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Key Technical Specifications
| Parameter | Value |
|---|---|
| Manufacturer | Honeywell |
| Part number | FC-PSU-240516 (also referenced as PSU-240516) |
| Product family | Honeywell Safety Manager / Safety Manager SC / FSC |
| Product type | 24 V DC to 5 V DC power supply module |
| Primary function | Converts 24 V DC input to regulated local and redundant 5 V DC outputs for controller backplane |
| Input voltage | 24 V DC, −15% to +30% (20.4–31.2 V DC) |
| Input current | Less than 6 A at 24 V DC with 16 A load; less than 7 A at 20.4 V DC |
| Inrush current | Less than 5 A |
| Output voltage | 5 V DC regulated |
| Output current | 0.5–16 A per output rail (local and redundant) |
| Output configuration | Local 5 V DC and redundant 5 V DC outputs |
| Overvoltage protection | Two independent overvoltage-protection circuits supervising the 5 V outputs |
| Galvanic isolation | At least 2.5 kV DC between 24 V DC input and 5 V DC outputs |
| Hold-up time | Less than 1 ms |
| Operating temperature | −5 to +70 °C (+23 to +158 °F) |
| Storage temperature | −40 to +85 °C (−40 to +185 °F) |
| Relative humidity | 10–95%, non-condensing |
| Coating | Conformal-coated FC version (V1.1 is a component-update revision with no functional change) |
| Physical dimensions | 176 × 35.2 × 212 mm (H × W × D) |
| Approximate weight | 0.85 kg |
| Replacement requirement | Match FC-PSU-240516, verify V1.0 vs V1.1, conformal coating, input voltage, output current, and chassis compatibility |
Honeywell documentation identifies FC-PSU-240516 as a conformal-coated 24/5 VDC, 16 A power supply unit for Safety Manager controller chassis. It converts 24 V DC input to local and redundant 5 V DC outputs, each rated up to 16 A, with two independent overvoltage-protection circuits. The V1.1 revision uses modified components but retains the same functional characteristics.
Product Introduction
The Honeywell FC-PSU-240516 is a 24 V DC to 5 V DC power supply module used in Honeywell Safety Manager, Safety Manager SC, and FSC controller chassis. It provides the regulated 5 V DC backplane power required by the controller, I/O modules, and associated electronics.
The module delivers local and redundant 5 V DC outputs, each capable of up to 16 A. It is designed for high-availability safety-instrumented systems where even a brief voltage deviation can trigger an unplanned shutdown. Confirm the installed revision (V1.0 or V1.1), conformal coating, and chassis compatibility before replacement.
FC-PSU-240516
FC-PSU-240516
Troubleshooting Quick Reference
| Symptom | Possible Cause | Relevance to This Part | Quick Check Method | Recommendation |
|---|---|---|---|---|
| Controller chassis has no 5 V DC power | Failed FC-PSU-240516, missing 24 V DC input, blown input fuse, loose power connector, backplane fault | ✅ High | Check 24 V DC input voltage at the power-supply terminals. Inspect input fuse and connector retention. Measure 5 V DC output at the backplane or test point. | Restore 24 V DC input and correct connector issues first. Replace the power supply only after confirming input power and connector integrity. |
| One 5 V rail is missing or low | Failed output section, overloaded backplane, shorted module, poor connector contact, backplane fault | ⚠️ Medium | Measure both local and redundant 5 V outputs. Check for short circuits or excessive current draw on the backplane. Inspect connector seating and pin condition. | Isolate the overload or short before replacing the power supply. A new PSU will fail again if the backplane remains shorted. |
| Controller reports power-supply fault or redundancy alarm | One PSU failed in a redundant pair, output voltage out of tolerance, overvoltage protection activated, configuration issue | ⚠️ Medium | Check Safety Manager diagnostics for power-supply status. Measure both 5 V outputs and compare with specifications. Verify redundant PSU configuration. | Correct voltage or configuration issues first. Replace the faulty PSU only after confirming the remaining PSU can sustain the load. |
| Intermittent power faults or resets | Loose input/output connectors, marginal 24 V DC supply, high ambient temperature, aging capacitors, vibration | ⚠️ Medium | Inspect connector tightness and cable strain relief. Monitor 24 V DC input and 5 V DC output under load. Check cabinet temperature and ventilation. | Improve connections and cooling. Replace aging power supplies proactively in critical systems. |
| Module area is hot or shows physical damage | Overload, short circuit, prior electrical event, contaminated cabinet, damaged backplane | ✅ High | Isolate power safely. Inspect the module, connector, and backplane for heat marks, discoloration, or damaged pins. Measure supply voltages before re-energizing. | Correct the electrical fault before installing a replacement. Do not re-apply power to a damaged backplane. |
| New power supply does not restore 5 V output | Wrong model, incompatible chassis, incorrect wiring, backplane fault, configuration issue | ✅ High | Verify the replacement is FC-. Check wiring against the approved diagram. Inspect backplane for shorts or damage. | Restore correct wiring and configuration. Do not assume a new module will automatically fix a backplane fault. |
| Overvoltage protection trips repeatedly | Output overvoltage, failed regulation circuit, external voltage backfeed, damaged load | ⚠️ Medium | Measure output voltage and check for external voltage sources backfeeding into the 5 V rail. Inspect load modules for faults. | Identify and remove the overvoltage source before replacing the power supply. |
| Power supply fails shortly after replacement | Unresolved overload or short, incorrect input voltage, poor ventilation, prior backplane damage | ✅ High | Check input voltage range, output load current, cabinet temperature, and backplane condition. Verify no short circuits exist. | Correct the root cause before installing another power supply. A replacement will fail again if the overload remains. |
Field note: The most common FC- issue is not the power supply itself but the 24 V DC input or backplane load. Before replacing it, measure the input voltage, check for shorts on the 5 V rail, and inspect connector seating. I have seen a new PSU fail within hours because a shorted backplane was never cleared.
