Metso Valmet A413325 Rev. 08 Metso Valmet PLC Board

I. Overview

Metso A413325 is a highly integrated multi-channel industrial control module, whose core positioning is to provide a full-link solution of "synchronous acquisition of multi-type signals - collaborative control of multi-parameters - multi-level safety interlocking" for combined mining crushing-conveying systems, auxiliary equipment for the entire metallurgical hot rolling process, and full thermal circuits of cement kilns in the building materials industry. As a core component of Metso's high-end automation systems (such as Metso DNA fully redundant DCS and Metso Outotec large-scale equipment control systems), its essence lies in achieving accurate and synchronous processing of three types of on-site signals—analog signals (temperature/pressure/flow), digital signals (equipment status/emergency stop), and pulse signals (speed/counting)—through a "high-channel-density hardware architecture + redundant control algorithm". It also enables dynamic collaborative adjustment of equipment operating parameters and millisecond-level redundant response to fault conditions. This module is particularly suitable for harsh industrial environments with high load, strong vibration, and multiple interferences (such as multi-equipment linkage in underground mines, metallurgical rolling mill clusters, and full systems of cement rotary kilns).

II. Technical Parameters

(I) Signal Input/Output Parameters (Highly Integrated Channel Configuration)

1. Input Channel Configuration (Full Coverage of Signal Types)

• Analog Input (AI): 12 independent isolated analog input channels, compatible with four types of signals: 4-20mA DC, 0-10V DC, RTD (PT100/PT1000), and thermocouple (Type K/J). The input impedance is ≥10MΩ (for voltage signals), 250Ω (for current signals), and 100Ω (for PT100). The measurement accuracy is ±0.05% FS (for current/voltage signals) and ±0.1℃ (for RTD signals). It can be directly connected to high-precision detection instruments such as bearing temperature sensors of heavy mining equipment, hydraulic pressure sensors of metallurgical rolling mills, and temperature sensors of cement kiln precalciners, ensuring accurate acquisition of weak signals (e.g., 0.05mA-level current changes).

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• Digital Input (DI): 24 dual-isolated digital input channels, supporting optional dual voltages of 24V DC/110V DC. The input response time is ≤0.5ms, suitable for status signals from mine deviation switches, metallurgical emergency stop buttons, and building materials equipment limit switches. The anti-interference voltage is ≥500V AC (for 1 minute), and it has passed the IEC 61000-4-4 electrical fast transient/burst immunity test (±4kV), preventing false triggers caused by strong electromagnetic interference (such as the start/stop of high-voltage frequency converters).

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• Pulse Input (PI): 8 high-speed isolated pulse input channels, supporting 0-50kHz pulse signals and A/B phase quadrature encoding signals. It can be connected to mine belt speed encoders, metallurgical roller speed encoders, and building materials feeder flow pulse sensors. The pulse counting accuracy is ±1 pulse, and the speed measurement range is 0-10000rpm, meeting the precise measurement requirements of high-speed equipment.

2. Output Channel Configuration (Support for Multiple Types of Drives)

• Analog Output (AO): 8 independent isolated analog output channels, supporting optional 4-20mA DC or 0-10V DC. The output accuracy is ±0.1% FS, and the load capacity is ≤600Ω (for current output) and ≥1kΩ (for voltage output). It can directly drive actuators such as mine frequency converters, metallurgical servo valves, and building materials control valves, realizing 0-100% stepless adjustment. The output ripple is ≤10mV (peak-to-peak), ensuring adjustment stability.

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• Digital Output (DO): 12 dual-isolated relay output channels, each with a rated load current of 8A@250V AC/15A@30V DC, supporting configurable normally open/normally closed contacts. It is also compatible with 4 high-speed transistor outputs (0.5A@24V DC, response time ≤10μs), meeting the on-off control needs of different types of equipment such as mine equipment contactors, metallurgical alarm lights, and building materials solenoid valves. The mechanical life of the relay is ≥20 million cycles, and the electrical life is ≥500,000 cycles (under rated load).

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• Communication Output (Optional): 2 redundant Ethernet interfaces (Profinet IRT/Modbus TCP) and 2 redundant RS485 interfaces (Modbus RTU), supporting dual-network redundant communication with a maximum communication rate of 1Gbps, ensuring the continuity and reliability of data transmission in large-scale systems.

