Application within industry
Industrial companies face a complex challenge in ensuring a consistent energy supply whilst simultaneously maximizing energy efficiency and minimizing operational costs. Monitoring and controlling energy consumption are of the utmost importance in optimizing production processes, reducing downtime and complying with legal requirements.
ISO 50001 with the UMG 800
The challenge
The UMG 800 provides industrial companies with a cost-efficient option for recording energy consumption and integration into a comprehensive energy management system as per ISO 50001.
The compact energy analyzer is ideal for use in tap-off boxes and distribution cabinet, meaning it can record energy flows and power quality parameters close to the machinery. Load peaks and network faults can also be recorded alongside potential energy savings.
In addition, the UMG 800 offers a range of modules, via which the basic device can be expanded using current measurement inputs or other features. This means the measurement device can adapt to changing requirements and new conditions without being replaced.
Solution
The UMG 800 offers industrial companies a cost-effective way of recording energy consumption and integrating it into a comprehensive energy management system in accordance with ISO 50001.
The compact energy analyzer is perfectly suited for use in tap-off boxes and distribution cabinets and can therefore record energy flows and power quality parameters close to the machine. In addition to potential energy savings, load peaks and grid faults can also be detected.
The UMG 800 also offers a selection of modules that can be used to add current measurement inputs or other functions to the basic device. This allows the measuring device to adapt to changing requirements and new conditions without having to be replaced.
Communication & integration with the UMG 800
The challenge
A major producer in the industry faced the challenge of integrating their complex machinery and energy management systems into a reliable network. Stable and secure data transmission was imperative with numerous devices and energy measurement points in order to ensure that production could take place without interruptions.
Solution
Using the UMG 800 with Dual Ethernet connectivity and the daisy chain feature meant the company was able to securely and efficiently connect several machines and monitoring units. The Dual Ethernet function ensures redundancy: If the connection is interrupted then the system automatically switches to a back-up connection without production being affected. Furthermore, the daisy chain function enables for flexible expansion of infrastructure so new machinery can be seamlessly integrated into the network.
Thanks to stable, secure network integration, operations can be maintained without downtime. Realtime data transmission optimizes energy management and increases production efficiency in general.
Dual Ethernet
Both Ethernet connections can be used in switched mode or as a daisy chain. They enable seamless integration into existing networks and also allow for connection of several devices for data transmission in real time.
Web server
The UMG 800 comes with an integrated web server, making it possible to remotely manage and monitor energy consumption data. Both configuration and initial commissioning can be easily carried out via the web server. No additional software required.
Modbus TCP/IP
The UMG 800 can be used as a gateway for up to 31 Modbus RTU slaves. This simplifies integration and monitoring of many devices within a network.
The Modbus white listing increases operational safety as well as safeguarding data integrity. This function makes it possible to monitor data traffic and only ensure that approved devices and communication requests are granted access whilst potentially hazardous or unauthorized accesses are blocked.
Power quality with the UMG 800
The challenge
Unexplained disturbances always occurred in a large production site that makes complex machines which produce precision components. Motors overheated, sensors failed and production lines had unexpected downtime. After an investigation the cause was discovered to be harmonics in the network. This voltage distortion leads to the machinery being overloaded, impairing their power capability.
Solution
With the introduction of the UMG 800, which detects and analyzes harmonics up to the 63rd harmonic current as well as flickers, the company was able to remedy these faults. The energy analyzer continuously monitors the power quality and detects critical deviations at an early stage. This prevents overloads whilst protecting sensitive machinery from damaging effects.
It results in smooth production operations, a longer service life for machinery, and greater operational efficiency. Expensive downtime is avoided and production increased considerably thanks to the accurate recording of power quality.
Modbus TCP/IP
The UMG 800 can be used as a gateway for up to 31 Modbus RTU slaves. This facilitates the integration and monitoring of many devices in a network. Modbus whitelisting increases operational reliability and data integrity protection. This function allows data traffic to be monitored and only permitted devices and communication requests to be granted access, while potentially dangerous or unauthorized access is blocked.
Power quality parameters
Records and analyzes harmonics in the voltage up to the 63rd harmonic current. The flicker measurement helps detect changes in the voltage that lead to flickers that damage sensitive devices and could also result in non-compliance with norms.
In addition, the UMG 800 records and analyzes events in real time (18µs).
Further highlights for the manufacturing industry
Large memory
The large 4 GB memory allows for comprehensive data acquisition that is required for in-depth analyses and long-term optimization of energy consumption. Furthermore, the data is secure even if communications are interrupted.
Virtual measurement groups
Create and combine measurement values for 3- and 4-phase applications efficiently and in virtual terms – without additional hardware. The use of virtual parameters means you can reduce hardware costs considerably by reducing the number of required physical devices whilst also ensuring maximum efficiency in your processes.
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