29/02/2016 Howtoselectanairhandlingunit|ConsultingSpecifyingEngineer

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Howtoselectanairhandlingunit
Airhandlingunitscomeinallshapesandsizes.Learntobalanceandprioritizeallofthechoicesrelatedtoperformance,
efficiency,maintainability,andspaceconstraints.
RobMcAtee,PE,andEvanRiley,PE,CEM,LEEDBD+C,H&AArchitectsandEngineers
12/27/2012

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LearningObjectives

1.KnowthedifferenttypesofAHUs,andtheirbasicanatomy

2.UnderstandthecodesandstandardsthatgovernAHUspecification

3.LearnabouthowenergycanbesavedinHVACsystemsthatuseAHUs.

Abasicdefinitionofanairhandlingunit(AHU)mightbeaboxwithafan,coils,
andfilters.Fromthereitgetsconsiderablymorecomplicated.Properselection
ofanairhandlerrequiresansweringmyriadquestionsrangingfromwhat
capabilitiesarerequired?towillitfit?Onlyafterestablishingthesebasic
projectconstraintscantheartofevaluatingandselectinganAHUbegin.

Beforestartingthisprocess,itsimportanttorealizethattherewillnotbea
perfectselectionforanyAHUasmanycompetingcriteria,nottheleastbeing
cost,willforcecompromises.Itistheengineersjobtobalanceandprioritizeall
ofthedecisionsrelatedtoperformance,efficiency,maintainability,andspace
constraintstoselectaunitthathasthelowestlifecyclecostforagiven
application.

Thisarticleprovidesgeneralinformationandguidanceontheselectionof
variousAHUcomponents,startingwithabriefdescriptionofthemajorcategoriesofAHUs.Whilemuchofthediscussioninthe
remainderofthearticlerelatesprimarilytolargeAHUs,thegeneralconsiderationscanbeappliedtoanysize.

TypesofAHUs

Fancoils/blowercoilsarethesmallestandsimplestcategoryofAHUand,asthenamesimply,theytypicallyconsistoflittle
morethanafanandaheattransfercoil(s).Tokeepthecoilsfromgettingdirtytooquickly,asimplefilterisalsoincluded.They
generallyhavesimplecontrolsandserveasingletemperaturezone.Whiletheyhavetheirapplications,theyaretypicallyless
efficientthanlargerAHUsandhavedifficultyprovidingtighttemperatureandhumiditycontrol.

PackagedAHUsareverycommoninsmallerbuildingsandcommercialapplications,particularlyasrooftopunits.Packaged
unitsgenerallycontainfans,coils,filters,anddampersinasinglecasing.Oftenthecasingincludesitsownairconditioning
compressorsandmeansforheatingsuchasgasburners,electricheatingcoils,orheatpumpcoils.Theyoftenservesingle
temperaturezones,butlargevariableairvolume(VAV)AHUsservingmultipleterminalboxes(zones)areavailable.Because
oftheircompactnessandlowerinitialcosts,packagedunitshaveareputationforbeinginefficientandmaintenanceintensive,
butperformanceandreliabilityareimproving.Theyareavailableinsizesfromafewthousandcfmtomorethan30,000cfm,
buttheirstandardizationcanbelimitinginsomeapplications.

ModularAHUsallowuserstoselectindividualcomponentshousedinmoduleshavingconsistentconstructionandcross
sections.Theusercanselectthetypeofcasings,fans,filters,coils,andaccessoriesfromavarietyofdifferentoptions.
Modulesareassembledatthefactoryorcanbeshippedindividuallyandassembledonsite.Modularunitsgenerallyallow
greatflexibilityandcanmeetmostairprocessingrequirements.

