AIRXCHANGE ERC-19 Series Manual

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OPERATION & MAINTENANCE
MANUAL
AIRXCHANGE ENERGY RECOVERY WHEELS
SERIES ERC-19 THROUGH ERC-125

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TABLE OF CONTENTS
SAFETY
PRODUCT OVERVIEW
ABOUT AIRXCHANGE ENERGY RECOVERY WHEELS
SERVICE TOOLS
OPERATING INSTRUCTIONS
PRESTARTUP
POSTSTARTUP
ROUTINE AND PREVENTATIVE MAINTENANCE
INSPECTION CHECKLIST
CLEANING AIRXCHANGE SEGMENTS
SEGMENT REMOVAL/INSTALLATION
19 TO 25INCH MONOLITHIC WHEEL
25 TO 30INCH SEGMENTED WHEEL
36 TO 86INCH SEGMENTED WHEEL
92 TO 125INCH SEGMENTED WHEEL
RECORD PRODUCT INFORMATION FOR REFERENCE
SAFETY
ELECTRICAL SAFETY
SAFETY AROUND METAL AND MOVING PARTS
2
3
3
5
6
6
8
9
9
10
12
13
14
16
18
20

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PRODUCT OVERVIEW
ABOUT AIRXCHANGE ENERGY
RECOVERY WHEELS
Unless noted, the information in this manual applies to all
available models of Airxchange energy recovery wheels.
Energy recovery wheels rotate between the incoming
outdoor air stream and the building exhaust air stream.
As the wheel rotates, it transfers a percentage of the heat
andmoisturedierentialfromoneairstreamtotheother.
Instead of wasting energy in the exhaust airstream, it is
temporarily captured by the energy transfer me-
dia and then released to pre-heat, pre-cool, hu-
midify, or dehumidify the incoming air, Figure 1.
Figure 1 An ERV system pre-conditions outdoor air
with recovered energy.
Airxchange wheels are designed with segmented energy
transfer media. The segments are mounted in a stainless
steel wheel, which then rotates within a galvanized met-
al cassette frame. The segmentation allows the transfer
media to be easily removed for cleaning or replacement.
Figure 2 Airxchange structural metal wheel and frame
assembly with removable polymer segments.
MOISTURE TRANSFER
Depending on the application, the energy recovery
media may include a desiccant. Desiccants trans-
fer water molecules between two air streams of
dierent vapor pressures. The vapor pressure dif-
ferential drives water molecules into/from desic-
cants to transfer moisture from the more humid air
stream to the drier air stream as the wheel rotates.
UL APPROVED AND AHRI CERTIFIED
• Airxchange energy recovery cassettes are
UL Recognized Components under UL Stan-
dard 1812, Ducted Heat Recovery Ventilators.
• Airxchange recovery performance ratings are
certified by the AHRI Air-to-Air Energy Recov-
ery Ventilation Equipment Certification Program.
Figure 3 Airxchange wheels are UL and AHRI
Certified.

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OVERVIEW OF WHEEL COMPONENTS
Refer to Figure 4 and the list below for the
high level components in an Airxchange wheel.
For an Illustrated Parts Breakdown of a particular
wheel, enter the serial number into the Parts Look-
up tool at www.airxchange.com/replacement-parts/.
Figure 4 Exploded view of typical Airxchange wheel.
(1) Removable Segment (Also referred to as “Media”)
(2) Permanent Tension Belt
(3) Pulley
(4) Embedded Segment Stieners
(5) Segment Retaining Latches
(6) Bearing Beam and Bearing Access Cover Plate
(Diameter Seals are behind Bearing Beam on both sides)
(7) Adjustable Purge
(8) Motor
IDENTIFY CASSETTES WITH SERIAL
NUMBER
All Airxchange wheels are labeled with Model, Serial,
and Part numbers. The label can be found on the sheet
metal adjacent to the drive pulley, Figure 5. You should
always have a serial number when contacting Airxchange
for product support or when ordering replacement parts.
See Record Product Information for Refer-
ence beginning on page 20 for a location to log
the details about numerous wheels in a system.
For more details on the Airxchange Parts Look-
up tool, see Service Tools beginning on page 5.
Figure 5 Product label (with serial number) on pulley
corner of each wheel.

