Modern distribution centres operate around the clock, relying on dependable HVAC systems to maintain comfortable working environments, protect equipment, and ensure continuous operation.
Behind every high-performing Air Handling Unit (AHU) is a carefully engineered control system that coordinates ventilation, heating, cooling, airflow monitoring and safety devices.
For this project, iACS worked alongside Mansfield Pollard to manufacture and support the installation of bespoke AHU control systems for one of the UK's largest supermarket distribution centres. The project involved multiple Air Handling Units, bespoke control panels and a dedicated thyristor control panel, all designed to support a reliable and energy-efficient HVAC installation.
Facilities of this scale place significant demands on HVAC systems. The controls must provide dependable ventilation, accurate environmental monitoring, reliable electrical protection and long-term maintainability while supporting continuous operation.
This project demonstrates how iACS supports customers throughout the entire project lifecycle, from control panel manufacture and documentation through to installation support, quality assurance and preparation for commissioning.
What This Project Covered
This project demonstrates how iACS delivered:
- Bespoke AHU control panel manufacturing
- Installation support
- Electrical integration
- Field wiring
- Quality assurance testing
- HVAC controls verification
- Documentation
- Preparation for commissioning
Project Overview
Customer
Mansfield Pollard Ltd
End User
One of the UK's Largest Supermarket Distribution Centres
Project Type
Retail Distribution & Logistics
Equipment Supplied
The project included the manufacture of multiple bespoke control systems, including:
- AHU01 Control Panel
- AHU02 Control Panel
- AHU03 Control Panel
- 135kW Thyristor Control Panel
1. Supporting Large-Scale Distribution Facilities
Distribution centres place significant demands on HVAC systems.
Unlike office buildings, these facilities often operate continuously while accommodating large open spaces, varying occupancy levels and considerable heat gains generated by equipment and logistics operations.
This places increased importance on dependable ventilation, robust control strategies and reliable monitoring.
For this project, iACS supplied bespoke control systems specifically engineered to support the Air Handling Units serving this major distribution facility.
2. Manufacturing Bespoke HVAC Control Panels
Every iACS control panel begins long before arriving on site.
Each panel is designed, manufactured, inspected and documented to ensure seamless integration with the mechanical equipment.
For this project, multiple Air Handling Unit control panels were manufactured alongside a dedicated 135kW thyristor control panel, demonstrating the scale of the installation and the bespoke nature of the solution.
Each panel underwent rigorous internal testing before dispatch, ensuring it was ready for installation and reducing the likelihood of delays once on site.
3. Installation Support
Following manufacture, the project progressed into the installation phase.
At this stage, the focus shifted from panel production to integrating the controls with the Air Handling Unit and preparing the system for commissioning.
The installation was completed by iACS engineers Ryan Donoghue, Daniel Dudman and Huzaifa Bukhari, working alongside the wider project team to ensure the HVAC controls were installed correctly.
4.
Preparing the AHU for Commissioning
Successful commissioning starts with a structured installation process.
During installation, our engineers completed the field wiring while also identifying outstanding mechanical items that required completion before final commissioning.
These included:
- Supply air temperature sensor to be installed within the duct
- Return air temperature sensor to be installed
- Gas leak detector to be fully fitted
- CO₂ sensor to be terminated and installed
- Fresh air damper actuator to be fitted
By identifying these items during installation, the wider project team could complete the remaining work before commissioning commenced, reducing delays and ensuring a smoother project handover.
5. Quality Assurance Throughout Installation
At iACS, installation quality is treated with the same importance as manufacturing quality.
Before the installation phase was signed off, our engineers verified:
- Electrical diagrams and documentation
- Warning labels and safety notices
- Conductor identification
- Earthing arrangements
- Protective device selection
- Equipment polarity
- Point-to-point field wiring
- Earth continuity testing
This structured verification process ensures every control system is installed safely and correctly before entering the commissioning phase.
