KIMBALL EGPS-1106A Retrofit Power Supply for Legacy Systems

KIMBALL EGPS-1106A Retrofit Power Supply for Legacy Systems

The KIMBALL EGPS-1106A is a ruggedized power supply module engineered for demanding industrial environments where reliability, continuity, and backward compatibility are non-negotiable. As legacy automation platforms approach end-of-life and OEM support windows close, the EGPS-1106A has become a critical retrofit component for maintenance engineers and system integrators tasked with extending the operational life of existing control infrastructure. Whether you are managing a phased migration, executing an emergency replacement, or planning a controlled upgrade of an aging control cabinet, the EGPS-1106A provides a proven, field-tested power delivery solution that integrates directly into existing rack and backplane architectures without requiring full system redesign.

Designed to operate across a wide input voltage range and deliver stable, regulated DC output to downstream I/O modules, communication cards, and processor units, the EGPS-1106A is particularly well-suited for environments where power quality is inconsistent or where legacy wiring infrastructure cannot be easily replaced. Its ruggedized construction addresses the thermal, vibration, and EMI challenges common in heavy manufacturing, process control, and energy sector installations.

Upgrade Compatibility Table

Retrofit Planning for Existing Automation Systems

Successful integration of the EGPS-1106A into an existing automation system requires a structured pre-installation assessment. Before removing the failed or end-of-life power supply, maintenance teams should document the current wiring layout, terminal block assignments, and any field modifications made to the original installation. In many legacy control cabinets, terminal blocks such as Phoenix Contact or Weidmuller DIN-rail mounted strips are used to distribute power and signal references — these should be photographed and labeled before any disconnection work begins.

The EGPS-1106A is designed for use within the D2-09B-1 rack chassis, a modular backplane system that may also house a range of companion modules. In a typical retrofit scenario, the power supply slot is adjacent to the CPU or processor module — often a unit such as the KIMBALL EPC-2100 or a compatible third-party controller — and feeds regulated voltage to all occupied I/O slots. If the rack also contains analog input modules, discrete output modules, or specialty function cards, each of these must be verified for voltage tolerance before the new power supply is energized.

Communication modules installed in the same rack — such as Profibus DP adapters, Modbus RTU interface cards, or DeviceNet scanner modules — draw their operating power from the backplane bus. A power supply replacement therefore directly affects the stability of all active communication links. Engineers should plan to temporarily suspend SCADA polling or DCS data acquisition during the changeover window to avoid false alarms or data integrity issues in the historian.

For systems that include remote I/O expansion racks connected via fiber or copper communication cables, the migration plan should account for the possibility that the replacement power supply may have slightly different startup sequencing characteristics. Signal isolators installed between the main rack and field instruments — particularly in hazardous area installations — should be checked for proper loop power levels after the new module is commissioned.

HMI panels connected to the control system, whether legacy operator terminals or modern touchscreen units, should remain powered independently during the power supply swap to preserve any active alarm states or process displays. Programming cables used for PLC backup and program verification — such as RS-232 to USB adapters or proprietary programming interfaces — should be connected and a full program backup confirmed before the old module is removed.

Where the installation includes a redundant power supply configuration, the standby unit should be tested for automatic switchover capability before the primary EGPS-1106A is replaced. This is particularly important in continuous process environments where even a brief power interruption can trigger safety interlocks or cause batch process failures.

Downtime Control During System Migration

Minimizing unplanned downtime is the primary operational concern when replacing a power supply module in a live automation system. The EGPS-1106A retrofit process is designed to be completed within a planned maintenance window, typically two to four hours for a single-rack installation, provided that all replacement components and tools are staged in advance.

Before initiating the physical swap, the control program should be backed up to an offline storage device and verified against the most recent approved revision. This protects against data loss in the event of an unexpected power interruption during the changeover. If the system uses battery-backed RAM or a flash memory card for program retention, the backup media should be confirmed as readable and current.

Field control continuity can be maintained during the transition by placing affected control loops in manual mode at the DCS or SCADA level, allowing operators to hold process setpoints while the power supply is exchanged. For discrete control applications, output modules should be de-energized in a safe sequence — typically following the machine’s documented lockout/tagout procedure — before the power supply is disconnected from the backplane.

After the EGPS-1106A is seated and secured, output voltage rails should be verified with a calibrated instrument before any downstream modules are re-enabled. Communication links should be restored one segment at a time, confirming that each module returns to its expected operating state before proceeding to the next. This staged re-energization approach reduces the risk of cascading faults and allows the commissioning engineer to isolate any pre-existing issues that may have been masked by the original power supply failure.

NINERMAS supplies the EGPS-1106A from verified stock with pre-shipment functional testing completed on every unit. Standard lead times support emergency procurement scenarios, and units can be dispatched globally with full export documentation. The 12-month warranty covers all units against manufacturing defects and provides a clear support path for post-installation issues.

Retrofit Support FAQ

Q: Is the EGPS-1106A a direct replacement for all EGPS-1106 series variants?
A: The EGPS-1106A is the primary variant in the EGPS-1106 family. Cross-reference the full part numbers 208-500700-2 and 281-500700 against your existing module label to confirm exact compatibility. If your installed unit carries a different suffix, contact NINERMAS with the full nameplate data for a compatibility assessment before ordering.

Q: What pre-shipment testing is performed on each unit?
A: Every EGPS-1106A unit supplied by NINERMAS undergoes functional power-on testing, output voltage verification across all regulated rails, and visual inspection for connector integrity and component condition. Test records are available upon request and accompany units shipped under warranty replacement or critical spares programs.

Q: Can the EGPS-1106A be installed without reprogramming the PLC or controller?
A: Yes. The EGPS-1106A is a passive power delivery module with no firmware, address configuration, or software dependency. Replacing the power supply does not require any changes to the PLC program, I/O mapping, or communication parameters. The control program and all module configurations remain intact provided the backplane and downstream modules are not disturbed during the swap.

Q: What is the warranty coverage and what does it include?
A: All EGPS-1106A units supplied by NINERMAS carry a 12-month warranty from the date of shipment. The warranty covers manufacturing defects, premature component failure, and output regulation faults under normal operating conditions. It does not cover damage resulting from incorrect installation, overvoltage events, or physical mishandling. Warranty claims are processed directly through NINERMAS with a target response time of one business day.