Honeywell FC-Tpsu-2430 FC-PSU-240516 FC-Tshart-1620m FC-Bkm-0001 FC-Tsdo-0824 FC-Sai-1620 DC/DC Converter Safety Manager System Module

Product Description

Technical Details

Honeywell Safety Manager Overview
FC-TPSU-2430, FC-PSU-240516, and FC-TSHART-1620M belong to the Honeywell Safety Manager hardware family but serve different layers of the system. FC-TPSU-2430 is a 24 VDC to 30 VDC converter for compatible field termination assemblies, FC-PSU-240516 is the controller-chassis 24/5 VDC power supply unit, and FC-TSHART-1620M is a sixteen-channel safe analog-input field termination assembly with a HART interface.

The other references cover controller backup and key-switch functions, digital-output field termination, and high-density analog input processing. They are complementary Safety Manager components, not interchangeable modules. Always match the complete catalog number, coating/version marking, chassis or FTA location, system interconnection cable, Safety Manager release and field-signal design before ordering.

Six-Reference Function Map

Full Reference	Verified Product Role	Main System Location	Critical Ordering Check
FC-TPSU-2430	24 VDC to 30 VDC / 1 A converter	DIN-rail FTA power architecture	Confirm converter version, 30 VDC load, redundancy arrangement and target FTA
FC-PSU-240516	Controller power supply unit, 24/5 VDC, 16 A class	Predetermined PSU slot in the controller chassis	Confirm chassis, PSU version, local/redundant 5 V load and existing module label
FC-TSHART-1620M	Safe 0(4)-20 mA analog-input FTA with HART interface, 16 channels	DIN rail between field transmitters and SAI-1620m	Confirm HART multiplexer, passive/active loop design, external 30 VDC power and SICC cable
FC-BKM-0001	Battery and Key switch Module	Dedicated BKM position in controller chassis	Confirm version, battery state, key-switch state and controller maintenance procedure
FC-TSDO-0824	Safe digital-output FTA, 24 VDC, 8 channels	DIN rail between SDO-0824 module and field wiring	Confirm it is TSDO-0824, not TSDO-0824C, plus SICC cable and connected output-module rating
FC-SAI-1620	Title reference requiring nameplate confirmation	Analog-input module position	Current Honeywell reference identifies FC-SAI-1620m; send a label photo before applying SAI-1620m data

TPSU-2430 24 Vdc to 30 Vdc / 1 A converter
Input
Nominal input voltage: 24 Vdc
Input voltage range: 18-36 Vdc
Inrush current: ≤ 4 A
Output
Output voltage: 30 Vdc ± 0.25 V
Output current: 1 A, short-circuit proof
Short-circuit current: < 3.3 A
Ripple (0-30 MHz): < 0.1 Vrms
Regulation: < 1 % (load + line)
Transient response: class C per NFC42801C
Power-on overshoot: output < 31 V
Overvoltage protection: 31 V
Long-term stability (after 30 min operation): < 0.3 %
Efficiency: > 75 %
Switching frequency: > 25 kHz
Physical
Module dimensions: 150 × 70 × 62.3 mm (5.91 × 2.76 × 2.45 in)
DIN EN rails: TS32 / TS35 × 7.5
Used rail length: 151 mm (5.94 in)
 

 

TSHART-1620m Safe 0-20 mA and 4-20 mA analog input FTA with HART interface (16 channels)
Description
Field termination assembly module TSHART-1620m is the interface between field components (sensors, etc.) and the safe high-density analog input module SAI-1620m in Safety Manager. The FTA provides HART interface. It can be used for interfacing signals from Class I, Division 2 Hazardous Locations.
The TSHART-1620m module has sixteen analog input channels, which may be used for both safety-related and non-safety-related applications. These sixteen channels (separated into two groups of eight channels with common 0 V) are connected via a system interconnection cable (SICC-0001/Lx), which is plugged into the SIC connector on the FTA module, and connects to a (redundant pair of) SAI-1620m module(s).
The FTA module has a universal snap-in provision for standard DIN EN rails, and screw terminals for connection of power supply, ground and field wiring.

Analog-Loop Ordering Check

1. Confirm whether each transmitter is active or passive.
2. Confirm the exact FC-TPSU-2430 and FC-TSHART-1620M versions used for external 30 VDC power.
3. Record the SICC cable catalog number and length.
4. Identify the HART multiplexer manufacturer and interface cable if HART access is required.
5. Confirm the installed input-module nameplate, especially the final m in SAI-1620m.
6. For safety-related passive loops, verify that the Safety Manager application monitors the external-power readback as required by the Honeywell architecture.

Batteries of FC-BKM-0001
   The BKM-0001 module contains non-rechargeable (lithium) batteries that supply the back-up power to maintain the diagnostic messages and the real time clock on the QPP modules, in case of a power outage.
   As the batteries are not recharged, the used back-up time is accumulating. The total back-up time of the lithium cells is approximately 3 months.
   If the system is switched off for a longer period (and during transport), the batteries can be switched off with the battery switch on the module.
   It is recommended to replace the batteries every five years and after every substantial discharge period.
Replacing the batteries requires no special tools.
   The side plate of the BKM-0001 module has an opening to enable battery replacement and battery-switch operation.

