Kele Blog

Current Sensors, Relays, and Transformers in Data Centers

Posted on by Kele Inc

Contributed by Functional Devices

 

Data centers — the infrastructure of servers, storage systems, and networking equipment powering much of our modern technology — demand an enormous amount of electricity. With the rise of cloud computing, AI, and IoT-enabled devices, demand is increasing yearly; therefore, careful data center power management is essential to ensure better energy efficiency, controlled utility costs, and uninterrupted operations.

Although you might only think of servers at first when you read “data center,” many electrical devices are working behind the scenes to keep those servers running smoothly, including current sensors for measuring electricity, relays for power switching, and transformers for regulating voltages. This post will cover how these three devices help optimize data center power management and improve energy efficiency.

Functional Devices has been manufacturing current sensors, relays, and transformers for over 50 years. We’ve honed our designs into dependable, efficient, easy-to-install components ready to power data centers, building automation systems (BAS), lighting controls, and more.

 

The Role of Current Sensors in Energy Management

To optimize energy usage in data centers, you must first know how much energy is used at any given point. Current sensors measure electrical currents flowing through circuits, translating them into measurable outputs like voltages or digital signals.
The real-time data a current sensor provides on energy consumption allows a data center manager to optimize power management in the following ways:

• Identify areas of high energy usage
• Make decisions that improve system efficiency and resource allocation
• Detect anomalies and potential problems in the electrical system

Optimizing power management in data centers is impossible without current sensors since no data or baseline informs the process.

Functional Devices’ RIBXGTA-ECM Current Switch has a very low current sensing capability and was specially designed for ECMs (Electronically Commutated Motors), which are associated with a new wave of very efficient HVAC systems, ideal for data center efficiency.

 

How Relays Enable Seamless Power Switching

Another important way to optimize data center power management is by ensuring a continuous power supply and balanced electrical loads. Nobody wants a spotty connection or slow performance in a data center. The power switching a relay performs means the data center gets the power it needs, in the amounts it needs, and when it needs it (especially if the relays are part of the BAS).

A relay is a sophisticated power switch that turns large currents on and off with only a small amount of electricity. Relays protect sensitive circuits, allow for the control of multiple circuits within a single input, isolate high-power and low-power systems from each other, and switch complex operations with minimal power consumption.

Energy needs proper distribution in a data center to prevent issues, and a relay’s automatic power switching helps do that. Good energy distribution optimizes power management by:

• Preventing overloading circuits, failures, and equipment damage
• Ensuring reliable operations
• Improving fault tolerance and detection
• Maximizing efficiency
• Minimizing downtime

Our RIBTW2421B-BCIP is a BACnet/IP Relay ideal for various applications in data centers, ensuring seamless power switching and maximum efficiency.

Transformers: Ensuring Proper Voltage Regulation

Finally, let’s talk about transformers. These devices regulate and convert voltages, amplifying (“stepping up”) or downgrading (“stepping down”) as needed. They play an essential role in improving efficiency and extending the lifespan of a data center.
Imagine your data center taking energy from the grid but with voltages that are much too high to power the sensitive equipment necessary for successful operations. The voltage regulation provided by a transformer protects while improving energy distribution.

In addition, transformers optimize energy management in data centers in the following ways:

• Maintain stable voltage levels for sensitive and critical equipment
• Minimize energy loss due to voltage fluctuations
• Work with relays to balance loads
• Improve performance and efficiency

Functional Devices’ TIB100A is the first-of-its-kind housed DIN rail-mountable power supply, an ideal choice for data centers to power thermostats, relays, contactors, zone control dampers, electronic locks, card readers, temperature sensors, humidity controllers, and emergency notification devices.

 

Optimal Data Center Power Management & Energy Efficiency with Functional Devices

Proper energy management is crucial because data centers require a lot of power and run 24/7. Current sensors, relays, and transformers work together to optimize power distribution by creating an efficient, responsive energy system. The real-time data from current sensors and the coordinated switching of relays and transformers optimize energy usage, reduce operating costs, provide better power quality and reliability, and lower carbon emissions.

Integrating high-quality current sensors, relays, and transformers into your data center makes a watt of sense.

If you have questions about anything you’ve reads in this article, drop a comment below or reach out to us. We’ll make sure you get the support you need to keep your systems up and running. Call us today or shop on kele.com for solutions.

Modulating Control of Fire & Smoke Dampers in Smoke Control

Posted on by Kele Inc

October is Fire Prevention Month, a reminder of the importance of building safety. Belimo FS Series fire and smoke damper actuators have a wide torque range and are important for fire safety. They work well, use little power, and follow safety codes and standards.

Special thanks to Belimo for providing this article on modulating control of fire and smoke dampers.

Jump to Article Sections:

Containment Fire and Smoke Damper Controls
Modulating Control System Dampers
Engineered Smoke Control System Dampers
Underfloor Air Conditioning Example
Sequence of Operation
Summary

In the US, Canada, and Latin America fire, smoke, and combination fire and smoke dampers are used in two general categories:

  1. Containment of fire and/or smoke to maintain building compartmentation. These are installed based on Chapter 7 of the International Building Code (IBC) which is the primary model code. These are sometimes referred to as passive systems although the dampers do close and fire alarms operate when a smoke detector operates.
  2. Engineered smoke control systems use dampers, fans, and some architectural features in a wide variety of applications. These are based on Chapter 9 of the IBC.

In the Americas smoke dampers are always actuated; fire dampers use mechanical means of sensing heat (fusible links that melt and gravity or spring release for closure). They can be actuated for ease of periodic inspection and maintenance. Smoke must be sensed using electrical sensing – smoke detectors. Spring return actuators are used to close the dampers and then the actuator motor used to open the damper. Combination fire and smoke dampers are actuated due to the smoke function.

Many smoke control applications require modulating control of dampers. Stairwell pressurization and underfloor air-conditioning are examples where they can be utilized.

In this article the common control methods for fire and smoke dampers (typically Chapter 7 applications) are described in order to help distinguish among applications. Then modulating control of the same dampers in different applications (typically Chapter 9 applications) is discussed and explained.

Containment Fire and Smoke Damper Controls

Figure 1 shows (from left to right) a duct smoke detector, high temperature switch, and actuated damper. Roughly 80% of fire and smoke dampers are installed this way although the smoke sensing may be via area smoke detection and a relay employed to operate the damper. The damper protects the integrity of the wall to maintain compartmentation so that neither smoke nor fire can pass to an adjacent compartment.