6. Electrical Verification
Electrical testing forms a critical part of every HVAC controls installation.
For this project, earth resistance values were recorded across all four supply fan motors to verify correct installation and electrical integrity.
Carrying out these checks before commissioning helps identify potential issues early, reducing project risk and improving long-term system reliability.
7.
Attention to Detail Makes the Difference
One aspect often overlooked within completed HVAC projects is installation quality.
Throughout this project, particular attention was given to:
- Cable routing
- Cable segregation
- Cable support
- Junction box positioning
- Sensor cable protection
- Panel termination quality
These details may seem small, but they significantly influence future maintenance, troubleshooting and long-term reliability.
The installation photographs clearly demonstrate the organised cable management, structured field wiring and tidy panel assembly that form part of every iACS installation.
8.
More Than a Control Panel
For iACS, supplying a control panel is only one part of the solution.
Every project includes engineering support to ensure the installed controls operate correctly alongside the mechanical equipment.
This includes verifying:
- Sensor installation
- Actuator positioning
- Electrical integrity
- Fan wiring
- Cable management
- Functional readiness
- Future commissioning requirements
This approach helps minimise commissioning time while improving overall system reliability.
9.
Supporting Modern AHU Control Strategies
This installation demonstrates how intelligent HVAC controls provide the foundation for modern Air Handling Units.
The bespoke control system supports functions including:
- Supply air temperature monitoring
- Return air temperature monitoring
- CO₂ monitoring
- Gas detection
- Damper control
- Fan control
- Alarm monitoring
- Future Building Management System integration
These control strategies help ensure reliable operation while providing building operators with greater visibility and long-term maintainability.
10. Why Installation Quality Matters
Even the most advanced HVAC controller cannot perform effectively if installation quality is compromised.
Professional installation ensures:
- Accurate sensor readings
- Reliable communications
- Safe electrical operation
- Faster commissioning
- Reduced maintenance
- Improved long-term reliability
Projects like this demonstrate why experienced HVAC controls engineers remain essential to successful project delivery.
11. End-to-End HVAC Controls Support
Working with iACS means working with a partner that supports every stage of the project.
Our services include:
- Controls design
- Control panel manufacturing
- Bespoke software development
- Electrical installation
- Site support
- Quality assurance
- Commissioning preparation
- Technical support
This integrated approach reduces project risk while delivering a consistently high-quality installation.
12.
Project Outcome
By the conclusion of the installation phase, the control panel had been successfully integrated with the Air Handling Unit, field wiring had been completed and comprehensive quality assurance testing had been carried out.
Outstanding mechanical items, including duct-mounted sensors, the gas leak detector, CO₂ sensor and fresh air damper actuator, were clearly identified to allow completion before commissioning. This structured approach ensures commissioning can proceed efficiently once all field devices are installed.
13.
Why This Project Matters
Every commercial HVAC installation presents unique challenges.
This project demonstrates that successful HVAC controls rely not only on manufacturing high-quality control panels, but also on detailed installation planning, thorough testing and close collaboration with the wider project team.
By identifying outstanding works early and maintaining high installation standards throughout the project, iACS helps customers move smoothly into commissioning while reducing future operational risk.
For major distribution facilities, where uptime, reliability and energy efficiency are essential, this attention to detail is what transforms a control panel into a dependable building control solution.
Looking for a Specialist HVAC Controls Partner?
Whether you're delivering a distribution centre, manufacturing facility, commercial office, healthcare project or specialist ventilation system, iACS provides complete HVAC controls support from panel manufacture through to installation and commissioning.
Our experienced engineers work alongside manufacturers, contractors and consultants to deliver intelligent control systems designed for reliability, maintainability and long-term performance.
If you're planning your next HVAC controls project, speak to the iACS team to discover how we can support every stage of your project lifecycle, from design and manufacture through to installation, commissioning and ongoing technical support.