Description
Key Technical Specifications
- Model Number: T8160
- Manufacturer: ICS Triplex (Emerson)
- Input Voltage Range: 20–32 VDC (redundant dual-input supported)
- Output Voltage: 24 VDC ±2% (regulated, isolated)
- Output Current Rating: 10A total (5A per redundant channel)
- Isolation Rating: 2500V DC input-to-output; 1500V DC channel-to-channel
- Protection Features: Overvoltage (28V threshold), overcurrent (6A per channel trip), short-circuit protection
- Operating Temperature: -40°C to 70°C (-40°F to 158°F)
- Redundancy Support: 1+1 hot-redundant configuration, automatic load sharing/failover
- Diagnostics: Input voltage monitoring, output current monitoring, fault status LED indicators, backplane communication health checks
- Certifications: IEC 61508 SIL 3, ATEX, IECEx, FM Class I Div 2, CSA
- Physical Form Factor: 2-slot rack-mounted, 266mm (H) × 62mm (W) × 303mm (D), 2.2kg (4.85lbs)
- Hot-Swap Capability: Supported (no system shutdown required for module replacement)
ICS TRIPLEX T8160
Field Application & Problem Solved
In refineries, chemical plants, and nuclear power auxiliary systems, the single most critical component of a safety instrumented system (SIS) is its power supply. Legacy non-redundant power modules create a catastrophic single point of failure—if the power supply dies, the entire SIS goes offline, leaving the plant unprotected from hazards like pressure spikes or gas leaks. Even dual-power modules without proper isolation often fail to switch over cleanly, causing voltage dips that reset the SIS controller and trigger unplanned shutdowns costing $100k+ per hour.
The T8160 solves these problems. You’ll find it as the backbone of every Trusted SIS installation, providing redundant, regulated 24 VDC power to controllers, I/O modules, and communication interfaces. In offshore oil platforms, its wide temperature range and corrosion-resistant design hold up to salt spray and humidity, eliminating the need for climate-controlled power cabinets. In chemical batch processing plants, its 1+1 redundant configuration ensures seamless failover—if one power channel fails, the other takes over 100% of the load in <1ms, with zero voltage dip that could disrupt the SIS.
Its core value is twofold: first, it eliminates power-related single points of failure, ensuring the SIS remains operational even if one power channel or input source fails. Second, its built-in protection and diagnostics prevent damage to downstream modules from overvoltage or short circuits—common issues in harsh industrial environments. Unlike generic power supplies, the T8160 is fully integrated with the Trusted system’s diagnostic framework, so operators can monitor power health from the HMI and schedule maintenance before a failure occurs.
Installation & Maintenance Pitfalls (Expert Tips)
Redundant Inputs Must Be Wired to Separate Power Sources
Rookies often wire both T8160 input channels to the same plant power supply, defeating the purpose of redundancy. If that supply fails, the entire SIS goes dark—exactly what you’re trying to avoid. Always connect each input channel to a separate, independent 24 VDC source: one to the plant’s primary UPS, the other to a backup UPS or generator-powered supply. Verify input voltage on both channels before commissioning (use a multimeter to check 20–32 VDC at the module terminals) and label the inputs clearly in the wiring diagram. This separation is non-negotiable for SIL 3 compliance.
Hot-Swap Requires Load Status Verification First
Yes, the T8160 is hot-swappable, but pulling a module without checking the load status is a rookie mistake that can take down the SIS. Before replacement, log into the Trusted HMI and confirm that the remaining T8160 module (in a redundant pair) is carrying 100% of the load without overcurrent faults. If the system is running on a single module and the load exceeds 5A, the module will trip, causing an SIS shutdown. Always size the T8160 pair for the system’s maximum load (add 20% headroom for future expansion) and verify load levels before swapping. Also, wait 10 seconds after removing the module before installing the replacement to avoid transient voltage spikes.
Output Polarity Is Not Reversible—Double-Check Wiring
A common, costly mistake is reversing the T8160’s output positive and negative terminals during installation. The module’s output is not protected against reverse polarity, and wiring it wrong will fry every I/O module and controller in the rack—we’re talking $50k+ in damage. Always use the module’s terminal labeling (V+ and V-) as your guide, and double-check polarity with a multimeter before energizing the system. For extra safety, install a reverse-polarity fuse between the T8160 and the backplane—this will blow before damage occurs if you make a mistake.
Ventilation Clearance Prevents Thermal Shutdown
The T8160 generates heat under full load, and rookies often cram it into a tight rack with no ventilation clearance. This causes thermal shutdowns, where the module cuts output to prevent overheating. Always leave a minimum of 50mm (2 inches) of clearance above and below the module for airflow. In hot environments (e.g., desert refineries), install rack-mounted cooling fans to maintain temperature within the module’s operating range. Check the module’s front-panel temperature LED regularly—if it glows amber, the module is running hot, and you need to improve ventilation immediately.
ICS TRIPLEX T8160
Technical Deep Dive & Overview
The T8160 is a dual-channel redundant power supply module engineered for Trusted Series safety instrumented systems, designed to deliver stable, fault-tolerant 24 VDC power to critical SIS components. At its core, it uses two independent power conversion channels—each with its own rectifier, regulator, and protection circuitry—configured in a 1+1 hot-redundant setup. Under normal operation, the channels share the system load equally (5A each for a 10A total load). If one channel fails (due to an input power loss, component failure, or short circuit), the other channel instantly takes over 100% of the load with a failover time of <1ms—fast enough to avoid any disruption to the SIS.
What sets the T8160 apart from generic redundant power supplies is its seamless integration with the Trusted system’s backplane and diagnostic framework. The module communicates with the SIS controller via the backplane, sending real-time data on input voltage, output current, and temperature. If a fault is detected (e.g., overvoltage, overcurrent, or thermal warning), the module triggers an HMI alarm and logs the event with a time stamp for root-cause analysis. It also includes a front-panel LED array that provides at-a-glance status: green for normal operation, red for fault, and amber for thermal warning.
The T8160’s 2500V DC input-to-output isolation protects the SIS from voltage transients in the plant’s power grid, and its overvoltage/overcurrent protection prevents damage to downstream modules. Unlike standalone power supplies, it’s designed to fit into the Trusted rack’s form factor, eliminating the need for external power enclosures and reducing wiring complexity. Its rugged industrial design—wide temperature range, vibration resistance (5g, 10–500Hz), and corrosion protection—makes it suitable for field mounting in the harshest industrial environments.
In summary, the T8160 is not just a power supply—it’s a safety-critical component that ensures the Trusted SIS stays online when it matters most. Its redundancy, protection features, and diagnostic integration make it the backbone of reliable, compliant SIS installations in high-risk industries.