Figure 2 shows the wiring. Starting at the far left, hot power is run to the smoke detector. As long as smoke is not present the detector passes power to the temperature switch. Power to the actuator drives the damper open and holds it in the open position.

If smoke is detected power is removed from the actuator and the alarm contact on the detector closes to issue an alarm. If an area smoke detection system is used, the smoke control system has a relay connected in place of the smoke detector contact.

In case smoke is not detected but the temperature at the damper rises to 165°F (74°C), then the temperature responsive switch opens. This cuts power to the actuator and the damper springs closed. The temperature switch is manually reset so the damper remains closed during the event.

In the cases where the damper is only a smoke damper, the temperature switch is not present. The smoke detector or a relay from the smoke control system is the only operating control.

Engineered Smoke Control System Dampers

Roughly 80% of fire and smoke dampers are installed in containment applications as shown above. About 20% are installed in more customized applications that are designed by the fire protection and mechanical engineers. Typical applications are atria, stairwell pressurization systems, underfloor air conditioning, underground floors, and large spaces like malls, auditoriums, and stages.

Figure 3 shows the basic controls employed in a smoke control system for one damper. The Firefighters’ Smoke Control System (FSCS) panel allows override control and provides status indication for all components of the system.

The dampers used for smoke control are typically of the same construction as containment. The primary difference is in the control methods. The damper blade position indication switches may be auxiliary switches on the actuator, damper blade switches, or magnetic contact switches. The smoke control system has a relay that allows the FSCS panel switches to place it in automatic, closed, or open position. Figure 3 also shows the connections to a networked system. The relays or cards are isolated from the line or 24V power used to operate the actuator.

The smoke control system components are UL 864, UUKL listed. The actuator has UL 873 or UL 60730 electrical listing and UL 2043 low smoke generation listings. The damper and actuator as a unit is UL555S listed.

Figure 4 shows a reopenable damper. Wiring for the Auto-Off-On Override switch is shown connected directly to the FSCS panel although typically there are network relays present to perform the functions. This damper serves both in containment and smoke control functions. It is connected to the FSCS panel so that the fire department incident commander can reopen the damper to remove smoke or pressurize a space. Status indication is provided.

 

Sequence of Operation

In Automatic mode the smoke relay responds to the programming of the control panel to cut power and spring the damper closed when appropriate. Alternately, if a fire is present and the temperature in the duct rises to 165°F (74°C) the primary temperature switch opens and the damper springs closed.

If the panel switch is moved to Override, then the smoke relay and primary sensor are bypassed. The actuator is again powered and the damper opens. However, if the temperature at the damper continues to rise then the secondary sensor opens at 250°F (121°C). (The fire is close enough that there is danger of flames or heat moving through the damper to the other side of the wall.)

In addition, if the fire department moves the switch on the FSCS panel to Off, then power is removed from the actuator and the damper closes.

Modulating Control System Dampers

Some systems require proportional control of the dampers in the fire and smoke applications discussed above. The controls must combine typical temperature and/or pressure control methods as well as fire and smoke functions.

Figure 5 shows the simplest of modulating control methods for a fire and smoke damper. It is used commonly for corridor ventilation. The potentiometer sets a balance position for the damper during normal operation. The relay can close the damper in the event of fire to avoid smoke spread.

Power is placed on the actuator terminals 1 and 2. The potentiometer has a varying signal of from 2 to 10VDC that goes to terminal 3, the signal input. The actuator positions from 0 to 100% to open the damper to the balanced position. The common acts as a source of electrons and carries both AC and DC currents. In an event, the override relay can cut power to the actuator which then springs the damper closed.

Figure 6 shows the same smoke damper as in Figure 4 with an added relay to override the damper open. By shorting hot power to terminal 3 of the actuator, it will drive open. While not always necessary, a contact opens to disconnect the signal terminal on the potentiometer. This prevents hot 24VAC from damaging the signal output. On DDC systems this is important.

There are optional wiring configurations that work just as well as that shown. For example, Override relay 2 could be placed in the common 24VAC wire. At times it is important to arrange the relay contacts so that in case of failure of one relay, the failsafe condition is the safest.

In Figure 7 instead of a minimum potentiometer controlling the actuator, a building automation system, direct digital control sends the signal to terminal 3 and the actuator is continuously adjustable. (Default is 2V, closed and 10V, full open. This is reversible when needed for some applications.) The signal path is from Sig + on the controller to 3 through the actuator electronics to 1 and back out to the controller Com. A complete loop is always needed for current flow out and into any device.

Figure 8 adds a high temperature switch. It is shown here in the common wire but could be placed in the hot wire also. If the temperature at the damper rises to 165°F (74°C) the switch opens to cut power to the actuator, and it springs the damper closed.

Normally, the damper modulates based on the output signal from the BAS controller. Typically, if smoke is detected, the automatic response is to make Override relay 2 and spring the damper closed. If the FSCS panel is set to Open, then Override relay 2 is de-energized and Override relay 1 is energized. The damper is then open 100%. However, if the temperature in the duct going into the damper reaches 165°F (74°C), then the damper again closes.

Figure 9 adds a secondary high temperature switch and a bypass relay in the common wire.

The sequence of operation is as follows:

With 24VAC present and all controls in the normal state, the actuator opens damper to the position the Signal indicates. Actuator will modulate to maintain the setpoint.

Cutting 24VAC power or making Override relay 2 closes the damper.

If the temperature at the damper reaches 165°F (74°C), the primary sensor opens, and the damper springs closed.

If the FSCS panel switch is set to Open, several actions occur.

  1. The primary sensor is bypassed reconnecting the common power to the actuator.
  2. Override relay 1 is made and Override relay 2 goes to normal. This causes the actuator to drive full open. (Hot 24VAC is shorted to the actuator terminal. Hot 24VAC is not allowed to reach Signal of DDC controller as that would destroy the output’s electronics.)

However, if the duct temperature reaches 250°F (121°C), then the secondary temperature switch opens, and the damper again closes. The FSCS panel cannot override this, and manual reset is necessary. It is presumed that the fire is too close to the damper and compartmentation is at risk.

Underfloor Air Conditioning Example

Figure 10 shows an example of an underfloor air conditioning system and how a modulating actuator could function.

