It 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 industrystandard 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.

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.”

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.

Continue reading the full article, “Chill or Thrill? Unravelling the Secrets of Smart HVAC Controls,” compiled by Eamonn Ryan, in the RACA Journal – May 2024 here.