HVAC

AHU types, components, and con gurations

In this second portion, engineers will understand the component makeup of air handling units
(AHUs) and their inclusion within various HVAC systems.
BY RANDY SCHRECENGOST, PE, CEM, STANLEY CONSULTANTS, AUSTIN, TEXAS JANUARY 21, 2019

Photo 2: A multi-zone (2 zones) cooling-only air handling unit (AHU) that serves fan power boxes (FPB) variable air
volume (VAV) boxes with hot water reheat coils. Courtesy: Stanley Consultants Inc.

The design of an air handling unit (AHU) within an HVAC system is dependent on the speci c project requirements,
as well as the designer’s approach to design, experience level, knowledge of code-driven requirements and standard
practices, and the ability to communicate the design intent clearly through the preparation of plans and
speci cations.

While the AHU is an important part of a building’s HVAC system, the entire system should be considered during a
complete design. The design, selection, and arrangement of an AHU for a project is based upon several factors,
some of which are: application, performance, maintenance requirements, related size and building location, overall
cost to purchase and install, and energy e ciency.

As HVAC designers, providing a system that can meet the building comfort requirements at a reasonable cost while
minimizing maintenance costs and energy use, is the primary goal. Indoor air quality (IAQ), energy use, and occupant
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thermal comfort are a few of the concerns facedPolicy by building operations and maintenance (O&M) staff.
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There are numerous articles and reviews regarding HVAC design. Many of these articles and other technical
information can be found through ASHRAE, a global society for heating, refrigeration, and air conditioning engineers.
Some information can be found in the 2016 ASHRAE Handbook – HVAC Systems and Equipment, Chapter 4, Air
Handling and Distribution. ASHRAE states “The basic all-air system concept is to supply air to the room at conditions
such that the sensible and latent heat gains in the space, when absorbed by supply air owing through the space, will
bring the air to the desired room conditions.”

The Air-Conditioning, Heating, and Refrigeration Institute (AHRI) is a trade association that represents global
manufacturers of air conditioning, heating, commercial refrigeration, and water heating equipment. It works closely
with ASHRAE in the development of standards for the HVAC industry.

For example, ANSI/AHRI Standard 430-2014 de nes a central station AHU (CSAHU) as “a factory-made encased
assembly consisting of a supply fan, or fans in parallel, which may also include other necessary equipment to
perform one or more of the functions of circulating, cleaning, heating, cooling, humidifying, dehumidifying and mixing
of air.”

In addition, AHU appurtenances are equipment or components that may be added to an AHU for purposes, including
but not limited to, control, isolation, safety, static pressure regain, and wear. Common appurtenances include, but are
not limited to, coils, lters, energy recovery devices, dampers, air-mixers, spray assemblies, eliminators, discharge
plenums, and inlet plenums. Figure 3 is an example of a preliminary AHU elevation selection that illustrates the
various physical internal components for a dual duct AHU with multiple plenum fans.

Figure 3: A preliminary dual duct air handling unit (AHU) selection elevation view. Courtesy: Stanley Consultants Inc.

By de nition, AHUs are used to condition and/or circulate air as part of an HVAC system. The control and operation
of AHUs is beyond the scope of this article, but these items become increasingly more complicated with the HVAC
application and the number of components within the AHU. AHUs can be small, used in local environmental spaces,
and include minimal components such as: a fan or blower, a single heat transfer coil, and lter(s).

These small, terminal-type AHUs are referred to as fan coil units (FCUs) or blower coil units (BCUs), based on size
and capacity. They generally have simple controls and serve a single zone within a building such as a loading dock or
maybe a stairwell in a larger building. Although not universal, typical load capabilities for FCUs are 200 to 1200 cfm
while BCUs might range from 400 to 3,000 cfm.

Slightly larger AHUs selected for outdoor use, located on grade outside or on the roof, are usually referred to as
packaged units or rooftop units (RTUs), respectively. In addition to the components noted above, these units will
typically have control dampers and serve larger areas or multiple zones within a building. The HVAC load capabilities
of these units generally range from a few thousand cfm to tens of thousands. They begin to be more de ned in
terms of total heating and/or cooling capacity, which are stated as Btu/h. Cooling capacity may also be stated in
tons (where 1 ton equals 12,000 Btu/h), with typical applications ranging from 3 to 10 tons or more.

