Material
Other, Global universal model
Condition
Other, Global universal model
Task
Other, Global universal model
Mathematical Model
Other, Global universal model
Signal
Other, Global universal model
Customized
Non-Customized
Structure
Other, Global universal model
Operating Temperature
-25℃~+65℃
Relative Humidity
5%~95% (non-condensing)
Supply Voltage
24V DC
I. Overview
Metso A413062 is a multi-parameter collaborative control module, whose core positioning is to provide a full-link solution of "synchronous acquisition of multi-type signals - collaborative regulation of multi-loops - intelligent fault early warning" for medium-sized processes such as preheater systems of building materials cement kilns, metallurgical steel rolling heating furnaces, and mine washing and separation production lines. As a core component of Metso's medium-sized automation systems (e.g., Metso DNA Mid DCS, Metso Outotec Medium-sized Process Controller), its essence lies in achieving accurate and synchronous processing of three types of on-site signals—analog signals (temperature/pressure/flow/weight), digital signals (equipment status/emergency stop), and pulse signals (speed/counting)—dynamic collaborative regulation of process parameters, and intelligent early warning response to fault conditions through a "multi-channel integrated hardware architecture + collaborative control algorithm". It is particularly suitable for industrial environments with medium-high load, moderate vibration, and multiple interferences (such as cement kiln preheaters, metallurgical heating furnace workshops, and mine washing and separation workshops).
Adopting a compact fanless heat dissipation design, it integrates multi-type signal input/output channels and supports seamless connection with Metso's dedicated high-precision sensors (e.g., high-temperature thermocouples for kilns, level transmitters for washing and separation), actuators (e.g., intelligent control valves, medium-sized frequency converters), and third-party mid-range industrial equipment (e.g., Siemens S7-1200 PLC, Schneider ATV630 frequency converter). Its integrated "multi-loop collaborative algorithm + intelligent diagnosis model" can significantly improve the control accuracy and operational stability of medium-sized processes. When used with Metso's medium-sized configuration software (Metso DNA Mid Studio), it can realize customized complex logic control and multi-system data interaction, forming a closed-loop management covering "perception - control - monitoring - diagnosis - early warning". Whether it is the collaborative regulation of "temperature-pressure-flow" for cement kiln preheaters, the synchronous control of "temperature-atmosphere-rhythm" for metallurgical heating furnaces, or the linkage of "level-flow-concentration" for mine washing and separation, the A413062 can enhance the automation level and product qualification rate of medium-sized processes through its multi-parameter collaboration capability, making it a key equipment for process industries to achieve "refined and intelligent" upgrading.
II. Technical Parameters
(I) Signal Input/Output Parameters (Multi-type Integrated Configuration)
1. Input Channel Configuration (Full Parameter Coverage)
Analog Input (AI): 10 channels of independent isolated analog input, compatible with four types of signals: 4-20mA DC, 0-10V DC, RTD (PT100/PT1000), and thermocouple (Type K/J/S). The input impedance is ≥10MΩ (for voltage signals), 250Ω (for current signals), and 100Ω (for PT100). The measurement accuracy is ±0.08% FS (for current/voltage), ±0.1℃ (for RTD), and ±0.5℃ (for thermocouple). It can be directly connected to high-precision detection instruments such as cement kiln preheater temperature meters, metallurgical heating furnace pressure gauges, and mine washing and separation level meters, ensuring accurate acquisition of weak signals (e.g., 0.03mA-level current changes).
Digital Input (DI): 16 channels of dual-isolated digital input, supporting 24V DC signals. The input response time is ≤0.8ms, suitable for cement kiln limit switches, metallurgical emergency stop buttons, and mine equipment operation feedback signals. The anti-interference voltage is ≥300V AC (for 1 minute), and it has passed the IEC 61000-4-4 electrical fast transient burst immunity test (±2kV), preventing false triggers caused by strong electromagnetic interference (such as the start/stop of medium-sized frequency converters).
Pulse Input (PI): 6 channels of high-speed isolated pulse input, supporting 0-100kHz pulse signals and A/B phase quadrature encoding signals. It can be connected to cement kiln speed encoders, metallurgical roller speed sensors, and mine washing and separation flow pulse meters. The pulse counting accuracy is ±1 pulse, and the speed measurement range is 0-6000rpm, meeting the precise measurement needs of medium-sized equipment.
2. Output Channel Configuration (Multi-type Drive)
Analog Output (AO): 6 channels of independent isolated analog output, supporting optional 4-20mA DC or 0-10V DC. The output accuracy is ±0.15% FS, and the load capacity is ≤600Ω (for current output) and ≥1kΩ (for voltage output). It can directly drive cement kiln control valves, metallurgical frequency converters, and mine washing and separation feed valves, realizing 0-100% stepless regulation with an output ripple of ≤5mV (peak-to-peak), ensuring regulation stability.
