High Performance Fan Arrays for Demanding Applications
When older air handlers need more airflow, more pressure, and more reliability, IntelliCUBE fan arrays deliver.
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 — 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
Motor Flexibility
EC, PMEC, and AC motor platforms — Mainstream selects the right technology for your specific goals, environment, and performance requirements.
Why It Matters
For engineers and owners, these capabilities translate into a practical path for replacing aging large-format fans in existing equipment without a full AHU replacement.
For contractors, the modular design helps simplify installation in mechanical rooms where access is limited — reducing downtime from weeks to days.
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 motor types, so IntelliCUBE fan arrays can be designed with the technology that best fits the project requirements, owner preference, operating environment, and performance goals.
AC Motors
Proven and familiar for HVAC applications. AC induction motors are readily available, widely used, and well suited to a broad range of retrofit projects. Typically the longest expected lifespan.
PMEC Motors
Permanent magnet motors offering very high efficiency in a smaller, lighter package. Strong efficiency, long lifespan, and reliability — a strong fit for high-performance applications.
ECM Motors
Integral electronics for simple control, high efficiency, and low cost. A good solution for lighter-duty applications, especially where profile and access are constrained.
Specialized options: Explosion-proof, severe-duty, and stainless-steel motor configurations available. Mainstream tailors IntelliCUBE to the application — not the other way around.
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. All Mainstream control panels are UL-listed.
Standard Features
- Single-point power with main disconnect
- Individual motor circuit protectors
- Dedicated, preprogrammed VFD per fan
- 0–10V speed signal for synchronized control
- HOA switches for local or remote operation
Premium Options
- 10" touchscreen display for live system monitoring
- BAS integration — monitoring, scheduling, trending, alarms
- BACnet MS/TP, BACnet IP, or Modbus RTU compatibility
- IntelliFLOW airflow monitoring independent of fan speed
Additional 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.
Options & Accessories
IntelliCUBE fan arrays can be configured with a wide range of options to meet performance, installation, environmental, and monitoring requirements. These options help tailor IntelliCUBE for challenging retrofit conditions, corrosive environments, sound-sensitive spaces, and projects where installation speed and maintainability matter.
Challenge
A major 35-story building in Baltimore was relying on aging inline fans for its return air system. A single motor supported the entire return system — if that motor failed, entire portions of the building would be without return air. For a high-rise of this size, continuous performance was non-negotiable.
Solution
Mainstream engineered 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
Uninterrupted airflow across all 35 floors — continuous operation guaranteed.
Meaningful energy savings with the flexibility to scale fans down during off-peak hours.
Performance exceeded expectations — significant energy savings beyond what the customer anticipated.