CONTROL SYSTEMS
​​
-
PLC Systems NZ
-
Field Devices
-
Systems Upgrades
-
Industrial Control Intergration
-
HMI Design & Integration
Automation Support
for
Electrical Contractors
We support electrical contractors with industrial control, PLC programming and automation integration services for industrial machinery, process systems and building plant room services.
​
We are not electrical contractors.
​
Our role is to provide the control architecture, PLC programming and systems integration that enables industrial automation projects to operate safely, reliably and efficiently. By working alongside electrical contractors, OEMs and project teams we help systems operate correctly, reliably and efficiently.
Commercial HVAC Load Shedding & Automation
A custom-designed and built automation system delivering independent control of 64 heat pumps and 8 intake/extract fans to ensure full Building Warrant of Fitness (BWOF) compliance.
System Architecture & Features:
-
Distributed Architecture: Uses five satellite control panels at local distribution boards to provide localized control, protection, and deterministic, coordinated operation.
-
Centralized HMI: All satellite panels link back to a central HMI, providing live monitoring, system alarms, operational data, and full HVAC network visibility.
About Safety Relays
Variable Speed Drives
Commercial Pool & Spa PLC Heating Control Integration
PLC-Based PID Heating Control System
Delivers precise and stable temperature regulation and comprehensive system monitoring.
Key Features:
-
Safety & Control: Fail-safe heating valve closure on power loss, with dedicated setpoint and safety temperature probes.
-
Diagnostics & History: Full history logging for setpoint/safety alarms, system temperatures, and valve command vs. feedback position.
-
Trending & Alerts: Historical trend data logging and automated email notifications for selected alarms and conditions.
Control Systems
&
Automation
We assist with:
​
-
PLC programming
-
HMI & operator interface development
-
Servo motion & VSD / VFD integration
-
Distributed and networked control systems
-
Industrial communication and telemetry
-
Building plant room automation
-
HVAC and utility control integration
-
Pump, fan and process control systems
-
Control panel specification & supply
-
System integration
-
Commissioning assistance
-
Fault finding & diagnostics
-
Machine and process optimisation
-
Legacy system upgrades
-
Technical support during implementation
Our focus is practical, reliable automation that works properly in the field.
Supporting
Electrical Contractors
We work alongside electrical contractors during installation, commissioning and system integration phases to assist with the control aspects of commercial and industrial automation projects and building services automation systems.
This may include:
​
-
PLC and HMI development
-
Integrating third-party equipment
-
Configuring industrial networks
-
Commissioning machine sequences
-
Plant room and HVAC control integration
-
Troubleshooting comms or control issues
-
Refining control logic and operation
-
Assisting with system optimisation and stability
We support implementation — not compete with it.
Off-Grid Distributed Energy Network – Multi-Dwelling Solar, Battery & Generator System
Custom Vehicle Control System Console
Distributed PLC-based control network providing centralized management for an off-grid, multi-dwelling development using reliable RF-to-Ethernet communications.
Integrated Systems & Capabilities:
-
Infrastructure Control: Manages compound access, accommodation units, standby power generation, water infrastructure, pumping systems, and storage tanks.
-
Centralized Monitoring: Comprehensive event logging, real-time alarms, and complete site visibility.
Commercial
&
Industrial
Complete end-to-end vehicle rewiring and integration for an extreme off road vehicle utilising an industrial PLC with HMI, delivering centralised vehicle control, telemetry, and power management.
Key Capabilities:
-
Vehicle & Engine Management: Live monitoring for RPM, engine heating/cooling systems, battery health, and calculated distance tracking.
-
Auxiliary, Air & Winch Automation: Automated control and monitoring for onboard air systems, winches, and auxiliary equipment.
-
Integrated CCTV System: Live camera feeds and dynamic views for front, rear, and side/indicator cameras.
-
Telemetry & Connectivity: Integrated industrial cellular router leveraging Modbus protocols for real-time GPS tracking, speed acquisition, and remote telemetry communication.
-
Smart Phone Monitoring and Control:
Mains and Off Grid Pump Control Panels
Collaborative
by
Design
Industrial automation and building services projects work best when electrical contractors, mechanical teams and control engineers work together effectively.
​
We operate collaboratively and professionally throughout implementation and commissioning, with a focus on practical outcomes, technical support and a reliable system.
We support a wide range of automation applications :
​
-
Industrial machinery and OEM equipment
-
Process and production systems
-
HVAC and mechanical plant rooms
-
VSD / VFD Pump and utility systems
-
Ventilation and extraction systems
-
Water treatment and transfer systems
-
Distributed building services control
-
Energy and infrastructure automation
Our focus is always on stable operation, maintainable systems and practical long-term reliability.
Practical Engineering
Good automation should improve reliability, maintainability and operational performance — not create unnecessary complication.
Our approach is based on what will actually work on-site under real operating conditions, not what simply looks good in theory.
We prioritise:
​
-
Stable and predictable operation
-
Maintainable programming structures
-
Practical diagnostics
-
Reliable communication between systems
-
Clean and supportable integration
-
EMC mitigation measures, including filtering where required, are applied based on drive manufacturer recommendations, cable lengths, installation environment, and system performance requirements.
The goal is simple: deliver control systems that are correctly aligned, reliable and easy to support.
Simple Commercial BMS Legacy PLC Upgrade for BWOF
Distributed remote PLC's networked back to a custom HMI control panel using a combination of hardwired TCP/IP and wireless RF/RTU communication protocols.
Key Features:
-
Access & Security: Access and egress control, foot traffic alarms, and remote access.
-
Safety: Emergency egress and fire alarm monitoring.
-
Climate Control: Full HVAC climate automation.
-
Alerts: Automated email notifications for all system conditions and alarms.
Schneider Modicon M221 Controllers, TM3 Flexible I/O with remote mounting expansion modules for MODBUS TCP/IP and/or MODBUS SERIAL control.
Real projects. Real engineering. Real automation.
If you value directness, honesty, accountability, facts over fiction and a partner who focuses on
real outcomes over noise, Align Automation is built for that.
Align Automation
Precision Engineered | Alignment Driven