YOKOGAWA AIP121-S00 Control Module

YOKOGAWA AIP121-S00 Control Module

Product Overview and Positioning

YOKOGAWA AIP121-S00 is a high-performance analog input module developed by Yokogawa Electric in Japan specifically for the industrial automation field. Its core positioning is as a key I/O component of Yokogawa CENTUM CS3000 DCS (distributed control system), responsible for the acquisition, conversion, and transmission of on-site analog signals. Its core value lies in building a reliable data bridge between on-site sensors/actuators and DCS control systems, converting continuously changing physical quantities such as temperature, pressure, flow rate, and liquid level into system recognizable digital signals, providing basic data support for real-time monitoring, precise control, and optimized scheduling of industrial processes.

This module adopts a standardized modular design and is fully compatible with the rack mounted installation architecture of the Yokogawa CS3000 system. It can seamlessly collaborate with other control modules and communication modules within the system and is widely used in process industry scenarios that require strict control accuracy and reliability. It is one of the core basic components in Yokogawa’s industrial automation solutions.

Core product features

1. High precision data collection capability

AIP121-S00 has high precision as its core advantage, using a 16 bit high-resolution A/D (analog-to-digital) conversion chip with a conversion accuracy of up to 0.1%, which can accurately capture subtle changes in on-site analog signals. Compared to ordinary analog modules, it has a wider signal adaptation range and is compatible with multiple industrial standard analog signal types. Whether it is weak sensor signals or standard industrial signals, it can achieve stable acquisition, effectively ensuring the accuracy of control decisions.

2. High reliability and strong anti-interference design

The module adopts fully industrial grade component selection, undergoes rigorous environmental adaptability testing, and has excellent anti-interference ability and operational stability. The core design highlight lies in the implementation of triple isolation protection: electrical isolation technology is used between input/output, power supply, and module and rack, which can effectively resist electromagnetic interference (EMI), radio frequency interference (RFI), and signal interference caused by ground potential difference in industrial sites. At the same time, its mean time to failure (MTTF) far exceeds the industry average, ensuring stable performance during long-term continuous operation and reducing the risk of system downtime.

3. Flexible configuration and convenient maintenance

The modular design makes installation and maintenance extremely convenient: modules can be directly inserted into the corresponding slots of the CS3000 system rack, without the need for complex mechanical fixing structures. When replacing, simply unplug the old module and insert the new module after power off, greatly reducing maintenance downtime. In terms of functional configuration, it supports flexible settings of input signal type, acquisition frequency, filtering parameters, PID control algorithm, etc. through DCS system software, adapting to personalized needs of different industrial scenarios. In addition, the module integrates status indicator LED lights, which can intuitively display power status, signal acquisition status, and fault information, making it easy for operation and maintenance personnel to quickly locate problems.

4. Wide environmental adaptability

AIP121-S00 has excellent environmental adaptability to the complex environmental conditions of industrial sites. Its working temperature range covers -40 ° C to+70 ° C, and its storage temperature range can reach -55 ° C to+85 ° C, which can adapt to extreme working conditions such as high and low temperatures; The relative humidity adaptation range is 5% to 95% (non condensing), and it can operate stably in high humidity and dusty industrial workshops. At the same time, the module has a protection level of IP67, with dust-proof and splash proof characteristics, and can be directly installed in areas close to on-site equipment to reduce signal attenuation during transmission.

Detailed technical parameters

1. Core electrical parameters

-Analog input range: Supports multiple standard industrial signals, including current signals (-320mA to+320mA, 0mA to 20mA, 4mA to 20mA) and voltage signals (-10V to+10V), and can be directly connected to common industrial sensors such as thermocouples, thermistors, pressure transmitters, flow sensors, etc;

-Resolution: 16 bits, ensuring the precision of signal conversion;

-Conversion accuracy: ± 0.1% FS (full range), maintaining high-precision acquisition over the entire input range;

-Response time: less than 2ms, can achieve real-time capture of rapidly changing process variables, meeting dynamic control requirements;

-Isolation performance: Input/output isolation, power isolation, rack isolation, isolation voltage meets industrial standards, effectively suppressing interference;

-Current consumption: maximum 0.7A, low power consumption, reduces overall system energy consumption;

-Communication interface: compatible with the internal bus of Yokogawa CS3000 system, supporting high-speed data transmission with the main control unit.