The shaft wall is a fire barrier and a smoke partition and therefore requires either separate dampers or a combination fire and smoke damper. The pressure under the floor must be maintained at somewhere between 0.05 and 0.10 in. w.c. (12 to 25 Pa). This would require another damper and modulating actuator. However, by using a modulating fire and smoke damper, only one damper and actuator can do the job of three. This saves material and labor costs and also helps alleviate space constraints.

It would be up to the fire protection engineer and the local authority having jurisdiction to determine if this damper is considered part of containment (Chapter 7) or part of the engineered smoke control system (Chapter 9). It could be used for both. If it is part of the smoke control also, then status indication and overrides would be required.

The sequence of operation is:

  • During normal operation the pressure under the floor is maintained by modulating the damper mounted in the shaft wall.
  • If a fire occurs and the temperature at the damper reaches 165°F (74°C), then the damper closes.
  • If smoke is present in duct (or space area), then damper closes.

Summary

There are a large number of methods to modulate fire and smoke dampers and apply fire and smoke safety controls. In containment applications, the damper is closed when either high temperatures or smoke is observed. In smoke control systems a number of ways exist to either open or close the damper to purge or pressurize spaces to prevent smoke from spreading.

Some, not all, of the methods of control are shown and explained in this article. Consult the referenced Codes and Standards or contact the author for additional information.

If you have questions about anything you’ve reads in this article, drop a comment below or reach out to us. We’ll make sure you get the support you need to keep your systems up and running. Call us today or shop on kele.com for solutions.

Top 10 DIN Rail Transformer Issues & Troubleshooting Guide

Posted on by Kele Inc

Contributed by Functional Devices

Let’s talk about transformers (and no, we don’t mean car-shifting robots). Although DIN rail mountable transformers are compact and easy to use, safe, and cost-effective, they can have issues like any other component in your lighting controls or other systems.

Tracing and correcting any faults in your lighting and control systems is essential to the day-to-day and long-term functioning of your entire building. Don’t let any straws break the camel’s back. In this post, you’ll learn how to diagnose and resolve common transformer issues and when to call in the professionals.

Signs of DIN Rail Mountable Transformer Malfunction

Before we jump into troubleshooting, you must know what to look for. Here are some signs that your transformer isn’t performing as it should:

  1. Unusual noises (humming, buzzing, etc.)
  2. Overheating or excessive heat generation
  3. Voltage fluctuations/ripple voltage
  4. Power delivery inconsistencies or output voltage issues
  5. Physical signs (discoloration, corrosion, or damage)
  6. Tripped circuit breakers or blown fuses

If you observe any of these signs, it’s time to turn off the power and investigate the cause and source.

 

Common Transformer Issues and Their Causes

After noticing the symptoms, you need to diagnose the root issue. But first, you need to know what those issues might be. Here are the most common problems your DIN rail mountable transformer might experience and why.

1. Input Voltage Problems

Issue: The input voltage the transformer receives is incorrect or unstable.

Why Does It Happen?

  • Power surges, drops in voltage, or fluctuations in the power supply
  • Incorrect voltage rating or improper wiring during installation
  • Faulty upstream electrical components, such as breakers or relays
2. Overloading

Issue: Excessive electrical load causes the transformer to overheat or fail.

Why Does It Happen?

  • Load exceeds the transformer’s rated capacity
  • Long-term overcurrent conditions without proper protection mechanisms
  • Miscalculation of the system’s total power requirements
3. Loose or Faulty Connections

Issue: Inefficient operation or power interruptions result from poor connections. Power disruptions or inefficient operation due to faulty connections.

Why Does It Happen?

  • Improperly installed on the DIN rail
  • Vibration or movement loosening connections over time
  • Corroded terminals due to moisture or environmental exposure
4. Damage by Environmental Factors

Issue: External environmental conditions affect the transformer’s performance.

Why Does It Happen?

  • Excessive dust or dirt blocking ventilation
  • High ambient temperatures lead to overheating
  • Moisture or humidity causing corrosion or short circuits
  • Installation in an environment with poor airflow or near heat sources
5. Insulation Degradation

Issue: Insulation breakdown causes transformer coiled windings to fail.

Why Does It Happen?

  • Aging of materials past their prime
  • Excessive heat weakening insulation
  • Mechanical/physical damage during installation or maintenance
6. Noise or Vibrations

Issue: The transformer produces excessive noise or vibrations.

Why Does It Happen?

  • Loose mounting or brackets
  • Harmonic distortion (change in the waveform) in the power supply
  • Core saturation due to incorrect voltage or load
7. Output Voltage Inconsistencies

Issue: Output voltage is unstable, low, or completely absent.

Why Does It Happen?

  • Faulty windings or internal connections
  • Incorrect or faulty wiring on the output side
  • Load with highly variable power demands
8. Tripped Breakers or Blown Fuses

Issue: The transformer trips circuit breakers or blows fuses frequently.

Why Does It Happen?

  • Short circuits in the windings or external wiring
  • Overcurrent conditions from excessive load
  • Electrical faults in downstream devices or circuits
9. Mechanical Damage

Issue: The transformer or its components are physically damaged.

Why Does It Happen?

  • Dropping or mishandling during installation
  • Wear and tear from vibrations
  • Improper mounting on the DIN rail
10. Poor Ventilation or Overheating

Issue: The transformer overheats, leading to performance degradation or failure.

Why Does It Happen?

  • Installation in an enclosed space without proper airflow
  • Ambient temperatures raised by nearby heat-emitting equipment
  • Blocked ventilation slots or insufficient cooling mechanisms

Step-by-Step Troubleshooting Guide

You’ve noticed the signs, and you know the possible root causes. Now, it’s time to follow a diagnostic protocol step by step.

  • Initial inspection. Shut off the power supply and check for visible damage, loose connections, corrosion, or any other sign that something isn’t right.
  • Verify input and output voltage. Use a multimeter to confirm that the input voltage matches the transformer’s specifications—test the output voltage to identify inconsistencies. If the voltages do not match, discontinue using the transformer and contact a manufacturer for assistance.
  • Examine load conditions. Ensure the load is within the transformer’s rated capacity. Disconnect and test the transformer without the load to isolate whether the issue is caused by the load conditions or the transformer itself. If the load is above the rated capacity, discontinue the use of the transformer and contact a manufacturer for assistance.
  • Inspect wiring and installation. Confirm proper wiring and mounting on the DIN rail according to the manufacturer’s diagram. Tighten any loose connections or screws and replace damaged wires.
  • Environmental assessment. Ensure adequate ventilation and remove any obstructions: clean dust or moisture buildup. Monitor the conditions surrounding the enclosure and consider relocating components as necessary.
  • Test components. Measure resistance in windings. Inspect fuses, circuit breakers, or thermal protectors and replace them as necessary.

