Data acquisition, monitoring, and control systems for photovoltaic power plants, battery storage and industrial facilities.

System capabilities

Configure the system around your operation

Project description

The basic project of a local SCADA system for a solar power station is built using a ready-made Application Set distributed by Copa Data.

The necessary minimum has been implemented to ensure the operation of the power station:

• •Dashboard with general station information: current power, energy meters, list of inverters, and their status.
• •Extended inverter information panel: power, AC and DC currents and voltages, generated energy, serial number, and decoded status and error registers.
• •Single Line Diagram (SLD) for substation monitoring: power, import/export energy meters, currents, voltages (over 50 parameters), and transformer temperature.
• •Operating mode control for the entire station and each inverter individually.
• •Alarm and event logging.
• •Historian.
• •Trends.

Network equipment configuration, remote access, and network monitoring are also implemented using Zabbix and Grafana.

Project description

SmartObject is a Zenon technology that makes implemented objects easy to reuse, much like classes in traditional programming. A SmartObject can include tags, screens, screen templates, functions, logic, and other project components.

When a SmartObject instance is added to a project, its variables, functions, screens, and other components are created and numbered automatically, saving development time. Changes such as adding tags are then automatically updated across all instances in the project.

The SmartObject for Huawei SUN2000 series inverters provides the core functions needed for diagnostics and control:

• •Overview screen with inverter current, voltage, frequency, and meter readings.
• •DC input status, including voltage and current.
• •Power indicator screen with a graph.
• •Inverter status details: temperature, insulation resistance, efficiency, operating mode, and error codes.
• •Error register decoding with status indication.
• •Settings and control screen.

Project description

The dispatching system for geographically distributed solar power plants is built on the Zenon SCADA platform.

One of its main advantages over ready-made systems from equipment manufacturers is the ability to monitor and control all available equipment at the same time: inverters, analyzers, controllers, relay protection, switches, power meters, and weather stations.

The system consists of individual solar power plant projects united under one global project. It provides centralized control, key metric calculations, event and alarm logging, graph visualization, and more. Each station has its own equipment types, templates, settings, and operating algorithms, which can be changed independently of other stations.

When power plants follow a typical design, as is often the case within one organization, a new station can usually be added by copying an existing project and making minor settings changes. This makes it possible to add another power plant to the SCADA system within hours.

Features

• •Dashboards for visualizing key station metrics.
• •Overall station management dashboard.
• •Alarm and event logging.
• •Historian.
• •Trends.

Every power plant project contains

• •Interactive diagram with a map of inverters.
• •Single Line Diagram (SLD).
• •Detailed inverter panel showing power, AC and DC currents and voltages, generated energy, serial number, and decoded status and error registers.
• •Control window for the entire station and individual sections or substations.
• •Settings window.

Project description

Equipment utilization monitoring for production machinery such as CNC machines, presses, and paint booths is implemented by measuring electrical current and determining the operating mode from its magnitude.

Each measurement point can be in one of three modes: off, idle, or operational. Analysis of current values from the network analyzers identifies downtime and operating periods across a shift, day, or week. Results appear on clear dashboards and update in real time.

In OEE (Overall Equipment Effectiveness) terminology, the system calculates the availability criterion, a fundamental input for further OEE calculations. Availability depends on different types of downtime, including breakdowns and failures, lack of raw materials, or lack of operator attention.

Advantages

• •Automatic operating mode detection eliminates the human factor and requires no operator action.
• •No intervention in the machine’s electrical circuit is needed.
• •Integrates with ammeters, electricity meters, and network analyzers equipped with a digital output.

System configuration

The monitoring system covers a production site supplied by multiple sources and serving multiple end-users. The electrical equipment includes:

• •Low-voltage input from the substation.
• •Genset.
• •Photovoltaic power plant.
• •Automatic transfer switch (ATS).
• •End-user measurement points.

