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A SAFE BET:Ex and Non-Ex in One System / Page 10

direct processInformation for Power and Process Technology, November 2014

Go with the Flow / Page 16

Interview: Module Masters / Page 20

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Dear Readers,

Modularization in power, chemical and process technologies, com-bined with decentralized intelligent controls, is increasingly gaining attention across the entire process industry sector. Systems engineers in process technology now either expect — or demand — these types of decentralized structures, as they are the only way that the modular system designs required by the process industry are possible.This type of modular, decentralized control architecture can be real-ized using the WAGO-I/O-SYSTEM 750. The WAGO-I/O-SYSTEM is an established and proven solution for these applications. Developed in the mid-90s, it was the first modular and fieldbus-independent auto-mation system for networks based on logically decentralized designs. And, the system’s performance and capabilities have continuously advanced with developments including completely programmable automation nodes that function within systems as controllers and autonomous PLCs. In fact, it features more than 500 I/O modules for virtually any function, signal or sub-bus and provides users with enough latitude to assemble automation networks that are powerful and individualized.Decentralized automation in mechanical and systems engineering be-gan in the late ‘90s. WAGO adapted this idea into our first LON® Con-troller for building automation. Now everyone is talking about applying this principle to power and process technologies. On the one hand, the first standards have been defined for connecting and incorporating

EDITORIAL

New Freedom in Water Resource Management Page 04

Consistent Control Technology:

Centralized Engineering up to the Decentralized I/O Module Page 07

A Safe Bet: Ex and Non-Ex in One System Page 10

Less Downtime on Oil Platforms Page 14

Go with the Flow Page 16

Seaworthy: WAGO-I/O-SYSTEM 750 XTR Earns GL Approval Page 19

Module Masters Page 20

Water Must Flow under all Conditions Page 24

Socket with Miniature Switching Relay and Base Load Module Page 27

Integrated PTC Thermistor and Resistance Sensors Page 27

Intrinsically Safe Field Level with Decentralized Intelligence Page 28

e!COCKPIT: New Engineering Software

Suite for the World of WAGO Automation Page 30

Legal Information Page 32

CONTENTS

decentralized, modular and flexible units. These include IEC 61850 for power technology and the NAMUR Recommendation NE 148 that cov-ers modularization in process technology systems. On the other hand, the functions, technologies and services within the WAGO automation landscape have been specifically developed for these applications, so supply and demand can continue to grow together.In this issue of WAGOdirect process, you will find a selection of proj-ects that were made possible thanks to our extensive product portfolio. In addition, there is always a chance to share thoughts and ideas by talking to us at tradeshows worldwide, such as the Nov. 6–7 2014 NAMUR Annual General Meeting in Bad Neuenahr, Germany. WAGO was the primary sponsor of the session on “Decentralized Intelligence — New Paths in Process Automation.”

Enjoy the articles!

Best regards,

Jürgen SchäferBusiness Management Sales

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■ Municipal drinking water and sewage management operations are obliged to ensure the safe supply of clean water and the dis-posal of wastewater 24 hours a day, 365 days a year. In order to accomplish this, reliable and flexible telecontrol solutions are needed. As part of a joint pilot project with HAMBURG WASSER (Hamburg Water Authority), WAGO developed a new telecontrol gateway (WTG) as an open interface between the field and control levels. After successful testing, HAMBURG WASSER now uses two of these gateways and 19 WAGO telecontrol substations in Germany’s Hamburg metropolitan area, with more to surely follow.

As a coordinating corporation, HAMBURG WASSER links the Hamburger Wasserwerke GmbH [Hamburg Waterworks] and the Hamburger Stadtenwässerung AöR [Hamburg City Sewage Public Works], making it Germany’s largest, municipally owned drinking water and wastewater utility. The primary functions of the enterprise include supplying drinking water and the proper disposal of waste-water in Hamburg and the surrounding environment. The latter flows from residential connections into a series of underground canals that form the city’s sewer network. This extends across an area of 300 km², has a length end-to-end of more than 5,800 km and collects wastewater from approximately two million households, businesses, industrial customers and 28 surrounding communities. This creates a need for the continuous uptime of all technical systems, placing high demands on the safety and reliability of telecontrol technology.

■ Birth of the Pilot ProjectThe project began when HAMBURG WASSER sought to replace some of the telecontrol substations controlling the sewer network. When searching for a suitable solution to link the substations to the control system via secure dial-up connections, Claus-Ulrich Axt, Project Manager for Electrical, Measurement and Control Systems Technology at HAMBURG WASSER contacted WAGO, and the joint pilot project was born.“My objective was to find a solution that would enable us to communicate using standardized telecontrol protocols. The end goal was to free HAMBURG WASSER from the technology of any single manufacturer. WAGO accepted the challenge and was ready to cooperate with us,” explains Axt.Initial Situation: HAMBURG WASSER uses a control system for mon-itoring and controlling the sewer equipment. This system primarily controls the pumps and the telecontrolled gates that regulate the

wastewater flow between the upper, local canals and the collec-tion network, which is approximately 20 m below the ground. The connection to the telecontrol substations was partially handled by a proprietary telecontrol protocol using dial-up connections. The con-sequence of using these interfaces was the inability to incorporate telecontrol components from the leading manufacturers in control technology.

New Freedom in Water Resource ManagementInnovation in telecontrol technology: WAGO develops a new type of gate-way that is an open interface between field and control levels.

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New Freedom in Water Resource Management

In the Köhlbrandhöft/Dradenau sewage treatment plant, HAMBURG WASSER performs multistage treatment and recycling of wastewater from Hamburg, Germany.

■ From Theory to PracticeFirst, HAMBURG WASSER and WAGO joint-ly formulated required specifications for the WAGO telecontrol gateway, ranking functions that were necessary, optional and possible in the future. Then they placed the first WTG into operation at one of two HAMBURG WASSER server locations in Hamburg. Over the following weeks, numerous tests were performed on the prototype, including Wireshark telegram record-ing and analysis, time synchronization and time stamps, as well as other IEC traces using tools such as WinPP. Interface adaptations to the con-trol system were also made.Once it was ready to deploy, the new technolo-gy was incorporated into the bid for replacing the telecontrol technology in the pumping station located in Hamburg’s municipality of Neu Wulm-storf. HAMBURG WASSER has been responsible for Neu Wulmstorf’s central wastewater disposal since 2008. In the meantime, two WTGs are operating redundantly within the project. This redundancy ensures greater levels of safety, since HAMBURG WASSER wants to prevent accidental wastewater release from polluting the environment, making it necessary to rely on the constant equipment uptime.

The link between gateways and the control technology was estab-lished using a TCP/IP connection. In addition, HAMBURG WASSER has connected 19 WAGO telecontrollers (750-880/025-001) to the control system where they function as substations according to IEC 60870-5-101. Fourteen units function via analog dial-up con-nections, four via GSM and one via ADSL (which directly uses the IEC -104 protocol thanks to a redundant front-end computer system from the existing control technology). “There were a few technical challenges that had to be overcome during the course of the project, including interoperability required by the IEC, redundancy behavior in coordination with the control tech-nology manufacturer, time synchronization, correctly archiving data in the control system and error-free system configuration. Now, the WTG satisfies every demand that we expressed at the beginning of the project, and has proven itself in the sewer network’s operation,” notes Axt.HAMBURG WASSER was assisted in implementing the project by ME-Automation Projects from Fuldabrück, Germany which oversaw delivery, installation, parameterization, programming and commis-sioning of the WTGs, telecontrollers and associated communication technology.

