Stirling RecoupAerator SD-95+ Programming manual

RecoupAerator®SD-95+
Energy Recovery Ventilator
Owner’s Manual and Installation Guide
Stirling Technology, Inc.
178 Mill Street
Athens, Ohio 45701
www.healthyairpeople.com
1-800-535-3448

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TABLE OF CONTENTS
Section 1: Owner’s Manual
Introduction..............................................................................................................3
Features.....................................................................................................................3
Specifications ...........................................................................................................4
General Information................................................................................................4
Service and Maintenance ........................................................................................5
Troubleshooting Guide ...........................................................................................7
Replacement Parts ...................................................................................................8
Control Options, Vent Hoods and Mounting Kits ................................................10
Wiring Diagram .......................................................................................................11
Section 2: Installation Guide
Installation ...............................................................................................................12
Installation Dimensions ...........................................................................................13
Installation Options .................................................................................................15
Location and position of the RecoupAerator®........................................................17
Planning the Ductwork............................................................................................19
Installing the Outside Ducts....................................................................................21
Installing the Inside Ducts.......................................................................................22
Wiring .......................................................................................................................22
System Start-up and Run Test................................................................................25
Balancing Airflow ....................................................................................................25
Filter Light................................................................................................................27
General Warranty Information..............................................................................27
Installation Record ..................................................................................................27
Revised: Thursday, May 29, 2003

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RecoupAerator®SD-95+
Section 1: Owner’s Manual
Introduction:
Your RecoupAerator®is designed to bring fresh air in to the home while
simultaneously exhausting stale air. The heat (or coolness) of the air being exhausted is
transferred to the fresh air coming in to the home. The RecoupAerator®is specifically
designed to provide good indoor air quality in a home or office while maintaining the
comfort of the occupants.
This unit is an energy recovery ventilator, which means that it recovers about 96% of
the heat as well as about 30-40% of the indoor moisture. As you read the specifications on
the following page, you will get a more complete picture of what the RecoupAerator®does,
and how it performs.
Features:
♦ 96% plus efficient
♦ 95% effective filtration to 5 microns
♦ Extremely quiet operation
♦ Environmentally sound
♦ Low/Easy maintenance
♦ Low cost
♦ Exceeds ASHRAE 62.2
♦ No drain required
♦ Permanently lubricated fan & wheel
bearings
♦ Fully insulated
♦ No desiccant required

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____________________________________________
Specifications:
Model: RecoupAerator®SD-95+ Energy Recovery Ventilator. Includes patented Rotary
Heat Exchange Core, filters, fans, and drive motor. Pre-heaters are optionally
available.
Air Flow Capacity: 197 cfm
Sensible Thermal Efficiency: 96% at full flow
Heat Exchange Type: Patented Rotary Random Matrix Polymer
Filtration: Washable Heat Exchange matrix 95% effective at 5 microns with washable
expanded aluminum pre-filter.
Motor Type: General Electric 1/3 hp programmable brushless motor
Electrical Ratings: 120/240 Vac, 60 Hz., 5.0/2.8 Amps
Dimensions: 42 cm D x 56 cm W x 58 cm H (16.8” x 22.5” x 23.4”)
Unit Weight: 30 kg (70 lbs.)
Shipping Weight: 36.3 (80 lbs.)
Mounting: May be mounted vertically or horizontally suspended from floor joists, or
placed on floor in conditioned spaces, such as attics, basements,
and utility rooms. Collars are 6”.
Maintenance: Clean filters once every 6 months, and clean or replace if necessary.
Certifications: ETL Testing Labs to ANSI/UL-1995 / CAN/CSA C22.2 No. 236 (heating
and cooling equipment).
General Information:
Application: The RecoupAerator®Energy Recovery Ventilator is designed to supply fresh
air and exhaust stale air while ventilating your home with conditioned and filtered
outside air. The RecoupAerator®draws fresh air from outdoors through the patented
rotary heat exchange core for distribution throughout the home. Stale air is exhausted
through the RecoupAerator®and ducted to the outdoors after transferring heat and
moisture to the incoming air stream.
Controls: Your RecoupAerator®comes equipped with a variable speed control knob, boost
function capability, “clean filter” indicator light, and furnace wiring terminals. This
allows you to adjust the airflow as needed to maintain a comfortable level of fresh air
into your home. The “clean filter” indicator light is designed to notify you when your
pre-filters and heat exchange material need to be cleaned. For systems where
constant ventilation is not required, a remote on/off switch, timer, and/or furnace
inputs can be wired directly to the controller.
Frost Control: A pre-heater (SH-1000) is recommended for colder climates in which the
outdoor air temperature will fall below 10oF for extended periods of time (24-48
hours). Each pre-heater comes equipped with a thermostat to automatically activate
and shut off pre-heater at pre-set temperatures. The pre-heater may additionally be
wired to a remote on/off switch.
____________________________________________

