Compiled by Eamonn Ryan
With the current trends of Internet of Things (IoT) and Industry 4.0 (4IR), all OEM air-handling-unit and chiller manufacturers are looking for intelligent components with bus-protocol communication.
FUNCTIONS IN THE FOLLOWING MANNER:
- Connect – the system connects every device within a machine and shop floor
- Collect – it captures critical data at every level from sensor to cloud
- Analyse – it converts data into meaningful analytics
- Act – it drives action through real-time information and business logic
Through Industry 4.0, all industrial networks have been standardised. Nevertheless, there are still many different industrial network systems such as Profinet, Profibus, Modbus, BACnet, EtherCAT, Bluetooth and more.
The use of connected capabilities integrating machine/asset health monitoring and providing analytics for failure prediction to improve operational efficiency and performance and establish product condition transparency also:
- Increases asset utilisation and availability
- Decreases operational cost and downtime
- Extends the lifespan of a machine and optimises energy consumption significantly
- Improves productivity, service and quality
SEAMLESS COMPATIBILITY AT THE CORE OF ZIEHLABEGG’S CONTROL SOLUTIONS
Ziehl-Abegg South Africa provides a comprehensive range of advanced control solutions tailored to meet the evolving needs of customers in respect of control systems and their integration into HVAC infrastructure.
Managing director Marius du Plessis of Ziehl-Abegg South Africa says, “When comparing us to a direct competitor on fans, it’s important to note that our control layout is unique. We manufacture our own sensors, which gives us a distinct advantage in offering tailored solutions for both small and large-scale applications. We’ve undertaken projects involving units with up to 15 fans, demonstrating an ability to cater to diverse needs.”
A significant aspect of Ziehl-Abegg’s offerings is its support for various communication protocols, enhancing interoperability and compatibility with different systems. “We support a wide range of communication protocols, including BACnet, CANbus, Modbus, PROFIBUS and more. This flexibility allows us to integrate seamlessly with existing HVAC systems and automation processes,” he says.
He adds that the fan manufacturer offers a wide range of industrial networks and add-on modules, ensuring maximum flexibility and ease of integration for customers. Bluetooth modules provide real-time monitoring, offering convenience and safety for operators.
“We offer a wide array of sensors tailored to different parameters, from temperature and velocity to flow, humidity, CO2 and CO sensors” explains Du Plessis.
Pointing to a setup demonstrating flow measurement, he elaborates, “This setup utilises a primary flow sensor to measure volumetric flow. By calculating the differential pressure across the unit, our controller accurately determines the flow rate. Moreover, our controllers feature temperature compensation capabilities, adjusting setpoints based on external temperature inputs for enhanced accuracy.”
Demonstrating the integration of its controllers into HVAC systems, Du Plessis highlights the flexibility of the solutions. “Our controllers can measure downstream pressure after filters and adjust fan speed accordingly. Whether it’s controlling airflow or compensating for external factors, they offer comprehensive control and monitoring capabilities.”
For larger installations such as centralised air conditioning systems, Ziehl-Abegg’s controllers seamlessly integrate with existing building management systems (BMS) infrastructure. Innovation is key when discussing advancements in sensor technology and control algorithms. “We’re investing in AI integration to enhance data collection and analysis, enabling predictive maintenance and optimising system performance.”
Future developments include wireless modules and advanced control algorithms. “We’re constantly innovating,” he says, “Our wireless modules offer flexibility in system design, while ongoing research in control algorithms promises even greater efficiency and functionality.”
He lists their controller’s key features and benefits as revolving around providing comprehensive control solutions that ensure optimal performance and energy efficiency:
- Accurate measurements: Sensors deliver precise data on temperature, velocity, flow, humidity, CO2 and more, enabling informed decision-making.
- Seamless integration: Whether it’s clean rooms, refrigeration or plumbing systems, its sensors and controls seamlessly integrate with existing HVAC infrastructure, enhancing functionality and performance.
- Scalability: From small-scale applications to large installations, a modular approach allows for scalability, catering to diverse needs and requirements.
- Energy efficiency: By optimising fan speed and airflow based on real-time data, its controls contribute to energy savings, reducing operational costs and environmental impact.
- With easy installation and compatibility with Ziehl-Abegg’s standardised wiring layouts, and compatibility with industry standard communication protocols such as Modbus, integration into existing systems is seamless.”
