AIRXCHANGE ERC-19 Series Manual

1
OPERATION & MAINTENANCE
MANUAL
AIRXCHANGE ENERGY RECOVERY WHEELS
SERIES ERC-19 THROUGH ERC-125

2
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.

4
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.

5
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.

6
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.

7
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.

9
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.

11
CLEANING METHODS
To clean a buildup of dry contaminants on the media
surface, brush or vacuum the surface on both sides to
remove all debris, including between the layers of poly-
mer. Clean, unobstructed passageways provide the
maximum energy savings for the lowest operating cost.
To clean media surfaces that have a buildup of con-
taminants, Airxchange recommends soaking the seg-
ment overnight to eectively remove all contaminants
and restore the heat/moisture transfer performance.
There are several methods to remove contaminantbuildup:
• The best method of removing buildup is to soak
the segment overnight in a five-percent solu-
tion of a non-acid based coil cleaner. WARN-
ING: Monolithic wheels with internal bearings
should not be soaked to avoid corroding bearing.
After soaking, rinse the segments until the water runs
clear and then allow excess water to drain prior to re-
installing the segments. A small amount of mois-
ture on the media will be dried out by the airflow.
• Another option is to run water from a hose through
the removed media while brushing, though this
method is not as eective as the overnight soak.
ABOUT DISCOLORATION
Once clean, media segments may remain
slightly discolored. Surface discoloration does
not aect the performance of the wheel.
OPTIONAL CLEANING METHODS
• If a tub is not available for soaking, a makeshift
tub can be easily constructed out of wood boards
and any waterproof material, such as a polyethylene
sheet. The non-acid based coil cleaner is not corrosive
to the polymer media or polyethylene sheet.
• For applications with multiple identical wheels,
keeping a spare set of segments available can
eliminate system disruptions during cleaning.
Contact Airxchange for more information.

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SEGMENT REMOVAL/INSTALLATION
PROCEDURE VARIES BY WHEEL SIZE
The procedure to remove and install the ener-
gy transfer media varies by size, Figure 11. Airx-
change wheels are oered in the following size ranges:
• Monolithic (25-inch and under, 1 wheel) -see 19 to
25-inch Monolithic Wheel beginning on page 13.
• Small Segmented (25-inch and 30-inch, 4 segments)
-see 25 to 30-Inch Segmented Wheel beginning on
page 14.
• Medium Segmented (36-inch to 86-inch, 6 or 8 seg-
ments) - see 36 to 86-inch Segmented Wheel begin-
ning on page 16.
•Large Segmented with Satellites (92-inch to 125-
inch, 8 inner segments and 8 satellite segments) - see
92 to 125-inch Segmented Wheel beginning on page
18.
INSTRUCTIONAL VIDEOS
Step by step instructional videos for these procedures
are available. See Service Tools beginning on page 5 for
detailsor visit www.airxchange.com/replacement-parts/.
Figure 11 A sample collection of the available wheels
from Airxchange.

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19 TO 25INCH MONOLITHIC WHEEL
Complete the following procedures to remove and
install a 19 to 25-inch monolithic segment.
TOOLS
• Phillips screwdriver
• Nut driver or socket set
• Gloves
SERIES 19 TO 21WHEEL REMOVAL AND
INSTALLATION
1) Disconnect power to the wheel.
2) If possible, remove wheel frame from cabinet.
3) If a beam is present on the pulley side, remove the
mounting screw from each end of the beam, Figure 12.
Figure 12 19 to 21-inch monolithic wheel.
4) Remove the beam.
5) Remove the two hub cover screws, Figure 12.
6) Remove center screw from the end of the wheel
shaft, Figure 13.
7) Remove the belt from the wheel, Figure 12.
8) Remove the wheel from the frame.
9) To install the wheel, complete the previous 8 steps in
reverse order.
10) Turn wheel clockwise by hand (when viewed from
pulley side) and check operation.
11) Replace frame in cabinet and apply power to system.
12) Observe the wheel operating under power.
Figure 13 Remove center screw and wheel from frame.
SERIES 25 REMOVAL AND
INSTALLATION
1) Disconnect power to the wheel.
2) If possible, remove wheel frame from cabinet.
3) From the pulley side, remove the wheel retaining
bolt and washer from the end of the shaft, Figure 14.
Figure 14 Remove bolt and washer, then beam retaining
screws.
4) Remove the two bearing support retaining screws
from each side of the beam, Figure 14.
5) Remove the pulley side beam.
6) Disengage the belt from the pulley.
7) From the motor side, remove the wheel retaining bolt
and washer from the end of the shaft, Figure 14.
8) Remove the wheel from the frame.
9) To install the wheel, complete the previous 8 steps in
reverse order.
10) Turn wheel clockwise by hand (when viewed from
pulley side) and check operation.
11) Replace frame in cabinet and apply power to system.
12) Observe the wheel operating under power.

