🌬️ Air Curtain Systems Redefined with a Custom Controller!

[Mucitler Elektrik]

🚀 Groundbreaking Solution from akYtec​

akYtec has developed a specialized OEM controller for air curtain manufacturers. This controller integrates application-specific control logic, HVAC interfaces, and communication functions into a single device. This simplifies the management of complex air curtain systems and increases efficiency.

🎯 Why Are Air Curtains Important?​

Used in openings between areas with different temperature or environmental conditions, air curtains create a controlled air jet to prevent the passage of heat, humidity, and pollutants. Their performance depends on factors such as discharge velocity, jet angle, door geometry, and temperature. These parameters directly affect infiltration through an open door.

• Loading docks
  
• Warehouse entrances
  
• Cold storage facilities
  
• Production access points
  
• Transitions between areas with different hygiene or temperature requirements
  

In these applications, air curtain operation must respond to conditions such as door opening, temperature, fan demand, and heating requirements.

💡 How Does akYtec's Custom Controller Work?​

akYtec developed a specialized OEM controller based on its PR103 programmable relay for a leading air curtain manufacturer. This project combines application-specific control algorithms, a simplified user interface, and a hardware configuration adapted to the manufacturer's equipment requirements.

This approach uses an existing controller platform instead of developing new control hardware and software architecture from scratch. According to akYtec, this reduces development effort and allows for the production of a customized device within a relatively short development cycle.

🔥 Control Functions for Heating, Airflow, and Door Operations​

The customized controller manages the necessary operating functions for commercial and industrial air curtain systems. These include automatic heating and temperature control, fan speed regulation, and various door contact operating modes.

The controller can also manage operating schedules, equipment protection functions, alarms, and fault monitoring. It supports electric and water-heated air curtains and can be adapted for different product families within the OEM manufacturer's portfolio.

Air curtain performance does not solely depend on whether the fan is running. Supply velocity, discharge angle, and pressure differences affect the stability and effectiveness of the air jet. Wind and other external factors can also alter airflow conditions in an opening.

For heated systems, temperature control is an additional consideration. It has been found that excessive heating can reduce aerodynamic efficiency under some conditions. This makes coordinated control of airflow and heating crucial when the system is used between areas with significant temperature differences.

🔌 PR103: I/O and Industrial Communication Combined​

The controller is based on the PR103, an Ethernet-enabled mini-PLC. This platform is designed for applications such as ventilation, heating, and equipment control, offering two RS-485 interfaces in addition to Ethernet. It supports Modbus TCP over Ethernet and Modbus RTU/ASCII over RS-485.

The PR103 is available in configurations with six digital inputs, four high-speed digital inputs, six analog inputs, and ten digital outputs or eight digital outputs plus two analog outputs. The four high-speed inputs can process pulse signals up to 100 kHz.

The analog inputs can accept 4-20 mA, 0-10 V, Pt1000, and NTC/PTC signals, among other configurable signal types. This allows temperature sensors and other analog field devices to be connected directly to the controller without the need for a separate signal conversion device. The specified maximum analog input refresh rate is 1 ms.

The controller can be expanded with up to two PRM expansion modules. Programming and configuration interfaces include microUSB, Ethernet, and RS-485, while the control algorithm is developed using the akYtec ALP programming environment. The controller includes an internal real-time clock for functions such as timing.

The PR103 operates with a nominal 24 V DC supply, and the specified supply range is 9 to 30 V. The operating temperature range is -40 °C to +55 °C. The DIN rail-mounted device measures 123 × 108 × 58 mm and has an IP20 protection rating.

For an air curtain OEM, this combination of digital inputs, analog temperature inputs, outputs, and industrial communications allows functions such as door contact monitoring, temperature measurement, fan control, heating control, and communication with supervisory equipment to be incorporated into a single control architecture.

🛠️ OEM Customization from Software to Hardware​

This project demonstrates a development model where a standard automation platform provides the core control hardware, while OEM-specific elements are implemented through software, user interface, and hardware adaptations.

akYtec states that the typical time from initial inquiry to a customized, ready-to-use device is approximately two months. The company offers white-label versions without the akYtec brand and private-label versions with customer-specific branding.

The OEM service also covers software modifications, adaptations to device algorithms, and customer-specific printed circuit board development. This allows the scope of customization to go beyond programming when the standard controller configuration does not fully meet an equipment manufacturer's requirements.

For manufacturers producing multiple air curtain models, application-specific software also allows a common hardware platform to be configured for different operating requirements. The extent of this reusability depends on the I/O configuration, heating technology, sensors, actuators, and communication requirements of each product family.