Expert Interview: Harnessing Data Intelligence for Smarter HVAC Systems
With years of experience supporting HVAC optimization across commercial, industrial and institutional environments, Badger Meter Sales Manager Tony Lopez understands the growing role of smart communication in building performance. In this interview, he discusses how today’s increasingly connected, energy-focused buildings benefit from real-time diagnostics, cellular-enabled endpoints and cloud-based platforms—technologies that give operators deeper insight, stronger control and more resilient HVAC performance.
What is BACnet, what are the benefits of using it and what’s the significance of BTL certification?
BACnet (Building Automation Control Network) is an open communication protocol that allows interoperability among different manufacturers’ devices in the BMS. The BACnet Testing Laboratories (BTL) certification confirms a product implements BACnet features correctly, which gives controls integrators confidence it will plug and play on the network. ModMAG® electromagnetic flow meters are BTL listed, meaning they’ve passed formal BACnet conformance testing and are ready for seamless integration.
What role do cellular endpoints and IoT connectivity play in modern HVAC systems?
Cellular endpoints—like ORION® with NB IoT/LTE M—unlock secure, reliable communication from locations that are hard to wire or sit outside the building network. They’re ideal when meters are beyond the BMS firewall, in remote plant rooms or distributed across a campus. The benefit is continuous telemetry without IT re wiring, plus over the air updates and strong encryption for data security.
When is AquaCUE® Flow Measurement Manager the right choice versus native BMS integration?
The BMS is used when integration is straight forward and customers want local control and trending. However, AquaCUE is usually chosen when operators need to aggregate data from multiple devices/sites, bridge past firewall constraints, or standardize reporting across mixed instrumentation. AquaCUE provides cloud dashboards, alarms and analytics—and pairs perfectly with our ORION cellular endpoints for dependable remote monitoring.
How does communicating flow measurement data through a BMS or cloud platform improve optimization?
Communication turns flow into actionable control. With real time data from ultrasonic and electromagnetic meters, teams can:
- Verify design flows and maintain hydronic balance.
- Detect over pumping and optimize pump speed to cut energy use.
- Correlate flow with ΔT (delta T) to improve thermal transfer and temperature stability.
- Trigger rules or alerts (e.g., excessive flow variance) that prompt a quick response instead of waiting for comfort complaints.
Why is continuous, real-time communication critical for sustaining commissioning level performance?
Loads change, water chemistry shifts and equipment drifts. Continuous telemetry and event driven alerts surface issues early—air in circuits, fouled strainers, drifting valves—so teams can intervene before efficiency is lost. It’s the difference between annual recalibration and ongoing optimization, which directly lowers energy consumption and improves comfort.
How does integrating multiple data streams into a single platform strengthen reliability?
A unified view combining flow, energy and water quality provides system context. For example, a rising pump kW with steady flow may indicate mechanical wear; a falling ΔT with stable flow can point to coil or control issues. When operators see the whole picture on one dashboard, they prevent failures, extend asset life and plan maintenance proactively.
What about cybersecurity and IT considerations when connecting devices?
We recommend TLS encrypted endpoints, role based access and clear network segmentation. Cellular paths avoid opening inbound firewall ports, while BTL listed BACnet devices keep integration predictable. AquaCUE supports secure authentication and auditability, which keeps both IT and facilities comfortable with wider connectivity.
What practical KPIs and alerts should teams start with?
Even with advanced communication and analytics tools, optimization starts with a few foundational metrics. These KPIs give teams immediate insight into system behavior and quickly highlight early signs of drift, inefficiency or component stress:
- Hydronic balance: Flow vs. design flow (±10–15%).
- Energy efficiency: Pump kW per gpm (or l/s) and ΔT stability.
- Health checks: Sudden flow drops/spikes, persistent valve overrides, sensor signal loss.
After selecting the initial KPIs, set alert thresholds that drive a clear action—such as checking a strainer, rebalancing a loop or adjusting a VFD—then expand your alert strategy as your team becomes more comfortable.
How do BlueEdge technologies support stronger communication and visibility across HVAC systems?
BlueEdge offers several tools that help operators build a reliable data pathway from field instrumentation to the BMS or cloud, including:
- ModMAG electromagnetic flow meters provide BTL listed for plug and play BACnet integration.
- AquaCUE delivers cloud visibility, alarms and analytics; ideal for multi-site rollups and firewall friendly deployments.
- ORION cellular endpoints offer secure connectivity for remote or hard to wire locations.
- Complementary sensing supports system context where water-quality monitoring is relevant, helping sustain coil efficiency and protect assets.
Final Thoughts
Smart communications aren’t just about connecting devices—they’re about turning trustworthy data into timely action, reshaping how HVAC systems are monitored and managed. By combining open protocols, secure cellular telemetry and cloud analytics, HVAC teams gain the visibility and automation needed to strengthen reliability, reduce energy waste and sustain performance across commercial, industrial and institutional buildings.
