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Home > Electrical & Electronics > Electrical Control System > Metso Valmet A413792 Control Module

Metso Valmet A413792 Control Module

Guizhou Yuanmiao Automation Equipment Co., Ltd.

1Yr

Metso Valmet A413792 Control Module thumbnail-1

Metso Valmet A413792 Control Module photo-1

Negotiable MOQ: 1 Piece (Price negotiable depending on order volume and customization)

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Material:

Other, Global universal model

Condition:

Other, Global universal model

Task:

Other, Global universal model

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guizhou

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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 -40°C to +85°C

Relative Humidity 5%~95% (non-condensing)

Operating Voltage 24V DC±15%

Dimensions 200mm×130mm×70mm

I. Overview

Metso A413792 is a high-end process control module developed to meet the demand for "precision collaborative control of multiple parameters in complex processes" in industrial process control. It belongs to the high-end Metso Automation Control System 800 series and is manufactured at Metso's Tampere factory in Finland. The core function of this module is to realize the synchronous acquisition, intelligent calculation, and precise linkage control of multiple types of high-complexity process parameters (such as temperature, pressure, flow rate, liquid level, concentration, and pH value) in industrial sites. It undertakes the integrated role of "multi-channel data fusion + complex logical calculation + collaborative regulation of multiple actuators" and is widely used in heavy industrial scenarios with extremely high requirements for control precision, response speed, and process complexity. These scenarios include multi-parameter control of petrochemical catalytic cracking units, gradient temperature regulation of fine chemical reactors, rolling force-speed linkage control of metallurgical cold-rolled steel strips, process parameter adjustment of special paper forming in paper mills, and liquid level-chemical addition collaborative control of multi-stage flotation processes in mines.

The module adopts a design of "titanium alloy reinforced frame + glass fiber reinforced engineering plastic shell + internal fully sealed dustproof and waterproof structure", with an IP67 protection rating, enabling stable operation in an ultra-wide temperature range from -40°C to +85°C. Meanwhile, it has obtained IEC 61010-1 electrical safety certification, IEC 61326-1 electromagnetic compatibility certification, SIL 3 functional safety certification, and ATEX Zone 1 explosion-proof certification. It can effectively resist high-intensity dust, high-pressure spraying, severe vibration, and extreme electromagnetic interference (such as harmonics from high-voltage frequency converters and start-stop impacts of large motors) in industrial sites, providing triple guarantees of "ultra-high precision + ultra-high reliability + explosion-proof safety" for complex process control scenarios. In addition, this module is compatible with the high-end Metso DNA control system and top-tier third-party DCS systems (such as Siemens PCS 7 High Availability and Rockwell ControlLogix Redundant). It supports seamless integration with the central control system through redundant industrial Ethernet links, allowing direct access to high-reliability industrial automation systems, which significantly reduces the difficulty of system construction and operation and maintenance in complex process control scenarios.

