Fan Coil Case Study
Leaders in Product Design, Manufacturing, and Supply Chain Management
Background
A leading European manufacturer of heating, cooling, and ventilation solutions was expanding its fan coil products into the North American market. Its fan coil systems are
designed for energy-efficient climate control of buildings, offering versatile installation options and low- temperature system operation.
The systems provide flexible temperature control using water or, optionally, CO₂, while also enabling the introduction of primary air. As the customer expanded into North America, it needed a control solution to transition from traditional thermostat-based fan control to modern 0–10V fan control.
AVNAN partnered with the customer to develop a custom electronics solution for its fan coil product line, supporting the transition to modern EC motor control.
At A Glance
Overview
- Project timeline: 8 months
- Benefit: Flexible 3-stage-to-0–10V fan control
- Project Scope: $31k
Challenges
- Thermostat-driven power cycling
- Single 0–10V signal for up to 10 EC motors
- Custom control logic and multiple configurations
- Electrical protection and isolation requirements
Results
- Resolved thermostat power-cycling
- Controlled up to 10 EC motors from one 0–10V signal
- Supported multiple fan coil configurations
Problem Statement
The customer needed a control solution that could bridge traditional thermostat controls with the 0–10V fan control used in its newer fan coil systems.
The solution needed to support different thermostat and fan coil configurations while remaining flexible and easy to integrate into the existing product line.
Challenge
The main challenge was developing a control board that could connect different thermostat control methods with the fan control requirements of newer fan coil systems while maintaining reliable and consistent operation.
The board needed to prevent the control board from cycling on and off with the thermostat, provide a single 0–10V signal to control up to 10 EC motors, implement the required control logic, support multiple fan coil configurations, and provide electrical protection and isolation between the thermostat inputs and the unit- side electronics.
The design also needed to be flexible enough to supportthe customer’s existing product requirements while providing a reliable, production-ready solution for future fan coil applications.
Solution
The Key Requirement:
Bridge legacy 3-stage thermostat control with modern 0–10V EC motor control in a flexible, production-ready platform.
Custom 3-Stage-to-0–10V Control Board
AVNAN developed a custom 3-stage-to-0–10V fan coil control board that converts traditional thermostat signals into the 0–10V control signal required by EC motors.
The board addresses the thermostat power-cycling issue while providing control for up to 10 EC motors from a single 0–10V signal. It also supports multiple thermostat and fan coil configurations through configurable control logic.
Additional features include adjustable fan control, visual status indicators, manual operation, electrical protection, and isolation between the thermostat inputs and unit-side electronics.
By developing a flexible control platform rather than a single-purpose board, AVNAN created a solution that could be adapted across multiple fan coil applications while maintaining a consistent control architecture.
Avnan's Approach
Avnan provided project management from end to end that made them a one stop shop for the entire manufacturing process of the electronic control/display boards. Avnan’s service included:
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Conclusion
From Concept Toward Production
AVNAN partnered with a leading European HVAC manufacturer to develop a custom fan coil control solution that bridges traditional thermostat controls with modern 0–10V EC motor technology.
AVNAN supported the project through design, engineering, sourcing, and manufacturing, helping move the control board from concept toward production.
The project demonstrates AVNAN’s ability to develop flexible, production-ready electronics for HVAC OEM applications, including control solutions that support multiple configurations and EC motor applications.
