⚡ Energy Monitoring System (EMS)

A complete IoT-based real-time energy monitoring solution using ESP32, Modbus RTU, MQTT, and Node-RED Dashboard with local DWIN HMI Display.

📸 Project Gallery

Hardware Setup	DWIN Display	Node-RED Dashboard

ESP32 + MAX485 + Energy Meter	Live HMI Display	Live Gauges

Block Diagram	Circuit Diagram

System Architecture	Complete Wiring

📋 Table of Contents

⚡ Overview
✨ Features
🏗️ System Architecture
🔧 Hardware Components
📌 Pin Connections
💻 Software Stack
📡 Communication Protocols
🗺️ Modbus Register Map
📊 Dashboard
⚠️ Alert System
🌐 Network Configuration
🚀 Getting Started
📁 Project Structure
🔮 Future Enhancements
👨‍💻 Author

⚡ Overview

The Energy Monitoring System (EMS) is a complete Industrial IoT solution that monitors electrical parameters of loads in real-time. The system reads data from a Modbus RTU energy meter using an ESP32 microcontroller, transmits data wirelessly via WiFi + MQTT, and visualizes it on a Node-RED dashboard. A local DWIN HMI display shows live readings on-site.

📊 5 Parameters  |  🔄 10s Update Rate  |  📡 WiFi + MQTT  |  🖥️ Local HMI  |  🚨 Smart Alerts

✨ Features

📡 Data Acquisition ✅ Modbus RTU over RS485 ✅ 5 electrical parameters ✅ 10-second update rate ✅ IEEE 754 float conversion	🖥️ Local Display ✅ DWIN HMI Touch Screen ✅ Real-time value updates ✅ UART @ 115200 baud ✅ 5 VP address mapping	🌐 IoT Connectivity ✅ WiFi 2.4GHz (STA mode) ✅ MQTT publish/subscribe ✅ Aedes local broker ✅ Auto reconnect
📊 Dashboard ✅ Live circular gauges ✅ Historical line charts ✅ Numeric text display ✅ 2-tab layout	🚨 Alert System ✅ Voltage range check ✅ Current overload ✅ Frequency instability ✅ Low power factor	🌐 HTTP API ✅ REST GET endpoint ✅ JSON response ✅ CORS enabled ✅ Latest data access

🏗️ System Architecture

┌─────────────────────────────────────────────────────────────────────────┐
│                    EMS SYSTEM ARCHITECTURE                              │
├─────────────────────────────────────────────────────────────────────────┤
│                                                                         │
│  ┌──────────────┐    RS485     ┌──────────────┐    UART     ┌────────┐ │
│  │ ENERGY METER │◄────────────►│   MAX485     │◄───────────►│ ESP32  │ │
│  │ Modbus Slave │   A+ / B-   │  RS485↔TTL   │  GPIO32,27  │DevKit  │ │
│  │  Slave ID:1  │              │  GPIO33(DE)  │             │        │ │
│  └──────────────┘              └──────────────┘             │        │ │
│                                                             │        │ │
│  ┌──────────────┐    UART1                                  │        │ │
│  │    DWIN      │◄────────────────────────────────────────►│        │ │
│  │   Display    │  GPIO16(RX) GPIO17(TX) @ 115200          │        │ │
│  │  HMI Touch   │                                          └───┬────┘ │
│  └──────────────┘                                              │      │
│                                                          WiFi  │      │
│                                                         2.4GHz │      │
│                                                                ▼      │
│  ┌──────────────┐  MQTT:1883  ┌──────────────┐   LAN  ┌──────────┐  │
│  │   NODE-RED   │◄────────────│ AEDES BROKER │◄───────│  ROUTER  │  │
│  │  Dashboard   │  Topic:     │ 192.168.1.8  │        │192.168.  │  │
│  │  :1880/ui    │  EMS/UCT    │   Port:1883  │        │   1.1    │  │
│  └──────┬───────┘             └──────────────┘        └──────────┘  │
│         │                                                             │
│    ┌────┴──────────────────────────┐                                 │
│    ▼              ▼                ▼                                  │
│ ┌──────┐    ┌──────────┐    ┌──────────┐                            │
│ │Gauge │    │  Charts  │    │  Alerts  │                            │
│ │  UI  │    │ Tab View │    │  Popup   │                            │
│ └──────┘    └──────────┘    └──────────┘                            │
└─────────────────────────────────────────────────────────────────────────┘

