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.

The post  Delivering a Turnkey Energy Efficient HVAC Solution for Yanmar Warehouses appeared first on Controlled Air.

In today’s world, sustainability is no longer just an option; it’s a necessity. Controlled Air has long been a leader in delivering full-service energy solutions to clients across the New England area, bringing expertise in designing and engineering advanced energy systems – including gas heat pumps (GHPs), co-generation combined heat and power (CHP), microgrids, and energy management systems.  

Since joining Yanmar Energy Systems in 2022, Controlled Air has been able to expand its operations and accelerate its mission, furthering its founder’s vision of creating smarter, more efficient energy solutions. Now, as an integral part of Yanmar, the company continues to push the boundaries of energy innovation, helping businesses across North America reduce emissions and optimize energy use. 

Vincent Chiocchio, President of Controlled Air and Yanmar Energy Systems North America, underscores their mission: “Building sustainability is the way of the future. We design, engineer, and install systems tailored to each building, ensuring long-term performance. And beyond installation, we continue to maintain them for the life of the building.” 

Energy Efficiency at Elm City Bioscience Center 

One of Controlled Air’s standout projects is the transformation of 55 Church Street in New Haven, Connecticut, home to the Elm City Bioscience Center. This office building has been reimagined as an energy-efficient space tailored for life science companies. 

Darlene Reilly, Director of Real Estate at The Hurley Group, explains, “Our goal was to create an asset in downtown New Haven that supports the growth of the life science community. Controlled Air has worked with us to maintain systems for our existing office tenants while also designing and building solutions to accommodate new life science tenants.” 

By integrating state-of-the-art heating, ventilation, and air conditioning (HVAC) solutions, Controlled Air improved energy efficiency and reduced the building’s operational costs and carbon footprint. “The more energy-efficient our buildings are, the lower our operating costs – and the greater the reduction in carbon emissions, helping to create a better planet for everyone,” Reilly adds. 

HVAC and Energy Management with Advanced Technologies  

One of the key innovations implemented at the facility is the use of Yanmar’s GHPs. These systems operate on natural gas, significantly reducing electrical demand while maintaining high efficiency. Todd Arnold, Senior Project Manager at Controlled Air, explains, “By using these GHPs, we’re creating a more sustainable future for both our clients and the wider New Haven community.” 

Controlled Air also introduced Yanmar Hydrobox technology to design a chiller plant, which integrates seamlessly with the GHPs. The Yanmar Hydrobox delivers chilled or hot water using its powerful VRF heat exchanger, transferring the energy created by the Yanmar GHP to any hydronic or boiler system.  

“The Yanmar Hydrobox communicates seamlessly with the GHP outside. All three Hydroboxes in the system work together, operating at peak efficiency based on demand,” Arnold explains.   

Controlled Air’s integration of Yanmar’s GHP technology at 55 Church Street serves as a model for future energy-efficient building projects. 

“In this application, instead of relying on the building’s limited electrical supply to power air handlers for lab buildouts or office spaces, we’re able to utilize Yanmar GHP technology. By using natural gas as the primary energy source instead of electricity, we can reduce strain on the building’s power infrastructure while maintaining efficient climate control,” Arnold adds.   

Furthermore, Controlled Air’s energy management solutions incorporate advanced analytics, allowing facility managers to optimize their energy use based on real-time data. This predictive approach reduces costs while enhancing system reliability.   

Smart, Efficient, and Quiet Chiller Systems 

Another major component of the renovation at this site involved upgrading the building’s aging chiller system. Controlled Air replaced outdated 1970s chillers with modern chiller packages featuring turbo-core compressors.  

Unlike traditional oil-based systems, these advanced compressors use magnetic bearings, improving efficiency, durability, and significantly reducing noise levels – an essential factor in a busy urban environment. 

Arnold explains: “What’s great about these chillers is their turbo core compressors, which use magnetic bearings. This design enhances efficiency and extends the lifespan compared to a standard scroll compressor.” 

These upgraded chillers integrate seamlessly with the building’s infrastructure, minimizing disruptions during installation. Predictive maintenance and remote monitoring ensure operational reliability, reducing the risk of unexpected downtime. 

Broadening the Reach of Energy Efficiency  

The success of the Elm City Bioscience Center project serves as a model for other commercial buildings looking to enhance energy efficiency. Controlled Air’s scalable solutions can be tailored to various industries, including healthcare, education, and manufacturing. 