“For instance, by precisely regulating airflow, adjusting fan speeds, and responding to changing environmental conditions, we ensure that HVAC systems operate at peak efficiency while maintaining optimal comfort levels,” he says.
HRCPDGA2R iop. Supplied by Schneider Electric
TAILORED SOLUTIONS FOR UNIQUE CHALLENGES IN HVAC
One notable aspect is Ziehl-Abegg’s expertise in addressing challenges related to building layouts and system configurations. While the company does not handle the actual installation, it works closely with consultants and system integrators to offer solutions tailored to the unique requirements of each project.
“Our products are highly customisable to meet specific client requirements, whether it’s adapting to new protocols or addressing unique challenges in building layouts. Our product range caters to a wide array of industries, including HVAC, refrigeration and cleanroom applications. We offer specific products tailored to niche industries, ensuring that our solutions meet the specific needs and challenges of each sector,” Du Plessis explains.
Cleanroom applications in particular present unique requirements, often involving precise control over air quality and pressure. Ziehl-Abegg’s expertise in this area allows them to provide specialised solutions, such as fan filter units designed to maintain negative pressure environments.
“Our experience extends to industries like healthcare and research, where maintaining sterile environments is critical,” he says. “We have developed control systems that ensure compliance with stringent regulations and standards, safeguarding the integrity of sensitive operations.”
SXWRCF12A10002. Supplied by Schneider Electric
The company’s services extend beyond just providing equipment. It ensures proper commissioning, assists customers in getting their systems up and running, and provides training to ensure they understand the functionality and applications. Product certification is another aspect of focus. “We adhere to all international standards, including EN and UL certification. Our products undergo rigorous testing and comply with ISO standards, providing customers with peace of mind regarding quality and safety,” says Du Plessis.
INNOVATIONS TRANSFORMING HVAC CONTROLS
Innovation is the cornerstone of progress in any industry, and the HVAC sector is no exception. Smart thermostats, automated systems, and advancements in sensors, controls and artificial intelligence (AI) are revolutionising how we manage heating, ventilation and air conditioning systems.
Ivan Potter, CEO of i4 Group and iLED (Pty) Ltd, shared insights into their cutting-edge developments in this field.
iLED’s journey of innovation started four years ago with a focus on releasing products tailored for general input-output monitoring. Their key value proposition lies in creating devices with intelligent control capabilities at the edge, allowing for customised configurations to meet specific deployment needs. This sometimes means that the device has no communication infrastructure such as BACnet MSTP or an IP connection – these devices operate in a disconnected state and only connect when there is a need to transfer data.
“Our aim was to offer devices that could be easily configured to fulfil precise requirements wherever they’re installed,” Potter explains. “That’s why we developed configurable controllers, providing a range of smart edge devices supporting multiple communication protocols for seamless integration into higher-level systems plus multiple hardware support for disconnected devices such as 4G, Wi-Fi or BlueTooth.”
J LSA. Supplied by Schneider Electric
Three product families have recently been released under the eZiControls family:
- Smart Edge input-output devices: These offer flexible configuration options to monitor and control various inputs and outputs, catering to diverse HVAC requirements. Two RS485 ports allow for sub bus communication to devices such as smart sensors.
- Smart Edge communication devices: Offer small input/ output count, two RS485 ports, Ethernet, Wi-Fi, Bluetooth and 4G. Potter illustrates the significance of these devices with a practical example involving a hospital’s need to monitor oxygen levels in remote tanks. The smart communication devices enable data transmission through various methods such as Wi-Fi, Bluetooth or 4G, eliminating the need for costly cable installations, particularly in remote monitoring scenarios.
- Visualisation devices: Recognising the demand for graphical representation of data, iLED introduced visualisation devices designed to enhance data interpretation. These touchscreen displays provide intuitive visuals, allowing users to easily comprehend complex data visualised via easy-to-understand widgets, empowering users to make informed decisions and take prompt action as needed. User input is supported with password protection optional.
Potter emphasises the distinction between connected and disconnected Edge devices. Connected devices are wired together or communicate among each other where each device is designed to be permanently on-line or connected – there are no data costs. An example of this is a BACnet MSTP bus with multiple devices. Disconnected devices are designed to only communicate when required – normally using a cellular or data connection where costs are incurred per data packet – underscoring the unique challenges and considerations associated with each. Disconnected Edge devices, while offering flexibility, introduce cost implications due to data transmission expenses, prompting the need for efficient communication management strategies.