■ Innovative Combined SolutionThe WTG, part of the finely modular and fieldbus independent WAGO-I/O-SYSTEM, consists of an I/O-IPC-C10 with WAGO tele-control software that can link up to 64 telecontrol substations to the control level. The distinctive feature of this solution is that the WTG com-bines traditional programmable control with standard telecontrol pro-tocols and an associated configuration tool, enabling the generation of IEC messages without requiring laborious programming. Thus, users can establish a standardized connection to the control technology and independently perform parameterization without specialized software.

Via Web-Based Management (WBM), operators can add participants and make system adjustments.

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• In the plant, the WAGO Telecontrol Gateway (WTG) forms an open interface between field and control levels

• The WTG communicates using standardized telecontrol protocols (IEC 60870-5-101/-104)

• Comprehensive system adjustments can be made using Web-Based Management

HAMBURG WASSER must maintain, monitor and control a sewer network extending more than 5,800 km — this includes a new transport sewer extending between La-dungsbrücken and Hafenstraße, Germany.

The WTG, pictured here in the HAMBURG WASSER control center, debuts an open transmission level between components at the field and the control levels.

A total of 19 WAGO controllers are used in the Neu Wulmstorf project. The controller pictured uses an analog or ISDN modem.

Using Web-Based Management (WBM), operators can — within the parameters of their license agreement — add participants and make system adjustments. This simplifies the integration of telecontrol substations and eliminates unnecessary service costs from external contractors.Up to twelve cards (RS-232 I/O modules) can be connected in series at the field level. Connections to the field level are provided via stan-dard wiring, dial-up connections or transparent TCP/IP connection (DSL, GPRS router or TETRA radio modem), and to the control level via ETHERNET or GPRS. Connecting to substations using a dial-up connection to the gateway guarantees extremely reliable data trans-mission. Greater connection security than radio connections makes this is vital to critical installations like wastewater disposal.

■ Forward-Looking Telecontrol SolutionFollowing the successful pilot project, HAMBURG WASSER plans to gradually replace a significant number of the stations connected us-ing dial-up connections to the new solution based on WAGO telecon-trollers and telecontrol gateways. In fact, the municipal utility recently installed two additional WTGs and has ordered approximately 60 more controllers. These will be coupled to the WTGs using the IEC 60870-5-104 protocol.“This demonstrates an additional strength of the WTGs. They were originally only conceived for dial-up stations and the IEC 60870-5-101 protocol; however, the WTG also supports the -104 version at the field level. This provides us with even greater flexibility. Overall, we are reducing our dependence on the control technology from a single manufacturer, giving us leverage in future negotiations. I have achieved my primary goal: the control and telecontrol technology at HAMBURG WASSER has been cost-effectively configured to be more flexible and more sustainable,” beams Axt.

Text: Kay Miller, WAGOPhoto: HAMBURG WASSER, ME-Automation Projects

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Consistent Control Technology: Centralized En-gineering up to the Decentralized I/O ModuleIn the Regensburg, Germany milk processing facility, operated by Bayernland eG, the WAGO-I/O-SYSTEM 750 forms the interface between the field level and the control technology. The WAGO-I/O-SYSTEM was selected due to its high integration density.■ The desire for continuity and a centralized engineering design up to the decentralized I/O module are among the demands placed on modern control technologies. Even in production facilities, such as the Regensburg milk processing facility owned by Bayernland eG, these forward-thinking approaches can be realized using multi-layered and consistent object descriptions. This is achieved through consistent des-ignation of signals from the field level on through the automation sys-tems and up to the control technology. Using the modular WAGO-I/O-SYSTEM 750, the I/O signals are transmitted to the automation and control system components, manufactured by ME-Automation Projects GmbH (formerly KH-Automation Projects GmbH), via the PROFIBUS fieldbus for further processing.

The Regensburg milk processing facility is the headquarters of the pre-viously independent dairy processor, Domspitzmilch eG. In 2008, a cooperative was formed that incorporated its two dairies in Regensburg and Amberg into the Bayernland eG. Nearly 1,800 active dairy farmers

deliver 270 million kg of raw milk annually for processing into milk, sour milk, yogurt, desserts, cream cheese, butter, skim milk and whey powder.To accommodate the farmers, the Regensburg facility provides auto-matic receiving stations for accepting milk deliveries. By using inductive flow and temperature measurements, approximately 250,000 liters of milk are accepted every hour. The raw material is extensively monitored as it undergoes further processing. From the receiving stations, the raw milk is transferred into an 820,000-liter storage tank. In the first step of production, the milk is pumped from raw milk storage into an operating chamber for separation, pasteurization and cooling. The milk and cream are then conveyed to their respective production areas via various con-duit systems. The connected production areas consist of storage areas, ripening vats of different sizes and machines for further processing milk products. And all of the conduit systems, tank farms and vats are con-nected to a cleaning system. The cleaning procedure occurs automati-cally at pre-designated intervals.

All process technology areas were to be operated and monitored by the new control system from both a central control room and from decentral-ized operator stations located throughout the facility.

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■ Narrow Time Frame, Cramped ConditionsBecause Bayernland eG’s control system technology had become outdated, making it difficult to source replacement parts, the firm de-cided to replace the process control system. The goals for system mi-gration included a significant increase in system uptime, which would yield a similar increase in productivity, and the implementation of a modern and flexible technology that would support future expansion. All process technology areas were to be operated and monitored by the new control system from both a central control room and from decentralized operator stations located throughout the facility. The PMSX®pro process management system from ME-Automation Projects enables the cost-effective, automated production of various milk prod-ucts, while simultaneously accommodating customers’ stringent quali-ty requirements. The specific challenges in this project stemmed from a limited time frame for the conversion, and the extremely space-restrict-ed areas that housed existing systems.

■ High Integration Density, Graphical DisplaysThe proven WAGO-I/O-SYSTEM 750 was selected in order to achieve a high I/O integration density while making the most the plant’s tight installation areas. Communication to higher-level automation systems, the MELSEC System Q from Mitsubishi, are performed via PROFIBUS DP. The inputs and outputs from both the WAGO-I/O-SYSTEM 750 I/O modules and those from the automation systems were uniquely designated and documented using Profigen, the PROFIBUS generator from the PMSX®pro process management system. Existing signal lists can be imported as .csv files. Profigen uses drag & drop to handle the administration and distribution of the signals for the inputs and outputs, as well as the graphical displays of the automation systems,

the WAGO-I/O-SYSTEM and any other PROFIBUS components. The designation documentation is automatically generated. Available documents include the cover sheet, table of contents, drawings of device construction and expansion and module-related designation schematics with detailed information on the input and output signals.

