Modern fulfilment centres never stop operating.
With thousands of employees, continuous logistics operations and strict environmental requirements, maintaining a reliable indoor climate is critical for productivity, equipment protection and energy efficiency.
For this project, iACS partnered with CIAT UK to deliver bespoke Air Handling Unit (AHU) control systems for a major Amazon fulfilment centre located at Symmetry Park, Kettering.
Unlike many HVAC projects, this wasn't simply about supplying a control panel.
The project involved the manufacture of multiple AHU control panels, bespoke software development, installation support, intelligent field integration, commissioning and the deployment of the latest generation iX HVAC control platform.
This project demonstrates how iACS supports customers from design through to commissioning, ensuring every control system is engineered for reliability, maintainability and long-term performance.
What This Project Covered
This project demonstrates how iACS delivered:
- Bespoke AHU control panel manufacture
- iX intelligent HVAC controls
- Installation support
- Site quality assurance
- Commissioning
- Fan control
- Thermal wheel heat recovery
- Modbus integration
- Damper automation
- Sensor verification
- HVAC optimisation
Project Overview
Customer
CIAT UK
End User
A Major Amazon Fulfilment Centre
Project Type
Logistics & Distribution
Project Scope
The overall project involved manufacturing and delivering control systems for multiple Air Handling Units serving both dock door areas and warehouse ventilation systems.
The project included:
- 12 Air Handling Unit control panels
- Multiple intelligent splitter boxes
- Bespoke panel modifications
- Dock Door ventilation systems
- Warehouse AHUs
- Complete installation support
- Full commissioning
The scale of the project demonstrates iACS's capability to support large multi-unit commercial HVAC installations
1. Engineering the Right Solution
Every project begins long before installation.
Working closely with CIAT UK, iACS manufactured bespoke HVAC control panels tailored specifically for the operational requirements of the fulfilment centre.
During design, a bespoke amendment was introduced allowing the Vario Duct actuator to change position automatically during heating and cooling operation.
To achieve this, an additional two-pole relay was manually incorporated into the control panel and linked to the chiller changeover signal.
This bespoke engineering modification demonstrates one of the key strengths of iACS, our ability to adapt standard control systems to suit specific project requirements rather than forcing customers to compromise their HVAC strategy.
2. Installing the HVAC Controls
Once manufacturing had been completed, the project progressed into installation.
Our engineering team attended site to integrate the control panel with the Air Handling Unit and prepare the system for commissioning.
Installation included:
- Control panel mounting
- Electrical integration
- Sensor installation
- Cable routing
- Fan connections
- Damper wiring
- Point-to-point testing
- Electrical verification
Every field connection was tested before commissioning commenced.
3. Preparing the AHU for Commissioning
As with every large commercial HVAC project, installation also identifies outstanding mechanical items requiring completion before final commissioning.
During installation, the following items were documented:
- Return air temperature sensor awaiting installation due to incomplete ductwork
- Frost protection sensor inaccessible until mechanical completion
- Room temperature sensors temporarily stored within the control panel
- Heat recovery electrical readings recorded
- Earth continuity testing completed
Rather than delaying the project, these items were documented and incorporated into the commissioning plan.
4.
Built Around the iX Control Platform
One of the highlights of this project was the deployment of the latest generation iX HVAC control platform.
Unlike traditional HVAC controllers, iX has been specifically developed for modern Air Handling Units, providing intelligent control strategies alongside significantly simplified commissioning.
For this project, iX managed:
- Supply air temperature
- Return air temperature
- Fresh air temperature
- Fan volume control
- Thermal wheel heat recovery
- Modbus devices
- Airflow monitoring
- Damper positioning
- Filter monitoring
- Frost protection
This intelligent platform gives engineers greater visibility while allowing future expansion through additional connected devices.
The commissioned panel was running iX software version 26 with the latest BIOS revision at the time of handover.
5. Commissioning the Air Handling Unit
Commissioning verifies far more than whether the system powers on.
Every sequence of operation was tested to ensure the AHU responded correctly under operating conditions.
6. Sensor Verification
The commissioning process included verification of:
- Fresh air temperature
- Supply air temperature
- Return air temperature
- Room temperature
- Differential pressure sensors
The fresh air, supply and return temperature sensors were confirmed as installed correctly and reading accurately.
The room temperature sensor had not yet been installed, and this was clearly documented for completion by the project team.
7.
