Air Mixing Handbook

How to Identify and Eliminate Air Stratification Problems

with Properly Designed HVAC Mixing Systems

Published by Blender Products, Inc.

Table of Contents
Section Page
1. Introduction ..............................................................2
The Company ............................................................2
Why this Manual Was Written...................................2
2. Glossary of Basic Terminology ................................3
3. Discussion of Stratification and Mixing..................4
How Stratification Develops .....................................4
How to Define Mixing Effectiveness ........................4
4. Thermal-Stratification Problems and Solutions .....5
Nuisance Freeze-Stat Trips........................................5
Poor Mixed-Air Control ............................................5
Wasted Energy Due to Sensor Error..........................5
Averaging-Bulb Inaccuracy.......................................5
Poor Economizer Control ..........................................7
Excessive Reheat Coil Use........................................7
Stratification Downstream of Face-and-Bypass
Sections .................................................................7
Ineffective Refrigeration-Coil Control ......................8
Stratified Steam-Coil Discharge................................8
Uneven Heating with Direct-Fired Burners ..............8
Uneven Moisture Absorption Across Humidifiers ....8
Improper Filter Loading ............................................8
5. Water-Coil Freeze-Up Problems and Solutions ......9
Glycol Solutions ........................................................9
Unit Heaters in Mixed-Air Plenum ...........................9
Heat Recovery ...........................................................9
Draining Water Coils ...............................................10
Pumping Fluid at Subfreezing Outside
Air Temperatures.................................................10
Static Mixing Devices .............................................10
Section Page
6. Indoor Air Quality (IAQ) Concerns.......................11
Outside Air Dampers Blocked Shut to Eliminate
Stratification Problems ........................................11
Dilution of Fresh Ventilation Air Into the
Supply-Air Stream...............................................11
Maintaining Minimum Ventilation Air Under
VAV Conditions...................................................11
7. Application Guidelines for Static Mixing
Devices ....................................................................12
How Much Mixing is Enough? ...............................12
VAV Concerns .........................................................12
Proper Placement of Mixers in HVAC Systems.....12
Effect of a Combination Filter/Mixing Box on
Mixing Performance............................................14
8. Velocity-Stratification Problems.............................15
Coil Condensate Carryover .....................................15
Coil Inefficiency ......................................................15
Filter Loading, Damage, and Particle Bypass .........15
9. Application Guidelines for Velocity-Equalizing
Diffusers..................................................................16
Distance Requirements............................................16
System-Effect Considerations .................................16
Bibliography.................................................................17
1
1 Introduction
The Company
Since 1962, Blender Products, Inc. (formerly known
as RM Products) has pioneered stratification
abatement developments in air-handler mixing
plenums and has been an innovator in the design of
static mixers.
Over the years, the applications personnel at Blender
Products have developed mixing systems for
thousands of applications in HVAC systems and
industrial process systems. As a result, they have
accumulated a large storehouse of knowledge and
valuable expertise in the disciplines of stratification
and static mixing.
2
Why This Manual Was Written
During its history, Blender Products has published a
great deal of material dealing with stratification and
mixing in HVAC systems. This material has appeared
primarily in technical bulletins, catalogs and articles.
To date, very little about stratification in the HVAC
environment has appeared in textbooks or journals.
Now, due to increased interest in adding ventilation
air to combat IAQ problems, there is an increasing
need to solve the associated stratification problems.
To help meet this demand, Blender Products has
compiled a significant body of technical information
and outside source articles into a single manual. This
manual will prove to be an invaluable resource in the
design and troubleshooting of stratification systems.
Although this reference is a relatively complete text
in itself, a comprehensive study of stratification
would, of necessity, include an investigation of the
references listed in the bibliography.
2 Glossary of Basic Terminology
Average Temperature (tavg): The average of the
downstream temperatures. It is found using the
following equation:
n Where:
tavg = 1n • ∑ ti n = number of temperature readings
ti = Individual temperature readings
i=1
Blow Through System: Usually refers to a system
where the filter or coil is installed downstream of the
supply fan. Therefore the fan is “blowing” through
the coil or filter.
Combination Mixing/Filter Box: A factory-made
section that includes filters within the mixing box.
Economizer System: An air-side economizer system
uses the outside air for “free” cooling during times
when the outside air conditions permit.
Freeze Stat: A low-limit thermostat used to protect
hydronic coils from freezing by activating freeze
protection sequences, such as air-handler shut down,
in the air-handler control system.
Inlet Temperature Difference (dT): The difference
in the temperatures between the two incoming air
streams. It is found using the following equation:
dT = tHot – tCold Where:
tHot = Temperature of hot air
tCold = Temperature of cold air
Mass Flow Rate (m): The mass flow rate of an air
stream. It is found using the following equation:
m = ρ•A•v Where:
ρ = Air density (lbs/ft3)
A = Area of duct (ft2)
v = Velocity of air stream (ft/min)
Mixing Box: A factory-made section that includes
control dampers and may include one or more static
air mixers.
Mixing Effectiveness: A means of quantifying
mixing in terms of “Range” or “Standard Deviation”
reduction across a static mixing device or other
mixing system (see section 3).
Mixing Section: A factory-made enclosure, which
includes one or more static air mixers, that is designed
to be mounted between sections of an air handling unit
and is supplied separately from the mixing box.
Mixing System: The entire mixing system consisting
of the mixing/control dampers and any other mixing
devices such as air mixers.
Modified Range Mixing Effectiveness (ERdT): The
absolute amount, expressed as a percentage, that a
mixing box or static air mixer reduces the temperature
spread entering the mixing device. It is typically used
in determining the freeze protection afforded by a
mixing system. See Section 3, page 4.
Range: The maximum temperature less the minimum
temperature for a set of readings.
Range = (Tmax – Tmin)
Standard Deviation: A statistical calculation applied
to a set of data. In essence it is an average variation
from the average data point. For thermal mixing
analysis the expression is as follows:
n
[ ]
.5 Where:
∑(
1
SD =
n–1
Ti - Tm ) 2
n = Number of samples
Tm = Average temperature
i=1
Ti = Temperature measurement
SD = Standard deviation
Static mixing device: A mixing device fixed in
position generally consisting of baffles and blades
arranged to induce mixing to a flow of water or air.
Temperature Averaging Bulb: A control sensor
designed to read the average temperature across a
plenum by using a capillary tube or a special
averaging wire approximately 15 to 25 feet long.
Theoretical Mixed Air Temperature: The mixed air
temperature based on a calculation of the combined
mass flow of two air streams. The theoretical mixed
air temperature is found using the following equation:
mhot • Thot + mcold • Tcold
Tmix =
mhot + mcold
Where:
mhot = Hot air mass flow (lbs/min)
mcold = Cold air mass flow
Thot = Hot air temperature (degrees F)
Tcold = Cold air temperature
3
3 Discussion Of Stratification And Mixing
How Stratification Develops
Stratification is normally thought of in terms of
vertical temperature gradients. However, stratification
within an air handler is different. Momentum in the
entering air streams as well as the combined flow
serves to hold the uneven profile of temperatures or
constituents as they are introduced into the combined
flow (see Figure 5, page 8).
One typical misconception about mixing box design
is the idea that cold air introduced high will drop due
to density difference and mix with the warmer air
actual, or theoretical, mixed-air temperature in the
mixed-air plenum. The latter is important to the proper
functioning of mixed-air thermostats and controls.
To simply state that a mixing system should provide
a set range of temperatures for all entering air-stream
conditions fails to recognize the variables mentioned
above. This manual recommends using the “Mixing
Effectiveness” method of rating static mixing systems.
This method takes the entering temperature
differential into account when rating a particular
mixing system. The equation is as follows:

below. In reality, the momentum of the main air
stream is typically so much greater than the force due
to the density difference that the cold air introduced
on top is simply carried downstream before it has
time to drop. In short, any potential mixing action
due to buoyancy forces are far less than the
momentum of the stratified air stream.
The primary conditions which produce stratification
in an air handler are as follows:
■ The mixing-box layout and damper size, relative
to the total plenum, greatly affect the degree of
stratification for a given mixing system.
( )
RangeDS Where:
ERdT = 1– ERdT = Mixing effectiveness based on
dT range
RangeDS = Maximum temperature
difference at testing grid (°F,°C)
dT = Temperature difference between
return and outside air streams (°F,°C)
Furthermore, it is important to state the mixing
effectiveness required in relation to various outside
air ratios and temperatures. An example of the
characteristic curve of required mixing effectiveness
as a function of percent outside air for various mixed
air temperatures is shown in Figure 1.
1.00

■ As the opposing air streams approach a 50/50 0.95

0.90
proportion, the mixing becomes more difficult.
0.85
Required Mixing Effectiveness (ERdT)

■ Most importantly, as the temperature differential

0.80
0°
F
between the two streams increases, the range of 0.75 5°
F
°F
10
downstream air temperatures widens. 0.70 °F
TM

15
ix

0.65 °F
=4

20
5°

Stratification is relatively easy to develop, however

F

0.60
°F
mixing two air streams together is neither automatic 0.55 25
50
°F

0.50
nor easy. Without some form of agitation or mixing
55

0.45
°F

a stratified air stream can continue many duct 30

°F
60°

0.40
diameters downstream.
F

0.35
0.30

How to Define Mixing Effectiveness 0.25

0.20 35°F
T OA=
In the absence of independently established standards 0.15
0.10
that define how effectively a mixing system is 0.05
performing, many “rule-of-thumb” standards have 0.00
been used. At a minimum, the HVAC mixing system 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75

should mix two air temperatures sufficiently to Percent Outside Air (By Mass)
eliminate freeze-stat trips and frozen coils, thus at Note: Chart based on the following conditions:
least ensuring continued operation of the air handler. TRA = 75°F, TFZ = 37°F TOA = Outside air temperature

A more stringent performance standard defines how Figure 1 – Required mixing effectiveness vs. percent outside
close the mixed-air temperature range approaches the air for various temperatures to eliminate freeze-stat trips
when freeze-stat is set at TFZ = 37°F.