After following these steps, you should have fixed the problem or at least isolated it. If the issue persists after these steps, you may need to consult a professional.

Troubleshooting can usually fix transformer issues caused by human error, such as incorrect installation or placement. However, if the problem persists, the transformer or specific components may need to be replaced. Regular maintenance of your electrical systems will help you stop common issues before they begin and improve your system’s overall reliability. If you’re already noticing the signs of a problem, troubleshoot carefully and take proactive care to extend the lifespan of your electrical devices.

Kele offers a large selection of Functional Devices transformers. If you run into problems while working through these troubleshooting tips, our team of qualified technicians is ready to help. We’ll make sure you get the support you need to keep your systems up and running. Call us today or shop on kele.com for solutions.

Protect Your Business: Why Commercial HVAC Maintenance Can’t Be Ignored

Posted on by Kele Inc

Maintaining your commercial HVAC system is critical for comfort, energy savings, and avoiding costly breakdowns. Late summer is the perfect time to prepare your system before winter arrives. Here’s what to look for—and how Kele can help.

Your commercial HVAC system is more than just equipment—it’s a critical investment that protects your business, impacts operating costs, and directly affects the comfort and safety of everyone inside your building. And while August may still feel like peak summer, it’s the ideal time to schedule maintenance before colder weather arrives. Addressing potential issues now gives you time to make necessary repairs and ensure your system is ready to perform reliably throughout the winter. 

 

 

5 Warning Signs That Your HVAC System Needs Attention

Rising Energy Bills — Unexplained spikes in utility costs often mean inefficiencies such as dirty coils, leaky ducts, or failing components. Upgrade to power meters to track energy use and prevent waste.

Uneven Temperatures or Weak Airflow — Hot/cold spots or weak airflow may point to ductwork issues, thermostat malfunctions, or overworked equipment. Install a smart room controller to balance comfort while extending system life.

Declining Indoor Air Quality — Complaints of headaches, fatigue, or odors can signal poor indoor air quality caused by clogged ducts, microbial buildup, or other contaminants. Installing an IAQ sensor helps monitor air quality in real time, giving you the data you need to identify problems early and maintain a healthy, productive environment.

Noises or Odors — Clunks, squeals, or burning/musty smells often signal mechanical or electrical problems. Add monitoring sensors to detect issues early and avoid costly breakdowns.

Humidity Problems — Excess moisture, condensation, or mold growth points to poor humidity control. Use a humidity sensor to protect both your property and your equipment.

Act Now to Protect Your Investment

Don’t wait until small problems turn into expensive repairs. Proactive maintenance with the right equipment can extend the life of your system, reduce energy costs, and create a healthier environment. Call us today or shop on kele.com. We’ve got you covered!

Unlock Optimal Comfort and Efficiency: Zone Control

Posted on by Kele Inc

In the dynamic world of HVAC and building automation, the pursuit of comfort and energy efficiency is constant. While central HVAC systems have long been the standard, a more intelligent and adaptable approach is continuing to rapidly grow: zoning control. For engineers, contractors, and everyone in between, understanding the principles, components, and advantages of zoning is crucial for designing and implementing truly optimized building climate solutions.

The Core Concept: Precision Climate Management

At its heart, HVAC zoning control is about segmenting a building into distinct “zones,” each with its own independent temperature and airflow control. Instead of a single thermostat dictating the climate for an entire structure, zoning empowers occupants (or building automation systems) to tailor heating and cooling to specific areas based on real-time needs. This stands in stark contrast to more traditional systems, which often lead to uncomfortable hot or cold spots and significant energy waste from working in unoccupied or less-utilized spaces.

The Engineering Backbone of Zoning

The effectiveness of a zoned HVAC system hinges on the precise integration of several critical components:

  1. Zone Thermostats/Sensors: These are the eyes and ears of each zone. When strategically placed, they provide accurate temperature readings and communicate demand signals to the central control system. Modern sensors often include humidity and occupancy detection for even more granular control. This is important for energy efficiency and cost savings!
  2. Zone Control Panel/Controller: This acts as the brain of the zoning system. It receives input from all zone thermostats and orchestrates the actions of the various mechanical components. Advanced controllers incorporate sophisticated algorithms to optimize energy use, manage airflow, and prevent system conflicts, while also communicating when things fail or break.
  3. Motorized Dampers: Installed within the ductwork, these are the muscular arms of the system. Controlled by actuators, dampers open and close or modulate to precisely regulate the volume of conditioned air delivered to each zone. Low-leakage dampers are critical for minimizing energy loss and ensuring efficient airflow distribution.
  4. Variable Speed Blowers/Air Handlers: To truly capitalize on zoning’s benefits, the central air handler or furnace often features a variable-speed blower. This allows the system to deliver only the necessary amount of air, rather than constantly operating at full capacity, further enhancing efficiency and reducing noise.

The Advantages Beyond Basic Comfort

From an engineering perspective, the benefits of HVAC zoning are compelling:

  • Superior Thermal Comfort: By addressing diverse thermal loads, solar exposure, and occupancy patterns across a building, zoning eliminates hot and cold spots, ensuring consistent and comfortable temperatures in every occupied space.
  • Significant Energy Efficiency: This is perhaps the most impactful advantage. By delivering conditioned air only where and when it’s needed, zoning drastically reduces energy consumption. Studies suggest energy savings of up to 30% compared to non-zoned systems are achievable. This translates directly into lower operating costs and a reduced carbon footprint.
  • Extended Equipment Lifespan: A zoned system avoids constant full-capacity operation, reducing wear and tear on major components like compressors and blowers. This leads to fewer breakdowns, lower maintenance costs, and a longer operational life for the entire system.
  • Enhanced System Flexibility and Control: Zoning allows for customized programming and scheduling for each zone, adapting to changing occupancy patterns or usage requirements. This level of control is invaluable in both residential and commercial applications.
  • Improved Indoor Air Quality (IAQ): While not a direct function, zoning can contribute to better IAQ by allowing for more precise ventilation strategies within specific zones, especially when integrated with advanced filtration and air purification systems.

