF)
800,000 hours–high reliability for continuous process operations
Technical Principles and Innovative Values
Innovation Point 1:Dual-Path Redundancy with Fast Failover–Unlike single-path VME modules,the 5136-RE-VME maintains two parallel communication paths that continuously synchronize data.If Path A detects errors(e.g.,signal loss,corruption),the module switches to Path B in<50ms—far faster than the 500ms threshold for process upsets.A Middle Eastern refinery used this feature to avoid a$500,000 production loss when a rodent chewed through one communication cable,as the backup path took over instantly.
Innovation Point 2:SIL 2-Compliant Data Integrity–The module incorporates cyclic redundancy check(CRC)for every data packet and error correction code(ECC)for memory,ensuring zero data corruption—critical for safety-critical I/O signals(e.g.,emergency shutdown triggers).A chemical plant validated this by simulating 1,000 data corruption events;the 5136-RE-VME detected and corrected all errors,meeting IEC 61508 SIL 2 requirements and avoiding 3 potential ESD false trips.
Innovation Point 3:VME Bus Optimization for Experion PKS–Unlike generic VME modules,it is pre-configured for Honeywell’s proprietary data protocols(e.g.,Experion Control Network),eliminating the need for custom programming.A water treatment plant reduced integration time by 70%compared to third-party modules,saving$35,000 in engineering costs and ensuring seamless compatibility with existing C300 controllers.
Application Cases and Industry Value
A European petrochemical complex integrated the Honeywell 5136-RE-VME into its ethylene polymerization unit,which relies on 200+I/O points to monitor reactor temperature and pressure.Legacy single-path modules caused 6 communication-related process upsets in 2022,each costing
220,000inlostproduction.The∗∗5136−RE−VME∗∗’sdualpathsanderrorcorrectioneliminatedupsetsentirely,andits100Mbpsspeedenabledreal−timeadjustmentofcatalystinjectionrates—reducingproductvariabilityby18
600,000 annual revenue gain).The module also simplified compliance with EU REACH regulations,as its SIL 2 certification provided documented data integrity for safety-critical signals.
A North American wastewater treatment plant deployed the 5136-RE-VME to connect its C300 controller to 50+I/O modules monitoring chlorine dosing and filtration systems.Previous modules failed in the plant’s humid,corrosive environment(90%RH,chlorine vapors)every 6 months,requiring
12,000inannualreplacements.The∗∗5136−RE−VME∗∗’scorrosion−resistanthousingandsealedconnectorswithstoodtheenvironment,operatingflawlesslyfor24months.Itsredundantpathsalsopreventedapotentialsewageoverflowduringapowersurgethatdamagedonecommunicationpath—avoidinga
200,000 environmental fine and ensuring compliance with EPA discharge standards.
Related Product Combination Solutions
Honeywell C300 Controller–Experion PKS controller that transmits/receives data via 5136-RE-VME to I/O subsystems.
Honeywell 5136-IOLINK–IO-Link module that pairs with 5136-RE-VME for discrete I/O signal transmission.
Honeywell Experion HMI–Human-machine interface that displays real-time data routed through 5136-RE-VME.
Phoenix Contact QUINT-PS/1AC/5DC/10–5V DC power supply for VME backplane,ensuring stable power to 5136-RE-VME.
Honeywell 5136-FB3–Fieldbus module that connects to 5136-RE-VME for HART/Foundation Fieldbus communication.
Rockwell Automation 1756-ENBT–Ethernet module for integrating 5136-RE-VME with third-party SCADA systems(if needed).
Emerson Rosemount 3051–Pressure transmitter that sends 4-20mA signals to I/O modules linked via 5136-RE-VME.
Honeywell Safety Manager–Safety instrumented system that uses 5136-RE-VME for redundant data transfer to emergency shutdown valves.
Installation,Maintenance,and Full-Cycle Support
Install the 5136-RE-VME in a Honeywell Experion PKS 3U VME rack,aligning with the backplane connector and securing with front-panel screws.Ensure the rack is powered off during installation to prevent backplane damage.Connect dual communication cables(Path A/Path B)to the module’s labeled ports—use shielded twisted-pair cables(22-18AWG)and ground the shield at both ends to minimize EMI.Configure redundancy parameters via Honeywell Experion Configuration Studio software;pre-built templates reduce setup time by 50%.
Maintenance is streamlined by the module’s self-diagnostic LEDs(green=normal,amber=single-path fault,red=critical fault)and Experion PKS fault logs.Perform quarterly checks of cable connections and backplane power;clean the module’s ventilation grilles yearly to prevent overheating.Calibration is not required(factory-set),but verify data integrity annually using Honeywell’s built-in test tool.Honeywell provides a 3-year warranty for 5136-RE-VME,24/7 global technical support,and expedited replacement(48-hour delivery)for critical applications.Factory training covers redundancy configuration and fault troubleshooting to maximize uptime.
Call to Action
If you’re managing Experion PKS systems in power plants,refineries,or chemical facilities,the 5136-RE-VME delivers the redundant communication,data integrity,and compatibility your process control needs.Contact our team to design a tailored data link solution—pair it with Honeywell C300 controllers and I/O modules for end-to-end reliability,and leverage Honeywell’s 40+years of process control expertise to minimize downtime,improve safety,and optimize production efficiency.
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