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Service & Maintenance
Before Performing Maintenance
Before any service to your RecoupAerator®is performed, be sure that the unit is switched
off and power has been disconnected from the unit. Using the wall mounted variable
controller and/or the external on/off switch on the unit does not terminate main power to the
unit. You must disconnect power by either unplugging the unit or by switching the
applicable breaker in your breaker box to off. Otherwise, the main power to the unit will
remain hot and could cause serious bodily injury.
Maintenance List
Pre filter (clean every 3-4 months if continuously operated, or every 6 months
otherwise)
Heat transfer core (check and if necessary clean every 3-6 months)
Belt drive (check belts for excessive wear yearly)
Weather caps (check for obstructions regularly)
General Cleaning (light vacuuming recommended yearly)
Aluminum Pre-filters
The aluminum pre-filters should be cleaned at least once every six months. Clean more
frequently if necessary. To clean the filters:
1. Unscrew the filter door thumbscrews and remove the filter doors.
2. Slide the aluminum pre-filters out, being careful not to bend the frames.
3. Check the filter for build-up and replace it if clogged. If it is soiled but not clogged, you
should be able to clean it by soaking it in warm soapy water. Dry pre-filter completely
before reinserting it in your RecoupAerator®.
4. Replace the filter.
5. Replace the filter door and tighten thumbscrews.
To order a replacement filter set, call for current prices:
1-800-535-3448
Stirling Technology, Inc.
P.O. Box 2633
Athens OH, 45701

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Heat Transfer Core
The RecoupAerator®’s patented Heat Exchange Wheel contains a removable core filtration
material (see photo below) that may require washing.
To check the core material:
1. Disconnect power to the RecoupAerator®.
2. Open the non-motor side access door (the side labeled “To clean heat exchange material,
REMOVE THIS COVER.”).
3. Remove the aluminum pre-filter as explained in the Aluminum Pre Filter Service Section.
4. If the heat exchange material is a medium gray or darker it is probably in need of
cleaning. Pull out the exposed filter material wedges by the plastic monofilament handle
embedded in each section, manually rotating the wheel to access the remaining wedges.
5. Wash the filter material wedges by hand or in the washing machine (gentle cycle) using a
mild detergent.
6. Air dry the pieces completely before reinserting them in the unit with the handle facing
out for easy access in the future.
7. Rotate the wheel by hand making sure that the pieces are completely and evenly replaced
so that none drags on the center frame as the wheel rotates.
8. Replace the aluminum pre-filter and tighten the filter door.
9. Replace the side access door and tighten the quarter turn latches.
10. Restore power to the unit.
Belt Drive
If the motor is operating but either the heat exchange wheel does not turn or the blowers are
not displacing air, check the pulley system for loose, worn or broken belts. Replace as
needed.
Weather Caps
Check periodically throughout the year to ensure that the fresh air inlet and stale air exhaust
outlet duct ends do not become clogged with debris such as leaves, grass, snow, or bird nests.