The substation, genset, and photovoltaic plant inputs are monitored by Socomec DIRIS A20 network analyzers with RS485 communication modules using Modbus RTU. The ATS controller connects through a MikroTik KNOT Modbus RTU/TCP gateway. End-user metering points are monitored by the Socomec Digiware system.

Python scripts write parameter values directly to a database hosted on a separate virtual machine.

Parameters collected at each measurement point

• •Phase-to-neutral voltages.
• •Phase-to-phase voltages.
• •Phase currents.
• •Per-phase active and reactive power.
• •Average voltage and current.
• •Total active, reactive, and apparent power.
• •Total harmonic distortion (THD) for voltage and current.
• •Power factor, averaged and by phase.
• •Import and export energy counters for active, reactive, and apparent energy.
• •Connection quality.

ATS parameters saved to the database

• •Operating mode.
• •Status code.
• •Error code.
• •Voltage on both inputs.
• •I/O state.

Grafana dashboards

• •Current electrical parameters for end-users.
• •Current ATS and genset parameters.
• •Trends and historian.
• •Power consumption report for each measurement point.

System configuration

The monitoring system supervises the power supply of a medium-sized factory. It consists of a low-voltage source input measurement point and five power distribution panels (PDPs) distributed across the site.

Each measurement point uses a Socomec DIRIS A20 with an RS485 communication module (Modbus RTU). A MikroTik KNOT gateway connects the analyzers using Modbus RTU/TCP.

Python scripts send parameter values to Zabbix and store them in a database hosted on a separate virtual machine.

Parameters collected at each measurement point

• •Phase-to-neutral voltages.
• •Phase-to-phase voltages.
• •Phase currents.
• •Per-phase active and reactive power.
• •Average voltage and current.
• •Total active, reactive, and apparent power.
• •Total harmonic distortion (THD) for voltage and current.
• •Power factor, averaged and by phase.
• •Import and export energy counters for active, reactive, and apparent energy.
• •Connection quality.

Grafana dashboards

• •Power by measurement point and total power.
• •Current values for every measurement point.
• •Trends and historian.
• •Power consumption report for each measurement point.

Project description

The SCADA system configures and controls heating at a printing company consisting of two office buildings and two production buildings. Each room has its own heating circuit with a pump and temperature sensor, controlled by an individual controller.

Implemented features

• •Overview screen showing room temperatures and the operating modes of heating circuits.
• •Circuit configuration screens for hour-by-hour daily schedules, weekend operating modes, and manual control.
• •Charts showing room temperatures and heating circuit pump operation.

Project description

Cleanliness and indoor climate are critical during the production and storage of medicines. Temperature and humidity are monitored in the rooms. In cleanrooms, the system also measures the positive air pressure supplied to prevent dust from entering.

Implemented features

• •Room layouts with visualized measurement values.
• •Data archiving and trend charts.
• •Alarm log.
• •Reports on measurement deviations.
• •SMS notifications for alarm conditions.

Project description

The system monitors the power supply of an office center with four electrical inputs. It stores the main electrical parameters, including phase and phase-to-phase voltages, currents, active, reactive and apparent power, power factor, and meter readings.

The status of all four automatic transfer switches (ATS) is also recorded, including switch position and the generator start signal.

The interface provides

• •A table of current parameter values.
• •Historical and real-time charts.
• •A dashboard with selected parameters.

Project description

The system records the number of parts produced by a stamping press. The part type is detected automatically in the PLC program according to the installed die. Accumulated counter values are read from the PLC at regular intervals and stored in a database.

Reports generated from the accumulated data

• •Production output (number of parts produced) for a selected period.
• •Amount of material used.
• •Number of parts produced in a selected period, grouped by part type.
• •Downtime.

Project description

The system monitors the temperature profiles of a hardening furnace. Current and setpoint temperatures from six measurement points are read over Modbus and stored in a database.

The interface allows users to

• •View real-time values with indication when they exceed permitted limits.
• •View current and historical charts.
• •Change settings.