SUMMARY
This reference explains how to configure, interpret, and analyse data collected from the Factbird Clip-on Current Transducer. It includes configuration recommendations, data multiplier calculations, measurement limitations, accuracy information, visualization options, and alarm configuration.
OVERVIEW
The Clip-on Current Transducer is an analog energy monitoring solution that estimates machine power consumption by measuring electrical current.
Unlike a digital energy meter, it estimates power consumption rather than measuring true electrical power directly. It supports both single-phase and three-phase installations and can be analysed alongside production data to identify energy waste and efficiency improvements.
BENEFITS
The Clip-on Current Transducer allows you to:
- Install energy monitoring without modifying machine wiring.
- Monitor standby energy consumption.
- Compare energy consumption across products, batches, and shifts.
- Identify abnormal energy usage.
- Trigger alarms when consumption exceeds expected levels.
- Reduce operating costs by identifying inefficient equipment.
CONFIGURATION REFERENCE
Sensor Type
Configure the sensor as:
- Measurement
Wiring
Configure:
- ANALOG
Analog Range
Select:
- 4–20 mA
Sensor Minimum
Normally:
- 0
If a small positive or negative reading appears while the machine is idle, adjust the minimum value to compensate for component tolerances.
Sensor Maximum
Set this to the maximum rating of your current transducer.
Examples:
| Current Transducer | Sensor Maximum |
|---|---|
| 50 A | 50 |
| 150 A | 150 |
| 250 A | 250 |
| 500 A | 500 |
Data Unit
Configure:
- Power
Custom label:
- kW
DATA MULTIPLIER
The data multiplier converts measured current into estimated power.
Formula:
Power (kW) = Current × Voltage ÷ 1000
Examples:
| Electrical System | Data Multiplier |
|---|---|
| 230 V (EU single-phase) | 0.23 |
| 400 V three-phase (balanced) | 0.23 |
If your installation uses another voltage, calculate the multiplier using the local supply voltage.
VISUALISING DATA
Energy consumption can be viewed in several places throughout Factbird.
Live View
Displays:
- Real-time power consumption (kW)
- Total energy consumed (kWh)
- Average energy consumption for the selected period
Overlay Graphs
Overlay production counts with energy consumption to identify relationships between production output and power usage.
Examples include:
- High energy during low production.
- High standby consumption.
- Increased power during machine wear.
Line KPI
When the data unit is configured as Power or Current, Factbird automatically creates a Consumed KPI.
If multiple energy sensors exist on the same line, their values are summed into a single KPI.
ALARMS
The Clip-on Current Transducer supports standard analog alarms.
Supported alarm criteria include:
- Value exceeds limit.
- Value below limit.
- Time outside limits.
- Multiple occurrences within a time window.
Notifications can be sent by:
- SMS
Alarm thresholds appear as red dotted lines on the Live graph.
MEASUREMENT ACCURACY
Overall accuracy depends on several factors.
Component Accuracy
| Component | Accuracy |
|---|---|
| LEM Current Transducer | ±1.5% FS |
| J&D Current Transducer | ±1.5–2% FS |
| ifm DP2200 | ±0.75% FS |
Additional Sources of Error
Estimated power may differ from actual power because the calculation assumes:
- Fixed supply voltage.
- Constant power factor (unless manually compensated).
- Measurements every five seconds.
- Balanced electrical loads where applicable.
Unbalanced three-phase delta systems may produce less accurate results.
LIMITATIONS
The Clip-on Current Transducer estimates power consumption using measured current.
It does not:
- Measure voltage directly.
- Measure power factor automatically.
- Replace certified energy meters.
- Provide billing-grade energy measurements.
For higher-precision measurements, use a supported digital energy meter instead.