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TROUBLESHOOTING GUIDE
Can you hear the motor runnin
g
?
Is the unit making a pulsating sound?
Turn off unit and unplug power cord. Remove motor-side access door, reconnect to power supply, and turn on unit. Check energy transfer wheel. Is it rotating?
Guide belt on to
p
ulle
y
s.
Unplug unit, and correct wiring.
A
re all airways and filters
clear of obstruction?
Check fuse. Does it need to be re
p
laced?
Replace fuse.
Replace any loose wiring.
Verify at least 100 Vac are reaching the electrical outlet.
Check the fuse/breaker box.
Check for loose or broken drive belts. Clear airway(s),and/or clean filter
(
s
)
.
Check to see if drive roller is making contact with the heat recovery wheel.
Is spring attached?
Reconnect sprin
g
.
Call our 800 number for technical support.
Check for broken belts on both sides of unit. Unplug unit before opening access doors.
1. Verify that any thermostats or switches
connected to the furnace are activated to supply power to the unit.
2. Verify that the power switch is in the ON position
and controller is turned past the OFF position.
3. Unplug unit and verify that the controller is wired
correctly to the 7-pole connector.
Is the wirin
g
for all the above correct?
Yes
No
Yes
Yes
Yes
Replace belt.
Turn off power and unplug unit. Remove motor-side access door and electrical box cover. Verify that electrical connections have been properly wired and grounded.
Yes
Yes
Yes
Yes
Yes
Yes
No No No
Yes
No
No
No
No
No
No
No
Turn on power to SD-95+. Is the green controller light on?
Check that the drive roller belt is running on the pulleys.

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PARTS DIAGRAM FOR THE 95+ ENERGY RECOVERY VENTILATOR
(Use when ordering replacement parts)

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REPLACEMENT PARTS LIST
015 - Small Filter Access Door
016 - Large Filter Access Door
023 - Power Cord
040 - Motor and Controller Can
043 - Fuse Holder and Cap
044 - Small Motor Pulley
103 - Motor Mount
110 - Blower Cone
115 - Blower Pulley
116 - Center Pulley (Single Groove)
117 - Center Pulley (Double Groove)
118 - Large Motor Pulley
120 - Fixed Motor Pin
121 - Motor Mount Grommet
122 - Motor Spacer
125 - Drive Roller Belt
126 - Blower Belt
127 - Center Shaft Belt
128 - Filter Door Knob (Threaded)
130, 131 - Aluminum Pre-filter Set
132 - Heat Recovery Material (Set of 6)
136 - Spring Mount
144 - Motor Pin Cap
148 - Strain Relief (Power Cord)
153 - Nylon Retaining Washer
161 - Fuse
164 - 7 Pole Connector (Terminal Strip)
166 - Transformer
170 - Strain Relief (Controller)
352 - Electric Box (Covers 7 Pole Connector)
Drive Roller Assembly (No Part Number)
CW and CCW Blower Assemblies
Controller – Wall Mounted (On/Off or Continuous)
If you need to order parts or have a question about parts ordering, call:
1-800-535-3448
MOUNTING KITS

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CM-02 – Ceiling Mount Kit
WM-04 – Wall Mounting Bracket
TERMINATION KITS
WT-06 – Wall Termination Kit (for 6 inch duct)
WT-07 – Wall Termination Kit (for 7 inch duct)
WT-08 – Wall Termination Kit (for 8 inch duct)
WT-10 – Wall Termination Kit (for 10 inch duct)
Note: Wall Termination Kits can be custom made to any standard size.
OPTIONAL DEVICES
SH-1000 – Pre-heater (Two different versions, for 95+ and 190 units)
Manometer – inclined vertical manometer – for balancing unit
A-612 – Portable stand for manometer
PR-101 – Low voltage relay
FR-102 – High voltage relay
Wound Timer – Can be set to boost the airflow up to maximum for a set
period of time.
Digital Timer – Can be set to boost the airflow up to maximum for a set
period of time.
Dehumidistat – Can be used to adjust humidity by boosting the airflow
up to maximum speed when a preset humidity
level is exceeded.
Digital Wall Switch Timer– Programmable timer allows the
RecoupAerator®to be turned off and on, or
boosted to maximum speed, at user specified
times.
If you need to order parts or have a question about parts ordering, call:
1-800-535-3448

