Compact Fan Arrays for Smaller AHUs
Designed for smaller air handling units, IntelliWALL delivers the core benefits of a fan array — efficiency, redundancy, low maintenance, and quieter operation — 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 solution.
Each IntelliWALL system is built around the requirements of the existing unit, helping engineers, contractors, and owners modernize aging equipment without the cost and disruption of full AHU replacement.
Performance Capabilities
Motor Flexibility
EC, PMEC, and AC motor platforms available — Mainstream selects the right technology for your specific requirements and environment.
Why It Matters
For engineers, IntelliWALL offers a practical way to upgrade smaller legacy units with a more efficient and reliable fan system — without a full AHU replacement.
For contractors, the modular design helps simplify installation in constrained spaces, reducing downtime and field complexity.
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 motor types, so IntelliWALL fan arrays can be designed with the technology that best fits the project requirements, owner preference, operating environment, and performance goals.
ECM Motors
Integral electronics for simple control, high efficiency, and low cost. A strong solution for lighter-duty applications, especially where profile and access are constrained — well suited to IntelliWALL applications.
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 fan array applications.
AC Motors
Proven and familiar for HVAC applications. Readily available, widely used, and well suited to a broad range of retrofit projects. Typically the longest expected lifespan.
Mainstream tailors IntelliWALL fan arrays to the application — selecting the right motor platform instead of forcing a one-size-fits-all approach.
Integrated Controls — Straightforward Startup & Simple Operation
IntelliWALL 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, IntelliWALL fan arrays provide a coordinated retrofit package — helping reduce field complexity and support smoother startup. Factory startup and technical support is available.
Options & Accessories
IntelliWALL fan arrays can be configured with a wide range of options to meet performance, installation, environmental, and monitoring requirements. These options help tailor IntelliWALL for challenging retrofit conditions and projects where installation speed and flexibility matter.
Challenge
A 20-story commercial office tower in downtown Seattle was operating with outdated fans that were noisy, inefficient, and offered no redundancy. The system limited airflow performance and created ongoing operational risk. The owner needed a smarter retrofit solution without replacing the entire air handling system.
Solution
Mainstream engineered a complete retrofit solution centered around four IntelliWALL fan arrays — two supply and two return — incorporating EC fans, smart control panels, backdraft dampers, and integrated controls for coordinated operation and precise modulation.
Results
Approximately 500,000 CFM of total airflow delivered across four fan arrays.
Improved energy efficiency with built-in redundancy for more reliable operation.
Quieter, smarter air movement supporting a healthier indoor environment for occupants.