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This chapter describes standard cabinets that are available for Safety Manager systems.

Using standard cabinets provides several advantages over specifically designed cabinets. Honeywell SMS policy is aimed at delivering standard engineered, tested and certified (modular) concepts to the market for these main reasons:

Reusing existing concepts saves valuable time (e.g. engineering, testing, certification).

Individual projects will be delivered at a guaranteed level of quality and in short turn-around times.

Applying modularity within a proven overall concept provides for flexibility toward customers.

Typically, Safety Manager is installed in a standard cabinet. It is possible to add or rearrange certain components or change their location within the cabinet.

Also, standard Safety Manager remote cabinets are available. Depending on specific application needs one or more types can be opted for.

Should you not wish to follow the standard cabinet layout, then you can only do so after prior consult with Honeywell SMS.

Standard Rittal enclosure for Safety Manager

The standard enclosure for Safety Manager is based on two cabinet types available in the Rittal TS 8 series.

Safety Manager enclosures are default equipped with a swing frame, support glands, fans, an enclosure frame with steel doors, louvres and filters, an enclosure light, a thermostat, earthing strips, a mounting plate, gland plates, a rear panel and a roof or bottom plate. Side panels are mounted to the outer walls.

A standard Safety Manager enclosure is painted in RAL 7035, with RAL 7022 for the plinth.

Below sections provide more details related to the Rittal TS series as assembled and delivered by Honeywell SMS.

Enclosure light

The Rittal enclosure light (PS 4155.000) has an auto-select input voltage detector (110/230 V AC) and is equipped with a motion sensor. You no longer require an additional door switch. If the shipping section consists of more than one Rittal cabinet enclosure, all cabinets will have an enclosure light. All enclosure lights use the same feeder. The feeder is wired from the first cabinet (with an interconnection cable) to the second and, if applicable, from the second to the third cabinet, etc.

Fans

A pair of fans are mounted in the roof. The following types are available:

Papst, type 4184NX, operating voltage 24 V DC

Honeywell SMS fan unit which can be delivered in 3 voltages 24 V DC, 115 V AC, and one for 230 V AC. For a data sheet of the 24 V DC fan unit see FANWR-24R.

FANWR-24R (Preferred) 24Vdc fan unit with readback CC

51199947-275 FAN ASSEMBLY KIT 230VAC EC CC

51199947-175 Fan Assembly Kit, 115VAC, EC, CC

The Honeywell SMS fan units consist of a pair of fans. A read-back contact indicates the operational status of the fans.

Thermostat

The thermostat gives an alarm to alert you of temperature increasing inside the Safety Manager cabinet (e.g. when filters are blocked or fans fail). When a Honeywell SMS fan unit is installed, the thermostat is not required.

The Rittal SK 3110.000 thermostat is mounted on the top right-hand side of each Rittal cabinet and is suitable for temperatures ranging from +5°C-+55°C (+41°F-+131°F).

Fan unit 24 V DC with readback

The 24 V DC fan unit (FANWR-24R) consists of two fans and a printed circuit board (PCB) 07209 on a mounting plate.

The external 24 V DC power and readback contact wiring for the fan unit terminates on a 4 pole connector which slots into the fan unit.

Electronics in the fan unit generate the signals to indicate the fan status. If the speed of a fan is above minimum, a green LED next to that fan illuminates to indicate this. If both fans are above minimum speed the readback contact closes.

Finger guards are mounted on both sides of the fans.

The “Layout of the FANWR-24R fan unit and direction of air flow” below shows the direction of airflow and the bottom and side view of the fan unit.

Block diagram

The “Functional block diagram of the FANWR-24R fan unit” below shows a functional block diagram of the FANWR-24R fan unit.

Fan status indication

The fan unit is equipped with a potential free readback contact and green LEDs to indicate the fan status.

The readback contact is closed for about 15 seconds during powerup and when the rotation speed (RPM) of both fans is above the minimum speed.

A LED is on when the rotation speed (RPM) of the related fan is above the minimum speed.

