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Product Overview: TRICONEX 3525A
The TRICONEX 3525A is a high-reliability relay output module designed for safety instrumented systems (SIS) in critical industrial environments. It is a key component of TRICONEX’s Tricon and Trident safety platforms, which are widely deployed in industries requiring uncompromising safety performance. The TRICONEX 3525A functions as a critical interface between safety controllers and high-power field devices, converting low-voltage control signals from the controller into robust relay outputs to actuate equipment such as emergency shutdown valves, fire suppression actuators, and isolation relays.
Built on TRICONEX’s patented triple modular redundancy (TMR) architecture, the TRICONEX 3525A processes each output signal through three independent channels, with a 2-out-of-3 voting mechanism to eliminate single points of failure. This design ensures that the module remains operational even if one channel malfunctions, a feature that is indispensable in environments where equipment failure could lead to accidents, production losses, or environmental harm.
The TRICONEX 3525A is engineered to withstand harsh industrial conditions, including extreme temperatures, electromagnetic interference, and corrosive atmospheres. Its rugged construction, combined with advanced diagnostic capabilities, makes it a staple in industries such as oil and gas, chemical processing, and nuclear power generation, where safety and operational continuity are paramount.
Technical Specifications
| Parameter | Value |
|---|---|
| Product model | TRICONEX 3525A |
| Manufacturer | TRICONEX |
| Product type | Relay output module |
| Physical dimensions | 110 mm (height) × 165 mm (width) × 60 mm (depth) |
| Weight | 1.05 kg |
| Electrical specifications | 24 V DC operating voltage; 2.0 A maximum current per channel |
| Output channels | 12 isolated relay outputs |
| Relay rating | 10 A @ 250 V AC / 30 V DC (resistive load) |
| Isolation | 2500 V DC channel-to-bus and channel-to-channel isolation |
| Working environment | Operating temperature: -40°C to 70°C; Relative humidity: 5%–95% (non-condensing) |
| Certifications | SIL 3 compliant (IEC 61508); ATEX/IECEx certified (Zone 1/2); UL 508 listed |
| Installation requirements | 19-inch rack mount; DIN rail compatible; vibration resistance up to 5 g (10–2000 Hz) |
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Related Products
- TRICONEX 3503E: A relay output module with 8 channels, serving as a lower-density alternative to the TRICONEX 3525A. It is suitable for smaller-scale safety systems where fewer outputs are required.
- TRICONEX 3504E: A 16-channel relay module with a higher channel count than the TRICONEX 3525A, designed for large-scale industrial systems needing more relay outputs.
- TRICONEX 3301S2: A digital input module that pairs with the TRICONEX 3525A to form a complete safety loop. It sends sensor signals to the controller, which then triggers outputs via the TRICONEX 3525A.
- TRICONEX MP 3101: The main processor module of TRICONEX SIS. It executes safety logic and sends control commands to the TRICONEX 3525A to actuate field devices during abnormal conditions.
- TRICONEX 4400: A redundant power supply module that provides stable 24 V DC power to the TRICONEX 3525A, preventing relay misoperation due to voltage fluctuations.
- TRICONEX 3211: A communication interface module that enables the TRICONEX 3525A to transmit relay status data to SCADA systems, supporting remote monitoring of safety loop performance.
- TRICONEX 3604E: A high-density relay module with 32 channels, used in large industrial complexes where the TRICONEX 3525A’s 12 channels are insufficient.
Main features and advantages
Triple Modular Redundancy (TMR) Architecture: The TRICONEX 3525A processes each output signal through three independent channels. A 2-out-of-3 voting mechanism ensures that only consistent signals are sent to field devices. This design eliminates single-point failures, guaranteeing operation even if one channel malfunctions. This is critical for applications such as offshore oil platform emergency shutdown systems, where any failure could lead to catastrophic consequences.
12 Isolated Relay Outputs: The TRICONEX 3525A offers 12 isolated relay outputs, striking a balance between channel density and operational flexibility. This makes it suitable for medium-scale safety systems, reducing the number of modules needed and simplifying wiring in control cabinets. Its isolated channels prevent cross-talk between signals, ensuring reliable operation in electrically noisy environments such as chemical plants.
