Honeywell TC-PPD011 – Extension Battery Module | Experion PKS / TDC 3000 Platform
Engineering Background: The Honeywell Experion PKS (Process Knowledge System) and its predecessor TDC 3000 represent one of the most widely deployed Distributed Control System (DCS) platforms in continuous-process industries globally. These architectures underpin critical control loops in refineries, power generation facilities, and municipal water treatment plants where unplanned downtime carries six-figure-per-hour cost consequences. Within this architecture, the TC-PPD011 Extension Battery Module serves a non-negotiable role: it sustains SRAM data retention and real-time clock integrity across the controller chassis during power interruption events, ensuring that process state, tuning parameters, and alarm histories are preserved without operator intervention.
Product Positioning: The TC-PPD011 is specifically engineered as an extension battery module, designed to supplement or replace the primary battery backup capacity within compatible Honeywell controller and I/O chassis. Unlike the base battery module (TC-PPD010), the TC-PPD011 extends backup duration for larger chassis configurations or high-memory controller nodes. It is not a universal battery pack — its connector interface, voltage profile, and firmware handshake are specific to the Honeywell C200/C300 controller family and associated Experion PKS infrastructure. Substitution with generic battery assemblies will result in failed self-test diagnostics and potential data loss.
Complete Technical Specifications
Electrical
- Module Type: Extension Battery Backup Module
- Nominal Battery Voltage: 3.6 V lithium chemistry
- Backup Duration: Extended (chassis-dependent; supplements TC-PPD010 base module)
- Charging Interface: Passive trickle-charge via backplane connector
- Self-Test: Automatic periodic battery health diagnostic via controller firmware
- Low-Battery Alarm: Hardware-level flag to controller; surfaced in Experion Station alarm banner
Mechanical
- Form Factor: Single-slot plug-in module, Honeywell standard card format
- Connector: Proprietary Honeywell backplane edge connector
- Weight: ~500 g (module with housing)
- Hot-Swap: Not supported — requires controlled power-down sequence per Honeywell SOP
Environmental
- Operating Temperature: 0°C to +60°C
- Storage Temperature: -40°C to +70°C
- Relative Humidity: 5% to 95% non-condensing
- Vibration: IEC 60068-2-6 compliant
- Pollution Degree: 2 (indoor industrial environment)
Certifications
- CE Marking: EMC Directive compliant
- UL Listed: Industrial control equipment
- RoHS: Compliant
- Functional Safety: Compatible with Experion PKS Safety Manager architecture (consult Honeywell FSE for SIL loop validation)
Data source: Honeywell Experion PKS Hardware Planning Guide (EP-DSC-HW-001), Honeywell TC-PPD011 Product Datasheet. Specifications subject to revision — verify against current Honeywell documentation for safety-critical applications.
Proven Application Environments
- Petrochemical Refinery | Crude Distillation Unit (CDU) | Continuous 24/7 operation: Sustains controller SRAM during planned power maintenance windows, preventing loss of PID tuning parameters across 200+ control loops.
- Coal-Fired Power Plant | Boiler Management System (BMS) | High-vibration turbine hall: Maintains real-time clock synchronization for sequence-of-events (SOE) logging during grid switching transients.
- Municipal Water Treatment | SCADA/DCS Hybrid Architecture | Unmanned remote pump stations: Provides data retention during utility power outages where UPS autonomy is limited to 15–30 minutes.
- LNG Terminal | Compressor Control System | Hazardous Area Zone 2 (controller in purged enclosure): Preserves compressor surge control parameters during emergency shutdown (ESD) and restart sequences.
- Pharmaceutical Manufacturing | Batch Process Control | FDA 21 CFR Part 11 regulated environment: Ensures audit trail and batch record integrity across controller power cycles, supporting regulatory compliance.
- Steel Mill | Electric Arc Furnace (EAF) Control | High electromagnetic interference (EMI) environment: Protects controller configuration data against power quality events common in heavy industrial electrical environments.
Engineering Advantages
- For extended maintenance windows requiring full chassis power-down, this battery module preserves all SRAM-resident controller data, because lithium cell chemistry maintains stable voltage output across the full discharge curve without the voltage cliff characteristic of alkaline alternatives.
- For multi-controller Experion PKS nodes with high memory utilization, this extension module supplements base battery capacity, because the TC-PPD011 is architecturally designed to parallel with TC-PPD010, doubling effective backup energy without chassis modification.
- For plants operating under IEC 61511 functional safety requirements, this battery module supports SIL-rated controller availability, because uninterrupted SRAM retention prevents the undefined controller state that would trigger a safety function demand.
- For facilities with aging TDC 3000 infrastructure migrating to Experion PKS, this module provides backward-compatible battery backup, because the TC-PPD011 connector and firmware interface are consistent across the C200/C300 controller generations.
- For procurement teams managing spare parts under ISA-55.1 asset management frameworks, this module carries a traceable part number with Honeywell’s global service network, because standardized part numbering enables cross-site inventory pooling and reduces emergency procurement lead times.
- For sites in tropical or high-humidity climates, this module maintains rated performance within its 5–95% RH envelope, because the sealed lithium cell assembly is protected against moisture ingress that degrades NiMH alternatives in humid industrial environments.
System Architecture & Signal Flow
Signal Flow: The TC-PPD011 connects via the Honeywell standard backplane edge connector. During normal operation, the controller backplane supplies trickle-charge current to maintain full cell charge. Upon detection of primary power loss (monitored by the Power Distribution Module, e.g., TC-PRS021), the battery module autonomously switches to discharge mode, supplying regulated voltage to the controller’s SRAM and RTC circuits. Battery status (charge level, fault flags) is communicated to the C200/C300 controller via the backplane diagnostic bus and surfaced as system alarms in Experion Station.
Compatible Modules:
- TC-PPD010 – Base Battery Module; TC-PPD011 extends its capacity in the same chassis slot pair
- TC-PRS021 – Power Supply Module; primary power source that the TC-PPD011 backs up
- C200 / C300 Controllers – Primary host controllers; TC-PPD011 is validated for both generations
- TC-CCN014 / TC-CCN024 – Controller chassis; physical housing that accepts the TC-PPD011 module
Substitution Conditions: The TC-PPD011 cannot be substituted with generic lithium battery assemblies. Any replacement must carry the Honeywell part number and pass the controller’s built-in battery self-test. Cross-reference with Honeywell’s current spare parts catalog before procurement to confirm revision compatibility with installed firmware versions.
Sourcing & Quality Verification
Units offered through Konmask.com are sourced from decommissioned plant upgrades, authorized distributor overstock, and verified secondary market channels. Each unit undergoes the following 4-step inspection process before listing:
- Visual Inspection: PCB, connector pins, housing, and label integrity checked against Honeywell OEM reference standards. Units with corrosion, pin damage, or label tampering are rejected.
- Battery Cell Voltage Test: Open-circuit voltage measured and compared against Honeywell’s minimum acceptance threshold. Cells below specification are replaced with equivalent lithium chemistry cells.
- Backplane Connector Continuity: All connector pins verified for continuity and correct impedance profile.
- Functional Bench Test: Where test equipment permits, module is seated in a compatible chassis and controller self-test diagnostic is executed to confirm “Battery OK” status flag.
Documentation available upon request:
- Inspection report with test date and technician ID
- Honeywell OEM datasheet (TC-PPD011)
- Certificate of conformance (CoC)
- Photos of actual unit (serial number visible)
- Decommission records (where available from source facility)
Procurement Process
- Submit Inquiry: Contact support@konmask.com with your required quantity, target delivery date, and installed firmware version (if known). Attach your plant’s spare parts specification sheet if available.
- Receive Quotation & Stock Confirmation: A technical quotation including unit price, lead time, and available inspection documentation will be issued within 24 hours of inquiry receipt on business days.
- Order Confirmation & Dispatch: Upon purchase order confirmation, units are packaged in anti-static ESD bags with foam cushioning, and shipped via tracked courier with full export documentation for international orders.
Technical Support: Pre-sales engineering consultation is available for compatibility verification, chassis configuration review, and spare parts BOM cross-referencing. Post-sales support covers installation guidance and controller diagnostic interpretation. Contact: support@konmask.com | +0086 19859288691.
Technical FAQ
- Q: Is the TC-PPD011 compatible with both C200 and C300 Experion PKS controllers?
- A: Yes. The TC-PPD011 is validated for use with both the C200 and C300 controller generations within the Experion PKS platform. The backplane interface and firmware diagnostic protocol are consistent across both controller types. Confirm chassis slot availability with your system integrator before ordering.
- Q: Can the TC-PPD011 replace a TC-PPD010, or must both modules be present?
- A: The TC-PPD011 is an extension module, not a direct replacement for the TC-PPD010 base module. In most chassis configurations, the TC-PPD010 must be present as the primary battery module; the TC-PPD011 extends total backup capacity. However, specific chassis revisions may support TC-PPD011 standalone operation — consult the Honeywell Hardware Planning Guide for your chassis part number to confirm the required configuration.
- Q: Does the TC-PPD011 carry any functional safety certification applicable to SIL 2 loops?
- A: The TC-PPD011 is a supporting infrastructure component within the Experion PKS architecture, which is certified for use in SIL 2 safety instrumented systems when configured per Honeywell’s Safety Manual. The battery module itself does not carry an independent SIL rating, but its correct operation is a prerequisite for maintaining the controller availability required by SIL 2 loop calculations. A Honeywell Functional Safety Engineer (FSE) should be consulted for site-specific SIL validation.
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