Flow rate/Static pressure

The ” Flow rate against static pressure (per fan)” below shows the flow rate per fan against the static pressure. The grey area indicates the optimum operating range.

Electrical connections

The fan unit is equipped with a 4 pole screw connector to wire the readback contact and the 24Vdc power.

“Layout of the FANWR-24R fan unit and direction of air flow” on page 43 shows the location of the connector on the fan unit. The “The FANWR-24R fan unit connector details” on the facing page shows the connection details of this connector
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Analog Input Module

Each TMR Analog Input Module has three isolated sets of electronics, called channels, which independently process field data input to the module. Each channel places the processed data in an array and transmits this array, on request, to the MP associated with that channel. The MPs vote the data before passing it to the application. In TMR mode, the data passed is mid-value. In dual mode, the data passed is the average.

AI Modules include complete, ongoing diagnostics for each channel. If the diagnostics detect a failure on any channel, the Fault indicator turns on and activates the system alarm. The Fault indicator identifies a channel fault, not a complete module failure. AI Modules are guaranteed to operate properly in the presence of a single fault and may continue to operate properly with multiple faults.

AI Modules support a hot-spare module. Each AI Module is mechanically keyed to prevent improper installation in a configured baseplate.

The Model 3351 AI Module can be used with these baseplates:

• Model 2351, which is used in typical 4-20 mA applications.

• AI External Termination Baseplate,which is used with the Model 9764-510 RTD/TC/AI External Termination Panel or the Model 9792-310 AI Hazardous Location External Termination Panel.

• Model 2354, which is used in 4-20 mA applications and enables communication between HART field devices and Configuration and Asset Management Software running on a PC.

• Model 2354A, which is used in 4-20 mA applications in hazardous

locations and enables communication between HART field devices and Configuration and Asset Management Software running on a PC.

Analog Input/Digital Input Module

The Analog Input/Digital Input Module has 16 digital input points (points 1–16) and 16 analog input points (points 17– 32).

The AI/DI Module has three isolated sets of electronics, called channels, which independently process field data input to the module. Sensing of each input point is performed in a manner that prevents a single failure on one channel from affecting another channel.

For analog input points, each channel receives variable voltage signals from each point, converts them to digital values, and transmits the values to the three MPs on demand.

For digital input points, an ASIC on each channel scans each input point, compiles data, and transmits it to the MPs upon demand.

For all points, the MPs vote the data before passing it to the control program. In TMR mode, the data passed is midvalue. In dual mode, the data passed is the average.

AI/DI Modules sustain complete, ongoing diagnostics for each channel. If the diagnostics detect a failure on any channel, the Fault indicator turns on and activates the system alarm. The Fault indicator identifies a channel fault, not a complete module failure. AI/DI Modules are guaranteed to operate properly in the presence of a single fault and may continue to operate properly with multiple faults.

Analog Input/Digital Input Modules include the hot-spare feature which allows online replacement of a faulty module. The AI/DI Module is mechanically keyed to prevent improper installation in a configured baseplate.

The Model 3361 AI/DI Module is compatible with the Model 2361 AI/DI Baseplate and the AI/DI External Termination Baseplate.

Analog Output Modules

Each TMR Analog Output Module has three isolated sets of electronics, called channels, which independently accept data from the MP associated with each channel. The channels provide input to voter circuitry to select a single channel to drive the output. Special circuitry is used to ensure that the channels that are not driving the output are shunted so they cannot affect the output.

AO Modules include complete, ongoing diagnostics for each channel. If the diagnostics detect a failure on any channel, the Fault indicator turns on and activates the system alarm. The Fault indicator identifies a channel fault, not a complete module failure. AO Modules are guaranteed to operate properly in the presence of a single fault and may continue to operate properly with multiple faults.

AO Modules support a hot-spare module. Each AO Module is mechanically keyed to prevent improper installation in a configured baseplate.

The Model 3481 AO Module can be used with these baseplates:

• Model 2481, which is used in typical applications.

• Model 2483, which enables communication between HART field devices and Configuration and Asset Management Software running on a PC.

