Description
Product Overview
The Tricon 3604E is a high-density, 32-point, 24V DC digital input module designed for the Tricon v9, v10, and v11 series Triple Modular Redundant (TMR) Safety Instrumented Systems (SIS), manufactured by Invensys (now part of Schneider Electric). It is a critical component in the Triconex I/O subsystem, responsible for safely and reliably acquiring discrete (on/off) signals from 24V DC field devices—such as emergency stop buttons, pressure switches, level switches, limit switches, and solenoid valve feedback—and transmitting this data in a TMR format to the Tricon’s Main Processor for logic solving. The 3604E module provides the vital interface between the plant’s field wiring and the fault-tolerant safety controller, converting 24V DC signals into a logic-level format that the controller can process. The «E» suffix indicates an enhanced version, typically offering improved diagnostics, performance, or compatibility with newer chassis.
The core value of the Tricon 3604E lies in its triple-channel safety architecture, high-density packaging, and robust design for industrial 24V DC control circuits. Similar to its AC counterpart, the 3604E contains three completely independent input circuits per channel. Each of the 32 field inputs is read by three separate internal circuits, and the results are voted upon within the module and the Main Processor. This TMR design ensures that a single failure in any part of the input circuitry (e.g., a failed opto-isolator, a wiring short) will be diagnosed and will not cause a dangerous, undetected failure of the safety function. For engineers and operators in industries like oil and gas, petrochemicals, and power generation, the 3604E is a trusted, high-integrity component essential for building safety systems that meet rigorous SIL 3 (IEC 61508/61511) certification requirements, where failure is not an option. Its 24V DC compatibility makes it the standard choice for interfacing with modern solid-state sensors, switches, and relay outputs in control panels.
Technical Specifications
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Parameter Name
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Parameter Value
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Product Model
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Tricon 3604E
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Manufacturer
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Invensys Triconex (now part of Schneider Electric)
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Product Family
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Tricon TMR Digital Input Module
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Primary Function
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32-point, 24V DC Triple Modular Redundant (TMR) Digital Input Module
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Electrical Characteristics (Per Channel)
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Input Type: Sinking (Dry Contact) or Sourcing (Wet Contact) compatible. Designed for switch, relay contact, or solid-state (NAMUR) inputs.
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Input Voltage: Nominal 24V DC. Operating range typically 10-30V DC.
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«ON» State Threshold: > 10V DC typically to recognize a logical «1».
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«OFF» State Threshold: < 5V DC typically to recognize a logical «0».
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Input Current: Typically 5-10 mA per point at 24V DC.
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Input Impedance: Approximately 3-5 kΩ.
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Response Time: Typically 5-10 milliseconds (including filtering for noise immunity). Faster than AC modules.
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Point Density: 32 points per module.Safety & Isolation
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Architecture: TMR (Triple Modular Redundant) per point. Each field input is connected to three completely isolated input circuits (A, B, C) within the module.
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Isolation:
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Channel-to-Channel: Optical isolation between each of the three internal input circuits and the field side.
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Field-to-System: High-voltage optical isolation (typically 1500V AC) between the field wiring terminals and the module’s internal logic/system side.
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Field-to-Field: Points are typically grouped (e.g., in banks of 8 or 16) with isolation between groups.
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Fusing: Each point or group of points includes internal fuses or electronic current limiting for overcurrent protection.Mechanical & Integration
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Form Factor: A hot-swappable module designed for the Tricon High Density (HD) I/O Terminator Baseplate (e.g., 9563-610, 9563-810 series).
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Termination: Field wiring connects to a removable terminal block on the associated terminator baseplate, not directly to the 3604E module itself.
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LED Indicators: Per-point status LEDs (green for ON, off for OFF) and module health LEDs (Power OK, Fault) for quick visual diagnostics.
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Diagnostics: Comprehensive built-in diagnostics for open field wiring, short circuits, loss of field power, internal circuit faults, and mismatch between the three channels. Faults are reported to the Main Processor and can be alarmed.Environmental
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Operating Temperature: 0 to 60°C (32 to 140°F)
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Certifications: Designed and certified for use in SIL 3 (IEC 61508) safety systems. Suitable for harsh industrial environments.
Key Features and Advantages
Inherent Safety with TMR Architecture: The triple-redundant design per input point is the paramount feature. It provides a high level of hardware fault tolerance (HFT) and a Safe Failure Fraction (SFF) that meets SIL 3 requirements. A single random hardware fault will be diagnosed, and the system will continue to operate safely.
High Density with Proven Reliability: Packing 32 isolated input points into a single module slot optimizes cabinet space and reduces system cost per point while maintaining the high reliability and diagnostic coverage expected from the Tricon platform.
Advanced Diagnostics and Hot-Swap Capability: The module continuously performs self-diagnostics. Any fault (field or internal) is immediately reported. Combined with online insertion and removal (hot-swap), this allows for maintenance or replacement of a faulty module without shutting down the safety controller or the process, maximizing system availability.
Robust Noise Immunity and Fast Response: Designed for industrial 24V DC environments, the input circuitry includes filtering to reject electrical noise (EMI/RFI) and contact bounce. Its faster response time (compared to AC modules) makes it suitable for high-speed safety interlocks.
Application Areas
The Tricon 3604E is used in safety-critical shutdown systems (ESD/PSD/F&G) across all major hazardous process industries where reliable acquisition of discrete 24V DC field signals is required for SIL 3 rated safety functions.
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Emergency Shutdown (ESD) Systems: Reading status from 24V DC emergency stop buttons, pressure switches, level switches, flame detectors, and gas detectors with relay outputs.
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Fire & Gas (F&G) Systems: Monitoring inputs from 24V DC manual call points, smoke/heat detectors, and gas detectors.
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Burner Management Systems (BMS): Acquiring signals from 24V DC flame scanner relays, fuel valve limit switches, and purge flow switches.
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Turbomachinery Control (TMC): Monitoring overspeed switches, vibration switches, and lube oil pressure switches with solid-state outputs.
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General Process Interlocks: Reading status of 24V DC pump running feedback, solenoid valve position feedback, and proximity switches.
Related Products
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Terminator Baseplate: The HD I/O Terminator Baseplate (e.g., 9563-610 for 24V DC DI) is required. It provides the field wiring terminals, fuses, and signal conditioning circuitry. The 3604E module plugs into this baseplate.
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Tricon Chassis & Main Processor: Such as the Tricon Chassis 3008/3009/3510/3511 and the corresponding Main Processor (MP), which houses and communicates with the I/O modules.
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Field Wiring Cables: Cables to connect from the terminator baseplate to the field devices.
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External 24V DC Power Supply: A reliable, clean 24V DC power source is required to power the field devices connected to the module inputs.
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Programming & Configuration Software: Triconex TriStation 1131 is used to configure the module, assign I/O addresses, and set up diagnostics.
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Other I/O Modules: In the same family: 8312 (120V AC, 32-point), 3605E (24V DC Digital Output), and various analog input/output modules.
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