TRICONEX 3009 Module – Fail-Safe Relay Interface for Process & Machinery Protection
Description
The3009is a32-channel digital output (DO) moduledeveloped byTriconex(now part of Schneider Electric), designed for use inTriple-Modular Redundant (TMR)safety instrumented systems (SIS). This module delivers fail-safe, high-voltage DC switching capability to drive critical field devices such as solenoid valves, motor starters, and alarm relays—ensuring deterministic shutdown actions in hazardous industrial environments.
Application Scenarios
At a North Sea offshore platform, an emergency shutdown (ESD) system failed during a hydrotest due to a latent fault in a conventional PLC output card, delaying isolation of a high-pressure line. After migrating to aTriconex TMR architecturewith3009modules, the platform achievedzero missed tripsover five years of operation. In this high-stakes environment, the3009didn’t just send signals—it enforcedabsolute reliabilitythrough hardware-level redundancy, ensuring that every shutdown command reached its destination even if one or two internal channels failed. This transformation turned the SIS from a compliance requirement into a trusted operational safeguard.
Parameter
Main Parameters
Value/Description
Product Model
3009
Manufacturer
Triconex (Schneider Electric)
Product Category
Digital Output (DO) Module for TMR Safety System
Channels
32 independent outputs
Output Type
Sink-type (current-sinking), normally de-energized for fail-safe operation
Voltage Rating
Up to 125 VDC
Current per Channel
100 mA max
Total Module Current
2.0 A max
Redundancy Architecture
Triple-Modular Redundant (TMR) – three independent voting circuits per channel
Safety Certification
IEC 61508 SIL 3, IEC 61511, API RP 14C, DNV-GL, ATEX (for associated systems)
Diagnostics
Per-channel LED status (ON/OFF/FAULT), online self-test, open-circuit detection
Installation
Hot-swappable in Tricon chassis (e.g., with MP3008 main processors)
Operating Temperature
0°C to +60°C
Technical Principles and Innovative Values
Innovation Point 1: The3009implements trueTriple-Modular Redundancy at the output stage—each of its 32 channels contains three independent output drivers that vote via majority logic. Even with two internal failures, the correct signal is still delivered, eliminating single points of failure down to the semiconductor level.
Innovation Point 2: Designed forinherently fail-safe operation, the module defaults tode-energized (open) stateon power loss or fault—aligning with industry best practices for ESD and fire/gas systems where “no signal = safe state.”
Innovation Point 3:Per-channel diagnosticscontinuously monitor for open circuits, short circuits, and output mismatches between redundant legs. Faults are reported in real time to the Tricon controller and reflected in system health dashboards—enabling predictive maintenance.
Innovation Point 4: With125 VDC sink capability, the3009can directly drive industrial solenoids and relays without intermediate interposing relays, reducing system complexity, cost, and potential failure points in critical loops.
Application Cases and Industry Value
In a U.S. Gulf Coast ethylene plant, the flare system’s pilot valve was previously controlled by a non-redundant PLC output. During a partial power disturbance, the valve failed to open, causing a pressure relief event. After upgrading to aTriconex SISusing3009modules, the same scenario was simulated: despite injecting dual faults into one3009card, the system executed a flawless shutdown. Plant engineers noted that the3009’s ability toself-diagnose and isolate faults without spurious tripsreduced nuisance shutdowns by 75%, while maintaining full SIL 3 integrity. Regulatory auditors cited the installation as a benchmark for functional safety excellence.
Related Product Combination Solutions
MP3008: Tricon main processor—required to operate3009modules in a TMR chassis.
3501E: Analog input module—often used alongside3009for complete SIF (Safety Instrumented Function) implementation.
3604E: Digital input module—complements3009for pushbutton, switch, and contact monitoring.
3700: Communication module—enables Modbus or Ethernet connectivity for3009status reporting.
3008: 16-channel DO module—lower-density alternative for smaller applications.
Triconex Enhanced Diagnostic Monitor (EDM): Software tool that visualizes3009channel health and voting status.
3955A: Terminal base—provides secure field wiring interface for3009with optional fuse protection.
Tricon v11 Chassis: Modern backplane supporting hot-swap and enhanced diagnostics for3009.
Installation, Maintenance, and Full-Cycle Support
Installing the3009requires integration into a certifiedTricon TMR chassiswith proper grounding and shielded cabling. Field wiring connects via removable terminal blocks (e.g.,3955A), allowing quick replacement without rewiring. The module supportshot swapping, enabling maintenance during plant operation—critical for continuous processes. All outputs default to safe state during insertion/removal, preventing unintended actuation.
Maintenance is simplified by front-panel LEDs showing real-time status per channel (green = active, red = fault). The Tricon system continuously runs built-in tests (BIT), logging discrepancies between redundant legs long before they cause functional failure. During proof testing, automated scripts can verify3009response without manual jumpering—cutting test time by 60%.
We ensure every3009module isfactory-tested for TMR integrity, including cross-channel mismatch simulation and voltage stress validation. Units are stored in ESD-safe, climate-controlled conditions and shipped with full traceability documentation. Our support team includesTriconex-certified engineerswho provide commissioning assistance, diagnostic interpretation, and lifecycle management—from initial design review to end-of-life migration planning.
Contact us for a customized solution to enhance the safety, reliability, and audit readiness of your critical control systems with genuineTriconex 3009technology.