• Model 2483A, which is used in hazardous locations and enables communication between HART field devices and Configuration and Asset Management Software running on a PC.

• DO External Termination Baseplate, which is used with the Model 9863- 610 External Termination Panel in hazardous locations. Note that “DO” is not a typo, the DO External Termination Baseplate is used with the 9863-610.

The Model 3482 High-Current AO Module is compatible with only the Model 2481 Analog Output Baseplate.

Digital Input Module

Each TMR Digital Input Module has three isolated sets of electronics, called channels, which independently process field data to the module. Each channel places the processed data in an array and transmits this array, on request, to the MP associated with that channel. The MPs vote on the data before passing it to the application.

DI Modules include complete, ongoing diagnostics for each channel. If the diagnostics detect a failure on any channel, the Fault indicator turns on and activates the system alarm. The Fault indicator identifies a channel fault, not a complete module failure. The DI Module continuously verifies the ability of the system to detect transitions to the opposite state. DI Modules are guaranteed to operate properly in the presence of a single fault and may continue to operate properly with multiple faults.

DI Modules support a hot-spare module. Each DI Module is mechanically keyed to prevent improper installation in a configured baseplate.

The Model 3301 DI Module can be used with these baseplates:

• Model 2301, which is used with typical applications.

• DI External Termination Baseplate, which is used with the Solid State Relay Input External Termination Panel in high-voltage applications, or the Model 9573-610 DI Hazardous Location External Termination Panel.

Digital Output Module

Each TMR Digital Output Module has three isolated sets of electronics, called channels, which independently accept data from the MP associated with each channel. The channels use the patented Quad Voter circuitry to vote on individual output signals as they are applied to the load.

This voter circuitry is based on parallelseries paths which pass power if two out of three switches (channels A and B, or channels B and C, or channels A and C) command them to close. The Quad Voter circuitry has multiple redundancy on all critical signal paths, guaranteeing safety and maximum availability.

For each point, the DO Module periodically executes the Output Voter Diagnostic (OVD) routine. To allow unrestricted safe operation under a variety of multiple-fault scenarios, OVD detects and alarms these types of faults:

• Points—all stuck-on and stuck-offs are detected in less than 500 milliseconds.

• Switches—all stuck-on or stuck-off switches or their associated drive circuitry are detected.

DO Modules include complete, ongoing diagnostics for each channel. If the diagnostics detect a failure on any channel, the Fault indicator turns on and activates the system alarm. The Fault indicator identifies a channel fault, not a complete module failure. DO Modules are guaranteed to operate properly in the presence of a single fault and may continue to operate properly with certain multiple faults.

DO Modules support a hot-spare module. Each DO Module is mechanically keyed to prevent improper installation in a configured baseplate.

These baseplates can be used with the Model 3401 DO Module:

• Model 2401, which is used with typical applications.

• Model 2401L, which is used with low-current applications where integral current limiting is required. Each output is provided with a 180 ohm series resistor.

• DO External Termination Baseplate, which is used with the Relay Output External Termination Panel in highvoltage applications, or the Model 9671-610 DO Hazardous Location External Termination Panel.
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You can use a half-duplex serial connection to connect multiple MODBUS Slave devices to the AADvance controller. To make the physical connection, do the following:

1. Select an applicable cable. We recommend 3-pair, overall shielded cable.

2. Remove the serial port connector from the T9100 processor base unit.

3. Make the connections shown in the illustration. Terminate the twisted pairs with a 120 Ω resistor in series with a 68 nF capacitor at the receiver ends.

4. Connect the signal ground (not illustrated) from the 0 V terminal to the slave device.

5. Insert the connector into the T9100 processor base unit.

System Security

Serial networks are closed and local and have limited protocol functionality, so they are immune to any external attack apart from local deliberate sabotage. The AADvance system, however, with its computers and DCS interfaces, uses Ethernet networks which are frequently part of a larger corporate network and can expose the system to accidental or malicious infection or attack.