Challenges and Considerations

While the benefits are clear, you must also account for potential challenges in designing and implementing zoning systems:

  • Proper Zone Definition: Incorrectly defining zones can negate efficiency gains and lead to persistent comfort issues. Engineers must conduct thorough load calculations and consider architectural layout, solar exposure, and occupant usage patterns.
  • Ductwork Design and Sizing: Effective zoning requires well-designed and properly sized ductwork to ensure adequate airflow to each zone without excessive pressure drops or noise. Bypass ducts may be necessary to relieve static pressure when multiple zones are closed.
  • Control System Integration: Seamless communication between thermostats, dampers, and the central HVAC unit is paramount. Choosing compatible components and ensuring robust wiring and programming is critical.
  • Commissioning and Balancing: Proper commissioning and air balancing are essential to ensure each zone receives the correct airflow and operates as designed. This often involves adjusting damper settings and verifying temperature differentials.

Kele.com: Your Partner in Zoning Control Components

For those in the industry seeking reliable and high-quality components for zoning control, kele.com offers a comprehensive selection. Here are some product categories and specific products that would aid in designing and implementing effective zoning solutions:

Standard Control Damper

Thermostatic Radiator Valves

Non-Programmable Thermostats

TJ Series VAV Box Duct Thermistor and RTD Sensors

KTV Series VAV Box Duct Thermistor and RTD Sensors

By leveraging these sophisticated components and adhering to sound engineering and design principles, HVAC and building automation professionals can design and implement zoning control systems that deliver unparalleled comfort, significant energy savings, and a more sustainably built environment.

Call today or shop on kele.com now—Kele’s got you covered!

Why Pressurized Stairwells Are Critical for Fire Safety in High-Rises

Posted on by Kele Inc

Contributed by Dwyer Instruments, a DwyerOmega brand

 

Modern high-rise buildings feature staircases designed to protect you in case of a fire. Staircases have a higher fire rating than the rest of the building, which means the stairs aren’t as likely to catch fire. Additionally, stair pressurization systems utilize clean air from outside to push smoke (which naturally rises) back onto the floors. This helps to make sure the smoke doesn’t fill up the stairwell, meaning easy breathing on the way down.

 

 

What is Stairwell Pressurization?

Stairwell pressurization is a life-saving building safety feature that prevents smoke from infiltrating stairwells during a fire. By maintaining a higher air pressure inside stairwells than in adjacent spaces, clean air is forced outward, keeping escape routes clear for occupants and providing safer access for emergency responders.

This is especially critical for high-rise buildings, where stairwells serve as primary means of egress during emergencies. Without pressurization, smoke can rapidly fill these shafts, compromising evacuation and rescue efforts. Pressurization systems address this by delivering filtered air into the stairwell, forming a protective barrier against smoke intrusion.

How Stairwell Pressurization Systems Work

These systems activate automatically during a fire alarm. Fans introduce clean air into the stairwell, monitored and regulated by differential pressure sensors and dampers to maintain a consistent pressure range (typically 0.05–0.15 in w.c.). The positive pressure ensures that when doors are opened, smoke-laden air from hallways cannot enter the stairwell.

Key Components

Fan/Stairwell Controller—Engages to supply fresh air when fire alarms trigger.

Differential Pressure Transmitter—Measures the pressure differential to ensure regulatory compliance and effective operation.

Damper Actuator—Modulates airflow to maintain the target pressure range and prevent door operation issues caused by over pressurization.

The fan for the stair pressurization system doesn’t need to run all the time. That would waste energy and increase building costs. Running the fan continuously may also result in over pressurization (excessive positive pressure) on the fire exit door, preventing the door from opening. Therefore, the fan needs to be notified when to turn on in case of emergency.

 

Compliance Standards and Best Practices

Pressurization systems are often required by building and fire safety codes established by recognized organizations and regulatory authorities, such as the National Fire Protection Association (NFPA) for smoke control. Best practices include:

  • Routine calibration of differential pressure sensors
  • Functional testing during fire drills
  • Integration with building automation systems for monitoring and alerts

 

DwyerOmega Solutions

DwyerOmega offers high-performance pressure sensing products ideal for stairwell pressurization applications. The Series MSX Magnesense® Differential Pressure Transmitter is a top choice example, delivering:

  • High accuracy for maintaining consistent pressure
  • Dual voltage and current outputs for flexible integration
  • Alarm signal capabilities to trigger local or central alerts

 

Real-World Benefits

In the event of a fire, a functioning stairwell pressurization system plays a critical role in preserving safe evacuation paths by keeping stairwells clear of smoke. This not only reduces the risk of smoke inhalation for building occupants but also enhances firefighter access to upper floors, allowing for faster and safer emergency response.

Advanced Cooling Strategies for Commercial and Industrial Buildings with Kele

Posted on by Kele Inc

With scorching summer temps on the rise, maintaining optimal indoor climate control in commercial and industrial buildings is no longer just about comfort; it’s a critical factor for productivity, equipment longevity, and energy efficiency. Sweltering heat can lead to an increase in heat related illness, costly system breakdowns, and skyrocketing energy bills. The solution to combating these things lie in a smart and thoughtful approach to building automation and HVAC  controls.

This technical guide explores advanced methods for keeping large buildings cool during hot weather—highlighting how Kele’s extensive range of products empowers precise control and significant energy savings.

The Challenges of Commercial & Industrial Cooling

Unlike residential cooling, commercial and industrial environments present unique challenges:

  • Vast Spaces: Large floor plans and high ceilings require evenly distributed cooling that reaches the entire square footage of the space.
  • Occupancy Fluctuations: Dynamic occupancy rates demand flexibility through adaptable systems that are easy to manage and manipulate.
  • Internal Heat Loads: Equipment, lighting, processes and more, generate significant heat, especially in industrial settings or data centers. These spaces have a critical cooling need.
  • Energy Consumption: Cooling can account for a substantial portion of a building’s energy usage. Efficiency is the name of the game here and can be tricky to achieve.
  • Regulatory Compliance: Meeting indoor air quality (IAQ) and energy efficiency standards is crucial. OSHA and ASHRAE have a host of standards and guidelines that must be met and followed.