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testing in the automation systems. The second step on the path to consistency is the automatic generation and/or synchronization in the PMSX®pro database of the communication variables required and of the function blocks used within the automation systems. This coordi-nation is executed using the “Engineering Workbench” centralized software environment and leads to consistent name assignment from the input/output signals to the process visualization in the process image. Static and dynamic function charts are generated in paral-lel. Function chart documentation according to IEC 61131-3 is also provided. The WAGO-I/O-SYSTEM has been completely integrated into the PMSX®pro graphical display and documentation tool, and is available to all users.Within three days, approximately 4,200 field signals were calculat-ed, tested and put into operation using the PMSX®pro process man-agement system so that at the beginning of the week, production in Regensburg could resume. The limited time frame for the conversion could be maintained because all relevant process stages had been simulated and tested in a comprehensive “Factory Acceptance” test.

Text: Michael Juch, ME-Automation Projects GmbH Kay Miller, WAGO

Photo: Bayernland eG, ME-Automation Projects

■ Automatic Generation, Complete IntegrationThe designations of all inputs and outputs within the automation sys-tems are declared through Profigen’s generation of a global variables list (GVL) according to IEC 61131-3, which provides the first step to-ward consistency. This ensures that the I/O names used in the module documentation are now identical to those used for programming and

Automatic receiving station at the Regensburg milk process-ing facility: By using inductive flow and temperature measure-ments, approximately 250,000 liters of milk are accepted hourly. The raw material is extensively monitored as it under-goes further processing.

• PROFIBUS fieldbus couplers form the interface be-tween the field level and the control system

• The WAGO-I/O-SYSTEM 750 is specified thanks to its high I/O integration density

• Complete integration of the WAGO-I/O-SYSTEM into the graphical display and documentation tool

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A Safe Bet:Ex and Non-Ex in One SystemThe Eggersmann Group of Marienfeld, Germany relies on the WAGO-I/O-SYSTEM in all Ex and Non-Ex areas of their dry fermentation systems.

■ Organic waste — not valuable food or feed stock: With their Kom-poferm process, the Eggersmann Group has developed a method for generating biogas from organic waste and grass clippings through dry fermentation. Their highly modular systems are so flexible, they can be set up within just 20 working days. This rapid installation and commissioning is made possible thanks to standardized construction using modified, standard overseas shipping containers, as well as other savvy design elements. Since biogas production automatically raises questions about Ex protection, safety becomes a primary focus during system planning. Eggersmann relies on the WAGO-I/O-SYS-TEM 750 at the automation level, as well as all Ex and Non-Ex areas.

The systems, manufactured in Bad Oeynhausen, Germany have earned an excellent reputation due to their high reliability, as well as their low investment and operating costs. This is evident in the fact that just a small fraction of the power generated goes to private consumption by the owner. In addition, the highly efficient dry fermentation process also

The vital control technology is installed in decentralized ATEX control cabinets so escaping gas does not paralyze the entire system.

produces fermentation residue, which, due to its structural characteris-tics and low water content, can be further processed into high-value compost. “I use the substrates myself as a slow-release fertilizer and to improve the soil,” comments Volker Niederfranke. The electrical en-gineering department manager at Eggersmann plant, who is also a part-time farmer, is also well acquainted with biological relationships thriving in the area’s native soil.Eggersmann’s dry fermentation methods are, by their own admission, technologically light years ahead of anyone else. The firm’s customers include composting and waste management facilities. “The source ma-terial is abundant and does not have to be specifically grown for this use. And, that is what makes this method so interesting,” explains Nie-derfranke. No productive farmland is used to supply biogas systems, nor does the process rely on the costly process of importing vegetation. Instead, refuse from organic waste collection bins, and other biomass that accumulates from the upkeep of gardens, parks, cemeteries or me-dian strips, goes into the fermenter.

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Compact design, easy on-site installations and commissioning: Eggersmann’s systems are engineered to require little space while operating effectively — even for small-scale waste disposal operations.

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Two fields of application, one system: the WAGO-I/O-SYSTEM 750 is used by Eggersmann in all Ex and Non-Ex areas.

■ Using Biogas Efficiently“Those operating our systems want to generate renewable energy from organic waste as efficiently as possible. Therefore, we work at the process level with a high degree of automation and very little manual labor,” explains Ralf Schröder of the firm’s electrical engineering design and automation technology department. And according to Schröder, this supports Eggersmann’s current marketing strategy. While the pro-cess itself runs with precise control, loading and emptying the dry fer-menter occurs on site using wheeled loaders. In order to maintain the favorable economics of generating power from the small amounts of organic waste created by local businesses, Eggersmann developed the Smartferm in 2007. These are compact systems with only four fermen-tation units, which are primarily designed to run in connection with a combined heat and power unit (CHP) for decentralized, local genera-tion of electricity and heat.Eggersmann primarily uses the WAGO-I/O-SYSTEM 750 to collect Ex i signals in close communication with the central control and a safety PLC. This technology is necessary, so that the system can be monitored even if there is an interruption. Schröder explains, “CH4 (methane), is always important to consider in biogas systems.” If the concentra-tion increases in locations such as the ductwork, creating an explosive mixture, methane sensors will detect it, evaluate it and report it to the safety controller. This initiates defined, preventive measures, like forced ventilation or disconnecting the voltage from sensors and actuators in affected operating areas.

■ Monitoring Processes Safely and SecurelyThis deliberate disconnection would inevitably result in a complete lack of ignition sources; however, that does not mean that the system will not be monitored. It should be noted that the bacteria involved in biologi-cal processes cannot be interrupted as easily — even by PLC. “For that

reason, we can’t simply shut down the entire system because we don’t know where the biological process is at any given moment,” explains Schröder while gesturing at the strategically located ATEX control cab-inets. These decentralized cabinets house the WAGO-I/O-Ex control components that are distributed throughout the system.In this case, the WAGO-I/O-SYSTEM 750 assumes the central func-tions within the vital measuring and control technology. While compo-nents without Ex protection remain powered off, systems with corre-sponding ATEX intrinsic protection continue operation. To prevent these separate sets of requirements from leading to separate automation systems, WAGO offers a solution with the WAGO-I/O-SYSTEM 750 that integrates Ex and Non-Ex I/O modules into the same node. Al-though the two I/O types can be distinguished within a node by white and blue module housings, their unique functionalities share the same foundation.

■ Using One Platform ConsistentlyThanks to this foundation’s structure, the WAGO-I/O-SYSTEM 750 enables consistent functionality on a single device platform. The same applies to the use of software tools. The blue, intrinsically safe Ex I/O modules are suitable for all the sensors and actuators located in Ex zones 0, 1 and 2. This range within just one series offers a long list of advantages — from design to commissioning — for mechanical and systems engineers.Because users are already familiar with the system, their knowledge will enable them to implement applications that are substantially less complicated despite the inclusion of Ex protection. The need for this type of versatile solution is common on the international market, for example, when identical processes are used but vary in execution. One country may call for the use of solvents in a particular process, but another may not. Instead of designing an entirely new system, the af-

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• The WAGO-I/O-SYSTEM 750 manages central functions within the system’s measuring and control technology.

• Ex and Non-Ex modules operate together in a single node.