4
4 Thermal-Stratification Problems and
Solutions
Nuisance Freeze-Stat Trips
The low-level thermostat, also called a freeze stat,
is designed with a long element that will trip if any
portion of the element is exposed to a temperature
below the set point. The set point is typically between
35 and 38 degrees F. Although the coil protection
provided by a low-limit thermostat is often beneficial,
the continuous trip out and resulting air-handler shut
down can be a headache for the building facilities
people.
Whenever a “nuisance” trip of the freeze-stat occurs
the building facilities staff gets the job of modifying
the system to eliminate the pesky problem. Often, in
an attempt to solve the problem, the outside air
dampers are wired shut or otherwise disabled to
eliminate cold, outside air altogether. Obviously, this
so-called solution will not allow the proper amount of
ventilation air into the building. Major problems with
the indoor air quality will result (see section 6). The
other common method of eliminating the problem is
to disable or move the freeze-stat. This “solution”
can, of course, meet with catastrophic results should
a freezing condition occur.
Poor Mixed-Air Control
In the past, HVAC mixing applications did not
demand strict performance requirements. As long as
the air-handling unit did not shut down, or a water coil
did not freeze due to stratification, the mixing was
assumed to be satisfactory. However, with the advent
of DDC and as control systems become more precise,
the problems of an improper sensor read become more
pronounced. The root cause of sensor error can often
be traced to a stratification problem in the mixed air
plenum1. The following sections address some of the
problems created by temperature stratification in the
control system of a typical HVAC installation.
1
Coggan, Donald, P.E., “Mixed Air Control with DDC,” Heating/Piping/Air Conditioning, May 1986.
2
Kato, James Y. “Sensor Errors,” AHSRAE Journal, Volume 27, No. 1, American Socity of Heating, Refrigeration and Air Conditioning
Engineers, Inc., Atlanta, Georgia – January, 1985.
3
ASHRAE Fundamentals Handbook, 1985 – Chapter 13, “Measurements and Instruments,” American Society of Heating, Refrigeration and
Air Conditioning Engineers, Inc., Atlanta, Georgia – 1985.
Wasted Energy Due to Sensor Error
Substantial energy is wasted by undetected errors
originating at the mixed-air temperature sensor.
The most common cause for error is temperature
stratification within the mixing plenum2. This
potential error has been accentuated by the use of
single-point electronic temperature sensors in large
mixing plenums. It is very difficult to place a single
temperature sensor in a position where it will read
the average temperature of the ever-changing
temperature profile downstream of mixing dampers.
Another source of error is a thermostat that is out
of calibration.
Averaging-Bulb Inaccuracy
A common solution to the stratification problem
has been to place an averaging style temperature
sensor on the face of the filter or coil downstream
of the mixing plenum. This solution has some merit,
provided the sensor capillary or wire is properly
mounted so that it will record a representative
sampling of temperatures. However, taking only
the temperature value at a series of points ignores
the effect of varying velocity or mass flow across
the sample area. In the ASHRAE Fundamentals
Handbook, Chapter 13, titled Measurements and
Instruments3, the Sampling and Averaging section
warns against assuming that a sampling of
temperatures accurately represents the average
temperature at a cross-section of a flowing stream.
The Section goes on to suggest that a weighted
mass-flow average be taken across the stream to
determine the true temperature of the air stream.
In an effort to show the potential error for an
averaging-bulb sensor applied to a mixing box
with a non-uniform velocity profile, a study was
performed at Blender Products. A 25-foot capillary-
5
tube averaging-bulb sensor was mounted to a test
grid as shown on the test setup drawing. Individual
temperature and velocity readings were taken at 25
Averaging-Bulb Test Results
points across the grid, providing data to calculate the Temperature and Velocity Traverse Without Air Blender Units
weighted mass average using the following equation4:
F° 90.8 103.5 109.2 100.1 87.1 77.2
Equation 1a Equation 1b FPM 125 50 50 38 50 162
Mass Flow Based Simplified Velocity Based F° 86.7 104.0 105 90.4 86.5 78.4
n n

Tmix = ∑
FPM 125 150 200 125 250 500
1
Tmix = m ∑ miTi i=1
TiVi
n F° 79.4 84.9 86.1 82.2 77.3 75.4
∑
t
i=1 Vi FPM 650 600 475 675 625 925
Where: Where: i=1 F° 69.3 71.1 71.2 73.2 72.7 69.4
Tmix = Mixed air temperature Tmix = Mixed air temperature FPM 900 1000 975 1200 1050 1075
mt = Total mass flow (lbs/min) Ti = Individual temperature
mi = Mass flow in partial areas Vi = Individual velocity Total Flow = 12,500 CFM Tavg = 84.6°F
Ti = Individual temperature sample in equal areas THot = 133°F Tmix = 76.9°F
n = Number of readings TCold = 68°F Error = Tavg - Tmix = 7.7°F
DT=(TH-TC) = 65°F
The first test was run for a standard mixing box.
A second test was run with a static mixer installed as
Temperature and Velocity Traverse With Air Blender Units
shown in Figure 2. The results are shown in Table I.
F° 90.7 89.8 81.5 83.3 91.3 91.1
Return Air Dampers FPM 475 525 500 650 575 525
F° 91.7 92.9 84.3 80.6 95.0 89.2
36" FPM 450 375 525 575 400 450
F° 102.7 93.2 84.7 81.8 88.1 89.5
Outside Air FPM 500 300 500 525 300 300
Dampers
F° 83.6 83.3 75.6 75.4 79.3 75.2
FPM 425 400 350 325 350 425

