Information About Tricon Model 8312 Power Module
1. Basic Overview of Model 8312
The Model 8312 is a 230 VAC Power Module designed specifically for Tricon v9–v10 systems. It is a key component of the Tricon controller's power supply subsystem, featuring a dual-redundant configuration when paired with another Power Module (of any compatible model like 8310, 8311) in the same chassis. This redundancy ensures that even if one Power Module fails, the other can independently support the power requirements of all modules in the chassis, maintaining uninterrupted operation of the Tricon controller. The module converts 230 VAC line power into stable DC power suitable for powering various Tricon modules (such as Main Processors, I/O modules, and communication modules) and integrates built-in diagnostic circuitry to monitor power supply status and detect faults in real time.
2. Key Specifications of Model 8312
2.1 Electrical Specifications
Isolation Performance: Provides a minimum isolation of 1000 VAC or 1500 VDC between the input and output, effectively preventing ground loops and electrical interference from affecting the normal operation of the module and connected devices.
Input Voltage Range: The nominal input voltage is 230 VAC, with a tolerance range of -15% to +10% (i.e., 195.5 VAC to 253 VAC). The extended input voltage range is 185 VAC to 285 VAC, allowing the module to adapt to fluctuations in the power grid and ensuring stable operation in different power supply environments.
Input Power Requirement: A minimum of 240 W of input power is required per power source to ensure the module can meet the power demands of all modules in the chassis under full load conditions.
Input Frequency: Operates at a frequency range of 47 to 63 Hz, compatible with the standard power grid frequencies used in most regions worldwide.
Power Factor and Crest Factor: The typical power factor is 0.70, and the typical crest factor is 2.5, ensuring efficient utilization of electrical energy and reducing the impact on the power grid.
Input Current: Under steady-state operation, the typical input current is 0.4 amps, with a maximum of 1.2 amps. The inrush current (for 1/2 AC cycle) can reach a maximum of 18 amps at 230 VAC, so appropriate circuit protection measures (such as matching circuit breakers) should be considered during installation.
Input Fuse: Equipped with a 2.5 amp time-delay fuse to protect the module from damage caused by overcurrent. The fuse is mounted inside the module for easy replacement when necessary.
Output Voltage: Delivers a stable output voltage of 6.5 VDC with a tolerance of ±1% under all operating conditions, providing reliable power for the Tricon backplane and connected modules.
Output Current: At an ambient temperature of 140°F (60°C) (measured at the bottom of the chassis), the module provides a minimum output current of 27 amps, which is sufficient to power multiple modules in the chassis.
Output Power: The maximum output power is 175 watts at 140°F (60°C) ambient temperature, ensuring that the module can meet the power consumption needs of the chassis even in high-temperature environments.
Output Hold Time: When the input voltage drops to 0 volts, the module can maintain the output for a minimum of 20 milliseconds and a typical of 80 milliseconds. This short-term power retention helps prevent data loss or system instability caused by momentary power interruptions.
Output Over-Voltage Protection: The module features over-voltage protection that typically triggers at 125% of the rated output voltage. When an over-voltage fault occurs, the module stops outputting power, and power needs to be recycled to restart the module, protecting downstream modules from damage due to excessive voltage.
Output Over-Current Limit: The typical over-current limit is 140% of the rated output current. When an over-current condition is detected, the module automatically limits the current and resumes normal operation once the fault is resolved, preventing damage to the module and the power supply circuit.
2.2 Environmental Specifications
Operating Temperature: The module operates within a temperature range of 32°F to 140°F (0°C to 60°C), which is suitable for the harsh temperature environments commonly found in industrial settings (such as factories, refineries, and power plants).
Storage Temperature: Can be stored at temperatures ranging from -40°F to 167°F (-40°C to 75°C), facilitating transportation and long-term storage without affecting the module's performance.
Relative Humidity: Operates normally at a relative humidity of 5% to 95% (non-condensing), ensuring stable performance in humid environments without issues like moisture-induced short circuits.
Vibration Resistance: Complies with the requirements of IEC 60068-2-6, capable of withstanding sinusoidal vibrations of 2 G at a frequency range of 10 to 150 Hz, making it suitable for installations in locations with mechanical vibration (such as near rotating machinery).
Shock Resistance: Meets the specifications of IEC 60068-2-27, able to withstand a shock of 15 G for 6 to 11 ms in each axis, protecting the module from damage during transportation or sudden impacts.
