Ignoring fall maintenance doesn’t just put your equipment at risk; it puts your entire operation—from tenant comfort to energy budgets—in jeopardy. Think of fall maintenance as your building’s seasonal insurance policy: it ensures safety, maximizes efficiency, and prevents costly, inconvenient failures when the weather turns truly cold.

The Critical Benefits of Fall Maintenance

The return on investment (ROI) for preventative fall maintenance far outweighs the cost of a service visit. Here’s why proactive service is non-negotiable for commercial properties:

• Maximize Heating Efficiency (and Savings): When components are dirty, worn, or misaligned, your furnace or boiler has to work harder to produce the same heat. A tune-up ensures the system operates at its peak Annual Fuel Utilization Efficiency (AFUE), directly translating into lower energy bills throughout the winter.
• Prevent Dangerous Failures: For gas-fired heating systems, safety is paramount. Technicians check for cracks in the heat exchanger (which can lead to carbon monoxide leaks) and ensure all gas lines and ignition systems are functioning correctly, protecting occupants and property.
• Extend Equipment Lifespan: Like any complex machinery, proper cleaning and calibration reduce stress on critical moving parts. This preventative care delays the need for expensive unit replacement, maximizing the useful life of your major capital equipment.
• Protect Against Winter Breakdowns: The worst time for your boiler or furnace to fail is during a winter freeze. Fall maintenance identifies worn parts (like contactors or blower motor bearings) that are likely to fail under continuous winter load, allowing you to replace them on your schedule, not in an emergency.

Equipment Serviced During a Fall HVAC Tune-Up

A comprehensive fall maintenance program covers all heating elements and prepares the ventilation system for seasonal changes. The equipment typically serviced includes:

1. Heating Equipment (Furnaces, Boilers, Unit Heaters)

This is the central focus of a fall check-up, ensuring the system can safely and efficiently generate heat.

2. Air Handling & Distribution

The system that moves the heat must also be optimized for winter operation.

3. Controls and Sensors

The “brains” of the system must be calibrated for seamless, efficient operation.

Proactive fall maintenance is a fundamental pillar of effective facility management, guaranteeing that your building stays safe, comfortable, and efficient all winter long.

If you have a contract we automatically scheduled your preventative maintenance. If you don’t have a contract, reach out and get a no obligation service contract proposal. Would you like to schedule a fall maintenance check for your commercial building’s HVAC system?

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What is Legionnaires’ Disease?

Legionnaires’ disease is not spread from person to person. You get it by inhaling tiny water droplets containing the Legionella bacteria. Symptoms, which typically appear 2 to 14 days after exposure, are similar to other types of pneumonia and can include:

• High fever
• Chills and muscle aches
• Cough and shortness of breath
• Headache

People over 50, current or former smokers, and those with weakened immune systems or chronic lung disease are at a higher risk of developing the illness. A milder, non-pneumonic form of the disease, called Pontiac fever, also exists, causing flu-like symptoms that usually clear up on their own without treatment.

The HVAC Connection

Large, complex HVAC systems, particularly those with cooling towers, are a significant source of Legionnaires’ disease outbreaks. Cooling towers use water to remove heat from a building, and if not properly maintained, the warm, stagnant water can create an ideal breeding ground for Legionella bacteria. The bacteria can then become aerosolized and spread throughout the building or even to nearby areas, infecting anyone who breathes in the contaminated mist.

This isn’t a concern for small, residential window units or central air conditioners that don’t use water to cool the air. The risk is primarily associated with large-scale systems found in places like:

• Hospitals and nursing homes
• Hotels
• Large office buildings
• Industrial facilities

A Recurring Concern: Recent Outbreaks in NYC

The threat of Legionnaires’ disease is not a historical footnote; it remains a current and serious public health issue. New York City, in particular, has seen a recent cluster of cases, highlighting the ongoing risk. In late July 2025, a sudden outbreak in Central Harlem sickened dozens and, tragically, led to several deaths. Health officials in the city quickly investigated and identified 11 cooling towers in the area that tested positive for Legionella bacteria. All of the contaminated towers were promptly cleaned and disinfected according to city regulations.