Kele’s Approach to Optimized Cooling

Kele’s strategy for effective cooling revolves around precise control, access to real-time data, and intelligent automation. By integrating a network of sensors, actuators, valves, and controllers, facility managers, building managers, and more, are able to adjust and control dynamic environments that respond quickly and intelligently to ever evolving conditions.

Key Components and Strategies:

Smart Sensing for Real-Time Data: Accurate, real-time data is the foundation of efficient cooling. Temperature, humidity, and occupancy sensors feed crucial information back to the Building Automation System (BAS), allowing for precise adjustments.

Temperature Sensors & Transmitters are the eyes and ears of any HVAC system. Kele offers a vast array of temperature sensors for various applications (duct, immersion, room, outside air).

Product Recommendation: Consider ACI Averaging Series (for duct applications) or Kele KTR Series Room Sensors (for precise zone control).

High humidity only exacerbates the feeling of heat. Humidity sensors give BA systems the ability to control dehumidification cycles more effectively—improving comfort and preventing mold growth.

Additionally, integrating occupancy sensors guarantees that cooling efforts are not wasted in unoccupied areas. These can be set up to trigger setback temperatures or even shut down HVAC units in empty zones.

Intelligent Air Handling Unit (AHU) Management: The AHU is the heart of many commercial cooling systems which is why optimizing its operation is critical.

Motors in AHUs (such as fans, pumps, etc.) are significant energy consumers. VFDs help adjust motor speed to match demand, rather than operating at full speed constantly. This helps avoid wear and tear and leads to substantial energy savings.

Product Recommendation: Kele stocks a range of VFDs from top manufacturers like Honeywell All-Purpose Variable Frequency Drives and Franklin Control Systems Cerus X-Drive Series. These drives offer advanced features for HVAC applications, including application-specific startup wizards and BACnet/Modbus integration.

Precise control of chilled water flow through coils is also essential for temperature regulation. Modulating control valves (that are driven by actuators) allow the BAS to have excellent control so that it can fine-tune its cooling capacity.

Product Recommendation: Explore Belimo Ball Valves with Modulating Actuators (e.g., LRB24-SR, ARB24-SR) or Honeywell Globe Valves with Electronic Actuators (e.g., ML7425A3013). These unique products allow for granular control of water flow, optimizing heat transfer at the coil.

During cooler outdoor temperatures, economizers use outside air for “free cooling,” which reduces the load on chillers and lets the system rest. Electronically controlled dampers regulate the mix of outside and return air.

Product Recommendation: Kele offers various damper actuators that integrate with BAS to manage airflow precisely.

BA System Integration: The BA system at the end of the day is THE central nervous system and ties all these components together. It collects data, executes control strategies, and provides a holistic view of building performance. So what are some key callouts?

Advanced Controllers: Modern BA system controllers offer powerful processing capabilities, enabling complex control algorithms, scheduling, and trend analysis.

Graphical User Interfaces (GUIs): User-friendly interfaces allow facility managers to monitor systems, adjust setpoints, and troubleshoot issues remotely.

Integration with Other Systems: A robust BA system is able to integrate with lighting, security, and fire safety systems for a truly unified building management approach.

Preventative Maintenance, Management, and Monitoring: Even the best systems require ongoing care. The 3 M’s of HVAC prevent minor issues from escalating into major problems.

Monitoring water and air flow rates, along with system pressures, helps identify inefficiencies or blockages early.

Product Recommendation: Kele offers various pressure transducers and flow meters essential for system diagnostics and performance verification.

Refrigerant leaks are costly and environmentally harmful. Modern leak detectors can quickly identify issues.

Product Recommendation: Kele offers refrigerant leak detectors compatible with various refrigerant types, including newer low-GWP options.

Keeping commercial and industrial buildings cool during increasingly hot summer temps demands a sophisticated, integrated approach. Relying on piecemeal solutions is inefficient and costly. By leveraging advanced building automation components and strategies—from intelligent sensing and VFDs to optimized control valves and comprehensive BAS integration—facility managers, building managers, and others can achieve precise temperature control, drastically reduce energy consumption, and ensure occupant comfort and equipment longevity.

Don’t just react to the heat; proactively manage your building’s climate with help from Kele. Visit Kele.com today to explore our full range of solutions and or call and talk to our experts. Kele’s got you covered!

Improving Data Center Reliability

Posted on by Kele Inc

*Contributed by DwyerOmega

Maintaining Optimal Performance Through Advanced Sensing and Control Solutions

Data centers are the core infrastructure behind our digital world. As they support everything from cloud services and streaming platforms to financial systems and industrial automation, their role has grown more critical and more complex.

Housing the servers, networking equipment, storage systems, and supporting infrastructure needed to store, process, and distribute large volumes of digital information, data centers must deliver reliable performance. In fact, with server racks pushing beyond 240 kW in high-density applications like AI, the need for precise environmental control has never been greater.

Maintaining uptime and efficiency requires more than just computing power. It calls for intelligent facility design, tight control over variables such as airflow, temperature, and humidity, and robust monitoring systems that provide real-time insight into conditions on the floor. From temperature sensors to differential pressure monitors, instrumentation plays a key role in keeping systems running smoothly and securely.

Monitoring Temperature and Humidity for Equipment Reliability

Excess heat and high relative humidity can compromise the performance and longevity of sensitive IT equipment. Studies from major data center operators, including IBM, have shown that poor control of these conditions increases the risk of hardware failure, reduces system efficiency, and contributes to unexpected downtime.

To help maintain optimal operating conditions, DwyerOmega offers robust sensing solutions designed for precise environmental monitoring. The Series RHP Humidity/Temperature Transmitter combines capacitive humidity sensing with accurate temperature measurement, offering ±2.5 % RH accuracy in a compact, configurable design. It’s ideal for monitoring hot and cold aisles, network closets, and other mission-critical zones within the data center.

For room-specific temperature tracking, the Series TE-E/N Wall Mount Temperature Sensor provides a cost-effective and reliable solution. Its low-profile enclosure blends easily into server rooms or control spaces, delivering accurate readings that support automated HVAC response and thermal regulation.

Airflow Monitoring to Support Efficient Cooling

Consistent and balanced airflow is critical to maintaining thermal stability in data centers. Poor air velocity control can lead to hot spots, reduced cooling efficiency, and overworked HVAC systems—compromising both energy usage and equipment health.