Total Flow = 12,500 CFM Tavg = 86.6°F

Test THot = 139°F Tmix = 86.5°F
Sensor
Grid TCold = 68°F Error = Tavg - Tmix = 0.1°F
® DT=(TH-TC) = 71°F
Patented Air Blender
Figure 2 – Test setup to determine error in an averaging- Tavg = Arithmetic average temperature based on multipoint
bulb sensor. or averaging bulb sensor.
In these tests, the averaging bulb was placed in Tmix = Velocity weighted mixed air temperature based on
12 different paths. From Table II (see page 7), it equations 1a and 1b as shown above.
can be seen that some paths were more accurate
than others. Overall, the error was greatest when Table I – Averaging-bulb test results.
the velocity profile across the bulb was non-uniform.
The study clearly demonstrated that non-uniform
velocity across an averaging bulb will cause the
mixed-air sensor to falsely represent the mixed-air
temperature. In short, an averaging bulb can only
sense the temperature. It cannot sense the mass flow
across a section. Therefore, it is important to mix
the air-stream temperatures and diffuse the velocity
evenly across an averaging bulb to provide the most
accurate temperature reading.
4
ASHRAE Standard, 41.1-1986 “Standard Method for Temperature Measurement,” American Society of Heating, Refrigeration and
Air Conditioning Engineers, Inc., Atlanta, Georgia – 1987.

6
 to squeeze as much free cooling from the outside air
1
by using only cool air and exhausting all the return air.
Path No Mixer 2 With Static Mixer2 For instance if the return-air damper leaks 12% into
Tavg Tmix Error Tavg Tmix Error the mixing plenum, the mixed air will be 55 degrees F
1 88.10 76.90 11.20 85.50 86.50 -1.00
when the outside air is only 51 degrees F. This
effectively shuts down the economizer cycle at 51
2 82.40 76.90 5.50 88.00 86.50 1.50
degrees, or 4 degrees higher than necessary. In a city
3 90.10 76.90 13.20 84.30 86.50 -2.20
like Omaha, this premature shut-down results in a loss
4 87.30 76.90 10.40 87.80 86.50 1.30
of 580 hours of potential free cooling. It also causes
5 87.30 76.90 10.40 83.50 86.50 -3.00
earlier start-up of mechanical cooling equipment.
6 80.20 76.90 3.30 85.80 86.50 -0.70
7 91.80 76.90 14.90 89.90 86.50 3.40 In order to keep economizers operating at maximum
8 80.90 76.90 4.00 90.00 86.50 3.50 efficiency, mixing systems must have tight seals on
9 88.40 76.90 11.50 88.90 86.50 2.40 both outside- and return-air dampers to insure positive
10 84.30 76.90 7.40 90.90 86.50 4.40
shut-off of either air stream.
11 87.80 76.90 10.90 89.40 86.50 2.90
12 82.70 76.90 5.80 84.10 86.50 -2.40 Excessive Reheat Coil Use
Average Error 9.04 0.84 Reheat coils are routinely used to heat the air
downstream of the mixed-air plenum. Often these
1
The 12 paths used are representative of paths used in a coils are controlled by an outside-air sensor and
typical system.
will run continuously at subfreezing temperatures.
2
Error is determined by using this equation: Error=Tavg-Tmix Obviously, this wastes large amounts of energy.
Additionally, if the heating-coil valve cannot be
Table 2 – Error comparison with and without static mixer. turned down sufficiently, the cooling-coil valve may
open, or outside air may be introduced, wasting
additional energy.
Poor Economizer Control
Generally, an air-side economizer offers free cooling Stratification Downstream of
when outside air temperatures fall below 50 degrees F,
provided the dew-point temperature is low enough. Face-and-Bypass Sections
Most economizers operate well down to about Face-and-bypass sections provide a good way to
35 degrees F. However, as the outside air temperature control temperature and humidity in the air handling
approaches freezing, the freeze stat is likely to trip. system. However, control of the discharge temperature
When this happens, the economizer is often abandoned downstream of a face-and-bypass coil is difficult
in the interest of keeping the unit operational. In the when the bypass air is located at the top or bottom of
absence of free cooling, the mechanical cooling the coil. A means of mixing the two air streams should
system is often used. This not only wastes energy, it be incorporated to assure proper control of the damper
also robs the building of fresh air during sub-freezing modulation, as shown in Figure 3.
temperatures. A properly operating mixing system
extends the economizer operation time. Bypass

Economizer systems may also be abandoned for Air

ineffective operation as the outside air temperature Flow

approaches the mixed-air set point. The problem often

stems from a leaky return-air damper. Leaking return-
air dampers can allow up to 15% of the warmer return
air into the mixing plenum, thereby causing the
mixed-air temperature to rise 5 degrees F or more.
For an economizer to function properly, it is important
Coil
Figure 3 – Internal face-and-bypass with Air Blender static
mixer to mix bypass air with coil discharge air, or to diffuse
bypass air across a plenum.