Intelligent Fan Control
The Air Handling Unit was configured for volume control using EC fans.
Commissioning verified:
- 0–10V control signals
- Fan enable outputs
- Alarm relays
- Fan rotation
- Air volume setpoints
Both supply and extract fans were configured for 18 m³/s airflow with matching K-factors, ensuring balanced system operation.
8.
Airflow Monitoring
Reliable airflow monitoring is essential for maintaining ventilation performance.
Supply and extract pressure transducers were verified including:
- Correct installation
- Pipe routing
- Wiring
- 50 Pa setpoints
- Controller integration
Unlike traditional airflow switches, the system monitored airflow using pressure transducers, providing more detailed operational feedback.
9.
Filter Monitoring
Filter differential pressure monitoring was also commissioned.
Supply and return filter monitoring was configured using differential pressure switches with a 200 Pa setpoint.
This allows maintenance teams to identify filter loading before airflow performance is affected.
10.
Frost Protection Strategy
One of the challenges encountered during installation was limited access to the frost protection sensor location.
Rather than delaying commissioning, iACS adapted the strategy by monitoring frost protection via the supply air temperature probe until permanent installation became possible.
This demonstrates how intelligent control strategies can provide practical solutions while maintaining system protection.
11.
Cooling Control
Cooling valve modulation was successfully verified.
However, because chilled water was unavailable and pumps had not yet been activated, live temperature control could not be demonstrated during commissioning.
Rather than ignoring this, the limitation was documented clearly for future verification once the mechanical systems became operational.
12.
Thermal Wheel Heat Recovery
Energy efficiency formed a major part of the control strategy.
Commissioning included complete testing of the thermal wheel heat recovery system including:
- Heat recovery activation
- Thermal wheel alarms
- 0–10V control signals
- Rotation verification
These checks ensure the heat recovery system contributes towards reducing building energy consumption during normal operation.
13.
Modbus Damper Control
Fresh air, exhaust air and mixing dampers were all integrated using Modbus communication.
Commissioning verified:
- Rotation direction
- Full travel
- Mechanical operation
- Actuator positioning
Using intelligent Modbus dampers simplifies wiring while providing enhanced diagnostics and future monitoring opportunities.
14. Final Operational Testing
Before completion, the AHU underwent operational testing.
This included verification of:
- Start-up sequence
- Shutdown sequence
- Run-on timing
- Supply temperature control
- Mixing box operation
The system operated successfully during the observed commissioning period before being left operational from the keypad.
15.
Lessons from the Project
Every HVAC installation provides valuable engineering insight.
For this project, several key lessons stood out:
Intelligent Controls Improve Flexibility
The bespoke Vario Duct modification demonstrates how software and hardware can be adapted to suit customer requirements.
Commissioning Identifies Remaining Mechanical Works
Items such as room sensors and chiller changeover wiring were documented rather than overlooked, ensuring clear communication between trades.
Modern HVAC Requires More Than Wiring
With Modbus devices, EC fans, thermal wheels and intelligent pressure monitoring, today's Air Handling Units rely heavily on advanced control strategies rather than traditional hard-wired systems.
Documentation Protects the Project
Every outstanding item, engineering decision and commissioning observation was formally recorded, helping ensure smooth project completion.
16.
Project Outcome
The project successfully delivered intelligent HVAC controls for a large-scale logistics facility using the iX platform.
Installation, commissioning and functional testing confirmed correct operation of:
- Fan control
- Airflow monitoring
- Thermal wheel heat recovery
- Damper control
- Sensor integration
- Electrical protection
- HVAC sequencing
The project also demonstrated iACS's ability to deliver bespoke engineering modifications while supporting customers throughout the manufacturing, installation and commissioning process.
17.
Why This Project Matters
Large logistics facilities demand HVAC systems that are reliable, maintainable and capable of continuous operation.
This project demonstrates how iACS combines intelligent controls, bespoke engineering and structured commissioning to deliver systems that are ready for long-term operation.
Rather than simply manufacturing control panels, iACS provides complete HVAC controls support throughout the project lifecycle.
Looking for a Specialist HVAC Controls Partner?
Whether you're delivering a logistics facility, warehouse, manufacturing plant, healthcare project or commercial development, iACS provides complete HVAC controls solutions from design through to commissioning.
From bespoke panel manufacture and intelligent iX controls to installation support and commissioning, our engineering team helps customers deliver reliable, energy-efficient HVAC systems that perform from day one.