Digital Output (DO): 8 channels of dual-isolated relay output, each with a rated load current of 6A@250V AC/12A@30V DC, supporting configurable normally open/normally closed contacts. It is also compatible with 2 channels of high-speed transistor output (1A@24V DC, response time ≤5μs), meeting the on-off control needs of medium-sized equipment contactors, alarm lights, and solenoid valves. The mechanical life of the relay is ≥15 million cycles, and the electrical life is ≥300,000 cycles (under rated load).
Communication Interfaces: 2 RS485 interfaces (Modbus RTU protocol) and 1 Ethernet interface (Profinet protocol), supporting bidirectional data interaction with upper computers and third-party equipment. The maximum communication rate is 100Mbps, ensuring the real-time performance of data transmission in medium-sized processes.
(II) Electrical and Performance Parameters (High Collaboration and Reliability)
1. Power Supply and Power Consumption (Stable Adaptation)
Supply Voltage: 24V DC (with ±15% fluctuation tolerance), compatible with industrial-grade 24V/10A switching power supplies. It supports dual-channel power supply redundancy (optional) to avoid module shutdown caused by a single power supply failure.
Standby Power Consumption: ≤6W; Power Consumption Under Full Load: ≤20W. It adopts a composite heat dissipation structure of "aluminum heat sink + thermal pad". The fanless design prevents dust blockage, and the surface temperature of the module is ≤50℃ (at an ambient temperature of 50℃) when operating under full load, making it suitable for high-density installation in medium-sized control cabinets.
2. Processing Performance (Multi-task Collaboration)
Control Cycle: The minimum control cycle is 10ms, supporting parallel processing of 12 independent control loops (such as PID regulation, logic interlocking, pulse counting, and cascade control). It meets the "multi-parameter - multi-equipment" collaborative control needs of medium-sized processes (e.g., synchronous regulation of the three parameters "temperature-pressure-feed rate" for cement kiln preheaters).
Collaborative Control Algorithm: Built-in enhanced cascade PID algorithm (supporting 5-level cascade control) and multi-parameter decoupling algorithm, which can solve the "parameter coupling interference" problem in medium-sized processes (e.g., "temperature rise leading to pressure fluctuation" in metallurgical heating furnaces). The control steady-state error is ≤±0.3% FS.
Data Processing Capability: Supports 1-second-level data sampling and storage (historical data storage for 6 months), and can calculate key process indicators in real time (such as cement kiln thermal efficiency, mine washing and separation recovery rate), providing data support for process optimization.
(III) Environmental and Compatibility Parameters (Adaptation to Medium-sized Scenarios)
1. Environmental Adaptability (Stability in All Scenarios)
Operating Temperature: -25℃~+65℃, humidity 5%~95% RH (no condensation). It has passed the -40℃~+80℃ high-low temperature storage test and can operate stably in environments such as cement kiln workshops (high temperature and dust), metallurgical heating furnace areas (high temperature), and mine washing and separation workshops (high humidity) without additional temperature control devices.
Protection Level: IP20 (module itself); when used with Metso's dustproof and heat-dissipating enclosure, it can be upgraded to IP54, effectively isolating dust and moisture and adapting to dusty environments in medium-sized industrial scenarios.
Anti-interference and Anti-vibration: Complies with IEC 61000-4-2 (ESD ±15kV air discharge/±8kV contact discharge) and IEC 61000-4-3 (radiated immunity 15V/m) standards. It can withstand mechanical vibration of 10-500Hz (acceleration 2.5g), ensuring stable signals in the vibration environment of medium-sized equipment.
2. System Compatibility (Flexible Expansion)
Controller Adaptability: Natively compatible with Metso DNA Mid DCS and Metso Outotec Medium-sized Process Controllers. It also supports third-party mid-range PLCs (e.g., Mitsubishi FX5U series), realizing data interaction through Modbus/Profinet protocols and supporting remote parameter configuration and status monitoring.
Expansion Capability: Supports multi-module cascading (up to 20 units), realizing input/output channel expansion through bus expansion. The cascading delay is ≤2ms, adapting to the centralized management needs of medium-sized production lines (e.g., linkage of 5-8 pieces of equipment) and reducing system integration costs.
