IntelliWALL Fan Arrays
Compact Fan Arrays for Smaller AHUs
IntelliWALL is Mainstream’s bulkhead-style fan array solution for retrofit applications where space is limited, access is tight, and reliable performance still matters.
Designed for smaller air handling units, IntelliWALL fan arrays deliver the core benefits—efficiency, redundancy, low maintenance, and quieter operation of a fan array—in a practical format built for real-world retrofit conditions.
What Is an IntelliWALL Fan Array?
IntelliWALL is Mainstream’s compact fan array platform designed for smaller AHUs and lighter-duty retrofit applications. IntelliWALL uses a bulkhead-style design with panels that bolt together in the field and fans mounted directly to the bulkhead.
This configuration makes IntelliWALL especially well suited for retrofit projects where existing unit dimensions, jobsite access, or mechanical room constraints make larger structural assemblies less practical. It provides a clean, modular way to replace older single-fan systems with a more modern direct-drive fan array solution.
Each IntelliWALL system is built around the requirements of the existing unit, helping engineers, contractors, and owners modernize aging equipment without taking on the cost and disruption of full AHU replacement.
Airflow up to 100,000+ CFM
Static pressure up to 10" TSP
Motor sizes up to 10 HP
Custom height and width to fit the existing AHU
Motor flexibility across EC, PMEC, and AC platforms
Structurally reinforced design available for larger, higher pressure applications
Why it matters?
For engineers, IntelliWALL offers a practical way to upgrade smaller legacy units with a more efficient and reliable fan system. For contractors, its modular design helps simplify installation in constrained spaces. For building owners and facilities teams, IntelliWALL supports improved uptime, lower maintenance demands, and better long-term serviceability.
Motor Options for the Application
Mainstream utilizes a range of different motors types, so IntelliWALL fan arrays can be designed with the motor technology that best fits the project requirements, owner preference, operating environment, and performance goals.
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.
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.
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.
This flexibility allows Mainstream to tailor IntelliCUBE fan arrays to the application instead of forcing a one-size-fits-all motor platform.
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, IntelliWALL 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
IntelliWALL fan arrays can be configured with a wide range of options to meet performance, installation, environmental, and monitoring requirements.
N+1 redundancy
Backdraft dampers
Pre-wired whips / wiring harnesses
Piezo rings for airflow and pressure sensing
Touchscreen controller
These options help tailor IntelliWALL fan arrays for challenging retrofit conditions, and projects where installation speed and flexibility matter.
Case Study: Commercial Office Building - Seattle, Washington
Challenge
This 20-story commercial office tower in downtown Seattle was operating with outdated fans that were noisy, inefficient, and offered no redundancy. The existing system limited airflow performance and created risk for ongoing building operations. The owner needed a smarter retrofit solution that could improve reliability without replacing the entire air handling system.Lorem ipsum dolor sit amet, consectetur adipiscing elit. Ut elit tellus, luctus nec ullamcorper mattis, pulvinar dapibus leo.
Solution
Mainstream engineered and delivered a complete retrofit fan solution for the building, centered around four IntelliWALL fan arrays—two supply and two return. The system included 52 EC fans, along with smart control panels for coordinated operation and monitoring. Backdraft dampers and integrated controls helped ensure precise modulation, dependable performance, and a smooth installation process.
Results
- Delivered approximately 500,000 CFM of total airflow across four fan arrays
- Improved energy efficiency while adding built-in redundancy for more reliable operation
- Created a quieter, smarter air movement solution that supports a healthier indoor environment
Do you have an application to discuss?
If your project calls for a more reliable replacement for an aging fan system, particularly where access or downtime is limited, IntelliWALL fan arrays offer an outstanding solution.
Talk with Mainstream about your airflow requirements, unit dimensions, motor data, and project conditions, and we’ll help configure the right IntelliWALL fan array solution for the application.