Commercial structures may exhibit signs of trouble well before their control systems fail altogether. These may come in the form of inconsistent temperatures, slow response times of the equipment, and increasing utility bills. A building automation system retrofit can address underlying problems by replacing outdated logic and components with modern control systems designed around the building’s current process flow.
Comfort Plus LLC is here to identify such problems for commercial structures in Maryland, NOVA, and Washington, DC. From faulty communication systems to controller support issues, we know what to look out for.
1. Inconsistency between Temperature Readings in Different Zones
If the temperature in one room is too cold and that in the neighboring room too warm, it may not be an issue with the thermostats. The issue may involve the controller misinterpreting sensor data or failing to operate according to the programmed sequence. Over time, minor inaccuracies can lead to recurring comfort complaints from employees or occupants.
It may be one of the clearest symptoms of improper control logic. A technician may be able to adjust sensors and sequences to better match the actual needs of the building, but if the hardware is too old, the complaints may return.
2. Higher Utility Expenses Lacking an Obvious Reason
Rising energy costs without altering either the technology involved or the staffing situation should prompt one to look further into things. Aging HVAC control systems leave fans, dampers, and compressors running too long, sometimes even letting cooling and heating equipment run counter to one another in a particular zone. These do not constitute a readily apparent equipment malfunction that would lead anyone to take action about them.
An HVAC controls retrofit can help reduce wasted energy by adjusting schedules and set points based on actual occupancy. Facilities that undergo such a process may cycle equipment less often, which can help support lower utility expenses.
3. Manual Overrides Have Been Adopted as a Routine Practice
Automation is designed to reduce the need for constant manual monitoring. If the maintenance team has to manually override setpoints every day just to keep the building comfortable, the automation may not be working as intended. In most cases, this practice starts as an exception and gradually turns into a routine activity.
A legacy control system upgrade can help address this problem by restoring schedules and sequences that operate more independently. Once programming is updated to reflect actual equipment performance and usage patterns, the team may have less need to interfere with the process constantly.
4. Finding Replacement Parts Is Becoming Difficult
Eventually, all control systems come to the end of their useful life, at which point their manufacture is abandoned. It becomes increasingly difficult to find replacement boards, sensors, and controllers because a technician will have to go searching for obsolete parts or even extract them from equipment that has been retired within another part of the building. An outdated building automation system operating on unsupported hardware can mean that a simple repair is no longer a quick process.
When finding replacement parts becomes unreliable or difficult, it makes more sense to do a building automation system replacement along with the control system upgrade.
5. The System Is Not Compatible with the New Equipment
Buildings rarely upgrade all their mechanical systems simultaneously. The addition of new air conditioners, variable air volume controllers, or chillers, along with an outdated system that is not able to interface with this new equipment, makes maintenance technicians use workarounds such as stand-alone control systems that are added to the side of the main system. Such temporary fixes can create additional challenges during troubleshooting.
With a building management system upgrade, new and existing equipment can often be connected through one interface to report data to a single management system rather than several isolated ones. This can improve visibility into issues before they lead to larger equipment problems.
6. Alarms Are Being Ignored As They Are Not Reliable
If a control system does not provide useful alarms, it may be harder for facility teams to identify issues that need attention. With old alarms constantly sounding in response to minor changes, employees get accustomed to ignoring them, and that could mean that in case of actual malfunctioning of the machinery, this could go unnoticed for hours or even days. This is one of the less obvious signs of old systems, as the alarms may still activate but fail to provide useful information.
With proper troubleshooting of control systems, the number of alarms that really matter can be determined, and unnecessary alarms can be filtered out, thus teaching employees to pay attention to the panel. The alarm logic reconstruction in the course of retrofit could prove to be a rather easy job as compared to other parts.
7. No One On Staff Knows How The System Works
Control systems are usually set up once, by some technician or vendor who may not be available anymore, and the documentation explaining the logic behind the system might be sketchy or non-existent. If people working in the facility today do not understand how the building automation system functions, any modification can become difficult and risky. Building automation system retrofits also provide a good opportunity to update the documentation and create graphics that would make sense to those running the building and allow them to change the settings. This can be just as important as the hardware because a system that is not understood may eventually end up in manual override.
