TRICONEX 3625 3625-610 | 32 Point 24VDC TMR Digital Output

Description

• Brand: Triconex / Invensys
• Full Model Number: 3625 / 3625-610
• System/Series Family: Tricon v10.2 and later
• Core Function: 32-point TMR supervised or non-supervised 24 VDC digital output switching
• Top 3 Hardcore Specs: 32 commoned output points; 16–32 VDC operating range; 1.7 A maximum per point
• Nominal Voltage: 24 VDC
• Maximum Voltage: 36 VDC
• Surge Capability: 5 A for 7 ms
• Total Output Current: 10 A per termination panel
• Minimum Required Load: 10 mA
• Off-State Leakage: 4 mA maximum
• Output Protection: Self-protected against over-voltage, over-temperature, and over-current
• Isolation: 1,500 VDC minimum system-to-field
• On-State Drop: <0.25 VDC typical at 250 mA; <1.7 VDC at 1.7 A at backplane
• Diagnostics: Programmable point supervision; output voltage-loopback diagnostics
• Status Indicators: Per-point On/Off; PASS, FAULT, LOAD, ACTIVE
• Hot Spare: Supported
• Termination Interface: 9662-610-family 16-point commoned termination panel
• Stock Status: New Surplus or Fully Tested Refurbished; exact revision to be confirmed

Tricon documentation identifies Model 3625 as a 32-point TMR supervised or non-supervised digital output module for Tricon v10.2 and later systems. It is designed for use with 16-point commoned field termination panels.

TRICONEX 3625 3625-610

Module 3: Technical Product Introduction

A 24 VDC output module in a safety controller has to handle the field load while also providing diagnostic information about the output circuit. The TRICONEX 3625, commonly referenced with the 3625-610 termination configuration, is a 32-point TMR digital output module for Tricon systems v10.2 and later. It can operate in either supervised or non-supervised mode, with all 32 output points commoned. Tricon documentation specifies the module for both energize-to-trip and de-energize-to-trip applications.

The electrical envelope is defined around a nominal 24 VDC field supply, with a recommended operating range of 16–32 VDC and a maximum of 36 VDC. Each point can switch up to 1.70 A ±10%, with a specified surge capability of 5 A for 7 ms; total module output current is limited to 10 A per termination panel. The outputs are self-protected against over-voltage, over-temperature, and over-current, eliminating the need for individual field fuses in the documented arrangement. System-to-field isolation is at least 1,500 VDC.

Module 4: Application Scenarios & Field Realities

• For 24 VDC solenoids, contactors, actuators, and shutdown-interface circuits, 3625 provides 32 output points within the Tricon TMR architecture. The module can be configured for point supervision where the field circuit requires monitoring for open- or short-circuit conditions.
• When a cabinet contains many high-current discrete loads, the 1.7 A-per-point limit and 10 A-per-termination-panel limit have to be calculated together. A module may have 32 available channels, but the connected load cannot simply be sized by multiplying 32 by 1.7 A.
• In de-energize-to-trip shutdown architectures, supervised output operation can provide additional visibility into the field path. The module reports PASS, FAULT, LOAD, and ACTIVE conditions, while individual point LEDs provide local output-state indication.
• During replacement of an older Tricon digital-output module, 3625 deserves particular attention because it is restricted to Tricon v10.2 and later. A mechanically similar 24 VDC Tricon output card from an earlier generation should not be assumed compatible without checking the system revision.

Module 5: Migration, Compatibility & Installation Traps

Replacement Matrix

Replacement classification: Drop-in Replacement when replacing an existing 3625 installation in a compatible Tricon v10.2-or-later system with the correct 16-point commoned termination hardware and unchanged field wiring.

Software compatibility: Configuration verification required. The module supports programmable point supervision, so the installed Tricon configuration must correspond to the intended supervised/non-supervised behavior and channel assignments.

Cross-model replacement: Hardware and system-version verification required. The related 3625A is fully compatible with the applications of the 3625 but changes the field-power arrangement by separating supply groups into 16-point sections. Therefore, 3625 and 3625A should not be treated as identical terminal configurations without reviewing the cabinet wiring.

Field Traps — Watch Out

1. Verify the field-power commoning arrangement. For the standard 3625, field power is commoned to all 32 points. Documentation distinguishes this from the 3625A, where field power is separated into groups of 16 while retaining a common return. A termination-panel change can therefore alter the actual field-power topology.