7
Ineffective Refrigeration-Coil Control
A staggered DX refrigeration coil-array will often
create stratified temperatures downstream, making
it difficult for the discharge thermostat to sense the
average temperature. A high reading will cause the
compressor to operate excessively and can lead to a
coil condensate freeze-up. A cold reading will result
in unnecessarily high supply-air temperatures and
resulting loss of the cooling load. Furthermore, the
resulting stratified air streams will often persist into
and through a tee fitting downstream resulting in
cooler air flowing down one duct and warmer air
flowing down the other duct. This condition creates
significant control and comfort problems.
Stratified Steam-Coil Discharge
Steam coils often result in a 20 to 50 degrees F
stratification. This stratified state creates problems
when a single downstream sensor is used to control
the coil valve. Control hunting is the usual result. The
addition of a static mixing device downstream has
proven effective in providing more precise steam-coil
control. In addition, it results in more homogenous
temperatures across processes downstream.
Uneven Heating with Direct-Fired
Burners
The temperatures downstream of a direct-fired burner,
which combines hot combustion gases with the air to
be heated (Figure 4), are highly stratified. The air
stream requires some form of mixing to ensure homo-
geneous temperatures at the controlling temperature
sensor, as well as for any process downstream. Static
mixers are ideal choices for these applications. They
have been used with much success on many projects.
Flame
Air
Flow
Figure 4 – Direct-fired burner with Air Blender device to
mix air with products of combustion.
8
Uneven Moisture Absorption Across
Humidifiers
Temperature stratification can create problems with all
plenum-mounted humidification systems. Normally,
the cooler the air stream the longer the vapor travel
downstream as shown in Figure 5. This condition
may cause problems such as air-filter saturation or
condensation on turning vanes or duct walls. The
best solution is to insure that the temperature of the
air stream is homogeneous and sufficient to absorb
the moisture.
Hot TRA
TOA Cold
Extended Vapor Travel in
Cold Area of Plenum
Figure 5 – Extended vapor travel in a stratified plenum.
Improper Filter Loading
A potential problem with stratified air streams in the
mixing plenum is uneven filter loading. This occurs
when one air stream has a greater particulate
concentration than another. An example would be
a street-level outside air intake that would introduce
larger amounts of particulate than the indoor air
stream. If the outside air stream is not adequately
mixed with the return air stream, the filter will have
a higher concentration of outside air particulate in
one localized area. This uneven loading may cause
excessive velocities across the balance of the filter
face, which will result in inconsistent velocity across
the downstream coil. To insure proper filter loading,
some form of mixing device should be used ahead of
the filter.
5 Water-Coil
Solutions
Freeze-Up Problems and

The most troublesome problem arising from heat exchangers in the system. Figure 6 shows coil
stratification is hydronic-coil freeze-up. If the air derating as ethylene glycol concentration is increased.
handler is running and the mixing-damper-control
sequence is operational when the coil freezes, the Unit Heaters in Mixed-Air Plenum
freeze-up is most likely due to thermal stratification.
In addition to a functioning low-limit freeze stat, Unit heaters are sometimes placed in mixing plenums,
there are a number of ways to protect coils from as shown in Figure 7, in an attempt to maintain a
freezing. This section will explore the various options minimum mixed-air temperature and thus protect
to provide coil-freeze-up protection. against coil freeze up or freeze-stat trips. Although a
unit heater may be a reasonable way to heat the mixed
Glycol Solutions air plenum during air-handler shut down, it is largely
ineffective when the air handler is operational. The
Mixtures of ethylene or propylene glycol with water primary reason for this failure is inherent in the unit-
are often used to protect hydronic coils during heater design. They are designed to heat a relatively
subfreezing weather conditions. The advantage of static air space. However, a mixed-air plenum has air
glycol solutions is their ability to protect all flowing at 400 to 500 FPM. This leaves little time for
components under any situation. For example, if the the unit heater to turbulate the air stream. Furthermore,
any heat introduced into the air stream serves only to
Pressure Drop as % of Pressure Drop
at 0% Etylene Glycol Concentration

100
create more stratification downstream, thus creating
Capacity as % of Capacity at 0%
Ethylene Glycol Concentration

Capacity
90 150 problems for mixed-air sensors, freeze stats, and coils.
The only reasonable use for unit heaters in mixed-air
80 140 plenums is during air handler shut-down to protect
water coils from cold outside-air migration through
70 130 leaky outside-air dampers, as shown in Figure 8.
60 120

Pressure
50 110

40 100
0 10 20 30 40 50 60
Ethylene Glycol Concentration
in % by Weight
Figure 6 – Effects of various concentrations of ethylene
glycol.

power shuts down, and the outside air damper stays

open, the glycol mixture will protect the coil and
associated piping. However, there are a number of Figure 7 – Typical unit heater in plenum configuration,
disadvantages of using glycol as a freeze-protection without Air Blender unit.
additive. The higher viscosity requires increased
pump horsepower. In addition, the lower specific heat
constant inhibits heat transfer, which requires higher
Heat Recovery
water flow and/or larger heat-transfer surfaces. It is Heat-recovery systems can be beneficial in reducing
also important to point out that some provision for the problems of stratification by preheating the cold
volume expansion must be included to protect the outside air with warm exhaust air. These systems

