Honeywell FC-QPP-0002 V2.1R Quad Processor Pack

Honeywell FC-QPP-0002 V2.1R Quad Processor Pack Safety Manager Module

The Honeywell FC-QPP-0002 V2.1R (Quad Processor Pack) serves as the central deterministic processing engine for Honeywell Safety Manager and upgraded FSC (Fail Safe Control) systems. Engineered for mission-critical marine automation, offshore drilling packages, and severe chemical process safety loops, the FC-QPP-0002 executes graphic Functional Logic Diagrams (FLDs) with deterministic cycle timing and high fault containment.

Operating on a dual-microprocessor architecture per pack (yielding a 1oo2D diagnostic structure per pack, scalable to a redundant 2oo4D system), the FC-QPP-0002 achieves hardware diagnostic coverage exceeding 99%. Integrated hardware data-comparators continuously cross-check every read/write execution cycle between processors and internal memory buses. Any discrepancies trigger immediate, failsafe watchdog intervention, driving connected safety-critical field loops to an engineered, de-energized fail-safe condition without relying on operating system software.

Model Details

• Manufacturer: Honeywell Process Solutions
• Model: Enhanced Performance Quad Processor Pack (QPP)
• Part Number (MPN): FC-QPP-0002
• Hardware Revision: V2.1R (Firmware R121+ compatible)
• Controller Slot Assignment: Dedicated CP slot in CPCHAS-0001 / CPCHAS-0002 chassis
• Interchangeability: Direct drop-in upgrade and one-on-one replacement for legacy FC-QPP-0001 modules

Technical Specifications

Key Features

1. High-Integrity Dual Architecture: Dual synchronized microprocessors with lockstep memory data comparators deliver >99% diagnostic coverage, allowing single-channel SIL 3 deployment without hardware run-time limits.
2. Integrated Hardware Watchdog & Direct 24 VDC ESD Trip: Built-in hardware watchdog circuit independently monitors loop execution deadlines, internal rail voltages (5 VDC logic and 24 VDC I/O), and a direct galvanic-isolated 24 VDC Emergency Shut Down (SD) backplane contact.
3. Hot-Swap Redundant Pairing (2oo4D): Supports bumpless online switchover and hot-swappable replacement in dual CP configurations, synchronizing I/O and register data via high-speed inter-processor memory channels without field interruptions.
4. Front Diagnostic Display & Secure Key Switch: Features an 8-character LED diagnostic matrix for immediate verification of loop times, supply rails, node ID, and fault codes, combined with a 3-position front keyswitch (RUN / IDLE / STOP).
5. Deterministic Flash & Battery-Backed SRAM: Houses 2 × 2 MB Flash for application firmware and dual 256 KB battery-backed SRAM for dynamic register/marker storage linked to the chassis battery backup module (BKM-0001).

Compatibility:

• Chassis Compatibility: Installs directly into CPCHAS-0001 and CPCHAS-0002 Controller Chassis.
• Backup Module Link: Operates in synchronization with the BKM-0001 Battery and Key Switch Module (which holds battery rails and system configuration keying).
• Communication Interface: Direct bus routing to COM-0001, COM-0002, and Safety Manager Ethernet Communication Interfaces (USI).
• Field I/O Integration: Controls non-interfering communication with all Honeywell Safety Manager I/O chassis, driving field modules including FC-SDI-1624, FC-SDO-0824, FC-SAI-1620M, and associated Field Termination Assemblies (FTAs).
• Firmware Requirements: Fully compatible with Honeywell Safety Manager firmware release R121 or higher.

Part Number Cross-References

• Honeywell Safety Manager: FC-QPP-0002
• Alternate Honeywell Legacy Ref: QPP-0002
• Predecessor Module: FC-QPP-0001 / QPP-0001 (Direct functional replacement)
• Kit Assembly Component Number: 51309223-175 (Internal manufacturing sub-assembly)

Applications

• Marine Automated Emergency Shutdown (ESD): Emergency trip logic, deep-well ballast safety interlocks, and cargo containment isolation for LNG/LPG carriers and chemical tankers.
• Offshore FPSO & Rig Process Safety: High-speed executive shut-in logic for high-pressure separation trains, subsea tie-backs, and gas export compression.
• Burner Management Systems (BMS): Safe furnace purging, continuous multi-burner flame validation, and fuel safety shut-off valves (SSVs) on industrial marine boilers and refinery heaters.
• Turbomachinery & Compressor Overpressure Protection: Anti-surge coordination trip interfaces and high-speed overspeed/vibration safety loops.
• Toxic Gas & Fire Containment Systems (FGS): Voting logic (1oo2, 2oo3) execution across open-path hydrocarbon detectors, toxic gas sensors, and automatic deluge/foam release systems.

Frequently Asked Questions

Can the FC-QPP-0002 directly replace an older FC-QPP-0001 module?

Yes. The FC-QPP-0002 is fully backwards compatible and serves as a direct one-on-one spare part for the legacy QPP-0001, provided your Safety Manager runs system firmware release R121 or higher.

What does the “Halt with Flt” code mean on the front 8-digit display?

This diagnostic warning occurs when the processor execution has stopped because the operating system detected an unrecoverable system, memory, or communication fault while the front keyswitch remained in the RUN position. Toggle the display push-buttons to view the secondary diagnostic string to pinpoint the fault cause (e.g., watchdog trip, cycle-time overrun, or logic error).

Does replacing a single QPP-0002 module in a redundant setup shut down the plant?

No. In a redundant Control Processor architecture (CPCHAS-0001 / CPCHAS-0002 with two QPP packs), the secondary module supports online hot-swapping. Provided the standby processor is synchronized and healthy, the faulty module can be isolated (keyswitch set to STOP) and replaced without disrupting active safety loops or field outputs.

What voltage ranges are supported by the integrated hardware watchdog?

The onboard watchdog circuit continuously monitors both the internal 5.0 VDC logic rail (±5%) and the external 24 VDC I/O supply (-15% / +30%). If either voltage exceeds overvoltage or falls below undervoltage trip thresholds, the hardware watchdog trips independently of processor logic, safely de-energizing critical outputs.

Why is the BKM-0001 module critical when replacing the FC-QPP-0002?

The FC-QPP-0002 relies on the chassis backplane connection to the BKM-0001 module for its battery backup power (maintaining the 2 × 256 KB SRAM registers) and system administration security keying. Always verify the battery health on the BKM unit during any QPP replacement.