II. Technical Parameters

Parameter Category	Specific Specifications	Remarks
Electrical Parameters	Operating Voltage: 24V DC±15%	Ultra-wide voltage design, suitable for extreme fluctuating power supply environments in industrial sites, preventing control interruption caused by sudden voltage drops/rise
	Rated Power Consumption: ≤20W	Low-power operation, suitable for centralized power supply schemes in control cabinets, reducing energy consumption
	Analog Input: 16 channels (4-20mA DC/0-10V DC/PT100 platinum resistor optional)	Input impedance ≥1MΩ, equipped with a 32-bit high-precision ADC, acquisition error ≤±0.01% FS, supporting synchronous acquisition of multiple types of parameters such as temperature, pressure, and flow rate
	Analog Output: 10 channels (4-20mA DC)	Output load capacity 0-800Ω, linear error ≤±0.03% FS, suitable for high-precision control valves, servo frequency converters and other actuators
	Digital Input: 24 channels (dry contact/wet contact optional)	Wet contact voltage range 18-30V DC, response time ≤0.1ms, supporting detection of high-speed status signals (such as encoder pulses, valve switch positions)
	Digital Output: 16 channels (relay output, 250V AC/30V DC, 6A)	Can directly drive medium and large-sized actuators (such as high-power contactors, solenoid valve groups) without additional intermediate relays
Physical Characteristics	Shell Material: Titanium alloy reinforced frame + PA66 + glass fiber reinforced engineering plastic	Impact strength up to 15kJ/m², resistant to strong acid and alkali corrosion, suitable for extreme industrial environments
	Dimensions: 200mm×130mm×70mm (Length × Width × Height)	Compact design, suitable for standard 35mm DIN rail installation, supporting tight cascading of multiple modules
	Weight: Approximately 850g	Sturdy structure, easy for installation and maintenance in high-altitude and vibrating environments
	Protection Rating: IP67	Fully dustproof and protected against short-term immersion (1m water depth for 30 minutes), suitable for humid, dusty, and spraying scenarios
Performance Parameters	Control Precision: Multi-parameter collaborative control error ≤±0.05% FS	Supports multiple advanced algorithms including PID, fuzzy PID, adaptive PID, cascade control, and feedforward-feedback composite control
	Response Time: Control cycle ≤5ms	Quickly responds to linkage changes of complex process parameters, avoiding parameter overshoot or lag
	Communication Interfaces: 2 Gigabit Ethernet ports (supporting redundancy), 4 RS485 serial ports	Ethernet supports Profinet IRT and EtherNet/IP protocols; RS485 supports Modbus-RTU protocol, facilitating redundant networking of multiple modules
	Data Storage: 8GB Flash memory + 2GB DDR4 memory	Can store 3 years of historical control data (1s sampling cycle), fault logs, and control parameters, supporting encrypted data storage
	Synchronous Acquisition Capability: Supports simultaneous acquisition of 16 analog signals with a synchronization error ≤0.5μs	Ensures time consistency of multi-parameter acquisition and improves collaborative control precision of complex processes
Safety Parameters	Overvoltage Protection: Automatically cuts off when input voltage ≥36V DC	Prevents damage to internal control circuits caused by excessive voltage due to power supply faults
	Overcurrent Protection: Triggers protection when output current ≥7.2A	Avoids burnout of the module's output circuit caused by actuator short circuits
	Surge Immunity: ±8kV (line-to-ground), ±4kV (line-to-line)	Complies with IEC 61000-4-5 standard, resisting strong power grid surge impacts
	Vibration Level: IEC 60068-2-6, 10-500Hz, 10g acceleration	Adapts to severe vibration scenarios (such as metallurgical rolling mills, mining crushers), preventing wire loosening or parameter drift caused by vibration

III. Functional Features

1. Ultra-High Precision Multi-Parameter Synchronous Acquisition and Collaborative Control

The module is equipped with a high-performance 32-bit ARM quad-core processor, combined with 16-channel 32-bit high-precision ADC synchronous acquisition channels (synchronization error ≤0.5μs). It can realize millisecond-level synchronous acquisition of 16 different types of process parameters such as temperature, pressure, and flow rate, ensuring absolute time consistency of multiple parameters. It supports multiple advanced control algorithms including PID, fuzzy PID, adaptive PID, and feedforward-feedback composite control, and can achieve intelligent collaborative regulation based on the parameter linkage relationships of complex processes (e.g., "temperature rise → pressure increase → flow rate needs synchronous adjustment"). For example, in the control of petrochemical catalytic cracking units, it can synchronously collect signals of reactor temperature, pressure, feed flow rate, and catalyst concentration. Through the feedforward-feedback composite control algorithm, it links and adjusts the feed valve, cooling system, and catalyst addition device, controlling the reactor temperature fluctuation within ±0.1°C and pressure fluctuation within ±0.005MPa, thus ensuring the efficient and stable progress of the catalytic cracking reaction.

2. Complex Logic Configuration and Redundant Control Capability

It is equipped with Metso Control Tool Premium, a dedicated high-end configuration software for Metso, which supports the integrated functions of "graphical complex logic configuration + modular algorithm library calling + simulation testing". Users can customize multi-parameter linkage logic according to the needs of complex processes (e.g., "automatic emergency pressure relief + feed cutoff + standby cooling activation when temperature and pressure exceed limits", "automatic discharge stop + alarm linkage when liquid level is too low and flow rate is abnormal"), and directly call the industry-specific high-end control templates built in the software (such as catalytic cracking multi-parameter control template and cold-rolled steel strip rolling control template), significantly shortening the development cycle of complex control programs. At the same time, it supports module hardware redundancy (active-standby module hot backup) and communication link redundancy (dual Ethernet link backup). When the active module fails, the standby module can be put into operation seamlessly within ≤10ms; when the communication link fails, it automatically switches to the standby link, ensuring uninterrupted control of complex processes.

3. Comprehensive Intelligent Fault Diagnosis and Explosion-Proof Safety Protection

It has a built-in "five-level intelligent fault diagnosis mechanism": the first level diagnoses the module's own power supply, communication, and core hardware status (such as ADC/DAC faults, memory abnormalities, and processor faults); the second level diagnoses input and output channels (such as signal disconnection, over-range, short circuit, and drift); the third level diagnoses external equipment (such as sensor accuracy attenuation, actuator jamming, and encoder faults); the fourth level diagnoses multi-parameter linkage logic (such as linkage failure due to parameter deviation and logic conflicts); the fifth level diagnoses abnormal process trends (such as gradual parameter deviation from the normal range and abnormal fluctuation frequency). When an abnormality is detected, it immediately triggers a local sound and light alarm (flashing red fault light + intermittent buzzer alarm + fault information display on LCD screen), and sends detailed information including "fault type + fault location + fault time + associated parameters + fault impact assessment" to the upper computer via the communication interface. At the same time, it automatically executes preset safety strategies (such as emergency cutoff of dangerous circuits, switching to standby equipment, and activating process emergency plans) to minimize the risk of safety accidents. In addition, the module adopts an "explosion-proof structure design + intrinsic safety circuit" and has obtained ATEX Zone 1 explosion-proof certification, allowing safe use in flammable and explosive scenarios such as petrochemical and oil-gas extraction, and avoiding explosion accidents caused by electrical sparks.

4. Extreme Environmental Adaptability and Stable Operation Capability

The IP67 protection rating can resist high-intensity dust, high-pressure spraying, and short-term immersion (such as equipment cleaning and rainwater immersion) in industrial sites. The ultra-wide temperature range from -40°C to +85°C can adapt to outdoor installation in extremely cold northern winters and high-temperature workshop environments in metallurgical and chemical industries, without the need for additional insulation boxes, protective covers, or temperature control equipment. The internal "partitioned independent heat dissipation structure + titanium alloy heat-conducting frame" separates the processor, power components, signal acquisition circuit, and power circuit for independent heat dissipation. Combined with an intelligent temperature-controlled fan (automatically activated when the temperature ≥60°C), it can quickly dissipate the operating heat of each area, avoiding control precision degradation or hardware damage caused by high temperatures. At the same time, the module has undergone strict severe vibration testing (in accordance with IEC 60068-2-6 standard), electromagnetic compatibility testing (in accordance with IEC 61000-4 series standards), and explosion-proof performance testing. It can maintain stable operation in extreme environments such as severe vibration, strong electromagnetic interference, and flammability and explosiveness, ensuring uninterrupted control of complex processes.

5. High-End Remote Monitoring and Intelligent Operation & Maintenance

It supports high-end remote monitoring and intelligent operation & maintenance via Ethernet. Maintenance personnel can view the module's operating status (such as high-precision data of each channel, control algorithm parameters, actuator status, and redundancy switching status), multi-parameter linkage curves, historical trend data, and fault statistical analysis reports in real time through the upper computer software. They can also remotely modify control parameters, adjust linkage logic, upgrade module firmware, and conduct remote simulation tests without on-site operations, significantly reducing operation & maintenance costs and downtime. In addition, the module supports intelligent fault early warning and predictive maintenance functions. By analyzing historical fault data and parameter change trends, it can predict potential faults of sensors, actuators, and the module itself in advance (such as "sensor accuracy attenuating to a critical value", "relay contact oxidation trend"), and proactively send early warning information and maintenance suggestions to the upper computer and operation & maintenance terminals, facilitating maintenance personnel to arrange maintenance in advance and avoid process interruption caused by sudden faults.