9
 tend to be costly and outside-air temperatures to prevent water-coil
are often difficult to freezing. This sequence is effective as long as the
design into a pump is properly maintained and the control system
restricted mechanical is functioning. The primary downside is the use of
layout because the additional pump horsepower and run time.
exhaust-air streams
must be brought to a Static Mixing Devices
single point and in
close proximity to the Static mixing devices, such as the one shown in
outside air stream. Figure 9, provide excellent freeze protection for
The benefits of this hydronic coils by continuously mixing the cold
type of system are in outside air into the warm
their potential to return air whenever air
recover otherwise is flowing across the
Figure 8 – Large bank of device. A static mixer
outside air dampers could cause wasted energy.
is the only option that
outside air migration.
provides excellent freeze
Draining Water Coils protection without the
need for maintenance.
A widely used practice to guard against water-coil Figure 9 – Typical static Furthermore, the device
freezing, is to drain the water and isolate the coil mixing device. provides a high degree
during periods of subfreezing weather. This method is of flexibility during seasonal changeovers, when
obviously effective when all the required maintenance chilled water cooling may be needed. In addition to
is done in a “timely” manner. Potential problems occur freeze protection, the static mixer provides a solution
when warmer-than-normal temperatures occur in early to problems created by stratified temperatures in the
spring or late fall (when the cooling coil is drained) mixed-air plenum. These include mixed-air control-
and the building requires mechanical cooling. sensor error and uneven air distribution across filters
and coils.
Pumping Fluid at Subfreezing A summary of various coil-protection alternatives is
Outside Air Temperatures shown in Table III.
Control systems are often designed with a control
sequence to turn on the water pumps at subfreezing

Consideration

Maintenance Reliability Flexibility Protection

Protection Attention Operating For Freeze During During AHU
Alternative First Cost Required Cost Protection Changeover Shutdown

Add Glycol High High High Med High Yes

Unit Heaters High Med Med Low Low Yes
Heat Recovery High Low Med Med High No
Drain Coil Low High Low Med Low Yes
Pump Fluid Low High Med Med High Yes
Below 32°F
Static Mixing Med None Med High High No
Device

Table III – Summary of coil-protection alternatives.

10
6 Indoor Air Quality (IAQ) Concerns
IAQ has become one of the most heavily discussed
topics in the HVAC industry. This issue will affect
the HVAC industry, and the design of systems, for
years to come. The following section discuss how the
application of ASHRAE Standard 62-1989 creates
new challenges for HVAC designers and building
engineers relative to stratification in the mixing
plenum.
Outside Air Dampers Blocked Shut to
Eliminate Stratification Problems
Control malfunctions due to equipment failure or
improper maintenance procedures can cause IAQ
problems. As discussed earlier, a typical practice
involves disabling the outside air dampers, or blocking
the damper shut, to eliminate freeze-stat trips or
frozen-coil problems. One situation was documented
in which an outside-air intake was blocked shut by
a 2x4 to prevent the water coil from freezing in the
winter. However, the 2x4 was left in place for years,
preventing the controls from functioning5.
Return air
Air Blender static mixer insures that fresh air is
evenly distributed throughout supply airstream
Without a static mixing device there is concern that
outside ventilation air may stratify and favor one side
of a centrifugal fan or duct branch fitting. The end
result can be a greater percentage of outside air
delivery to one portion of the building at the expense
of the rest of the building. Obviously, the ventilation
system should be designed to properly diffuse the
ventilation air into the return air stream. Figure 10
shows such a design.
Maintaining Minimum Ventilation
Air Under VAV Conditions
ASHRAE Standard 62-1989 requires a minimum of
15-20 CFM of ventilation air per person. This
translates to about 15-20% fixed outside air based on
maximum airflow. If the 15% rate is used, and the
supply airflow turns down to 30%, the proportion of
fixed outside air increases to 50% of the total air
supply, as shown in Figure 11. This increased
percentage of sub-freezing outside air gives rise to
freeze-stat trip and potential frozen coils. To guard
against freeze problems the heating coil is often
activated as soon as the outside air drops below
freezing.
100%
Actual Outisde Air (OA) Flow

90%

.
Without Air Blender,

OA
80%
fresh air and return air

.
OA
in
can stratify through M

A.
70%
in
Percentage

nO
coils, fans and branch M
25

.
%

A
take-offs downstream 60%
Mi

nO
20

A.
Mi
15

50%

nO
Fresh outside air %
10

Mi
40% 5%
30%

20%

10% Turn Down

Percentage
0%
Figure 10 – Design to 100% 90% 80% 70% 60% 50% 40% 30% 20% 10%
effectively diffuse Full Flow
Varying Supply Air (SA) Flow
ventilation air into the Fresh air is evenly
distributed in supply air
return air stream. Figure 11 – Outside air percentage based on fixed outside
air with varying supply air.
Dilution of Fresh Ventilation Air Into
The Supply-Air Stream
One of the principal concerns in the IAQ discussion
is the ability to prove that adequate and proportional
ventilation air is delivered to each building occupant.
5
Roberson, Wayne K. “Troubleshooting IAQ Troublespots,” Engineered Systems, July/August 1993.