These steps help prevent such issues:

• Consider network and computer security, for example:

• The AADvance system must not be on a network with open unsecured access to the Internet.

• The Firewall must be active on the computer, helping prevent access to the relevant Ethernet ports on each communication interface. Antivirus software must be installed and be kept up-to-date.

• The computer must be password-protected. If using a laptop, keep the laptop locked when not in use.

• If the software uses a hardware license USB dongle, keep the USB dongle secure. The software will not run without the USB dongle.

• The application must be password-protected.

• Removable media, such as USB storage devices and CDs, must be virus checked before use in the system.

Connecting Field Wiring

Connect the field wiring to the screw terminal blocks on the termination assemblies.

Use conductor wire with a cross section of 16 AWG. The stripping length should be 6mm (1/4 in.) and a conductor temperature rating of 85 ºC. Apply a tightening torque of 0.5 Nm (0.37 ft. lb.) to the terminal screws.

Digital Input Field Loop Circuits

This section contains recommended field loop circuits for line monitoring digital inputs used in Emergency Shutdown or Fire & Gas applications.

Digital Input Slew Tolerance

It is possible during sustained periods of abnormal input voltage slewing that channels can be declared faulted as a consequence of diagnostics otherwise designed to verify that the channels are operating within their designed safety accuracy.

To avoid spurious declaration of channel faults it is necessary to ensure that the input signal condition satisfies the maximum slew rate criteria defined in the Solutions Handbook. Accordingly it may be necessary to condition the input signal such as by filtering or by appropriate choice of process safety time.

Analogue Input Field loop Circuits

These circuits can be used for simplex, dual and triple configurations of analogue input modules. Fit a fuse (as shown) in each circuit to protect the field wiring.

The recommended field loop circuits for analogue inputs are as shown below.

It is possible during sustained periods of abnormal input current slewing that channels can be declared faulted as a consequence of diagnostics otherwise designed to verify that the channels are operating within their designed safety accuracy

To avoid spurious declaration of channel faults it is necessary to ensure that the input signal condition satisfies the maximum slew rate criteria defined in the Solutions Handbook. Accordingly it may be necessary to condition the input signal such as by filtering, sensor slew rate configuration or by appropriate choice of process safety time.

Recommended Field Circuit for Digital Outputs

This circuit is applicable for simplex and dual configurations of digital output modules. The two 10 A fuses shown are included on the termination assembly within the controller. The 5 A fuses satisfy UL508 requirements for digital output field supplies, see illustration below:

The 10A fuses are fitted into the termination assembly and are:

• T9902: SMF Omni-Block, Surface Mount Fuse Block 154 010, with a 10A, 125V Fast Acting Fuse, Littelfuse.

It is possible during sustained periods of abnormal input current slewing that channels can be declared faulted as a consequence of diagnostics otherwise designed to verify that the channels are operating within their designed safety accuracy.

To avoid spurious declaration of channel faults it is necessary to ensure that the field supply voltage and output signal condition satisfies the maximum slew rate criteria defined in the Solutions Handbook. Accordingly it may be necessary to condition the field supply voltage or output signal such as by filtering or by appropriate choice of process safety time.

Recommended Circuit for Analogue Outputs

These circuits are suitable for simplex and dual configurations of analogue output modules. All channels are isolated from each other but may be bridged at the ‘+’ terminal if fed by a common system mounted supply.

The above circuit is appropriate for devices that are powered by the system. The channel will pass a requested current between 0mA and 24mA. The field device could also be connected between the 24V supply and the Loop Plus terminal

The above circuit is appropriate for devices that are powered locally and expect a current-controlled signal loop. Ensure that the loop is wired to pass current to the Loop Plus terminal and return it on the Loop Minus terminal.

Analogue Output Slew Tolerance

Analogue output channels voltage slew is unconstrained with the limits set by the module’s compliance operating voltage range.

To avoid spurious declaration of channel faults it is necessary to ensure that the field supply voltage and output signal condition satisfies the maximum slew rate criteria defined in the Solutions Handbook. Accordingly it may be necessary to condition the field supply voltage or output signal such as by filtering or by appropriate choice of process safety time.