• The WAGO-I/O-SYSTEM communicates according to IEC 60870 and IEC 61850 for remote maintenance.

“We can’t just shut the system down,” emphasizes Ralf Schröder.Fully developed technology is needed, “because we export a lot of systems,” states Volker Niederfranke.

fected components are simply swapped thanks to the consistency of the WAGO-I/O-SYSTEM. This flexibility ensures that machines and systems can be easily tailored to market conditions and national regulations, which improves competitiveness through reduced engineering times and faster delivery.

■ Better Control of SystemsWith just one system, it is also easier to take an in-depth look at the details. “We really have to be in control of the products we use. And they have to to up to the job, because we export a lot of systems,” emphasizes Niederfranke. “Technical reliability is of paramount

importance to us,” summarizes Schröder. It is then equally advan-tageous for Eggersmann’s vendors to have international expertise, like WAGO does, so that replacement components can be readily available on site.However, the automation expertise itself remains proprietary to the company in Bad Oeynhausen. “Biogas systems have highly special-ized process technologies. If there are interruptions, then the entire process must be thoroughly analyzed,” explains Niederfranke, re-ferring to the extensive use of telecontrollers on the biogas systems.

“We use those primarily for troubleshooting,” he adds. The WAGO systems offers standardized communication protocols for this accord-ing to IEC 60870 and IEC 61850. In the Ex protection area, the fieldbus-independent control system shines due its compact footprint and free programmability according to IEC 61131-3, as well as its ability to flexibly create new applications and its open communica-tion protocols. All components feature WAGO’s gas-tight, mainte-nance-free spring clamp connections and high vibration resistance to dramatically improve system uptime.

Text: Konstantinos Chatzis, WAGOPhoto: WAGO

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Alternative Solutions: Since it is equipped with the X-COM®S-SYSTEM with the “Ex nA” protection type, complete modules can be exchanged more easily and signifi-cantly faster. Expensive on-site installations for offshore oil platforms is now a thing of the past.

■ Offshore oil platform repair and maintenance is expensive. In most cases, a specialist has to be flown in as fast as possible via helicop-ter, and then often has to perform complicated repairs under extreme conditions. WAGO’s X-COM®S components now offer an alternative:

Less Downtime on Oil PlatformsFaster and easier replacement in Ex zone 2: Using the X-COM®S-SYSTEM with “Ex nA” protection type provides the integration of completely finished modules.

Equipped with the first pluggable rail-mounted terminal blocks that pro-vide the “Ex nA” protection type, complete modules can be exchanged much easier and significantly faster than before. Expensive on-site in-stallation will become a thing of the past.

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Clearly marked components facilitate secure and reliable installation, without the need for specialists.

A prominent European drilling equipment manufacturer sought a maintenance-friendly and economical alternative, leading it to de-velop the following criteria:

- Reduce the downtime of sensitive equipment- Enable component replacement without requiring a specialist- Minimize the time and expense for system wiring- Reduce the potential for errors during installation- Use Ex-protected components.

■ Prefabricated Components Simplify InstallationWAGO’s approach to the solution is based on preventing com-prehensive on-site installation and wiring. With the X-COM®S-SYS-TEM, the oil rig manufacturer gains the possibility of incorporating completely finished modules. WAGO prefabricates the pluggable rail-mounted terminal block system at the factory, so that system wir-ing on the drilling rig is straightforward and fast. To eliminate the need for systems specialists to perform on-site service calls, WAGO incorporated five additional improvements:

- By mechanically coding groups having the same number of poles, mismating can be prevented.

- In addition, a shorter, factory-mounted lock makes accidental dis-connection even more difficult. The female plug can now only be removed by using a tool. This provides additional safety — partic-ularly for sensitive applications in hazardous areas.

- Additionally, the mechanical structure provides touch-proof protec-tion of the voltage-carrying components when disconnected.

- Going even further, WAGO expanded the marking possibilities to clearly identify replacement components. In fact, marking strips can be printed with up to three lines of information for greater wiring accuracy.

- And, the module marking can be generated directly from the system documentation for initial installations or alternations.

■ Ex Certification for a Pluggable Rail-Mounted Terminal Block SystemWAGO’s X-COM®S-SYSTEM is the first pluggable rail-mounted ter-minal block system that carries the ATEX/IEC certification with the “Ex nA” protection type for use in Zone 2 hazardous areas. The pluggability simplifies installation — even in extrmely tight spaces. The clamping units are securely protected from mechanical loads by a strain relief plate and a cable tie. The rail-mounted terminal block system employs maintenance-free and vibration-resistant CAGE CLAMP® S connection technology. X-COM® S can be combined with the TOPJOB® S rail-mounted terminal block system to integrate Ex and Non-Ex signals into one automation system.

Text: Benjamin Böhm, WAGOPhoto: Getty Images by Digital Vision, WAGO

• The X-COM®S-SYSTEM is the first pluggable rail-mounted terminal block system with ATEX/IEC certification.

• Pluggable modules simplify and expedite system wiring.

• The highly detailed marking strips, with up to three printed lines of information, ensure greater wiring accuracy.

WAGO’s modular designs mean that important system components can arrive on site as pre-tested and pre-fabricated parts for final installation, and that replace-ment parts can be stored at the point of installation as well.

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Go with the FlowInstallation and parameterization made easy: CODESYS libraries from WAGO reduce programming expenses and simplify system operations.

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■ The demands for automation in water resource management and process technology are diverse. One reason for this is the variety of system types that extends from small, decentralized units through larger, centralized ones up to package units. Another reason is the increasing complexity of programming and networking. During com-missioning or system adaptations, it is not unusual to generate applica-tion-specific programs for controlling and visualization. However, these services are time-intensive and costly for system suppliers. A possible workaround: CODESYS libraries with prepackaged system macros are available for WAGO-I/O-SYSTEM 750 users, which significantly reduce both programming time and expenses while simplifying system operations.

In water resource management, reliable and safe system operation are the highest priorities. At the same time, pressure is mounting to keep costs low. This has driven companies to constantly seek innova-tive solutions that reduce costs across the board. Beyond life cycle costs, expenses related to installation, commissioning and on-going maintenance are in the crosshairs during the planning and design of new systems, as well as plant retrofits and upgrades. An additional concern in process automation is the ability to react quickly to cur-rent, specific demands.For system integrators, this means that standard systems must adapt quickly to customer-specific conditions and do so with minimal ex-pense. This contrasts with system operators’ needs for intuitive oper-ation of the process controls. The new “Water” and “Process” func-tion libraries from WAGO fulfill both these demands in combination with the I/O system.