11
7 Application Guidelines For Static Mixing
Devices
How Much Mixing is Enough? VAV Concerns
Mixing performance levels are defined in various The mixing performance of the Air Blender static
ways. Blender Products has chosen the range-mixing- mixing device requires a minimum amount of airflow
effectiveness method as the most definitive way to to maintain adequate mixing action. Generally, if the
rate a mixer’s ability to mix. Generally effectiveness velocity through the Air Blender mixer is 400 FPM
can be grouped into three categories. Low-efficiency or above, the mixer will perform properly, as shown
mixing includes standard mixing boxes available in Figure 13. Therefore, if a 3 to 1 turndown is desired,
on typical air handlers. Medium-efficiency mixing the design velocity through the mixing device should
systems include some form of static mixing device be no less than 1200 FPM.
mounted after the mixing box. High-efficiency 90%
systems include a specially designed damper
80%
configuration in combination with a static mixing
device to provide the highest possible level of mixing Effectiveness
70%
performance. Figure 12, taken from the article “How
Much Mixing is Enough?”6 provides a way to 60%

determine the level of mixing required to prevent 50%

freeze-stat problems. It should be stressed that these
levels represent the minimum mixing required. It is 40%

also necessary to provide good mixing to ensure 30%

proper mixed-air control performance. 200 400 600 800 1000 1200 1400
Mixed Air Temperature: 55 F
Feet Per Minute (FPM) Velocity
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volume conditions.
Efficiency Mixing System Required
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Proper Placement of Mixers in HVAC
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Efficiency
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7

%
Systems
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There are a number of constraints on the proper
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AA placement of static mixers in an air-handling system.
0.45 The first is to ensure that each mixing unit is
Low Efficiency Mixing System Required
0.40 positioned so that a proportionate amount of each
0.35
stream is introduced into each mixer. It is also
0.30
important to provide the proper mixing distance
0.25

0.20
downstream so there is adequate time for the air
0.15 stream to turbulate after flowing through the mixing
0.10 blades. Normally the static mixing units are centered
-25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
in the plenum top to bottom and side to side. Figure
Outside Air Temperature (°F)
14 shows correct and incorrect placements of static
mixers.
Figure 12 – Mixing required to prevent freeze-stat
problems.

6
Robinson, Keith D., P.E., “How Much Air Mixing is Enough?” Heating/Piping/Air Conditioning, November 1995.

12
Sketch 1 – Correct Placement

A Turning
Vanes
Patented
Air Blender Air
Units Filter Handler

Air
Flow

Patented
Air Blender
Units

Side Elevation Front View

Sketch 2 – Incorrect Placement

RA RA
Air Air
Filter Handler Filter Handler

RA RA

OA Air Flow

Air Flow OA OA

Top View Top View

OA

• Use only in one single line.

• Each Air Blender device must see equal amounts of damper area and air flow.
• Inlet ducts can cause an unequal effect on air flow. Fresh air and return air dampers should be the same length. Use turning vanes,
as shown in (A), to equalize flow across Air Blender units when air enters from the side.
• Mixing dampers must open so that air streams face each other.
•. When a minimum outside damper is used it must be the full width of the return air damper and supply equal amounts of air to each
mixer. Note that a minimum air damper is available as an option on the BlenderBox™ mixing box.
• Blender Products tests, plus independent lab tests, show that multiple mixer configurations do perform when applied properly.
• When looking at available mixers, always question whether they have been tested under all standard operating and installation
conditions, including:
– Multiple mixer configurations,
– VAV Systems to 33% turn-down.
• Sketch 2 shows two misapplications of multiple Air Blender units.
• Parallel or opposed blade dampers with blade axles across the short dimensions of the damper opening will cause air flow to favor
the side of the mixing plenum and should not be used with multiple Air Blender applications. Blade axles should be oriented across
the long dimensions of the damper opening as shown in Sketch 1.

Figure 14 – Comparison of correct and incorrect configurations when using static mixers.