High-Power Relay Capability: Each relay in the TRICONEX 3525A is rated for 10 A @ 250 V AC / 30 V DC (resistive load), making it capable of controlling high-power devices such as large motorized valves, industrial heaters, and fire suppression system pumps. The relays are hermetically sealed to resist dust, moisture, and chemical fumes, extending their service life in harsh industrial settings.
Advanced Diagnostic Features: The TRICONEX 3525A includes real-time monitoring of relay contacts, coil integrity, and power supply status. It detects faults such as welded contacts or open coils in under 20 ms, reporting these issues to the SIS controller immediately. LED indicators on the module provide at-a-glance status checks, simplifying on-site troubleshooting and reducing maintenance time.
Hot-Swap Functionality: Technicians can replace the TRICONEX 3525A without powering down the SIS, minimizing downtime. This feature is particularly valuable in continuous-process industries such as pharmaceuticals, where production halts can result in significant financial losses.
Safety Certifications: The TRICONEX 3525A is certified to SIL 3 (IEC 61508) and ATEX/IECEx for Zone 1/2 hazardous areas, ensuring compliance with global safety standards. This certification is essential for industries handling flammable or toxic materials, where equipment failure could cause explosions or environmental contamination.
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Installation and maintenance
Pre-installation preparations: Before installing the TRICONEX 3525A, verify that the SIS controller’s firmware is compatible with the module. Inspect the module for physical damage, such as bent pins or cracked casing, to ensure it is in good condition. Ensure the 19-inch rack or DIN rail is securely mounted and level to prevent vibration-induced stress on the module’s connectors. Connect the 24 V DC power supply and confirm voltage stability (within ±10% tolerance) to avoid damaging the relay coils. Label all output wiring according to the system schematic to ensure correct connection to field devices, reducing the risk of misoperation.
Maintenance suggestions: Clean the TRICONEX 3525A’s ventilation slots monthly using compressed air to prevent dust buildup and overheating. Perform quarterly diagnostic tests using TriStation software to check relay operation and contact resistance; replace relays if contact resistance exceeds 100 mΩ, as this indicates wear. Update the module’s firmware annually to access improved diagnostic features and bug fixes. If the TRICONEX 3525A reports a persistent fault, such as an unresponsive relay, use the hot-swap feature to replace it, ensuring minimal disruption to system operation.
Application fields
The TRICONEX 3525A is widely used in safety-critical industries where reliable relay operation is essential. In oil and gas refineries, it controls emergency shutdown (ESD) valves, closing them quickly when pressure or gas detectors detect abnormalities to prevent leaks and explosions. Its 12 channels allow it to manage multiple valves in a single module, simplifying system design in large refineries with complex safety loops.
In chemical processing plants, the TRICONEX 3525A triggers fire suppression systems when heat or gas detectors sense hazards. Its hermetically sealed relays resist corrosion from chemical fumes, ensuring reliable operation in aggressive environments where equipment durability is critical.
In power generation facilities, the module controls isolation switches in turbine and generator systems, isolating faulty components during emergencies to protect expensive equipment from damage. Its TMR architecture ensures these switches operate even if one channel fails, maintaining system integrity during critical events.
In pharmaceutical manufacturing, the TRICONEX 3525A manages cleanroom access systems, locking doors if contamination is detected to prevent product spoilage. Its hot-swap capability allows maintenance without stopping production, supporting the continuous manufacturing goals of the industry.
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Product guarantee
Our company offers a one-year quality warranty service for the TRICONEX 3525A, covering hardware malfunctions not caused by human factors. During the warranty period, if the TRICONEX 3525A shows abnormal performance or functional failure, we will provide replacement services. As a leading import and export trade distribution company with 17 years of experience, we maintain a large inventory of TRICONEX 3525A and other industrial control parts, including unpopular and discontinued models. Our global supply chain network enables us to quickly respond to urgent procurement needs, ensuring the continuous and stable operation of your industrial systems.
Whatsapp:+86 18859254943
E-mail :sales@ygplc.com
E-mail :sales@ygplc.com
