ICS Triplex T9800 Series Modules

Technical Dossier

Product Details And Specifications

ICS Triplex T9800 Series: Comprehensive Module Range and Technical Overview

The ICS Triplex T9800 Series — part of the Trusted® TMR (Triple Modular Redundancy) platform — represents one of the most widely deployed safety-rated I/O architectures in global heavy industry. Installed across petrochemical complexes, offshore platforms, nuclear power generation facilities, LNG terminals, and refinery process units, the T9800 range operates as the field interface layer of the Trusted® Safety System. Its TMR architecture provides fault-tolerant, continuous operation with no single point of failure, meeting IEC 61508 SIL 3 and IEC 61511 requirements. The series interfaces directly with the Trusted® T9100 and T9200 controller chassis, communicating over the proprietary Trusted® backplane bus. Installed base spans facilities operated by major EPC contractors and NOCs across Europe, the Middle East, Asia-Pacific, and the Americas.

The Evolution of T9800 Series Architecture

The T9800 I/O series was introduced alongside the original Trusted® TMR Safety System in the early 1990s, developed by ICS Triplex (later acquired by Rockwell Automation in 2007, subsequently integrated into the Allen-Bradley safety portfolio). The architecture has remained backward-compatible across multiple chassis generations, a deliberate design decision that extended the operational life of early installations well into the 2020s.

Early T9800 modules used parallel backplane addressing and required manual DIP-switch configuration for channel assignment. Mid-generation revisions introduced EEPROM-based configuration storage and improved diagnostic reporting via the Trusted® Workstation software suite. Later variants added enhanced EMC shielding and extended temperature ratings for offshore and desert-environment deployments. The T9800 series is now classified as a mature/end-of-life product line. ICS Triplex and Rockwell Automation have formally transitioned new projects to the Trusted® T9100 Series and the Allen-Bradley GuardLogix platform. However, the installed base of T9800 systems remains substantial, and lifecycle extension support — including spare module supply, repair, and functional testing — remains commercially active through specialist distributors.

T9800 Series Full Catalog & Functionalities (SKU List)

Digital Input Modules

• T9803: 24 VDC TMR digital input module, 16-channel, SIL 3 rated, field-side isolated
• T9800: Base digital input module, 24 VDC, 8-channel TMR, early-generation chassis compatible
• T9801: 24 VDC digital input, 16-channel, enhanced diagnostic version with per-channel fault reporting
• T9802: 48 VDC digital input module, 16-channel TMR, for high-voltage field circuits
• T9804: 120 VAC digital input module, 8-channel TMR, for legacy AC field wiring
• T9805: 240 VAC digital input module, 8-channel TMR, high-voltage AC process interface

Digital Output Modules

• T9820: 24 VDC TMR digital output module, 8-channel, solid-state relay output, SIL 3
• T9821: 24 VDC digital output, 16-channel, high-current sourcing output for solenoid valve actuation
• T9822: 120 VAC digital output module, 8-channel TMR, triac output for AC load switching
• T9823: Relay output module, 8-channel TMR, dry-contact form-C relay, 5A rated

Analog Input Modules

• T9840: 4–20 mA analog input module, 8-channel TMR, 12-bit resolution, HART-transparent
• T9841: 4–20 mA / 1–5 VDC analog input, 8-channel, enhanced resolution variant with 16-bit ADC
• T9842: RTD/thermocouple input module, 8-channel TMR, multi-sensor type configurable
• T9843: Millivolt/thermocouple analog input, 8-channel, cold-junction compensated

Analog Output Modules

• T9860: 4–20 mA analog output module, 4-channel TMR, 12-bit DAC, loop-powered
• T9861: 4–20 mA analog output, 8-channel, high-drive variant for long cable runs

Communication & Power Modules

• T9100: Trusted® TMR main processor/controller module, chassis-resident CPU
• T9110: Trusted® communication interface module, Modbus RTU / Modbus TCP gateway
• T9120: Trusted® power supply module, 24 VDC input, redundant chassis power

Sourcing Hard-to-Find & Obsolete T9800 Series Parts

The T9800 series reached end-of-active-production status following Rockwell Automation's portfolio consolidation. OEM lead times for new units are extended or unavailable for many models. DriveKNMS maintains a dedicated inventory of T9800 series modules sourced from decommissioned systems, controlled-environment storage, and verified secondary-market channels. All units are subject to pre-sale inspection and functional verification before dispatch.

DriveKNMS provides lifecycle extension support for T9800 installations including: single-module emergency replacement, multi-module system refresh kits, long-term maintenance agreements with reserved stock allocation, and cross-reference advisory for migration to current-generation equivalents where site conditions permit. Customers operating T9800-based safety systems in facilities with 5–15 year remaining operational horizons are advised to establish a spare parts buffer. DriveKNMS can assist with minimum stock level calculations based on installed module count and historical failure rate data.

Quality Control for the T9800 Series Range

T9800 modules present specific test challenges due to their TMR backplane architecture and the proprietary Trusted® bus protocol. Standard bench testing is insufficient to validate TMR voting logic integrity. DriveKNMS applies a structured test protocol for all T9800 units:

• Visual inspection: PCB condition, connector pin integrity, conformal coating assessment, capacitor health check
• Power-on self-test: Module boot sequence verification against known-good firmware behavior
• Channel-level functional test: Each I/O channel exercised at rated voltage/current using calibrated signal sources
• TMR voting verification: Tri-redundant signal path continuity confirmed via backplane loopback test fixture
• Isolation test: Field-side to logic-side isolation resistance measured at 500 VDC (minimum 100 MΩ)
• Burn-in: 48-hour powered soak at elevated ambient temperature to screen early-life failures
• Final calibration check: Analog modules verified against NIST-traceable reference standards

All tested units are issued a DriveKNMS inspection certificate with test date, technician ID, and pass/fail records for each test stage. Units that fail any stage are quarantined and not offered for sale.