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CustomAHUsareavailableinnearlyanyconfigurationthatausermightrequire.Theygenerallyhavethehighestquality
constructionandaremostcommonlyusedininstitutionalorindustrialapplicationswherehighflowrates,veryclosecontrol,
andharshconditionsexist.Theymayalsobeappliedinirregularspacesthatwouldnotconformtoamodularline.Custom
unitscanbeconfiguredtoincludevirtuallyanycombinationofairprocessingcomponents.Theyalsocanincludewalkwaysand
serviceareaswithinthemandcanevenaccommodatespaceforskidmountedequipmentlikepumpsorheatexchangers.
Theyarethemostcostlyofallofthetypesofunitsdiscussed,butcanbeexpectedtohavethelongestlifespan.

AnatomyofanAHU

Casingandconstruction:AqualityAHUcanlastmorethan30yearswithproper
maintenance.Doublewalledconstructionisnowstandardforallbutthesmallestunits,
buttheapplicationoftheinsulationbetweenthewallsalsoisimportant.Injectedfoam
insulationwithnothroughmetalconnections(nothermalbridging)isavailablefroma
varietyofmanufacturersandgenerallyhasbetterthermalandacousticalperformance
thanfiberglassinsulation.Iftheunitistobeinstalledoutdoors,extrainsulationis
recommendedandcorrosionresistanceshouldbeatoppriority.

Mixingbox:MostAHUssupplysomepercentageofoutsideairforventilation.Themixing
boxistheplacewhereoutsideairiscombinedwithreturnairfromthebuilding.Controldampersareusedtoproportionthe
incomingairstreamsandreliefair.

Filters:Airfiltersremovecontaminantsfromtheairstreamandsignificantlyimproveairquality(IAQ).Ratingsystemsforair
filters,suchasASHRAEStandard52.22007MethodofTestingGeneralVentilationAirCleaningDevicesforRemoval
EfficiencybyParticleSize,definethemeanefficiencyreportingvalue(MERV)providingacomprehensiveandconsistent
indicationofafilter'scaptureperformancewitharangeofparticlesizes.

Newerratingsystems,suchastheEuropeanCommitteeforStandardizationEN779:2012,rateairfiltersbasednotonlytheir
abilitytocaptureparticles,butalsoontheirpredictedannualenergyuse.Itisexpectedthatasimilarapproachwilladoptedin
theUnitedStatesinthecomingyears.

Thelifecyclecostoffiltersshouldbecarefullyconsideredduringthedesignandsubsequentpurchasingofthefilters.Overall,
thefirstcostoffilterscanbeaslittleas4%ofthelifecyclecostofthefilterswhenconsideringenergyuse,changeout,and
disposalcosts.Itsalsoextremelyimportantnottoskimponaccessspace.IfanAHUisdifficulttoaccessandfiltersaredifficult
toreach,theywontgetchanged,andtheunitwilluseexcessiveenergyandunderperform.

Supplyandreturnfans:FansaretheheartofanyAHUandcan
representasignificantportionofthebuildingstotalannualenergy
usage.Thesupplyfanpushesorpullstheairthroughfiltersand
coilsandthendistributesitthroughductworkdirectlytospacesor
toterminalboxes.NotallAHUsrequireareturnfan,butunits
servingmultiplespacesorusingairsideeconomizerstypically
requireafantoreturnairtotheAHUandtorelieveairfromthe
building.

AHUsinwhichthesupplyfanisinstalledaftertheheatingand
coolingcoilsarereferredtoasdrawthroughunitssincethesupply
fandrawstheairthroughtheunit.

InblowthroughAHUs,thesupplyfanislocatedpriortothecoils.
Thisarrangementallowsfanheat:whichcanbesignificanttobe
removedfromtheairstreamwithouthavingtosubcoolthesupply
airasisnecessaryfordrawthroughunits.Althoughmuchlesscommonthandrawthrough,blowthroughunitsdohave
applications,particularlyinhealthcare.Theyalsoareseeingincreasedapplicationinlowtemperatureairsystems.

