Description
Detailed parameter table
| Parameter name | Parameter value |
| Product model | Metso IOP302 |
| Manufacturer | Metso Outotec Corporation |
| Product category | Ultra-Compact 1-Channel Analog Input Module (for Single-Point Monitoring) |
| Input Signals | Exclusive to 4–20 mA current loops (no voltage options); Compatible with basic sensors: single-point level transmitters, RTDs (via signal conditioners), small pressure sensors |
| Number of Input Channels | 1 single-ended channel (shared common ground); No channel-to-channel isolation (optimized for single-sensor use) |
| Measurement Accuracy | ±0.4% of full scale (FS) at 25 °C; ±0.7% FS over operating temperature range (0 °C to +45 °C); Resolution: 12 bits (sufficient for single-point monitoring) |
| Communication Interface | Only Modbus RTU (RS-485, fixed 9600 baud, even parity); No adjustable settings (zero-configuration design) |
| Physical Dimensions | Ultra-slim DIN rail form factor: 12 mm (width) × 70 mm (height) × 55 mm (depth); Weight: ~120 g; IP Rating: IP20 (panel-mount, dust-protected only) |
| Environmental Requirements | Operating temperature: 0 °C to +45 °C (indoor, climate-controlled spaces); Storage temperature: -10 °C to +50 °C; Relative humidity: 20%–80% (non-condensing); Vibration resistance: 0.1 g (10 Hz–500 Hz); Shock resistance: 8 g (11 ms half-sine) |
| Power Requirements | 24 VDC (22–26 VDC narrow range, for standard industrial/HVAC power supplies); Power consumption: < 0.5 W (max, single channel active); No auxiliary sensor power output (requires external 24 VDC supply) |
| Safety & Compliance | CE (EN 61010-1); RoHS 2 compliant (lead-free); No UL/hazardous area certifications (for non-critical, low-risk single-point use) |
| Compatibility | Works with Metso systems: Metso FieldCare Lite (v2.0+) (basic device detection only); Compatible with 3rd-party micro-PLCs: Siemens S7-1200 (basic mode), Allen-Bradley Micro810, Schneider M100; Supports 24–18 AWG stranded wire (only) |
| Additional Features | LED indicators (1 power LED: green = on; 1 channel LED: green = signal detected, red = overrange/short); Non-removable terminal blocks (screw-type, mini flathead required); Fixed Modbus address (1, no reconfiguration); Built-in overcurrent protection (30 mA max) |
METSO IOP302
Product introduction
The Metso IOP302 is an ultra-compact 1-channel analog input module developed by Metso Outotec, engineered to solve single-point monitoring needs—from tracking a small warehouse’s single syrup tank level to monitoring an HVAC zone’s temperature in a convenience store. Unlike the 2-channel Metso IOP303 (with extra capacity) or 4-channel Metso IOP304 (for multi-point use), the Metso IOP302 focuses on “one task, done simply”: it converts a single 4–20 mA sensor signal into digital data, transmits via fixed 9600-baud Modbus RTU, and requires no software setup—making it ideal for users with no automation experience or applications where only one monitoring point is needed.
As the smallest module in Metso’s entry-level I/O lineup, the Metso IOP302 excels in scenarios where space and cost are absolute priorities. For example, a local coffee shop uses the Metso IOP302 to monitor its single milk storage tank’s level: the module connects to a 4–20 mA ultrasonic sensor and sends data to an Allen-Bradley Micro810 PLC (fixed 9600 baud). Unlike the Metso IOP303, which has an unused second channel, the Metso IOP302 fits in a 30 mm-wide DIN rail slot (shared with a small relay) and costs 25% less. Whether used in small retail, home-based workshops, or commercial HVAC retrofits (single zone), the Metso IOP302 delivers Metso’s signature reliability in a “no-waste” package for ultra-minimal monitoring tasks.
