New Standards for Production:
Modular, Digital, Flexible
Standards ensure reliability and safety in production. However, at one of its key manufacturing sites, a major automotive manufacturer reached the limits of this approach. For years, a company-wide standard had been in place for building distribution systems, specifying a fixed number of sections and circuit breakers. While this approach reduced installation times for new systems and simplified maintenance, it came with a critical drawback: it lacked flexibility for future modifications. In addition, operators installed components that, in some cases, remained unused throughout their entire lifecycle.
In 2001, the company began transitioning to digital metering technology, starting with an initial test device from Janitza. This led to the development of new measurement concepts and internal standards. The UMG 801 expandable modular power analyzer introduced a new level of flexibility. With multiple modules, the device can monitor up to 22 outgoing circuits with 3- and 4-channel measurement.
Janitza’s local partner, sys.tec building automation, supported the development. “The basic allocation of circuits within a distribution panel can be planned, but changes almost always occur during the construction phase,” explains sys.tec employee Mike Rösch. The project therefore required a system that could evolve alongside changing requirements. The result was a building distribution system in which only the incoming feeder is measured as standard. Once all connections are in place, technicians decide where and how outgoing circuits should be monitored. sys.tec can easily add new current measurement channels by attaching additional modules to the pre-installed data rail and configuring them. The measurement data is then immediately available.
From Displays to Panels – Rethinking Visualization
In this setup, the UMG 801 acts as an independent network device and connects directly to Janitza’s central GridVis® power grid monitoring software. This allows technicians to access measurement data on-site via an operator panel mounted on the distribution system or check the status of circuit breakers at any time. “Without needing to carry a PC, users can access all information through centralized web applications, including both real-time and historical data.” This combination of modular measurement technology and touch panel significantly enhances flexibility.
Current transformers are no longer pre-installed either. Instead, technicians install them as needed, depending on the application. In addition, residual current transformers detect leakage currents, enabling early identification of developing insulation faults. Operators can take corrective action long before such issues lead to production downtime.
Transparency from Day One
In many cases, these measurements begin long before a building becomes operational. Even during the construction phase, they provide transparency and safety across the entire site. It is particularly beneficial to implement residual current monitoring already in temporary construction power distribution systems. If critical values are detected, systems can be disconnected from the grid early—before any damage occurs.
The full digitalization of measurement data also unlocks new possibilities for monitoring and energy management. In the future, technicians will be able to access all relevant information through centralized applications—whether on desktop systems or via smart glasses—enabling virtual system inspections and targeted selection of measurement points. All data is integrated into a unified interface, providing a fast and comprehensive overview. With modular measurement devices and GridVis® software, users gain a wide range of options.
What was once a rigid standard evolved into a flexible system that adapts to new requirements—laying the foundation for future, demand-driven standards.