Macclesfield Hospital

The Challenge

Macclesfield Hospital’s air source energy system (ASES) needed more than a like-for-like controls swap – it needed a smart, future-ready controls retrofit that would restore confidence in operation and give the client clear visibility of performance. The existing MCC plant controls and HMI were dated, difficult to support, and not aligned with the latest functional design and description of operations issued for the site.

Centrica Business Solutions required a specialist partner to take ownership of the controls retrofit, software development, testing, and recommissioning – delivering a robust, well-documented solution that could be trusted in a live healthcare environment.

What We Delivered

Link Energy Services delivered a complete controls modernisation package for the Macclesfield Hospital ASES, combining engineering detail with a strong focus on usability and risk reduction.

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Control Panel Retrofit & Hardware Upgrade

• Retrofitted the existing MCC within the ASES packaged plantroom using free-issued Honeywell Optimizer hardware and modular I/O.

• Installed new 230 V to 24 V DC power supplies to support the updated Optimizer I/O architecture.

• Supplied and installed an industrial HTML5-compatible touchscreen, giving operators a modern, intuitive front end to the plant.

Smart Controls & HMI Experience

• Developed a new control strategy on the Tridium / Niagara N4 platform, aligned with the latest Description of Operations and system designer intent.

• Rebuilt I/O, trunk, COM port and network register lists to provide a clean, well-structured controls database.

• Designed and implemented new HMI graphics to replace the legacy interface, improving clarity, navigation, and on-site operability.

Assured Testing & Recommissioning

• Bench-tested the Honeywell controller configuration off-site, including COMs, I/O, equipment points, pump points, heat and electricity meters, and control sequences by section.

• Delivered full point-to-point testing of BMS field cabling against the ASES point schedule to de-risk recommissioning.

• Completed a structured pre-commissioning phase (wiring reviews, controller commissioning, I/O integration, sensor initialisation) followed by on-site commissioning, flow verification, sensor calibration, and equipment sign-off.

• Prepared a new commissioning pack and redlined MCC electrical drawings to reflect the final retrofitted solution.

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Key Technical Highlights

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• Honeywell Optimizer plant controller with modular I/O deployed as the new platform, integrated with a Niagara N4-based control strategy.

• HTML5 industrial touchscreen HMI installed to provide a modern, responsive interface in the plantroom.

• Comprehensive bench testing and point-to-point verification used to reduce on-site risk and compress commissioning time.

• Control philosophy checked and refined against the functional design and Description of Operations to ensure system behaviour matched design intent.

• Updated MCC drawings and commissioning pack issued as part of a fully auditable, handover-ready controls solution.

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Results

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✓ Modern, User-Friendly Controls: Macclesfield Hospital now benefits from a refreshed controls platform with a clean, intuitive HMI, making day-to-day operation and fault finding significantly easier for site teams.

✓ Reduced Commissioning Risk: Bench testing, structured pre-commissioning, and full point-to-point checks meant issues could be identified early, supporting a smoother, more predictable site commissioning phase.

✓ Aligned with Design Intent: The new strategy and configuration were developed directly against the functional design and Des Ops, helping ensure the ASES operates as the system designer intended.

✓ Healthcare-Ready Documentation: A full commissioning pack, redlined MCC drawings, and clear records give the client and project partners confidence in the integrity and traceability of the retrofit.

✓ Stronger Platform for Future Optimisation: With a modern controller, structured I/O, and improved visibility of plant operation, the ASES is now better positioned for future performance tuning, energy optimisation, and integration with wider estate systems.

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