Factory submetering system

https://episensor.com/system-builder/examples/factory-submetering

A food factory wants to see where its electricity and gas go, and to keep a record of two freezer rooms.

€8,791.00 hardware, before tax and delivery

System diagram

  • Zigbee
  • Wired
  • Edge
Field measurement
Interface
Gateway
Local Edge
12 circuitsElectricity
1 meterNatural gas
2 locationsCold rooms, fridges and freezers
12 × ZEM-65Wireless 3-Phase Electricity Monitor
1 × ZPC-10Pulse Counter
2 × TES-22Probe Temperature Sensor
ZGW-20Gateway
EdgeLocal data, alarms and rules
Zigbee mesh
Voltage and CT inputs
Pulse input
Probe
Runs locally
Energy management: electricity, gas and cold rooms. Field measurements connect through the planned EpiSensor devices to a ZGW-20 Gateway, which runs Edge locally.

Parts list

Field devices

Gateway and software

Optional

Support Subscription
€16.00 / monthbilled annually, €192.00 ex VAT

Engineering support for each Gateway, billed annually.

Core Subscription
€30.00 / monthbilled annually, €360.00 ex VAT

Remote fleet management for each Gateway, billed annually.

Hardware
€8,791.00once, before tax and delivery
Optional support and Core
€552.00a year, if you add them

How the plan was chosen

Each of the 12 three-phase circuits is fed through a breaker rated 120 A or less, and every phase conductor fits a 14 mm aperture, so each circuit gets its own Wireless 3-Phase Electricity Monitor with 120 A split-core CTs. The CTs arrive fitted and calibrated to the monitor, so the Class 0.5S accuracy covers the whole measurement.

The gas meter has a pulse output that never exceeds 4 Hz at full flow, so a battery-powered pulse counter reads it without a supply at the meter. The meter is outside any hazardous zone, so the counter sits beside it.

Each freezer room has two waterproof probes on 2.5 m leads, read by one dual-channel temperature sensor mounted outside the room. The waterproof probe holds ±0.5 °C down to −40 °C.

Fifteen EpiSensor devices report over a Zigbee mesh to one ZGW-20 Gateway, which runs Edge on site. EpiSensor devices need no licence. Support and Core are optional.

Read more

More example plans

  • Cold store temperature monitoring system

    A cold store runs four chill rooms and two freezers, and wants every room recorded with alarms, plus the energy the refrigeration plant uses.

    • 6 6 × Probe Temperature Sensor
    • 2 2 × Wireless 3-Phase Electricity Monitor
    • 1 1 × Gateway

    €3,913 hardware, before tax and delivery

  • Demand response site system

    A distribution centre with a 1,000 A incomer wants to shed a non-critical load when grid frequency falls, for a static frequency response programme.

    • 1 1 × Demand Response Controller
    • 1 1 × Gateway

    €5,244 hardware, before tax and delivery

Plan your own site

EpiSensorSystem plan

Energy management: electricity, gas and cold rooms

Equipment, connections and selection notes for your proposed system.

1 site · 15 EpiSensor devices · 1 Gateway

Open and edit this plan · episensor.com

System diagram

  • Zigbee
  • Wired
  • Edge
Field measurement
Interface
Gateway
Local Edge
12 circuitsElectricity
1 meterNatural gas
2 locationsCold rooms, fridges and freezers
12 × ZEM-65Wireless 3-Phase Electricity Monitor
1 × ZPC-10Pulse Counter
2 × TES-22Probe Temperature Sensor
ZGW-20Gateway
EdgeLocal data, alarms and rules
Zigbee mesh
Voltage and CT inputs
Pulse input
Probe
Runs locally
Energy management: electricity, gas and cold rooms. Field measurements connect through the planned EpiSensor devices to a ZGW-20 Gateway, which runs Edge locally.

Parts list

Budget planning only. Prices exclude VAT, delivery and installation. Confirm availability and final pricing before ordering.

Field devices

Equipment / ordering codeQtyUnit priceLine total
Wireless 3-Phase Electricity MonitorZEM-65-120120 A per phase split-core CTs, 14 mm aperture, 2 m cablesDatasheet 12 €593.75 €7,125.00
Pulse CounterZPC-10Single channel, battery powered, up to 4 HzDatasheet 1 €229.00 €229.00
Probe Temperature SensorTES-22-w2.5Dual channel, waterproof probes on 2.5 m cablesDatasheet 2 €269.00 €538.00

Gateway and software

Equipment / ordering codeQtyUnit priceLine total
GatewayZGW-20-UZ-NC-NW-EU-DT-C4-NS-NP-NIO-NR-W1-NSIMCommercial, standard compute, Zigbee, Ethernet, EU power supplyDatasheet 1 €899.00 €899.00

Optional · excluded from required totals

Equipment / ordering codeQtyUnit priceLine total
SupportSUP-GW-YEngineering support for each Gateway, billed annually. 1 €192.00per year €192.00per year
CoreCORE-GW-SUB-YRemote fleet management for each Gateway, billed annually. 1 €360.00per year €360.00per year
Hardware
€8,791.00
Optional annual services
€552.00 per year

Selection notes and confirmations

ZEM-65-120 · Wireless 3-Phase Electricity Monitor

For 12 circuits: Electricity

The 120 A split-core CTs close around a cable up to 14 mm across and cover the circuit rating on each phase, so nothing has to be read from an existing meter.

  • The CTs arrive fitted and calibrated against this meter, so Class 0.5S covers the whole measurement rather than the meter alone.
  • They are fitted inside a live panel, so a qualified electrician does the work and confirms the phase arrangement and the voltage reference.

ZPC-10 · Pulse Counter

For 1 meter: Natural gas

The battery-powered single-channel counter accepts pulses up to 4 Hz.

  • Pulses have to be at least 10 ms long with 10 ms between them, which is what sets the 4 Hz ceiling, and the input takes at most 35 V DC.

TES-22-w2.5 · Probe Temperature Sensor

For 2 locations: Cold rooms, fridges and freezers

Two points at one location, in a cold room, a freezer, a liquid or a damp area, on 2.5 m waterproof probes.

  • Waterproof probe, IP68. Holds ±0.2 °C from −20 to 70 °C, and ±0.5 °C down to −40 °C. In a freezer, mount the sensor outside and pass the lead through the door seal or a gland.

ZGW-20-UZ-NC-NW-EU-DT-C4-NS-NP-NIO-NR-W1-NSIM · Gateway

Every EpiSensor device reports over the Zigbee mesh to a Gateway, which runs Edge on site. One Gateway carries up to 250 devices.

  • Edge comes pre-installed and licensed for unlimited EpiSensor devices.

SUP-GW-Y · Support (optional)

Direct access to EpiSensor engineers for commissioning questions, faults and firmware, for each Gateway.

CORE-GW-SUB-Y · Core (optional)

Core manages every Gateway from one place: health, updates, backups and remote access.

Your answers

Electricity
12 three-phase circuits up to 120 A per phase, cables up to 14 mm, measured with CTs
Natural gas
1 gas meter with a 4 Hz pulse output, outside any hazardous zone
Cold rooms, fridges and freezers
2 locations with two waterproof probes on 2.5 m leads