Fanselection

Therearemanytypesoffansappliedtoairhandlerstheprimarydifferencesamongthemrelatetobladeconfigurationand
whetherthefanwheelisfullyhousedoropen.(Anopenwheelarrangementisreferredtoasaplenumfan.)

Theenergyrequiredforanyfanisafunctionoftheamountofairtobemovedtogetherwiththeairpressurethefanmust
generate.ASHRAEStandard90.12010,EnergyStandardforBuildingsExceptLowRiseResidentialBuildings,provides
maximumfanpowerrestrictionsonHVACsystemsbasedontheflowrateandavarietyoffactorsrelatedtoapplicationand
filtrationlevel.FutureversionsofStandard90.1willbeincorporatingaminimumfanefficiencygrade(FEG)asdescribedin
AMCA2052010.Fansmorethan5hpwillberequiredtohaveaminimumFEGof67andwillneedtooperatewithin10%of
theirpeakefficiency.(Thismaynotapplytopackagedunits,whicharecertifiedintheirentirety.

Acriticalpartofanyfanselectionisacousticperformance.Itsalwaysimportanttoknow
themaximumacceptablenoiselevelonaproject.Properselectionandspecifyingof
fansandAHUcasingcanreducetheneedforsilencersandothercostlynoisemitigation
techniques.Becausethebestwaytoreducefansoundistoreducethefanpower,
efficientfansfrequentlyhavethebestacousticperformance.

Coils:Coilsareusedtoheat,cool,anddehumidifyair.Theheatsourcecanbefromhot
water,steam,electricresistance,orhotrefrigerantvapor(aswithaheatpump).Cooling
anddehumidificationcanbeprovidedviaexpansionofrefrigerant(referredtoasDirect
eXpansion,orDX),orindirectlythroughthecirculationofchilledwaterorglycol.Indry
climates,coolingalsocanbeeffectedbyspraycoilsthatreducethedrybulbtemperatureoftheair,butincreasetheairs
humidity.

Access:AccesssectionsarefrequentlyomittedfromAHUseitherthroughdesigneroversightorintentionallyduetospaceor
budgetrestrictions.Butskimpingonaccesscanproveshortsightedaseachcomponentwithinanairhanderwillrequireroutine
service,repair,orreplacementmanytimesoverthelifeoftheunit.Coilsmustbecleanedfrequentlytomaintainproperheat
transfer,andtheymustbeaccessiblefromfrontandbacktodoso.Themoredifficultitistoreachacomponent,thelesslikely
maintenancewillbeperformed,whichwillresultinloweroverallefficiencyandreducedlongevity.

Humidifiers:Therearenumerousmethodsfordeliveringhumidification,includingsteam,ultrasonicdispersion,infraredheating,
andatomizationofwater.Carefulconsiderationisnecessarytodeterminewhichmethodisbestsuitedforagivenproject,but
humidifiersingeneralaremaintenanceintensive.Theymustthereforebeinstalledineasilyaccessiblelocationssinceserious
damageandIAQissuescanariseifhumidifiersarenotoperatingproperlyforextendedperiods.

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Codesandstandards

TheInternationalBuildingCode(IBC)andInternationalMechanicalCode
(IMC)providerequirementsfor,amongotherthings,equipmentlocation,
disposalofcondensate,andminimumoutsideairquantity.Energy
efficiencyrequirementsforindividualcomponentsandpackagedunitsare
providedwithintheInternationalEnergyConservationCode(IECC),
ASHRAE90.1,andCaliforniaEnergyCommissionsTitle24.Eachstate
andlocalitydeterminestheapplicabilityofthesecodesandstandards.

Thereissignificantpressuretogobeyondcodeminimumperformance,
andmanymandatesareinplaceforfederalprojectsrequiringnew
buildingstooperatewithmuchlessenergythanminimallycodecompliant
ones.TheU.S.GreenBuildingCouncilsLEEDratingsystemrequiresnew
buildingstohaveatleast10%lessannualenergycoststhanacode
compliantbuildingandawardspointsbasedonincrementalsavingsabove10%.TheInternationalGreenConstructionCode
(IgCC)andASHRAEStandard189.1alsotightenenergyperformanceandarebeingincreasinglyadoptedbystatesand
localities.

