Kele Blog

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!

Kele, Inc. Completes Acquisition of Ponton Industries

Posted on by Kele Inc

Acquisition Expands Kele’s Industrial Automation Portfolio and Geographic Reach

MEMPHIS, TN and YORBA LINDA, CA, May 13, 2025 (Newswire.com) – Kele, Inc. (“Kele”), a portfolio company of The Stephens Group, LLC (“Stephens Group”), is pleased to announce its acquisition of Tom Ponton Industries, Inc. (“Ponton Industries”), an instrumentation sales and consulting firm. The acquisition further expands Kele’s footprint within the instrumentation sales market. Ponton Industries will become an integral part of the industrial offerings of the Kele Companies, which include Lesman Instrument Company (Bensenville, IL), A-Tech Inc. (Tulsa, OK), and AC Controls (Concord, NC). Ponton Industries specializes in providing its customers with complete solutions to their flow, level, temperature, pressure, and process control requirements. The company serves customers through engineering consulting and technical support for process instrumentation selection. The transaction marks Kele’s seventh acquisition in the last seven years.

Kele President and CEO Danny Lyons said, “We are thrilled to welcome Ponton to the Kele Companies. Marty Ponton, President of Ponton Industries, and the Ponton team bring a wealth of experience serving the industrial markets, OEMs, and municipalities across California, and we look forward to leveraging that experience across Kele.”

Mike DeLacluyse, President of Kele Industrial, said, “We have worked with Marty and his team for many years and have great respect for the organization they have built. We are excited to join forces with them and continue expanding along the West Coast.”

“After carefully evaluating our options for a strategic partner to propel our company forward, we firmly believe that Kele’s robust tools and forward-thinking vision align perfectly with our customers’ increasing demands for cutting-edge technology and exceptional service. We are thrilled to unite with Kele Industrial and drive our shared goals to new heights!” said Marty Ponton, President of Ponton Industries.

Grant Jones, Managing Director at Stephens Group, added, “The acquisition of Ponton Industries further strengthens Kele’s position in the industrial automation space. This is a natural fit with Kele’s existing operations and will provide new growth opportunities, particularly in the Western U.S. We are thrilled to support this acquisition as we continue to build a market leader in the industrial automation sector.”

About Kele, Inc. 
Kele, Inc. is a leading distributor of Commercial and Industrial Automation products and controls solutions globally. Kele serves the Commercial and Industrial Automation markets with more than 300 brands and 3+ million parts in stock, including actuators, gauges, relays, sensors, switches, transmitters, valves, and more. Value-added services include custom panel assembly, specialized sourcing, and technical support. Kele is a portfolio company of The Stephens Group, LLC of Little Rock, Ark. To learn more about Kele, visit kele.com.

About Ponton Industries 
Ponton Industries has been providing automation machinery manufacturing solutions since 1972. It specializes in providing its customers with complete solutions throughout all of California and Western Nevada. Its focus is to support customers from product selection to start-up and commissioning. Ponton Industries is committed to its customers with a goal of making it as easy as possible to do business and providing the latest, most reliable and most cost-effective technologies to solve customers’ measurement and control applications.  Learn more about Ponton Industries at pontonind.com.

About The Stephens Group, LLC
The Stephens Group, LLC (https://www.stephensgroup.com) is a private investment firm that partners with talented management teams to help build valuable businesses. Backed by the resources of the Witt Stephens and Elizabeth Campbell families, the firm combines the operational expertise of a private equity firm with the flexibility provided by long-term capital. With over $2 billion of private equity assets under management, the firm has a long history of providing informed, sophisticated expertise and working with owners and managers to help them successfully achieve their strategic visions and build long-term value. Since 2006, The Stephens Group has invested in over 50 companies, targeting investments in industries across the U.S., including industrial products and services, specialty distribution, and vertical software.

 

 

Building the Future: Why Net-Zero is No Longer a Dream

Posted on by Kele Inc

The buzz around “net-zero” buildings isn’t just trendy jargon; it represents a fundamental shift in how we design, construct, and operate our built environment. Imagine a building that produces as much energy as it consumes annually. Sound like science fiction? Think again. Net-zero buildings are becoming a tangible reality, driven by urgent climate concerns, advancements in technology, and a growing understanding that sustainability and economic viability can go hand-in-hand.

What Exactly is a Net-Zero Building?

At its core, a net-zero building achieves a balance between the total amount of energy used by the building and the amount of renewable energy generated on-site or procured from renewable sources over a specific period, typically a year. This can be achieved through a combination of aggressive energy efficiency measures and the integration of renewable energy technologies.

