IntelliCUBE Fan Arrays
High Performance Fan Arrays for Demanding Applications
When older air handlers need more airflow, more pressure, and more reliability, IntelliCUBE fan arrays deliver. Mainstream’s IntelliCUBE Fan Arrays are engineered for larger applications where conventional fans fall short—adding redundancy to aging units, improving system efficiency, and eliminating preventative maintenance requirements.
What is an IntelliCUBE Fan Array?
IntelliCUBE is Mainstream’s heavy-duty cube-style fan array platform, developed specifically for larger fans, greater airflow, and higher static pressure applications. IntelliCUBE fan arrays are manufactured with a welded structural steel frame and configured to stack six or more fans high, making it well suited for large AHU retrofits.
Each IntelliCUBE fan array is custom sized to fit the existing unit and designed around the project’s airflow, pressure, access, and control requirements. The result is a retrofit solution that helps owners and engineers upgrade performance without replacing the entire air handling unit.
Performance Capabilities
Airflow up to 300,000+ CFM
Static pressure up to 14" TSP
Motor sizes up to 30 HP
Stackable construction for 6 or more fans high
Custom cube height and width to fit the existing AHU
Motor flexibility across EC, PMEC, and AC platforms
Why it matters?
For engineers and owners, those capabilities translate into a practical path for replacing aging large-format fans in existing equipment. For contractors, the modular design helps simplify installation in mechanical rooms where access is limited. For facilities teams, IntelliCUBE brings the key advantages of fan arrays—redundancy, reduced maintenance, lower vibration, and controllability—to larger and more critical systems.
Motor Options for the Application
Mainstream utilizes a range of different motors types, so IntelliCUBE fan arrays can be designed with the motor technology that best fits the project requirements, owner preference, operating environment, and performance goals.
AC Motors
A proven and familiar option for HVAC applications. AC induction motors are readily available, widely used, and well suited to a broad range of retrofit projects. They also typically have a much longer expected lifespan than EC motors.
PMEC Motors
Permanent magnet motors offer very high efficiency in a smaller, lighter package. They combine strong efficiency, long lifespan, and reliability, making them a strong fit for many high-performance fan array applications.
ECM Motors
ECMs include integral electronics for simple control, high efficiency and low cost. They are a good solution for light-duty applications, especially where profile and access are constrained.
This flexibility allows Mainstream to tailor IntelliCUBE fan arrays to the application instead of forcing a one-size-fits-all motor platform.
Specialized Motor Solutions
For more demanding environments, IntelliCUBE fan arrays can also be configured with:
Explosion-proof motors
Severe-duty motors
Stainless-steel construction options
IntelliCUBE Fan Arrays
Integrated Controls:
Straightforward Startup & Simple Operation
IntelliCUBE fan arrays are available with control panels designed to simplify installation, startup, and ongoing operation. Panels are engineered and built to order, giving the project team flexibility to meet custom electrical and control requirements. Mainstream control panels are UL-listed.
Standard control features include:
- Single-point power with main disconnect
- Individual motor circuit protectors
- Dedicated, preprogrammed VFD for each fan
- 0–10V speed signal for synchronized control
- HOA switches for local or remote operation
Premium control options include:
- 10″ touchscreen display for live system monitoring
- BAS integration for monitoring, scheduling, trending, and alarms
- BACnet MS/TP, BACnet IP, or Modbus RTU compatibility
- IntelliFLOW airflow monitoring independent of fan speed
Additional panel options:
- NEMA 3R outdoor-rated enclosures
- 100k SCCR ratings
- 100 kAIC fused disconnects
- Custom-built solutions for project-specific requirements
Because the panel is designed as part of the overall system, IntelliCUBE fan arrays provide a coordinated retrofit package—helping reduce field complexity and support smoother startup.
Factory startup and technical support is available for all Mainstream fan arrays.
Options & Accessories
IntelliCUBE fan arrays can be configured with a wide range of options to meet performance, installation, environmental, and monitoring requirements.
Available options include:
N+1 redundancy
Backdraft dampers
Pre-wired whips / wiring harnesses
Acoustic insulation
Piezo rings for airflow and pressure sensing
Touchscreen controller
Stainless or coated fan wheels
Mesh fan guarding
These options help us tailor IntelliCUBE fan arrays for challenging retrofit conditions, corrosive environments, sound-sensitive spaces, and projects where installation speed and maintainability matter.
Case Study: 35-Story Building – Baltimore, Washington
Challenge:
A major 35-story building in Baltimore was relying on aging inline fans for its return air system. With a single motor supporting the existing return fan, the facility faced a serious risk: if that motor failed, entire portions of the building would be without return air. For a high-rise of this size, reliability and continuous performance were non-negotiable.
Solution:
Mainstream stepped in with a custom IntelliCUBE fan array solution. By replacing the old single-motor fan with multiple fans, the building gained full redundancy. Even if one fan requires service, the rest of the array keeps the system operating without disruption.
Results:
- Peace of mind: The new IntelliCUBE system ensures uninterrupted airflow across all 35 floors.
- Energy efficiency: With the flexibility to scale fans down during off-peak hours, the customer now enjoys meaningful energy savings.
- Exceeding expectations: The IntelliCUBE fan array not only solved the reliability concern but delivered significant performance boost and energy savings beyond the customers expectations.
Do you have an application to discuss?
If your project calls for higher airflow, higher pressure, and a more reliable replacement for an aging fan system, IntelliCUBE offers a scalable path forward.
Talk with Mainstream about your airflow requirements, unit dimensions, motor data, and project conditions, and we’ll help configure the right IntelliCUBE solution for the application.