BKM Maintenance Warning

The module can be placed or removed while the system is running without interrupting the application program, but removal always clears all active forces. Put the Force Enable key switch in OFF before extraction and follow the approved Safety Manager maintenance procedure. Do not use the Reset or Force Enable keys as ordinary operating controls.

Installation

Installation, Diagnostics & Replacement
Pre-Replacement Checklist

• Record the complete FC/FS model, version marking and coating designation from the front label.
• Identify whether the part is a controller-chassis module, I/O card or DIN-rail FTA before selecting a replacement.
• Save the controller diagnostic messages, module type and timestamp before disturbing hardware.
• Isolate field and controller power according to the site safety procedure; verify all external loop supplies separately.
• Label every SICC cable, HART cable, terminal and 24/30 VDC feed before removal.
• Do not insert an FTA in a controller chassis slot or apply backplane-module data to a DIN-rail FTA.
• After installation, verify status LEDs, diagnostics, channel behavior, external-power readback and configured redundancy before returning the safety function to service.

Troubleshooting Guide

Symptom	Relevant Reference	Verification Before Ordering a Spare
No regulated 30 VDC at the FTA supply	FC-TPSU-2430	Check 18-36 VDC input, 3.15 A slow fuse, overload/short circuit, output LED and readback relay
Controller PSU status LED is red	FC-PSU-240516	Check 24 VDC input range, 5 V load, chassis connection and redundant PSU condition
Passive analog loops lose process data	FC-TSHART-1620M / FC-TPSU-2430	Check both external power feeds, group fuses, common 0 V and Safety Manager external-voltage readback
HART access is unavailable but analog value remains	FC-TSHART-1620M	Check the specified HART multiplexer, interface connector/cable and common reference; do not alter the safety loop blindly
One or more analog channels drift or fail self-test	FC-SAI-1620m path	Check the exact input-module suffix, FTA conversion resistance, cable, channel mapping and diagnostic message
Digital load does not energize	FC-TSDO-0824	Check the connected SDO-0824 module, SICC cable, field supply, output-module rating and terminal wiring
BKM status LED remains red	FC-BKM-0001	Check battery switch position, battery voltage, fuse/diagnostic message and accumulated backup history
Forces disappear after BKM service	FC-BKM-0001	Removal always clears forces; restore only through the approved, authorized forcing procedure

Compatibility Disclaimer

Safety integrity is a property of the complete approved Safety Manager configuration, not of a spare part considered alone. No claim is made that a different coating version, base model, m suffix, FTA, SICC cable, HART multiplexer or Safety Manager release can be substituted without engineering review.

Inventory Photos

 

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FAQ

Why does the FC-SAI-1620 model require a label photo?

The current Honeywell Hardware Reference identifies the safe high-density analog input type as FC-SAI-1620m. Because the title omits the final m, the installed nameplate must be checked before the 16-channel SAI-1620m technical data or compatibility is applied.
 

What is the difference between FC-TPSU-2430 and FC-PSU-240516?

FC-TPSU-2430 converts 24 VDC to regulated 30 VDC for compatible FTA and transmitter-loop power arrangements. FC-PSU-240516 is a controller-chassis module that converts 24 VDC to local and redundant 5 VDC rails. They have different outputs, mounting and system roles.
 

Is FC-TPSU-2430 always required with FC-TSHART-1620M?

Not always. Honeywell states that no external power is required when all inputs are active transmitters. Passive-transmitter loops require guaranteed external power, and FC-TPSU-2430 may be used in a monitored or redundant 30 VDC arrangement. Confirm the actual loop design.
 

Can FC-TSHART-1620M operate without the SAI input module?

It is a field termination assembly, not the final A/D input module. Its converted signals are intended for SAI-1620m through the correct SICC cable and Safety Manager configuration.
 

Does FC-TSHART-1620M support every HART multiplexer?

No universal compatibility is claimed. The Honeywell reference describes specific MTL and P-epperl+Fuchs multiplexer/cable solutions. Send the installed multiplexer and cable references before ordering.
 

Is 1.5 A per channel the usable output rating of FC-TSDO-0824?

It is the published maximum continuous-current boundary of the FTA. Honeywell explicitly states that the actual maximum current is defined by the connected output module, so both the SDO module and the field load must be checked.
 

Can FC-BKM-0001 be removed while Safety Manager is running?

Honeywell permits placement or removal without interrupting the application program, but removal always clears all forces. The Force Enable switch must be OFF, and the action must follow the site's authorized safety maintenance procedure.
 

When should the FC-BKM-0001 batteries be replaced?

Honeywell recommends every five years and after substantial discharge. Also review the accumulated backup time, battery-switch position and BKM diagnostics rather than relying only on calendar age.
 

What information is needed for an accurate quotation?

Send complete front and side label photos, FC/FS type and version, Safety Manager release, chassis or FTA position, SICC and HART cable references, quantity and destination. For analog loops, include whether transmitters are active or passive.