What a Controls Retrofit Really Entails
Retrofitting is not a one-size-fits-all solution; typically, it means a combination of new controllers, revised programming, and graphics put in place over the existing wiring and field devices that have held up over time. The scope depends on which components are still usable, which are failing, and which have become obsolete, which is why assessment should come before any plan.
Since field devices such as sensors and actuators have been designed to last longer than the controllers and programming, a retrofit usually involves making use of the existing wiring instead of replacing it. This makes retrofitting somewhat more akin to repairing the system than replacing it entirely.
Comparisons between Costs of Retrofitting and Costs of a Complete System Replacement
The cost factor tends to be the first one that comes to mind for a facility manager, and this is completely legitimate because a complete building automation system replacement will usually cost more than a retrofit, taking labor costs and downtime into account. The ability to reuse existing hardware when appropriate can make a retrofit more cost-conscious than a full replacement.
However, any such cost-based comparison may not be relevant if the wiring and field devices that are used can no longer be salvaged. Once a system ages beyond about 10 to 15 years, reliability may become more of a concern, depending on equipment condition, maintenance, and manufacturer support.
What Should Be Expected in the Retrofit Process
The first step for any retrofit usually involves a visit to the mechanical room along with an existing points list and a proposal of what is going to be replaced as opposed to reprogrammed. The actual installation process occurs in a phased manner, depending on whether it is done floor by floor or system by system so that occupied parts of the building are not all affected at once.
The final step in this whole process is commissioning, and it is also the step that is most commonly overlooked when the retrofitting process is rushed. Sequences have to be commissioned under the actual operating conditions, and not just checked on a laptop in the mechanical room, before the whole thing can be considered completed.
Getting a Head Start on a Plan for Your Outdated System
Identifying these issues early can give facility teams more options and help reduce the risk of emergency repairs. Comfort Plus assists with assessments and retrofit scope recommendations based on the particular system and equipment present in commercial, medical, institutional, and multi-unit properties in Maryland, NOVA, and D.C.
Our team will deal with the diagnostics first so that the retrofit recommendation can be based on the real condition of the building system and not just some assumptions. If there are at least two of the above symptoms in your system, it would be wise to get it checked.
Contact Comfort Plus LLC to request a system assessment and quote today.
FAQs:
1. How long do building automation systems last?
The useful lifespan of a building automation system can vary, but many systems may require evaluation for upgrades or replacement as components age and manufacturer support changes. However, this figure significantly depends on the system’s maintenance and whether or not its manufacturer can support it. Building automation systems with proprietary or unavailable components tend to reveal their obsolescence faster despite good mechanical equipment operation.
2. How do I know if my BAS needs an upgrade?
Constant manual override, energy usage increases, and ignored alarms may indicate that the building automation system needs to be evaluated for an upgrade. Also, problems in replacing components and lack of compatibility with new equipment signal that the system requires evaluation for further improvements.
3. What’s the difference between a controls retrofit and a full BAS replacement?
In general, the former is done through the use of existing wiring and field equipment but with the update of controllers, programming, and graphics. In contrast, the latter involves the complete replacement of the whole platform. A full replacement may be considered when a building automation system is too outdated, unsupported, or damaged for a practical retrofit.
4. Is it possible to do a controls retrofit on a facility while the building continues operating?
Yes, that is often possible, and many retrofits occur gradually, from zone to zone or from one system to another, to help keep the facility operating during the retrofit process. A brief analysis of the existing installation will allow you to see how it can be accomplished with minimal disturbance of occupants.
5. What should one keep in mind when choosing the contractor for a controls retrofit?
Choose a contractor who has practical experience with various building automation systems, since most facilities have equipment of different ages in operation. Find out how they document the project and train facility personnel after the retrofit is complete.
