Metso Valmet A413040 DCU Board

I. Overview

Metso A413040 is a scenario-specific control module, whose core positioning is to provide an integrated solution of "signal acquisition - logical operation - execution control - basic diagnosis" for mine feeding-screening auxiliary systems, single-machine production lines in the building materials industry (such as concrete mixing plants), and small-scale drive equipment in the metallurgical industry (such as cooling fans). As a key component of Metso's lightweight automation systems (e.g., Metso DNA Compact DCS, Metso Outotec single-machine controller), its essence lies in achieving accurate processing of two types of core on-site signals—analog signals (temperature/pressure) and digital signals (equipment status)—dynamic adjustment of equipment operating parameters, and rapid response to fault conditions through a "simplified channel hardware architecture + scenario-specific control algorithm". It is particularly suitable for industrial environments with medium-low load, regular vibration, and low dust levels (such as mine ground feeding stations, building materials mixing plants, and metallurgical cooling workshops).

II. Technical Parameters

(I) Signal Input/Output Parameters (Simplified and Efficient Configuration)

1. Input Channel Configuration (Focusing on Core Needs)

• Analog Input (AI): 6 independent analog input channels, compatible with standard industrial signals of 4-20mA DC and 0-10V DC. The input impedance is ≥10MΩ (for voltage signals) and 250Ω (for current signals). It can be directly connected to mine feeder load sensors, building materials mixing plant pressure transmitters, and metallurgical cooling water temperature sensors. The measurement accuracy is ±0.15% FS, which meets the signal acquisition accuracy requirements of small and medium-sized equipment (e.g., feeder quantity error ≤0.8%).

• Digital Input (DI): 12 isolated digital input channels, supporting 24V DC signals. The input response time is ≤1.5ms, suitable for mine limit switches, building materials emergency stop buttons, and metallurgical equipment operation feedback signals. The anti-interference voltage is ≥250V AC (for 1 minute), preventing false triggers caused by electromagnetic interference in conventional industrial environments (such as the start/stop of small motors).

2. Output Channel Configuration (Adapting to Small and Medium-Sized Actuators)

• Analog Output (AO): 4 analog output channels, supporting optional 4-20mA DC or 0-10V DC. The output accuracy is ±0.25% FS, and the load capacity is ≤500Ω (for current output) and ≥1kΩ (for voltage output). It can directly drive mine feeder frequency converters, building materials control valves, and metallurgical cooling fan frequency converters, realizing 0-100% stepless adjustment with an output stability error of ≤0.5% FS.

• Digital Output (DO): 6 relay output channels, each with a rated load current of 5A@250V AC/10A@30V DC, supporting configurable normally open/normally closed contacts. It meets the on-off control needs of mine equipment contactors, building materials indicator lights, and metallurgical solenoid valves. The mechanical life is ≥10 million cycles, and the electrical life is ≥100,000 cycles (under rated load).

(II) Electrical and Performance Parameters (Lightweight and Efficient Operation)

1. Power Supply and Power Consumption (Low-Energy Adaptation)

• Supply Voltage: 24V DC (with ±15% fluctuation tolerance), compatible with commonly used 24V/5A switching power supplies in industry. No dedicated power supply equipment is required, making it suitable for power supply scenarios of small and medium-sized equipment control cabinets.

• Standby Power Consumption: ≤4W; Power Consumption Under Full Load: ≤12W. The low-power design reduces system energy consumption, and it can be directly connected to the equipment's built-in power supply (e.g., 24V power supply of the feeder control cabinet) without separate wiring.

2. Processing Performance (Meeting the Needs of Small and Medium-Sized Processes)

• Control Cycle: The minimum control cycle is 15ms, supporting parallel processing of 6 independent control loops (such as basic PID adjustment and simple logic interlocking). It meets the real-time control needs of small and medium-sized processes like mine feeding-screening linkage and building materials mixing batching.

• PID Function: Built-in scenario-specific PID algorithms (supporting standard PID and intermittent PID), supporting online adjustment of proportional (P) and integral (I) parameters. It has functions of bumpless auto/manual switching and anti-integral windup, suitable for closed-loop control of continuous parameters such as temperature, pressure, and flow. The control steady-state error is ≤±0.8% FS.

