Metso Valmet A413160 FIU1 Frequency Input Board

I. Overview

The Metso A413160 is an industrial-grade safety interlock and logic control module, mainly designed to be compatible with the control systems of Metso crushing and screening equipment (such as jaw crushers, cone crushers, heavy-duty conveyors, etc.). It undertakes the core functions of "safety signal acquisition - logic judgment - emergency control command output", and focuses on safety-related scenarios such as equipment overload protection, emergency stop interlocking, and safety door monitoring. Its design strictly complies with industrial safety standards, adopting dual hardware redundancy and a Fail-Safe architecture. It can trigger safety protection actions under abnormal working conditions such as sensor faults and signal interruptions, effectively preventing equipment damage and personal injury. It is widely used in industries with extremely high safety control requirements, such as mining, building materials, and metallurgy.

Compared with general-purpose logic control modules, this module features "compatibility with Metso equipment safety protocols", "safety level certification", and "fast interlock response". It can be directly integrated into Metso C100/C200 series safety control cabinets, enabling seamless connection with crusher emergency stop buttons, overload sensors, safety door switches, and main motor contactors. This ensures the safety and reliability of crushing equipment during normal operation and abnormal shutdown processes.

II. Technical Parameters

1. Basic Specifications

2. Electrical Performance

Power Supply Parameters:

• Supply Voltage: 24V DC ±20% (compatible with wide-range DC power supplies for industrial equipment);

• Rated Power Consumption: ≤10W (no-load); ≤20W (full-load logic operation);

• Power Redundancy: Supports dual-channel 24V DC input (main/standby switching time ＜10ms, preventing safety function failure caused by single power supply fault);

• Power Isolation: Triple isolation (input - output - ground) with an isolation voltage of 2500V AC (for 1 minute, preventing power crosstalk and signal interference).

Safety Input Characteristics:

• Input Channels: 8 safety input channels (compatible with safety sensors, such as emergency stop buttons, safety door switches);

• Input Type: Dual-channel redundant input (each safety signal requires simultaneous acquisition by 2 channels to ensure signal reliability);

• Input Signal: 24V DC wet contact signal (compatible with NPN/PNP safety sensors);

• Input Current: ≤8mA (per channel, low-power design);

• Response Time: ≤15ms (quickly captures changes in safety signals, such as emergency stop button press).

Safety Output Characteristics:

• Output Channels: 4 safety output channels (driving safety actuators, such as main motor contactors, emergency stop relays);

• Output Type: Dual-contact redundant relay output (each output includes 2 sets of independent contacts, ensuring that a single contact fault does not affect protection actions);

• Contact Rating: 5A/250V AC or 8A/30V DC (per contact, can directly drive high-power contactors);

• Output Protection: Each channel has built-in overcurrent protection (fusing current 10A) and surge suppressor (preventing damage from switching arcs).

Communication and Logic Control:

• Communication Interface: RS485 (half-duplex, supporting safety protocols);

• Supported Protocols: Modbus RTU (compatible with Metso's exclusive safety control sub-protocol, Metso Safety Protocol);

• Logic Operation: Built-in 100 sets of configurable safety logic (such as "AND/OR/NOT", "delay trigger", "edge detection", configured via Metso's dedicated software);

• Address Range: 1-247 (slave address set via DIP switches, supporting multi-module safety bus networking).

3. Environmental Adaptability Parameters

III. Functional Features

1. High Safety Level and Redundancy Design

• Safety Standard Certification: Complies with EN ISO 13849-1 PL d and IEC 61508 SIL 2 safety levels, meeting the safety control requirements of heavy industrial equipment. It can be used for key interlock circuits to protect personnel and equipment (such as crusher overload shutdown, and prohibition of startup when the safety door is not closed);

• Dual Hardware Redundancy: Dual-channel power input (automatic main/standby switching), dual-channel input acquisition (each safety signal requires verification by 2 channels), and dual-contact output redundancy (each output includes 2 sets of independent relay contacts). This avoids safety function failure caused by a single hardware fault and significantly improves system reliability.

2. Flexible Safety Logic Configuration

• Visual Logic Programming: Supports configuration of safety logic via Metso Safety Configurator dedicated software, with 100 built-in customizable logic modules (such as "emergency stop button pressed + overload signal triggered → main motor shutdown", "safety door closed → feeder startup allowed"). No complex code writing is required, reducing on-site debugging difficulty;

• Dynamic Logic Monitoring: Real-time monitors the execution status of configured safety logic. If logic conditions are not met (such as a startup command issued when the safety door is not closed), it immediately triggers safety output actions and records fault events (including timestamps and trigger conditions) for easy post-event traceability.

3. Fast Response and Fault Self-Diagnosis

• High-Speed Safety Response: Input response time ≤15ms, output action time ≤20ms. It can quickly cut off the main motor power under emergency working conditions (such as crusher spindle overload, accidental triggering of emergency stop by personnel), preventing equipment damage due to overload or personal injury;

• Full-Scenario Fault Diagnosis: Equipped with a built-in fault detection circuit, it can identify more than 20 fault types, such as "power fault", "input signal loss", "output contact adhesion", and "communication interruption". It sends fault codes to the main controller via RS485 (e.g., E03 indicates power redundancy fault, E15 indicates input channel mismatch, E22 indicates output contact adhesion), and simultaneously triggers the red alarm light to stay on. When used with the Metso TP150 operation panel, the fault location and cause can be intuitively displayed, shortening fault location time.

4. Exclusive Adaptation to Metso Equipment

• In-Depth Safety Protocol Compatibility: Supports Metso Safety Protocol, an exclusive safety protocol for Metso equipment. It can directly communicate with the Metso C100 safety main controller and TP150 safety operation panel without additional development of safety drivers. This enables seamless safety interlocking of "safety sensor - control module - actuator" (such as real-time display of safety door status, remote reset of safety faults);

• In-Cabinet Integration and Collaboration: Its size is adapted to the layout of Metso standard safety control cabinets. The DIN rail mounting method is compatible with Metso power modules (such as Metso A413200) and digital modules (such as Metso A413345). It can work in collaboration with other control modules (e.g., after the safety module triggers a shutdown, it notifies the digital module to cut off the feeder power), forming a complete equipment control closed loop;

• Safety Event Recording: Built-in storage function for 1000 safety events (non-volatile after power-off), recording information such as fault trigger time, fault type, and recovery time. It meets industrial safety audit requirements and facilitates analysis of fault causes and optimization of safety control strategies.

IV. Common Faults and Troubleshooting Methods