OdpniPripniZapri

Integrated power measurment in the EtherCAT I/O system

EtherCAT Terminals for grid monitoring, process control, and power monitoring

Transparent energy monitoring

Transparent energy monitoring reduces both machine standstills and the necessity to oversize the corresponding components for reasons of plant availability. Added to that are the preventive maintenance and ultimately a considerably increased production efficiency. With its portfolio of integrated power measurement, Beckhoff simplifies energy management while at the same time optimizing the availability of machines and plants. Due to the continuous, system-integrated power measurement, deviations from the standard state can be detected quickly, thus enabling quick intervention. For example, the continuously increasing current consumption of a machine may indicate bearing wear. On the other hand, a decreasing current consumption may indicate quality problems, which need to be corrected at an early stage. By monitoring the power supply, erroneous behavior can be attributed to a possible phase failure in the power grid. The speed of reaction is reduced and possible downtimes are avoided.

Scalability for all areas of application

Scalability is a principle at Beckhoff: This also applies to the EtherCAT power measurement terminals, which cover applications from simple grid monitoring to power monitoring in all areas of application. They are scaled by different levels of performance in terms of measuring accuracy, measuring speed, and measured and internally calculated values. Beckhoff EtherCAT I/Os provide a comprehensive range of EtherCAT terminals for this that is highly scalable in terms of both price and performance.

Comprehensive system portfolio

In addition to the EtherCAT terminals, the power measurement portfolio also includes current transformers as reliable power sensors with optimum compatibility with the I/Os. A software library for power monitoring for our TwinCAT automation software also rounds off the power measurement. Suitable accessories are available for additional safety in the control cabinet. This results in a complete power measurement portfolio, so that all components can be procured from a single source.

There is a wide variety of requirements in energy management in the machine environment and in the energy economy, ranging from pure grid monitoring and process control through to high-end power monitoring. The EL34xx and EL37x3 energy and power measurement terminals set different focal points and are therefore designed for a wide range of applications.

Starting with simple threshold checking for voltage, frequency and phase with output of warning and status bits with IoT and energy management projects with the EL3423. The EL3443 and EL3453 are also the right terminals for high-feature applications for 3-phase grids, which pre-process the measured current and voltage values internally and thus provide the controller with up to 600 values for extensive grid analysis, as well as for energy management. The EL3773 and EL3783 can be used for power monitoring with oversampling function. This allows current and voltage to be measured simultaneously at speeds of up to 10 kSps on all channels for temporally precise state detection.

Distributed power measurement can be realized with the EL3446 in combination with the EL3443, so that effective power values can be calculated with spatially separated voltage and current measurement. The EL3446 pure current measuring terminal can be positioned as often as desired in a grid. To calculate the real power data, the required voltage values are transmitted from the EL3443 three-phase power measurement terminal, which is installed once only in each grid. This concept of distributed power measurement – with just one EL3443 and any number of EL3446s – reduces the hardware and installation expenditure to a minimum.

Beckhoff's energy and power measurement portfolio also features products for the medium voltage level. Voltages in the medium voltage level can simply be connected to our terminals with a measuring range of up to 130 V AC via standard voltage transformers with a 100 V or 110 V output.

Calibration of the terminals is necessary in some applications if, for example, knowledge of the measuring behavior and uncertainty is to be gained for quality reasons. We can also meet these requirements with our calibrated power measurement terminals.

With the SCT current transformers, Beckhoff, as a system provider, offers the possibility to implement reliable power sensors as an integral part of the PC-based controller directly in the field and completes the measuring chain from the recording of the physical measurement value to the data transmission to the cloud.

Users can choose between different concepts, each of which are highly scalable via different designs and performance classes and are therefore suitable for any application. For current intensities from 1 to 5,000 A, as well as from ring-type and split-core current transformers up to 3-phase transformers. The SCT series is extremely diversified and offers low-cost transformer sets for building services, standard industrial transformers for mechanical engineering and solutions for test benches with particularly high requirements for accuracy.

Decisive for the selection of the suitable variant is the respective type of use. Whereas the data acquisition can be implemented cost-efficiently and with high measurement accuracy, in particular in new systems, using the ring-type current transformers, the split-core current transformers are ideal for use as an uncomplicated retrofit solution due to the simplicity of their attachment.

The TwinCAT Power Monitoring Function is a PLC library for the evaluation of raw current and voltage data, which are usually provided by the EL3773 and EL3783 grid monitoring oversampling terminals. Function blocks are available for calculating RMS values for current, voltage and power. These can be output as instantaneous or average values. Maximum and minimum values are also available on the function block. Frequency and frequency spectra can be determined, such as e.g., harmonics in the network and their load in the form of the Total Harmonic Distortion (THD).