(II) Electrical and Performance Parameters (High Reliability and Redundant Design)

1. Power Supply and Power Consumption (Redundant Power Supply Guarantee)

• Supply Voltage: Dual-channel redundant input of 24V DC (with ±15% fluctuation tolerance), supporting seamless switching between two power supplies (switching time ≤1ms). It is compatible with industrial-grade redundant power modules (such as Metso 24V/20A redundant power supply), preventing module shutdown due to single power supply failure.

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• Standby Power Consumption: ≤8W; Power Consumption Under Full Load: ≤25W. It adopts a redundant heat sink design (fanless), with heat dissipation efficiency increased by 40%, suitable for high-density installation scenarios in large control cabinets (a module spacing of ≥15mm is sufficient to meet heat dissipation requirements).

2. Processing Performance (Multi-Task Collaboration and Redundant Control)

• Control Cycle: The minimum control cycle is 5ms, supporting parallel processing of 16 independent control loops (such as PID adjustment, logic interlocking, pulse counting, and cascade control). It meets the "multi-equipment - multi-parameter" collaborative control needs of large-scale production lines (such as the synchronous adjustment of four parameters—temperature, pressure, feeding quantity, and speed—of cement kilns).

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• PID Function: Built-in enhanced PID algorithm (supporting standard PID, cascade PID, feedforward PID, and adaptive PID), supporting online auto-tuning of proportional (P), integral (I), and derivative (D) parameters. It has functions such as bumpless switching (auto/manual/remote), anti-integral windup, alarm interlocking, and parameter backup/restoration. The control steady-state error is ≤±0.2% FS, suitable for high-precision closed-loop control of continuous process parameters.

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• Redundancy Performance: Supports module-level hot redundancy (1+1 redundant configuration) with a redundancy switching time of ≤10ms. It also has channel-level fault self-repair function (e.g., automatic switching to a standby channel when an AI channel fails), ensuring control continuity.

(III) Environmental and Compatibility Parameters (Adaptation to Harsh Environments)

1. Environmental Adaptability (Stable Operation in All Scenarios)

• Operating Temperature: -30℃~+70℃, humidity 5%~95% RH (no condensation). It has passed the high-low temperature storage test of -40℃~+85℃ and can operate stably in extreme environments such as underground mines (high temperature and high humidity), metallurgical workshops (high temperature and dust), and outdoor building materials equipment (low temperature and severe cold) without additional temperature control devices.

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• Protection Level: IP20 (module itself); when used with Metso's dedicated explosion-proof enclosure (Ex d IIB T4 Gb), it can be upgraded to IP65 explosion-proof level, suitable for chemical explosion-proof areas and underground mine explosion-proof scenarios.

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• Anti-Interference and Anti-Vibration: Complies with IEC 61000-4-2 (ESD ±15kV air discharge/±8kV contact discharge), IEC 61000-4-3 (radiated immunity 20V/m), and IEC 61000-4-6 (radio-frequency field-induced conducted immunity 10V/m) standards. It can withstand mechanical vibration of 10-500Hz (acceleration 5g) and impact of 500m/s2 (11ms half-sine wave), ensuring stable signals in the vibration environment of heavy equipment.

2. System Compatibility (Full Ecosystem Adaptation)

• Controller Adaptability: Natively compatible with Metso DNA fully redundant DCS and Metso Outotec large-scale equipment control systems. It also supports third-party high-end PLCs (such as Siemens S7-400H and Rockwell ControlLogix). Through the OPC UA protocol, it realizes data interaction with MES/ERP systems and supports remote parameter configuration, status monitoring, and firmware upgrading.

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• Expansion Capability: Supports multi-module cascading (up to 32 units), realizing input/output channel expansion and data synchronization through Metso's dedicated bus (Metso Bus) with a cascading delay of ≤1ms. It adapts to the centralized management needs of large-scale production lines (such as more than 10 belt conveyors in mines and more than 5 rolling mill auxiliary equipment in metallurgy), reducing the complexity and cost of system integration.

III. Functional Features

(I) High Integration + Redundant Design to Ensure the Reliability of Large-Scale Systems

1. Hardware Level: Full-Link Redundancy and Isolation Protection

• Channel-Level Isolation: AI/DI/PI channels all adopt a dual optoelectronic isolation design (isolation voltage ≥2500V DC) to block ground loops and electromagnetic interference, preventing the spread of single-channel faults to the entire module. DO channels adopt a dual-contact relay design, and key loops (such as emergency stop and shutdown) support parallel output of dual contacts to improve execution reliability.

