INDUSTRIAL CONTROL SYSTEM
Digitron 2.0 Vario
DIGITRON 2.0 VARIO CONTROL SYSTEM
Digitron 2.0 Vario is the control system developed by Aeris, based on a Siemens S7 standardised platform and designed to ensure maximum operational efficiency of air treatment systems. Equipped with an advanced interface and a fully open architecture, the system is ready for Industry 4.0 integration, ensuring full connectivity and intelligent system supervision.
Digitron 2.0 Vario is the ideal solution for companies seeking a reliable, flexible control system designed to evolve with production requirements, delivering high performance and maximum energy efficiency.
OPERATING OF THE DIGITRON 2.0 VARIO CONTROL SYSTEM
Digitron 2.0 Vario provides advanced control of all system components through Modbus communication with sensors, actuators (dampers and valves), and motor drive units.
In addition to thermo-hygrometric control, the software:
- Monitors command execution in real time;
- Receives feedback on actuator position, status, and power consumption;
- Automatically adjusts operating parameters in response to actual system conditions.
SELF-ADAPTIVE OPERATION
Fan motors and humidification pumps operate with variable capacity, controlled by dedicated algorithms that take into account:
- Internal thermo-hygrometric conditions;
- External environmental conditions;
- Thermal load of the production areas and heat losses;
- Solar radiation and real-time demand
This ensures fully self-adaptive operation, maintaining precise control and maximum energy efficiency.
ADVANTAGES OF THE CONTROL SYSTEM
- Complete and continuous system control;
- Optimisation of energy and water consumption;
- Continuous monitoring with immediate response to any operational variation;
- Remote access from any PC, both on-site and remotely;
- Historical data logging of operating conditions and system events;
- Real-time monitoring of energy, thermal fluids, and water consumption;
- Open, scalable architecture with seamless integration into existing plant systems.
All monitoring, remote control, and advanced analysis functions—often offered as optional features—are included as standard in Digitron 2.0 Vario.
Aeris is the ideal partner to improve comfort and productivity in your industrial environment with our customised solutions.
Request a free technical evaluation to identify the most suitable solution for your application.
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APPLICATIONS AND INDUSTRIES
FAQ
What is Digitron 2.0 / Vario and what is its primary purpose within an industrial system?
Digitron 2.0 / Vario is an advanced automation, control and intelligent supervision system developed to monitor and manage industrial dust extraction, filtration and ventilation systems in real time.
Its primary purpose is to coordinate the operation of fans, dampers, valves and filter cleaning systems according to the actual production requirements of the facility.
By automatically controlling the key aerodynamic parameters, the system ensures that the installation always operates at its optimum efficiency, minimizing energy waste while eliminating the need for manual system adjustments.
How does the control system achieve measurable energy savings?
Energy savings are achieved through the automatic and dynamic modulation of airflow rates by means of Variable Frequency Drives (VFDs) controlling the main fans.
Whenever production lines or individual machines stop operating, field sensors detect changes in airflow or system pressure.
Digitron automatically reduces the speed of the main fan, preventing unnecessary air extraction.
This significantly reduces electrical energy consumption—which decreases according to the fan affinity laws—while minimizing the loss of conditioned air from the facility.
Which operating parameters are monitored in real time?
The system continuously acquires and analyses critical operating data from sensors installed throughout the plant, including:
• Differential Pressure – Monitoring filter pressure drop to optimize the automatic pulse-jet cleaning cycles.
• Air Pressure and Airflow – Ensuring stable and safe capture velocity at extraction hoods.
• Temperature and Electrical Power Consumption – Preventing motor overloads and abnormal operating conditions.
• Operating Hours – Recording equipment operating time to support maintenance planning and component lifecycle management.
Does Digitron 2.0 / Vario support remote monitoring and Industry 4.0 integration?
Yes. Digitron 2.0 / Vario has been specifically developed for digital connectivity and is fully compatible with Industry 4.0 and modern smart manufacturing requirements.
Through standard industrial communication protocols—including Modbus, PROFINET and EtherNet/IP—the system can be seamlessly integrated with factory SCADA, MES and Building Management Systems (BMS).
This enables plant managers and HSE personnel to remotely monitor system performance, receive alarm notifications and analyse operating and energy consumption reports from PCs, tablets or smartphones.
What are the benefits of Digitron 2.0 / Vario for plant safety and predictive maintenance?
Digitron 2.0 continuously monitors all critical operating parameters, including differential pressure, temperature, airflow and automatic cleaning cycles.
Whenever operating conditions deviate from the predefined limits—such as abnormal pressure drops, motor overheating or dust discharge failures—the system generates local visual alarms and remote notifications.
Where required, automatic safety shutdown procedures can also be activated to prevent mechanical failures, filter damage or potentially hazardous operating conditions.
From a predictive maintenance perspective, the software continuously analyses historical operating data and filter loading trends.
This enables accurate estimation of the remaining service life of filter bags or cartridges, allowing maintenance activities and filter replacement to be scheduled during planned production shutdowns while minimizing unexpected downtime.