🔧 Hardware Components

#	Component	Model	Qty	Purpose
1	🧠 ESP32 DevKit	ESP32-WROOM-32	1	Main IoT Controller
2	⚡ Energy Meter	Modbus RTU Type	1	Measure Electrical Parameters
3	🔌 MAX485 Module	RS485 to TTL	1	RS485 Interface
4	🖥️ DWIN Display	HMI Touch Screen	1	Local Real-time Display
5	📶 WiFi Router	2.4GHz Router	1	Wireless Network
6	⚙️ Power Supply	5V DC Adapter	1	Power for ESP32
7	💻 PC / Laptop	Linux/Windows	1	Node-RED Host
8	🔗 Jumper Wires	M-F Set	Set	Connections

📌 Pin Connections

🖥️ DWIN Display ↔ ESP32

DWIN Pin	ESP32 Pin	GPIO	Signal
TX	RX1 (U1RXD)	GPIO 16	DWIN → ESP32
RX	TX1 (U1TXD)	GPIO 17	ESP32 → DWIN
VCC	5V	5V	Power
GND	GND	GND	Ground

🔌 MAX485 Module ↔ ESP32

MAX485 Pin	ESP32 Pin	GPIO	Signal
RO (Receive Out)	Custom RX	GPIO 32	RS485 → ESP32
DI (Data Input)	Custom TX	GPIO 27	ESP32 → RS485
DE (Driver Enable)	Control	GPIO 33	TX Enable
RE (Receiver Enable)	Control	GPIO 33	RX Enable (tied to DE)
VCC	5V	5V	Power
GND	GND	GND	Ground

⚡ MAX485 ↔ Energy Meter

MAX485	Energy Meter	Description
A+	A+	RS485 Positive Line
B-	B-	RS485 Negative Line

🔌 Complete Wiring

ESP32 DevKit
├── GPIO 16 (RX1) ──────────────→ DWIN Display TX
├── GPIO 17 (TX1) ──────────────→ DWIN Display RX
├── GPIO 32       ──────────────→ MAX485 RO
├── GPIO 27       ──────────────→ MAX485 DI
├── GPIO 33       ──────────────→ MAX485 DE + RE (tied)
├── 5V            ──────────────→ DWIN VCC + MAX485 VCC
└── GND           ──────────────→ DWIN GND + MAX485 GND

MAX485
├── A+  ──────────────────────→ Energy Meter A+
└── B-  ──────────────────────→ Energy Meter B-

💻 Software Stack

Layer	Technology	Version	Purpose
Firmware	Arduino IDE (C++)	2.x	ESP32 Programming
IoT Protocol	MQTT (PubSubClient)	2.8+	Data Publishing
Serial Protocol	Modbus RTU (ModbusMaster)	2.0.1	Meter Reading
Data Format	ArduinoJson	6.x	JSON Serialization
Dashboard	Node-RED	3.x	Visualization
MQTT Broker	Aedes (Node-RED)	Latest	Local Broker
UI Framework	node-red-dashboard	3.x	Gauges & Charts

📦 Arduino Libraries

#include <WiFi.h>           // WiFi connection
#include <PubSubClient.h>   // MQTT client
#include <ModbusMaster.h>   // Modbus RTU master
#include <ArduinoJson.h>    // JSON v6+
#include <SoftwareSerial.h> // Modbus UART
#include <HardwareSerial.h> // DWIN UART

📡 Communication Protocols

1️⃣ Modbus RTU (RS485)

┌─────────────────────────────────────┐
│         MODBUS RTU CONFIG           │
├─────────────────┬───────────────────┤
│ Baud Rate       │ 9600 bps          │
│ Data Bits       │ 8                 │
│ Parity          │ None              │
│ Stop Bits       │ 1 (8N1)           │
│ Slave ID        │ 1                 │
│ Function Code   │ 0x04 (Read Input) │
└─────────────────┴───────────────────┘

2️⃣ MQTT Protocol

┌─────────────────────────────────────┐
│           MQTT CONFIG               │
├─────────────────┬───────────────────┤
│ Broker          │ Aedes (Local)     │
│ Host            │ 192.168.1.8       │
│ Port            │ 1883              │
│ Topic           │ EMS/UCT           │
│ QoS             │ 0                 │
│ Publish Rate    │ Every 10 seconds  │
└─────────────────┴───────────────────┘

3️⃣ MQTT JSON Payload

{
  "Voltage"     : 230.5,
  "Current"     : 1.25,
  "Frequency"   : 49.98,
  "PowerFactor" : 0.95,
  "Energy"      : 0.52
}

