How to select an air handling unit

Air handling units come in all shapes and sizes. Learn to balance and prioritize all
of the choices related to performance, efficiency, maintainability, and space
constraints.
Rob McAtee, PE, and Evan Riley, PE, CEM, LEED BD+C, H&A Architects and
Engineers
12/27/2012
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Learning Objectives

1. Know the different types of AHUs, and their basic anatomy

2. Understand the codes and standards that govern AHU specification

Data Aire
3. Learn about how energy can be saved in HVAC systems that use AHUs.

A basic definition of an air handling unit (AHU) might be a box with a fan, coils,
and filters. From there it gets considerably more complicated. Proper selection
of an air handler requires answering myriad questions ranging from what
capabilities are required? to will it fit? Only after establishing these basic
project constraints can the art of evaluating and selecting an AHU begin.

Before starting this process, its important to realize that there will not be a
perfect selection for any AHU as many competing criteria, not the least being
cost, will force compromises. It is the engineers job to balance and prioritize all
of the decisions related to performance, efficiency, maintainability, and space
constraints to select a unit that has the lowest lifecycle cost for a given
application.

This article provides general information and guidance on the selection of various
AHU components, starting with a brief description of the major categories of
AHUs. While much of the discussion in the remainder of the article relates
primarily to large AHUs, the general considerations can be applied to any size.

This side-view cutaway drawing of a draw-through AHU shows the plenum return
fan, exhaust/mixing boxes, filters, cooling coil, humidifier, heating coil, and
plenum supply fan. Note that no preheat coil is present as this unit receives
pretreated outside a

Types of AHUs

Fan coils/blower coils are the smallest and simplest category of AHU and, as the
names imply, they typically consist of little more than a fan and a heat transfer
coil(s). To keep the coils from getting dirty too quickly, a simple filter is also
included. They generally have simple controls and serve a single temperature
zone. While they have their applications, they are typically less efficient than
larger AHUs and have difficulty providing tight temperature and humidity control.

Packaged AHUs are very common in smaller buildings and commercial

applications, particularly as rooftop units. Packaged units generally contain fans,
coils, filters, and dampers in a single casing. Often the casing includes its own air
conditioning compressors and means for heating such as gas burners, electric
heating coils, or heat pump coils. They often serve single temperature zones, but
large variable air volume (VAV) AHUs serving multiple terminal boxes (zones) are
available. Because of their compactness and lower initial costs, packaged units
have a reputation for being inefficient and maintenance intensive, but
performance and reliability are improving. They are available in sizes from a few
thousand cfm to more than 30,000 cfm, but their standardization can be limiting
in some applications.

Modular AHUs allow users to select individual components housed in modules

having consistent construction and cross sections. The user can select the type
of casings, fans, filters, coils, and accessories from a variety of different options.
Modules are assembled at the factory or can be shipped individually and
assembled on-site. Modular units generally allow great flexibility and can meet
most air processing requirements.

Custom AHUs are available in nearly any configuration that a user might require.
They generally have the highest quality construction and are most commonly
used in institutional or industrial applications where high flow rates, very close
control, and harsh conditions exist. They may also be applied in irregular spaces
that would not conform to a modular line. Custom units can be configured to
include virtually any combination of air processing components. They also can
include walkways and service areas within them and can even accommodate
space for skid-mounted equipment like pumps or heat exchangers. They are the
most costly of all of the types of units discussed, but can be expected to have
the longest lifespan.

Figure 2: This building information model (BIM) rendering shows a multi-story

office buildings HVAC ductwork and piping. This image was generated
approximately halfway through the design process and, together with sections
and walk-throughs, identified areas of the design that required additional
coordination. Autodesks Revit and Navisworks programs were used to render
this. Courtesy: H&A Architects and Engineers

Anatomy of an AHU

Casing and construction: A quality AHU can last more than 30 years with proper
maintenance. Double-walled construction is now standard for all but the smallest
units, but the application of the insulation between the walls also is important.
Injected foam insulation with no through-metal connections (no thermal bridging)
is available from a variety of manufacturers and generally has better thermal
and acoustical performance than fiberglass insulation. If the unit is to be installed
outdoors, extra insulation is recommended and corrosion-resistance should be a
top priority.

Mixing box: Most AHUs supply some percentage of outside air for ventilation. The
mixing box is the place where outside air is combined with return air from the
building. Control dampers are used to proportion the incoming airstreams and
relief air.