All blocks are available for single-phase and 3-phase systems. The TwinCAT products TE1300 TC3 Scope View Professional and TF6420 TC3 Database Server are suitable for displaying or permanently storing the data.

BZ3201 | Pluggable inscription cover with
BZ3201 | Pluggable inscription cover with "HIGH VOLTAGE" marking

Standard signal voltages in the I/O system are usually ≤ 48 V. When measuring power, the signal voltage is in most cases much higher, often ≥ 230 V, so additional safety must be ensured in order to avoid endangerment of the fitter or operator. For this purpose, Beckhoff offers various options for marking the power measurement terminals.

The terminals can be spatially separated via an additional I/O station by means of an additional EtherCAT Coupler. Thus, voltages < 48 V are not simply placed next to < 690 V in the I/O line, but separated.

A further possible separation can be realized via the EL9080 separation terminal. This passive terminal has an orange front panel and additionally provides for optical separation.

The third option can be implemented by the BZ3201 plug-in label cover. The transparent cover is marked with "High Voltage!" The wires on the power measurement terminals can only be loosened after flipping up this cover, thus accidental loosening can be ruled out.

Power Quality Factor: a single value for simplified, faster diagnostics and error correction
Power Quality Factor: a single value for simplified, faster diagnostics and error correction

In order to simplify the assessment of current performance values for the user as much as possible, Beckhoff has developed the so-called Power Quality Factor (PQF). This guide value makes it possible to assess the voltage quality in the environment of a machine or plant on the basis of a single numerical value without having to analyze frequency, voltage, THD/harmonics and symmetry separately. For example, if an error occurs on a machine and the PQF drops to zero at the same time, it can be concluded that it is probably not the machine itself, but a change in the power supply that caused the error. In this way, not only the signs and effects of a fault can be rectified more quickly, but above all the causes. At the same time, a falling PQF can be used as an early warning system.

More content

The complete energy measurement chain: from the sensor to the cloud

By completing the power measurement chain from the sensor to the cloud, PC-based control specialist Beckhoff simplifies energy management approaches and improves the availability of machines and production facilities.

Integrated measurement technology for a power utility in western Switzerland

Romande Energie SA, one of the five largest energy utilities in Switzerland, employs EL3453 power measurement terminals and other EtherCAT Terminals from Beckhoff in its substations to safeguard the availability of its grid. This is implemented with the help of a secondary data acquisition system that can compensate for partial or total failures of the primary acquisition path.

High-precision frequency measurement with eXtreme Fast Control technology

In order to protect against grid fluctuations, Korean engineering firm, Power21 has developed an Energy Storage System (ESS) for frequency control. The system is already successfully deployed in power supplier, KEPCO‘s (Korea Electric Power Corporation) West Anseong substation.

PC-based control for heat and energy supply

In conjunction with a new building for switchgear production, international company Hermos AG realized an advanced energy center at its Mistelgau, Germany site. PC-based control technology from Beckhoff offers a common platform for automation and building management.

Embedded PCs and power measurement terminals provide flexible energy data collection for lumber mill

The drying and processing of wood is a process that requires a lot of energy. Holzwerke Weinzierl GmbH in Germany nevertheless manages to generate more power than it consumes. The basis for this achievement is a modern energy management system that uses power measurement I/O terminals and Embedded PCs from Beckhoff to make the plant’s energy use transparent while continually optimizing it.

EtherCAT networking for efficient and flexible wind turbines

The backbone for Alstom's onshore project in a Scottish wind farm with a total of 217 MW is the fast EtherCAT, together with suitable Beckhoff I/O components.

Date Topic Speaker Language Duration
08.09.2020 Distributed power measurement with SCT current transformers Dr. Fabian Assion english 30 minutes
19.06.2018 EtherCAT Terminals for energy management Dr. Fabian Assion english 30 minutes

Products

EL3423

The EL3423 EtherCAT Terminal enables the measurement of relevant data for an efficient energy management system. The voltage is measured internally via direct connection of L1, L2, L3 and N. The current of the three phases L1, L2 and L3 is fed via simple current transformers. The measured energy values are available separately as generated and accepted values. In the EL3423 Terminal, the effective power and the energy consumption for each phase are calculated. In addition, an internally calculated network quality factor provides information about the quality of the monitored voltage supply. The EL3423 offers basic functionality for mains analysis and energy management.

EL3443

The EL3443 EtherCAT Terminal enables the measurement of all relevant electrical data of the supply network and carries out simple pre-evaluation. The voltage is measured via direct connection of L1, L2, L3 and N. The current of the three phases L1, L2 and L3 is fed via simple current transformers. All measured currents and voltages are available as root-mean-square values. In the EL3443 terminal, the effective power and energy consumption for each phase are calculated. The RMS values of voltage U and current I as well as the active power P, apparent power S, reactive power Q, frequency f, phase shift angle cos φ and harmonic are available. The EL3443 offers extended functionality for mains analysis and energy management.