The next level of AHUs could be considered semi-custom, highly exible, but cataloged, AHUs that can be selected to
meet most any commercial, institutional, or even industrial applications. Most manufacturers have a line of these
type of AHUs, which can be modi ed to meet a designer’s speci c job requirements for new or existing building
projects. These units typically use a building-block or modular construction methodology to allow for a wide range of
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The modules, sometimes called splits, are engineered in a manner that allows for ease of shipping and then
assembled in the eld. These modules can be stacked or arranged in a variety of con gurations to address a
project’s constraints (i.e. access and space requirements). Available standardized components—including a wide

assortment of fans, coils, lters and controls packages—allow for optimal AHU performance. Many optional
components can also be added and may include: air-to-air, xed-plate heat exchangers, sensible and total energy
wheels, and face-and-bypass dampers. The energy related components follow rating and testing requirements by
AHRI 106 – Performance Rating of Air-to-Air Exchangers for Energy Recovery Ventilation Equipment, and ASHRAE
Standard 84-2013 — Method of Testing Air-to-Air Heat/Energy Exchangers (ANSI Approved).

Finally, designers may have a need to specify a custom AHU. A custom AHU may be used if there are special
application or capacity requirements for the project beyond standard manufactured equipment, there are physical
size constraints, or abnormal inlet and outlet connections. Custom AHUs are often used in applications such as
laboratories, large industrial and manufacturing facilities, or in renovations where a semi-custom unit cannot t.
These units are engineered and designed such that their size, material type, and thickness of construction, insulation,
and internal components can be altered to meet speci ed performance. These units, however, can be very expensive.

For example, in a semiconductor manufacturing plant, custom AHUs might be sized at 200,000 cfm with a 150 hp
motor on the fan, and have a preheat coil, a primary and secondary chilled water coil, a glycol coil, a reheat coil, and a
humidi er section to pre-condition and treat outside airstreams.

An HVAC system’s AHU may connect to a corresponding ductwork system that distributes the conditioned discharge
or supply air to a section or HVAC zone of the building. Typically, the HVAC ductwork system returns some, if not all,
of the return air (RA) back to the AHU; however, AHUs can simply supply and return air directly to and from the space
they serve with very little or no ductwork. Fan and blower coils above are typical examples.

By most de nitions, an HVAC zone has very similar occupancy and similar HVAC thermal characteristics but does
not necessarily have a de ned area or size. An exterior row of three or four o ces in a commercial o ce building, for
example, may be considered a small HVAC zone because the occupant density and usage patterns are similar.
Likewise, an interior area comprised of multiple work spaces or cubicles within the building also could be considered
a larger HVAC zone. Physical size does not matter, as a room or area is only partitioned from others and may not
need to be controlled separately. In fact, ASHRAE Standard 90.1-2016 de nes an HVAC zone as “a space or group of
spaces within a building with heating and cooling requirements that are su ciently similar so that desired conditions
(e.g., temperature) can be maintained throughout using a single sensor (e.g., thermostat or temperature sensor).”

An AHU is just a metal box of various sizes, dependent upon the necessary internal components (e.g. appurtenances
of various sorts). It typically is constructed around a framing system with insulated roo ng, ooring, and side panels,
sometimes built in modules, sections, or splits as required for the overall con guration of the components.
Depending upon the manufacturer and size of the AHU, the framing system can be constructed from metal c-
channels or square steel framing, with internal wall posts and sectionalized steel base rails under the unit. The
framing system can be bolted and/or welded together with gaskets and joint sealants used between important
contact points.

The oor is typically insulated and covered with a thick metal plate, sometimes in a diamond pattern to assist in
providing a walkable surface. The sides or wall panels can be single or double skin insulated metal panels. Fiberglass
insulation can be laid into the panel voids prior to closure, or with recent construction methods, sprayed in as a foam
product that then dries and adheres to the metal. The roof can be like the sides of the AHU unless it’s in an outdoor
application where additional weatherproo ng and joint sealing may be required. Much of the metal for the AHUs is
galvanized, or of aluminum or similar construction as necessary, for long-term protection and strength and typically
can be painted as required. Photo 1 indicates a variety of AHUs of different size arranged on the rooftop of a building.

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 Photo 1: A rooftop view shows multiple air handling unit (AHU) of varying sizes. Courtesy: Stanley Consultants Inc.

AHU construction methods must be tight to avoid air leakage, minimize heat gains or losses from the air handler, and
assist in reducing noise by providing sound attenuation. AHUs should have thermal breaks built into the structural
components to alleviate any thermal pathways within the outer con nes of the unit. An AHU that sweats and drips
condensate on a mechanical room oor indicates poor construction.

