Client Showcase Archives | Controlled Air, Inc.

Delivering a Turnkey Energy Efficient HVAC Solution for Yanmar Warehouses

Karnold@controlledair.com — Mon, 08 Dec 2025 21:25:36 +0000

When a world-class equipment manufacturer needs to upgrade their own facilities, they need a partner who can manage the job from the structural engineering down to the final software programming.

We are proud to announce the successful completion of a massive HVAC integration for the Yanmar Tractor and Parts Warehouses. For this project, Controlled Air served as the lead organizer and turnkey provider, delivering a seamless “design-to-execution” experience that modernized the climate control for two massive industrial spaces.

Here is a look behind the scenes at how Controlled Air managed this complex infrastructure project.

The Scope: Total Project Management

This was not a simple “swap and drop” equipment changeout. This was a comprehensive facility upgrade.

Beyond the mechanical installation, our team managed the critical logistics to keep the project running smoothly:

Structural & Architectural: We handled the structural reviews and the installation of pre-engineered deck support systems to safely hold the new heavy-duty equipment.
Roofing & Rigging: From crane rentals and rigging to the necessary roofing repairs and curb installations, we ensured the building envelope remained secure.
Utilities & Safety: We managed the complete gas piping infrastructure, electrical connections, and fire alarm tie-ins (including duct smoke detectors).

The Technology: High-Efficiency Synergy

One of the most exciting aspects of this project was the equipment selection. We paired high-performance air handling with Yanmar’s own cutting-edge engine technology.

To condition this massive space, we furnished and installed a robust system designed for longevity and efficiency:

Air Handling: Seven (7) Aaon 30-ton Rooftop AHUs, fully equipped with VFD blowers for energy efficiency and a high-grade filtration system using MERV 8 and MERV 13 filters.
Heating & Cooling: These units are powered by fourteen (14) Yanmar 14-ton Gas Heat Pumps (GHP). This 2-pipe natural gas system utilizes Yanmar’s engine technology to provide efficient heating and cooling with reduced electrical demand.
Reliability: The system includes custom 14″ roof curbs, stainless steel drain pans, and vibration isolation to ensure quiet, long-term operation.

2. The Parts Warehouse

Similar to the tractor facility, the parts warehouse received a top-tier upgrade:

Three (3) Aaon 30-ton Rooftop AHUs paired with six (6) Yanmar 14-ton GHPs.
This setup ensures that valuable inventory is kept at consistent temperatures while maintaining high air quality standards through double-wall cabinets and advanced filtration.

Intelligent Controls

Controlled Air furnished and installed a complete Johnson Controls ecosystem to tie the entire facility together.

We deployed panel-mounted controllers across both warehouses, complete with all necessary sensors, relays, and current switches. For the Parts Warehouse, we installed a Johnson Controls Supervisory front-end controller. This web-based user interface allows facility managers to monitor the system remotely, ensuring peak performance and immediate diagnostics.

The Controlled Air Difference

By handling everything from the certified air balancing and start-up testing to the permits and gas meter coordination, Controlled Air ensured that Yanmar could focus on their business while we handled their building.

We are thrilled to hand over a facility that is energy-efficient, structurally sound, and controlled by the latest in building automation technology.

Do you have a complex commercial or industrial HVAC project? Contact Controlled Air today to see how we can organize your next project from start to finish.

Learn More about our Gas Heat Pump Solutions

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CHP Installation, Norwalk CT | The Maritime Aquarium Center

Karnold@controlledair.com — Fri, 05 Sep 2025 12:22:38 +0000

The Maritime Aquarium at Norwalk recently worked with Controlled Air, inc, to improve their energy efficiency and reliability, we installed a Tedom CHP unit.