“Operating in a disconnected state entails managing connectivity and data costs, which require specialised technologies,” Potter says. “Our Edge devices are engineered to communicate on change of state or on specific time intervals, lowering data costs. This leverages the latest technologies for efficient communication, ensuring seamless data flow to cloud databases and integration with building management systems.”
The testo 570. Supplied by Testo
SIMPLIFIED USER INTERFACES ENHANCE OPERATIONAL EFFICIENCY
Potter notes that simplicity often proves to be the ultimate sophistication, which is why their range of visualisation devices are designed to streamline operations through intuitive user interfaces.
“It’s not about a sophisticated operator interface; plenty of those are available. It’s about a simple user interface,” he says. He provides a practical example of their approach by highlighting the need for effective temperature and humidity monitoring in sensitive environments such as operating theatres. Instead of constantly displaying raw data which would be a distraction, iLED’s visualisation devices are engineered to capture attention through subtle notifications, ensuring crucial information doesn’t go unnoticed amid the hustle and bustle of critical operations.
“These devices are set up to alert operators with a flashing screen, avoiding disruptive buzzers that could potentially pose safety risks,” Potter explains. The goal is to provide a user-friendly interface that allows for quick corrective actions when anomalies are detected.
“All products are designed to seamlessly integrate with existing building management systems, leveraging open protocols for compatibility across different platforms. By decentralising processing tasks and moving them to the Edge, iLED’s solutions optimise system efficiency while reducing the burden on central processors.
“The application of these innovations extends across various HVAC environments, from variable air volume systems to fan coil units and branch static pressure control. By leveraging our technologies and in-house manufacturing capabilities, we ensure quality and reliability of our products, from hardware design to firmware development.
Testo 570 wireless freedom infographic. Supplied by Testo
“The response from both local and international markets has been positive. Local uptake has been strong, with notable implementations among financial institutions for various monitoring applications. However, we are, in particular, placing an outward focus on the international market through our international partnerships. The international response has been great. Our development costs are lower in South Africa, giving us a competitive edge in terms of pricing,” says Potter.
He notes that iLED’s offerings complement existing solutions in the market, making them a valuable addition for addressing diverse requirements, especially their display products which have garnered significant attention.
One of the key factors contributing to iLED’s success is its commitment to quality and compliance. Potter highlights that their products have already received CE certification, a crucial step for entering international markets. He outlines their phased approach to obtaining certifications for all products, ensuring they meet the necessary standards for global distribution.
Ongoing innovation through research and development (R&D) remains a priority for iLED. With a dedicated team of engineers focusing on hardware and firmware development, the company continues to explore new product ideas to address evolving market demands.
“We’re always looking ahead. Our goal is to stay at the forefront of technological advancements in the HVAC sector, delivering innovative solutions that meet the needs of our customers.” An example of deploying intelligent Edge devices is in the commercial property market vertical to meet the ever-evolving needs of property portfolios as they undergo significant transformation to mitigate the risk of load shedding through self-power generation, plus improve data collection of utility billing. These requirements include continuous water and electrical metering, as well as the integration of various power sources such as solar, grid and generator power.
“One of the key challenges is ensuring billing-quality metering. They cannot afford to compromise on accuracy, especially when it comes to billing for utilities.” These products include metering solutions for water and electricity, utilising protocols such as DLMS and Modbus to ensure compatibility across different industries.
Potter emphasises the modular nature of their product stack, allowing for easy customisation through the integration of plug-in cards. This approach enables clients to tailor their devices to match their unique requirements, whether it’s implementing DLMS for electricity metering, utilising Mbus for water metering or Modbus for generator monitoring.
“Our goal is to provide configurable devices that can adapt to the changing needs of our clients. This flexibility ensures that our solutions remain relevant and effective in a rapidly evolving landscape,” he adds.
As iLED continues to push the boundaries of innovation through their eZiControl family of products, Potter is optimistic about the impact they will have on the industry. With a strong focus on quality, reliability and adaptability, iLED Group aims to lead the way in shaping the future of smart building technologies, one innovation at a time.
The testo smart app. Supplied by Testo
ENHANCING BUILDING COOLING EFFICIENCY
Within Schneider Electric’s product lines, Eliwell is a brand within the refrigeration space, distributed by Keystar, though the company’s controls offerings extend beyond that. By offering seamless integration, versatility and advanced features, Schneider Electric aims to drive efficiency and sustainability in the building and data centre operations landscape.
Thabang Byl, buildings segment leader at Schneider Electric notes that while Elliwell is owned by Schneider Electric, there is a distinct separation in terms of how products are made available. This distinction allows for greater flexibility in distribution and purchasing channels.
“EcoStruxure Building Operation (EBO) is the primary platform in our portfolio. It serves as a comprehensive HVAC control solution, leveraging a mesh platform to optimise building operations. Its various components include field devices (sensors), programmable logic controller (PLC) controls, and integration with security offerings. It has evolved over the years through acquisitions and strategic integrations,” he notes.
He describes the key feature of EcoStruxure as being its seamless integration with other Schneider Electric products and platforms. It is compatible with Power Monitoring Expert (PME), a power management solution offered by the company. This integration enhances the platform’s value proposition by providing comprehensive power management, quality monitoring, and metering capabilities.
While EBO is commonly associated with building environments, it is equally versatile in data centre applications. Byl cites examples of notable data centres in South Africa utilising EcoStruxure Building Operation for efficient operations.
“Field devices, including sensors for valves and actuators, temperature, humidity, CO2 levels and pressure, form the foundation of the system. These devices are complemented by Schneider’s field control systems, namely the trademarked
SpaceLogic AS-Bs and RP-Cs (room purpose controllers), which facilitate the monitoring and adjustment of HVAC and associated equipment. These are all programmable modules that can be added to the basic EBO platform.
The software component, EBO, serves as the central platform for managing and optimising HVAC operations based on aserver client architecture. Byl outlines the features of EBO as including licensing options, workstation architecture, and server infrastructure (i.e. ES enterprise server). “The system provides real-time monitoring, alarm and exception handling, reporting and trend analysis, enabling clients to achieve energy efficiency and performance optimisation.”
Sensors and controls are of course key to achieving energy efficiency through continuously monitoring environmental conditions and adjusting HVAC equipment accordingly. Schneider Electric’s solutions minimise energy waste and enhance operational efficiency.
Byl highlights the ability of their systems to implement adaptive control strategies, predictive maintenance, and occupancy-based optimisation to achieve energy efficiency goals, whether it be at a data centre, shopping centre or office building.
This is the overarching purpose of having an automated controls or BMS system, he notes. Byl confirms that its products are highly customisable to meet specific client requirements. From field devices to control mechanisms and software configurations, clients have the flexibility to tailor solutions according to their unique needs and preferences. “We collaborate closely with the client in all instances. This customisation ensures that our HVAC control systems align closely with client objectives, whether it be helping safeguard critical infrastructure, maximising energy efficiency, optimising performance, or enhancing occupant comfort.”
Byl reinforces the necessity of collaboration with clients to tailor solutions to their specific requirements, especially in environments like data centres where stringent cooling requirements are paramount. “EBO ensures precise control over temperature, humidity and other environmental factors.”
Ivan Potter, CEO of i4
Group and iLED (Pty) Ltd. ©RACA Journal
TECHNICAL EXPERTISE AND SUPPORT
Schneider Electric provides comprehensive technical support services, which include in-house technical experts known as solution architects or product application engineers. These experts collaborate closely with its partner network of value-added resellers (VARs) and systems integrators – also known as Eco Xperts – to ensure seamless installation, commissioning and ongoing support.
The company offers training programmes to certify technicians within their partner network, ensuring that they possess the necessary skills and expertise to deploy and maintain EBO control solutions effectively. The trademarked Eco Xpert network is a programme designed to certify partner networks based on their experience, expertise and project execution capabilities.
The programme includes three different levels:
- Eco Xpert Master for the most experienced partners with sufficient trained staff
- Certified Eco Xpert, which meets the minimum requirements of experience
- Registered Eco Xpert, which is an organisation that has simply expressed the aspiration to become certified, and is commencing on that journey
“Each represents varying degrees of competency and project experience. By certifying partners through this world-renowned programme, Schneider Electric ensures that only qualified and reputable professionals handle their products and solutions.
We’re committed to maintaining high standards of quality and reputation. Unlike standard and extensive offers from Schneider equipment available through well-known distributors, Schneider Electric’s configurable solutions like EBO are only available directly from the company or a certified system integrator. This ensures that clients receive reliable, high-performance products and that technicians have the necessary training and expertise to deploy them effectively,” he adds.
The future of controls, says Byl, is to move beyond mere on-site operational capability, to include cloud-based artificial intelligence (AI) or machine learning, with paramount importance devoted to cybersecurity.
The company’s EcoStruxure Building Advisor is a cloud-based platform that is the sister product to EBO. It leverages AI and machine learning for predictive analytics, fault detection and adaptive control strategies. By infusing AI into HVAC control systems, it enhances operational efficiency, optimises energy consumption, and proactively addresses maintenance needs.
Byl notes that it is an evolving technology that has been installed at only a few key customers to date, but he anticipates a widespread deployment of such platforms over the next five years into building management practices and empowering informed decision making. “Integrating the Internet of Things into our offering is increasingly becoming a requirement from our clients.”
Byl acknowledges the inherent vulnerabilities of any system to hacking and emphasises the importance of proactive security measures. “There are growing cybersecurity concerns in the HVAC industry, requiring robust security measures to safeguard critical infrastructure. Our systems prioritise data privacy and security, adhering to industry standards such as ISO 27001 and implementing secure communication protocols like HTTPS. Equally important at an operational level is vulnerability management, regular security assessments and stringent access control measures with data encryption to mitigate the risk of cyber threats.” These include regular patches, updates and vulnerability assessments to address potential security loopholes. Additionally, Byl stresses the importance of physical security measures, such as restricted access and stringent identification protocols, to complement cybersecurity efforts and protect sensitive infrastructure.
This is particularly so with data centres, which are driven by competitive considerations and the desire to maintain technological differentiation. Some international data centre operators differentiate themselves by demanding industrial-grade control systems over traditional building management systems (BMS). The reluctance of data centres operators to divulge details about their infrastructure and technology choices, is well known.
iLED’s factory for local manufacturing of sensors and controls. ©RACA Journal
CAREL INNOVATIONS IN HVAC&R CONTROLS EQUIPMENT
CAREL, a leading player in HVAC&R controls equipment, is setting new standards in the industry with its cutting-edge products designed to meet the twin demands of optimisation and efficiency.
“Our product is versatile and adaptable, catering to both refrigeration and air conditioning needs,” says Andrew Damari, CAREL CONTROLS-SA national sales manager for HVAC.
“While the underlying concepts remain similar, the use of natural refrigerants such as CO2 can significantly impact airconditioning systems, especially in terms of energy efficiency, more and more with Heatpump AC units.”
The company’s dedication to R&D means a significant portion of its turnover is invested in R&D activities. “We focus on testing new technologies and ideas in our laboratories to ensure that we offer high-efficiency solutions within the refrigeration space,” he adds.
CAREL’s expertise lies in controls and optimisation strategies rather than hardware manufacturing. For instance, in CO2 transcritical refrigeration systems, CAREL’s role revolves around optimising the performance of components like expansion valves and compressors to minimise energy consumption and maximise efficiency.
In recent years, CAREL has expanded its scope through strategic acquisitions, incorporating additional products and solutions into its portfolio. These acquisitions have enabled CAREL to offer complete packages for air handling units including heat exchangers, heat recovery wheels and various accessories.
“Although we don’t manufacture the physical units, our involvement in temperature, humidity and pressure control is fundamental to the operation of HVAC&R systems,” says Damari. “From controlling EEV operations to monitoring environmental conditions, our solutions contribute to system efficiency and performance.”
c.pCO sistema is the solution that CAREL offers its partners for managing HVAC&R applications and systems. c.pCO sistema includes programmable controllers, user interfaces, communication interfaces, remote management systems and cloud services, providing OEMs operating in the HVAC sector a powerful yet flexible control system that can easily interface with the most common BMS.
c.pCO sistema guarantees highly reliable control of air conditioning and refrigeration units, while at the same time allowing maximum adaptability for differentiation both in terms of appearance and function.
