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Energy management in energy-intensive operations using wireless technology

Overview

  • Highly energy-intensive branches of industry, such as the steel and the chemical industry, can benefit from energy management systems.
  • With the network-capable energy meters from Phoenix Contact, you can acquire characteristic electrical data of machines and systems both centrally and on site.
  • Thanks to the Radioline wireless system, far-off and difficult to access measuring points can be acquired wirelessly.

Application

Increased energy efficiency, reduced costs  

Identify potential energy savings and reduce energy costs

The forging industry ranks among the most energy-intensive branches of the German economy. In addition to reducing the total energy consumption, particular focus is on reducing reactive power and increasing the total efficiency of production systems, such as systems for induction heating of metal blocks, or punching before forming.

Given the constantly increasing price of energy, in order to survive on the market, operators are well advised to monitor and optimize their energy consumption. This results in the need for transparent acquisition of machines' and systems' electrical parameters. If a large number of wires are required to connect the measuring devices, equipping a company with a suitable system involves considerable costs. In this case, a wireless solution is the ideal choice, as it reduces both the cabling time and costs.

Solution

Radioline network  

Connect your controller to serial field devices using wireless technology

Network-capable EMpro energy meters acquire and monitor electrical parameters of machines and systems centrally and directly on-site.

With the Radioline wireless system, far-off and difficult to access measuring points can be acquired wirelessly. The wireless system replaces the RS-485 cables between the controller and the EMpro energy meters.

Radioline wireless modules and EMpro energy meters are not affected by electromagnetic radiation of transformers and induction heaters, high temperatures and the permanent vibration of hammers.

The data is encoded in Modbus/RTU, transmitted wirelessly, and processed in a central controller. Users can access analyses and evaluations stored on a web server – from their office desks, via the Ethernet network at any time. Moreover, the data is stored in an SQL database, which ensures that supporting documents can be provided to the tax authorities.

EMpro energy meters  

EMpro energy meters monitor the characteristic electrical data of your systems

Phoenix Contact's EMpro energy meters are your ideal energy management solution:

  • Direct access to measured values – at the touch of a button on the device, or remotely from the host computer
  • User-friendly configuration – on site by following the operator guidance, or via integrated web server
  • Easy integration into network structures, thanks to flexible connection options
  • High degree of planning reliability and investment security, thanks to the option of expansion with additional function and communication modules
Radioline wireless module with Trusted Wireless technology  

Reliable wireless transmission thanks to Trusted Wireless technology

Whether a serial I/O device or several controllers: Trusted Wireless 2.0 technology also ensures reliable transmission in harsh industrial environments, whatever the protocol type.

  • Range of up to several kilometers – thanks to adjustable data rates
  • High degree of reliability, thanks to new Trusted Wireless 2.0 technology, AES encryption, frequency hopping method, and coexistence management
  • Flexible network construction – Radioline supports both point-to-point connections and complex mesh networks with up to 250 devices

Your advantages

  • Save time and money, as routing cables is a thing of the past
  • Secure and reliable data transfer in environments with electromagnetic interference, thanks to tolerant wireless technology
  • Increased overall efficiency, thanks to transparent acquisition of energy consumption
  • Future-oriented solution for energy-intensive operations, thanks to flexible expansion with additional measuring points
  • Tax incentives and attractive power tariffs, thanks to easy reporting of energy consumption to the authorities

Product overview

See an overview of the products from Phoenix Contact, which are used in the described solution.