3. Installation Guidelines for Model 8312
3.1 Chassis Compatibility
The Model 8312 Power Module is compatible with Tricon v9–v10 Main Chassis (Model 8110), Expansion Chassis (Models 8111, 8121), and RXM Chassis (Model 8112). It must be installed in the dedicated Power Module slots at the lower left of the chassis. During initial installation, the chassis should be powered off to avoid electrical shock and damage to the module or backplane.
3.2 Wiring Requirements
Input Power Wiring: Use appropriate-gauge wires (selected based on local electrical codes, considering current ratings, temperature, and wiring length) to connect the 230 VAC power supply to the terminal strip on the backplane above the Power Module. The terminal strip includes terminals for Line (L), Neutral (N), and chassis ground (protective earth). Ensure that the wiring is secure to prevent loose connections that could cause overheating or power interruptions.
Grounding: The chassis ground terminal must be connected to a reliable safety ground (protective earth) to protect personnel from electrical shock and shield the module from electromagnetic interference. The ground wire should be a heavy-gauge (e.g., 8-gauge or larger) solid or stranded wire, and the connection should be low-impedance.
Alarm Wiring: The Power Module is equipped with alarm contacts (normally open (NO), common (C), and normally closed (NC)) on the backplane terminal strip. These contacts can be connected to external alarm devices (such as buzzers, lights, or annunciators) to alert maintenance personnel when a fault (such as over-temperature or low voltage) occurs. However, it is important to note that these alarm contacts must not be used in hazardous locations to avoid safety risks.
3.3 Special Installation Notes for Hazardous Locations
ATEX Compliance Restriction: The Model 8312 Power Module is not suitable for use in Tricon systems located in hazardous locations that must meet ATEX requirements. If the system operates in such locations with 230 V line power, it is recommended to use the Model 8311 24 VDC Power Module together with an ATEX-certified 24 VDC power supply (e.g., Phoenix Contact part number QUINT-PS100-240AC/24DC/10/EX) to ensure compliance with safety standards.
Hazardous Location Wiring: When installing the module in non-ATEX hazardous locations (such as Class I, Division 2), the enclosure housing the chassis must provide adequate protection (e.g., NEMA 4 rating) to prevent the entry of flammable gases or dust. All wiring must comply with the relevant hazardous location electrical codes, and the module should only be replaced when the area is confirmed to be free of ignitable gas concentrations.
4. Diagnostic and Alarm Functions of Model 8312
4.1 Built-in Diagnostic Circuitry
The Model 8312 integrates comprehensive diagnostic circuitry that continuously monitors the module's operating status, including:
Voltage Monitoring: Tracks the input and output voltages in real time. If the input voltage is outside the specified range or the output voltage exceeds the over-voltage threshold, the diagnostic circuitry triggers a fault alarm.
Over-Temperature Monitoring: Equipped with an over-temperature warning sensor. When the internal temperature of the Power Module exceeds 181°F (83°C) (typically occurring when the ambient temperature reaches 140°F (60°C) or higher), the sensor activates the over-temperature alarm, preventing the module from being damaged due to overheating.
Current Monitoring: Monitors the output current to detect over-current conditions. When the output current exceeds the over-current limit, the module limits the current to protect the power supply circuit and connected modules.
4.2 Status Indicators
The front panel of the Model 8312 Power Module is equipped with LED indicators that provide visual feedback on the module's status, enabling on-site personnel to quickly identify operational conditions and faults:
PASS Indicator (Green): Illuminates when the module passes self-diagnostics (including checks for normal power supply, proper backplane communication, and no internal faults), indicating that the module is operating normally.
FAIL Indicator (Red): Turns on when the module detects a fault (such as input voltage out of range, output over-voltage, over-current, or over-temperature), alerting personnel to address the issue promptly.
ALARM Indicator (Red): Activates when an alarm condition occurs (e.g., over-temperature, low input voltage, or a fault in another module in the chassis). It works in conjunction with the alarm contacts to notify personnel of abnormal conditions.
TEMP Indicator (Yellow): Lights up when the internal temperature of the module approaches the over-temperature threshold (but has not yet reached the fault level), serving as a pre-warning for potential overheating issues.
BAT LOW Indicator (Yellow): Although the Model 8312 itself does not have a battery, this indicator may be related to the chassis's backup battery status. If the chassis's backup battery voltage is low, this indicator turns on, reminding personnel to replace the battery.