Stirling Technology, Inc. 11

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RecoupAerator®SD-95+
Section 2: Installation Guide
Instructions for Licensed Contractors
Installation:
Note: It is recommended that a licensed HVAC Technician install this product. There
are numerous considerations that must be taken in to account when installing a
ventilation system, including airflow dynamics and condensation issues. As a minimum
level of preparation, obtain a manual on Residential Ventilation Installation prior to
installation by non-licensed individuals. Installation by non-licensed HVAC personnel
may invalidate the warranty.
Unpack your RecoupAerator®and check to make sure that the following are included and
undamaged:
• SD-95+ Energy Recovery Ventilator with starting collars.
• Literature package with maintenance guide, parts list, and warranty.
• Mounting hardware. (optional)
• SH-1000 pre-heater. (if required)
• Wall Mount Controller
When installing the RecoupAerator®:
1. Read these instructions carefully before beginning any installation procedure. Failure to
follow them closely may reduce ventilation effectiveness or cause a hazardous condition.
2. Review your plan for the installation, with the RecoupAerator®sitting out of the box in
front of you. Familiarize yourself with the intake and outlet duct configuration,
installation dimensions, and plan which direction you will orient the unit.
3. After installation is complete, test the operation of this product according to the
instructions. Fill in contractor’s name and phone number on the last page of this manual.
! CAUTION
Disconnect power supply before wiring to prevent
electrical shock or equipment damage.
The RecoupAerator®is equipped with a three-prong grounding plug for your
protection against shock hazards and should be plugged directly into a PROPERLY
GROUNDED THREE-PRONG WALL RECEPTACLE. Where only a two-prong
outlet is available, IT MUST BE REPLACED WITH A PROPERLY GROUNDED
THREE-PRONG RECEPTACLE in accordance with the National Electrical Code and
local codes and ordinances. This work should be done by a qualified electrician.
Use proper circuit protection. If you have any doubts about the grounding in your
house, contact a qualified electrician.

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Installation Dimensions:
Allow clearance in
marked areas for access to
the unit for regular
maintenance and
servicing.
Also, you must leave
room on both ends (with
collars) to connect
ductw
ork to the unit.

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Allow clearance in
marked areas for access to
the unit for regular
maintenance and
servicing.
Also, you must leave
room on both ends (with
collars) to connect
ductw
ork to the unit.

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Installation Options
There are three basic ways to install the inside ducts for the RecoupAerator®.
Option 1: Dedicated Ductwork
This is the most complete installation option and is ideal for new construction. It should
be used when the customer has a specific problem associated with indoor air quality. It is
also the only option for homes without forced air heating systems.
The more rooms to which ductwork is run, the more effective the system. Dedicated
duct-work is installed for the exhaust intake and the fresh air delivery. The kitchen, laundry
room, or other areas with high contamination should contain registers for the exhaust intakes.
Areas such as the living room, den, and bedrooms should receive the full benefit of the fresh
air being brought in. See illustration below for sample dedicated ductwork layout.
Depending on the layout of the building in which the RecoupAerator®will be installed
and the amount of time and effort the installer wishes to spend, a simpler but somewhat less
effective version of this system could be used which would utilize just one exhaust and one
or more delivery registers located strategically to encourage circulation throughout the
house.
DEDICATED DUCTWORK FOR THE 95+

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Option 2: Shared Ductwork
Method 1. This method utilizes the existing home HVAC duct system completely. Both
the stale air removal and the fresh air in ducts from your RecoupAerator®will be attached to
the cold air return duct of your HVAC system. Be sure to keep at least 3 feet of space along
the cold air return line between the two ventilator lines (see diagram). We recommend that
you keep both lines 3 to 6 feet away from the furnace. When this method is used, your
RecoupAerator®and your air handler must be wired to run simultaneously (interlocked).
Method 2. This method also utilizes the existing home HVAC duct system completely.
The fresh air in duct from the RecoupAerator®gets ducted into the main supply duct to the
house. A minimum of 18” distance between this line and the furnace is recommended. The
stale air out duct from the RecoupAerator®gets ducted into the cold air return duct of the
furnace. A 3 foot to 6 foot distance between this line and the furnace is recommended. For
use of this method, it is recommended that your RecoupAerator®and your air handler be
wired to run simultaneously (interlocked).