This diagram shows the T9882. The T9881 has the same terminal arrangement.

Install Modules

The modules of the AADvance controller mount onto the base units. The processor module(s) mount onto the T9100 processor base unit, while the various I/O modules mount onto the T9300 I/O base unit and associated termination assemblies.

The product range includes two sizes of blanking covers to conceal unused module positions. The shorter cover is for a spare position on the processor base unit, while the taller coveris for a spare position on an I/O base unit.
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When the safety and protection of your most valuable assets is critical to the success of your business, you can rely on TriconexTM. For more than 30 years we have been delivering safety for life, protecting people and keeping equipment and production operating safely and continuously for the life of the asset.

The latest Triconex innovations

Triconex is the world’s leading supplier of safety instrumented systems for high-hazard industries. There are more than 15,000 Triconex systems installed worldwide in more than 80 countries, operating for approximately 1 billion hours. We are dedicated to delivering safety for life, protecting people, and keeping plants and production operating safely and continuously for the life of the asset

What’s new from Triconex at a glance

• New Tricon version 11.2

• New TriStationTM version 4.14

• New TriStation Emulator version 1.6.0

• New Enhanced Diagnostic Monitor version 2.11

• New Triconex Safety Validator application version 1.0

• New Safety View version 1.1

• New DDE Server version 4.6.0

• New Triconex Report generator version 4.14

• New Triconex safety template object version 1.1.0

• New Triconex SOE recorder version 4.5.0

• New Triconex TSAA DI Object version 1.3.0

• New enterprise safety calculation and life cycle management software

• New functional safety education and learning services

Continuously innovating for enhanced performance

At Triconex we are proud of our pedigree, passion, and focus on safety. We continue to innovate as demonstrated by decades of technology breakthroughs and industry recognition. Never satisfied, we believe in finding new ways to make our clients safer and more successful, working closely to ensure that every aspect of the safety life cycle is addressed, leaving no stone unturned or opportunity for improvement uncovered.

Triconex highlights

• More than 15,000 systems in operation

• More than 650 dedicated safety engineers

• More than 1 billion hours of safe operation

Benefits

Some of the many benefits of the latest Triconex offerings include:

• Enhanced operational efficiency\

• Increased plant uptime

• Reduced downtime costs

• Lower investment costs

• Lower life cycle costs

• Improved productivity

Tricon version 11.2

Online upgrade starts here

The latest release of the Tricon Main Processor module (3009) now provides the ability to upgrade from a Tricon 10.3, 10.4, or 10.5 system with 3008 Main Processors to a Tricon 11.2 system with model 3009 Main Processors, while the system is online.

New features of the latest Tricon release include:

• Ability to seamlessly upgrade from a Tricon 10V.3,x – V10.5 system with 3008 Main Processors to a Tricon V11.2 system with model 3009 Main Processors while the system is online (module swap process).

• When only Tricon Communication Modules (TCMs) are installed, the maximum number of tagnames is now approximately 29,000 (previous versions supported a maximum of approximately 13,000 tagnames) with a corresponding increase in bin sizes.

• Ability to make changes to the SOE and peer-topeer configuration, and increase the I/O memory allocation, while in the Download Changes state.

• Improved, more secure versions of the TSAA and TriStation protocols

• Addition of extended module information for the Main Processor and TCM.

TriStation version 4.14

Powering productivity

The latest release of TriStation delivers an improved, easier-to-use interface for configuring, developing, and testing Triconex systems and applications. New tabular layouts simplify configuration and data management, increasing productivity and efficiency.

New features of the latest TriStation release include:

• New improved graphical user interface (GUI) providing easier-to-use functionality and navigation for configuring modules and editing/ creating tagnames.

• Support for Tricon system version 11.2.

• Support for an increased number of tagnames in Tricon 11.2 systems using the model 8120E Enhanced Performance Main Chassis. The maximum number of tagnames is now approximately 29,000 (previous versions supported a maximum of approximately 13,000 tagnames).