■ Scalable HardwareProcess technology integration requires the connection and network-ing of any number of different sensors and related components. In addition to standardized analog and digital signals, these compo-nents often have specialized interfaces that have to be operated by the automation systems. Networking occurs via various bus proto-cols and communication media; in water resource management, this generally means ETHERNET, PROFIBUS DP, MODBUS or a remote protocol based on IEC 60870-5-101/104. Even connecting the protection technology, such as the for the medium-voltage level for a clarification unit according to IEC 60870-5-103, is among the many challenges. In addition, there are signals from measurement technol-ogy that are protected by specific protocols and must be recorded using serial interfaces that are supported by function blocks. The use of radio technology and integration in potentially explosive areas complete the list of demands.The modular, fieldbus-independent WAGO-I/O-SYSTEM 750 offers a suitable solution that supports applications from simple regulated measurements up to the automation of entire clarification systems. Extremely versatile, control can be individually tailored to a specific purpose via different I/O modules, as well as adapted to an entire system. In fact, the system boasts 500+ different modules, meaning almost

any device can be connected to the universal system. Programming occurs via CODESYS using prominent languages that comply with IEC 61131-3. Alternatively, a Master-Slave connection is possible with the higher-level PLC or control system assuming supervision and control monitoring.

■ Low Programming ExpensesWAGO developed the “Water” and “Process” CODESYS libraries in close collaboration with specialists in water and wastewater treatment and process technology. The fundamental insight: A complex problem can be solved by assembling a number of simple applications into a comprehensive solution. Thus, simplicity is brought to the forefront. The comprehensive “Water” and “Process” libraries have pre-fabricated system macros for many typical applications. These include function blocks for pump and fan control, ventilation, limit value monitoring, function blocks for counters, rakes and controllers, as well as process technology blocks for motors, mixers and stirrers. In addition, they con-tain function blocks like PID controllers, which allow easy expansion of available system macros.The system macros ensure that the user only has to configure the cor-responding application, i.e., assign the data points and system param-eters, and can then directly commission the system. Comprehensive programming, which is necessary for conventional systems, can be bypassed. This can dramatically reduce costs and commissioning time; for additional economy, the reuse of macros simplifies standardized solutions. Keeping this in mind, WAGO offers the best possible custom-er service because more complex tasks, such as pump function blocks, are individually tailored to suit a user’s needs. In all, the libraries con-tain approximately 50 function blocks for water resource management and process technology.

Hardware and software in harmony: Easily regulated measure-ments and automation of entire clarification systems can be achieved by using CODESYS function blocks in combination with the WAGO-I/O-SYSTEM 750.

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■ Superior Customer ServiceCommissioning a system takes place using a logical, web-based user interface. The user can set all parameters there and perform any addi-tional application configurations. Visualizations are also available for components like pump elements and motor controllers, without requiring extensive amounts of programming. A webserver is integrated into the control, which graphically formats the system technology (almost com-pletely automatically), displays current component parameters and en-ables convenient operation — for example, using operating panels from WAGO’s PERSPECTO® family. The only thing that the user needs is a standard web browser.In order to obtain the standardized system macros, the users simply connect with their local WAGO sales office and register for the system. Shortly afterward, they will receive a link that enables the download of the “Water” and “Process” libraries as part of a comprehensive, free software package. This also includes function blocks like Bluetooth® communication, TO-PASS® telecontrol connection, web connectors, data loggers and energy measurement tools. We constantly update and ex-pand our library as a direct result of closely interacting with customers to address their needs.

■ Lower Cost, Greater EfficiencyThe new CODESYS “Water” and “Process” libraries, in combination with the I/O system from WAGO, enable users in water resource management, process technology and water-intensive industries to implement cost-efficient and consistent solutions for highly complex and technical systems, without incurring large programming expens-es. The system macros streamline installation and commissioning of automation components, while simplifying system adaptations to re-duce overall project times. System operators benefit from web-based visualization, thoroughly tested function blocks and standard engi-neering tools, as well as from a reduction in errors during commis-sioning and operation. Standardizing the process ultimately contrib-utes to significant money and time savings, increased system uptime and the reduction of training expenditures.

Text: Kay Miller, WAGOPhoto: Fotolia, WAGO

• The “Water” and “Process” CODESYS libraries significantly reduce programming expenses.

• System macros simplify installation, commissioning and modificaitons.

• Prefabricated visualization elements provide pro-fessional displays at the push of a button.

Parameterization instead of programming: CODESYS libraries from WAGO consist of fully developed function blocks for many typical appli-cations, such as controls for pumps and valves, engines or ventilation.

Practical software function blocks for process tech-nology applications: The “Water” and “Process” libraries, available free of charge, can be specifically adapted to fit the most varied demands.

Professional displays with the press of a button: CODESYS librar-ies from WAGO include not only the actual function blocks but also pre-packaged visualization elements.

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■ The WAGO-I/O-SYSTEM 750 XTR is the automation system for extreme demands. Maritime shipping and the entire offshore sector are definitely among the most taxing environments. So it comes as no surprise that the 750 XTR Series has already received approvals from Germanischer Lloyd, Underwriters Laboratories and the Na-tional Radio Research Agency (RRA, South Korea).Temperatures between -40 °C and +70 °C, vibrations up to 5g, and EMC stability according to EN 60870-2-1 — the WAGO-I/O-SYSTEM 750 XTR is designed for the most demanding applications. And it does so economically, by eliminating the need for expensive specialty solutions, like air conditioning and protection circuits.

■ Extreme Resistance to Adverse Weather ConditionsThe error-free start-up of automation systems, after a power outage for example, can be critical at very low temperatures. Thus, the WAGO-I/O-SYSTEM 750 XTR starts without a hitch — even at a frosty -40 °C, and it does so without pre-warming. At the other end of the temperature scale, it is easy to reach +70 °C when a control cabinet is placed in direct sunlight. Even in this case, the XTR version of the I/O system is unphased.

■ Extreme Resistance to Impulse Voltage and InterferenceWith an increased isolation of up to 1 kV (< 60 V, class VW1) and 5 kV (>= 60 V, class VW3) of impulse voltage, according to EN 60870-2-1, the WAGO-I/O-SYSTEM 750 XTR ensures continuous, smooth operation because the electronics are protected against malfunctions. This optimized EMC behavior also prevents nega-

SEAWORTHY:GL APPROVAL FOR THE WAGO-I/O-SYSTEM 750 XTRCertified safe and reliable: KC, UL 508 and GL approvals verify that the WAGO-I/O-SYSTEM 750 XTR is ready for marine applications.

tive electromagnetic interference emissions, permitting use in direct proximity to highly sensitive third-party systems. These characteris-tics completely satisfy stringent demands for dielectric strength and EMC interference immunity, including requirements posed by tele-control devices and for use on the bridge of ships in close proximity to the compass (“Compass” certification from BSH).

■ Extreme Vibration Resistance up to Accelerations of 5gIncreased vibration- and shock-resistance are required, particularly when the modules are located in direct proximity to high-perfor-mance maritime diesel engines or power circuit breakers. With vi-bration resistance of 5g, which corresponds to an acceleration of 50 m/s², and resistance to continuous shocks of 25g, the WAGO-I/O-SYSTEM 750 XTR sets the bar extraordinarily high.

■ Extreme Flexibility in UseBeing based on the proven WAGO-I/O-SYSTEM means the XTR provides users with several other industry-leading features. The XTR is extremely compact, boasts a finely modular and fieldbus-in-dependent design and has a tremendous amount of application flexibility. With approvals from KC, UL 508 and, in particular, GL, the WAGO-I/O-SYSTEM 750 XTR is also well equipped for marine applications. Other approvals will follow.