(III) Environmental and Compatibility Parameters (Adapting to Conventional Scenarios)

1. Environmental Adaptability (Covering Small and Medium-Sized Equipment Scenarios)

• Operating Temperature: -15℃~+60℃, humidity 5%~95% RH (no condensation). It can operate stably in conventional environments such as mine ground workshops, building materials mixing plant control rooms, and metallurgical cooling workshops without additional temperature control devices.

• Protection Level: IP20 (module itself); when used with Metso's simple dustproof enclosure, it can be upgraded to IP40, effectively isolating low dust (such as dust from building materials mixing) and adapting to medium-low dust scenarios.

• Anti-Interference and Anti-Vibration: Complies with IEC 61000-4-2 (ESD ±12kV air discharge) and IEC 61000-4-3 (radiated immunity 8V/m) standards. It can withstand mechanical vibration of 10-500Hz (acceleration 1.5g), ensuring stable signals in the vibration environment of small and medium-sized equipment.

2. System Compatibility (Flexible Adaptation)

• Controller Adaptability: Natively compatible with Metso DNA Compact DCS and Metso Outotec single-machine controllers. It communicates with the upper computer through the RS485 communication interface (Modbus RTU protocol), supporting remote parameter configuration (e.g., PID parameter modification) and status monitoring.

• Expansion Capability: Supports multi-module cascading (up to 12 units), realizing input/output channel expansion through bus expansion. It adapts to the centralized management needs of small and medium-sized production lines (such as the linkage of 3-5 feeders), reducing integration costs.

III. Functional Features

(I) Scenario-Specific Design to Adapt to the Needs of Small and Medium-Sized Processes

1. Channel Configuration Accurately Matching Scenarios

2. Built-In Scenario-Specific Control Algorithms

• Mine Feeding Dedicated Algorithm: Aiming at the "large load fluctuation" characteristic of feeders, a built-in "load-speed" linked PID algorithm is adopted. When the feeder load exceeds 110% of the rated value (AI signal), the feeder speed is automatically reduced (AO output) to avoid material accumulation, with a control accuracy of ±0.5%.

• Building Materials Mixing Batching Algorithm: Supports "weight-flow" intermittent PID control, adapting to the batching scenario of concrete mixing plants. For example, after setting the target value of sand and gravel weight, the module automatically adjusts the feeder valve opening (AO), with a batching error of ≤0.8%.

• Metallurgical Cooling Adjustment Algorithm: Optimizes PID integral parameters for the "temperature lag" characteristic of cooling fans. When the cooling water temperature exceeds the set value (e.g., 40℃), the fan speed is quickly increased (AO), with a water temperature adjustment response time of ≤300ms.

Application Example: In the control of a mine ground vibration feeder, the A413040 collects the feeder load (4-20mA) through AI. When the load suddenly increases from 80% to 120%, the built-in algorithm reduces the feeder speed from 1000rpm to 800rpm within 200ms to avoid material overflow. At the same time, it interlocks with DO to trigger an audible and visual alarm, ensuring stable feeding.

(II) Basic Logic Interlocking and Safety Protection to Ensure Equipment Operation

1. Simple Logic Configuration to Reduce Operation Difficulty

2. Multi-Level Safety Protection

• Equipment Protection: When motor overload (DI signal) or actuator fault (AO output and feedback deviation exceeding 10%) is detected, the output is immediately cut off (DO shutdown) to avoid equipment damage.

• Process Protection: For the "batching timeout" scenario in building materials mixing plants, a built-in timing function is provided. When the batching time exceeds the set value (e.g., 5 minutes), batching is automatically stopped and an alarm is triggered to prevent raw material waste.

• Power Supply Protection: The module has built-in overvoltage/undervoltage protection. When the supply voltage is

(III) Simple Operation & Maintenance and Status Monitoring to Reduce Management Costs

1. Intuitive Status Indication and Fault Diagnosis

• Panel Visualization: The module panel is equipped with 6 AI indicator lights (green), 12 DI indicator lights (yellow), 4 AO indicator lights (blue), 6 DO indicator lights (red), and 1 power indicator light (orange). The status of channels can be intuitively judged through the on/off/flashing of the indicator lights (e.g., a flashing AI light indicates signal overrange).