III. Functional Features
(I) Multi-parameter Collaborative Control to Solve Coupling Problems in Medium-sized Processes
1. Cascade and Decoupling Algorithms to Improve Control Accuracy
Multi-level Cascade Control: Supports cascade regulation of "primary parameter - secondary parameter - tertiary parameter". For example, in the control of a cement kiln preheater, "C5 outlet temperature" is used as the primary parameter (AI1), "coal feed rate" as the secondary parameter (AI2), and "fan speed" as the tertiary parameter (PI1). The primary loop adjusts the coal feed rate according to the temperature deviation, and the secondary loop adjusts the fan speed according to the coal feed rate deviation. The temperature control accuracy is ±2℃, avoiding fluctuations caused by single-parameter regulation.
Multi-parameter Decoupling: Aiming at the "temperature-pressure-atmosphere" coupling problem in metallurgical heating furnaces, a built-in decoupling algorithm is adopted. When the temperature rise of the heating furnace leads to pressure increase, the opening of the exhaust valve (AO2) is automatically adjusted to offset the interference of temperature on pressure, with a pressure control error of ≤±0.02MPa.
2. Synchronous Processing of Multi-signals to Ensure Process Collaboration
Clock-synchronized Acquisition: AI/DI/PI channels adopt unified clock synchronization (synchronization accuracy ≤0.5μs), ensuring synchronous acquisition of multi-parameters such as "temperature-pressure-speed" for cement kilns and "temperature-flow-atmosphere" for metallurgical heating furnaces, avoiding regulation deviations caused by signal delay.
Cross-type Signal Linkage: Supports mixed logic operations of analog, digital, and pulse signals. For example, "mine washing and separation level exceeding 80% (AI) + flow exceeding 50m³/h (PI) → reducing feed valve opening (AO) + starting standby pump (DO)", meeting the complex interlocking needs of medium-sized processes.
Application Example: In the control system of a cement kiln preheater, the A413062 collects the outlet temperatures of C1-C5 through 10 AI channels and the kiln speed and fan speed through 2 PI channels. After cascade PID regulation, it controls the coal feed valve, fan frequency converter, and discharge valve through 6 AO channels, controlling the fluctuation of C5 outlet temperature within ±3℃ and increasing the thermal efficiency of the preheater by 3%~5%.
(II) Intelligent Diagnosis and Early Warning to Reduce O&M Costs of Medium-sized Processes
1. Equipment Health Status Monitoring
Key Component Diagnosis: Collects current and temperature signals of medium-sized equipment (e.g., cement kiln fans, metallurgical heating furnace pumps) through AI, and analyzes the equipment health status (e.g., "fan bearing temperature exceeding 75℃ → early warning of bearing wear") in combination with the built-in diagnosis model. The diagnosis accuracy is ≥95%.
Process Abnormality Early Warning: Real-time monitors deviations of key process parameters in medium-sized processes (e.g., cement kiln feed rate fluctuation exceeding ±5%), and predicts process abnormalities through trend analysis (e.g., "continuous decrease in feed rate → early warning of silo blockage"). It triggers DO alarms in advance to avoid unplanned shutdowns.
2. O&M Optimization Functions
Fault Log and Traceability: Built-in storage of 6 months of historical fault logs, recording fault types, occurrence time, and handling results (e.g., "E08: AI5 thermocouple open circuit, 2024-XX-XX 14:30, replaced"). It supports data export to Excel for easy O&M analysis.
Remote O&M Support: Realizes remote parameter modification (e.g., PID threshold adjustment) and firmware upgrade through the Ethernet interface. O&M personnel can complete basic O&M without going to the site, reducing the O&M cost of medium-sized processes by 20%~30%.
(III) High-reliability Design to Ensure Continuous Operation of Medium-sized Processes
1. Hardware Level: Isolation and Protection
Channel-level Dual Isolation: AI/DI/PI channels adopt dual optoelectronic isolation (isolation voltage ≥2000V DC) to block ground loops and electromagnetic interference, preventing the spread of single-channel faults. AO/DO channels adopt output short-circuit protection, which automatically cuts off the output when the load is short-circuited, protecting the module and actuators.
Component Selection: Key components (e.g., relays, capacitors) are industrial-grade long-life models with a Mean Time Between Failures (MTBF) of ≥80,000 hours, adapting to the "24/7" continuous operation needs of medium-sized processes.
2. Software Level: Fault Tolerance and Backup
Parameter Backup and Restoration: Module parameters (e.g., PID parameters, interlocking logic) support local dual-zone backup and remote cloud backup. Parameters are automatically synchronized after modification to prevent parameter loss.
Communication Fault Tolerance: When Ethernet communication is interrupted, it automatically switches to RS485 communication. If both communications are interrupted, the module maintains the current control output and executes preset fault actions (e.g., maintaining the current cement kiln feed rate) to avoid process out of control.
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