Multipleorganizationsprovidestandardsforthetesting,rating,andinstallationofAHUsandassociatedcomponents.Some
examplesoftheseincludeAirMovementandControlAssn.(AMCA),International,AirConditioning,Heating,andRefrigeration
Institute(AHRI),ASHRAE,andSheetMetalandAirConditioningContractorsNationalAssn.(SMACNA).Theseorganizations
producetestingandratingstandardsthatcanbeusedbymanufacturersandspecifierstogaugeperformance.

Largeinstitutionaluserstypicallyhavetheirownstandardsinadditiontocodestoensureconsistencyandeaseofmaintenance
forairhandlingequipment.

EmergingtrendsinAHUs

AlthoughmuchofthetechnologyinAHUshasremainedrelativelyunchangedfordecades,somerelativelynewcomponents
andpracticesarebeingincorporatedthatcanbeusefulintherightapplication.

Directdrivefanscouplethefanwheeldirectlytothemotorshaftandaretypicallyappliedwithvariablefrequencydrives
(VFD).Thiseliminatesthedrivelossesassociatedwithbeltsandcanresultinhigherefficiencyandloweroverallnoise.

Fanarraysusemultiplesmall,directdrivefansinlieuofasinglelargefan.Appliedproperly,thefanarraycanreducethe
overallspacerequiredfortheAHUwhileprovidingredundancyandenergyefficientoperation.Dependingonthenumberof
fans,theycanbecontrolledinunisonbyoneormoreVFDs.LikesomanyotherthingsrelatedtoAHUs,caremustbetaken
whenapplyingafanarraytoensurethegoalsoftheprojectaremetasefficientlyaspossible.

EnergyrecoveryisincreasinglyappliedinAHUsandmayberequiredbyenergycodesincertainapplicationshavinghigh
percentagesofoutdoorair.

Energyrecoveryenablesincomingairtoexchangeheatandmoisturewithbuildingexhaustairviadesiccantcoatedwheelsor
specialmaterialsinaflatplate,counterflowarrangement.Successfulapplicationisdependentonmanyfactors,most
importantlyclimate.Itisgenerallyeasiestandmostcosteffectivetoapplywhendedicatedoutsideairunitsareused.

Dedicatedoutsideairunitsareincreasinglybeingappliedinlieuoftraditionalairunitsthatmixoutdoorairandreturnair.For
manyclimates,thetoughestpartofanAHUsjobistreatingoutdoorair.Coilsmustbesizedtohandletomostextremeambient
temperatures.Inhumidclimates,dehumidificationrequiresairtobecooledbelowthemixedairsdewpointevenifthe
occupancyofthebuildingmightnotrequiresuchlowtemperaturestomeetspacetemperaturesetpoints.Additionally,the
mixingdampersandtheirassociatedcontrolsequencesinAHUsarecommonmodesoffailure,whichtogetherwithsensordrift
canresultinoverventilation(higherenergyuse)orunderventilation(poorIAQ).

AbetterapproachformanybuildingsisconsolidatingalloftheoutdoorairtreatmentintodedicatedAHUsthatsupply100%
outdoorair.Treatedair(dehumidifiedorhumidified)fromtheseunitscanbesupplieddirectlytooccupiedspacesorcanbe
injectedintomixingboxesintootherAHUsdedicatedtotemperaturecontrol.

WhiletheadditionofdedicatedoutdoorAHUsmightatfirstsoundlikeafarmoreexpensiveapproach,theirusemayaddlittle
totheoverallcostofajobastheycanallowsimplificationofotherAHUs.