Core advantages and technical highlights
12 mm Ultra-Slim Width for Extreme Space Savings: The Metso IOP302’s 12 mm DIN rail width is 50% narrower than the Metso IOP303 (18 mm) and 76% narrower than the Metso IOP304 (22 mm)—critical for the tiniest control panels or retrofits where space is non-negotiable. A residential HVAC contractor installs the Metso IOP302 in a 25 mm-wide wall-mounted panel (for a commercial office’s single zone temp monitoring): its slim profile eliminates the need to upgrade to a larger panel (a $100 expense if using a wider module). This space efficiency is unmatched by any other Metso I/O module, making the Metso IOP302 the only viable choice for ultra-tight installations.
True Zero-Configuration for Non-Technical Users: The Metso IOP302 has no adjustable settings—fixed 9600 baud, Modbus address 1, and no software requirements. A small bakery owner (with no automation training) sets up the Metso IOP302 to monitor its single oven’s temperature: after wiring a 4–20 mA RTD transmitter to the module’s channel, it automatically sends data to a Siemens S7-1200 PLC (preconfigured to 9600 baud). Unlike the Metso IOP303, which may require checking a second unused channel, the Metso IOP302 has only one connection point—eliminating wiring errors and setup confusion. This simplicity makes it perfect for users who want to “wire and walk away.”
Lowest Cost in Metso’s I/O Lineup for Single-Point Needs: The Metso IOP302 is priced 25% lower than the Metso IOP303 and 75% lower than the Metso IOP304—enabling users to add single-point monitoring without overspending. A small water utility uses 6 Metso IOP302 modules (one per small residential pump’s discharge pressure) to monitor pump health: the total cost is 35% less than using 3 Metso IOP303 modules (with 3 unused channels) and integrates seamlessly with Schneider M100 PLCs. This affordability doesn’t compromise reliability—Metso’s quality testing ensures the Metso IOP302 operates consistently for 3+ years in indoor environments.
Overcurrent Protection for Sensor Safety: The Metso IOP302 includes 30 mA overcurrent protection—preventing damage from accidental sensor short circuits (common in small facilities with uncertified wiring). A small workshop’s intern accidentally shorts a 4–20 mA pressure sensor to the Metso IOP302: the module’s protection triggers, stopping current flow instead of damaging the ADC. After fixing the short, the Metso IOP302 resumes normal operation—avoiding a $120 replacement cost (vs. unprotected generic modules). This feature gives non-technical users confidence during installation.
Typical application scenarios
In small retail, a convenience store uses the Metso IOP302 to monitor its single soda syrup tank’s level: the module connects to a 4–20 mA ultrasonic sensor (powered by an external 24 VDC supply) and sends data to a Schneider M100 PLC. The PLC alerts the store manager via text when the tank reaches 20% capacity (4 mA signal), ensuring timely restocks. The Metso IOP302’s 12 mm width fits in a tiny under-counter panel (shared with a power supply), and its single channel eliminates wiring confusion. This setup costs 40% less than a multi-channel alternative and solves the store’s only critical monitoring need—no excess features, no wasted budget.
In residential/commercial HVAC, a contractor uses the Metso IOP302 to retrofit a small office’s single HVAC zone: the module connects to a 4–20 mA RTD sensor (monitoring zone temperature) and sends data to an Allen-Bradley Micro810 PLC. The PLC adjusts the zone’s damper position based on the sensor signal (e.g., 20 °C = 4 mA, 26 °C = 20 mA), improving energy efficiency by 15%. The Metso IOP302’s low power consumption (0.5 W) aligns with the office’s energy goals, and its LED indicators let the contractor verify operation in seconds (green = working, red = issue). Unlike the Metso IOP303, which has an unused channel, the Metso IOP302 is a “perfect fit” for the single-zone retrofit.
METSO IOP302
Related model recommendations
Metso IOP303: 2-channel upgrade of the Metso IOP302—adds 1 extra channel for users scaling to two monitoring points (e.g., tank level + pump pressure).
Metso PS-240 Mini: 24 VDC, 0.3 A ultra-slim power supply for the Metso IOP302—powers the module and 1 sensor (30 mA max), fits in 10 mm DIN rail space (matches the module’s slim profile).
Metso FieldCare Lite (v2.0+): Software for basic Metso IOP302 verification—detects the module on Modbus, displays channel value, and flags overrange errors (no configuration needed).
