Modern manufacturing facilities place enormous demands on HVAC systems.
Maintaining precise airflow, temperature control and indoor environmental conditions is critical, particularly within battery manufacturing where production quality and environmental stability go hand in hand.
This project took the iACS engineering team to Northvolt Ett in Skellefteå, Sweden, where we were responsible for the installation and commissioning of bespoke Air Handling Unit controls for a large industrial AHU supplied by Swegon. The project required detailed planning, careful installation, thorough testing and a structured commissioning process to ensure the system operated reliably before handover.
What This Project Covered
For this project, iACS provided:
- AHU control panel manufacturing
- Installation of HVAC control systems
- Sensor installation and verification
- Fan control commissioning
- Airflow verification
- Damper commissioning
- Heat recovery testing
- Fire alarm integration
- End-user training
- Complete commissioning documentation
Project Overview
Customer
Swegon Ltd
End User
Northvolt Ett, Skellefteå, Sweden
Industry
Battery Manufacturing
Services Provided
- HVAC Controls Installation
- AHU Controls Commissioning
- Control Panel Integration
- Functional Testing
- Site Support
- Customer Training
1. The Challenge
Large manufacturing facilities require significantly more than simply installing a control panel.
Every sensor, actuator, inverter, fan, damper and safety device must operate together as a single coordinated system.
For this project, our engineers needed to ensure that every field device had been correctly installed, wired, tested and commissioned before the Air Handling Unit could be placed into operation.
Because the unit would undergo pressure testing, particular attention was given to sealing cable glands and grommets to minimise air leakage. The thermal wheel controller was also repositioned to improve accessibility for future maintenance, demonstrating how practical engineering decisions can improve long-term serviceability.
2. Installation Activities
During installation, our engineers completed a wide range of tasks to prepare the AHU for commissioning.
These included:
Control Panel Installation
The control equipment was installed and integrated with the Air Handling Unit ready for commissioning.
Thermal Wheel Modifications
The thermal wheel controller was relocated to improve future accessibility while maintaining correct operation.
This small modification significantly improves future maintenance for service engineers.
Electrical Installation
Our engineers:
- Installed field wiring
- Loomed sensor cables
- Sealed cable penetrations
- Checked cable routing
- Prepared inverter connections
Every cable was point-to-point tested before commissioning commenced.
Sensor Installation
The installation included:
- Supply Air Temperature
- Return Air Temperature
- Outdoor Air Temperature
- CO₂ Sensors
Each sensor was installed in its correct location and prepared for commissioning.
3. Commissioning the AHU
Once installation had been completed, the project moved into commissioning.
This stage verifies that every component operates exactly as intended.
Rather than simply checking that equipment powers on, commissioning confirms the complete operational sequence of the Air Handling Unit.
Sensor Verification
Each installed sensor was checked to ensure:
- Correct location
- Correct wiring
- Accurate readings
- Correct controller assignment
Temperature, CO₂ and differential pressure sensors were all verified successfully.
Fan Commissioning
The Air Handling Unit utilised volume-controlled supply and extract fans with airflow setpoints of 84,300 m³/h.
During commissioning our engineers verified:
- Fan enable signals
- 0–10V control signals
- Alarm outputs
- Motor rotation
- Frequency limits
- Current limits
- Inverter configuration
Both supply and extract fan systems were successfully tested.
Airflow Verification
Differential pressure switches were inspected to confirm:
- Correct installation
- Correct tubing
- Correct pressure settings
- Correct controller operation
Both supply and extract airflow proving devices were commissioned successfully with a 50 Pa setpoint.
Filter Monitoring
Filter differential pressure monitoring was commissioned to ensure the control system could detect filter loading and maintenance requirements.
Both supply and return filters were configured with 250 Pa differential pressure settings.
Fire Alarm Integration
Fire safety integration formed part of the commissioning process.
The fire alarm input was verified to ensure the AHU shut down correctly whenever a fire signal was received.
Heat Recovery Testing
The heat recovery strategy was tested by creating the appropriate operating conditions and confirming that the system activated correctly.
This ensured the energy-saving functions of the Air Handling Unit operated as designed.
Damper Commissioning
Fresh air, exhaust air and mixing dampers were all commissioned.
Each actuator was checked for:
- Correct direction
- Full travel
- Mechanical operation
- Secure installation
Proper damper operation is essential for maintaining airflow, energy efficiency and safe HVAC operation.
4. Delivering More Than Just Controls
Projects like this demonstrate that successful HVAC controls are about much more than supplying a control panel.
At iACS we provide support throughout the entire project lifecycle, including:
- Design
- Manufacturing
- Factory testing
- Installation
- Site commissioning
- Customer training
- Documentation
- Technical support
By following structured installation and commissioning procedures, we help ensure every Air Handling Unit performs exactly as intended from day one.
5. Why Commissioning Matters
Commissioning is one of the most valuable stages of any HVAC project.
A correctly commissioned system provides:
- Improved energy efficiency
- Better indoor air quality
- Reliable operation
- Reduced maintenance
- Lower operating costs
- Greater confidence for building owners
It also ensures that every sensor, actuator and control strategy has been fully verified before handover.
6. Project Outcome
Following installation and commissioning, the Air Handling Unit was successfully tested, all major HVAC functions were verified, and operational training was provided to the Northvolt engineering team before handover. The commissioning process confirmed correct start-up and shutdown sequences, fan control, sensor operation, damper functionality and overall system performance.
7.
Looking for a Partner for Your Next HVAC Controls Project?
Whether you're manufacturing Air Handling Units, installing ventilation systems or commissioning complex HVAC projects, iACS provides complete support from panel manufacture through to on-site commissioning.
Our experienced engineers have delivered projects across healthcare, manufacturing, commercial buildings, education, hospitality and industrial facilities throughout the UK and internationally.
If you're looking for a trusted HVAC controls partner who understands the entire project lifecycle, we'd love to discuss your next project.