Panel Builder US


May 11, 2021

Building systems, such as HVAC, consist of thousands of components that work together to keep occupants comfortable and safe. Preventative maintenance helps ensure all these pieces stay in good condition, through inspecting and checking for worn parts.

However, inspections can’t find every issue. Even with a detailed maintenance program in place, you may not uncover some problems until it’s too late. The solution? Using a building maintenance system to reveal hidden issues.

Here are five problems that a maintenance system can “see” that you can’t.

1. Dampers Not Opening/Closing All The Way

When dampers fail to open or close completely, it affects their operation but doesn’t necessarily cause a system malfunction. Unless you’re specifically checking dampers, you won’t find this problem without the help of a building automation maintenance system.

A maintenance system tracks conditions over time to look back at past readings—if they begin deviating from expected values it indicates a potential issue. For example, if normal operations require dampers to be 30% open and they’ve been trending closer to 50% to reach the same conditions, you know something’s off. Problematic dampers left unfixed will increase energy costs and eventually cause equipment damage.

2. Sensor Drift

Sensor accuracy shifts as time goes by, and readings become less and less reliable. Simply looking at a sensor won’t reveal that it needs recalibration because sensor drift happens slowly over time.

An astute technician or facility manager with an eye for unusual output can spot sensor drift using data from a building automation system (BAS). On a heat exchanger, for instance, the temperature going in is typically higher than coming out. If the output sensor is drifting, it may show a lower reading than the input—which doesn’t make sense. Recalibrating drifted sensors keeps equipment running to the proper setpoints and provides accurate feedback so a BAS can keep a building comfortable.

3. Blown VAV Box Fuse

A VAV (variable air volume) box can blow a fuse in a multi-stage electric reheating system without drawing any attention. That’s because even with a blown fuse in the VAV box’s second or third stage, heating continues, making this issue difficult to detect.

A blown VAV box fuse won’t appear in BAS readings, but the result of the blown fuse will. You’ll know something’s amiss when heating takes longer than usual. If raising the heat typically takes 30 minutes, and the system now runs for an hour and a half without reaching its setpoint, there’s a problem. Unaddressed, a blown VAV box fuse will overwork other components, ultimately shortening equipment lifespan.

4. Detached Electrical Contacts

Electrical connections coming detached from contactors can lead to lights not coming on when they’re supposed to—or staying on when they’re supposed to be off. For something like parking lot lights, you’ll notice when they don’t come on at night, but not necessarily when they’re on during the day.

A BAS that displays energy use will be able to point a technician to potential electrical problems. Lighting systems with increased energy use during times that aren’t typical may indicate an electrical issue, such as detached or incorrect electrical contacts. If left uncorrected, improper electrical connections can cause safety issues, unnecessary energy waste, and increased operating costs.

5. Equipment Nearing Failure

Machinery begins to break down as it nears the end of its useful life and will draw more energy than usual to compensate for weakened or worn parts. An older fan, for example, may need more power to achieve normal operation if its bearings are locking up.

An increased power draw indicates a problem, and an experienced building automation technician can view maintenance readings and detect equipment running on the edge of its amp capacity. Preventative maintenance combined with expert BAS analysis can reveal components in need of repair (or replacement), so they can be fixed before equipment fails.

BAS Maintenance Is Critical To Facility Management

Many organizations put time, effort, and resources into maintaining their HVAC equipment but neglect to maintain their building controls. As a key resource for detecting issues and zeroing on maintenance needs, it’s important to include your building automation system as part of a comprehensive facility maintenance plan.



Editor's Pick: Featured Product News


Extremely space-saving and flexible

The C60xx series of scalable ultra-compact Industrial PCs combines maximum computing power in what is currently the most compact format with a wide range of options for installation in the control cabinet. It is ideally suited for control, visualization and communication, for example into the cloud.

The latest Intel processors − in three different performance classes, from the Intel Atom with one core to the Intel Core i7 with eight cores – offer maximum scalability and power density with an optimal price-performance ratio.

Performance classes and application areas

The C601x series offers Intel Atom computing power for a wide range of automation and visualization tasks. Due to their impressive computing power in relation to their size, the PCs are mainly suited for use in Industrie 4.0 applications, for example as an IoT gateway.

The C603x series unites high-performance Intel Core-i processors with extremely compact housing dimensions. The processors from the 65 W class have only been used in the much larger ATX-based Industrial PCs up to now. The devices thus represent a new dimension in terms of power density. They are suitable above all for particularly complex automation and visualization tasks, but also for a wide range of other applications in the field of image processing, the handling of large volumes of data and in the IoT environment.

The C602x series is the link between the C601x and the C603x, and the fanless integration of Intel Core-i-U processors of the 15 W class opens up new application areas and options.

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TE Connectivity has recently upgraded its rugged, high-speed Mezalok mezzanine connector family to support the growing demand for higher data rates and improved processing power in military electronics. The upgraded connectors have increased data rate support up to 32+ Gb/s. The Mezalok connector family has been designed specifically for mezzanine cards in rugged applications and is standardized as the interconnect for XMC 2.0 (VITA 61). Rapidly evolving technologies in signal intelligence, radar, communications and surveillance are driving the need for more powerful embedded computing solutions. 

Mezzanine cards are often used to provide additional functionality and processing capability within a small form factor. TE designed the Mezalok connector family to support these applications. Typical applications include application-specific high-speed input/output (I/O) protocols, graphics, memory and digital-signal processing.

“New designs in rugged embedded computing require higher speeds and high pin counts in order to pack more functionality into smaller plug-in modules,” said Jason Dorwart, product manager for TE’s Aerospace, Defense and Marine division. “TE recognizes this trend and is continuing to build on this platform to help solve customer needs, offering new options in stack height, pin density and higher speeds, giving the system designer a broader solution set to work with when needing a fast, rugged and reliable mezzanine connector for extreme environments.” 

TE’s highly reliable Mezalok mezzanine connectors more than double the speed and durability of competing technology, making it one of the most viable options for today’s military and commercial aerospace applications.

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Article Feature - Monthly Industry Focus


For their next meeting with an OEM or system integrator, can panel builders simply grab their smartphone and project the digital prototype of a control cabinet onto the desk of the managing director? Or right into the customer’s production facility? This admittedly sounds fantastical – but is already a reality. The new augmented reality (AR) add-on for the EPLAN eVIEW Free cloud software, in combination with the free Vuforia app from PTC, enables the free projection of completely assembled control cabinet into virtual space.

With EPLAN eVIEW Free AR, a new augmented reality (AR) application, EPLAN now brings the digital twin wherever users happen to find themselves. Designers can share their 3D designs of the control cabinet layout from EPLAN Pro Panel with co-workers and business partners via the cloud. EPLAN Program Manager Digitalisation Tim Oerter oversees the development of AR solutions and explains how to get started with EPLAN eVIEW Free AR: “A control cabinet is constructed in EPLAN Pro Panel and subsequently uploaded to the EPLAN ePULSE cloud environment. This makes it possible to share 3D designs with other users within an ePULSE organisation.” This also automatically generates both a link and a QR code that can be forwarded to the desired recipients. They can then use their smartphone or tablet computer to scan the code using the gratis app Vuforia View from PTC. Now the 3D design can be displayed anywhere using the camera of the end device – and can thus be projected onto a desktop or in the production environment as examples. Changes can also be made by touching any control cabinet components: simply tap the component and the system opens the 2D view of the schematics, for instance for further finetuning using the redlining and greenlining functions.

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