• Embedded upgrade wizard to support the new online system upgrade functionality

• Ability to automatically save a TriStation 1131 project file (.pt2) at a user-defined time interval.

• Improved build and download verification times.

• Addition of new function blocks

TriStation Emulator version 1.6

Avoid application errors

The TriStation emulator allows you to emulate, execute, and test Triconex applications without the need for a physical controller. Applications can be tested in an offline environment without exposing your online process to potential application errors.

New features of the latest TriStation Emulator version include:

• Support for Tricon system version 11.2.

• Support for an increased number of tagnames with a corresponding increase in bin sizes in Tricon 11.2 and later systems with only TCMs installed. The maximum number of tagnames is now approximately 29,000 (previous versions supported a maximum of approximately 13,000 tagnames).

• When emulating a Tricon 11.2 and later system with a TCM installed, the new extended alias number ranges are supported when using the Modbus TCP and TSAA protocols or communicating with the DDE Server
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The NRC has certified that the Tricon controller is suitable for use in nuclear 1E applications within the limitations and guidelines referenced in the NRC Safety Evaluation Report (SER) ML120900890, Final Safety Evaluation By The Office Of Nuclear Reactor Regulation, Triconex Topical Report 7286-545-1, Revision 4. This report is available from the NRC via the Agency Document Access and Management System (ADAMS) website. This qualification was based upon EPRI TR-107330, Generic Requirements Specification for Qualifying a Commercially Available PLC for Safety-Related Applications in Nuclear Power Plants.

Notes

For compliance with the CE 102 conducted emissions requirements, the Model 8311N2 24 VDC Power Module requires installation of an external line filter (Corcom Model 60DCB6F) on the input power leads. For the Model 8310N2 120 V Power Module and the Model 8312N2 230 VAC Power Module, please contact the Global Customer Support (GCS) center.

The Model 3009 Main Processor and the Model 4610 Unified Communication Module are not certified for use in nuclear 1E applications.

For details on models and revisions qualified for 1E applications, please contact the Global Customer Support (GCS) center.

European Union CE Mark

Based upon independent TÜV evaluations and test results, Invensys has certified that:

The Tricon v10.x and Tricon v11.x controllers are suitable to use in the European Union and all other jurisdictions requiring compliance with the European Union EMC Directive No. 2004/108/EC and Low Voltage Equipment Directive No. 2006/95/EC.

The Tricon v9.x controller is suitable to use in the European Union and all other jurisdictions requiring compliance with the European Union EMC Directive No. 89/336/EEC and Low Voltage Equipment Directive No. 72/23/EEC

See the EC Declarations of Conformity for details.

Refer to Chapter 3, Installation and Maintenance for application-specific installation instructions.

Declaration of Conformity

The following declarations of conformity with the European Union directives for electromagnetic compatibility and low-voltage equipment are provided as a convenience. These declarations are the latest available at publication time and may have been superseded. For updates, contact the Global Customer Support (GCS) center.

EU Directives Covered by this Declaration

2004/108/EC Electromagnetic Compatibility Directive

2006/95/EC Low Voltage Equipment Directive

Products Covered by this Declaration

Tricon (Triple Modular Redundant Controller) Version 11.x—2770H, 2870H, 3008, 3009, 3501T, 3502E, 3503E, 3504E, 3505E, 3510, 3511, 3515, 3564, 3601T, 3603T, 3604E, 3607E, 3614E, 3615E, 3617E, 3623T, 3624, 3625, 3625A, 3636T, 3664, 3674, 3700, 3700A, 3701, 3703E, 3704E, 3706A, 3708E, 3720, 3721, 3805E, 3805H, 3806E, 3807, 4200, 4201, 4210, 4211, 4351, 4351A, 4351B, 4352, 4352A, 4352B, 4353, 4354, 4409, 4610, 8310, 8311, 8312, chassis, termination products

Basis on which Conformity is being Declared

The product identified above complies with the requirements of the above EU Directives by meeting these standards.