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Installation and parameterization made easy: CODESYS libraries reduce programming expenses and simplify system operations


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 commissioning or system adaptations, it is not unusual to generate applicationspecific 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 innovative 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 current, specific demands.

For system integrators, this means that standard systems must adapt quickly to customer-specific conditions and do so with minimal expense. This contrasts with system operators’ needs for intuitive operation of the process controls. The new “Water” and “Process” function libraries from WAGO fulfill both these demands in combination with the I/O system.

Scalable Hardware

Process technology integration requires the connection and networking of any number of different sensors and related components. In addition to standardized analog and digital signals, these components often have specialized interfaces that have to be operated by the automation systems. Networking occurs via various bus protocols 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 technology 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 Expenses

WAGO 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 contain 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 corresponding application, i.e., assign the data points and system parameters, 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 customer service because more complex tasks, such as pump function blocks, are individually tailored to suit a user’s needs. In all, the libraries contain approximately 50 function blocks for water resource management and process technology.

Superior Customer Service

Commissioning a system takes place using a logical, web-based user interface. The user can set all parameters there and perform any additional 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 completely automatically), displays current component parameters and enables 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 expand our library as a direct result of closely interacting with customers to address their needs.

Lower Cost, Greater Efficiency

The 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 expenses. The system macros streamline installation and commissioning of automation components, while simplifying system adaptations to reduce overall project times. System operators benefit from web-based visualization, thoroughly tested function blocks and standard engineering tools, as well as from a reduction in errors during commissioning and operation. Standardizing the process ultimately contributes to significant money and time savings, increased system uptime and the reduction of training expenditures.


Text: Kay Miller, WAGO
Photo: WAGO