If you need technical support, provide photos of the FC- label, chassis type, input/output wiring, measured voltages, Safety Manager diagnostics, and any related alarm text.
Frequently Asked Questions
What does the Honeywell FC- do?
The FC- is a 24 V DC to 5 V DC power supply module for Honeywell Safety Manager, Safety Manager SC, and FSC controller chassis. It converts 24 V DC input to regulated local and redundant 5 V DC outputs for the controller backplane and associated electronics.
What input voltage does FC- require?
The module requires 24 V DC nominal, with an operating range of 20.4 to 31.2 V DC (−15% to +30%). Input current is less than 6 A at 24 V DC with a 16 A load, and less than 7 A at the low-line condition of 20.4 V DC.
What output does FC- provide?
It provides regulated 5 V DC outputs on two rails: local 5 V DC and redundant 5 V DC. Each output rail supports 0.5 to 16 A. The outputs are supervised by two independent overvoltage-protection circuits.
What is the difference between V1.0 and V1.1?
V1.1 is a component-update revision with no functional change compared to V1.0. Both revisions provide the same 24 V DC to 5 V DC conversion at up to 16 A. The V1.1 marking indicates updated internal components while retaining the same electrical specifications.
Is FC- conformal coated?
Yes. The FC- is a conformal-coated version designed for harsh industrial environments. The conformal coating provides additional protection against moisture, dust, and corrosive atmospheres.
Can I use FC- in a redundant power configuration?
Yes. Safety Manager controller chassis can support redundant power supplies. Each FC- provides local and redundant 5 V outputs. Verify the chassis configuration and approved redundancy arrangement before installation.
Can I hot-swap FC-?
Do not hot-swap it. The module is part of the controller’s primary power infrastructure. Removing it can affect the entire chassis and potentially cause a process shutdown. Follow the approved Safety Manager maintenance procedure, manage process risk, and use lockout/tagout where required.
Why is my controller chassis not powering up?
Check these items in order:
- Verify 24 V DC input voltage at the power-supply terminals.
- Check input fuse and connector retention.
- Measure 5 V DC output at the backplane or test point.
- Inspect for short circuits or excessive current draw on the 5 V rail.
- Review Safety Manager diagnostics for power-supply status.
If 24 V DC input is correct but 5 V DC output is missing, the power supply or backplane becomes a credible suspect.
Is FC- compatible with other Honeywell DCS platforms?
No. The FC- is specific to Honeywell Safety Manager, Safety Manager SC, and FSC controller chassis. Do not use it as a generic 24 V to 5 V power supply for other Honeywell DCS or PLC families. Confirm the chassis type and approved hardware list before ordering.
Is this FC- New Surplus or Refurbished?
The condition must be stated explicitly. New Original / New Surplus means unused legacy inventory with verified labels, clean connectors, and documented storage inspection. Refurbished (tested) means a previously used module that has been inspected and functionally checked.
For a refurbished FC-, request actual-unit photos, label verification, input/output voltage test under load, overvoltage-protection verification, connector inspection, conformal-coating condition check, and a written test report. Test videos and photos should be available upon request.
What should I verify before ordering FC-?
- Exact module label: FC- and revision (V1.0 or V1.1)
- Controller chassis type and compatibility
- Input voltage: 24 V DC range and capacity
- Output load: total 5 V DC current requirement
- Redundant power configuration, if applicable
- Existing diagnostics, alarms, and event logs
- Cabinet temperature and ventilation condition
- Required condition: New Original/New Surplus or Refurbished (tested)
Keep these checks in mind and you will avoid most FC- replacement rework.