One of the rst AHU appurtenances to be considered from those mentioned above is the inlet air section for the AHU.
Some AHUs have simple inlet only plenum sections (e.g. a 100% outside air unit), while others will have mixing
plenums. A mixing plenum is where the different airstreams of outside air (OA) and RA mix prior to being conditioned
for delivery of the supply air to the building. The inlet and/or mixing plenum will almost always contain other AHU
components such as control dampers and lters, and may have other devices such as an air ow measuring
stations. Photo 2 shows an AHU mixing plenum with the OA entering on the side and the RA entering on the top. In
this picture an air ow measuring station is shown in the vertical section of the OA ductwork.

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 Photo 2: A multi-zone (2 zones) cooling-only air handling unit (AHU) that serves fan power boxes (FPB) variable air
volume (VAV) boxes with hot water reheat coils. Courtesy: Stanley Consultants Inc.

Dampers

Automatic control damper assemblies within the mixing plenum should be corrosion resistant and, because mixing
and controlling the amounts of OA and RA airstreams is sometimes critical, the selection, size, and orientation and
location of the dampers is important. Both parallel- or opposed-blade dampers can be used for controlling the overall
proportions of the airstreams, but pressure relationships and sizing for wide-open and/or modulating pressure drops
needs to be considered.

Opposed-blade dampers typically have lower pressure drops when modulating. ASHRAE Guideline 16 – 2014
Selecting Outdoor, Return, and Relief Dampers for Air-Side Economizer Systems can be referenced for input on these
dampers as well as for relief dampers during economizer mode of operation. Other references a designer should
review are AMCA 511 – Certi ed Ratings Program Product Rating Manual for Air Control Devices and ANSI/AMCA
STANDARD 500-D-2012, Laboratory Methods of Testing Dampers for Rating.

The OA damper can be one size and equal to the OA intake louver or ductwork for use in the 100% economizer
operation; or, as a better option, can be split into a smaller minimum OA damper and another larger one to
accommodate the additional OA needed for 100% intake. Because most designers oversize the dampers, the
advantage is better control. Due to the installed ow characteristics of a damper, they are somewhat linear between
10% and 80%.

There is no need to fully open or fully close a damper (except in emergencies or when off-line), and splitting the OA
damper will help limit the dampers to their respective portions and can be used for controlling the required air ows
more e ciently. The RA damper is then selected on the difference between the total design supply air and the
minimum OA ow rate, and considered the maximum RA ow rate. During economizer mode, this RA damper would
be closed. The dampers should be speci ed to meet the leakage requirements of ASHRAE Standard 90.1 and of the
International Energy Conservation Code by leaking less than 3 cfm/sq ft at 1 in. of static pressure, and shall be
AMCA (Air Movement and Control Association International Inc.) licensed as a Class 1A damper.

To ensure the proper amount of ventilation or OA is provided to an AHU, many designers today add air ow
measuring stations either in the OA ductwork (see Photo 2) or at the entrance of the mixing plenum with a
combination damper and air ow measuring device. Again, AMCA is involved with ratings standards: AMCA 610 –
Laboratory Methods of Testing Air ow Measurement Stations for Performance Rating, and AMCA 611 – Product
Rating Manual for Air ow Measurement Stations.

Filters

Filters are typically placed in the section of an AHU ahead of other components, such as fans, coils, etc. as their
primary function is to lter out dirt and other contaminants and protect the AHU’s other components. Based upon
the application, lters may be arranged in one or more layers, or sets. The lters are placed within a lter holding
frame assembly or racking system that could be con gured as either at, or of an angular bank arrangement. The
lter frame is typically constructed from a heavy gauge galvanized steel with vertical stiffeners and appropriate
frame-to-frame sealant and/or gaskets to provide a rigid leak tight assembly. The lter frame is generally built to
accommodate standard size lters (e.g. 24×24-in. or 12×24-in.) with an appropriate type fastener to meet or exceed
the face area speci ed by the AHU schedule.

In applications with more than one set of lters, a preliminary or rough grade lter would be provided rst in the
direction of air ow. Intermediate and/or nal lters, where provided, will be of varying grades of ltration or e ciency
to assist in removing smaller and smaller contaminants. The function of each set of lters is to help extend the life
and improve the e ciency of the next set of lters. The rst set of lters are typically the cheapest to replace and
thus maintain, while succeeding sets are more expensive to replace.