This isn’t an isolated incident. The New York City Department of Health and Mental Hygiene has a robust system for surveillance and has previously addressed other outbreaks. The city’s regulations, which mandate the registration and regular maintenance of all cooling towers, are a direct response to the recurring public health threat posed by improperly managed water systems. These incidents serve as a stark reminder of why proactive maintenance is not just a best practice, but a critical legal and ethical responsibility for building owners.

The Importance of HVAC Maintenance

Regular, proactive HVAC maintenance is the single most effective way to prevent the growth and spread of Legionella bacteria. By implementing a comprehensive water management plan, building managers can significantly reduce the risk of an outbreak. Key maintenance practices include:

• Routine cleaning and disinfection: Cooling towers should be cleaned and disinfected at least twice a year, and more often if heavy biofouling or high bacteria levels are detected.
• Temperature control: Legionella thrives in warm water. Maintaining cold water systems at temperatures below 68°F (20°C) and hot water systems above 140°F (60°C) can inhibit bacterial growth.
• Avoiding water stagnation: Stagnant water in unused pipes, tanks, or drain pans provides a perfect environment for Legionella to multiply. Regularly flushing unused outlets and ensuring proper drainage is essential.
• Biocide treatments: Using chemical biocides, such as chlorine, helps control microbial growth in the water systems.

Proper HVAC maintenance isn’t just about efficiency and comfort—it’s a critical for health. By following a regular maintenance schedule, building owners and managers can protect occupants from a serious and preventable disease.

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HEAVY DUTY INDUSTRIAL POWER GENERATORS

For industrial use, their HEAVY DUTY INDUSTRIAL power generators are designed to supply power for multiple heavy-duty equipment types at the same time. This means production and operations won’t be interrupted when the power suddenly goes out.

With an increasing number of extreme weather events, combined with the outdated, problematic power grid in the U.S., UL2200 certified HIPOWER SYSTEMS’ backup generators are the perfect choice.

If your business relies heavily on electricity, whether you have equipment running round-the-clock or you have daily production processes that require heavy use of electrical power, it’s important to have a backup power supply. For these purposes, we recommend our UL 2200 certified Heavy-Duty Industrial Diesel Standby generator series.

HIPOWER backup power generators are built to suit each client’s specific power generation needs.

HS STATIONARY product line is versatile, adaptable and, an affordable optional standby diesel generator, which was designed for light commercial power needs in mind.

As regulations tighten, gas generators are becoming an environmental and economic requisite for many companies. Our HNI product line leads the field in reliability, performance and durability. Our wide assortment of generator and enclosure features and options enables these models to meet every possible application and need..

Key Features of our Backup Generators

HIPOWER IS NOW CERTIFIED WITH THE 2021 INTERNATIONAL BUILDING CODE (IBC) – SEISMIC CERTIFICATION

The International Building Code (IBC) requires that critical systems and components must not only maintain structural integrity during an earthquake, but also remain operational and continue to carry out their primary functions (per 2015 IBC Chapter 17). To ensure the highest quality in the HEAVY DUTY INDUSTRIAL (HDI) product line up to HDI-600, HIPOWER SYSTEMS used for its seismic certification, an independent Earthquake Simulator Laboratory – The Pacific Earthquake Engineering Research Center (PEER) Lab at the University of California in the city of Berkeley, CA.

FLYER/SPEC DOWNLOADS

HDI 60-2000 BROCHURE

EHR BROCHURE

HNI 80-150 SPARK IGNITED

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Even new high efficiency boilers need maintenance. Many would think that if you have brand new equipment that you have a few years to wait until maintenance is required. Unfortunately, that is not the case, especially with high efficiency boilers.

Here is an example:

Last winter we received a call for service due to no heat. The customer had a high efficiency boiler which was just over a year old. They had not had any preventative maintenance performed, since its installation earlier in the year. Upon arrival our service tech discovered that components of the boiler had literally melted (see photo above). Upon further inspection it was discovered that the ignitor had failed and someone in the customer’s organization was repeatedly resetting the boiler to try and keep it lit. The repeated process caused over-heating and melting of some of the components.