Arnold states, “We’ve always looked for new technologies and solutions to tackle our clients’ everyday challenges. Innovation is part of what we do – we’re constantly exploring new approaches to help clients overcome obstacles, whether in building operations or system design.” 

As more organizations look for ways to reduce carbon emissions and lower operational costs, Controlled Air remains a trusted partner in delivering innovative energy solutions. Their work is contributing to a larger movement towards environmentally responsible commercial properties nationwide. 

Commitment to a Sustainable Future 

The collaboration between Controlled Air and Yanmar Energy Systems demonstrates the potential of innovative energy solutions to transform commercial buildings. By adopting cutting-edge technologies, Controlled Air is setting new standards in commercial building sustainability. 

Vincent Chiocchio adds, “Imagine transforming buildings into models of efficiency and sustainability. Partnering with Yanmar has given us the ability to innovate and develop new technologies that can help reduce energy use in any commercial building or facility.” 

As the industry moves toward a more sustainable future, Controlled Air continues to lead by example, proving that with the right solutions, buildings can be models of energy efficiency and environmental responsibility. 

With a commitment to next-generation energy solutions, Controlled Air and Yanmar Energy Systems are driving real change in sustainable commercial development across North America. 

About Yanmar 

With beginnings in Osaka, Japan, in 1912, Yanmar was the first ever to succeed in making a compact diesel engine of a practical size in 1933. A pioneer in diesel engine technology, Yanmar is a global innovator in a wide range of industrial equipment, from small and large engines, agricultural machinery and facilities, construction equipment, energy systems, marine, to machine tools, and components — Yanmar’s global business operations span seven domains. On land, at sea, and in the city, Yanmar provides advanced solutions to the challenges customers face, towards realizing A Sustainable Future. For more details, please visit the official website of Yanmar Holdings Co., Ltd. 

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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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Bauer Hall was a major renovation of an old house which was converted to offices for the Universities use. The home had been vacant for many years and required a complete renovation. We worked alongside RAM Building Group. Controlled Air, Inc, furnished and installed a Lennox VRF system which included 2 outdoor units, 23 indoor units with 6 bring floor standing and 17 ceiling cassettes.

A Johnson Controls building controls system was also installed with a FX80 supervisory front end controller to allow for per room temperature controls.

The post VRF Installation, Bridgeport CT | University of Bridgeport Bauer Hall appeared first on Controlled Air.

The variable refrigerant flow (VRF) heat recovery system serves the parking level, ground floor, 2nd floor and 3rd floor. The installed system includes 10 VRF Heat Recovery outdoor condenser units; 34 Med Static ducted indoor units;  and 108 indoor Cassettes varying in size between 2×2 and 3×3 with a compact 360-degree airflow design for uniform air distribution.

Additionally we installed two (2) Aaon RN 25 rooftop units with heat wheel defrost, digital compressor, high turndown natural gas heat section with stainless steel heat exchanger, variable speed condenser fans with head pressure control, modulating hot gas reheat and nonfused disconnect switch. The AAON units supply the required fresh air to the indoor VRF units and recovers the energy from the exhaust air.

Our in house controls department will install a  Johnson Controls system with a FX-80 web-based user interface supervisory front-end controller. The system will control the two AAON rooftop dedicated outdoor air units and monitor the temperature in the areas served by the four ductless splits. Additionally the BMS will monitor the VRF system, and act as a gateway for remote connection, monitoring and trouble shooting.

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Just to give you an idea of the enormity of this project, it required over 58,000 ft. of ductwork with a combination of insulted and non-insulated. A brief overview of just some of the HVAC equipment we installed includes:

• Seven AAON units with humidity control, return air bypass, energy efficient dehumidification and economizers; one AAON units with a premium efficiency motor, economizer with power exhaust and a VFD; one AAON unit with an Energy Recovery wheel, premium efficiency motor, and 2 motors on 2 VFDs; and two 25 Ton High Efficiency Lennox RTUs with variable volume air flow and economizers. All new RTU’s installed use R-410A refrigerant per the EPA requirements.
• We also installed six (6) Sterling Linear Radiant Hydronic Ceiling Panels. Radiant Panel ceiling systems are an energy and cost saving method of heating. They provide distributed heating radiantly rather than by forced air providing a “draftless” environment.
• 2 PK Gas fired condensing boilers with Axiom Condensate Neutralization Tank and Nuro touch-screen control system.
• 8 Nortec Humidifiers, The industry’s most precise humidifier. An isothermal system that produces mineral free, odorless, sterile steam from any water type.
• Ceiling Grid System by Titus which allows for the building of critical environment spaces with flexibility. Each system is custom engineered to meet the requirements of codes and guidelines, such as ASHRAE Standard 170 and the Facility Guidelines Institute (FGI) ‘Guidelines for Design and construction of Hospitals and Outpatient Facilities.’