13
Effect of a Combination Filter/Mixing
Box on Mixing Performance
Filters are sometimes placed in mixing boxes to
save space in the air handler. Placing air filters in
this seemingly “unused” space causes a significant
Combination Filter/Mixing Box
Without Air Blender
Mixing Efficiency = 45%
Lowest Temperature
at Coil Face = 28°F
Standard Mixing Box with
Filter Section Downstream
No Air Blender
Mixing Efficiency = 55%
Lowest Temperature
at Coil Face = 32°F
Notes:
Lowest temperature at coil face is based on return air temperature = 75°F, outside air = 15°F, 55°F mixed air temperature.
Figure 15 – Comparisons of mixing effectiveness with various filter configurations.
14
reduction in mixing effectiveness, as shown in
Figure 15. The preferred method is to place the
static mixer before the filter section. This provides
better mixing and diffusion across the filter and the
coil downstream.
Standard Mixing Box with
Blender Section and Filter
Section Downstream
Mixing Efficiency = 80%
Lowest Temperature
at Coil Face = 45°F
BlenderBox Mixing Box with
Filter Section Downstream
Mixing Efficiency = 85%
Lowest Temperature
at Coil Face = 47°F
8 Velocity-Stratification Problems
This section defines the problems that occur with an
uneven velocity profile and suggests practical
remedies to rectify these problems.
Coil Condensate Carryover
When a coil begins to remove moisture from the air
stream, water is formed as droplets on the coil fins.
Normally the droplets fall to a condensate drain pan
at the bottom of the coil and are drained away.
However, if the velocity profile across the coil is
uneven some of the condensate will “spit off” and
miss the drain pan. This carryover causes problems
by wetting the downstream areas such as duct liner
and other equipment. Equalizing the velocity profile
is very important to ensure that the coil condensate
stays on the face of the coil and drains harmlessly
into the drain pan.
Coil Inefficiency
Non-homogeneous velocity through a coil also
degrades coil performance. Coils are generally tested
with even velocity across the face. However, when a
coil is applied in a system, the velocity across the coil
face is far from homogeneous. This is especially true
if the coil is applied in a blow-through configuration
down-stream of a fan discharge. The effect of this
velocity variation is difficult to quantify, but it is
obvious that performance will not be the same as that
shown by the test data.
Filter Loading, Damage and Particle
Bypass
Velocity variations across a bank of filters often
cause the filters to load unevenly or in some cases
to be damaged. This improper loading, coupled with
the high localized velocity, will often cause particle
bypass. Again, this condition occurs downstream of
a fan discharge.
15
9 Application Guidelines For Velocity-
Equalizing Diffusers
In blow-through applications, coils and/or filters
are located downstream of a fan discharge. These
components require relatively low velocities to
operate correctly. This typically requires a large
change in area downstream of a fan.
Figure 17 – No-outlet duct arrangement.
Distance Requirements
coil/filter, as shown in Figure 18. Like the no-outlet
To minimize the pressure loss of this expansion, it is duct arrangement, this configuration has a substantial
necessary to install a full-length outlet duct ahead of system-effect penalty. It can provide velocity diffusion,
the expansion, as shown in Figure 16. Although this but it is difficult to predict how well a system will
duct minimizes the pressure loss, its length can be work until after system startup. In general, the closer
quite large, especially with large fans. An additional a diffuser plate is to the fan discharge, the better the
drawback is that it provides no diffusion of the fan velocity profile. Unfortunately, as the diffuser plate
discharge jet. There is still a need for a diffusion is moved closer to the fan, the system-effect penalty
device or an extremely long diffusion distance increases rapidly.
between the fan outlet and downstream coil. A long
distance is needed because the discharge jet expands
at an angle of about 15°.

Figure 18 – Target plate, vertical diffuser plate and angled

diffuser plate configurations.

The use of the BlenderConeTM fan diffuser/mixer

Figure 16 – Full-length outlet duct, providing an ideal
installation for system effect.
System-Effect Considerations
The “No-outlet duct arrangement,” shown in Figure
17, may be used to save space. Like the full-length
outlet-duct arrangement, this configuration does not
provide additional diffusion of the air stream. Thus
the distance between the fan outlet and downstream
component must be sufficient for the jet to naturally
expand and fill the plenum. This arrangement has a
large system-effect penalty.
To enhance the diffusion of the no-outlet duct
arrangement, a diffuser plate or target plate can be
mounted between the fan outlet and the downstream
(Figure 19) provides an alternative approach. The
pressure drop of the BlenderCone is greater than the
pressure drop of the full outlet duct, but is less than
half the pressure drop of the other arrangements.
The distance required by the BlenderCone is less
than the distance required by the full-outlet duct and
is essentially the same as that required by the other
arrangements.
Figure 19 – Short BlenderCone, for retrofit applications in
tight spaces, and the more efficient long BlenderCone for
new construction.

16
 Application Guidelines For Velocity-
Equalizing Diffusers
Bibliography
Amoroso Jr., Victor, P.E. & Gjestvang, Ryan, P.E., “Air Handling Units for Hospitals,” Consulting/Specifying
Engineer, October 1989.
Faison Jr., T.K., Davis, J.C., & Achenbach, P.R., “Performance of Louvered Devices as Air Mixers,” Building
Science Series 27, US Dept. of Commerce, National Bureau of Standards, March 1970.
Haines, Roger W., “HVAC Systems Design Handbook,” Section 4.8 (pp 109-111) TAB Books, 1988.
Haines, Roger W., “Stratification,” Heating/Piping/Air Conditioning, November 1980.
Hallstrom, Arthur D., “Fixing the Frozen Coil Problem,” Contracting Business, October 1986.
Robinson, Keith D., P.E., “Blender Cone Basics,” Blender Products, Inc., December 1992.
Robinson, Keith D., P.E., “Fan Basics,” Blender Products, Inc., December 1992.
5010 Cook Street, Denver, CO 80216
Toll-Free: 800-523-5705
Fax: 303-296-1520
Phone: 303-295-6111