The Series AVUL and Series AVLV Air Velocity Transmitters are designed to accurately measure air velocity or volumetric flow within ductwork. These devices provide a reliable linear output that integrates easily with building management systems (BMS) for real-time control and analytics.

For data centers, the AVLV’s high-accuracy, low-range capabilities are particularly well-suited to quality-sensitive environments where precise airflow regulation is essential to cooling performance. By monitoring airflow through supply and return ducts, these transmitters help ensure efficient air distribution, improve energy optimization, and reduce the risk of thermal overload on critical infrastructure.

Differential Pressure Control for Clean and Balanced Airflow

In high-density data centers, even small fluctuations in airflow or static pressure can impact cooling efficiency, energy use, and equipment reliability. Monitoring differential pressure across air handling units, filters, and ductwork is essential for maintaining stable environmental conditions and ensuring clean, well-balanced airflow to server racks.

The Series MSX and Series MSX Pro Magnesense® Differential Pressure Transmitters deliver the high-accuracy pressure measurement required for these critical applications. Built-in square root capability allows the transmitter to convert velocity pressure into airflow or volumetric flow, reducing the need for additional instruments and simplifying BMS integration.

With dual voltage and current outputs, the MSX series supports both real-time system control and alarm notification. In data centers, these transmitters are commonly used to control variable frequency drive (VFD) air handlers and to monitor pressure drop across HVAC filters—ensuring proper airflow delivery while helping to maintain contaminant-free cooling.

Flow Monitoring for Critical Cooling System Uptime

Data centers rely heavily on liquid-based cooling systems to manage the high thermal loads generated by dense server environments. Ensuring consistent coolant flow—and the ability to service components without shutdown—is vital to maintaining uptime and preventing thermal events.

The Series IEF Insertion Electromagnetic Flowmeter is designed specifically for this type of application. Its hot-tap capability allows the sensor to be installed, removed, or replaced without interrupting the operation of chillers or taking the system offline. This enables maintenance teams to make adjustments or conduct replacements without risking server downtime.

For added redundancy, the IEF also offers a unique configuration option that allows three sensors to be installed in the same pipe location. This triple-sensor setup provides a critical layer of failover protection, ensuring continuous monitoring even if one flowmeter requires service—an ideal solution for mission-critical environments like data centers where reliability is non-negotiable.

Looking for even more DwyerOmega products to help you win on and off the job site? Start sourcing here or call Kele today for more help—Kele’s got you covered…with help from DwyerOmega!

Keeping Data Centers Cool: How HVAC Controls Improve Efficiency and Reduce Costs

Posted on by Kele Inc

Contributed by Functional Devices (Matt Long)

Data centers produce enormous amounts of heat. If they get too hot, though, the sensitive equipment housed within can fail, causing downtime, increased operating costs, and potential fires.

Proper airflow management is essential for data centers to ensure the correct temperature and humidity. This post explores how HVAC controls and relays can improve operational efficiency and sustainability in data centers.

Here at Functional Devices, we have extensive experience helping facility managers maximize HVAC efficiency. Our preassembled “Relay In a Box®” is the perfect blend of versatility and functionality, allowing you to optimize and automate your building easily. 

The Challenge of Cooling Data Centers

The average data center can produce 20 MW of heat, or enough to power 16,500 homes. Data center managers must properly cool servers, storage systems, and other components, or else they risk:

  • Increased energy costs
  • System failures
  • Equipment degradation
  • Fires

Just one cooling method isn’t sufficient, so managers use a variety, including air conditioning, liquid cooling, and evaporative cooling. To reduce wasted energy, control operating costs, and ensure optimal equipment performance, managers need all these cooling systems to work as efficiently as possible.

For this post, we’ll stick to HVAC controls. Let’s explore how this system is crucial to data center operational efficiency.

The Role of HVAC Controls and Relays in Data Center Cooling

The HVAC controls in data centers do much more than blow cool air on servers all day. While that’s certainly part of it, these specialized systems house components that work together to maintain the precise environmental conditions necessary for properly operating sensitive equipment.

Components of Data Center HVAC Controls

Here are the parts of HVAC controls needed to control temperature and humidity in a data center:

  • Computer room air conditioners and handlers (CRAC/CRAH) cool computer equipment and achieve various cooling densities.
  • Chillers cool water utilized by CRAH units.
  • Cooling towers help chillers operate efficiently by dissipating heat from the chilled water.
  • Air distribution systems deliver air properly to computer equipment and efficiently remove hot air.
  • Hot aisle/cold aisle containment separates hot and cold airflow, ensuring cold air reaches server intakes and hot air reaches cooling units.
  • Raised floors allow for cables, wires, cooling elements, and proper airflow management.
  • Relays switch power on and off to different HVAC components.

Relays are necessary for any industrial-scale system, whether HVAC, security, or lighting. In data centers specifically, relays are essential in controlling motors, protecting sensitive equipment, and enhancing the building automation system (BAS). Automation allows for more precise and responsive control of temperature and humidity.

Benefits of HVAC Controls in Data Centers

A properly designed and implemented HVAC control system in a data center brings many benefits besides cooling the equipment enough to keep it functioning optimally.

With an efficient and automated HVAC system cooling a data center, managers can rest easy knowing they are protecting their computer equipment and bottom line.

Best Practices for Integrating HVAC Controls into Data Centers

While we won’t get into all the specifics for implementing HVAC controls in a data center, here are some basic best practices to follow when designing or updating this important system:

  • Conduct a comprehensive cooling audit to determine specific needs.
  • Select the right HVAC controls and relays for your data center size and design.
  • Integrate HVAC controls with your building management systems (BMS) for centralized monitoring.
  • Integrate HVAC controls with your BAS for operating efficiency.
  • Perform routine maintenance and calibration.

These are general best practices. To ensure proper integration, consult all the necessary parties, such as electrical engineers, manufacturers, consulting firms, and construction companies.

Keep Your Cool with Functional Devices

HVAC controls and relays are integral parts of data centers, and choosing the correct configurations and devices helps ensure better operating efficiency, sustainability, and reduced costs.

Browse Functional Devices products at Kele. We’ve got you covered—and so does Functional Devices!

Plus, check-out Kele’s data center solutions here.

Powering the Future: Why Renewable Energy Integration is the Next Frontier for Industrial HVAC & BAS

Posted on by Kele Inc

For industrial facility owners and managers, the relentless pursuit of efficiency and cost savings often clashes with the growing demand for environmental responsibility. But what if the solution to both challenges lay in one powerful integration? We’re talking about renewable energy sources becoming the backbone of your industrial HVAC and building automation systems.