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SERVICE TOOLS
If you have any questions, a representative from Airx-
change will oer guidance and support for main-
taining, servicing, and ordering parts for your en-
ergy recovery wheel. Call [phone] or email
[email protected] for product support.
SERVICE WEBSITE
www.airxchange.com/replacement-parts/provides main-
tenance and parts information to technicians working in
the field:
• Parts Lookup - Access replacement parts information,
drawings & more for your Airxchange wheel(s) using
the six digit serial number on the product label, Figure
5.
• Instructional Videos - View our library of short in-
structional videos on how to maintain Airxchange
cassettes.
• Supporting Documents - View our library of support
and maintenance documents.
• Contact information for the Airxchange Service De-
partment.
IDENTIFY REPLACEMENT PARTS
To identify the exact replacement part for any wheel,
contact Airxchange with the wheel serial number or en-
ter the serial number into the Airxchange Parts Lookup
tool on the Product Support Website.
Airxchange oers replacement parts for the following
components:
• Belt
• Media Segments
• Bearing
• Diameter Seals
• Purge
• Motor
• Pulley
• Segment Latches
• Shafts
• Retaining Straps
• Seal Material
QR LABEL ON EACH WHEEL
For each wheel manufactured after 2014, a quick
response (QR) label is provided below the prod-
uct label. and can be scanned with any smart phone.
The label and location are shown in Figure 6.
Figure 6 Airxchange QR Label directing to Product
Support Website.

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OPERATING INSTRUCTIONS
PRESTARTUP
MOTOR GUIDELINES
Note the following for proper motor function:
• Always follow motor manufacturer’s wiring instruc-
tions.
• All wheels should rotate clockwise when viewed from
the pulley side.
• On 3-phase motors, if the wheel does not rotate
clockwise (when viewed from pulley side), shut o pow-
er to the system and interchange any two power supply
leads to reverse rotation.
• Inverter duty motors should not exceed a 20:1 turn
down ratio.
INSPECT DIAMETER SEALS
Diameter seals, Figure 7, are set at the facto-
ry, but should be inspected before operation.
To check the seal, slide a piece of paper (“feeler gauge”)
between the seal and the media at multiple locations on
both sides of the bearing as you rotate the wheel slowly by
hand (clockwise when viewed from the pulley side). Verify
thatthemediaslightlygrabsthepaperduringtherotation.
If necessary, loosen adjusting screws along
the bearing beam and reset seal to a slight in-
terference fit with the wheel media, Figure 7.
Figure 7 Setting diameter seals.
SET PURGE ANGLE IF NECESSARY
The purge sector is an option available on channeled
matrix Airxchange wheels, Figure 8. A “P” in the
model number designates that the wheel includes a
purge sector.
When installed, the purge angle is factory-set to
5-degrees. If the HVAC system design specification
requires a dierent angle, complete the following steps
to adjust the purge:
(1) Loosen the three purge adjusting screws, Figure 8.
(2) Adjust purge sector to the specified angle, Figure 9.
Figure 8 Purge installed on motor side of wheel.

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Figure 9 Setting purge angle.
(3) Tighten the purge adjusting screws.
(4) Turn the wheel by hand clockwise (when viewed
from pulley side) to check for interference.
CHECK PURGE SEAL
If a purge is installed, check for a slight interference fit
between the seal and the face of the wheel by sliding
a piece of paper (“feeler gauge”) between the seal and
the media at multiple locations along the purge seal as
you rotate the wheel slowly by hand (clockwise when
viewed from the pulley side), Figure 10. Verify that the
media slightly grabs the paper during the rotation.
If it is necessary to adjust a purge seal to the face of the
wheel, loosen the two or three screws (depending on
the wheel size) along the bearing beam, Figure 10, and
adjust to the proper distance from the media surface.
Tighten the screws and re-test the seal.
Figure 10 Check purge seal and adjust (if necessary).
INSPECTION
Before starting the system, confirm the following:
• Wheel spins freely by hand in a clockwise direction,
with no interference noise.
• Wheel is not “racked” (wheel rotates parallel to bear-
ing beams).
• Belt tracks near middle of rim (not against rim sup-
port).
• Belt is not flipped (on a stretch belts for 36-inch
wheels and above, the narrow face contacts the wheel
rim; on a continuous link belt, small tabs contact wheel
rim).
• All media segments are installed in the wheel and
latches are closed. For instructions, see Segment Re-
moval/Installation beginning on page 12.
• Diameter Seals are properly set and secured (seal is
parallel to and just touching media surface). See Inspect
Diameter Seals beginning on page 6.
• If purge is specified, it is set at proper angle - for in-
structions see Set Purge Angle (if necessary) beginning
on page 6.