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■ Flexibility, service, engineering: there are a number of advantages to creating an entire system from individual, standardized modules — even for the process industry. Jürgen Schäfer and Ulrich Hempen re-alize, however, that the modularization of highly complex systems and processes is anything but an easy sell. In an interview, the Managers of Sales and Market Management reveal what this involves.

■ The process technology branch is discussing modular system design. What are the reasons for this?Jürgen Schäfer: The traditional process technology system is, rela-tive to types and quantities of products, extremely inflexible and thus too expensive for market demands that are changing faster than ever. This significantly impacts food products, cosmetics and pharmaceuti-cals. New products, which in these particular sectors are needed in amounts influenced by strong regional fluctuations caused by popula-tion changes and globalization, are being introduced to the market in increasingly shorter time frames.Ulrich Hempen: This then necessitates very flexible suppliers — even

Module MastersDIMA – Decentralized Intelligence for Modular AggregatesWAGO’s new method for engineering modular, process technology production systems.

in the chemical sector. These conditions directly affect the process technology used in the systems, they have to be scalable in order to react to changes. However, scalability can only be achieved by the modularization of systems. This likewise means a modular design for automation that must adapt to these changes, while achieving a high level of hardware scalability.

■ As a sponsor of this year’s NAMUR Annual General Meeting, WAGO introduced a design of this type for the modular automa-tion of process systems. Where do you see substantial advantages for users?Ulrich Hempen: In 2013, a NAMUR task force defined the chal-lenges for modular automation. The NAMUR recommendation “NE 148” contains requirements for automation technology in modular system design. We strictly adhered to these demands, and with our DIMA design, introduced a solution for modular automation using decentralized intelligence. The essential advantages for users are found in the system’s open architecture.

Jürgen SchäferBusiness Management Sales, WAGO

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Jürgen Schäfer: In this manner, intelli-gent modules can be flexibly integrated into, or coupled with existing systems — just like the operating level is connected to HMI, Batch, Alarm Management and other higher-level tools. An additional advantage for users is cost-efficient en-gineering. Modules can be input and designed offline using a module descrip-tion language.

■ What core elements does DIMA have?Jürgen Schäfer: DIMA stands for “Decentralized Intelligence for Modular Aggregates” and is a method for engineering modular pro-duction systems using process technology. It specifies a standard com-munication architecture for connecting individual modules within the process technology and the description method for these modules. The primary challenge is systematically networking the individual modules to the system as a whole.Ulrich Hempen: The modules in the DIMA design are not integrat-ed using individual variables, as is conventionally done; instead, in-tegration is based on their individual services according to DIN EN 61512. For example, this can relate to a blender, and its designated

service would be “mixing” with the associated parameters. In addi-tion, each module has its own visualization, which is communicated to a higher-level system via specialized semantics. The higher-level system thus functions using the same visualization elements for all modules. Each module only communicates the part of the visualiza-tion that corresponds to it. The NAMUR task force 1.12 is currently working on this library. DIMA has thus consolidated the following elements: standardized communication in the network, open service interface for the module, open visualization interface for the mod-ule and a digital module description method (MTP). In this context, design engineering software should be able to design both the indi-vidual module and the entire system.

Ulrich HempenManager of Market Management Industry & Process, WAGO

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■ What does DIMA change in application planning for package unit suppliers?Jürgen Schäfer: The supplier of package units or modules designs and programs a system, and subsequently generates a digital mod-ule description — very similar to a printer driver. We call this MTP in the DIMA concept. The application designer uses suitable designing software. This type of tool is not only used for programming individual controllers, but also for designing the controllers in the system network; it then generates the digital module description for the subsequent sys-tem design.

■ How does a systems engineer plan an entire system?Jürgen Schäfer: The system engineer inputs the different module descriptions as “MTP” for the decentralized, process technology modules into the design tool and plans the entire system. Then the engineer generates the communication connections between mod-ules by determining all of the services that should be exchanged. Executable services of a process technology module — for exam-

ple, tempering or mixing and the associated parameterization — are declared to the design tool via module description. The service connections to the higher-level tools can be designed for batch or continuous operation. The transfer parameters for the higher-level HMI are also created using the design engineering software.

■ Is the new concept only designed for WAGO systems?Ulrich Hempen: No. DIMA is an open concept for modular au-tomation. It is a solution that should establish itself as an open standard. In fact, NAMUR is a big supporter of this. By using the WAGO automation product portfolio, we have the optimum com-ponents for use with DIMA.

■ What are the advantages for a package unit supplier who de-cides to use WAGO products?Ulrich Hempen: First of all, WAGO places extremely high demands on the quality of its products. This quality assurance is the decisive factor that has led to high acceptance of our products in the global

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process industries. And, this applies to both the smallest terminal block as well as our comprehensive automation systems. WAGO offers package unit suppliers an expansive product portfolio for au-tomating their systems.Jürgen Schäfer: In addition to quality, acceptance is also due to high scalability, particularly in the most demanding environments like Ex zones or within expanded temperature ranges of -20 °C to +60 °C. With the WAGO-I/O-SYSTEM 750, we have further expanded the operating temperature range from -40 °C to +70 °C. Maritime cer-tifications GL, ABS, DNV, LR, BV, KR, NKK, PRS and RINA, have also been incorporated. It is also possible to connect Ex i signal circuits within a single system. WAGO automation is supplemented by modern power supplies in various performance categories with redundancy modules, a complete offering of relays and, specifically for decentralized applications, compact signal conditioners with an installation width of just 6 mm. Not to mention a comprehensive portfolio of rail-mounted terminal blocks. Module producers can thus

turn to WAGO for every product need within their control cabinets. WAGO’s greatest advantage as a “one stop shop” for automation and electrical interconnection components in control cabinets is that our components meet the highest quality standards.

Text: Anja Jakimenko, WAGOPhoto: WAGO

• The DIMA concept is based on the NAMUR rec-ommendation NE 148.

• Modules are integrated based on their individual services according to DIN EN 61512.

• Intelligent modules can be flexibly integrated into, or coupled with, existing systems.

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Water Must Flow under all ConditionsThe WAGO-I/O-SYSTEM 750 XTR: Automation for pumping stations, where other systems reach their limits

■ Even under extreme conditions: reliable and safe system operation is always the highest priority in water resource management. This particularly applies to pumping equipment. Pumps should reliably en-sure that water is supplied throughout the distribution network to con-sumers, that irrigation water is provided for the cultivation of fields, or that the ground water level is lowered to keep open-pit mines from flooding. In cases like this, the WAGO-I/O-SYSTEM 750 XTR readily ensures reliable operation where conventional automation systems hit their limits due to extreme weather or environmental conditions.

For many applications in the water management sector, the WAGO-I/O-SYSTEM 750 XTR’s strengths make it an ideal solu-tion compared to standard automation systems. This is especially important for pump installations outside of temperate climates in

countries like Russia or Kazakhstan, where winter temperatures can reach negative double digits in Celsius. It’s equally important for applications in the desert regions of China, Australia or America, where the blazing sun beats down on control cabinets, making their temperatures soar.