Energy metersTypeOrder number
Energy meter up to 500 V, acquisition of total harmonic oscillationsEEM-MA2002901362
Energy meter up to 500 V, acquisition of total harmonic oscillations, with RS-485 interfaceEEM-MA2502901363
Energy meter for up to 500 V, acquisition of total harmonic oscillations, can be extended with communication and special function modulesEEM-MA4002901364
Energy meter for up to 700 V, acquisition of individual harmonic oscillations, can be extended with communication and special function modulesEEM-MA6002901366
Energy meter for up to 700 V, acquisition of individual harmonic oscillations, can be extended with communication and special function modules, with 24 V DC supply voltageEEM-MA600-24DC2902352
   
Wireless modulesTypeOrder number
2400 MHz wireless transceiver with RS-232/485 2-wire interface, expandable with I/O extension modulesRAD-2400-IFS2901541
868 MHz wireless transceiver with RS-232/485 2-wire interface, expandable with I/O extension modulesRAD-868-IFS2904909
900 MHz wireless transceiver with RS-232/485 2-wire interface, expandable with I/O extension modulesRAD-900-IFS2901540
   
AccessoriesTypeOrder number
Configuration stick, unique network ID, RF band 3, 2.4 GHzRAD-­CONF­-RF32902814
Configuration stick, unique network ID, RF band 5, 2.4 GHzRAD-­CONF­-RF52902815
Configuration stick, unique network ID, RF band 7, 2.4 GHzRAD-­CONF­-RF72902816
Configuration stick, unique network ID, RF band 1, 868 MHzRAD-868-CONF-RF12702197
Configuration stick, unique network ID, RF band 1, 900 MHzRAD-900-CONF-RF12702122
Memory stick for saving custom configuration dataRAD­-MEMORY2902828
DIN rail connector for DIN rail power supplyME 17.5 TBUS 1,5/5­ST­-3,81 GN2709561
USB cable for diagnostics and configuration of the wireless modulesRAD-­CABLE­-USB2903447
DIN rail power supply, primary-switched, narrow designMINI-­SYS-­PS­-100-­240 AC/24 DC/1,52866983
Energy metersTypeOrder number
Energy meter up to 500 V, acquisition of total harmonic oscillationsEEM-MA200
Energy meter up to 500 V, acquisition of total harmonic oscillations, with RS-485 interfaceEEM-MA250
Energy meter for up to 500 V, acquisition of total harmonic oscillations, can be extended with communication and special function modulesEEM-MA400
Energy meter for up to 700 V, acquisition of individual harmonic oscillations, can be extended with communication and special function modulesEEM-MA600
Energy meter for up to 700 V, acquisition of individual harmonic oscillations, can be extended with communication and special function modules, with 24 V DC supply voltageEEM-MA600-24DC
   
Wireless modulesTypeOrder number
2400 MHz wireless transceiver with RS-232/485 2-wire interface, expandable with I/O extension modulesRAD-2400-IFS
868 MHz wireless transceiver with RS-232/485 2-wire interface, expandable with I/O extension modulesRAD-868-IFS
900 MHz wireless transceiver with RS-232/485 2-wire interface, expandable with I/O extension modulesRAD-900-IFS
   
AccessoriesTypeOrder number
Configuration stick, unique network ID, RF band 3, 2.4 GHzRAD-­CONF­-RF3
Configuration stick, unique network ID, RF band 5, 2.4 GHzRAD-­CONF­-RF5
Configuration stick, unique network ID, RF band 7, 2.4 GHzRAD-­CONF­-RF7
Configuration stick, unique network ID, RF band 1, 868 MHzRAD-868-CONF-RF1
Configuration stick, unique network ID, RF band 1, 900 MHzRAD-900-CONF-RF1
Memory stick for saving custom configuration dataRAD­-MEMORY
DIN rail connector for DIN rail power supplyME 17.5 TBUS 1,5/5­ST­-3,81 GN
USB cable for diagnostics and configuration of the wireless modulesRAD-­CABLE­-USB
DIN rail power supply, primary-switched, narrow designMINI-­SYS-­PS­-100-­240 AC/24 DC/1,5

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Application examples
  • Energy management in energy-intensive operations using wireless technology

PHOENIX CONTACT (Pty) Ltd.

36 Lyn Road
P.O. Box 916
ZA-Ferndale 2160
+27/11/801-8200

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