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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 ensure that water is supplied throughout the distribution network to consumers, 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 solution 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 Environment

The extreme variant of the modular, fieldbus-independent WAGOI/ 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 operational 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 systems also means lower energy, wiring and maintenance costs, as well as fewer potential fault points.

In regions with high fluctuations between day and night temperatures, 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 equipment 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 Resistant

An 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 groundwater 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 performance enables the automation system to be mounted in direct proximity to equipment that generates strong vibrations or impacts.

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 surges 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 interference 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 Capacity

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

Water Library with Complete Pump Controls

WAGO offers comprehensive CODESYS function libraries specifically designed for water and process technology applications. These substantially reduce programming expense and simplify system operations. Prefabricated system macros for many typical 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 system. 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.

The 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 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. This results in many possible uses within and beyond water resource management.


Text: Kay Miller, WAGO
Photo: WAGO