■ Automation System for a Harsh EnvironmentThe extreme variant of the modular, fieldbus-independent WAGO-I/O-SYSTEM 750 was developed specifically for these types of harsh climates and conditions. As such, the 750 XTR Series’ main feature is its extraordinary combination of dielectric strength paired with high levels of resistance to extreme weather, interference and vibrations. Due to the expanded temperature range, high operation-al reliability is guaranteed, even in conditions ranging from -40 °C to +70 °C. The system’s strengths enable it to eliminate expensive and space-consuming insulation and climate control devices, like air conditioners and heaters, leading to the use of smaller control cabinets or terminal boxes. Omitting separate climate control sys-tems also means lower energy, wiring and maintenance costs, as well as fewer potential fault points.In regions with high fluctuations between day and night tempera-tures, dew can negatively impact the equipment uptime. This is particularly critical for intermittent operations in which pumps only run part time, and where condensation can develop from equip-ment cooling during downtime. However, this is a non-issue for the WAGO-I/O-SYSTEM 750 XTR, as its controllers, couplers and I/O modules are protected against short-term condensation formation according to class 3K7 (IEC EN 60721-3-3).

■ Shock and Voltage ResistantAn additional characteristic of the WAGO-I/O-SYSTEM 750 XTR is an increased mechanical loading capacity, which is extremely important to mining industry. There are high numbers of pumps in underground and open pit mines that are used to lower ground-water levels. Strong impacts and vibrations caused by explosives and heavy vehicles are daily occurrences in these locations. XTR features extreme vibration resistance of 5g according to DIN EN 60068-2-6 (corresponding to an acceleration of 50 m/s2), shock resistance of 15g (150 m/s2) and a resistance to continuous shocks of 25 g (250 m/s2) according to IEC 60068-2-27. This per-formance enables the automation system to be mounted in direct proximity to equipment that generates strong vibrations or impacts.

By using the WAGO-I/O-SYSTEM 750 XTR, expensive and space-consum-ing climate control components, like air conditioners, heaters or insulation, are not necessary, leading to the use of smaller control cabinets or terminal boxes.

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The WAGO-I/O-SYSTEM 750 XTR is the right solution for de-manding use in external stations like wells, pumping stations, pipelines and disposal sites.

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With an isolation rating per EN 60870-2-1 up to 1 kV (< 60 V, class VW1) and 5 kV (≥ 60 V, class VW3) of impulse voltage, the WAGO-I/O-SYSTEM 750 XTR is reliably protected against surg-es resulting from switching operations or lightning strikes in close proximity to a pumping station. An additional advantage is the system’s reduced interference emissions and increased interfer-ence immunity. This makes it ideal for telecontrol applications that have intensified hardware demands. Therefore, the 750 XTR Series Telecontroller supports the telecontrol protocols commonly used in water resource management according to IEC 60870-5-101/-103/-104, IEC 61850-7, IEC 61400-25 and MODBUS.

■ Large Memory CapacityDue to requirements for continuous documentation of failures and measurement data, including water level and throughput measure-ments at rivers or dams, another feature of the WAGO-I/O-SYS-TEM 750 XTR is especially useful: the SD memory card slot in the ETHERNET Controller (750-880/040-000 or the telecontrol ver-sions 750-880/040-001). The data memory can be expanded up to 32 GB, providing reserves for all applications.

■ Water Library with Complete Pump ControlsWAGO offers comprehensive CODESYS function libraries specif-ically designed for water and process technology applications. These substantially reduce programming expense and simplify system operations. Prefabricated system macros for many typi-cal applications are found in these free libraries, which include visualization elements. Thus, users only have to configure a pump application, for example, and can then directly commission the sys-tem. Programming expenses, which are required for conventional systems, can be significantly reduced. Commissioning itself is also

accelerated and markedly more cost-efficient. WAGO also offers comprehensive customer service, including product experts who can adapt complex tasks to meet an individual user’s needs.

■ ConclusionThe WAGO-I/O-SYSTEM 750 XTR is a perfectly tailored solution for demanding applications in external stations like wells, pumping stations, pipelines and disposal sites that are exposed to extreme climate influences, vibrations, shocks and surges. This robust vari-ant of the proven WAGO-I/O-SYSTEM 750 not only has the same fundamental advantages of greater flexibility, modularity and a compact size, but is also especially resistant to temperatures, inter-ference, voltage spikes and vibrations. This results in many possible uses within and beyond water resource management.

Text: Kay Miller, WAGOPhoto: WAGO

• The WAGO-I/O-SYSTEM 750 XTR is particularly suited to many applications in water resource management

• An SD card slot is useful for continuous documentation of failures and measurement data

• WAGO offers CODESYS libraries specifically for the water and process sectors.

The robust variant of the proven WAGO-I/O-SYSTEM 750 not only has the same fundamental advantages of greater flexibility, modularity and a compact size, but is also especially resistant to temperatures, interference, voltage spikes and vibrations.

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To ensure safe operation of a basic relay, voltage levels must remain above the response voltage and below the release voltage. Capaci-tive coupling, sensor power supply and leakage current are common reasons why a voltage level sometimes fluctuates between the base load voltage and the release voltage. Proper operation can no longer be ensured in these cases.The socket with a miniature switching relay and integrated base load module (857-358/006-000) ensures that a greater load is applied to the coupling to reduce voltage at the relay module input. This guar-antees that the voltage level remains below the release voltage. A version of the socket with a miniature switching relay and an integrat-ed base load module featuring gold contacts (857-368/006-000) is also available.

SOCKET WITH MINIATURE SWITCHING RELAY AND BASE LOAD MODULELine capacities, 2-wire sensors and leakage current: WAGO’s socket with a miniature switching relay and base load module provides safe and dependable operation at voltage levels below the release voltage for diverse applications.

The 750-1425 PTC Digital Input Module features eight channels to connect PTC thermistors according to DIN 44081 and DIN 44082 for thermal monitoring (overload protection) of machines or systems. Up to six PTC thermistors can be connected in series per channel. Upon exceeding a nominal response temperature during a wire break or short circuit, a bit is set in the input process image of the 12 mm wide module. One green and one red status LED per channel in-dicate an overtemperature warning or wiring errors on the PTC digital input module. Field and system levels are electrically isolated.The 4- and 8-Channel RTD Analog Input Modules enable direct con-nections of Pt and Ni resistance sensors. A sensor error (short circuit, wire break or out-of-measurement range) is indicated by a red sta-tus LED. The modules can be freely configured using WAGO-I/O-CHECK or GSD files. When using the 8-Channel Analog Input Mod-ule (750-451), connection is made using 2-wire technology; when using the 4-channel analog input module (750-450), 2-, 3- or 4-wire technology is employed. Potentiometers are connected via 3-wire

INTEGRATED PTC THERMISTOR AND RESISTANCE SENSORSNew 8-Channel PTC Digital Input Module, as well as 4- and 8-Channel RTD Analog Input Modules expand the functionality of the WAGO-I/O-SYSTEM 750.

technology Multiple setting options, as well as high resolution and accuracy, characterize these modules.

New 8-Channel PTC Digital Input Module, as well as 4- and 8-Channel RTD Analog Input Modules provide additional measure-ment options for the WAGO-I/O-SYS-TEM 750.