Filters: Air filters remove contaminants from the airstream and significantly
improve air quality (IAQ). Rating systems for air filters, such as ASHRAE Standard
52.2-2007 Method of Testing General Ventilation Air-Cleaning Devices for
Removal Efficiency by Particle Size, define the mean efficiency reporting value
(MERV) providing a comprehensive and consistent indication of a filter's capture
performance with a range of particle sizes.

Newer rating systems, such as the European Committee for Standardization

EN779:2012, rate air filters based not only their ability to capture particles, but
also on their predicted annual energy use. It is expected that a similar approach
will adopted in the United States in the coming years.

The lifecycle cost of filters should be carefully considered during the design and
subsequent purchasing of the filters. Overall, the first cost of filters can be as
little as 4% of the lifecycle cost of the filters when considering energy use,
changeout, and disposal costs. Its also extremely important not to skimp on
access space. If an AHU is difficult to access and filters are difficult to reach, they
wont get changed, and the unit will use excessive energy and underperform.

Figure 4: This chart shows a breakdown of end-use energy for a large building in
a hot climate as calculated from a whole-building energy simulation. Fans
represent a significant portion of the total predicted annual energy use. Courtesy:
H&A Architects and EngineersSupply and return fans: Fans are the heart of
any AHU and can represent a significant portion of the buildings total annual
energy usage. The supply fan pushes or pulls the air through filters and coils and
then distributes it through ductwork directly to spaces or to terminal boxes. Not
all AHUs require a return fan, but units serving multiple spaces or using air-side
economizers typically require a fan to return air to the AHU and to relieve air
from the building.

AHUs in which the supply fan is installed after the heating and cooling coils are
referred to as draw-through units since the supply fan draws the air through the
unit.

In blow-through AHUs, the supply fan is located prior to the coils. This
arrangement allows fan heat: which can be significantto be removed from the
airstream without having to subcool the supply air as is necessary for drawthrough units. Although much less common than draw-through, blow-through
units do have applications, particularly in healthcare. They also are seeing
increased application in low-temperature air systems.

Fan selection

There are many types of fans applied to air handlers; the primary differences
among them relate to blade configuration and whether the fan wheel is fully
housed or open. (An open wheel arrangement is referred to as a plenum fan.)

The energy required for any fan is a function of the amount of air to be moved
together with the air pressure the fan must generate. ASHRAE Standard 90.12010, Energy Standard for Buildings Except Low-Rise Residential Buildings,
provides maximum fan power restrictions on HVAC systems based on the flow
rate and a variety of factors related to application and filtration level. Future
versions of Standard 90.1 will be incorporating a minimum fan efficiency grade
(FEG) as described in AMCA 205-2010. Fans more than 5 hp will be required to
have a minimum FEG of 67 and will need to operate within 10% of their peak
efficiency. (This may not apply to packaged units, which are certified in their
entirety.

Figure 4: Custom AHU at a factory. Controls and starters have been installed prior
to unit shipping. This often reduces overall project cost and start-up time.
Courtesy: Buffalo Air HandlingA critical part of any fan selection is acoustic
performance. Its always important to know the maximum acceptable noise level

on a project. Proper selection and specifying of fans and AHU casing can reduce
the need for silencers and other costly noise mitigation techniques. Because the
best way to reduce fan sound is to reduce the fan power, efficient fans frequently
have the best acoustic performance.

Coils: Coils are used to heat, cool, and dehumidify air. The heat source can be
from hot water, steam, electric-resistance, or hot refrigerant vapor (as with a
heat pump). Cooling and dehumidification can be provided via expansion of
refrigerant (referred to as Direct eXpansion, or DX), or indirectly through the
circulation of chilled water or glycol. In dry climates, cooling also can be effected
by spray coils that reduce the dry bulb temperature of the air, but increase the
airs humidity.

Access: Access sections are frequently omitted from AHUs either through
designer oversight or intentionally due to space or budget restrictions. But
skimping on access can prove shortsighted as each component within an air
hander will require routine service, repair, or replacement many times over the
life of the unit. Coils must be cleaned frequently to maintain proper heat transfer,
and they must be accessible from front and back to do so. The more difficult it is
to reach a component, the less likely maintenance will be performed, which will
result in lower overall efficiency and reduced longevity.