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POSTSTARTUP
INSPECTION
After applying power to system, confirm the following:
• Verify that the wheel is rotating in the direction of the
rotation arrow located on cassette frame.
• On 3-phase motors, if the wheel does not rotate in
the direction of the arrow, shut o the power to the
system and interchange any two power supply leads to
reverse rotation.
• Visually inspect belt; ensure belt is tracking near the
center of the rim.
• No excessive noise (scraping, brushing, banging etc.).
• Running amps do not exceed nameplate Full Load
Amperes (FLA).
CONFIGURING WHEEL CONTROLS
Airxchange does not oer any direct speed controls for
the wheel.
To confirm that wheel speed is responding to the field
supplied speed control, consult the energy recovery
wheel portion of the original equipment manufacturer
(OEM) operating manual.
ITEMS TO CHECK BEFORE BEGINNING
NORMAL OPERATION
Verify the following:
• The area around the energy recovery wheel is free of
debris.
• Cabinet doors are closed and secure.
• Power is restored to unit.

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ROUTINE AND PREVENTATIVE
MEASURE
INSPECTION CHECKLIST
Airxchange recommends inspecting the wheel once per
year to verify that the wheel, motor, belt, energy transfer
segments, and seals are all in good working order. Rou-
tine maintenance is not required other than to clean the
energy transfer media periodically on a schedule that is
determined by the application (see next page for details).
Table 1 lists inspection steps for Airxchange wheels.
Table 1 Recommended inspection checklist for Airx-
change wheels.

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CLEANING AIRXCHANGE SEGMENTS
All Airxchange wheels 25-inches in diameter and larg-
er feature segmented energy transfer segments for
easy removal and cleanings - per the application re-
quirements. The polymer media segments are light-
weight and can be lifted by a single person. This section
briefly describes how to determine the need for clean-
ing and, if necessary, clean the Airxchange segments.
CLASSES OF AIR
Cleaning the energy transfer media will help maintain
optimal performance. The frequency of cleaning is
largely dependent on the application and air quality.
Using ASHRAE’s Classes of Air categories, Table 2, is
useful in understanding the application and creating a
routine cleaning schedule.
Table 2 Classes of air.
DETERMINE CLEANING FREQUENCY
Airxchange oers the following general guidelines for
removal and cleaning of the energy transfer media, Table
3, based on ASHRAE’s Classes of Air categories, Table
2. Actual cleaning frequency should ultimately be de-
termined based on the results of the annual inspection.
Table 3 Recommended cleaning frequency (based on
class of air).
NOTE: When applied to smoking or industrial envi-
ronments with visible airborne contaminants, Airx-
change recommends inspection and cleaning once
or twice per year to maintain optimal performance.
CLEANING REQUIREMENTS VARY BY
APPLICATION
All surfaces exposed to an air stream will need to be
cleaned over time. Generally, rotary energy recovery
wheels self-clean when exposed to small amounts of dry
dust and dirt as the wheel rotates between two counter
flowing air streams.
However, when exposed to air streams contain-
ing oils, VOCs, aerosols, or smoke, these con-
taminants will build on the surface of the me-
dia to reduce its energy transfer eectiveness.
VISUAL INSPECTION
Annual inspection of the media surface during pre-
ventative maintenance checks is recommend-
ed. Check both sides of the wheel. Mild discol-
oration of the surface of the media is normal.