EL3446

The EL3446 EtherCAT Terminal enables the measurement of all relevant electrical data of the supply network and carries out simple pre-evaluation. Since the EL3446 itself has no voltage inputs, the voltage measured values are transmitted via EtherCAT by an EL3443 to be installed once per network. The current of up to six phases is fed via simple current transformers. All measured currents and voltages are available as root-mean-square values. In the EL3446 terminal, the effective power and energy consumption for each phase are calculated. The RMS values of voltage U and current I as well as the active power P, apparent power S, reactive power Q, frequency f, phase shift angle cos φ and harmonic are available. The EL3446 offers extended functionality for mains analysis and energy management.

EL3453

The EL3453 EtherCAT power measurement terminal is an advancement based on the EL3413. With up to 690 V AC, the voltage inputs are optimised for the direct monitoring of high-capacity generators, as in the wind power industry, for example. No upstream voltage transformer is required. The four current inputs are electrically isolated so that the terminal can be used in all common grounded current transformer configurations such as 2- or 3-transformer configurations with star or delta connection incl. neutral conductor current measurement. The EL3453 can be used for simple grid analysis up to the 63rd harmonics analysis. Alternatively, all readings can be combined in a power quality factor for simplified diagnostics. Like all measured terminal data, the harmonic content can be read via the process data. The EL3453 offers the “ExtendedRange” feature enabling the use of the full technical measuring range, which equals 130 % of the specified nominal measuring range.

EL3453-0100

The EL3453-0100 EtherCAT power measurement terminal is an advancement based on the EL3413. The adapted voltage measuring range to 130 V is optimally suited for connecting medium voltage transformers, for example. The four current inputs are electrically isolated so that the terminal can be used in all common grounded current transformer configurations such as 2- or 3-transformer configurations with star or delta connection incl. neutral conductor current measurement. The EL3453-0100 can be used for simple grid analysis up to the 63rd harmonics analysis. Alternatively, all readings can be combined in a power quality factor for simplified diagnostics. Like all measured terminal data, the harmonic content can be read via the process data. The EL3453-0100 offers the “ExtendedRange” feature enabling the use of the full technical measuring range, which equals 130 % of the specified nominal measuring range.

EL3483

The EL3483 EtherCAT Terminal enables the monitoring of relevant electrical data of the supply network. The voltage is measured internally via direct connection of L1, L2, L3 and N. The internal measured values are compared with threshold values preset by the user. The result is available as digital information in the process image. The EL3483 checks for the correct phase order L1, L2, L3, phase failure, undervoltage and overvoltage, and possible phase asymmetry. An error bit is set in the case of an incorrect phase order or the failure of a phase. Should, for example, an asymmetry or voltage error occur, only a warning bit is set initially. In addition, an internally calculated mains quality factor provides information about the quality of the monitored voltage supply. The EL3483 offers basic functionality for mains monitoring and analysis.

EL3483-0060

The EL3483-0060 EtherCAT Terminal enables the monitoring of relevant electrical data of the supply network. The voltage is measured internally via direct connection of L1, L2, L3 and N. The internal measured values are compared with threshold values preset by the user. The result is available as digital information in the process image. The EL3483-0060 checks for the correct phase order L1, L2, L3, phase failure, undervoltage and overvoltage, and possible phase asymmetry. An error bit is set in the case of an incorrect phase order or the failure of a phase. Should, for example, an asymmetry or voltage error occur, only a warning bit is set initially. In addition, an internally calculated mains quality factor provides information about the quality of the monitored voltage supply. The EL3483-0060 offers basic functionality for mains monitoring and analysis. In addition, the -0060 version also outputs current RMS values of the voltage in the process image.

EL3773

The EL3773 and EL3783 power monitoring terminals are designed for state monitoring of 3-phase AC voltage systems. For each phase voltages and currents are sampled as instantaneous values with a resolution of 16 bits:

EL3783

The EL3783 EtherCAT Terminal is a power monitoring I/O terminal used for state monitoring of a 3-phase AC voltage system. For each phase, voltage up to 400/690 Vrms and current up to 1 Arms/5 Arms are sampled as instantaneous values with a resolution of 16 bits. The six channels are measured simultaneously based on the EtherCAT oversampling principle with a temporal resolution of up to 50 µs and then passed on to the control system. The control system has sufficient computing power for true RMS or performance calculations and complex custom algorithms based on the measured voltages and currents. Through the oversampling principle, the terminal is able to measure at significantly shorter intervals than the cycle time of the control system. AC and DC parameters must be connected and measured with a common reference potential.