Humidifiers: There are numerous methods for delivering humidification, including

steam, ultrasonic dispersion, infrared heating, and atomization of water. Careful
consideration is necessary to determine which method is best suited for a given
project, but humidifiers in general are maintenance intensive. They must
therefore be installed in easily accessible locations since serious damage and IAQ
issues can arise if humidifiers are not operating properly for extended periods.

Figure 5: The curves define fan efficiency grade (FEG) as function of fan wheel
diameter and a fans total peak efficiency. Note that peak total efficiency (%) can
be very different than a fans FEG, especially with smaller-diameter fans.
Courtesy: Air Movement and Control Association (AMCA) International Standard
205-2012Codes and standards

The International Building Code (IBC) and International Mechanical Code (IMC)
provide requirements for, among other things, equipment location, disposal of
condensate, and minimum outside air quantity. Energy efficiency requirements
for individual components and packaged units are provided within the
International Energy Conservation Code (IECC), ASHRAE 90.1, and California
Energy Commissions Title 24. Each state and locality determines the
applicability of these codes and standards.

There is significant pressure to go beyond code-minimum performance, and

many mandates are in place for federal projects requiring new buildings to
operate with much less energy than minimally code-compliant ones. The U.S.
Green Building Councils LEED rating system requires new buildings to have at
least 10% less annual energy costs than a code-compliant building and awards
points based on incremental savings above 10%. The International Green
Construction Code (IgCC) and ASHRAE Standard 189.1 also tighten energy
performance and are being increasingly adopted by states and localities.

Multiple organizations provide standards for the testing, rating, and installation
of AHUs and associated components. Some examples of these include Air
Movement and Control Assn. (AMCA), International, Air-Conditioning, Heating,
and Refrigeration Institute (AHRI), ASHRAE, and Sheet Metal and Air Conditioning
Contractors National Assn. (SMACNA). These organizations produce testing and
rating standards that can be used by manufacturers and specifiers to gauge
performance.

Large institutional users typically have their own standards in addition to codes
to ensure consistency and ease of maintenance for air handling equipment.

Emerging trends in AHUs

Although much of the technology in AHUs has remained relatively unchanged for
decades, some relatively new components and practices are being incorporated
that can be useful in the right application.

Direct-drive fans couple the fan wheel directly to the motor shaft and are
typically applied with variable-frequency drives (VFD). This eliminates the drive
losses associated with belts and can result in higher efficiency and lower overall
noise.

Fan arrays use multiple small, direct-drive fans in lieu of a single large fan.
Applied properly, the fan array can reduce the overall space required for the AHU
while providing redundancy and energy-efficient operation. Depending on the
number of fans, they can be controlled in unison by one or more VFDs. Like so
many other things related to AHUs, care must be taken when applying a fan
array to ensure the goals of the project are met as efficiently as possible.

Energy recovery is increasingly applied in AHUs and may be required by energy

codes in certain applications having high percentages of outdoor air.

Energy recovery enables incoming air to exchange heat and moisture with
building exhaust air via desiccant-coated wheels or special materials in a flatplate, counter-flow arrangement. Successful application is dependent on many
factors, most importantly climate. It is generally easiest and most cost effective
to apply when dedicated outside air units are used.

Dedicated outside air units are increasingly being applied in lieu of traditional air
units that mix outdoor air and return air. For many climates, the toughest part of
an AHUs job is treating outdoor air. Coils must be sized to handle to most
extreme ambient temperatures. In humid climates, dehumidification requires air
to be cooled below the mixed airs dewpoint even if the occupancy of the
building might not require such low temperatures to meet space temperature
setpoints. Additionally, the mixing dampers and their associated control
sequences in AHUs are common modes of failure, which together with sensor
drift can result in over-ventilation (higher energy use) or under-ventilation (poor
IAQ).

A better approach for many buildings is consolidating all of the outdoor air
treatment into dedicated AHUs that supply 100% outdoor air. Treated air
(dehumidified or humidified) from these units can be supplied directly to
occupied spaces or can be injected into mixing boxes into other AHUs dedicated
to temperature control.

While the addition of dedicated outdoor AHUs might at first sound like a far more
expensive approach, their use may add little to the overall cost of a job as they
can allow simplification of other AHUs.

Condensate collection from cooling coils can save a considerable amount of

water and money. The air conditioning process removes water from the air, which
is then typically sent to a drain. Humid climates, including much of the eastern
half of the United States, are generally good candidates for recovery of
condensate. The recovered water may be collected in a cistern together with
rainwater or grey water, or may be used as make-up for cooling towers.

