Description
| Product model | IOP302 |
| Manufacturer | Metso |
| Product category | Intelligent I/O Processing Unit |
| Platform | Metso DNA Distributed Control System (DCS) |
| Function type | High-performance processor for mixed analog and digital I/O signals |
| Communication interface | Dual redundant DNA network (Ethernet-based) |
| Processing capability | Fast cyclic I/O scanning with deterministic timing |
| Redundancy support | Full hot-standby redundancy (dual-unit configuration) |
| Channel capacity | Supports multiple I/O modules (e.g., AI, AO, DI, DO) via local or distributed I/O stations |
| Operating temperature | 0°C to 50°C |
| Humidity range | 5% to 95% RH, non-condensing |
| Power supply | 24 V DC (redundant power inputs supported) |
| Mounting type | DIN-rail mountable in control cabinet |
| EMC compliance | IEC 61326-3-1, suitable for industrial environments |
Product introduction
The Metso IOP302 is a high-capacity intelligent Input/Output Processor designed for the Metso DNA distributed control system, serving as a central processing unit for managing large-scale analog and digital field signals in complex industrial automation environments. As a key component in the Metso DNA architecture, the IOP302 delivers high-speed, deterministic processing of real-time process data, making it ideal for applications requiring precise control, fast response times, and seamless integration across extensive plant networks.
Engineered for mission-critical operations in mining, mineral processing, and heavy industry, the Metso IOP302 supports both local and distributed I/O configurations, enabling flexible system design and scalability. It functions as a bridge between field instrumentation—such as transmitters, actuators, motor controllers, and sensors—and the central automation logic, ensuring reliable data acquisition and command execution. With native support for redundant network and processor configurations, the IOP302 ensures continuous operation even during hardware failures, minimizing unplanned downtime.
The Metso IOP302 is particularly suited for large processing plants where centralized I/O management, high channel density, and synchronization across multiple subsystems are essential. Its deep integration with the Metso DNA engineering environment allows for streamlined configuration, diagnostics, and maintenance, reducing engineering effort and improving system availability.
IOP302 METSO
Core advantages and technical highlights
High-performance processing engine:
The Metso IOP302 features a powerful real-time processor optimized for fast scanning and processing of hundreds of I/O points with minimal latency. With cycle times configurable down to milliseconds, it supports time-critical control loops such as pump sequencing, pressure regulation, and conveyor interlocking, ensuring precise coordination across large-scale processes.
Full hardware redundancy for maximum reliability:
Designed for 24/7 operations, the Metso IOP302 supports full hot-standby redundancy. When deployed in dual-unit configuration, the standby unit continuously monitors the active processor and takes over seamlessly in the event of a failure—without interrupting I/O communication or control logic. This redundancy extends to the DNA network and power supply, eliminating single points of failure and ensuring uninterrupted plant operation.
Scalable and flexible I/O architecture:
The Metso IOP302 can manage multiple local or remote I/O stations, supporting a wide range of Metso I/O modules (e.g., AI531, DIO571, AO521). This allows system designers to build highly scalable control systems tailored to specific process needs. Whether deployed in a concentrator plant, smelter, or bulk handling facility, the IOP302 adapts to evolving requirements through modular expansion.
Native integration with Metso DNA ecosystem:
Unlike third-party I/O processors, the Metso IOP302 is fully integrated into the Metso DNA engineering suite. This enables automatic module detection, tag database synchronization, and built-in diagnostics. Engineers can configure, monitor, and troubleshoot the IOP302 directly from the DNA Control Builder or DNA View software, reducing commissioning time and minimizing configuration errors.
Advanced diagnostics and system health monitoring:
The Metso IOP302 provides comprehensive diagnostic capabilities, including real-time status of I/O modules, communication errors, power health, and network performance. These diagnostics are accessible via the DNA system, enabling predictive maintenance and rapid fault isolation—critical for maintaining high plant availability.
Typical application scenarios
The Metso IOP302 is widely deployed in large mineral processing plants where centralized, high-reliability I/O processing is required. In concentrator facilities, it manages critical signals from flotation cells, thickeners, and reagent dosing systems, ensuring stable process control and optimal recovery rates. Its ability to handle mixed signal types makes it ideal for integrating flow meters, level sensors, valve feedback, and pump status signals into a unified control platform.
In grinding circuits, the Metso IOP302 plays a central role in monitoring SAG and ball mill performance by collecting data from power transducers, vibration sensors, and bearing temperature monitors. Its fast processing ensures timely response to abnormal conditions, protecting equipment from damage and reducing maintenance costs.
For large-scale conveyor systems and overland transport, the Metso IOP302 aggregates digital status signals (e.g., emergency stops, belt sway, motor run feedback) and analog variables (e.g., tension, speed) from multiple zones, enabling coordinated control and rapid fault response across extended material handling networks.
In OEM skid packages—such as filter plants or reagent systems—the Metso IOP302 serves as a standalone or satellite processor, providing a standardized interface to the main plant DCS. This simplifies integration, reduces engineering risk, and ensures consistent data quality across the entire operation.
Related model recommendations
Metso IOP353: A next-generation I/O processor with enhanced processing power and support for advanced fieldbus protocols (e.g., Profibus, FOUNDATION Fieldbus), ideal for hybrid or multi-vendor systems.
Metso IOP111: A cost-effective, compact I/O processor suitable for smaller control zones or remote I/O stations where full IOP302 capacity is not required.
Metso CPU510: The central processing unit in the Metso DNA system, often used in conjunction with the IOP302 for executing high-level control strategies and supervisory logic.
Metso NCM511: Network Communication Module that complements the IOP302 by providing additional Ethernet ports and OPC UA server functionality for enterprise integration.
Metso AI531: High-precision analog input module frequently used with the IOP302 for temperature, pressure, and flow measurement.
Metso DIO571: Digital I/O module ideal for discrete control tasks such as motor start/stop, valve actuation, and interlock management.
IOP302 METSO
Installation, commissioning and maintenance instructions
Installation preparation: Install the Metso IOP302 on a DIN rail in a clean, well-ventilated control cabinet meeting IP54 standards. Ensure proper grounding and use shielded cables for all field and network connections. Verify that both DNA network switches are operational and that redundant 24 V DC power supplies are correctly connected. For redundant setups, install both primary and standby units with matching firmware versions.
Commissioning steps:
- Power up the unit and verify status LEDs (POWER, RUN, REDUND, NET).
- Connect to the Metso DNA engineering station and confirm module recognition.
- Download the correct configuration and firmware.
- Test I/O signal flow using simulation or field input.
- Activate redundancy and verify failover functionality by manually stopping the active unit.
Maintenance suggestions: Regularly monitor the IOP302 status via DNA diagnostics. Check for error logs, network retries, or power fluctuations. Perform configuration backups after any changes. Clean dust from the module and cabinet every 6 months. Replace units proactively if diagnostic trends indicate aging components.