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25 TO 30INCH SEGMENTED WHEEL
TOOLS
• Flathead screwdriver
• Gloves
REMOVAL
1) Disconnect power from wheel.
2) Remove cabinet covers to gain access and slide wheel
frame out of cabinet (if applicable).
3) Position first segment to be removed at the top of
the wheel, Figure 15.
4) From the pulley side, unhook the flexible retaining
strap on each side of the segment from the wheel rim
and then remove both straps, Figure 16.
Figure 15 Remove or install opposing segments to mini-
mize wheel imbalance.
Figure 16 Remove retainer straps.
5) Use hand pressure from the motor side to remove
segment from the spokes while supporting front with
your other hand (segment slides straight out), Figure
17.
If necessary, use a flathead screwdriver or pry-bar at
the top corner of the segment. Be careful not to bend
the segment frame or wheel rim.
Figure 17 Remove segment.
6) Rotate wheel and remove remaining two retaining
straps, Figure 16.
7) Remove the remaining segments.

15
INSTALLATION
1) Ensure that power is disconnected from wheel.
2) From the pulley side, install each of the four
segments by sliding them straight into the wheel
opening, Figure 17.
NOTE:
The face of the segment with the embedded stiener
must face the motor side of the wheel, Figure 18.
3) Install the flexible retaining straps by inserting the
ends under the hub plate and then into the slot on the
rim at the end of the spoke, Figure 16.
4) Confirm that segments and straps are firmly
retained in the wheel structure before applying power
to the wheel.
Figure 18 Embedded stiener faces motor side.

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36 TO 86INCH SEGMENTED WHEEL
TOOLS
• Flathead screwdriver
• Gloves
• 3/16-inch Allen wrench (for ERC-81 and ERC-86)
REMOVAL
1) Disconnect power from wheel.
2) Gain access to wheel and slide wheel frame out of
cabinet (if applicable).
3) From the pulley side, rotate segment to be removed
to the top of the wheel.
4) Using a flathead screwdriver, unlock and open the
two segment retaining latches, Figure 20, at the outer
corners of the segment to be removed.
Figure 15 Remove or install opposing segments to mini-
mize wheel imbalance.
Figure 20 Release retaining latches following steps 1 and
2 in diagram.
5) For ERC-81 and ERC-86, use a 3/16-inch Allen
wrench to remove the nose bolt securing the segment
to the hub plate, Figure 21.
Figure 21 Nose entering hub plate (ERC 81-86 ONLY
includes a screw).
6) Remove segment by sliding outer portion of
segment out first before disengaging the nose, Figure
21. A flathead screwdriver may be used to aid segment
removal. Be careful not to bend the segment frame or
wheel rim.
7) Once segment is removed, close both latches.
WARNING: THE WHEEL IS NOW UNBALANCED.
8) Slowly rotate wheel 180-degrees and remove the
opposing segment to re-balance the wheel, Figure 19.
9) Remove the remaining segments by repeating the
previous three steps.

17
INSTALLATION
1) Ensure that power is disconnected from wheel.
2) Begin by positioning one empty segment bay at the
top of the wheel and opening the two retaining latches,
Figure 20.
NOTE:
The face of the segment with the embedded stiener
must face the motor side of the wheel, Figure 22.
3)From the pulley side, slide segment into place nose
first, Figure 21, then push outer portion of segment
in to wheel frame. If you are installing an ERC-81 or
ERC-86, use a 3/16-inch Allen wrench and the nose
bolt to secure the segment to the hub.
4) Close the retaining latches on outer corners of
segment to secure the segment inside the wheel, Figure
20.
5) Rotate first segment 180-degrees and install the
opposing segment to re-balance the wheel, Figure 19.
6) Repeat until all of the remaining segments are
installed, ensuring balance throughout the procedure,
Figure 19.
7) Apply power to wheel to confirm rotation.
Figure 22 Embedded stiener faces motor side.