The Expected completion date is 10/31/2018.

What is always challenging about medical facilities and pharmacies, are the extensive regulations for air changes, filtration, as well as humidity and temperature controls. Unlike office buildings where the building requires consistent settings throughout the building, medical facilities can have different requirements per area. Surgical rooms and pharmacies, have different settings from the offices and also from each other. It take extensive controls and programming to make sure each area functions as required.

The post HVAC and VRF, Rocky Hill CT | Surgery and Medical Center appeared first on Controlled Air.

The Executive Energy Summit is prepared especially to assist in the understanding of energy as it applies to their company.

Seminar Topics Include:

1. Energy Compliance Laws for Building Owners and Ratepayers
2. Best Energy Conservation, Efficiency and Generation Methods
3. The Economics of Energy and How to capture all Available Money
4. Options for Financing Energy Measures
5. Understanding the Pricing of Electricity and Natural Gas Supply
6. Understanding your Energy Bill and the impact of Stabilizing Demand
7. The Corporate Communication Process to Best Manage Energy Costs

This program will educate you and assist you in the implementation of an energy plan.

Speakers Include:

1. Vincent Chiocchio, President of Controlled Air, Inc., discussing energy efficiency and energy generation.
2. Elena Cahill, JD, CEM, BEP, globelé Energy, discusses economics of energy, financing and more.
3. Alex Discepolo, CPA, covering the new tax changes as they relate to both energy conservation and generation.
4. Kristilee Lahaye, CEP (certified energy procurement specialist), covering electricity and natural gas markets.

Details:

September 20, 2018
Check-in begins at 8:30am
Program: 9:00-11:30am
Lunch & Networking: 11:30am-12:30pm

Located at the: Fairfield Museum & History Center, 370 Beach Rd, Fairfield, CT 06824 (map)

Register Today It’s FREE

Or contact Kendra Arnold with questions.

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Bates Hall is the largest Lennox VRF System in New England. The VRF system includes 2 outdoor units and 18 indoor units. VRF Systems provide simultaneous heating and cooling throughout the building, as well as auxiliary heaters for negative temperatures. The VRF system further includes variable speed drives with stage up/stage down capabilities. 

What is VRF? 

Variable Refrigerant Flow, VRF, is a system that provides simultaneous heating and cooling by absorbing excess heat energy in one zone and transferring it to heat another. This helps you maintain the ultimate level of comfort while operating at maximum efficiency. By offering a building the ability to create localized comfort with independent temperature control, VRF can help every occupant enjoy a perfectly heated, cooled, and humidified area.  This makes customization easy and efficient. VRF is a flexible system in operation and installation. Multiple configurations of indoor units are available, including wall and floor mounts. Lennox VRF is ideal for a wide range of buildings and workplaces. Perfect applications for VRF include: Lodging, Healthcare, Multi-family structure, Hospitals, Education, Retail and Dining. It is equally suited for new building or upgrades in an existing building.

What are the Benefits?

• 20%-25% more efficient then conventional systems: VRF systems may cost more than traditional central air systems up front, but this cost can be offset by lower energy bills and repair expenses over time.
• Higher comfort with individual zone control: No matter how your building is used, this customizable solution allows you to control different comfort needs independently. Unused rooms’ climate controls can be switched off entirely.
• Smaller Footprint Quiet: In a VRF system, the noisier condensing unit is typically outside, and the indoor air handlers are smaller and quieter than a traditional systems.
• Consistent comfort: The VRF HVAC system can detect the precise requirements of each zone, and send the precise amount of refrigerant needed to do the job. As a result, each area of your space is consistently comfortable with well-controlled humidity and no hot or cold spots.
• VRF systems take up much less space than forced-air systems—a benefit that’s especially important in existing structures.

Multiple Control Options

• Up to 16 Zone Levels
• Centralized level (up to 128 indoor units)
• Integrated building level (multiple VRF systems)
• Integrated connectivity (for control using any web-connected device)

Financing/Rebates can work with CPACE financing. VRF is so new that it doesn’t have specific tax credits and rebates but it does/can qualify for rebates and incentives with proper energy modeling.

Contact us for more information 203-481-3531

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