Description:

The TRICONEX 3604E​ is a 16-channel, high-density, Triplicated Digital Output Module for the Tricon Safety Instrumented System (SIS). It is engineered to execute the final commands from the safety logic solver with extreme reliability. The module receives voted commands from the Triple Modular Redundant (TMR) main processors and activates its outputs to control critical field devices—such as solenoid valves, motor starters, and alarm annunciators—to bring a process to a safe state during an emergency.

Application Scenarios:

In a hydrocarbon processing plant, a high-level switch in a separator vessel triggers a Safety Instrumented Function (SIF) to prevent overfilling. The Tricon controller’s logic determines a trip is required. This command is sent to a TRICONEX 3604E​ digital output module. The module’s internal TMR circuits process the command, and it energizes a specific output channel. This action sends 24VDC power to the solenoid valve (SOV) on the vessel’s inlet line, causing it to close and stop the flow. The 3604E’s design ensures that even if a fault occurs in one of its three internal output paths, the command is still correctly executed via the remaining two, guaranteeing the safety function is performed and the process is secured.

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Technical Principles and Innovative Values:

The TRICONEX 3604E​ is designed for fault-tolerant action, transforming logical safety decisions into physical outcomes with maximum availability.

Innovation Point 1: Triple Redundancy in Output Execution:​ Each of the 16 output channels contains three independent, isolated output circuits. The module receives three separate command signals from the three main processors (A, B, C). Its internal logic performs a 2-out-of-3 vote on these commands. Only if at least two processors agree is the output energized. This ensures a single faulty processor cannot cause an unintended output action (a “false trip”) or fail to initiate a required action.

Innovation Point 2: Advanced Load Diagnostics and On-State Verification:​ The module provides sophisticated diagnostics beyond simple output switching. It can detect critical field-side faults, such as a broken wire (open circuit) to the solenoid or a short circuit at the load. Crucially, it provides on-state verification—confirming that the output device (e.g., a solenoid) actually energized when commanded. This feedback loop is vital for proving the health of the entire Safety Instrumented Function (SIF) loop, from logic to final element.

Innovation Point 3: High-Density, Fault-Tolerant Design:​ Packing 16 fully triplicated and diagnosed output channels into a single module represents a significant advancement in safety system packaging. This high density reduces the chassis footprint and cost per point for large systems while maintaining the highest safety integrity. The module’s design ensures that a fault in one channel is electrically isolated and cannot affect the operation of adjacent channels, preventing fault propagation.

Application Cases and Industry Value:

Case 1: Gas Compressor Station Emergency Shutdown (ESD):​ A Tricon system protects a large gas compressor station. Multiple TRICONEX 3604E​ modules are used to command the shutdown of fuel gas valves, vent valves, and initiate unit isolation. During a routine partial stroke test of an Emergency Shutdown Valve (ESDV), the diagnostics on a 3604E​ channel detected a developing issue with the solenoid’s coil (a rising resistance). The system generated a maintenance alarm beforethe coil failed completely. This allowed for planned replacement during the next outage, avoiding a potential situation where the valve would have failed to operate during a real emergency. This predictive capability, enabled by the module’s diagnostics, prevented a potential safety system impairment and costly unplanned shutdown.

Case 2: Turbomachinery Control (TMC) and Protection:​ In a gas turbine-driven power plant, a Tricon system acts as the primary protection system. A TRICONEX 3604E​ module is responsible for critical shutdown commands: tripping the fuel control valves, activating the CO2 fire suppression system, and engaging the turning gear. The module’s ultra-reliable, fault-tolerant design ensures that no single point of failure can prevent these commands from being issued. Its fast response time is critical during a turbine overspeed event, where milliseconds count. The plant’s reliability engineering team values the 3604E​ for its proven track record in preventing catastrophic turbine failures, protecting multi-million dollar assets.

Related Product Combination Solutions:

Tricon Main Processor (e.g., 3008. 3009):​ The TMR controller that computes the logic and sends commands to the 3604E.

Tricon Digital Input Module (e.g., 3664):​ Monitors the state of field devices (e.g., valve limit switches) that may be activated by devices controlled by the 3604E, closing the loop.

Tricon Communication Module (e.g., 4351B):​ Integrates the safety system with the plant DCS, allowing status of 3604E​ outputs to be displayed and alarms to be acknowledged.

Solenoid Valves (SOVs) and Relay Interfaces:​ The final elements directly controlled by the 3604E’s outputs. Often connected through intrinsic safety (IS) barriers in hazardous areas.

Tricon System Power Supply (e.g., 8312):​ Provides clean, redundant power essential for the reliable operation of all output modules.

TriStation 1131 Software:​ Used to configure the 3604E, including assigning outputs, setting pulse durations, and configuring diagnostic alarms.

External Load Power Supply:​ Provides the 24VDC/48VUC power that the 3604E​ switches to the field devices. This supply must be highly reliable, often redundant.

Installation, Maintenance, and Full-Cycle Support:

Installation requires strict adherence to safety lifecycle procedures. The module is inserted into a powered-down or appropriately isolated slot in the Tricon chassis. Field wiring to solenoid valves or relay coils is terminated at the module’s front connector block, with careful attention to proper fusing and wire sizing for the load. Configuration in TriStation 1131 is mandatory, defining each output’s associated logic variable, pulse width (if used), and diagnostic behavior.

Maintenance is driven by the module’s extensive diagnostics, visible through TriStation and the system HMI. Scheduled testing, such as partial stroke testing of valves, will exercise the 3604E​ outputs. The module is hot-swappable. If a fault is diagnosed, the module can be replaced online by following a specific procedure: placing the I/O bus in a secure state, replacing the module, and letting the system auto-reintegrate it. Crucially, the field wiring must be de-energized before disconnection.​ We supply the genuine TRICONEX 3604E​ module. Our support includes verifying hardware/firmware revision compatibility with your system and can provide procedural guidance for replacement to ensure your safety system’s integrity is maintained.

Contact us for the genuine TRICONEX 3604E digital output module to ensure your safety system’s final actions are executed with absolute reliability.