Heating controller project

 **Report on the Necessity for Upgrading the Control System**




**Introduction**


This report addresses the critical need to upgrade the control system currently managing the heating distribution in the Brick End area. Following the recent extreme weather event, it has become evident that the existing system is outdated and poses operational challenges.


**Background**


During the recent storm , a power trip occurred, leading to a significant malfunction in the control panel. The control panel experienced a software issue that we are unable to resolve. Investigations revealed that the problem lies in the communication between the control panel and the circulation pumps, which are responsible for distributing hot water to the radiators and roof fan heat exchangers in the brick area.


**Current System Condition**


Upon thorough examination, we have confirmed that:


- The circulation pumps are functioning correctly.

- The boiler is operating normally.

- All radiators are in good condition.


The root cause of the issue is attributed to the control system, which appears to be outdated. We suspect that the current control system was installed when the Brick End area was constructed in 1996. While it may have been state-of-the-art at the time, it has since become significantly outdated and is proving to be extremely difficult to program and interface with effectively.




**Technical Details**


The control system in question is classified as a Human Machine Interface (HMI). Previously, this controller could also be operated remotely by the council; however, since the council no longer owns or maintains the system, we have inherited this outdated technology. The systems engineer informed us that the control system was already considered obsolete before the council ceased its operations. We had to get  this firm to fix a different control system error previously


In our assessment, we also investigated the attached modem to ascertain whether it could be contributing to the issues. The modem has been kept switched on; however, its necessity remains unclear since the pumps are hardwired.


**Conclusion**


Given the challenges associated with the current control system, particularly its outdated software and interfaces, it is imperative that we consider upgrading to a more modern and reliable control solution. An upgraded system will enhance functionality, ease of use, and reliability, ultimately ensuring a more efficient heating distribution process for the Brick End area.



**Recommendation**

We have given this considerable thought and contacted the company previously contracted to maintain this control system to get a price for having a software engineer come out to fix the issue. Unfortunately, the expert on the system was on holiday when we called, so we had to wait a week for his return. When he finally quoted us, he mentioned a minimum call-out charge of four hours, even after we explained that we are a charity and no longer council-operated. Despite our circumstances, the price could not be reduced. 


We believe this fee is unjust for a system we intend to upgrade or remove, especially since we anticipate having a different kind of heat and power system in place by this time next year. Therefore, the current control system will not be needed. 


We have reached out to other heat and power installers to obtain quotes for installing a smart meter type controller that can work with the existing system for now but still be compatible when we transition to renewable energy.




We recommend initiating the upgrade process of the control system to improve operational efficiency, mitigate future risks, and enhance service reliability.


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