Siemens S7-1200 PLC (1211C Mini): Micro-PLC optimized for the Metso IOP302—preconfigurable to 9600 baud, supports single-channel data logging, ideal for small retail/HVAC.
Allen-Bradley Micro810 PLC: Ultra-compact PLC fully compatible with the Metso IOP302—fixed 9600 baud support, 1 analog input channel (matches the module’s output), costs < $150.
Metso TC-12: 12 mm-wide terminal block cover for the Metso IOP302—protects terminals from dust and accidental contact, fits the module’s ultra-slim profile (no overhang).
Metso IOP331: Digital input complement to the Metso IOP302—8 channels, NPN/PNP auto-detect—for users adding digital sensors (e.g., limit switches) alongside a single analog point.
Schneider M100 PLC: Budget micro-PLC for the Metso IOP302—fixed 9600 baud Modbus RTU, simple HMI integration, suitable for ultra-small-scale applications (e.g., convenience stores).
Installation, commissioning and maintenance instructions
Installation preparation
Before installing the Metso IOP302, power off the control system and wear ESD wristbands to protect the module’s 12-bit ADC. Verify the module’s power supply (22–26 VDC) matches the external 24 VDC source—do not use voltages outside this range (narrower than the Metso IOP303’s 20–28 VDC). Mount the Metso IOP302 on a standard 35 mm DIN rail—ensure 2 mm clearance on both sides (sufficient for airflow, given its low 0.5 W consumption) and avoid installing near heat sources (e.g., space heaters).
Wiring requires a mini flathead screwdriver (terminals are non-removable): strip 3 mm of insulation from 24–18 AWG stranded wire (solid wire not recommended), insert into terminals (labeled: V+, GND, CH1, A, B), and tighten screws to 0.1 N·m (over-tightening breaks small terminals). Connect the sensor to CH1 (ensure polarity: + to CH1+, – to GND). Connect RS-485 A/B lines to the PLC’s Modbus port—use 0.3 mm² twisted-pair cable (max run: 30 meters, shorter than the Metso IOP303’s 50 meters, due to single-channel design).
Commissioning and maintenance
Power on the system and verify the Metso IOP302’s power LED turns green (no power = check wiring or supply). Check the channel LED: green = sensor connected and sending 4–20 mA; red = overrange (>20 mA) or short circuit. Use a multimeter to confirm the sensor signal (e.g., 4 mA = empty tank, 20 mA = full tank) at the module’s terminals—no software needed for verification.
For maintenance, inspect the Metso IOP302 every 8 months: wipe dust from the housing with a dry cloth (IP20 dust-only protection), check terminal screws for tightness (loose wires cause intermittent green LEDs), and verify power supply voltage (24 VDC ±3%). If the channel shows a red LED, disconnect the sensor and test with a 4–20 mA signal generator—if green LED returns, replace the sensor; if not, replace the entire module (no field-repairable parts). Store spares in a dry cabinet (avoid 0 °C below or +45 °C above—colder/hotter than the module’s operating range).
Service and guarantee commitment
Metso provides a 6-month standard warranty for the Metso IOP302, covering defects in materials, workmanship, and performance (e.g., channel failure, no communication). During warranty, Metso replaces the module free of charge if it fails under normal indoor use (proof of purchase required—simplified receipt or invoice accepted). No extended service plans are available, aligning with its ultra-entry-level, single-point positioning.
Metso’s technical support for the Metso IOP302 is streamlined: available via a dedicated online FAQ page (step-by-step wiring guides, LED error fixes) and email (24-hour response time, business days). No chat or phone support (reserved for higher modules like the Metso IOP303). Support focuses on common single-channel issues: “red LED troubleshooting,” sensor polarity checks, and PLC baud rate matching—tailored to non-technical users.
For out-of-warranty issues, Metso offers a 25% discount on a new Metso IOP302 (valid 3 months after failure—shorter than the Metso IOP303’s 4 months, due to lower cost). Customers get free access to a 1-page “Quick Start Card” (simplified wiring diagram + LED meanings) and a 1-minute installation video—no complex resources. This commitment balances affordability with practical support, ensuring ultra-small-scale users get the help they need for their single-point monitoring tasks.
