Application within industry
In manufacturing, energy determines competitiveness. Without stable supply, machines stand still. Without efficiency, costs rise. Companies must therefore not only ensure reliable supply but also monitor energy flows in detail. Only then can processes be optimized, downtime avoided, and regulations met.
ISO 50001 with the UMG 800
The Challenge
Implementing an energy management system in line with ISO 50001 is essential for many companies. Certified management requires full transparency of energy consumption. It is no longer sufficient to only measure total consumption; detailed data is needed on which machines use how much energy and when.
Solution
The UMG 800 provides a cost-efficient way for manufacturers to capture energy consumption and integrate it into a comprehensive ISO 50001 energy management system. Its compact design makes it ideal for use in tap-off boxes and distribution panels, enabling machine-level monitoring of energy flows and power quality parameters.
A range of expansion modules can be connected to the UMG 800, adding current measurement channels or other functions as needed. This adaptability ensures the analyzer grows with changing requirements without the need for replacement.
Communication & Integration with the UMG 800
The Challenge
A large production company needed to reliably connect its machines and energy management systems. With many devices and measurement points, secure data transmission was critical 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
Two Ethernet ports can be used in switched mode or as a daisy chain. This enables seamless integration into existing networks, allowing multiple devices to transmit data 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 act as a gateway for up to 31 Modbus RTU devices, simplifying integration and monitoring. Modbus Whitelisting enhances security by allowing only authorized devices and blocking unauthorized access.
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.
Power Quality Parameters
Captures and analyzes voltage harmonics up to the 63rd order. With flicker measurement, you can detect voltage fluctuations that cause flickering, damage sensitive equipment, and lead to non-compliance with standards. In addition, the UMG 800 detects and analyzes events in real time (18 µs).
Waveform Capture
The UMG 800 records and analyzes waveforms in detail (10 ms RMS half-wave values, 51.24 kHz sampling rate, 1024 samples) and identifies voltage events. This enables targeted root cause analysis and allows faults to be resolved quickly and reliably.
Further Highlights for the Manufacturing Industry
Large Memory
The large 4 GB memory enables comprehensive data collection, essential for detailed analysis and long-term optimization of energy consumption. In addition, data is secured in case of communication interruptions.
Virtual Measurement Groups
Create and combine measurement values for 3- and 4-phase applications virtually and efficiently – without any additional hardware. By using virtual parameters, you can significantly reduce hardware costs by lowering the need for physical devices, while still ensuring maximum efficiency in your processes.
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