EL3783-0100

The EL3783-0100 EtherCAT Terminal is a power monitoring I/O terminal used for state monitoring of a 3-phase AC voltage system. For each phase, voltage up to 400/690 Vrms and current up to 1 Arms/5 Arms are sampled as instantaneous values with a resolution of 16 bits. The six channels are measured simultaneously based on the EtherCAT oversampling principle with a temporal resolution of up to 50 µs and then passed on to the control system. The control system has sufficient computing power for true RMS or performance calculations and complex custom algorithms based on the measured voltages and currents. Through the oversampling principle, the terminal is able to measure at significantly shorter intervals than the cycle time of the control system. AC and DC parameters must be connected and measured with a common reference potential.

Mini ring-type current transformers

Mini ring-type current transformers

The space-saving SCT1xxx series for the tightest installation spaces. A removable terminal enables pre-wiring.

Ring-type current transformers

Ring-type current transformers

The SCT2xxx series offers a wide selection and impresses with innovative, screwless connection technology.

3-phase ring-type current transformers

3-phase ring-type current transformers

The compact SCT3xxx series for direct mounting under commonly used power switches.

Split-core current transformers

Split-core current transformers

The separable measuring system of the SCT6xxx series enables flexible retrofitting without disconnecting the primary conductor.

Busbar split-core current transformers

Busbar split-core current transformers

The SCT7xxx series supports the highest primary currents and is suitable for convenient retrofitting.

Coil current transformers

Coil current transformers

The SCT0xxx series is specially designed for low primary currents and is used for corresponding applications.

TF3650

The TwinCAT Power Monitoring function is a PLC library for the evaluation of raw current and voltage data, which are usually supplied by EL3773 and EL3783 EtherCAT Terminals. Function blocks are available for the calculation of RMS values for current, voltage and power. These can be output as a momentary or average values. Maximum and minimum values are also available on the function block. Frequency and frequency spectra can be determined, such as e.g. harmonics in the network and their load in the form of the Total Harmonic Distortion (THD).

EL9080

The EL9080 separation terminal is used for the separation and marking of different potential groups (e.g., 230 V AC/24 V DC). It is inserted between two potential groups, and indicates the separation through an orange colored cover. The E-bus is passed through in the usual way to the adjacent terminal.

BZxxxx

The EtherCAT Terminals and Bus Terminals can be individually labeled with standard contact signs. The marking material is not included in the Terminal delivery. Signs with markings for the supply voltages are supplied together with the EtherCAT and Bus Couplers, but can be changed if required.

ELxxxx-0020/-0030 | Calibration certificates

ELxxxx-0020/-0030 | Calibration certificates

Analog calibration certificates enable the verification of the precise measurement deviation of the device.

EL3403

The EL3403 EtherCAT Terminal enables the measurement of all relevant electrical data of the supply network. The voltage is measured via the direct connection of L1, L2, L3 and N. The current of the three phases L1, L2 and L3 is fed via simple current transformers. All measured currents and voltages are available as root-mean-square values. In the EL3403 version, the effective power and the energy consumption for each phase are calculated. The root-mean-square value of voltage U, current I and the effective power P, apparent power S, reactive power Q, frequency F and phase shift angle cos φ can be derived. The EL3403 provides a comprehensive network analysis and an energy management option.

EL3403-0010

The EL3403-0010 EtherCAT Terminal enables the measurement of all relevant electrical data of the supply network. The voltage is measured via the direct connection of L1, L2, L3 and N. The current of the three phases L1, L2 and L3 is fed via simple current transformers. All measured currents and voltages are available as root-mean-square values. In the EL3403-0010 version, the effective power and the energy consumption for each phase are calculated. The root-mean-square value of voltage U, current I and the effective power P, apparent power S, reactive power Q, frequency F and phase shift angle cos φ can be derived. The EL3403-0010 provides a comprehensive network analysis and an energy management option.

EL3413

The EL3413 EtherCAT power measurement terminal is a further development of the EL3403. With up to 690 V AC the voltage inputs are optimised for direct monitoring of high-performance generators, as used in the wind power industry, for example. No upstream voltage transformer is required. The current inputs are galvanically isolated so that the terminal can be used in all common grounded current transformer configurations such as 2- or 3-transformer configurations with star or delta connection. The EL3413 can deal with simple network analysis up to the 21st harmonic analysis. Like all measured terminal data, the harmonic content can be read via the process data.

EL3433

The EL3433 EtherCAT power measurement terminal is a further development of the EL3403. Currents of up to 10 A can be directly measured with the internal current transformers. This way, there are no additional costs for external current transformers. The external bridges 5 & 1', 6 & 2' and 7 & 3' are already pre-wired. As a result, it is possible to directly connect the supply voltage (5', 6' and 7') and the consumer (1, 2 and 3). The EL3433 can deal with simple grid analysis up to the 21st harmonic analysis. Like all measured terminal data, the harmonic content can be read via the process data.