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Method 3. This method partially utilizes the existing home HVAC duct system. The fresh
air in duct from the RecoupAerator®gets ducted into the cold air return line of the furnace.
A minimum of 3 to 6 foot distance between this line and the furnace is recommended. The
stale air out duct from the RecoupAerator®is ducted separately to strategically located points
throughout the house where it is desirable to remove stale air from. This method allows for
independent control between the air handle and the RecoupAerator®(no interlock).
Location and position of your RecoupAerator®
Mounting Location: Mount your RecoupAerator®in a central location that will be
convenient to existing ducting and furnace, if using existing ductwork. Do not install
the RecoupAerator®in an unheated space, as this will affect the performance of the
motor. If possible, locate equipment away from the quiet rooms of the house. Avoid
directly suspending the RecoupAerator®from the mid-span area of joists. This can
result in structural vibration. Allow adequate space for maintenance and service of
the unit (use the guidelines outlined below).
Mounting Positions:
Vertical:The RecoupAerator®rests on four rubber feet when mounted vertically. Set
the unit on a flat, dry, level surface at least 18 in. by 24 in., which is able to support a
minimum of 80 lbs. Wall Mounting Bracket Kit (WM-04) may be used to mount the
RecoupAerator®on a wall (SHOWN BELOW). Allow 24 in. above the unit for
removal of the pre-filters. Position the cover marked “To clean heat exchange
material, remove THIS cover” so that it may easily be removed for cleaning of the
heat recovery material. Allow 24 in. on the motor side of the unit for annual
servicing.

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Horizontal: Use Ceiling Mounting Kit (CM-02) to suspend the RecoupAerator®
from the ‘D’ rings located on the four corners of the unit (SEE BELOW). The motor
side of the unit should be facing the floor. Allow adequate space (12 inches) between
the ceiling and the unit to allow for servicing of pulleys and belts. Allow 24 in. below
the unit for servicing. Allow 24 in. on the side of the unit with the two filter access
doors to facilitate removal of the heat recovery material and aluminum pre-filters, and
for airflow balancing. It is not recommended that the unit rest on joists or decking
when installed in the horizontal position, because it would limit access for motor (and
belt) servicing.

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Ducting: Ducting between the RecoupAerator®and the outdoors (those collars marked
CONNECT TO OUTSIDE) and all ducting in unconditioned spaces must be
insulated. Use vapor barriers as needed to prevent condensation. Vapor barriers
always go on the warm side of a duct.
Planning the Duct Work
The unit has four 6-inch starting collars. Two collars are marked CONNECT TO OUTSIDE:
The other two collars are marked CONNECT TO INSIDE:

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To insure maximum airflow, use the largest practical duct for the installation. Under no
circumstances should the trunk duct size be less than 6 inches, as this will restrict the airflow
considerably. Insulated flex ducts tend to reduce blower noise levels but add airflow
resistance, while galvanized ducts provide least resistance to air flow and are easiest to install
properly. Depending on the customer's needs, the duct connections inside the house
will vary. The outside duct connections are the same for all installations and must
be insulated. Design and installation of ductwork must be in accordance with HVAC
regulations to allow required quantities of fresh air to circulate through the home, and to
exhaust equivalent quantities of stale indoor air.
General Duct Design Guidelines
1. Use a minimum of 6 in. diameter round duct or equivalent for all connections to and from
the RecoupAerator®. Use of 8” ducts on main trunks is recommended, especially for
ducts running to the outside.
2. To minimize backpressure: Make intake and exhaust duct runs as short and as straight as
possible, with few elbows or bends. Always use 45-degree elbows instead of 90-degree
where practical. Where flex duct is used, make sure that no ‘crimping’ occurs. Flex duct
should be as evenly stretched as possible to avoid air restriction. Use “Y” connections
instead of “T” connections wherever possible.
3. Position fresh air intakes away from known sources of pollution such as dryer vents,
chimneys, and automobile exhaust. Locate fresh air intake and stale air exhaust at least 6
to10 feet apart and 40” from the corner of the building.
4. Position vents such that fresh air does not blow directly onto occupants or thermostat.
5. Joints between duct components must be fastened with screws, sealant and/or rivets and
wrapped with duct tape (aluminum foil tape seems to be the best).
6. Noise transmission through the ducts can be minimized by using a short run of insulated
flex duct on any duct trunks coming from the unit and going to the inside of the house.
7. Branches from main trunks should not be smaller than 5 inches typically.