$50,000 HVAC Install Mistake Required Two Minute Fix

Product/Equipment Reviewed

• HVAC system at a commercial building

  • Multiple York 5-ton package units installed around 2019 (total cooling capacity mentioned: 13 tons).
  • Later additions of mini-split systems by Comfort Bros, including a 1.5-ton mini split.
  • The claimed outcome of the mini-splits was an increase of cooling by about 4.5 additional tons.

• Core problem (system-level failure)

  • The “product” issue was not a single piece of equipment, but an HVAC setup failure, specifically:
    • Wrong thermostat programming (the unit ran in heat mode when cooling was requested).
    • The resulting costly corrective actions that followed.

What Went Wrong (Key Findings)

• A specific package unit (in an office/ducted-to-rafters area) was blowing hot air even though the building was supposed to be cooling for ~6 years.
• The building reportedly was “always hot” and never reached proper cooling, despite regular maintenance visits.
• The eventual diagnosis found:
  • The thermostat was not programmed correctly, causing the unit to operate in heat mode when cooling was called for.
  • After reprogramming, the building cooled.

Attempts to Fix the Problem (and Comparisons Made)

• Earlier service companies concluded the system was “working fine”, without identifying the root cause.
• After another maintenance company began recommending filter/maintenance, the issue persisted.
• A contractor proposed adding mini splits:
  • They claimed the system didn’t have enough BTUs.
  • The installation reportedly cost $30k+, including new refrigerant lines, roof penetrations, and electrical circuits.
  • The added cooling (+ ~4.5 tons) still did not resolve overheating, because the original control problem remained (the system was effectively still working against cooling).

Main Features / System Behavior Described

• Communicating blowers/motors
  • The blower motor was described as bad.
  • The blower wheel was seized, and replacement was delayed due to parts availability.
• Economizers
  • Economizers are mentioned on the units.
  • The reviewer questions whether they were set up correctly.
  • Even when it was cooler outside, the compressor was still running.
• Nonstop operation
  • Due to the misbehaving unit and ongoing heat loads, the units ended up running continuously.

Pros

• Emergency response and successful repair
  • Once the right cause was found and the thermostat was reprogrammed, the space cooled.
• Restoration via parts/replacement
  • After blower/motor and related components were replaced, the system was described as working today.

Cons (Major Issues)

• Long-term misdiagnosis / failure to detect
  • The system was effectively in a “heating while cooling” condition for 6 years despite multiple maintenance companies.
• Expensive but ineffective “capacity increase”
  • Mini-split additions ($30k+) reportedly failed to fix the root cause.
• Potential code/installation quality concerns
  • The reviewer states the installation is “not even up to code” (specific code details not provided).
• Higher operating costs and accelerated wear
  • With San Diego’s high electric rates, the reviewer estimates electric bills exceeded $10,000, on top of the mini-split cost.
  • Continuous operation likely shortened equipment lifespan.
  • The reviewer notes communicating motors often fail later than the timeline shown, suggesting unusual stress from sustained runtime.
• Economizer setup questionable
  • Possible improper fresh air/economizer configuration may have contributed to unnecessary compressor operation.

User Experience (How It Felt to the Client)

• For years, tenants/owners reported: “It’s always hot.”
• After the correct fix: they were “stoked” the system finally worked—but were unhappy with the amount of money spent to get there.

Overall Cost Impact / Verdict

• Total spend referenced: “$50,000 later” (implied costs include mini splits, energy bills, and service/activity).
• Recommendation (implied by the reviewer):
  • Don’t treat the issue as just insufficient BTUs.
  • If the system may be misconfigured, verify thermostat controls and operating mode first.
• Verdict:
  • The equipment can work correctly once configured, but the diagnosis and service/installation process here was poor and led to unnecessary expense.
  • Do not rely on adding capacity as the first solution.

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Unique Points Mentioned (Consolidated)

1. York package units installed in 2019; building was hot from early on.
2. One unit (high duct/rafters) was blowing hot air for ~6 years.
3. Multiple companies misdiagnosed the issue; one claimed units were “working fine.”
4. Maintenance/filter plan was attempted, but the problem persisted.
5. Mini-split addition (~$30k+) included new refrigerant/electrical/roof penetrations.
6. Capacity claim: building allegedly needed more BTUs; added ~4.5 tons (and referenced a 1.5-ton mini split).
7. Mini splits did not solve the overheating because the root control issue remained.
8. Emergency service involved a blower motor failure (bad motor; seized blower wheel; delayed parts).
9. Final resolution: thermostat reprogramming, after which the building cooled immediately.
10. Units ran nonstop, increasing wear and contributing to motor issues.
11. Electric bills estimated > $10,000, plus mini-split costs.
12. Reviewer doubts code compliance and questions economizer setup.
13. Potentially shortened lifespan due to continuous operation.
14. Reviewer observed 20–30 HVAC techs over the years without anyone noticing the real cause until he did.

Different Speaker Contributions

• Main reviewer/speaker (HVAC tech)

  • Provides diagnosis, cost estimates, operational analysis (unit running heat), and critiques of code/installation/economizers and continuous runtime.

• Building/clients mentioned (owner/staff)

  • Report persistent symptoms (“always hot”), mention maintenance plans, and confirm that cooling never happened for 6 years.

• Other companies/vendors referenced (no separate speaker identified)

  • Suggested units were “working fine,” recommended maintenance, and later recommended adding mini splits due to alleged insufficient BTUs.