• Basic Fault Diagnosis: Built-in fault detection functions for power supply faults, channel open circuits, and communication interruptions. After a fault is identified, an alarm is triggered through DO (e.g., "E02: AI2 channel open circuit" triggers the DO6 alarm light), and the fault code is uploaded to the upper computer for easy and quick troubleshooting.

2. Tool-Free Operation & Maintenance Design

(IV) Wide Environmental Adaptation and Low Power Consumption to Improve Scenario Flexibility

• Full Coverage of Conventional Environments: The operating temperature of -15℃~+60℃ and optional IP40 protection cover conventional scenarios such as mine grounds, building materials indoor spaces, and metallurgical auxiliary workshops, without the need for additional protection measures.

• Low-Power Adaptation: With a full-load power consumption of ≤12W, it can be connected to the equipment's built-in 24V power supply (e.g., 24V/5A power supply of the feeder control cabinet), eliminating the need for separate power supply circuits and simplifying on-site wiring.

• Third-Party Compatibility: It supports connection to domestic PLCs (e.g., Siemens S7-200 SMART) and human-machine interfaces (e.g., Weintek MT6071IP) without modifying module parameters, reducing system integration difficulty.

IV. Application Scenarios

(I) Mining Industry: Ground Vibration Feeder Control System

• Signal Acquisition: 6 AI channels are respectively connected to feeder load (4-20mA), silo level (4-20mA), vibration motor temperature (4-20mA), ambient temperature (4-20mA), feeder quantity (4-20mA), and motor current (4-20mA); 12 DI channels are connected to silo low-level switch, feeder limit switch, emergency stop button, and motor overload protection signal.

• Control Logic: The PID logic of "silo level >90% (AI2) → feeder acceleration (AO1)" and "motor temperature >75℃ (AI3) → feeder deceleration (AO1)" is configured through the configuration software to ensure stable feeder quantity (error ≤0.8t/h).

• Interlocking Protection: When the DI detects an emergency stop signal (DI12) or motor overload (DI4), it immediately triggers DO1 to cut off the feeder power supply, DO2 to activate the braking device, and DO3 to trigger an audible and visual alarm, while uploading fault information to the mine auxiliary control system.

(II) Building Materials Industry: Concrete Mixing Plant Batching Control System

• Signal Acquisition and Control: AI1-AI4 respectively collect sand and gravel weight (4-20mA), cement weight (4-20mA), water flow (4-20mA), and admixture flow (4-20mA); AO1-AO4 respectively drive the sand and gravel feeder valve, cement feeder valve, water valve, and admixture valve; DO1-DO6 control the start/stop of the mixing motor, batching completion indicator light, and fault alarm light.

• Batching Control: After setting the sand and gravel weight to 500kg (AI1 corresponding to 10mA) and cement weight to 200kg (AI2 corresponding to 8mA), the module adjusts the feeder valve opening through AO1/AO2. When the weight reaches the target value, the feeder valve is closed (DO auxiliary cutoff), with a batching accuracy of ±0.5%.

• Fault Response: When the batching time exceeds 5 minutes (built-in timing) or the weight deviation exceeds 5% (AI comparison), DO6 is triggered to alarm, and batching is stopped at the same time (DO1 turns off the mixing motor) to avoid raw material waste.

(III) Metallurgical Industry: Rolling Mill Auxiliary Cooling Fan Control System

• Temperature and Speed Control: AI1 collects the rolling mill cooling water temperature (4-20mA corresponding to 0-80℃), and AI2 collects the fan speed feedback (4-20mA corresponding to 0-1500rpm); AO1 drives the fan frequency converter (to control speed), and AO2 is for standby (to adjust the cooling water valve); DO1 controls the fan start/stop, and DO2 controls the standby fan start/stop.

• PID Adjustment: The target value of the cooling water temperature is set to 40℃. The module dynamically adjusts the fan speed through AO1. When the water temperature rises to 42℃, the fan speed is increased from 1000rpm to 1200rpm, with a water temperature fluctuation of ≤±1℃.

• Standby Interlocking: When the main fan has been running for more than 12 hours (built-in timing), DO2 is automatically activated to start the standby fan, and DO1 stops the main fan to realize alternate operation of fans and extend equipment service life; when the water temperature continuously exceeds 50℃ (for 30 seconds), DO3 is triggered to alarm and fault information is uploaded to the rolling mill control system.