Combined Heat and Power (CHP) systems offer significant benefits for aquariums, addressing their substantial and continuous energy demands for maintaining precise environmental conditions. Here are the key advantages:

High Energy Efficiency: Aquariums require consistent heating, cooling, and electricity for life support systems (pumps, filters, lighting). Traditional methods often waste a significant amount of heat during electricity generation. CHP systems, by producing both electricity and useful thermal energy from a single fuel source, can achieve overall efficiencies of 65% to 80%.
Reduced Operating Costs: Due to their high efficiency, CHP systems require less fuel to produce the same amount of energy (electricity and heat). This directly translates to lower energy bills and can lead to substantial cost savings, potentially offsetting energy expenses by 20% to 50%.
Enhanced Reliability and Resiliency: Maintaining stable water temperatures and continuous power for pumps and filtration is critical for the health and survival of aquatic life. CHP systems provide on-site generation, which means aquariums can operate independently or in parallel with the grid. This enhances energy reliability and resiliency, ensuring critical functions continue even during grid outages or disruptions, protecting valuable marine specimens.
Environmental Benefits: By maximizing the use of fuel and avoiding transmission and distribution losses associated with grid electricity, CHP systems reduce overall fuel consumption. This leads to a significant decrease in greenhouse gas (GHG) emissions, such as carbon dioxide (CO2), as well as other air pollutants like nitrogen oxides (NOx) and sulfur dioxide (SO2), contributing to decarbonization efforts.

Learn more About Cogeneration (CHP)

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Microgrid, Middletown CT | Middletown Recreation Center

Controlled Air Inc. — Fri, 08 Aug 2025 14:52:17 +0000

Middletown Recreation Center Embraces a Resilient and Sustainable Future with a New Microgrid

In a significant step towards energy independence and sustainability, the Middletown Recreation Center has completed the installation of a new microgrid system. This project is a cornerstone of the city’s broader efforts to modernize its infrastructure and ensure the community’s safety and comfort, particularly during extreme weather events.

The new recreation center, built on the former site of the Woodrow Wilson Middle School, is not only a hub for community activities with renovated gyms and pools but also serves a vital role as a designated heating and cooling center during power outages. The microgrid is the key to this resilience, allowing the facility to operate independently of the main power grid.

The system is a complex, hybrid energy solution designed and engineered by Clarke Energy in collaboration with other partners. Controlled Air, Inc. worked with Clarke Energy to create an energy-efficient solution that integrated a Yanmar combined heat and power (CHP) unit and a Yanmar gas heat pump (GHP) system. The core of the microgrid is the 35kW CHP unit, which provides both electricity and high-efficiency hot water for showers and the pool. This is complemented by a solar photovoltaic (PV) array that generates renewable electricity, with a battery energy storage system (BESS) to save surplus energy for later use. A backup gas-fueled generator from Kohler provides an additional layer of resilience, ensuring the facility can remain powered for extended periods.

This innovative system is designed to provide both parallel power during normal operation and “island mode” capability during a grid outage. The entire system is managed by a centralized microgrid controller, which optimizes the different energy sources for maximum efficiency and reliability. The project is expected to reduce the center’s carbon dioxide emissions by 192 tons per year, aligning with the city’s goals for a more sustainable future.

The Middletown Recreation Center microgrid is an excellent example of how communities can invest in infrastructure that not only serves their daily needs but also provides critical support in emergencies. It represents a forward-thinking approach to energy management, combining sustainability with an unwavering commitment to public safety and resilience.

The Middletown Recreation Center’s new system is fully protected by a 20-year parts and labor contract. Controlled Air and Yanmar are committed to providing a reliable, long-term, and energy-efficient solution by guaranteeing dedicated parts and service for the equipment.

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CHP Installation, Southington CT | YMCA

Controlled Air Inc. — Fri, 28 Feb 2025 14:44:38 +0000

SOUTHINGTON YMCA

Controlled Air installed a Yanmar cogeneration system in coordination with a new boiler plant and domestic hot water production to reduce energy costs for the Southington YMCA. Our work included the mechanical demolition and removal of existing oil tanks, boilers, domestic hot water tanks, and remaining equipment from the previous co-generation system. At the heart of the new system, we furnished and installed two 35kW Yanmar high-performance CHP systems with the ability to produce a total of 70kw of power for the facility and hot water to be used in the production of heat and domestic hot water. These systems incorporate a heat exchanger, with a glycol-based system for heat recovery. To increase the efficiency of the new system, we replaced the old, worn-out boilers with two high-efficiency Patterson Kelley Storm ST-2000, 2,000,000 BTU, gas-fired condensing boilers equipped with a BACnet interface.

