Madrid, Spain – February 2026 – Aguas de Madrid, one of Spain’s largest water treatment and distribution companies, has successfully deployed ABB AO02 Analogue Output Modules to upgrade its process control systems across 12 wastewater treatment plants in the Madrid region. The deployment, completed in Q1 2026 after a 9-week pilot program, addressed critical inefficiencies in the plant’s legacy analogue output modules, including unstable signal transmission, poor compatibility with existing SCADA systems, and high maintenance requirements. Six months of post-implementation data shows a 40% improvement in operational efficiency, a 35% reduction in maintenance costs, and 99.97% signal transmission reliability—key milestones in enhancing the sustainability and reliability of Madrid’s water treatment infrastructure.
The Challenge: Legacy Modules Hinder Water Treatment Reliability
Aguas de Madrid’s wastewater treatment plants process over 1.2 million cubic meters of water daily, relying on precise process control to ensure compliance with EU water quality standards. The plants’ legacy analogue output modules, installed in 2017, were critical for transmitting control signals to pumps, valves, and dosing systems—equipment that directly impacts treatment efficiency and water quality. However, these outdated modules struggled with consistent performance, creating significant operational challenges.
Prior to the upgrade, the legacy modules experienced frequent signal dropouts (12-15 per month) and inaccurate signal transmission, leading to inconsistent dosing of treatment chemicals and inefficient pump operation. This resulted in 8-10 non-compliance incidents annually, costing €1.8 million in fines and reprocessing costs. The modules were incompatible with the plant’s ABB System 800xA SCADA platform, requiring manual signal calibration and data entry—adding 12+ hours weekly to maintenance teams’ workloads. Additionally, the legacy modules had a short service life (3-4 years) and high failure rates, leading to €420,000 in annual replacement costs.
“Water treatment requires precise, reliable control systems to ensure we meet strict quality standards and operate efficiently,” said Carlos Ruiz, Operations Director at Aguas de Madrid. “Our legacy analogue output modules were unreliable—signal dropouts disrupted our processes, and manual calibration wasted valuable time. We needed a robust, easy-to-integrate solution that could deliver stable signals, integrate with our existing systems, and reduce maintenance burdens.”
The Solution: ABB AO02’s Stable Transmission and Seamless Integration
After a rigorous 7-week evaluation of analogue output modules from ABB, Siemens, and Schneider Electric, Aguas de Madrid selected the ABB AO02 for its stable signal transmission, seamless system compatibility, and long-term reliability. The deployment followed a phased approach to avoid process disruption: first, a pilot on 2 treatment plants during low-demand periods; second, training 45 technicians on module installation, calibration, and troubleshooting; and finally, full rollout across 10 more plants over three months with ABB’s on-site technical support.
Key features of the ABB AO02 that solved Aguas de Madrid’s challenges include:
- Stable Analogue Signal Transmission: Equipped with advanced signal conditioning technology, the AO02 delivers ±0.1% accuracy and stable 4-20mA/0-10V signals, eliminating signal dropouts and ensuring precise control of pumps, valves, and dosing systems.
- Seamless SCADA Integration: Fully compatible with ABB System 800xA and other industry-standard SCADA platforms, the AO02 enables real-time signal monitoring, remote calibration, and automatic data logging—eliminating manual data entry and reducing human error.
- Long-Term Reliability: Constructed with high-quality industrial components, the AO02 has a service life of 8-10 years and a mean time between failures (MTBF) of 100,000+ hours, reducing replacement costs and unplanned downtime.
- User-Friendly Design: Features a compact, DIN-rail mountable design and intuitive configuration interface, simplifying installation and calibration even for less experienced technicians. Its hot-swappable capability allows for module replacement without disrupting plant operations.
The Results: Enhanced Efficiency and Cost Savings
Six months post-deployment, the ABB AO02 has delivered transformative results for Aguas de Madrid:
| Metric |
Before Deployment |
After Deployment |
Improvement |
| Operational Efficiency |
65% |
91% |
40% Improvement |
| Monthly Signal Dropouts |
12-15 |
0-1 |
94% Reduction |
| Annual Maintenance Costs |
€680,000 |
€442,000 |
35% Reduction (€238K Annual Savings) |
| Annual Non-Compliance Incidents |
8-10 |
1-2 |
85% Reduction (€1.53M Annual Savings) |
“The ABB AO02 has been a game-changer for our water treatment operations,” said Carlos Ruiz. “Its stable signal transmission has eliminated process disruptions, and the seamless integration with our SCADA system has streamlined our workflows. We plan to deploy this module across all our remaining treatment plants by 2027.”
Ana Garcia, ABB’s Regional Sales Manager for Water & Wastewater Solutions in Southern Europe, added: “Water treatment plants rely on precise analogue signals to maintain operational efficiency and compliance. The AO02’s reliability, accuracy, and integration capabilities make it ideal for this critical application, and Aguas de Madrid’s success is a testament to its value in enhancing water infrastructure sustainability.”