With a preventative maintenance contract this issue could have been avoided, saving money for the organization in the long run. Ignitors and flame rods are replaced yearly during maintenance which would have prevented the occurrence.

During a typical service, we flush the system using a cleaner that removes any build up in the system such as calcification from the condensation.  We also brush the system to further remove any build up that will lead to poor heat exchange or blockages of the fins. The fins in the boiler are checked to make sure they are clean and a tool is run between each fin to remove any build up. Plugged fins can lead to poor heat transfer and hot spots in the boiler heat exchanger.

Even if you have a brand new high efficiency boiler it is important to schedule preventative maintenance. Not only can things breakdown or melt, but a high efficiency boiler that is not properly maintained can be running far lower than the 95% efficiency you expected. The heating season is fast approaching. Having preventative maintenance performed in advance will help to ensure that your equipment is running safely and efficiently.

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RTU’s need regular system maintenance to function at peak efficiency. The roof exposes your unit to extreme weather. It is colder and/or hotter up there depending on the weather. Unlike other types of heating and air conditioning systems that are either inside the building or outside on the ground, the RTU is exposed to much more extreme temperatures and more pollutants. Ambient temperatures on the roof of a building can reach 120 degrees on hot summer days. Pollutants collect on the components of the unit causing it to lose efficiency and even degrade. Excessive heat causes the unit to work harder to produce comfortable conditions in your building.

Regular system inspections prevent inconvenient system breakdowns, increase the life of your system and will reduce utility bills. HVAC systems have over 100 components and many common component issues increase energy usage. You can see more on this chart of the Building efficiency initiative that describes in detail the greatest energy impacts with the various components.

“Portland Energy Conservation Inc. found that building operation and maintenance programs specifically designed to enhance the operating efficiency of HVAC and lighting systems decreased energy bills 5 to 20 percent in commercial buildings, without significant capital investment.^“

Controlled Air, Inc. offers custom service and maintenance packages. Below is a list of items typically done during a maintenance appointment.

• Changing filters to keep dirt and debris out of the ductwork and the system components
• Checking blowers for proper airflow
• Checking the electrical system, fuses, thermostats, and contactors
• Checking belts and replacing if necessary
• Cleaning dirt, soot and mold from the condenser coil, including measuring before and after temperatures to verify effectiveness
• Inspecting evaporator coils and clean as needed
• Checking refrigerant charge and fix any leaks
• Checking cabinet integrity for air leaks caused by cracks, missing screws, loose latches and faulty gaskets

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1. Short-Cycling: Air conditioners cycle on and off occasionally throughout the day, but a dirty air filter can cause those cycles to become more frequent. The constant cycling creates noise pollution, wasted energy,  uncomfortable temperature changes, and damage to the unit.
2. Freezing Up: A dirty air filter restricts the flow of cold air. The cold air then builds up inside the air conditioner and lowers the internal temperature. The buildup of cold air can eventually cause ice to form on the coils.
3. Uneven Cooling: Even if coil freezing does not occur, restricted airflow is not good for the air conditioner’s cooling power. Lower cooling power will lead to hot and cold spots, which means lower comfort levels at a higher cost.
4. Allergen Buildup: Dirty air filters can cause allergens to build up in your duct system. Whenever you have a forced-air system running, those allergens will be released into the air. There have been numerous studies conducted comparing indoor air quality to worker productivity. Poor indoor air quality has been found to lower attention span and productivity, and OSHA estimates that poor indoor air costs employers $15 billion annually due to worker inefficiency and sick-leave.
5. General Wear and Tear: Air conditioners last longer when maintained properly. A good air filter prevents dust and dirt from building up on internal components. When dust and dirt are allowed to buildup, the air conditioner’s performance becomes stressed thereby decreasing the life span of the unit. This results in having to replace units much sooner than expected.
6. Reduced System Efficiency: An air conditioning unit with a dirty filter will use much more power to cool, and will increase your payments to the utilities.