Filters can be a variety of types and sizes, from throwaway 2-in.-thick type through reusable 36 in. deep type, based
upon the application for which they are needed in the AHU. Filters are rated by ASHRAE Standard 52.2 – 2012 test
methods and classi ed by minimum e ciency reporting value (MERV). Filter MERV ratings range from 1 to 20.
Nearly all AHUs will have a MERV 7 or 8 lter assembly that have dust spot e ciencies of 25% to 30% or 30% to 35%,
respectively. In addition to lter assemblies of standard AHU applications, a hospital inpatient care application would
also use a MERV 15 with greater than 95% e ciency while a cleanroom would use MERV 20 at greater than or equal
to 99.999%
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phase as well as electrostatic and ultraviolet for air treatment requirements.

Filters should also be Underwriters Laboratories Inc. (UL) classi ed. Classi cation for HVAC air lters con rms that
the lters will meet local and state requirements for most applications, and particularly in accordance with the

standards of the NFPA. A UL 900 classi ed lter is “an air lter which, when clean, will burn moderately when
attacked by ame, or emit moderate amounts of smoke, or both” as tested within the standard. UL 900 covers both
washable and throwaway lters, used for the removal of dust and other airborne particles from mechanically
circulated air in equipment and systems.

This mixing plenum and/or lter section of the AHU should have service access door(s) as well as differential
pressure devices across lter assemblies for indication when the lters are dirty. By monitoring the pressure drop
through the lters, as related to the air ow through the AHU, the lter life can be assessed and decisions can be
made regarding the appropriate time to change them. Dependent upon the existence of a BAS, this monitoring can
also be done by using a visual display from a simple magnehelic differential pressure gauge, or by a pressure switch
linked to an input (I/O) alarm point.

Figure 4: This schematic illustrates multiple options for component positions within an air handling unit (AHU) serving
a single zone or up to three multiple zones. Courtesy: Stanley Consultants Inc.

Refer to Figure 4, a typical AHU schematic which illustrates multiple options for component positions within an AHU.
The OA portion of the schematic is at (A) as it connects with the RA portion of the schematic at (B). This section is
the mixing plenum with the associated OA and RA dampers (OAD and RAD, respectively), and with the lters
represented a little further to the right. The amount of OA required to enter the mixing box is dictated by ASHRAE
Standard 62.1-2013: Ventilation for Acceptable Indoor Air Quality, while optimizing the energy use as dictated by
ASHRAE Standard 90.1. Figure 4 shows an air ow measuring station (AMS) that is sometimes provided to ensure
the amount of OA entering the AHU meets the ventilation requirements. Measuring the OA will allow a BAS to
modulate the OA damper and, in turn, the RA damper as needed to maintain the appropriate amount of ventilation air
at varying operating conditions.

An HVAC system’s AHU may contain other components necessary to perform a combination of the four basic
psychrometric processes of cooling, heating, dehumidi cation, and humidi cation. Psychrometrics is the study of
the thermodynamics of air and its moisture content (or air/vapor mixtures), and is used to analyze conditions and
processes which require control of moisture content and temperature. For any good project design, HVAC designers
must have a working knowledge of psychrometrics.

The result of performing a variety of these HVAC processes is the delivery of properly conditioned supply air to the
spaces it serves. For heating, these components could be steam or heating-hot water coils, direct or indirect gas
red heat exchangers, or even electric strip heat coils. For cooling, the components could be chilled water or direct
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expansion (DX) cooling coils, or direct and indirect evaporative
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components used such as energy recovery devices that could be employed to assist in the processes.

Referring again to Figure 4, there is both a heating and cooling coil in the center of the horizontal section. Dependent
upon the application, if this heating coil were located to the OA inlet ductwork near (A) it could be referred to as a pre-
heat coil; or, if moved downstream of the cooling coil closer to (C) referred to as a reheat coil.

Fans

Fans are very important components of an AHU as well. ASHRAE and AMCA are also involved in testing and rating
fans through both ANSI/AHSRAE Standard 51 and ANSI/AMCA 210 – Laboratory Methods of Testing Fans for
Certi ed Aerodynamic Performance Rating; and, AMCA 300 – Reverberant Room Method for Sound Testing of Fans.
All AHUs will have a supply air fan (SAF, or SF for short). Dependent upon the size and application, this supply fan
component can be composed of a single or double inlet centrifugal fan, one or more plenum or plug fans, or a vane
or mixed- ow, axial fan, etc. The AHU can also have a RA fan (RAF or RF) in some instances where needed. The 2016
ASHRAE Handbook – HVAC Systems and Equipment, Chapter 21, Fans, provides information on fans and helps in
understanding selection criteria.

The HVAC system’s AHU fans (SF, RF, exhaust fan or EF) considered should be based upon the desired design
operation point for the air ow required and at the static pressure of the system. Fan e ciencies, sound levels, and
redundancies are also considerations in fan selections.

