LOCON 24-0360-A32I Retrofit-Compatible Relay for Legacy Systems

LOCON 24-0360-A32I Retrofit-Compatible Relay for Legacy Industrial Control Systems

The LOCON 24-0360-A32I is a ruggedized, general-purpose relay module engineered for demanding industrial environments and designed as a retrofit-compatible replacement for aging relay assemblies found in legacy control panels, process automation cabinets, and distributed control system (DCS) marshalling racks. As original equipment manufacturers discontinue support for older relay platforms, facilities running continuous process operations — including oil and gas, chemical processing, power generation, and heavy manufacturing — face increasing pressure to source reliable, pin-compatible replacements that can be installed without redesigning existing wiring infrastructure.

NINERMAS maintains verified in-stock inventory of the LOCON 24-0360-A32I with pre-shipment functional testing and a 12-month warranty, supporting both emergency breakdown replacements and planned maintenance programs. Each unit is inspected against original LOCON specifications before dispatch, ensuring that coil voltage ratings, contact configurations, and mechanical dimensions conform to the original design envelope.

Upgrade Compatibility Table

Retrofit Planning for Existing Automation Systems

Replacing a relay module such as the LOCON 24-0360-A32I within an operating automation system requires a structured approach that accounts for the full scope of the control architecture. In most legacy installations, the relay assembly sits between the PLC digital output card — often a module such as a GE Fanuc IC693MDL940 or Siemens 6ES7 322-series DO module — and the field device being switched. Before removing the existing relay, engineers should document the wiring schedule from the terminal block, noting wire labels, ferrule numbers, and the associated I/O address in the PLC program.

In installations where the relay panel feeds into a Bently Nevada 3500-series machinery protection system or an Emerson DeltaV I/O subsystem, the signal path must be traced carefully to avoid inadvertent trips or false alarms during the changeover window. Where the relay is part of a safety interlock loop, the relevant SIL rating and proof-test interval should be reviewed before any component substitution is approved.

The physical installation environment also demands attention. Many legacy control cabinets housing LOCON relay assemblies were designed to IEC 60439 or older national standards, and available DIN rail space may be constrained by adjacent components such as Phoenix Contact TRIO power supplies, Weidmüller terminal blocks, or Murrelektronik signal isolators. Measure the available slot width and confirm that the replacement module’s footprint does not conflict with cable routing channels or adjacent I/O marshalling strips.

For systems that include a Rockwell Automation 1756 ControlLogix or ABB AC500 controller as the primary PLC, the I/O address assigned to the relay output channel should be verified in the ladder logic or function block diagram before the replacement is powered up. If the original relay was wired to a specific rung condition or interlock permissive, the program logic should be reviewed to confirm that the replacement contact configuration — normally open or normally closed — matches the original design intent. In some aging installations, relay contact numbering conventions differ between manufacturers, and a direct pin-for-pin substitution may require a wiring adapter or jumper modification at the terminal block.

Where the control system includes an HMI panel — such as a Siemens SIMATIC TP700 or a Weintek MT8000-series touch panel — the relay status may be reflected in a faceplate display or alarm summary. After replacement, verify that the HMI tag linked to the relay output channel reads correctly and that any alarm setpoints associated with the relay state are functioning as expected. This is particularly important in installations where the relay drives a motor starter, solenoid valve, or heating element that is monitored for runtime hours or cycle counts.

Downtime Control During System Migration

Minimizing unplanned downtime during a relay replacement is a primary concern for maintenance teams operating continuous process lines. For the LOCON 24-0360-A32I, the recommended approach is to pre-stage the replacement unit alongside the existing installation, perform a full continuity check on the new relay’s contacts using a calibrated loop tester, and prepare a wiring transfer sequence that allows the changeover to be completed within a single planned maintenance window.

Where the process cannot tolerate a full shutdown, a temporary bypass relay can be wired in parallel with the existing unit to maintain field device control while the primary relay is removed and replaced. This technique is commonly used in installations where the relay controls a critical pump, compressor, or valve that must remain operational during the maintenance period. The bypass should be documented in the maintenance record and removed immediately after the replacement relay has been verified in service.

To protect the existing PLC program logic during the changeover, the relevant output channel should be forced to a safe state — typically de-energized — before any wiring is disturbed. This prevents inadvertent actuation of the field device and protects both personnel and equipment. After the replacement relay is installed and wired, the force should be removed and the output channel tested through a full operate-and-release cycle before the process is returned to automatic control.

Pre-shipment functional testing performed by NINERMAS on every LOCON 24-0360-A32I unit reduces the risk of receiving a defective component, which is a significant concern when sourcing spare parts for discontinued or end-of-life relay platforms. Each unit is tested for coil pull-in voltage, contact resistance, and mechanical operation before dispatch, and is accompanied by a test record that can be retained in the site maintenance file. In-stock availability means that emergency orders can typically be dispatched within one business day, supporting rapid response to unplanned failures without the extended lead times associated with factory-order or broker-sourced components.

Retrofit Support FAQ

Q1: Is the LOCON 24-0360-A32I a direct drop-in replacement for the original LOCON relay assembly?
In most installations, yes. The 24-0360-A32I is designed to the original LOCON dimensional and electrical specification. However, customers should verify coil voltage, contact configuration, and terminal block pitch against their existing wiring diagram before installation, as some legacy panel variants may have used non-standard wiring adaptors or modified terminal assignments.

Q2: What pre-commissioning checks are required after installing the replacement relay?
After installation, perform a coil continuity check, a contact resistance measurement on each pole, and a full operate-and-release cycle test with the associated PLC output channel forced active. Confirm that the HMI display and any alarm tags linked to the relay output reflect the correct state before returning the loop to automatic control.

Q3: Can NINERMAS supply multiple units for a planned spare parts program?
Yes. NINERMAS maintains buffer stock of the LOCON 24-0360-A32I to support both emergency single-unit orders and bulk procurement for planned maintenance programs. Volume pricing and scheduled delivery arrangements are available. Contact sale@ninermas.com or call +0086 187 5021 5667 to discuss your requirements.

Q4: What does the 12-month warranty cover?
The 12-month warranty covers manufacturing defects, coil failure, and contact malfunction under normal operating conditions. It runs from the date of shipment from NINERMAS. Units that fail within the warranty period will be replaced or credited at NINERMAS’s discretion. The warranty does not cover damage resulting from incorrect installation, overvoltage, or operation outside the rated environmental envelope.