Condensatecollectionfromcoolingcoilscansaveaconsiderableamountofwaterandmoney.Theairconditioning
processremoveswaterfromtheair,whichisthentypicallysenttoadrain.Humidclimates,includingmuchoftheeasternhalf
oftheUnitedStates,aregenerallygoodcandidatesforrecoveryofcondensate.Therecoveredwatermaybecollectedina
cisterntogetherwithrainwaterorgreywater,ormaybeusedasmakeupforcoolingtowers.

UVClights(ultravioletlightintheCband)reducethegrowthofbacteria,mold,andalgaeoncoilsanddrainpans.Keeping
coilscleanandfreefromdepositsimprovesheattransferandcancontributetooverallIAQ,particularlyincriticalenvironments
suchashospitals.TheUVCemittersmustprovidepropercoverageofthewetsideofthechildwatercoil,andcaremustbe
takentoensurethatplasticandrubbercomponentswithintheAHUarenotexposedtotheultravioletlightastheywillbe
degraded.Additionally,theemittersrequireperiodicreplacementastheyloseoutputpowerandefficacywithinafewyears.

CommissioningisamustforallAHUs,regardlessofsizeandcomplexity.Althoughthecommissioningprocessisfarfrom
new,ithasonlyachievedwidespreaduseinHVACsystemsinthepastdecadewiththeincreasedadoptionofsustainability
ratingsystemswhichrequireit.

AHUsthatarentcompletelycommissionedarealmostguaranteedtonotoperateproperly.Periodicrecommissioningisalso
necessarysincesensorsanddampersdriftovertime.BetteryetiscontinuouscommissioninginwhichtheHVACsystemskey
parametersarebaselinedandcontinuouslymeteredandmonitoredtogiveanearlyindicationoflaggingperformance.

Trainingisalsoanimportantcomponentofcommissioning.Systemoperatorsmustbeproperlytrainedtounderstandall
operatingmodesofeachpieceofequipment.Trainingmaterialsmustbeleftonsitesothatnewpersonnelcancomeupto
speedeasily.

Energyusecomparison

AsafinalnoterelatedtotheenergyuseofAHUs,acomparativeannualenergysimulationwasmadeforatypicalnewoffice
buildingmeetingorinsomecasesimprovinguponminimumprescriptiverequirementsofASHRAE90.12007(seeTable1).
Thebuildingis175,000sqftandislocatedinRichmond,Va.TheHVACsystemiscomprisedoffourlargeVAVAHUs,each
supplying32,000cfmtosingleductterminalboxeswithhotwaterreheat.

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AllsystemsinthemodelareheldconstantexceptfortheAHUs.ThebasecaserepresentsadecentAHUmeetingASHRAE
90.1whiletheAlternateCaseusesanimprovedFEG,premiumefficiencymotor,andastaticpressurereductionof0.5in.wc
easilyachievablethroughcarefulAHUandductsystemdesign.

Theresultsshowatotalenergyreductionofnearly2%forthebuildingandanenergycostreductionofgreaterthan3%,which
couldearntheprojectatleastoneincrementalLEEDpointforcreditEA1OptimizeEnergyPerformance.

Conclusion

Theprecedinginformationisnecessarilygeneralandisnowayacomprehensiveguidetoproperselectionandapplicationof
AHUs.Everyprojectcarrieswithitauniquesetofcriteriawhichmustbebalancedtoarriveatthebest(notperfect)solution.
Designengineerswilldowelltoorganizethesecriteriaearlyinaprojectandeconomicanalysisisusuallyrequiredtosupport
theultimatepathforward.

EachindividualcomponentwithinanAHUmustbeselectedwithacombinationofresearch,analysis,andexperience.By
keepingenergyefficiencyandmaintainabilityfirmlyinmindthroughouttheselectionprocess,itislesslikelytherewillbe
regretswhenprojectiscomplete.

EventhebestAHUsandinstallations,however,requireastrongcommitmentfromthebuildingsoperatorstokeepthem
runningwell.Preventivemaintenanceprogramstogetherwithcontinuouscommissioningwillhelpensurethelowestpossible
ownershipcostforanysystem.

