Description
- Model: ICS Triplex 9802
- Brand: Rockwell Automation / ICS Triplex
- Series: Trusted® TMR (Triple Modular Redundant) System
- Core Function: High-reliability power supply module for Trusted TMR controller racks.
- Condition: Brand New Surplus (Original factory unit, legacy warehouse stock).
- Product Type: Power Supply Module (PSU).
- Key Specs: 24V DC Output | Redundant Load Sharing | Hot-Swappable.
ICS TRIPLEX 9852 1-9802
Key Technical Specifications
- Input Voltage: 20V DC to 32V DC (Nominal 24V DC)
- Output Voltage: 24V DC (Regulated for TMR backplane)
- Output Current: Up to 40A (System dependent)
- Redundancy: Triple Modular Redundant (TMR) architecture support
- Efficiency: >90% at full load
- Isolation: 500V DC between input, output, and chassis
- Protection: Overvoltage, Overcurrent, and Over-temperature shutdown
- Status Indicators: Front panel LEDs for Input OK, Output OK, and Fault
- Weight: ~3.5 kg (7.7 lbs)
- Certification: SIL 3 rated (when used in a Trusted TMR configuration)
Installation & Configuration Guide
Phase 1: Pre-Installation (Preparation)
Safety & Critical Strategy:
- TMR Integrity: The 9802 is designed for the Trusted TMR system. In a healthy system, you should have at least two power modules running. If you are down to your last functional PSU, this is a Critical Level 1 emergency.
- Input Verification: Ensure your bulk 24V DC supply (the source feeding the 9802) is stable. A “dirty” input can cause the internal filters of a new module to stress prematurely.
- Handle Position: Check that the injector/extractor handle is in the “Open” (unlocked) position before attempting insertion.
Phase 2: Removing the Faulty Module
- Identify the Fault: Confirm the “Fault” LED is red or the “Output OK” LED is off on the specific module.
- Unlock: Use a flat-head screwdriver to release the retaining screw on the module handle.
- Extraction: Pull the handle down/out firmly to disengage the backplane connectors. Slide the module out of the rack.
- Note: The 9802 is heavy for its size; keep a firm grip to avoid dropping it onto cables below.
Phase 3: Hardware Installation
- Visual Alignment: Peer into the empty slot to ensure no debris or bent pins are on the Trusted backplane.
- Insertion: Slide the new 9802 into the guide rails.
- Seating: Once the module hits the backplane, use the injector handle to “cam” the module into place. You will feel a distinct resistance followed by a solid “seat.”
- Securing: Tighten the retaining screw to ensure the module cannot vibrate loose (critical for offshore/high-vibration environments).
Phase 4: System Validation
- LED Check: * Input OK (Green): Confirms the module is receiving field power.
- Output OK (Green): Confirms the module is successfully powering the TMR bus.
- HMI Verification: Check the Trusted Explorer or Workbench software. The module status should transition from
Missing/FaulttoHealthy. - Load Sharing: If you have redundant 9802s, verify that the current load is being shared relatively equally between the modules.
ICS TRIPLEX 9852 1-9802
Customer Cases & Industry Applications
Case 1: Offshore Oil Platform “Blackout” Prevention An FPSO (Floating Production Storage and Offloading) unit in the North Sea reported a “Power Supply Degraded” alarm on their Fire & Gas system (ICS Triplex Trusted). One of their 9802 modules had failed due to salt-air corrosion over 12 years. Because the system is SIL 3 rated, they could not operate legally with a single PSU for long. We dispatched a New Surplus 9802 via helicopter-courier. The hot-swap was performed while the platform stayed live, avoiding a forced production shutdown.
Case 2: Petrochemical Refinery ESD Support During a planned turnaround, a refinery in the Middle East found that three of their 9802 modules failed to “cold start” after the main power was cycled. This is a common issue with aged electrolytic capacitors. The refinery had no spares. We provided two Original New 9802 units from our climate-controlled warehouse. These units, having been stored properly, powered up instantly, allowing the Emergency Shutdown (ESD) system to pass its safety validation on schedule.
Frequently Asked Questions (FAQ)
Q: Is the 9802 hot-swappable? A: Yes. The Trusted TMR architecture is built for “Online Repair.” You can remove and replace a 9802 while the system is energized, provided at least one other PSU is healthy and sharing the load.
Q: Can I use a 9802 in a non-TMR rack? A: Technically, the 9802 is designed for the Trusted TMR Power Distribution Unit (PDU). Using it in a non-standard or third-party rack is not recommended and will void the SIL 3 safety rating of your system.
Q: These modules are expensive; why not just repair my old one? A: In my experience, “repairing” a 9802 usually involves replacing capacitors. However, in a Safety Instrumented System (SIS), using a field-repaired module often voids your insurance and safety certifications. A New Surplus unit provides a clear audit trail and original factory reliability.
Q: What is the difference between the 9802 and the 9803? A: The 9802 is the standard 24V DC power module for the Trusted system. The 9803 is often a different voltage variant or specialized version. Always check your specific rack’s part number before ordering.
Q: Do these units come with the “Trusted” firmware pre-loaded? A: The 9802 is a hardware-based power module. It doesn’t carry “firmware” in the same way a TMR Processor (9001) does, but it does communicate its health via the backplane. It is “Plug-and-Play.”