🗺️ Modbus Register Map

Parameter	Register (Hex)	Register (Dec)	Data Type	Unit
⚡ Voltage	`0x15`	21	32-bit IEEE Float	V
🔌 Current	`0x17`	23	32-bit IEEE Float	A
〰️ Frequency	`0x1B`	27	32-bit IEEE Float	Hz
📐 Power Factor	`0x19`	25	32-bit IEEE Float	PF
🔋 Active Energy	`0x0E`	14	32-bit Float (Swapped)	kWh

🖥️ DWIN VP Address Map

Parameter	VP Address	Unit
Voltage	`0x64`	V
Frequency	`0x65`	Hz
Energy	`0x66`	kWh
Current	`0x67`	A
Power Factor	`0x68`	PF

📊 Dashboard

Tab 1 — ⚡ Live Dashboard

Gauge	Min	Max	Yellow	Red	Unit
Voltage	0	300	200	260	V
Current	0	100	50	80	A
Frequency	45	55	49	51	Hz
Power Factor	0	1	0.7	0.9	PF
Active Power	0	50	20	40	kW

Tab 2 — 📈 Historical Charts

Chart	Y-Min	Y-Max	Color	Points
Voltage (V)	200	260	`#00d4ff` 🔵	60
Current (A)	0	50	`#ff6b35` 🟠	60
Frequency (Hz)	49	51	`#a8ff3e` 🟢	60
Power Factor	0	1	`#ff3ecc` 🟣	60
Active Power (kW)	0	50	`#ffd700` 🟡	60

🌐 Access Dashboard

Dashboard URL : http://127.0.0.1:1880/ui
HTTP API      : http://192.168.1.8:1880/api/ems
Node-RED      : http://127.0.0.1:1880

⚠️ Alert System

Parameter	Condition	Alert Message
⚡ Voltage	`< 200V` or `> 260V`	`Voltage OUT OF RANGE: xxV`
🔌 Current	`> 80A`	`Current HIGH: xxA`
〰️ Frequency	`< 49.5Hz` or `> 50.5Hz`	`Frequency UNSTABLE: xxHz`
📐 Power Factor	`< 0.8`	`Low Power Factor: x.xx`

🔔 Alerts appear as popup notifications on the dashboard in real-time!

🌐 Network Configuration

┌─────────────────────────────────────────────┐
│              NETWORK TOPOLOGY               │
├──────────────┬──────────────┬───────────────┤
│ Device       │ IP Address   │ Port          │
├──────────────┼──────────────┼───────────────┤
│ WiFi Router  │ 192.168.1.1  │ —             │
│ PC (WiFi)    │ 192.168.1.8  │ 1883, 1880    │
│ ESP32        │ 192.168.1.x  │ —  (DHCP)     │
│ MQTT Broker  │ 192.168.1.8  │ 1883          │
│ Node-RED     │ 127.0.0.1    │ 1880          │
└──────────────┴──────────────┴───────────────┘

⚠️ Important: ESP32 supports 2.4GHz WiFi only — 5GHz will NOT work!

🚀 Getting Started

Prerequisites

# Arduino IDE Libraries (Install via Library Manager)
✅ PubSubClient       by Nick O'Leary
✅ ModbusMaster       by Doc Walker
✅ ArduinoJson        v6+ by Benoit Blanchon

# Node-RED Packages
✅ node-red-dashboard
✅ node-red-contrib-aedes

Step 1 — ESP32 Setup

// Update WiFi credentials in code
const char* ssid     = "YOUR_WIFI_SSID";
const char* password = "YOUR_WIFI_PASSWORD";
const char* mqtt_server = "YOUR_PC_IP";  // e.g. 192.168.1.8

# Upload via Arduino IDE
Board   : ESP32 Dev Module
Port    : COMx (Windows) or /dev/ttyUSB0 (Linux)
Upload Speed : 115200

Step 2 — Node-RED Setup

# Install Node-RED (if not installed)
npm install -g node-red

# Start Node-RED
node-red

# Open browser
http://127.0.0.1:1880

Step 3 — Import Flow

☰ Menu → Import → Select file → Node Red JSON file/nodered_aedes_flow.json → Import → Deploy

Step 4 — View Dashboard

🌐 Open browser: http://127.0.0.1:1880/ui

Step 5 — Verify Serial Monitor

✅ WiFi Connected!
✅ IP Address: 192.168.1.x
✅ MQTT Connected!
✅ Active Power (kW): xx.xx
✅ Publish message: {"Voltage":230.5,...}

