Honeywell FC-QPP-0001

Description

Detailed parameter table

Honeywell FC-QPP-0001

Product introduction

The FC-QPP-0001 is a high-integrity safety controller module from Honeywell, designed to monitor and control critical safety functions in industrial processes. As a key component of Honeywell’s Safety Manager system, this module combines advanced safety logic processing with flexible I/O capabilities, ensuring reliable protection for personnel, equipment, and the environment in high-risk applications.

FC-QPP-0001 serves as a dedicated safety layer in automation systems, executing safety interlock logic, emergency shutdown (ESD) sequences, and process safety functions. Its 16 safety inputs and 8 safety outputs enable direct connection to emergency stops, gas detectors, pressure switches, and shutdown valves, while its SIL 3 certification guarantees fault tolerance and reliability in mission-critical scenarios. Whether deployed in oil and gas refineries, chemical plants, or pharmaceutical facilities, FC-QPP-0001 provides a robust safety barrier, preventing hazardous events and ensuring compliance with global safety standards.

Core advantages and technical highlights

SIL 3 compliance: FC-QPP-0001 meets the stringent requirements of SIL 3 (per IEC 61508), the highest safety integrity level for industrial safety systems. This certification is achieved through redundant hardware design, built-in self-diagnostics (with 99% fault coverage), and software that prevents common cause failures. In practice, this means the module can detect and respond to faults before they escalate into hazardous conditions—critical in applications like hydrocarbon processing, where a single failure could lead to explosions or toxic releases.

Flexible safety I/O: With 16 configurable safety inputs (24 V DC) and 8 relay outputs, FC-QPP-0001 adapts to diverse safety sensors and actuators. Inputs support both PNP and NPN signals, eliminating the need for signal converters when integrating third-party devices like flame detectors or level switches. Outputs feature changeover relay contacts (5 A rating) to directly control shutdown valves or alarm horns, reducing component count and potential failure points in the safety loop.

Secure communication: FC-QPP-0001 incorporates Safety over Ethernet (SIL 2) for encrypted data exchange with Honeywell’s Safety Manager, ensuring safety logic updates and diagnostic data are transmitted without interference. It also supports Modbus for non-safety data sharing with SCADA or DCS systems (e.g., Experion PKS), enabling operators to monitor safety system status without compromising safety integrity. This dual communication layer separates safety-critical and operational data, enhancing system security.

Simplified integration: The module is pre-certified for use with Honeywell’s Safety Builder software, allowing engineers to configure safety logic using function block diagrams (FBD) without writing custom code. This reduces engineering time and minimizes human error during setup. FC-QPP-0001 also supports hot-swap replacement, enabling maintenance without shutting down the entire safety system—critical for continuous processes like chemical batch production.

Typical application scenarios

In oil refineries, FC-QPP-0001 monitors pressure and temperature in distillation columns, triggering emergency shutdowns if values exceed safe thresholds. Its 16 inputs connect to pressure transmitters and thermocouples, while outputs activate isolation valves and sound alarms. Safety over Ethernet ensures the Safety Manager receives real-time fault data, allowing operators to diagnose issues without entering hazardous areas. The module’s SIL 3 rating ensures these actions are executed within 100 ms, preventing overpressure incidents.

Chemical processing plants use FC-QPP-0001 to manage gas detection systems. It connects to multiple toxic gas sensors (via input channels) and controls ventilation fans, emergency shutdown valves, and evacuation alarms (via outputs). If a gas leak is detected, the module executes a pre-programmed logic sequence: isolating the affected area, activating fans, and sounding alarms—all within 50 ms. Modbus communication shares non-safety data (e.g., sensor health) with the plant DCS, enabling proactive maintenance of detection equipment.

Pharmaceutical manufacturing facilities deploy FC-QPP-0001 to protect sterile production areas. It monitors access doors (via safety interlocks on inputs) and controls air handling units (via outputs). If a door is opened during production, the module shuts down the filling machine and alerts operators, preventing contamination. Its hot-swap capability allows technicians to replace the module during scheduled breaks without disrupting batch production, ensuring compliance with FDA regulations for continuous process integrity.

Honeywell FC-QPP-0001

Related model recommendations

FC-QPP-0002: A redundant variant of FC-QPP-0001 with dual processors, designed for SIL 3 applications requiring 2oo2 (two-out-of-two) voting logic in mission-critical loops.

FS-SDI-16: 16-channel safety digital input module that expands FC-QPP-0001’s input capacity, ideal for plants with extensive sensor networks (e.g., refineries with multiple pressure points).

FS-SDO-8: 8-channel safety digital output module that pairs with FC-QPP-0001 to add high-current outputs (10 A) for controlling large shutdown valves or motor starters.

Safety Manager SC: Honeywell’s central safety controller that coordinates multiple FC-QPP-0001 modules in large-scale systems (e.g., petrochemical complexes with distributed process units).

XP100: Explosion-proof enclosure for FC-QPP-0001, certified for ATEX Zone 1 hazardous areas, ensuring safe operation in environments with flammable gases.

SM-IO-Link: Interface module that connects FC-QPP-0001 to IO-Link-enabled safety sensors, simplifying wiring and enabling sensor-level diagnostics.

Experion PKS: Honeywell’s distributed control system that integrates with FC-QPP-0001 via Modbus, providing operators with a unified view of safety and process data.

Installation, commissioning and maintenance instructions

Installation preparation: Before installing FC-QPP-0001, ensure the DIN rail is mounted in a climate-controlled enclosure (temperature -20°C to +60°C) with minimal vibration. Use a torque wrench (set to 1.2 Nm) to secure the module, ensuring a stable connection. Verify the 24 V DC power supply is isolated, regulated, and protected by a 1A fuse with appropriate surge protection. Use shielded twisted-pair cables for safety inputs/outputs (minimum 0.5 mm²), and route them separately from power cables to avoid EMI. Ground the module’s chassis to the enclosure using a 4 mm² wire for ESD protection.

Maintenance suggestions: For FC-QPP-0001, perform weekly checks of status LEDs to verify power, communication, and fault conditions. Use Safety Builder software monthly to run diagnostic tests, including input/output loop verification and communication link checks. Calibrate connected sensors (e.g., pressure transmitters) quarterly, ensuring input signals remain within calibrated ranges. If a fault is detected, replace the module using hot-swap procedures to avoid safety system downtime—always use Honeywell-certified spare parts to maintain SIL 3 integrity. Back up safety logic configurations to a secure server quarterly, and test restore procedures annually to ensure data recoverability.

Service and guarantee commitment

FC-QPP-0001 is backed by Honeywell’s 5-year warranty, covering manufacturing defects and ensuring compliance with SIL 3 specifications under normal operating conditions. Honeywell’s global safety support team provides 24/7 technical assistance, with certified safety engineers available to assist with configuration, troubleshooting, and SIL verification.

We offer on-site commissioning services, including safety logic validation, loop testing, and integration with Safety Manager systems, performed by TÜV-certified professionals. Extended warranty options (up to 7 years) include annual SIL revalidation audits and priority access to firmware updates. In the event of a fault, Honeywell maintains regional stock of FC-QPP-0001 modules, enabling next-day delivery to minimize safety system downtime. All repairs use genuine components, ensuring the module retains its original safety certifications and performance metrics. This commitment underscores Honeywell’s dedication to industrial safety and customer operational reliability.