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• Power Supply and Communication Redundancy: Dual-channel 24V DC redundant power supply (automatic switching) and dual Ethernet/RS485 redundant communication ensure that the module can still operate normally and transmit data when power supply is interrupted or communication fails.

• Redundant Heat Dissipation: Adopts a composite heat dissipation structure of "aluminum heat sink + thermal silica gel". The fanless design avoids heat dissipation failure caused by dust blockage. The surface temperature of the module is ≤55℃ (at an ambient temperature of 60℃) under full load operation, extending the service life of components.

2. Software Level: Fault-Tolerant and Self-Repairing Algorithms

• Fault Self-Diagnosis: Built-in real-time fault monitoring algorithm to perform 24-hour self-inspection on module power supply, communication links, channel status, and component temperature. The fault identification accuracy is ≥99.9%, and detailed fault logs (such as "E05: AI3 channel RTD open circuit" and "F02: Ethernet 1 link interruption") are generated. It also supports local storage of fault information (10 years of historical fault data).

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• Channel Self-Repair: When a fault is detected in an AI/DI/PI channel, it automatically switches to a standby channel (requires pre-configuration of the standby channel) with a switching time of ≤10ms, avoiding production interruption caused by single-channel faults.

• Data Redundant Backup: Module parameters (such as PID parameters, interlocking logic, and channel configuration) support local dual-zone backup and remote cloud backup. After parameter modification, they are automatically synchronized to the backup zone to prevent parameter loss.

Application Example: In the control system of multiple underground mine belt conveyors, the A413659 ensures that the module can still control the normal operation of the belt conveyors when there are fluctuations in the underground power grid or fiber optic cable interruptions through dual-channel redundant power supply and communication. When a belt speed encoder (PI channel) fails, it automatically switches to the standby encoder channel, avoiding the shutdown of the belt conveyor due to the loss of speed signals. The Mean Time Between Failures (MTBF) is ≥120,000 hours.

(II) Synchronous Processing of Multi-Type Signals to Adapt to Complex Process Control

1. Signal Acquisition and Collaborative Calculation

• Synchronous Acquisition of Multi-Signals: AI/DI/PI channels adopt unified clock synchronization (synchronization accuracy ≤1μs) to ensure the synchronous acquisition of multi-parameters such as "temperature - tension - speed" of mine belt conveyors, "pressure - thickness - speed" of metallurgical rolling mills, and "temperature - pressure - flow" of cement kilns, avoiding control deviations caused by signal delays.

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• Cross-Signal Type Logic Calculation: Supports mixed logic calculation of analog signals, digital signals, and pulse signals, such as "belt speed

• In-Depth Processing of Pulse Signals: PI channels support functions such as pulse counting, frequency measurement, speed calculation, and phase difference measurement. They can directly calculate the conveying capacity of mine belt conveyors (number of pulses × material quantity per pulse) and the linear speed of metallurgical rollers (speed × roller diameter) without additional calculation modules, simplifying the system architecture.

2. Multi-Loop Cascade Adjustment

• Supports 8-level PID cascade control (such as the 4-level cascade adjustment of "temperature - coal feeding quantity - fan speed - secondary air temperature" for cement kiln precalciners). The main loop adjusts the coal feeding quantity set value according to the temperature deviation, the secondary loop adjusts the fan speed according to the coal feeding quantity deviation, and the tertiary loop adjusts the secondary air temperature according to the fan speed deviation. This ensures the temperature control accuracy of the precalciner is ±3℃, avoiding incomplete decomposition of raw meal.

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• Supports feedforward PID control, which can take interference factors such as "silo level" of mine belt conveyors and "incoming material thickness" of metallurgical rolling mills as feedforward signals to adjust the control output in advance, reducing the impact of interference on the controlled parameters. For example, when the silo level of the belt conveyor rises sharply, the belt speed is reduced in advance to avoid material accumulation.

Application Example: In the full thermal control system of a cement rotary kiln, the A413659 collects signals such as kiln head temperature, precalciner pressure, and cooler outlet temperature through 12 AI channels, and collects signals such as feeder speed, kiln speed, and fan speed through 8 PI channels. After synchronous calculation, it adjusts the coal injection quantity, feeding quantity, and fan speed through 8 AO channels, forming a "temperature - pressure - speed - flow" multi-parameter collaborative control. The kiln head temperature fluctuation is controlled within ±5℃, and the qualified rate of cement clinker is increased by 2%~3%.