HVAC System Design in New Jersey (NJ)

Leaders in HVAC System Design

Lightning Mechanical has been providing HVAC System Design services to the New York Tri-State area since 2005. Our deep experience working on commercial HVAC projects ensures that we provide well-designed systems no matter the scope of the work.

We have partnered with dozens of companies in our area to improve existing or design new HVAC systems. Our dedication to this work means a technically sound HVAC system design strategy and one that is economically feasible for the client.

HVAC System Design
HVAC System Design

Lightning Mechanical is proud of our ability to provide creative solutions so clients can have their "ideal" system even if it's not the most convenient option available.

The result is an HVAC System design that works. When it comes to your facility, you can rely on our experience and dedication to excellence to provide the best possible outcome for your company's needs.

Design Factors

When we start work on designing your custom climate control solution, we need to consider a range of factors to provide the best possible solution. Every HVAC system relies on different cooling and heating equipment to achieve total air control. Your requirements dictate how we evaluate each parameter and our recommended choice of solution. 

When we start to discuss your heating and cooling needs, we'll talk about:

The dimensions of the unit will determine how much air it can move. We'll consider the physical space in your building, availability of floor real estate for placement, and room needed for service and maintenance. High-performance units need to be regularly checked on, and ensuring ease of access for maintenance teams is essential to long-term effectiveness.
Capacity is how much heat or cooling energy the unit can provide to maintain proper conditions throughout your facility. It depends on the type of equipment used, the number of internal components, and the property's size. Large open spaces usually require higher capacity units than multiple smaller rooms.
Heat Exchangers

The type of heat exchanger used is determined by the volume, temperature, and flow requirement of air as it moves throughout a space. In large open spaces where different zones can have different refrigeration demands, multiple heat exchangers will perform differently depending on their orientation.

In order to save space and energy moving forward, we'll make sure your system uses the best type of exchanger for all spaces within a building.

A discussion on the number of stages and types of filtration needed to keep your facility's air clean is required. We'll consider the amount of dust, dirt, microorganisms, allergens, odors, smoke, or other pollutants in your building. We work closely with customers in the medical and pharmaceutical manufacturing industries to meet the stringent air quality requirements they need to operate within.

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Internal Configuration

Capacity is how much heat or cooling energy the unit can provide to maintain proper conditions throughout your facility. It depends on the type of equipment used, the number of internal components, and the property's size. Large open spaces usually require higher capacity units than multiple smaller rooms.

The internal configuration determines how we position system components to transfer heat and energy and how that energy is moved throughout the space. Every type of climate control system has its way of maintaining the refrigeration cycle.

Though the basic principles of the cooling process remain the same, heat pump placement and air handling unit configuration are informed by the particularities of each site. We take into consideration state and federal building codes.

Our Design Engineers make sure to utilize any existing ductwork or refrigerant lines when designing HVAC systems intending to replace aging or obsolete heating and cooling solutions.

External Configuration

External Configuration refers to various HVAC components on the exterior of a building such as heat exchangers like cooling towers. The way air moves into, through, and out of a system can influence how effectively it controls the environment within your facility.

Local Weather conditions will have to be assessed when designing a system that needs to draw air in. The location of the building and its proximity to any natural barriers like woodland, mountains, and even other buildings will determine what kind of cooling tower system is best.

Mechanical and Electrical Features

Mechanical features refer to internal components and how they interact with one another. We assess both heat transfer mechanisms and noise-reduction systems when evaluating this aspect of your system.

Electrical features refer to automatic controls and the actual system architecture.

Energy Efficiency

The amount of energy your air conditioning needs to function is one of our primary focus areas when designing a new system. The best possible design for you will provide the perfect combination of mechanical efficiency and occupant comfort. To keep your costs down, we'll make sure your new HVAC System design is as efficient as it can be. Our designs aim to integrate as much smart cooling system control as possible.

Newer HVAC systems feature sophisticated logic controllers capable of precise, second to second cooling load calculation, heat exchanger optimization, direct expansion control, and chilled water store management, leading to greatly reduced overall energy consumption.

HVAC System Design

Our Design Strategies

Total System Architecture

The number of zones, components, and layout of a complete HVAC system will determine how many devices can be controlled by one another. For example, a larger configuration that serves multiple areas with different needs will need to have separate air handlers capable of independent operation.

Lightning Mechanical engineers use a top to bottom approach when designing such complex systems. We look at the whole and work our way down to the specifics. Where other air conditioning system contractors might design a suite of solutions for different needs within a facility, we are able to plan systems that are more energy-efficient and grant you more control.

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VRV / VRF Variable
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HVAC Sheet Metal
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Who (Manufacturers)
Who (Manufacturers)
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VRV Design
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Full Piping Services
Full Piping Services
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HVAC System Design
Control Wiring Services
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Future-Proof Heating and Cooling Solutions

Our design strategies take into account the prospective use of a new system and will recommend a relevant upgrade or update paths before the system is even installed. We can achieve this because of our close relationships with our supported manufacturers. Not only are we up to date on their latest equipment, but we are also kept abreast of future product development and air conditioning system modular update plans.

Design philosophy

Like all good things, our design philosophy comes in three's; all our designs are:

  • By the Book
  • Modular
  • Energy Efficient

By the book:

All design decisions we make are informed by Manual J, Manual D, and Manual S. These manuals outline industry best practices for the design and installation of HVAC equipment in residential settings.

  • Manual J outlines the protocols for Residential load calculation.
  • Manual D covers residential duct design (sizing and installation)
  • Manual S is a methodology for selecting the right residential heating system and air conditioners to match Manual J load calculations. Manual S guidelines are a requirement under the 2009 International Residential Code (IRC).


We'll offer you choices that are compatible with one another and easy to upgrade later on.

Lightning Mechanical's HVAC system design service will customize a comprehensive solution for your needs. We go beyond the basics to fully cover all aspects of heating, cooling, filtration, and ventilation in order to provide future-proof solutions without sacrificing system performance today.

This way, our customers can rest assured that their comfort and productivity levels will always be prioritized, no matter the weather conditions or the number of people on-site.

This added benefit has made us a favorite among commercial building owners and hospital managers. We have successfully designed and integrated numerous indoor cooling systems for variable foot traffic zones that, at the same time, provide indoor air quality management.

Energy Efficient:

Whether you need domestic hot water, forced air heating, air cleaning, or specialized commercial cooling equipment, our HVAC design process remains the same. By properly optimizing cooling loads and taking into account the relevant ventilation rate procedure, we can ensure high-performance air conditioning systems don't use any more power than they need to reduce energy costs for most buildings effectively.

HVAC System Design

Do you need HVAC design?

Lightning Mechanical's design services are available for any business or air conditioning contractors across North America who need a comprehensive approach to their HVAC system design.

We take into account the size and function of any space that needs heating or cooling, and we apply our three-pronged design philosophy in order to achieve optimal performance without sacrificing efficiency.

Contact us here and let us know if you need a simple load calculation, equipment selection, ventilation design, or a total air conditioning system conceived from the ground up.

We look forward to helping you achieve the most efficient and cost-effective solution for your needs.


Contact Us

65 Newark Way, Maplewood, NJ 07040, US
Monday - Friday: 8am - 6pm
24 Hour on call emergency service available