📁 Project Structure

📦 Energy Monitoring System/
├── 📂 Code/
│   └── 📄 EMS_Final_Code.ino          # ESP32 Arduino Firmware
│
├── 📂 Document/
│   ├── 📄 EMS_Documentation.docx      # Full Technical Documentation
│   └── 📄 EMS_Full_Documentation.docx # English Detailed Doc
│
├── 📂 image/
│   ├── 🖼️ EMS_Block_Diagram.png       # System Block Diagram
│   ├── 🖼️ EMS_Circuit_Diagram.jpg     # Circuit Wiring Diagram
│   ├── 🖼️ image1.jpg                  # Node-RED Dashboard
│   ├── 🖼️ image2.jpg                  # Live Gauges
│   ├── 🖼️ image3.jpg                  # DWIN Display
│   ├── 🖼️ image4.jpg                  # Hardware Setup
│   └── 🖼️ image5.jpg                  # Energy Meter
│
├── 📂 Node Red JSON file/
│   └── 📄 nodered_aedes_flow.json     # Node-RED Flow Export
│
└── 📄 README.md                       # This File ← You are here!

🔮 Future Enhancements

💾 Database Integration — InfluxDB / MySQL for historical storage
📧 Email/SMS Alerts — Critical event notifications
📱 Mobile App — React Native / Flutter
💰 Billing Calculator — Monthly electricity bill from kWh
📊 Grafana Dashboard — Professional time-series visualization
☁️ Cloud Integration — AWS IoT / Azure IoT Hub
🔧 OTA Updates — Over-the-air ESP32 firmware updates
📈 Multi-Meter Support — Monitor multiple energy meters

🐛 Troubleshooting

Problem	Cause	Solution
WiFi not connecting	Wrong SSID or 5GHz router	Use 2.4GHz, check credentials
MQTT failed (rc=-2)	Wrong broker IP	Check `mqtt_server` IP
Modbus no data	Wrong A+/B- wiring	Swap RS485 wires
DWIN blank	Wrong GPIO or baud	Check GPIO 16/17, 115200
Dashboard empty	MQTT disconnected	Redeploy Node-RED flow

👨‍💻 Author

Ramsudarshan Maurya

Embedded Systems & IoT Engineer

B.Tech ECE — AKTU Lucknow (2025) | CGPA: 7.4 UniConverge Technologies, Noida (Intern)

Skills: C C++ ESP32 STM32 FreeRTOS MQTT BLE Modbus IoT

🏆 RoboRace 1st Prize | 📄 Published Researcher | 🟢 Open to Work

📄 License

MIT License — Free to use, modify, and distribute with attribution.
Copyright (c) 2025 Ramsudarshan Maurya

⭐ If this project helped you, please give it a star!

Made with ❤️ by Ramsudarshan Maurya

ESP32 + Modbus RTU + MQTT + Node-RED = Complete EMS Solution ⚡

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⚡ Energy Monitoring System (EMS)

📸 Project Gallery

📋 Table of Contents

⚡ Overview

✨ Features

📡 Data Acquisition

🖥️ Local Display

🌐 IoT Connectivity

📊 Dashboard

🚨 Alert System

🌐 HTTP API

🏗️ System Architecture

🔧 Hardware Components

📌 Pin Connections

🖥️ DWIN Display ↔ ESP32

🔌 MAX485 Module ↔ ESP32

⚡ MAX485 ↔ Energy Meter

🔌 Complete Wiring

💻 Software Stack

📦 Arduino Libraries

📡 Communication Protocols

1️⃣ Modbus RTU (RS485)

2️⃣ MQTT Protocol

3️⃣ MQTT JSON Payload

🗺️ Modbus Register Map

🖥️ DWIN VP Address Map

📊 Dashboard

Tab 1 — ⚡ Live Dashboard

Tab 2 — 📈 Historical Charts

🌐 Access Dashboard

⚠️ Alert System

🌐 Network Configuration

🚀 Getting Started

Prerequisites

Step 1 — ESP32 Setup

Step 2 — Node-RED Setup

Step 3 — Import Flow

Step 4 — View Dashboard

Step 5 — Verify Serial Monitor

📁 Project Structure

🔮 Future Enhancements

🐛 Troubleshooting

👨‍💻 Author

Ramsudarshan Maurya

📄 License

⭐ If this project helped you, please give it a star!

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