Measurement System with Added Value

The new “WAGO Energy Data Management” system easily records and manages energy data without any programming and can be upgraded at any time.
Corporations are increasingly scrutinizing the efficiency of their buildings and equipment. On the one hand, legal regulations require this; on the other, potential savings, which could ultimately bring decisive competitive advantages, also appear enticing. However, the level of potential savings can only be determined once all types of energy and their consumers are systematically recorded, and the data is viewed in the appropriate context. The foundation for all of this is a good measurement system.

Practically speaking, however, this has often proven quite difficult, because, in order to establish transparency across energy types, it is necessary to funnel the different measurement data types into a single system. The measurement solution is typically tailored to the situation, and is also extremely complex. In addition to defining individual measurement points, selecting suitable measurement devices, meters and sensors and then installing them, programming the measurement system is complicated, time-consuming and usually the driver of high costs. And when the measurement system finally runs, it quickly collects mountains of data, which then have to be dealt with.

A suitable measurement system must satisfy three criteria: It must be easy to integrate into the system, it must operate economically, and it must ensure that processing the collected data is simple. This is exactly the solution offered by the new “WAGO Energy Data Management” system. Combining preconfigured hardware and user-friendly software into one package, WAGO’s measurement system can be readily integrated into both systems and building technologies. The distinctive feature: In addition to energy-specific values, like electrical currents or voltages, many other measurement values can also be recorded that are relevant for industrial and process technologies or for building applications. For example, current, gas, heat, water, compressed air and temperature can be measured in one system, providing a comprehensive view into a company’s energy flows and production processes.

The industry-proven PFC200 Controller and the WAGO-I/O-SYSTEM 750 hardware form the basis on the hardware side. The modular design make the system readily adaptable to the respective requirements. For recording device- and process-specific consumption, a number of I/O modules are connected in series to the controllers, e.g., 3-Phase Power Measurement Modules for energy consumption measurements, pulse counters, interfaces for linking M-bus meters and for radio-based EnOcean sensors. Numerous other modules are also included for recording analog and digital current and voltage signals.

The system’s standard software application makes the powerful “WAGO Energy Data Management” suite incredibly easy to use. Preloaded onto the PFC200, this software automatically detects connected I/O modules at start up. The inputs for data recording are adjusted via simple parameterization. All settings, both for commissioning and during operation, can be performed with the click of a mouse – no programming required. Since the graphic user interface can be accessed via HTTPS and standard browser, there is no need for local software installation. The web visualization takes all the complications out of configuring the energy monitoring system. Forwarding data to higher-level energy management software is performed via MODBUS TCP/IP or as a CSV file via FTPS. In addition, it is possible to save the history on an SD card. WAGO’s flexible solution was engineered for adapting to existing infrastructures and management systems, giving companies with basic energy management procedures a better overview of their measuring points in an elegantly simple way.

Different evaluations can be generated using the integrated visualization tool, which provides various types of diagrams and representations for visualizing the data. Companies can thus generate consumption curves that are synchronized to their power supplier (PSC) or determine which consumers are responsible for peak loads by using the second-by-second display. In addition, energy use may be monitored relative to specific process adaptations to determine how much energy would be saved by using variable speed motors or new lamps, or by reducing leaks in the compressed air system. The “WAGO Energy Data Management” system is also ideal for corporations just starting energy monitoring or wishing to do so without higher-level energy management software.

Energy monitoring is worthwhile, primarily for industrial companies, as evidenced by the numbers. According to the energy efficiency sector monitoring of the German Industry Initiative for Energy Efficiency (DENEFF), this sector consumed a total of 2,508 petajoules in 2014. That is just under one third of the entire energy consumption of the country. Almost 65 percent of that was used to generate process heat. According to the German Energy Agency (DENA), approximately 15 percent of that energy could have been saved. The proportion of electrical energy used for process heating was marginal; however, electricity is gaining significant importance within the industrial energy mix. Today, industrial operations consume 45 percent of the electrical energy consumed in Germany. The Federal Environmental Agency estimates the savings potential in this case to be around 20 percent. These statistics make it clear: Successfully transitioning to greater energy efficiency depends heavily on industry.

In order to achieve greater energy efficiency, companies in Germany have been obligated, starting in 2015, to perform regular energy audits or introduce energy management. The new “WAGO Energy Data Management” system is the right foundation for both. In order for measurement results to ultimately be meaningful, however, companies must consider them in the context of energy performance indicators (EnPIs), as well as other relevant operational data. Individual evaluation provides new information in each phase of the energy management regarding savings potentials in the company.

Text: Julia Ockenga, Lukas Dökel ǀ WAGO
Photo: Fotolia.com, WAGO