UVC lights (ultraviolet light in the C band) reduce the growth of bacteria, mold,
and algae on coils and drain pans. Keeping coils clean and free from deposits
improves heat transfer and can contribute to overall IAQ, particularly in critical
environments such as hospitals. The UVC emitters must provide proper coverage
of the wet side of the child water coil, and care must be taken to ensure that
plastic and rubber components within the AHU are not exposed to the ultraviolet
light as they will be degraded. Additionally, the emitters require periodic
replacement as they lose output power and efficacy within a few years.

Commissioning is a must for all AHUs, regardless of size and complexity.

Although the commissioning process is far from new, it has only achieved
widespread use in HVAC systems in the past decade with the increased adoption
of sustainability rating systems which require it.

AHUs that arent completely commissioned are almost guaranteed to not operate
properly. Periodic re-commissioning is also necessary since sensors and dampers
drift over time. Better yet is continuous commissioning in which the HVAC
systems key parameters are baselined and continuously metered and monitored
to give an early indication of lagging performance.

Training is also an important component of commissioning. System operators

must be properly trained to understand all operating modes of each piece of
equipment. Training materials must be left on-site so that new personnel can
come up to speed easily.

Energy use comparison

As a final note related to the energy use of AHUs, a comparative annual energy
simulation was made for a typical new office building meeting or in some cases
improving upon minimum prescriptive requirements of ASHRAE 90.1-2007 (see
Table 1). The building is 175,000 sq ft and is located in Richmond, Va. The HVAC
system is comprised of four large VAV AHUs, each supplying 32,000 cfm to
single-duct terminal boxes with hot water reheat.

Table 1: This table illustrates an energy and cost comparison between systems
based on typical, but well-performing, AHUs, and a system using higher
efficiency fans and reduced static pressure. Courtesy: H&A Architects and
Engineers

All systems in the model are held constant except for the AHUs. The base case
represents a decent AHU meeting ASHRAE 90.1 while the Alternate Case uses an
improved FEG, premium efficiency motor, and a static pressure reduction of 0.5
in. wceasily achievable through careful AHU and duct system design.

The results show a total energy reduction of nearly 2% for the building and an
energy cost reduction of greater than 3%, which could earn the project at least
one incremental LEED point for credit EA1 Optimize Energy Performance.

Conclusion

The preceding information is necessarily general and is no way a comprehensive

guide to proper selection and application of AHUs. Every project carries with it a
unique set of criteria which must be balanced to arrive at the best (not perfect)
solution. Design engineers will do well to organize these criteria early in a project
and economic analysis is usually required to support the ultimate path forward.

Each individual component within an AHU must be selected with a combination

of research, analysis, and experience. By keeping energy efficiency and
maintainability firmly in mind throughout the selection process, it is less likely
there will be regrets when project is complete.

Even the best AHUs and installations, however, require a strong commitment
from the buildings operators to keep them running well. Preventive maintenance
programs together with continuous commissioning will help ensure the lowest
possible ownership cost for any system.

Design tips

Follow these design and troubleshooting tips when specifying air handling units
(AHUs).

When beginning a project, spend the time to list all the various goals and
constraints including proposal requirements, applicable codes and standards,
energy goals, and owner preferences. Create a matrix of each system option and
document their relative strengths and weaknesses.

Try hard to sell energy efficiency and maintainability at the beginning of a

project. First cost is hugely important, but many owners will be willing to come
up with extra money up front if they can be shown the benefits of lower total
ownership costs.

Consider having control dampers, electrical disconnects, and VFDs installed at

the factory. More up-front coordination can be required, but the result is often a
higher-quality installation and can also be less expensive when considering the
savings in on-site electricians and controls contractors.

Pay close attention to duct design and limit the pressure losses both inside and
outside of the AHUs. Decreasing the required pressure in a fan system by just a

few tenths of an inch of water can result in thousands of dollars a year in fan
savings.

When selecting and scheduling fans for AHUs, work closely with the AHU
manufacturer to ensure that all losses associated with internal components are
considered. This is especially important for plenum fans, which will have casing
exit losses that can be significant.

Dont forget to leave space for maintenance including the space to remove and
change coils in the future. Many facilities require a clear space for service equal
to the width of the AHU.