Control Wiring Services

Lightning Mechanical offers control wiring services for HVAC systems. These tasks include the installation, configuration, and termination of local controls such as your control panel, wall-mounted thermostats, and zone valves, as well as working with businesses to design electrical control solutions that meet the specifications of their industries.

HVAC Machine Control Wiring Design

We have experience with construction projects for industrial and commercial facilities requiring control system design and panel build services. We create precise schematics for any required wiring up to and exceeding 5,000 feet. We also provide project management services for large-scale commercial installations that require the use of multiple contractors and coordination of efforts to meet tight deadlines.

These designs include a review of HVAC load calculations to ensure equipment capacity meets or exceeds demand before we recommend a system configuration. Once the design is complete, we create a layout to meet all code compliance regulations and facilitate an efficient installation process.

On occasion, we have been asked to create wiring redundancy systems to protect our clients from unscheduled downtime as a result of faulty communication between HVAC components.

Lightning Mechanical has extensive experience with control wiring design for large-scale commercial projects, including distribution centers, retail stores, office buildings/complexes, and other facilities that require highly customized HVAC solutions.

Our work doesn't end with the design of a control system; we also provide hands-on HVAC installation and start-up services for all our supported manufacturer equipment.

Packaged Rooftop Units
Packaged Rooftop

Thermostat Installation, Configuration & Termination

Thermostats manage heating and cooling by adjusting temperature settings in a home or business to ensure a comfortable indoor environment. In residential settings, the most common package includes a wall-mounted thermostat and one or more remote sensors (thermometers)that measure temperature in various rooms to ensure even heat distribution throughout the space.

The typical installation process for a wall-mounted thermostat begins with mount preparation and wiring termination. Once all wires have been hooked up to the thermostat, the device is mounted on the wall and programmed for each unique case. Afterward, sensors are installed in predetermined locations throughout a building or home. Finally, the entire system must be tested and calibrated.

Lightning Mechanical provides professional wall-mounted parameter settings and programming of traditional HVAC programmable logic controllers for both residential and commercial customers. We also install and terminate zone valves to effectively manage cooling and heating in your building.

Zone Valve Installation, Configuration & Termination

Zone valves help regulate temperature control by allowing or preventing coolant flow to different parts of a system. They can be used with both traditional HVAC systems and packaged rooftop systems to regulate hot and cold water flow in heating and cooling applications. Zone valves also provide the ability to monitor system status.

The installation process typically begins with electrical terminations on the valves, then mount preparation before the final securement into position. The valve's wiring is then hooked up to an air handler control board to provide control of the zones that it serves. Next, the valves and zone boards must be calibrated and tested, after which the system is ready for use.

Lightning Mechanical provides zone valve installation services for both traditional HVAC systems and packaged rooftop units. In addition to these, we also provide testing and calibration of valves when required.

Building Management System (BMS) Integration Services

Control Panel Installation, Configuration & Termination

An HVAC control panel is responsible for controlling all functions related to equipment operation, including cooling, humidification, ventilation, and heating. The installation process begins with an analysis of the system circuit before routing the wires terminating at the control board. Next, mount preparation takes place, followed by the final mounting of the enclosure in its designated area. Panel wiring then begins. From there control panel is programmed for its specific automation needs and tested before being put into service. Control panels are usually installed in maintenance rooms but can also be integrated with building management systems or controlled remotely.

As a full-service commercial HVAC contractor, Lightning Mechanical is able to configure and terminate control wiring for a wide variety of HVAC systems.

Service Panel Installation, Configuration & Termination

A service panel is the main electrical distribution point within a building. It supplies power to equipment such as air handlers, pumps, chillers, boilers, furnaces, and other devices that make up an HVAC system. The installation process begins with the service panel box and wires being prepped for connections to the circuit breaker and control wiring. Once preparations are complete, all components must be mounted securely in place and wired together appropriately before the final testing and calibration phases of installation.

Lightning Mechanical installs new service panels as well as upgrades existing ones to accommodate the addition of new components. We also terminate control wiring to the appropriate terminals on distribution boards or main control units.

Lightning Mechanical provides professional service panel installation and termination for all HVAC systems throughout New York, New Jersey, Southern Maine, and Northern Maryland.

What is HVAC Control Wiring?

HVAC control wiring is the electrical system that provides power and data to different components of an HVAC system. It is essentially machine control wiring for your air conditioning. The machinery needs to provide power and control for including equipment such as heaters, pumps, fans, dampers, actuators, digital controllers, and more. Wiring must be neatly installed on accurate diagrams before being tested for optimal functionality. Following this process ensures that systems work as intended to provide the desired climate control.

Total System Analysis

Types of Control Wiring

Control wiring can vary based on a number of factors, including location, building type, and equipment being installed. There are two main categories: Factory-Actuated Control Wiring & Field-Actuated Control Wiring.

Factory-Actuated Control Wiring

Factory-Actuated Control Wiring is typically used for commercial buildings where equipment is installed in large enclosed spaces. Each piece of equipment uses a different wire type to communicate with the control board, where every circuit is wired back to the main breaker panel.

Field-Actuated Control Wiring

Field-Actuated Control Wiring is used in smaller commercial or residential buildings that have multiple HVAC components that are more spread out, each requiring different wire types. Since each piece of equipment is separate from one another, all wire types are combined into a single cable that is traditionally run as the main power line. The wire then branches off into individual circuits that terminate at their respective components.

In addition to these two categories, control wiring can also vary depending on its intended use and location within a building. There are three general types of control wiring that we commonly see: low-voltage, line-voltage, and high-voltage.

Low-Voltage Control Wiring

This type of control wiring uses less than 600 volts for its designated function and typically contains four or fewer conductors (wires). It is used in residential HVAC systems and some commercial ones. The wire is often white in color with a rubber insulation jacket.

Line-Voltage Control Wiring

Using 600 to 35,000 volts of electricity, this type of wiring can run several miles within a facility before it branches out to different areas. It supplies power directly to the various components within an HVAC system. Cable jackets are traditionally orange in color with a smooth or corrugated design.

High-Voltage Control Wiring

This type of wiring is used when the electrical load exceeds 35,000 volts in commercial and industrial facilities. There can be a single wire in a 12 to a 72-inch conduit that powers large systems such as elevators, generators, machine tools, and high-capacity air handlers or a battery of large compressors. Conduit jackets are traditionally yellow in color with a smooth or corrugated design.

Tools of the Trade

Before any work can begin, our technicians arrive on-site with the appropriate equipment to ensure that installations are done correctly. Tools are kept clean at all times to prevent contamination so that they do not affect the quality of work or interfere in any way with our customer's systems. A typical Lightning Mechanical technician will bring:

  • Multimeter (Volt-Ohm-Milliammeter)
  • Cable Tray System
  • Multimeter (Volt-Ohm-Milliammeter)
  • Wire Stripper
  • Crimp Tool
  • Tape Measure
  • Torpedo Level
  • Multifunction Tool (including Hex Keys, Pliers, Screwdrivers, Flashlight, etc.)
  • Top of their field skills, training, and expertise.  

Using this equipment ensures that the wiring is installed to the manufacturer's specifications and that all code requirements are followed. Lightning Mechanical Services has some of the best HVAC technicians in the area who will do their best to make sure that customer systems are working properly before they leave.

Call us today for more information on our services.


Contact Us

65 Newark Way, Maplewood, NJ 07040, US
Monday - Friday: 8am - 6pm
24 Hour on call emergency service available