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Home & Building AutomationReference design

HVAC Automation Control

A supervisory layer for building HVAC that reads controller and energy meter points, learns setpoints from the building's own history, and writes them back only after checks pass. Every write is read back, and a mismatch raises an alarm and rolls the change back. It suits offices, malls and factories with central HVAC controllers, not split air conditioners.

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Outdoor air conditioning plant with chillers and large insulated pipes beside a building in Kolkata — Photo: Biswarup Ganguly, CC BY 3.0, Wikimedia Commons. Shows the setting, not this installation.

349.99 events/s: Collection rate for 2,000 points from 4 sources, measured against protocol simulators
46.27 ms: Longest prediction cycle time, unloaded, on simulators
217.3 MiB: Peak memory use in the same test
2,000 / 50: Maximum points read and points that can be written

Results reported by the design's authors on their own test setups. Yours depend on the site, so we confirm them in a pilot.

The problem

Why it matters.

HVAC controllers and energy meters sit on separate protocols, and setpoint changes go unverified.

The flow

From signal to action.

01SenseField pointsThe existing HVAC controller and an Eastron SDM630 meter provide setpoints, temperatures and energy data.
02ConnectPoint modelA gateway collects all points over OPC UA, Modbus TCP or RTU, and BACnet/IP into one model.
03DecidePredictionA KNN model trained on the site's own history suggests setpoints.
04ActApproved writeA setpoint is written only when the safety rules allow it.
05DecideReadback checkAfter a settling delay the value is read back, and any mismatch triggers an alarm and rollback.
06PeopleEngineer consoleEngineers watch predictions, approve limits and export logs from a browser console.

Deployment architecture

How it is wired.

The devices on site, what carries their data, where the decision is made and where the result goes.

01SenseOn site

Eastron SDM630 energy meter

02ConnectCarries the data

Modbus RTU (RS-485)

03DecideRuns the model

reComputer R1100 (4 GB RAM, 16 GB eMMC)1 per site

04Your systemsWhere results land

OPC UA
Modbus TCP
BACnet/IP
MQTT
Home Assistant

05ActWhat happens next

HVAC controller (existing)
Approved write

How it works

Step by step.

01Connect the controller and meter to the gateway over Ethernet, or RS-485 for Modbus RTU.
02Register points and confirm the meter's byte and word order before trusting the values.
03Train the model on site history and watch its suggestions in observe-only mode.
04Test faults on purpose to check that alarms and rollback work.
05Once an engineer signs off the limits, enable writes.

The hardware

What goes on site.

Items we stock can go straight in the bag. Everything else we source and quote with the installation.

reComputer R1100 (4 GB RAM, 16 GB eMMC)Gateway host with RS-485, RS-232, digital I/O and Gigabit Ethernet1 per siteSourced on quote
reComputer R1100 (4 GB RAM, 32 GB eMMC)Gateway host with room for months of local history1 per site, as an alternativeSourced on quote
Eastron SDM630 energy meterRead-only energy data, already on siteSourced on quote
HVAC controller (existing)Source and target of setpoint and temperature pointsSourced on quote

Before you install

A gateway host (x86-64 or arm64) with Docker Engine 20.10 or newer, about 1 GB free disk, and ports 8280 and 4841 free.
Network access to the controller and meter on the plant network. No internet is needed.
Controllers whose points can be read back after a write.
A named engineer to approve the safety limits before writes are switched on.
A check of the meter's byte and word order during setup.

Good to know

It ships in observe-only mode with placeholder limits (18 to 30°C, 1°C per 5 minutes) that must be approved first.
Only Modbus writes are read back and confirmed. BACnet outputs are not.
It is not for safety loops, fast processes or split AC units.
No energy saving is claimed, and logs rotate, so the audit trail must be exported on a schedule.

How we deliver it

Paper to site, one team.

01Site surveyWe walk the site, or review photos and drawings, and agree what to measure and where each device goes.
02PilotOne lane, one line or one room first. We tune it on your conditions and agree what good looks like.
03Roll outWe supply the hardware in India with GST invoices, install it, and connect it to the systems you already run.
04SupportSpares, remote checks and model updates, with one team to call when something changes.

Questions

Asked before buying.

Does it work with split ACs?

No. It needs a central HVAC controller that speaks OPC UA, Modbus or BACnet/IP.

How much energy will we save?

The page does not claim a figure. Savings must be measured against your own baseline and weather.

Does it need cloud access?

No. Everything runs on the plant network.

Want this on your site?

Tell us the site and the problem. We come back with a pilot plan and a priced hardware list.

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