2. Physical and environmental parameters

-Size: 130mm x 110mm x 22mm (length x width x height), compact design, saving rack installation space;

-Weight: 0.5kg, lightweight design, easy to install and transport;

-Protection level: IP67, dustproof and anti short-term water immersion;

-Working temperature: -40 ° C to+70 ° C;

-Storage temperature: -55 ° C to+85 ° C;

-Humidity: 5% to 95% (non condensing), no risk of condensation.

3. Compliance and Certification

The module complies with multiple international industrial standards, including IEC (International Electrotechnical Commission) related standards, ensuring compliant use in industrial scenarios in different regions around the world. The product comes with a 12-month original factory warranty to protect users’ rights and interests.

Installation and maintenance precautions

1. Installation specifications

-Installation location: An area with good ventilation and away from strong electromagnetic interference sources (such as frequency converters and high-power motors) should be selected, while avoiding direct sunlight and direct rainwater erosion;

-Rack installation: The module needs to be correctly inserted into the designated I/O rack slot of the Yokogawa CS3000 system, ensuring good contact between the module and the rack, locking and fixing the buckle to prevent poor contact caused by vibration;

-Wiring requirements: Before wiring, the module power must be disconnected to avoid module damage or personnel safety risks caused by live wiring; Shielded isolation cables (recommended 15AWG/17AWG/22AWG specifications) should be used, with the cable shielding layer grounded at one end to reduce signal interference; Strictly follow the product wiring diagram to connect signal lines, distinguish the wiring methods of current signals and voltage signals, and avoid connecting the wrong lines; Do not directly connect AC 110~220V power supply to the module to prevent burning of internal circuits;

-Power configuration: It is necessary to connect a DC 24V power supply that meets the specifications to ensure stable power supply voltage and avoid voltage fluctuations affecting module operation.

2. Daily maintenance and fault diagnosis

-Status monitoring: Real time monitoring of operating status through the LED indicator lights on the module. When the power light is on, it indicates normal power supply. When the signal light is on, it indicates normal signal acquisition. If the fault light is on, it is necessary to promptly troubleshoot the problem;

-Regular inspection: Regularly check the connection status between the module and the rack, as well as the tightness of the wiring terminals, to prevent signal loss caused by looseness; Check if the cable shielding layer is intact to avoid interference caused by damage to the shielding layer;

-Fault handling: If there is inaccurate signal acquisition, first check whether the sensor is normal, whether the wiring is loose or short circuited; If there is no response from the module, check whether the power supply is normal and whether the module is correctly inserted into the rack; If the fault cannot be eliminated, the module can be directly replaced, and after replacement, the parameters can be reconfigured through the system software to restore operation.

Application Fields and Typical Scenarios

AIP121-S00, with its high precision, high reliability, and wide environmental adaptability, is widely used in automation control systems of various process and discrete industries, especially in scenarios that require high process control accuracy and complex environmental conditions. Its main application areas include:

1. Petrochemical industry

In the production processes of petroleum refining and chemical synthesis, it is used to collect parameters such as temperature and pressure of reaction vessels, flow rate and liquid level of crude oil/chemical raw materials in pipelines, etc., providing data support for precise control and safety interlocking of reaction processes, ensuring stable production processes and compliance with quality standards.

2. Power industry

In scenarios such as thermal power plants, hydropower stations, and substations, parameters such as boiler temperature and pressure, turbine speed and vibration, grid voltage and current are collected to assist in the start stop control, load regulation, and safety monitoring of the units, ensuring the stability and safety of power production.

3. Metallurgical industry

In the process of steel and non-ferrous metal smelting, the temperature and pressure of blast furnaces and converters, the flow rate and liquid level of smelting materials, as well as the temperature, thickness and other parameters during the rolling process are collected to achieve precise control of the smelting and rolling processes, improve product quality and production efficiency.

4. Paper and textile industry

In the process of paper production, collect parameters such as pulp concentration, temperature, flow rate, paper thickness, moisture, etc; In the textile production process, parameters such as humidity and temperature of textile raw materials are collected to achieve automated adjustment of the production process and ensure consistency in product quality.

5. Other fields

It can also be applied to industries such as food and beverage, medicine, and water treatment, such as temperature and pressure control in food processing, reaction parameter collection in pharmaceutical production, and water quality parameter (such as turbidity and pH) collection in water treatment, providing reliable data collection support for automated production in various industries.