Ingeteam AK9499 Series Modules: AS3179A7404001753 AK9499-J

Technical Dossier

Product Details And Specifications

Ingeteam AK9499 Series: Comprehensive Module Range and Technical Overview

The Ingeteam AK9499 series is a programmable logic controller and distributed I/O platform deployed across heavy industrial sectors globally, including petrochemical refineries, nuclear auxiliary systems, combined-cycle power plants, and water treatment infrastructure. Ingeteam, headquartered in Zamudio, Basque Country, Spain, has supplied automation and control hardware to European, Latin American, and Middle Eastern industrial markets since the 1980s. The AK9499 platform was engineered for deterministic real-time control in environments requiring high electromagnetic compatibility (EMC) ratings per IEC 61000, extended operational temperature ranges (−10°C to +60°C), and compliance with IEC 61131-3 programming standards. Installed base records confirm deployment in SCADA backbone architectures, distributed control system (DCS) hybrid configurations, and safety-instrumented system (SIS) auxiliary loops where long lifecycle support is a mandatory procurement criterion. The platform's modular rack architecture supports hot-swap capability on select I/O modules, reducing planned maintenance downtime in continuous-process facilities.

The Evolution of AK9499 Architecture

The AK9499 architecture traces its lineage to Ingeteam's INGECON automation platforms developed in the late 1990s, which were designed for standalone CPU operation with proprietary backplane bus communication at 5 Mbps. The first-generation AK9499-A and AK9499-B modules (circa 1999–2003) used RS-232 and RS-485 serial interfaces and supported Modbus RTU as the primary fieldbus protocol. Program memory was limited to 256 KB, constraining application complexity in large-scale process loops.

The mid-generation expansion (2003–2010) introduced PROFIBUS-DP master/slave capability with the AK9499-K communication adapter, enabling integration with third-party SCADA platforms including Wonderware InTouch, Citect SCADA, and Siemens WinCC. The AK9499-C introduced an integrated 10/100 Mbps Ethernet port, supporting Modbus TCP and OPC DA server functionality. Rack bus bandwidth was upgraded to 12 Mbps in this generation. Compatibility constraints exist between pre-2003 backplanes and post-2005 high-density I/O modules; rack firmware version must be verified at or above v2.4 before module substitution to avoid bus arbitration conflicts.

The late-generation AK9499-D through AK9499-J variants (2010–2018) introduced redundant CPU hot-standby configurations, IEC 61131-3 structured text (ST) and function block diagram (FBD) programming environments, and enhanced diagnostics with module-level fault isolation. The AS3179A7404001753 AK9499-J represents the final production revision of the series, incorporating extended MTBF ratings (>80,000 hours at 40°C), improved conformal coating for humid environments, and a 32-bit RISC processor core. The AK9499 series entered end-of-active-production status in 2021. Ingeteam's current successor platform is the INGESYS IC3, which requires a full rack and wiring replacement and is not backward-compatible with AK9499 I/O modules.

AK9499 Full Catalog & Functionalities (SKU List)

CPU / Controller Modules
AS3179A7404001753 AK9499-J: Final-revision main CPU, 32-bit RISC, IEC 61131-3, PROFIBUS-DP master, MTBF >80,000 h
AK9499-A: First-generation CPU module, RS-232/RS-485, Modbus RTU, 256 KB program memory
AK9499-B: Enhanced CPU, expanded 512 KB program memory, Modbus RTU master/slave
AK9499-C: CPU with integrated 10/100 Mbps Ethernet, Modbus TCP, OPC DA server
AK9499-D: Redundant CPU module, hot-standby configuration, bumpless switchover <10 ms

Digital I/O Modules
AK9499-E: Digital input module, 32-channel, 24 VDC, IEC 61131-2 Type 1/3, sink/source configurable
AK9499-F: Digital output module, 32-channel, 24 VDC, 0.5 A per channel, short-circuit protected
AK9499-S: Relay output module, 16-channel, SPDT contacts, 2 A at 250 VAC, mechanical life 10M ops

Analog I/O Modules
AK9499-G: Analog input module, 16-channel, 4–20 mA / 0–10 V selectable, 12-bit resolution, ±0.1% accuracy
AK9499-H: Analog output module, 8-channel, 4–20 mA, 12-bit resolution, loop-powered
AK9499-R: RTD/thermocouple input module, 8-channel, PT100/PT1000/Type J/K, 0.1°C resolution
AK9499-P: High-speed counter module, 4-channel, 500 kHz max input frequency, quadrature encoder support

Communication Adapter Modules
AK9499-K: PROFIBUS-DP slave communication adapter, 12 Mbps, GSD file configurable
AK9499-L: DeviceNet communication module, scanner/adapter mode, 500 kbps, 64-node support

Power Supply Modules
AK9499-M: Power supply module, 85–264 VAC input, 24 VDC / 5 A rack bus output, >90% efficiency
AK9499-N: Redundant power supply module, load-sharing configuration, N+1 redundancy, hot-swap capable

Infrastructure / Backplane Modules
AK9499-T: Backplane bus extender module, rack-to-rack fiber optic link, up to 1 km distance, multimode fiber

Sourcing Hard-to-Find & Obsolete AK9499 Parts

The AK9499 series reached end-of-active-production in 2021. Ingeteam no longer manufactures new units for the majority of AK9499 sub-models, and OEM channel lead times are indeterminate or closed. For facilities operating AK9499-based control systems with 5–20 year remaining operational horizons — a common scenario in nuclear auxiliary, refinery, and water utility environments where control system replacement requires regulatory re-qualification — sourcing verified replacement modules from the secondary market is the primary lifecycle extension strategy.

DriveKNMS maintains a dedicated inventory of tested surplus and refurbished AK9499 modules sourced from decommissioned plant equipment, controlled facility shutdowns, and authorized reseller networks across Europe, Southeast Asia, and the Middle East. Services provided for AK9499 lifecycle support include: verified replacement units with full functional test documentation traceable to each serialized unit; cross-reference mapping to compatible successor platforms (Ingeteam INGESYS IC3, third-party PLC substitution) where direct replacement is feasible; and long-term consignment stocking agreements for high-volume maintenance contracts. All units are shipped with a 12-month warranty against functional failure under normal operating conditions. Emergency same-day quotation is available for critical plant breakdown situations.

Quality Control for the AK9499 Range

AK9499 modules incorporate a proprietary backplane bus protocol and multi-layer PCB construction that requires specialized test procedures beyond standard bench power-on verification. DriveKNMS applies the following QC protocol to all AK9499 units processed through its facility:

(1) Visual Inspection: Per IPC-A-610 Class 2 criteria, covering solder joint integrity, connector pin condition, electrolytic capacitor health assessment, and conformal coating continuity.
(2) Backplane Bus Communication Test: Using a dedicated AK9499 rack test fixture, verifying slot addressing, module enumeration, and data throughput at rated 12 Mbps bus speed across all populated slots.
(3) CPU Module Functional Test: Full program load/execute cycle using a reference IEC 61131-3 ladder logic program, with I/O scan time measurement against factory specification (<5 ms at 512 I/O points).
(4) Analog I/O Calibration Verification: Full-range sweep across 4–20 mA and 0–10 V ranges using a traceable signal source (NIST-traceable calibrator), with linearity error and offset recorded against factory tolerance (±0.1% FS).
(5) Burn-In Test: 48-hour continuous operation at 45°C ambient temperature to screen latent component failures per MIL-HDBK-217 accelerated life principles.
(6) Final Documentation: Test records retained per serialized unit and available upon request with each shipment.