18
92 TO 125INCH SEGMENTED WHEEL
TOOLS
• Flathead screwdriver
• Phillips wrench
• Gloves
• 5/32-inch Allen wrench
REMOVAL
NOTE: In order to remove inner segment, first remove
the satellite segment.
1) Disconnect power from wheel.
2) Gain access to wheel.
3) Position a satellite segment at the top of the wheel.
Figure 23 Remove or install opposing inner and satellite
segments to minimize wheel imbalance.
Figure 20 Release retaining latches following steps 1 and
2 in diagram.
5) Remove and set aside the bar latches on each side of
the satellite segment, Figure 24.
6) Remove satellite segment by sliding top end of
segment out before the bottom, Figure 24. A flathead
Screwdriver may be used in the corners to aid in
removal.
7) Close the retaining latches, Figure 24.
4) Use a flathead screwdriver to unlock and open the
two segment retaining latches at the top corners of the
satellite segment, Figure 24. BE CAREFUL NOT TO
BEND SEGMENT FRAME OR WHEEL RIM.
Figure 24 Release retaining latches (following steps 1
and 2 in diagram) and bar latches.

19
8) To remove the inner segment, support segment
with one hand while removing 1/4-20 flat head nose
bolt in the hub with a 5/32-inch Allen wrench, Figure
25. WARNING: AS SOON AS THE NOSE BOLT
IS REMOVED, THE SEGMENT IS NO LONGER
SECURE.
9) With weight of segment resting in the lower spoke
pocket, carefully slide segment out from between hub
plates, Figure 25.
10) Rest segment on lower spoke, grasp nose of
segment with one hand and the outer corner of the
segment in the other hand, then remove segment from
wheel, Figure 25.
11) Reinsert 1/4-20 bolt in segment nose bracket,
Figure 25, to avoid loss.
12) Rotate wheel 180-degrees to remove opposing
satellite and inner segment to restore balance, Figure
23.
13) Repeat previous eleven steps for each set of inner
and satellite segments, always taking steps to keep the
wheel balanced.
Figure 25 Remove nose bolt and remove interior seg-
ment.
INSTALL SEGMENTS
1) Move the empty bay to the top of the wheel.
2) Remove ¼ - 20 flat head bolt from segment nose
bracket, Figure 25.
3) Center and rest segment on lower spoke. Slide inner
segment along spokes until nose bracket contacts stop
in hub plate, Figure 25.
4) Insert nose bolt and tighten until bolt is firmly
seated, Figure 25.
5) Install the corresponding satellite segment by placing
the bottom end into position first, then the top end,
Figure 24.
6) Press straight in against all four corners to fully
engage, Figure 24. A sharp rap with heel of hand on
segment corners will assist entry when needed.
7) Temporarily engage the retaining latches and rotate
wheel 180-degrees.
8) Repeat previous six steps to install inner and
satellite segment sets, ensuring balance throughout the
procedure, Figure 23.
9) When all segments are installed, open the retaining
latches of one segment bay at a time to install bar
latches on each side of the satellite segments, Figure
24.
10) Install each bar latch and reengage the
corresponding retaining latch, Figure 24.
11) Repeat until all bar latches and retaining latches are
engaged. Rotate wheel 360-degrees by hand clockwise
(when viewed from pulley side) to confirm that the
wheel rotates freely.
12) Return the wheel to operation.

20
[email protected] | 85 Longwater Drive | Rockland, MA 02370 | 781.871.4816
airxchange.com/upgrade-to-airxchange
Table 4 Record product information for use when ordering replacement parts and planning maintenance schedules.
Use Table 4 below to record useful information about Airxchange Energy Recovery Wheels.
RECORD PRODUCT INFORMATION
FOR REFERENCE