TRICONEX 3000602-100 Main Chassis Assembly with Power Supplies and Processors

The TRICONEX 3000602-100 is a complete main chassis assembly for the Tricon triple modular redundant (TMR) safety instrumented system. This assembly includes the chassis backplane (part of 3000602-100), two 8312 power supply modules (230 VAC), and two MP 3008 main processor modules. The configuration provides the core of a Tricon safety controller, capable of hosting I/O modules and executing safety logic up to SIL 3.

Chassis Backplane Specifications

The chassis (model 3000602-100) is a 19-inch rack-mountable enclosure with 16 I/O slots and 2 dedicated processor slots. The backplane is a passive printed circuit board with 18 slots (16 I/O, 2 processor) and two additional slots for power supplies (positions P1 and P2). The backplane distributes power (5 VDC, 24 VDC) and TMR communication buses (triplicated serial buses for voting). The chassis dimensions are 483 mm (width) × 266 mm (height) × 220 mm (depth). Weight without modules is 5.5 kg; with two processors and two power supplies, approximately 8.2 kg. The chassis includes a grounding bar for protective earth and a terminal for connecting a cabinet ground.

Power Supply Modules: TRICONEX 8312

Two 8312 power supply modules are installed in the dedicated power slots. Each 8312 accepts 230 VAC input (range 187–253 VAC, 47–63 Hz) and provides the following outputs:

• 5 VDC at 20 A for logic circuits.

• 24 VDC at 8 A for field power to I/O modules (isolated).

• 24 VDC at 1 A for auxiliary purposes.

Efficiency is 85% typical. The modules operate in a redundant configuration: if one supply fails, the other automatically carries the full load. Each 8312 includes overvoltage, overcurrent, and overtemperature protection. Front panel LEDs indicate input present, output OK, and overload status. The modules are hot-swappable: a failed supply can be replaced without shutting down the controller, provided the other supply is operational. The 8312 measures 90 mm wide × 266 mm high × 200 mm deep and weighs 1.8 kg.

Processor Modules: MP 3008 (TRICONEX MP 3008)

Two MP 3008 main processor modules are installed in the processor slots (positions 1 and 2). The MP 3008 is a high-performance TMR processor with:

• 64-bit processor at 400 MHz.

• 2 MB user program memory (expandable to 8 MB via external memory card).

• 1 MB retentive variables with battery backup.

• Built-in Ethernet (10/100 Base-T) for Modbus TCP and TriStation access.

• Two RS-485 ports for expansion chassis communication.

• One RS-232 port for local programming.

The two processors operate in duplex mode (1-out-of-2) for the processor function; actually, each MP 3008 contains three internal channels (TMR), so two modules provide six processors in a 2-3-2 configuration. This yields extremely high availability. The modules are hot-swappable; one processor can be removed while the other continues operation. TriStation software version 5.0 or later is required for MP 3008 configuration.

Assembly Configuration and Interconnections

In this factory-assembled configuration, the two 8312 power supplies are wired internally to the backplane. The two MP 3008 processors are seated in slots 1 and 2. The chassis is pre-configured with jumpers setting the processor slot assignment (Primary and Secondary). A special diagnostic bus runs between the two processors and the backplane to synchronize their execution. The assembly also includes a front-accessible battery pack for processor memory retention; batteries are installed and should be replaced every 5 years.

I/O Module Capacity

The remaining 16 I/O slots can accommodate any combination of Tricon I/O modules:

• Analog input: 3720, 3721, 3722, 3722X

• Analog output: 3805E, 3806E

• Digital input: 3501E, 3502E, 3503E, 3504E

• Digital output: 3601E, 3603E, 3604E, 3607E

• Pulse input: 3511

• Specialty modules: 3564 (speed monitor), etc.

The chassis supports up to 2048 I/O points (depending on module mix). Remote expansion chassis (up to 16) can be connected via the MP 3008’s RS-485 ports using Triconex Trident or Tricon expansion cables.

Environmental and Electrical Ratings

Operating temperature: 0°C to 60°C (with forced air cooling; the chassis includes two 12 VDC fans). Storage: -40°C to 85°C. Humidity: 10–90% non-condensing. Power consumption: 200 W typical (including processors and two power supplies). Input current: 2 A at 230 VAC per power supply (redundant pair). Heat dissipation: 700 BTU/hour. The assembly is TÜV certified for SIL 3 and meets IEC 61508, IEC 61511, and ISA 84.01 standards. CE marking and UL 508 listing are also provided.

Installation Requirements

Mount the chassis in a 19-inch rack or on a panel using the supplied rack ears. Allow 100 mm clearance above and below for airflow. The chassis must be bolted to the rack using four M6 screws. Connect protective earth to the grounding stud on the chassis rear. Supply 230 VAC to both power supply inputs (separate circuits recommended for redundancy). Use a minimum wire gauge of 1.5 mm² for AC input. The fan exhaust must not be obstructed; ambient temperature should not exceed 60°C at the air intake.

After installation, power up the assembly; the two 8312 supplies should show green OUTPUT LEDs, and the MP 3008 processors should display a steady green RUN LED. Load the application program via TriStation Ethernet or serial connection. The assembly is now ready for I/O module insertion and field wiring.

Maintenance and Spares

Regular maintenance includes: cleaning air filters (if installed) every 3 months, verifying fan operation (audible noise), and checking battery voltage status via TriStation. Replace the processor backup batteries (part number 7400076-100) when a low battery alarm appears. The 8312 power supplies have internal fuses that are not user-replaceable; if a supply fails, replace the entire module. The MP 3008 processors can be firmware-upgraded in situ via Ethernet. The chassis backplane itself has no failure-prone components; however, in the event of physical damage (cracked PCB), replace the entire chassis assembly.

The TRICONEX 3000602-100 assembly is a ready-to-use core for a Tricon safety controller, suitable for emergency shutdown, fire and gas, and burner management systems in hazardous industries.