4.3 Alarm Behavior in Different Chassis Types
Main Chassis Alarm Behavior: In the Main Chassis, the alarm contacts of the Model 8312 Power Module are activated when any of the following situations occur: a mismatch between the controller configuration and the control program configuration; a Status/Status error in a Digital Output (DO) Module; a missing module in the controller; a failure of a Main Processor or I/O module in the Main Chassis; a failure of an I/O module in an Expansion Chassis; a system fault detected by a Main Processor; or incorrect installation of inter-chassis I/O bus cables (e.g., connecting the cable for Channel A to Channel B by mistake). Additionally, an alarm contact on at least one Main Chassis Power Module is activated if a Power Module fails, the primary power supply to a Power Module is lost, or a Power Module has a Low Battery or Over Temperature warning.
Expansion Chassis Alarm Behavior: In an Expansion Chassis, the alarm contacts of both Power Modules (including the Model 8312) are activated when an I/O module fails. An alarm contact on at least one Power Module is activated if a Power Module fails, the primary power supply to a Power Module is lost, or a Power Module has an Over Temperature warning.
5. Maintenance and Replacement of Model 8312
5.1 Routine Maintenance
Regular Inspection: Periodically inspect the module's status indicators to ensure the PASS indicator is on and no fault or alarm indicators are illuminated. Check the wiring connections (including input power, grounding, and alarm wiring) to ensure they are secure and free from corrosion or damage.
Cleaning: Keep the module and the surrounding chassis area clean to prevent dust accumulation, which can affect heat dissipation and lead to overheating. Use a dry, lint-free cloth to wipe the front panel and vents of the module (ensure the chassis is powered off before cleaning to avoid electrical shock).
Proof Testing: Conduct regular proof tests on the Model 8312 Power Module to verify its ability to provide power for the entire system when the redundant Power Module is disabled. The maximum recommended interval between proof tests depends on the Risk Reduction Factor (RRF): for an RRF > 1000 (roughly equivalent to the risk reduction required for SIL 3 safety applications), the interval is 2 years; for an RRF > 100 (required for SIL 2 applications), the interval is 5 years. The proof test should ideally be performed during scheduled plant maintenance when the controlled process is offline. The test procedure involves turning off one power source, leaving it off for several minutes, restoring power, and then repeating the test for the other power source.
5.2 Module Replacement
Replacement Preparation: Before replacing the Model 8312 Power Module, ensure that the redundant Power Module is connected to an active power source and is operating normally to maintain power supply to the chassis during the replacement process. Prepare a replacement Model 8312 module and necessary tools (such as a 1/4-inch flat-bladed screwdriver).
Replacement Procedure:
Use the screwdriver to loosen the retractable fasteners on the faulty Power Module. Grasp the fasteners firmly and slide the module out of the chassis.
Carefully slide the replacement Model 8312 Power Module into the empty slot, ensuring it is properly aligned with the backplane connectors. Push the module firmly to seat it in the bus.
Tighten the retractable fasteners to secure the module in place. The recommended torque is 10 inch-pounds; do not overtighten to avoid damaging the module or chassis.
After installation, check the status indicators of the replacement module. The PASS indicator should illuminate within a short time, indicating that the module is operating normally.
Post-Replacement Notes: After replacing the module, verify that all modules in the chassis are functioning properly and that there are no fault or alarm indicators illuminated. For the faulty module, record its model and serial numbers, contact the IPS Global Client Support (GCS) center to obtain a Returned Material Authorization (RMA) number, and return the module to Triconex for repair or replacement. Additionally, if a Power Module has been removed for any reason, do not attempt to reinstall it for at least 60 seconds to allow the module to discharge and prevent damage from inrush current during reinstallation.
6. Compatibility and System Integration
6.1 Compatibility with Tricon Systems and Modules
The Model 8312 Power Module is fully compatible with Tricon v9–v10 systems, including all types of Tricon chassis (Main, Expansion, and RXM Chassis) and modules (Main Processors, I/O modules, communication modules, etc.). It can be used in combination with other Power Module models (8310, 8311) in the same chassis to form a dual-redundant power supply system, ensuring high reliability of the power supply. When configuring the system, the total logic power consumption of all modules in the chassis should not exceed 175 watts (the maximum output power of a single Model 8312 module at 140°F (60°C) ambient temperature) to avoid overloading the module.
6.2 Integration with Uninterruptible Power Supply (UPS)
In critical applications (such as nuclear power plants, petrochemical refineries, and oil & gas pipelines) where power supply continuity is crucial, the Model 8312 Power Module can be connected to an Uninterruptible Power Supply (UPS). The UPS should be rated for the total number of chassis it needs to power and the duration of the maximum expected power outage. Connecting the module to a UPS ensures that the Tricon system remains operational during power grid failures, preventing process shutdowns or data loss caused by power interruptions. When selecting a UPS, ensure it is compatible with the 230 VAC input voltage and the power consumption requirements of the Tricon system.
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