Beyond the Grid

Traditional industrial HVAC systems rely heavily on grid power, often generated by fossil fuels. This exposes facilities to fluctuating energy prices, grid vulnerabilities, and an ever-increasing carbon footprint. Renewable energy integration changes this paradigm entirely.

Here’s how these innovative approaches are revolutionizing industrial HVAC and BAS:

  • Geothermal Heat Pumps: Imagine a heating and cooling system that leverages the stable, year-round temperature of the earth a few feet beneath your facility. That’s the power of geothermal. These systems exchange heat with the ground, providing highly efficient heating in winter and cooling in summer. For large industrial complexes with substantial land, geothermal offers an incredibly stable, low-operating-cost solution that significantly reduces reliance on conventional fuels. It’s a long-term investment that pays dividends in energy savings and environmental stewardship.
    • For a geothermal system to operate efficiently, precise control of fluid flow and temperature is paramount. You’ll rely on:
      • Control Valves: Essential for managing water or refrigerant flow through the geothermal loop and into your HVAC system. Kele offers a wide range of industrial-grade ball, butterfly, and globe valves with various actuators to handle the demanding flow requirements of geothermal systems.
      • Temperature Sensors & Transmitters: Crucial for monitoring ground loop temperatures, supply and return water temperatures, and space temperatures. Accurate data ensures your geothermal system is performing optimally.
      • Flow Meters & Switches: To monitor the flow rate of the geothermal fluid, ensuring efficient heat exchange. Kele provides a variety of flow sensors and meters for water and other liquids.
  • Solar-Powered HVAC: The sun is a free and abundant energy source. Integrating solar power into your HVAC strategy can take several forms:
    • Solar PV (Photovoltaic) Systems: Generating electricity directly from solar panels to power your chillers, fans, and pumps. This can significantly offset your electricity consumption, especially during peak daylight hours when cooling loads are often highest.
    • Solar Thermal for Cooling & Heating: Utilizing solar collectors to generate hot water or steam, which can then drive absorption chillers for cooling or directly provide process heat. This approach can be particularly impactful for facilities with significant heating or cooling demands.
    • While Kele doesn’t sell solar panels directly, we provide the vital control and monitoring components that make solar-powered HVAC feasible:
      • Energy Meters: Critical for tracking the energy generated by your solar array and how much your HVAC system is consuming from that source versus the grid.
      • Variable Frequency Drives (VFDs):To efficiently manage the motors in your pumps and fans, allowing them to precisely match demand with available solar power. VFDs reduce energy waste significantly.
      • Relays & Contactors: For switching loads and ensuring safe integration between your solar inverter and HVAC equipment, often controlled by your BAS.
      • Power Monitoring & Protection Devices: To safeguard your valuable solar and HVAC equipment from power surges or fluctuations.
  • Hybrid HVAC Systems: Recognizing that a purely renewable system might not be feasible for every industrial application, hybrid solutions offer a pragmatic bridge. These systems intelligently combine renewable energy sources with traditional HVAC components, optimizing energy use based on real-time conditions and cost considerations. For example, a hybrid system might prioritize geothermal heating when temperatures are moderate, then seamlessly switch to a high-efficiency boiler during extreme cold, always aiming for the most efficient and sustainable operation.
    • The “hybrid” aspect demands sophisticated control and communication:
      • Network & Wireless Components: For seamless communication between different system components, whether they are traditional or renewable.
      • Controllers & Thermostats: Intelligent controllers are vital for decision-making in a hybrid system, determining when to prioritize renewable energy and when to switch to conventional sources for optimal efficiency and comfort.
      • Gas Flow Meters: If your hybrid system includes natural gas boilers or furnaces, precisely metering gas consumption allows you to compare the efficiency and cost of your renewable vs. conventional energy use. This data is invaluable for optimization.
      • Current Switches: Useful for monitoring the operational status and energy draw of specific loads, helping your BAS make informed decisions about load shedding or source switching in a hybrid setup.

 

Building Automation Systems as the Intelligent Orchestrator

The true power of renewable energy integration in industrial settings lies in its seamless connection with advanced BAS. Your BAS isn’t just about controlling temperatures anymore; it becomes the brain that orchestrates the entire energy ecosystem:

    • Real-time Monitoring & Optimization: Your BAS can monitor energy generation from solar panels or geothermal systems, compare it to demand, and dynamically adjust HVAC setpoints and equipment operation for maximum efficiency.
    • Predictive Analytics: AI-driven BAS can learn your facility’s energy patterns, anticipate upcoming loads (based on weather forecasts, production schedules, etc.), and pre-condition spaces using renewable energy when it’s most available or cost-effective.
    • Demand Response Integration: By integrating renewable energy, your facility can more effectively participate in utility demand response programs, reducing strain on the grid and earning incentives by shedding load during peak periods.

 

The Tangible Benefits for Your Bottom Line

The integration of renewable energy into your industrial HVAC and BAS delivers concrete financial advantages:

  • Significant Energy Cost Reductions: Reduce your reliance on volatile utility prices, leading to more predictable and lower operating expenses.
  • Reduced Carbon Footprint: Meet corporate sustainability goals, enhance brand image, and comply with evolving environmental regulations.
  • Increased Energy Independence & Resilience: Less susceptible to grid outages and energy supply disruptions.
  • Potential for Incentives & Rebates: Government and local utility programs often offer significant incentives for adopting renewable energy technologies, improving your ROI.
  • Enhanced Equipment Lifespan: Optimized operation through BAS and reduced stress on traditional components can extend the life of your HVAC equipment.
  • Improved Indoor Environmental Quality (IEQ): While not directly tied to energy source, green buildings often lead to better IEQ, which can boost employee comfort, health, and productivity.

 

Ready to Explore Your Renewable Future?

Integrating renewable energy into your industrial HVAC and BAS isn’t just about being “green” – it’s about being smarter, more resilient, and more cost-effective. Kele has the expertise to assess your facility’s unique needs, design tailored renewable energy solutions, and seamlessly integrate them with your existing or new BAS.

Let’s discuss how we can help you unlock the full potential of renewable energy for your industrial operations. Contact us today to take the first step towards a more sustainable and profitable future. Kele’s got you covered!