Ensuring safe operation below the release voltage: socket with miniature switching relay and base load module, available with (857-368/006-000) and without (857-358/006-000) gold contacts.

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■ The future of the process industry belongs to both modular systems and increasingly decentralized automation. In many cases, decentral-ized designs are better suited because continuous processes, which are often be better controlled and scaled, can be built from batch process-es by using modularization and miniaturization. Intrinsically safe I/O modules, such as those found in the WAGO-I/O-SYSTEM 750, are the foundation for modular automation in the process industry.

Modular systems will play a central role in the future. Due to miniatur-ization in individual process technology modules, demanding batch processes can be converted into scalable continuous processes. By supplementing or replacing certain modules, manufacturing firms can react more quickly to the market while simultaneously producing min-imum quantities much more efficiently. The efficiency and flexibility found in this type of system design can be further increased — in con-trast to current systems and automation hierarchies — if the individual modules can manage their own automation functions.This relieves a substantial burden from the control system, freeing it to regulate its intended function: namely controlling the process, for example, by monitoring formulas and analyzing process data. The actual control takes place decentrally at the modules, which are con-nected to the control station via a fieldbus system. The modules report to the control system and receive their commands based on their avail-able functions. The implementation of the automation tasks ultimately occurs autonomously. The interface to the field level is formed, as it is currently, by the I/O modules in control.

■ Sleek Shape, Large ImpactWhen selecting a suitable system, many criteria must be considered. In planning for increasing modularization — and thus miniaturization — the actual form factor of the modules themselves is as important to consider as other variables such as electrical engineering data, po-tential environment and the operating conditions. A compact design quickly pays for itself because numerous signals must be processed in the smallest footprint, and the space for controlling the process itself is becoming incredibly valuable.

Intrinsically Safe Field Level with Decentralized IntelligenceEstablishing the foundation for modular automation in the process indus-try: the WAGO-I/O-SYSTEM 750 and its intrinsically safe I/O modules

With installation widths of 12 mm and 24 mm, the intrinsically safe I/O modules from the WAGO-I/O-SYSTEM 750 fulfill these de-mands. They are among the “blue bloods” of the process industry, and supply controllers with all of the necessary information from the field level. So that two basic worlds — “Ex i” and “Non Ex i” do not require two separate automation systems, the WAGO-I/O-SYSTEM 750 enables both to reside in the same node; “Ex i” and “Non Ex i” modules can be operated together on one PLC. Although the two I/O types can be distinguished within a node by white and blue module housings, their unique functionalities share the same foundation.

■ Reliable and CertifiedIn particular, certification for installation in Zone 2 (ATEX/IECEx/ANSI/ISA) and in an Ex-d housing or in pressurized Ex-p housing, make the WAGO-I/O-SYSTEM a highly flexible solution. From pres-sure transmitters to a position controller, field devices are directly con-nected without additional units such as Zener barriers or isolation amplifiers. The entire system is also certified for use worldwide by authorities including: ABS (American Bureau of Shipping, BV (Bureau Veritas), DNV (Det Norske Veritas), GL (Germanischer Lloyd), KR (Korean Register of Shipping), LR (lloyds Register), NKK (Nippon Kai-ji Kyokai), PRS (Polski Rejestr Statkow) and RINA (Registrato Italiano Navale) among others.Satisfying the requirements for these strict maritime certifications also guarantees important advantages to the process industry such as high vibration resistance and greater resistance to electrostatic discharg-es (ESD), voltage surges and low frequency interference. A larger voltage fluctuation range, from -25 % to +30 %, ensures additional safety. In almost every maritime test, the system being evaluated must function without fault both during and after the test to meet evaluation criterion A. In the industrial sector, in contrast, evaluation criterion B is overwhelmingly preferred: in this case, the system only has to function error-free after the test.In addition to comprehensive certification, project designers also want a system that supports international fieldbus standards, like PROFIBUS DP, Modbus, TCP/UDP, Modbus RTU or CANopen. Both

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criteria are important in order to globally standardize the design of process modules, which then facilitates data exchange. Due to the fieldbus-independent design of the WAGO-I/O-SYSTEM, all relevant protocols are supported. In the case of the PFC200 Controller, they are even united into a single device — including web visualization.

Text: Benjamin Böhm, WAGOPhoto: Fotolia, WAGO

• Mixed design with Ex and Non-Ex modules operating on one PLC.

• Intrinsically safe modules have installation widths of only 12 mm and 24 mm.

• Certification for installation in Zone 2 provides tremen-dous application flexibility for the WAGO-I/O-SYSTEM.

Modular systems will play a central role in the future. Due to miniaturization in individual process technical modules, demanding batch processes can be converted into scalable continuous processes.

Guaranteed safety in just 24 mm: The 4-Channel Digital Input Module (750-663) unifies functional and intrinsic safety in one compact module.

High integration density in only a width 24 mm: The 8-Channel Digital Input Module (750-439) receives NAMUR binary signals from sensors operating in Zone 0 and 1 hazardous environ-ments.

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■ The new, integrated e!COCKPIT engineering software suite supports the entire development process for WAGO automation components, from software design up through machine operation. The established CODESYS 3 industrial standard platform forms the basis for e!COCKPIT.

This foundation provides users with the ability to quickly navigate the software and readily command the control software as they are already familiar with it. The software suite is also characterized by innovative operation. In fact, familiar interaction mechanisms have found new uses in automation: For example, context-sensitive menu prompt-ing offers only functions that are relevant to task at hand. This approach significantly boosts productivity for both software engineers and electricians. Combined with the PFC200 Controller and the WAGO-I/O-SYSTEM 750, users can now implement and run their automation appli-cations more quickly and cost-effectively.On the hardware side, even complex topologies can be easily and efficiently handled — from an I/O module on up to the entire network. e!COCKPIT capabilities include application planning, configuration, parameterization and programming based on IEC 61131; this enables the design of modern visualization tools and target-oriented commissioning. End-to-end data storage and a uniform ap-pearance help simplify complex projects while pinpointing errors more quickly.The pre-release of e!COCKPIT will be available online on January 30, 2015.

Text: Dr. Sven Kreft, WAGOPhoto: WAGO

: The engineering software suite for the world of WAGO automationFrom software design to machine operation, from an I/O module to the entire network, from a software engineer to electrician: One engineer-ing software suite for any task.

WAGO uses industry-proven standards for the e!COCKPIT engineering software: use is based on modern applications and programming per IEC 61131-3 (CODESYS 3).

INVITATION TO DISCOVER

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: The engineering software suite for the world of WAGO automation

• Integrated engineering: One software for every task

• A smart design that invites you to discover

• Modern software

• Based on CODESYS 3 technology

• Graphical network configuration

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LEGAL INFORMATION

WAGOdirect process November 2014

Editor: Torsten Schimanski (responsible editor)

Phone: +49 571 887-531 Fax: +49 571 887-8531

Re-use of this content free of charge is possible following approval and appropriate citation. Contact: Torsten Schimanski We assume no liability for unsolicited manuscripts and photos submitted. WAGOdirect process is published periodically.

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