Designtips

Followthesedesignandtroubleshootingtipswhenspecifyingairhandlingunits(AHUs).

Whenbeginningaproject,spendthetimetolistallthevariousgoalsandconstraintsincludingproposalrequirements,
applicablecodesandstandards,energygoals,andownerpreferences.Createamatrixofeachsystemoptionanddocument
theirrelativestrengthsandweaknesses.

Tryhardtosellenergyefficiencyandmaintainabilityatthebeginningofaproject.Firstcostishugelyimportant,butmany
ownerswillbewillingtocomeupwithextramoneyupfrontiftheycanbeshownthebenefitsoflowertotalownershipcosts.

Considerhavingcontroldampers,electricaldisconnects,andVFDsinstalledatthefactory.Moreupfrontcoordinationcanbe
required,buttheresultisoftenahigherqualityinstallationandcanalsobelessexpensivewhenconsideringthesavingsinon
siteelectriciansandcontrolscontractors.

PaycloseattentiontoductdesignandlimitthepressurelossesbothinsideandoutsideoftheAHUs.Decreasingtherequired
pressureinafansystembyjustafewtenthsofaninchofwatercanresultinthousandsofdollarsayearinfansavings.

WhenselectingandschedulingfansforAHUs,workcloselywiththeAHUmanufacturertoensurethatalllossesassociated
withinternalcomponentsareconsidered.Thisisespeciallyimportantforplenumfans,whichwillhavecasingexitlossesthat
canbesignificant.

Dontforgettoleavespaceformaintenanceincludingthespacetoremoveandchangecoilsinthefuture.Manyfacilities
requireaclearspaceforserviceequaltothewidthoftheAHU.

NeverskimponcommissioninganAHU.

REFERENCES

AirMovementControlAssociation,AMCAStandard2052010(Rev.2011):EnergyEfficiencyClassificationforFans.

2012InternationalGreenConstructionCode.InternationalCodeCouncil(ICC),Inc.,CountryClubHills,Illinois.

ASHRAE/ANSI/IESNAStandard90.1:EnergyStandardforBuildingsexceptLowRiseResidentialBuildings.ASHRAE.Atlanta,
2007.

ThomasLawrence,JasonPerry,TylerAlsen,AHUCondensateCollectionEconomicsASHRAEJournal,May2012.

MarkStutman,UsingFieldMeasurementsofAirFilterPerformanceandHVACFanEnergyMeasurementtoSelectAirFilters
withLowestLifecycleCost,StrategicPlanningEnergyandtheEnvironment,Volume32,No.1,2012,TaylorandFrancis
Group.

RobMcAteeisvicepresidentandmechanicaldepartmentheadandhasmorethan20yearsexperienceinenergyandbuilding
systems.EvanRileyhasmorethan10yearsexperienceindesign,commissioning,andmodelingofHVACsystems.

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<Backto:Home

Anonymous,INDIA,01/04/1301:37AM:

It'saverygoodarticleforguidingtheHVACdesignEngineer.

Richard,UnitedStates,01/17/1310:07AM:

RarelydoIevercommentonarticlesbyotherengineersbutthisexcellentpiecebyMcAteeandRileyrequiresanenthusiastic
"well done". It is well written, succinct, and informative. This should be required reading for all new design engineers in the
industry.

Anonymous,03/05/1307:50AM:

Goodarticle.Ioftenseedirectdrivefansspecifiedasplenumtypefansinsteadofhousedcentrifugalhowever.Thiscannegate
theefficiencygainfromusingdirectdrivetechnologyalbeitagaininIAQ(nobeltdust)andnoisereduction.

Greg,IL,UnitedStates,03/20/1309:35AM:

WellDoneGentlemen!Thanksforyoureffortstomakethebasicssimpleandeasytograsp!
GregSaganichWIKA
HVAC/RBusinessDevelopment

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