2. Check the 10 A termination-panel limit. The individual 1.7 A rating does not mean the complete termination panel can carry 54.4 A. Tricon specifies a 10 A total output current per termination panel, which becomes a cabinet load-distribution constraint when many outputs operate simultaneously.

3. Do not assume external fuses are required for every output. The documented 3625 output switches are self-protected against over-voltage, over-temperature, and over-current. Adding external protection may still be appropriate at the cabinet or load level, but it should not be confused with the module’s specified internal output protection.

4. Verify the minimum load for supervised circuits. The published specification gives a 10 mA minimum required load. A very small relay, indicator, or high-impedance electronic input may not provide the electrical characteristics required for reliable supervision.

5. Confirm the 3625-610 identification. Technical product guides identify 3625 as the module and list 9662-610 among its compatible termination panels. The supplied identifier “3625-610” should therefore be checked against the actual module and termination-panel labels rather than automatically treated as a distinct processor or I/O model.

Module 6: Quality Assurance SOP

Pre-Shipment Inspection Protocol for TRICONEX 3625 / 3625-610

• OEM identity inspection: Verify Triconex/Invensys marking, exact 3625 designation, hardware revision, serial number, front-panel labeling, and associated termination reference.
• System-version verification: Confirm the intended controller is Tricon v10.2 or later, as specified for Model 3625.
• Mechanical inspection: Examine the module housing, card-edge/backplane interface, locking mechanism, LED indicators, connectors, and accessible PCB surfaces for corrosion, contamination, deformation, cracked components, or unauthorized repair.
• Termination verification: Confirm the intended 16-point commoned termination panel and inspect its terminal blocks, cable interface, common buses, and mounting hardware.
• Power-on self-test: Install the module in a compatible Tricon test chassis and verify PASS, FAULT, ACTIVE, LOAD, and individual channel indications.
• 32-channel verification: Exercise all 32 output points independently under controlled laboratory conditions.
• Voltage-range test: Apply representative 24 VDC field power within the documented 16–32 VDC recommended range and verify stable output operation.
• Load test: Use calibrated resistive and appropriate representative inductive loads to verify output switching, current capability, voltage drop, and thermal response.
• Current verification: Confirm representative operation below the 1.7 A-per-point limit and verify total termination-panel loading remains within the 10 A specification.
• Surge test: Where the laboratory procedure permits, verify controlled transient response against the specified 5 A / 7 ms surge capability without exceeding test limits.
• Output-drop measurement: Measure on-state voltage drop under representative loads and compare against the published backplane values, including <0.25 V typical at 250 mA and <1.7 V at 1.7 A.
• Leakage measurement: Measure off-state load leakage and compare it with the applicable 4 mA maximum specification.
• Supervision verification: For configured supervised points, simulate representative open- and short-circuit conditions and verify the expected LOAD/FAULT diagnostic behavior.
• Output diagnostic test: Exercise voltage-loopback diagnostics and controlled output-fault conditions using the approved Tricon test environment.
• TMR verification: Where the test bench permits, validate all three internal processing paths and confirm correct voted output operation.
• Hot-spare test: Use a compatible active/spare Tricon arrangement and verify transfer behavior according to the approved maintenance procedure.
• Field-power architecture test: Confirm that the commoned field-power arrangement matches the intended 3625 or 3625A configuration before energization.
• Thermal observation: Run multiple outputs under representative loads for an extended period and monitor for abnormal heating, diagnostic faults, output instability, or protection trips.
• Final QC record: Record exact model, revision, serial number, termination-panel identification, supply voltage, all 32 output results, current measurements, voltage-drop measurements, diagnostic results, supervision results, hot-spare result where applicable, test duration, and inspector approval.
• ESD-controlled packaging: Place the module in an ESD-safe package and protect connectors, locking hardware, LEDs, and PCB surfaces against impact, moisture, contamination, and electrostatic discharge.

Procurement note: The technically supported identity is TRICONEX 3625 — 32-point TMR 24 VDC Digital Output Module, with 3625-610 referring to an associated termination configuration rather than a separate processor model. Official Tricon documentation specifies 16–32 VDC operation, 36 VDC maximum, 1.70 A ±10% per point, 5 A / 7 ms surge, 10 A per termination panel, 10 mA minimum load, programmable point supervision, self-protected output switches, and 1,500 VDC minimum system-to-field isolation. Model 3625 is restricted to Tricon v10.2 and later.