energy monitoring

A sound data basis is required to develop suitable measures and monitor their success. This is where energy monitoring comes in: measurement and analysis systems can be used to visualise energy flows, identify excessive consumption and derive targeted measures to increase efficiency. The effectiveness of introduced savings measures can be assessed by analysing archived data. In addition to electrical energy, non-electrical forms of energy, such as district heating, gas or hot water, can also be recorded.

Another positive effect is that many of these measures directly contribute to environmental and climate protection goals by saving resources or making processes more energy efficient, for example. In addition, the carbon footprint of individual products can be accurately recorded and analysed. Based on this data, targeted measures can be developed to reduce emissions, resulting in a sustainable reduction in the company's overall CO₂ emissions. These ecological improvements also have a positive effect on the company's image.

In Germany, companies with an average annual energy consumption between 2.5 and 7.5 GWh must conduct an energy audit every four years. At least 90% of energy consumption, including heat, electricity and fuels, must be recorded. The audit aims to identify economic measures to increase efficiency.

Although an energy monitoring system is not mandatory for the audit, it can facilitate the process significantly, particularly through structured data collection, evaluation and the development of strategies.

Companies with an annual consumption of over 7.5 GWh are considered energy-intensive and must implement a certified energy management system in accordance with ISO 50001. This requires detailed data collection, which is significantly facilitated by an energy monitoring system.

If you introduce an energy monitoring system, you can apply for funding from the Federal Office of Economics and Export Control (BAFA). Funding is available for both software and hardware components, as well as structural measures. Prerequisite: The hardware must be combined with a listed energy monitoring system.

There is a wide range of devices available for measuring electrical energy. The range of functions available varies depending on the device. As a minimum, the following variables can be recorded: current, voltage, mains frequency, and reactive, active, and apparent power. Additionally, there are measuring devices that can measure the harmonic content (THD) or individual harmonics of current and voltage, which is an important aspect for identifying electromagnetic interference.

Direct measurement is possible for low currents. Higher currents in the kiloampere range are measured using current transformers or Rogowski coils.

Clamp-on transformers and Rogowski coils are particularly suitable for existing systems as they can be installed without the need to disconnect the conductor. Medium voltages can also be measured using suitable voltage transformers and commercially available energy meters.

As well as electrical energy, other types of energy such as gas, district heating, compressed air or hot water can be measured, with the values transferred to the energy monitoring system.

Energy meters can be easily integrated into existing Ethernet-based infrastructures via Modbus TCP. Flexible solutions are also useful in industrial environments, such as devices that can be connected directly to a PLC (programmable logic controller) as peripheral modules, enabling easy integration into existing control systems.

Modern switching devices with integrated measurement technology combine switching and monitoring functions within a single, compact system. They enable electrical consumers to be safely switched off and also record important electrical parameters and device data, such as the switching status and wear on the contact system. This integration eliminates the need for additional measurement technology, saving space in the control cabinet and reducing installation costs.

In cooperation with our long-standing partner Siemens, one of the leading providers in the field of energy monitoring, Frequenz Elektro GmbH offers powerful solutions for visualising your consumption data.

Our current range of visualisation solutions includes:

The EE Monitor (Energy Efficiency Monitor) is used to record and analyse the energy consumption of machines and systems in detail. Running directly on the PLC, it is ideal for production-related applications in the industrial sector.

Consumption can be assigned to individual operating states and compared with reference measurements, enabling the effectiveness of savings measures to be demonstrated transparently and inefficient behaviour to be quickly identified. Additionally, energy consumption per unit produced can be determined.

The EE Monitor is integrated directly into the process visualisation, ensuring maximum transparency during operation and production-related energy monitoring.

The Powercenter 3000 is a standalone solution that runs as a separate visualisation on an industrial PC. The device can store measured values at 15-minute and 10-second intervals and display archived data. Optionally, the data can be exported to a server or the cloud. All information can be accessed via the integrated web interface across platforms. The visualisation can be customised for specific projects using image modules to optimally display current and historical measured values. Modbus TCP and Modbus RTU can be used to connect measuring devices and establish an interface with other control systems. In the event of irregularities during operation, such as switch tripping or limit violations, alarms or messages can be generated and forwarded by email.

The Powercenter 3000 is suitable for new installations and retrofitting into existing systems, and is independent of existing technology. Its flexible design allows it to be used in industrial settings, data centres, and buildings, for example.

As a certified Siemens Solution Partner, we implement energy monitoring systems that are precisely tailored to your requirements. Frequenz Elektro GmbH will select suitable measuring devices and accessories for you, take care of professional installation and handle all parameterisation. We then integrate the measuring devices into the relevant software and develop customised visualisation software tailored to your system.

We are, of course, on hand to assist you with applying for any subsidies, clarifying any uncertainties, and ensuring that the process runs smoothly.

We can also support you in selecting and implementing measures to reduce your energy consumption.

If you have any questions, please do not hesitate to contact us: