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Industrial HVAC Predictive Maintenance & Energy Efficiency

Rayven's Industrial HVAC IoT solution: implement predictive maintenance and use energy efficiency insights to deliver big results.

The problem

Large Industrial HVAC is expensive, with costs coming from energy consumption, efficiency and support issues related to maintenance requirements, and the need to be always in working-order to meet customer demands.

Owners expect more from suppliers than temperature control and simple service contracts - they need deeper insights into energy efficiency to reduce running costs and wish to get performance insights so as to implement predictive maintenance regimes that can prevent failures.

Industrial HVAC IoT solution: bringing together real-time asset, energy and efficiency data.

The solution

To assist our customer, we created an Industrial HVAC IoT solution on our integrated data, AI + IoT platform. Our Industrial HVAC IoT solution gives them an easy-to-use, highly-interoperable application that enables them to collect real-time data from HVAC PLCs, weather reports and 4G energy meters; and then combine those data sets and analyse them in real-time so as to identify new performance metrics and maintenance requirements.

Defining what data to collect is critical
In order to create the solution we started by identifying the data needed to deliver these metrics. In our Industrial HVAC IoT solution, this included:

  1. Energy consumption
  2. Power factor
  3. Current and predicted temperature and humidity
  4. Operating hours and CO₂ as a proxy for occupancy
  5. Filter pressure
  6. Fan speeds
  7. Operating status

Initial goals of the solution
The first goal of the solution was to focus on connecting to the meters, PLCs and external weather service to collect data in a consistent and reliable manner, as well as ensuring data quality and integrity, so we built our Industrial HVAC IoT solution with the following features:

  1. Monitor critical operational data received from the equipment via a web-based system
  2. Ensure device management monitoring for was set in place
  3. Define business logic for the application to meet the business objectives
  4. Provide alarm and alert notifications via email or SMS messages
  5. Start collecting historical data to enable energy consumption forecasting
  6. Provide the right dashboards to the right users with the right insights
  7. Test the application, making sure all of the above goals are met, based on the below solution architecture

Industrial HVAC Predictive Maintenance & Energy Efficiency – Rayven


Before go-live, we test four critical aspects of our Industrial HVAC IoT solution:

Our platform is built with security as a top priority and our proprietary security architecture ensures that data is secure at all points of the environment.

The Industrial HVAC IoT solution includes data encryption in transit from device-to-cloud, as well as device authentication; security (Bearer) tokens; SSL, AES and RSA encryption; as well as additional device security checks done via automated polling.

Data from HVAC PAC PLCs is sent to LV power meters over MODBUS. The LV meter transmits data from the PAC and meter to the Rayven cloud via a 4G connection. Weather data is accessed via a WebAPI, whilst additional system metadata is added directly through data entry screens.

Data integrity
Your ability to make the right decisions is highly reliant on the integrity of your data. Making sure that you have reliable connections means that your data is always up-to-date and that you can rely on it, giving you the confidence to make critical business decisions in real-time based on it. As part of implementation, we tested and ensured that the raw data matched what was being seen in the dashboards and enabled back-fill capabilities just in case communication ever went down.

Industrial data science
The objective of the exploratory data analysis was to identify trends in the data,  which included:

  1. Energy usage patterns compared with temperature and humidity
  2. Maintenance and failure alerts

What’s next?

We are gathering data that will help us to build models of energy forecasting and HVAC predictive maintenance to deliver further financial and time savings.

Create integration, real-time data + IoT solutions that improve your business.

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Key features of our Industrial HVAC IoT solution:

All of these features were customised to fit the customers specific business objectives.

Energy monitoring

Continuous monitoring of energy consumption including power factor, current, voltage, and frequency.


Alarms and alerts

Receive immediate SMS and email alerts for energy alarms, PAC warnings and alarms or when any metric crosses your preset thresholds.


Complete history

Even if a device can’t connect due to network issues, you can rely on the automated backfill to retrieve device history and fill the gaps in the historical data set.


Predictive maintenance

Identify when filter pressures are rising, when system checks fail, when compressor motors start to misbehave and take proactive action.


Issue management

Ensure that there is a process in place to have the right people respond based on agreed protocols.


Automated reporting

Create custom reporting dashboards and schedule them to be sent at any periodic time schedule to any specific user or user group.


Bringing together real-time energy and efficiency data.

Our Industrial HVAC IoT solution drives real business outcomes.

Lower cost of maintenance Lower cost of maintenance

With centralised, continuous real-time monitoring, you can avoid the need to visit sites to monitor critical performance metrics and alerts and proactively maintain your PACs.


Better resource utilization Better resource utilisation

Sending technicians to monitor equipment or to fix-as-fail is not a good use of your technicians’ time or your money. Send technicians out when they are needed with specific purpose in mind.


Less downtime Less downtime

Centralised, continuous real-time monitoring allows you to proactively repair and maintain equipment, improving uptime and customer service.


Reduce energy consumption Reduce energy consumption

Compare PAC performance across a site or across an entire fleet to learn what makes some units more efficient than others.


Greater predictability Greater predictability

You can understand the impacts of 3rd party variables on costs and predict expenditure across different machines, sites and businesses.


Fault detection Fault detection

You can detect a fault immediately, enabling you to dispatch maintenance crews and fix machines before potentially triggering broader failures.


Our Industrial HVAC Predictive Maintenance & Energy Efficiency AI + IoT solution drives real business outcomes

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Pricing & plans

Simple, fair pricing that scales with your business model.



Rayven integrates with any asset, device or system.

4 Weeks

Solution live

Create custom solutions in weeks not months.

2 Weeks

Demonstrate ROI

Discover opportunities for business improvement.

See Rayven in action

One of our data science, AI + IIoT specialists will contact you for a live one-on-one demonstration or to answer any questions.