These new boilers will significantly increase efficiency, while working in conjunction with the Yanmar CHPs to produce domestic hot water and heating at the most efficient rate. We also installed new circulating pumps, associated pump specialties, and the necessary gas piping to the new equipment. To control the system, we installed a new Johnson Controls BMS system to operate the heat exchanger, radiators, boilers, and the cogeneration system.

Yanmar Cogeneration Systems offer significant advantages. By simultaneously generating both electricity and heat, they achieve high energy efficiency, reducing energy costs and environmental impact. The YMCA can lower their reliance on the grid, improving energy security and reducing vulnerability to price fluctuations.

Learn more about cogeneration (CHP)

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Boiler Replacement, Southbury CT | Pomperaug High School

Controlled Air Inc. — Fri, 04 Oct 2024 16:55:13 +0000

Pomperaug High School has been a long time customer of Controlled Air Inc. We have had many projects over the years. We currently have two large projects in process. One is the pool room complete renovations and the second is updating the heating for the gym. Details will be coming soon.

The current gym heating system failed and due to the age of the equipment there was no easy way to repair the system. Controlled Air, came up with a retrofit in order to fix the heating issue before the temperatures drop as we head into winter.

Controlled Air, furnished and installed a custom, design build hot water heating system inside the existing unit. The new system will offer better temperature control and comfort and efficiency than the existing furnace type heat exchanger. Additionally, we installed (3) Lochinvar Knight XL Commercial boilers inside of the unit and custom hot water coils in the unit.

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VRF Installation, Simsbury CT | Ethel Walker School

Controlled Air Inc. — Tue, 20 Aug 2024 17:45:25 +0000

Ethel Walker School is located in Connecticut on a 175-acre campus sits amidst farms and meadows. For more than 100 years, The Ethel Walker School has been an all-girls school for grades 6-12 plus postgraduate education.

This past summer Controlled Air, Inc. Worked with A.P. Construction to provide the HVAC portion of recent new building for a campus expansion. Controlled Air installed a Variable Refrigerant Flow System (VRF) system.

The VRF system included 29 exhaust fans, 16 electric duct heaters, (4) cabinet unit heaters and six (6) electric unit heaters as well as one (1) 1.5-ton Lennox mini split heat pump system with low ambient and wall mounted indoor evaporator units with a programmable thermostat. We also installed Seven Lennox VRF outdoor heat recovery system with Six (6) 16-ton outdoor heat pumps, two (2) 10-ton outdoor heat pumps, sixty-four (64) one-way indoor cassette units, five (5) compact 2×2 indoor cassette units, five (5) 3×3 indoor cassette units, one (1) high static ducted indoor unit, two (2) vertical air handler ducted indoor unit, and eight (8) outside air ducted air handler units.

A new Johnson Controls FX-80 Supervisory front-end controller was installed with a Web-based user interface complete with enclosure and accessories. 85 touchscreen programmable controllers were also installed to allow for customized controls in each of the rooms.

This extensive VRF system allows for individualized controls for all dorms and classrooms. Lennox VRF systems allow for customized heating and cooling schedules. They can also operate in a wide range of temperatures, from -13°F (-25°C) for heating to 126°F (52°C) for cooling. Lennox VRF systems use heat recovery technology to move heat from areas that need cooling to areas that need heating, which can be an efficient way to condition spaces. The inverter-driven compressor can also reduce energy use by adjusting its speed based on demand from each indoor unit.

Additionally, we furnished and installed two (2) Mitsubishi Water Source Heat pumps and two (2) corresponding heat exchangers for the domestic Hot water system, this included circulators, buffer tanks, storage tanks and an electric swing heater.

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VRF Installation, New Haven CT | Friends Center for Children School

Controlled Air Inc. — Tue, 30 Jul 2024 13:20:53 +0000

Controlled Air, Inc. is thrilled to be part of this wonderful project alongside O, R & L Construction. Friends Center for Children provides much needed early childcare and education for kids 3 months to 5 years, year-round. They aim offer a safe affordable place for children while also paying teachers a livable wages.

The new facility located in an old cinema building plans to open Fall of 2024.

