HTS KS – Protective System Control FCU 500 / FCU 505

Overview

The Honeywell FCU 500 and FCU 505 are protective system controls designed for monitoring and controlling central safety functions in multiple burner systems on industrial furnaces. The FCU 500 serves as a central control unit while the FCU 505 is configured for zone control — together covering a broad range of multi-burner furnace applications requiring coordinated safety management.

The FCU series is certified for use in systems up to SIL 3 (compliant with Performance Level e) and carries FM, EU-GAR, CSA, and Eurasian CU approvals. Integrated tightness testing, temperature monitoring, pre-purge sequencing, and programmable logic make the FCU 500/505 a comprehensive solution for industrial combustion safety on high-temperature equipment.

Features & Benefits

• Monitors and controls central safety functions across multiple burner systems on a single industrial furnace — reducing the need for independent per-burner safety controls
• Integrated valve proving system (VPS) checks valves and the system for tightness before each start cycle, providing a critical pre-ignition safety check
• Temperature monitoring via STM (high-temperature mode ≥750°C) and STL/FSTL (max furnace temperature 200–1600°C) with support for double thermocouple Types K, N, and S (H1 versions)
• Replaceable power module for fail-safe outputs extends service life and simplifies maintenance without full unit replacement
• Replaceable parameter chip card stores configuration settings — transferable to a unit with an identical type code for fast commissioning and replacement
• PROFINET and Modbus TCP communication via optional BCM 500 module — provides cyclic and acyclic data including status, faults, remaining times, and STM/STL temperatures
• Programmable sequences and timing parameters (pre-purge, post-purge, valve opening delays, measurement times) configurable to customer requirements
• Certified to SIL 3 per EN 61508 and Performance Level e per ISO 13849 — suitable for high-integrity safety applications
• FM Approved, EU-GAR 2016/426, EMC 2014/30/EU, LVD 2014/35/EU, ANSI/CSA Z21.20, and Eurasian CU approved — supports global project requirements
• DIN-rail mountable (35 × 7.5 mm) and rated for control cabinet environments ≥IP54; OCU operator panel faceplate rated IP65

Technical Specifications

• Power Supply: 120 VAC (Q suffix), 230 VAC (W suffix); 24 VDC control voltage ±10%
• Operating Temperature: −20°C to +60°C
• Enclosure Rating: Control cabinet ≥IP54; OCU faceplate IP65
• Safety Integrity Level: SIL 3 (EN 61508), PL e (ISO 13849)
• Approvals: FM, EU-GAR 2016/426, EMC 2014/30/EU, LVD 2014/35/EU, ANSI/CSA Z21.20, Eurasian CU (EAC)
• Communication: PROFINET / Modbus TCP via BCM 500 module
• Temperature Monitoring: STM ≥750°C (high temp mode); STL/FSTL 200–1600°C; double thermocouple Types K, N, S (H1 versions only)
• Installation: DIN-rail 35 × 7.5 mm; control cabinet environment, no condensation permitted
• Inputs (24 VDC): Start, Controlled air flow, Remote reset, Burner operation, Fan ready, VPS/POC, Emergency stop, Air min, Air flow, Gas min, Gas max, Programmable inputs
• Outputs (AC/24 VDC): Gas valves V1, V2, V3; LDS start limits; Purge; High Temp; Fault 24V; Operation 24V; Capacity control; Fan; Safety interlock
• Actuator Compatibility: IC20, IC40, RBW three-point step; frequency converter fan control
• Valve Configuration: V1, V2, V3, relief valve options per tightness test scenario
• Programmable Timing: tGV (fan run-up), tPV (pre-purge), tPN (post-purge), tRF (enable delay), tMP (min pause), tE (switch-on delay), tL1/tL2 (valve opening), tM (measurement time)
• Program Sequences: Startup, Safety Interlock Checks, Pre-Purge, Airflow Monitoring, Tightness Test, Ignition Enable, Operation, Post-Purge
• Parameter Storage: Replaceable chip card; settings transferable between units with identical type code

Applications

• Multi-burner industrial furnaces requiring centralized safety function control
• High-temperature process equipment requiring temperature limiting and monitoring (STM/STL/FSTL)
• Applications requiring pre-ignition valve tightness testing (valve proving system)
• Gas-fired industrial burner systems requiring pre-purge and post-purge sequencing
• Furnace systems with zone-based capacity control and airflow monitoring
• SIL 3 / PL e-rated safety applications in industrial combustion environments
• Systems requiring PROFINET or Modbus TCP integration for plant-level communication

Models / Configurations

• FCU 500 – Central protective system control; monitors and controls central safety functions across all burner zones on a single industrial furnace
• FCU 505 – Zone control variant; used for distributed zone-level control within a multi-burner furnace system
• FCU 500 H1 versions – Adds double thermocouple temperature monitoring support (Types K, N, S) for high-temperature furnace applications
• FCU 500 Q (120 VAC) / W (230 VAC) – Power supply voltage variants to suit local supply requirements

FCU 500 / FCU 505 Accessories

• BCM 500 – Bus communication module enabling PROFINET and Modbus TCP connectivity; provides cyclic and acyclic data (status, fault codes, remaining times, temperature values) to plant control systems
• OCU – Operator control unit providing a local operator interface with IP65-rated faceplate for system status display and control at the furnace
• LM + PCC 500 – Load manager and process control components for capacity and zone management in conjunction with the FCU 500/505
• BCSoft V3.9.0 / V4.0.0 – PC-based configuration and commissioning software for FCU 500/505 parameter programming and diagnostics

Documentation