Thermostat Settings – Facts

1. Raising and lowering the thermostat significantly does not heat or cool the air faster
   • Unless you have Variable Air Volume (VAV), which would vary air flow to your system they only work at one speed. Lowering temperature below what you need or raising the temperature above what you need will only increase energy costs and not reduce the time to get to optimum temperature.
2. Leaving your thermostat at the same setting can save money
   • Using programmable thermostats can save your business money. According to the U.S. Department of Energy, simply turning down your thermostat by 7º -10º for an 8-hour period can save your business as much as 10% a year in energy costs. Schedule the temperature to be lower in the winter and higher in the summer when the building is unoccupied and higher in the winter and lower in the summer when occupied. If you have older pneumatic thermostats it might be time to upgrade these to programmable ones so that the temperature can be controlled automatically throughout the day.
3. Messing with your thermostat too much can cause problems
   • Constantly changing the set temperature on your thermostat causes your air conditioner and furnace and/or boiler to stop and start, which causes them to run inefficiently.

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• Replace filters
• Clean and adjust dampers
• Check Condensate traps for water
• Check fans and belts
• Dampers to make sure bolts are secure, parts are lubricated, blades open and close securely
• Inspect evaporators and condenser coils; check refrigerant – These should be all set from the Spring Maintenance
• Basic Operational Check

If any issues are noticed we will notify our customers of the issue and prove a quote on repair costs.

Call Our Service Department

Questions about your equipment or service? Give us a call.

203-483-5000

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In a rooftop unit, the heat exchanger has been exposed to condensation all summer because it is positioned after the cooling coil and the interior of it is exposed to the outdoor humidity. The humidity will condense on the inside and will over time cause rust to form. This rust will cause the heat exchanger to crack and allow an opening between the fire and air side of the exchanger. Under the right conditions carbon monoxide may enter the airstream into the building.

In most cases, we find the crack in the exchanger allows system air to flow into the fire chamber due to the positive pressure from the system fan. This air flow tends to impinge or distort the flame on the burner and blow the fumes into the unit cabinet. In a worse case scenario, the system air will cause the flame on the burner to roll out of the exchanger into the compartment of the unit.

It is important to be aware that when a contractor finds a bad heat exchanger that could cause harm, injury, fire, or damage to property, technicians are instructed to shut off the equipment. If inspected by a utility company, they will red-tag the equipment and lock off the gas supply.

Maintenance for a heat exchanger is an inspection only as there is little that can be done to stop the condensation and decaying process. Proper heat exchanger performance also ensures that the unit operates at its peak efficiency. A yearly inspection service will look for cracks, plugged or blocked passages, and proper flame color, size or appearance across or out of the burner.

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Cooling towers, evaporative condensers and fluid coolers use a fan to move air through a recirculated water system. This allows a considerable amount of water vapor to be introduced into the surrounding area. This water may be in the ideal temperature range for Legionnaires’ disease bacteria growth, 68°-122°F. Legionella grows easily in the water, especially if algae and scale are present. Legionella can be dispersed with aerosolized drift or with the evaporate, but it may enter the air-conditioning system if there is a break between its ducts and those of the cooling tower or evaporative condenser.

Proper maintenance can prevent the spread of this bacteria.The cleaning of cooling towers should occur quarterly. Corroded parts, such as drift eliminators, should be replaced. Algae and accumulated scale should be removed. These measures will not only control the growth of bacteria, but will also maintain operating efficiency. During cleaning operations in confined spaces, safety procedures for entry into confined spaces should be applied.

Cooling water should be treated constantly. Ideally, an automatic water treatment system that continuously controls the quality of the circulating water should be used.

Fresh air intakes should not be built close to cooling towers since contaminated aerosols may enter the ventilation system. Air filters should be examined, cleaned and/or replaced periodically and tested for leaks. Cooling towers should be positioned so the drift or evaporate does not enter the fresh air intake.  The water system should be flushed out on a regular basis to prevent the water from stagnating.

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