Several models are available based on the number and type of inputs/outputs, with or without built-in terminal. The plastic enclosure with DIN rail mounting guarantees high mechanical protection of the board and reduces the risk of electrostatic discharges, while also housing an optional built-in user interface with semi-graphic LCD and six LED backlit buttons.
The c.pCO family of programmable controllers is the latest evolution of CAREL control technology, featuring unprecedented communication capabilities. With a multitasking operating system and the adoption of standard protocols, local and remote connectivity are the key innovations in the new c.pCO sistema.
The c.pCO controller features specific new functions to improve the efficiency of HVAC&R systems:
- Connectivity: The c.pCO family controllers are the evolution of the pCO5+, with unprecedented connectivity. They offer even the most demanding designers up to two built-in Ethernet interfaces, five serial lines, three of which built-in and configurable in terms of protocol (CAREL or Modbus) and type (FieldBus or BMS), and two optional ports, configurable in terms of protocol (Modbus, BACnet, CAREL, CANbus, Konnex, LonWorks) and physical layer (RS485, Ethernet, CAN, Konnex, FTT-10). Standard USB ‘host’ and ‘device’ ports are available for programming the c.pCO using a standard USB pen drive, or via a direct connection to a PC without needing an additional external serial converter.
- Operating system: The multitasking operating system ensures optimum use of system resources, extends the data types that can be used to develop the application (32-bit floating point numbers), increases the application program execution speed and allows independent management of communication protocols.
- I/O flexibility: The CAREL-proprietary ASIC chip used means all c.pCO controllers feature universal I/O channels that can be configured via software as analogue inputs, digital inputs and analogue outputs.
- High efficiency: Built-in EVDEVO drivers for controlling electronic expansion valves with Ultracap technology ensure that the stepper electronic expansion valve closes in the event of power failures.
THE MINI MODEL
c.pCOMini is a compact programmable controller in just 4 DIN modules, with high connectivity capabilities and integrated features. It is available in a range that includes models for DIN rail mounting (with or without LCD) and panel mounting. Both models are available in three versions (basic, enhanced and highend), which differ in terms of connectivity and number of I/Os.
The main benefits are:
- Built-in high-efficiency ExV, energy saving algorithms and smart device guide.
- Intuitive semi-graphic LCD with icons, languages customisable user interface and easy wiring.
- System interoperability with third-party devices via standard protocols (Modbus, CAN and BACnet).
- Cost savings through universal channels for I/O optimisation and fast programmability during production and maintenance.
c.pCOe is the new I/O expansion card, built using a CARELproprietary microchip, that allows considerable flexibility in the configuration of the various pins, both as inputs (support for passive NTC, PTC, PT1000 probes, digital inputs and active voltage and current probes) and as outputs (0–10V, PWM).
The c.pCOe card is available in two versions:
- bBasic version, with a total of 16 I/O channels available, 10 of which can be configured as analogue inputs or outputs, and six relays.
- eEnhanced version, same I/O configuration as the basic version, with the addition of a built-in driver for managing a CAREL unipolar electronic expansion valve.
C.SUITE – SOFTWARE DELVELOPMENT PACKAGE
c.suite is the programming suite for the c.pCO family programmable controllers, designed as a set of interdependent modules for each stage of application development for HVAC/R units or systems.
c.suite allows a group of professionals with different skills to work as a team on the same project, increasing the efficiency of each team member. The application program is developed as logically independent parts by different professionals, each of whom uses a different software tool. All these SW tools cooperate with each other by continuously exchanging data, and as an option can be managed by a software versioning control system (SVN).
To each their own tool: With c.strategy, the expert in thermodynamic algorithms can prepare the heart of the system’s operating logic. With c.mask, the developer can create the most suitable user interface: when the application program is ready, in c.design it can be transferred to any hardware configuration by configuring the controller type and size, I/O mapping, communication protocols, default parameters, data loggers and more. For OEMs, then, c.factory can be used to Ivan Potter, programme the controllers on the production line, load the application program onto the controller as configured, while in the field the commissioner can use c.field to help set-up the system, with full access to parameters, alarms and real-time monitoring with graphs.
c.suite provides a wide range of libraries with different functions from basic logic-arithmetic functions, to complex control algorithms for managing various devices, both CAREL and third-party. Combining these elements with the AHU manufacturer’s know-how allows the application to be designed and developed to make every system your system.
