The responsible use of water as it becomes an increasingly scarce resource raises many questions. How do you ensure reliable plant operation while striking a balance between a safe drinking water supply and environmentally friendly wastewater disposal? Is it possible to implement technical upgrades for the future while protecting existing investments? This is where the modular PC-based automation system offers all the answers, as plant operators in water supply and wastewater disposal can use it to plan complete control solutions or retrofit new functions with ease. Whether the aim is to integrate new sensors and actuators, or optimize plant operation through a greater level of digitalization, PC-based control offers extensive support across the board. An increased level of networking is also making it easier for utilities and associations to respond to extreme weather situations, such as droughts, heavy rains, and floods.
PC-based control for water treatment:
- open control technology for compatibility with all plants
- simple integration of field devices as well as higher-level systems
- custom retrofits for existing systems
- centralized and decentralized control concepts for distributed systems
- reliable communication from the field level into the cloud
Our technologies for water and wastewater treatment
Universal platform for plant control
By consistently consolidating control intelligence in software and using established IT and automation technology standards, PC-based control combines all functions in a single system. With software and hardware interfaces, EtherCAT- and PC-based control technology supports all common communication standards from the field level to the higher-level process level. These include PROFINET, PROFIBUS, EtherNet/IP, OPC UA, the telecontrol protocols of IEC-60870-5-10x, and cloud communication protocols such as MQTT or AMQP.
Highlights of PC-based control:
- integrates PLC, visualization, safety/measurement technology, and explosion protection
- combines IT and automation standards in the PC platform
- supports automation software as well as other programs
- protects investments through long-term availability of hardware and software components
- increases availability through cable and controller redundancy
Connectivity at field level and beyond
EtherCAT technology was launched by Beckhoff in 2003 and made available as an open automation technology standard. With outstanding performance, flexible topology selection, comprehensive diagnostics, and simple configuration, EtherCAT is ideally suited for use in water management. As an Ethernet-based real-time communication system, EtherCAT supports high-performance fieldbus communication with devices in the plant and outstations, as well as online data transmission.
EtherCAT highlights for water management:
- large selection of EtherCAT-compatible sensors and actuators on the market
- lean system cabling through remote I/O
- no loss of performance in extended plants
- simple commissioning by scanning the devices
- fast troubleshooting through diagnostic functions
Software modules for all control requirements
The TwinCAT 3 automation software integrates all engineering and runtime processes and features a consistent development environment for implementing all control tasks. Programming is carried out using the most appropriate method for the user, including IEC 61131-3, high-level languages such as C/C+, MATLAB® and Simulink®. Microsoft Visual Studio® as a programming workbench facilitates version management and teamwork.
Efficient engineering for water management:
- easy programming due to prefabricated software blocks
- recording, pre-processing, and analysis of measurement data with TwinCAT Analytics
- libraries for proactive power monitoring and condition monitoring controller design and simulation with MATLAB® and Simulink®
- secure transmission of process data with TwinCAT IoT Communicator
- support for industry-specific standards and protocols (e.g., HART)
Our product highlights for water and wastewater treatment:
EtherCAT Terminals integrate all control functions
With support for over 400 signal types, the Beckhoff I/O portfolio enables seamless integration of all common sensors and actuators into the control platform. All common bus systems and communication standards are supported, including EtherCAT, EtherNet/IP, Ethernet TCP/IP, Modbus TCP, RTU, PROFIBUS, PROFINET, and RS232/RS422 or RS485.
The I/O system for every scenario:
- IP20-protected EtherCAT Terminals for control cabinet installation
- IP67-protected EtherCAT Box modules for installation in the plant
- custom design with 1 to 16 channels per terminal
- acquisition of process parameters such as filling levels, temperatures, volume flow, pH level, and oxygen or nitrogen content
- measurement technology, functional safety and explosion protection integrated into the system
- energy and power measurement for network monitoring
I/O modules for intrinsically safe signal acquisition
The ELX terminals combine highly compact remote I/O modules with safety barriers for the direct connection of intrinsically safe field devices from zone 0/20 and 1/21. The resulting absence of intermediate external barriers not only leads to a significant reduction in the space needed in the control cabinet, but also offers cost-saving advantages.
The EtherCAT Box modules in the EPX series combine intrinsic safety with a protection rating of IP67 and an extended temperature range of -25 to +60°C. The modules in the robust housing enable reliable data acquisition in areas where a control cabinet cannot – or should not – be installed. This makes them suitable for implementing modular and control cabinet-free system concepts in harsh and hazardous environments.
Highly compact I/O modules with integrated barrier:
- for comprehensive control from zone 0 to the cloud
- cost advantages resulting from the elimination of separate safety barriers
- installation possible inside and outside the control cabinet
- compact design, large signal variety, consistently high resolution
- certification according to ATEX, IECEx, and NEC/CEC
Compact controllers for outstations
The extensive performance range of the DIN rail-mountable embedded PCs allows them to cover all control tasks from the smallest to the highest segment. With their integrated interface, the controllers not only save on space and costs, but also facilitate the direct connection of I/O terminals without the use of bus couplers. Depending on requirements, embedded controllers for decentralized control can be combined with more powerful embedded PCs, industrial PCs, and existing control systems for central plant control.
Scalable embedded PCs for any application:
- from small-scale control through to high-performance multicore solutions
- flexible expansion through interface modules
- robust device with high vibration and shock resistance
- extended temperature range from -25 to +60°C
- certification according to ATEX, IECEx, and NEC/CEC
Ultra-compact industrial PCs as IoT gateways
The scalable series of C60xx ultra-compact Industrial PCs combines maximum power density with a wide range of options for control cabinet installation in even the smallest of installation spaces. The universal controllers are ideal as edge devices for seamless retrofitting into existing plants. Together with the TwinCAT software, they enable the collection, processing, and provision of data from pumps, valves, and sensors, as well as pre-processing of the data before transmission to the cloud. Add transparency to plant operations, identify scope for optimization, and monitor trends to take proactive action.
Secure communication from the sensor to the cloud:
- powerful control computers with a small footprint
- compatible with existing control technology
- secure, standard-based cloud integration with TwinCAT IoT
- cycle-synchronous analysis of process data with TwinCAT Analytics
- predictive maintenance through integrated condition monitoring
Standard protocols simplify communication
Additional TwinCAT libraries can be easily installed for communication according to the IEC 60870-5-10x, IEC 61850, and IEC 61400-25 telecontrol protocols. Communication in these standardized telecontrol protocols enables monitoring and control of distributed plants and supports secure access to operational data, alarm functions, and software updates remotely.
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