The movie theater has been closed for some time and although the building has undergone a complete renovation, one of the theater rooms have been left operational so that they can host movies.

Controlled Air installed four Daikin Comfort VRV systems which include air cooled heat recovery, 9 concealed ducted indoor units, 7 indoor ceiling cassettes, 5 suspended indoor ceiling cassettes, and BACnet Communcation panel with remote controllers.

An AAON DOAS with heat pump and 2-stage compressor, modulating gas reheat, VFD supply and EC condenser fan speed control. There will be 2 electric wall heaters, as well as circulator pumps, and hot water coils. Additionally, radiant floor heating for first floor rooms A-01 to A-04 was also installed.

A new Johnson Controls FX-80 Supervisory front-end controller with a web-based interface will be installed to provide for easy monitoring and controls.

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Closed Circuit Cooler Replacement

Controlled Air Inc. — Wed, 17 Apr 2024 13:56:00 +0000

Controlled Air, Inc. recently replaced an Evapco Cooler with an Evapco closed circuit cooler. The new Evapco cooler has low fan sound, an easy-to-maintain drive system, and a swing-out motor. We also installed a new VFD one-source power control panel with an integral variable frequency fan drive. Additionally, the steel supports were replaced so that the building was up to code and would be able to support the cooler for 20 years or more.

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VRF, Rooftop Units and Controls, Plantsville CT | LiveWell Care Facility

Controlled Air Inc. — Wed, 11 Oct 2023 15:10:02 +0000

Controlled Air is part of a 50 million expansion at Dementia-focused LiveWell in the Plantsville section of Southington. LiveWell is a not-for-profit care provider that is solely focused on providing services for people with Alzheimer’s disease and dementia. Its 8-acre campus features nursing, assisted living, and adult day facilities.

The new facility will add more assisted living beds and community services, to help support those with dementia who aim to stay at home longer. The project also will increase campus capacity from 133 to 141 residents.
Construction at the LiveWell campus started in 2022. The work is being done in phases, with three new facility buildings and modifications to the existing facility. The entire project is on track to be finished by mid-2024.

Controlled Air has installed multiple systems in three new facility buildings, including gas/electric Aaon rooftop units and make-up air units; two Lennox VRF systems with heat recovery in each of the new River Homes buildings with 15 to 16 ducted indoor units and multiple high wall units for each system; and 2 to 4 outdoor units ranging from 8 to 10 tons. Each new facility is equipped with a Johnson Controls FX building management system. The project has been work intensive with tight deadlines. Controlled Air assigned our senior project manager and foreman to make sure the deadlines are met with the quality that Controlled Air is known.

Lennox VRF® systems are a flexible solution that is ideal for a wide range of applications and commercial buildings. Lennox VRF makes customized comfort easy and efficient. Lennox VRF® Heat Recovery units offer simultaneous heating and cooling. The heat recovery process moves heat from spaces requiring cooling into spaces requiring heating, maximizing energy efficiency and occupant comfort.

Keep your eye out, more information will be coming soon.

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Gas Heat Pumps, New Haven CT | The Elm City Bioscience Center

Controlled Air Inc. — Thu, 06 Oct 2022 19:32:51 +0000

Controlled Air Inc. provided mechanical design build support to the Elm City Bioscience building infrastructure upgrades located in New Haven. The bioscience building is 113,620 sq ft which includes 8 stories plus a lower level and mechanical penthouse. The project will be on-going with multiple floors being converted from smaller office spaces to larger open lab space and smaller office areas.

The completed work includes Lab/office suites for BSL-1 and BSL-2 biotech companies. The lab spaces required a minimum of 8 Air Changes per Hour (ACH) of 100% outdoor air, no more than 60% Relative humidity and N+1 redundancy for exhaust. Additionally, two new boilers were installed with 5,000 MBH total capacity.

Controlled Air Inc. installed a Yanmar GHP Heat Recovery System for comfort cooling in the offices and supplemental cooling in labs. One 14-Ton GHP with Heat Recovery was installed for each office suite.

A new Johnson Controls building management system was installed to control and monitor the HVAC system, as well as trend energy usage by each tenant.

More information will be coming as this energy efficient project progresses.

Learn More about Gas Heat Pumps

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