IV. Common Faults and Solutions

Fault Phenomenon	Possible Causes	Solutions
1. No response from the module, no indicator light on, and no display on the LCD screen when powered on	1. Open circuit of the power supply line or loose terminal blocks; 2. Insufficient power or failure of the power adapter; 3. Damage to the module's internal power circuit; 4. Static damage to the core circuit due to poor grounding of the shell	Use a multimeter to measure the on-off status of the 24V DC power supply line, check the terminal blocks and re-tighten them, and repair the open circuit point; 2. Replace with a high-end spare power adapter with power ≥30W and conforming to the 24V DC±15% specification (Metso original accessories are recommended), and test whether the power supply is normal; 3. If there is still no response after replacing the power adapter, contact Metso-authorized high-end maintenance personnel to check whether the internal power chip (such as TI TPS7A4700) is burned out and replace the damaged component; 4. Check the grounding condition of the module shell to ensure the grounding resistance ≤2Ω, avoiding static accumulation that damages the core circuit
2. Large deviation of analog input data or abnormal synchronous acquisition	1. Sensor fault, accuracy attenuation, or uncalibrated sensor; 2. Poor contact, open circuit, or impedance mismatch of the signal line between the sensor and the module; 3. The signal line does not use double-shielded cable, resulting in strong electromagnetic interference; 4. Damage to the module's analog input channel or fault in the synchronous acquisition circuit	Calibrate the sensor with a high-precision standard signal generator (such as FLUKE 754); if the accuracy attenuation exceeds 5%, replace with a high-precision sensor; 2. Check the signal line terminal blocks, re-plug and tighten them, use a multimeter to measure the on-off status and impedance of the signal line, ensure impedance matching (e.g., impedance of 4-20mA signal line ≤50Ω), and repair the open circuit point; 3. Replace with double-shielded twisted pair, ground the inner shield layer at one end (near the module end) and the outer shield layer at both ends to reduce strong electromagnetic interference; 4. Connect a normal high-precision sensor to another spare input channel; if the data is normal, it indicates that the original channel is damaged; if the synchronous acquisition is abnormal, contact maintenance personnel to inspect the synchronous acquisition circuit (such as FPGA chip)
3. Degradation of multi-parameter collaborative control precision, failure of parameter linkage, or severe overshoot	1. Unreasonable configuration of control algorithm parameters (such as unbalanced PID parameters, incorrect feedforward coefficient setting); 2. Actuator faults (such as jamming of high-precision control valve, unstable output of servo frequency converter); 3. Process interference (such as severe fluctuation of feed composition, sudden change of external temperature); 4. Excessively long module sampling cycle or abnormal synchronous acquisition function	Optimize the control algorithm parameters through Metso Control Tool Premium software (such as using adaptive PID for automatic parameter tuning and adjusting feedforward coefficients), and correct linkage logic errors; 2. Check the operating status of the actuator, repair the jammed high-precision control valve with a high-precision debugging tool (such as ABB TZID-C debugger), calibrate the output accuracy of the servo frequency converter, and ensure the actuator responds normally; 3. Investigate the source of process interference and take measures such as stabilizing feed composition, adding high-efficiency insulation layers, and increasing buffer devices to reduce external interference; 4. Shorten the module sampling cycle (it is recommended to set it to 3-5ms), check whether the synchronous acquisition function is normal; if abnormal, re-enable the synchronous acquisition configuration and calibrate
4. No action, incorrect action, or relay sticking of digital output	1. Output channel not enabled, incorrect configuration of control logic, or abnormal redundancy switching; 2. Oxidation, burnout, or sticking of relay contacts; 3. Output circuit load exceeding the rated current or short circuit; 4. Damage to the module's output control circuit (such as driver chip ULN2804)	Check the output channel enable status, control logic, and redundancy switching status through the software, correct incorrect configurations, and ensure normal redundancy switching; 2. Turn off the module power, use a multimeter to measure the on-off status of the relay contacts (normal on-resistance ≤0.5Ω, off-resistance is infinite); if the contacts are oxidized, polish them with fine sandpaper; if burned out or stuck, replace with a high-reliability relay (such as Omron G5LE-14); 3. Check the output load current to ensure it does not exceed the rated value of 6A; if the load is too large, add an intermediate relay to expand the load capacity; if there is a short circuit, repair the short circuit point; 4. If the above inspections are normal, the driver chip may be damaged, and the module needs to be returned to the factory for replacement of the high-reliability driver chip
5. Communication interruption or redundancy switching failure, unable to interact with the central control system	1. Open circuit, poor contact of the Ethernet line, or fiber optic link fault (if fiber optic is used); 2. Inconsistent configuration of communication protocol parameters (such as IP address, baud rate, slave address, redundancy configuration); 3. Damage to the communication interface or fault in the redundancy switching circuit; 4. Fault of the central control system's communication software or network switch (redundant)	1. Use a network cable tester to detect the on-off status of the Ethernet line; if fiber optic is used, use an optical power meter to detect the fiber optic link; re-plug the line and tighten the connector, and repair the faulty line; 2. Verify the communication parameters and redundancy configuration between the module and the central system, ensure the IP address is in the same network