Referring again to Figure 4 at point (C), the schematic illustrates a draw-through system con guration with the
supply fan where the airstream is drawn through both a heating and cooling coil, respectively. Many designers prefer
this arrangement for a better air distribution over the coils. If the supply fan was positioned back prior to the coils
and closer to the lters (shown dashed), this would be considered a blow-through system con guration. This gure
also indicates how a return fan might be con gured into the HVAC system. A return fan may be needed to assist in
overcoming static pressures to get the RA back to the AHU; or, typically because of air-side economizer applications
and/or building pressurization controls may require a return fan and/or an exhaust fan application.

Coils

Most coils found in AHUs are used to provide sensible heating or sensible and latent cooling, and/or in conjunction
with humidi cation and dehumidi cation. Coils are primarily constructed of tubes, typically of copper, with copper or
aluminum ns pressed or extruded on the external surface of the tubes for several heat transfer processes. The
tubes may be staggered or installed in line with respect to the air ow, and can come in various styles to enhance
performance. They are typically interconnected by return tube bends to form several different serpentine
arrangements which create multi-pass circuiting options for the tube circuits. Chilled water and refrigerants for
cooling, and hot water, steam and even refrigerants (e.g, hot gas reheat, variable refrigerant ow systems) for
heating, are typically used for various psychrometric applications, respectively. The 2016 ASHRAE Handbook – HVAC
Systems and Equipment, Chapters 23 and 27 provide more information on coils.

Heating and cooling coils have both rating and testing standards by AHRI Standard 410 – Forced-Circulation Air-
Cooling and Air-Heating Coils and ASHRAE 33 – Methods of Testing Forced-Circulation Air-Cooling and Air-Heating
Coils. Coils are typically selected using coil programs, with the performance dictated by the system designer and
provided by a manufacturer’s representative that is providing the various options included in the AHU.

There are several basic things to know about coils. For cooling coils, they are built to be piped in a counter- ow
arrangement; or, the air ows in the opposite direction as the chilled water (CHW), and/or the refrigerant in DX coils.
For a 4-row coil, the air would pass through rows 1-4 at the same time the CHW or refrigerant is owing through
rows 4-1. The coil programs default to this con guration. A designer can select a coil that is not counter- ow, but the
coil’s performance will be reduced, based on its size, by anywhere from 8% to 12%. In particular, the dehumidi cation
capabilities for the coil are signi cantly reduced.

Secondly, all water coils should be fed from a bottom connection so once the header piping is full, and the air is bled
out of the system, every tube in the coil will be fed evenly with water. Feeding the coil header from the top will
typically cause some level of short circuiting with higher water ow in the tubes at the top in the coil.

In heating coils, circuiting the coil is not as critical except to ensure the piping connections are on the side you want.
However, steam coils need to be piped at the top connection so that all the condensate will be able to leave from the
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cool. In colder climates, another problem when condensate builds up in the coil and steam is unable to move through
the top portion of the tubes, the coil could freeze and break.

Designers should pay close attention to the location of the fan in relation to the AHU coils. Fan heat is always added
to the airstream. If the fan is located after the air has crossed the cooling coil, this fan heat must be considered when
calculating the desired leaving supply air temperature. Because any AHU fan will convert its input energy to move the
air through the unit and into an HVAC system, the air temperature will rise slightly. Designers need to understand that
this is an additional load for the building load calculations (cooling as well as heating) for which it must be
accounted.

The ASHRAE Handbook-Fundamentals provides a general estimates of fan heat as approximately 0.5°F per inch of
total fan pressure. However, using the basic formulas for fan horsepower (hp), and the psychrometric sensible heat
(Qs) equation, it is recommended that the designer calculate the temperature rise across the fan to be more
accurate.

As an example, assume an AHU supplies 100,000 cfm using a 125 hp SF, the fan heat is calculated as:

125 hp = (0.746 kW/hp) x 3,413 Btu/h/kW = 318,262 Btu/h.

Using the sensible heat equation below, the airstream temperature rise can be determined as:

Qs (Btu/h) = 1.085 x cfm x (T1 – T2)

(T1 – T2) = 318,262 Btu/h / (1.085 x 100,000)

(T1 – T2) = 2.9°F for a temperature rise

Note that with a draw-through fan arrangement, this example shows that the fan leaving air temperature will be
higher than the cooling coil leaving air temperature by almost 3°F.

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Author Bio: Randy Schrecengost is the Stanley Consultants Austin mechanical department manager and is a
principal mechanical engineer. He is a member of the Consulting-Specifying Engineer editorial advisory board.

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