Why the Net-Zero Push?

The urgency behind the net-zero movement is undeniable:

  • Combating Climate Change: Buildings are significant contributors to greenhouse gas emissions. Transitioning to net-zero is crucial for mitigating our environmental impact.
  • Reducing Operating Costs: While the initial investment might be higher, net-zero buildings drastically reduce or even eliminate energy bills, leading to substantial long-term savings.
  • Enhancing Occupant Comfort and Health: Often, net-zero designs prioritize superior insulation, natural lighting, and excellent indoor air quality, creating healthier and more comfortable spaces for occupants.
  • Increasing Property Value: As sustainability becomes more valued, net-zero buildings are likely to command higher market values and attract environmentally conscious tenants.
  • Energy Independence and Security: Generating energy on-site reduces reliance on traditional energy grids and enhances energy security.

Key Strategies for Achieving Net-Zero

Reaching net-zero requires a holistic approach encompassing various design and operational aspects:

  • Energy Efficiency First: Implementing high levels of insulation, energy-efficient windows and doors, and minimizing air leakage significantly reduces the building’s energy demand.
  • Efficient HVAC Systems: Utilizing high-performance HVAC technologies like heat pumps, variable refrigerant flow (VRF) systems, and demand-controlled ventilation minimizes energy consumption for heating and cooling.
  • Smart Building Controls: Implementing advanced Building Automation Systems (BAS) to optimize energy use based on occupancy, weather conditions, and other factors is crucial.
  • Renewable Energy Integration: On-site generation through solar photovoltaic (PV) panels is the most common method. Other options include solar thermal systems and geothermal heat pumps.
  • Water Conservation: Reducing water consumption also contributes to overall sustainability and can impact energy used for water heating and pumping.
  • Sustainable Materials: Choosing building materials with low embodied energy and environmental impact further enhances the sustainability of a net-zero building.

Kele Products Paving the Way to Net-Zero

Kele offers a wide range of products that are instrumental in achieving the energy efficiency and control necessary for net-zero buildings. Here are a few product recommendations to help you get there:

  • High-Accuracy Temperature and Humidity Sensors: Precise monitoring of temperature and humidity is essential for optimizing HVAC system performance and ensuring occupant comfort. Kele offers a variety of highly accurate sensors like the ST Series, HW20, HD20, ST-W, and ST-D, which provide reliable data for efficient control strategies. This data allows the BAS to make informed decisions, preventing overheating or overcooling.
  • Variable Frequency Drives (VFDs): VFDs allow for precise control of motor speeds in fans and pumps, matching energy consumption to actual demand.  VFDs available through Kele can significantly reduce energy waste compared to constant-speed motors. By modulating motor speed, these drives ensure that only the necessary amount of energy is used at any given time.
  • Smart Thermostats and Controllers: Intelligent thermostats like the Honeywell T6 Pro Smart Thermostat, and other Honeywell thermostats often found on Kele, learn occupancy patterns and allow for remote control, optimizing comfort and energy savings. Advanced controllers from manufacturers like Johnson Controls, also available through Kele, enable sophisticated zoning and scheduling for HVAC systems. These devices provide granular control over different building zones, ensuring energy is only used where and when needed.
  • Energy Metering Solutions: Accurate energy metering is crucial for tracking consumption, identifying areas for improvement, and verifying net-zero status. Kele offers a range of energy meters like the ACI KW350 that provide detailed energy usage data, allowing building managers to make informed decisions about energy management.
  • CO2 Sensors for Demand-Controlled Ventilation: Monitoring carbon dioxide levels helps determine actual ventilation needs. Kele provides CO2 sensors like the Kele KCO2, KCD, and KNET which enable demand-controlled ventilation (DCV) systems to adjust fresh air intake based on occupancy, saving energy by avoiding unnecessary ventilation.
  • Natural Gas Metering: Another up-and-coming metering and/or low energy initiative is natural gas metering. They are critical for billing accuracy, energy management, and leak detection in building automation systems. Kele stocks Sage meters that will help you do all of the above!

The Future is Net-Zero:

Net-zero buildings are no longer a niche concept but a growing movement shaping the future of the built environment. By prioritizing energy efficiency, embracing smart technologies, and integrating renewable energy, we can create buildings that are not only environmentally responsible but also economically sound and contribute to healthier, more comfortable living and working spaces. The time to build a net-zero future is now.

For more information on how Kele can help you maximize profit while minimizing costs—call us today or visit kele.com. Kele makes it easy!