UltimateAir 200DX Installation and operating instructions















The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 

Thank you for your recent purchase of the most
advanced air filtration and energy recovery
ventilation available today. Your RecoupAerator
is designed to bring fresh filtered air indoors to
your home or business while simultaneously
exhausting stale air.
The 200DX is an Energy Recovery Ventilator (ERV),
meaning the RecoupAerator captures
temperature and moisture from the stale,
outgoing air and transfers it to the incoming Fresh Air. No matter what the
season, you will be comfortable breathing fresh clean air.
In addition to having an energy transfer rating of 96%, the RecoupAerator
moderates indoor humidity in the winter and turns away outdoor humidity in
the summer.
Automatically self-balances air flow
96%+ heat recovery efficiency
95% filtration at 1.8 microns (MERV 12)
Up to 75% moisture transfer capability (depending on season)
UL listed and certified
ECM motors with Permanently lubricated Ball Bearing
Optional Pressure Transmitter (senses and adjusts for changes in indoor air
pressure)
Optional CO2Guard™ (senses and adjusts for elevations in CO2)
EconoCool™ (brings in cool, filtered night air in summer)
Compatible with many IAQ monitors and fans
Automatic frost prevention down to 10° F
Variable blower speed
Quiet operation
Low/easy maintenance
Exceeds ASHRAE 62.2 ventilation recommendations
No drain required
Filter service indicator
Fully insulated
5-year Warranty

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 

Model
RecoupAerator 200DX Energy Recovery Ventilator
(ERV). Includes pre-filters, patented energy
transfer/filtration material, fans, controls, and motors.
Airflow Capacity
~ 50-339 CMH
Sensible Apparent
Efficiency
96%
Heat Exchange Type
Patented rotary random matrix polymer
Filtration
Energy transfer/filtration material 95% effective at 1.8
microns (MERV 12), replaceable, with washable
aluminum pre-filter
Electrical Ratings
230VAC, 50/60Hz., 3.0amp (start up)
Fuse (low voltage)
¼ Amp, 250V 3AG slow blow fuse
Dimensions
25 in. H x 19 in. W x 25 in. D (63.5 cm H x 48.25 cm W x
63.5 cm D)
Unit Weight
72 lb (32 kg)
Shipping Weight
80 lb (36 kg)
Mounting
May be mounted by vertically or horizontally by
suspending from floor joists, or placed on floor or shelf
in conditioned spaces such as attics, basements, and
utility rooms. Collars (four) are 6” in diameter.
Maintenance
Clean filters approximately every 6 months and replace
when necessary

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 

Application
The 200DX is an Energy Recovery Ventilator (ERV),
meaning that the RecoupAerator captures temperature
and moisture from the stale, outgoing air and transfers
it to the incoming air stream.
Controls
RecoupAerator is equipped with a variable speed
controller, unlimited boost function capability (i.e., you
can add timers and controllers), “check filter” indicator
light, EconoCool™ equipped, auxiliary IAQ and timer
inputs, furnace wiring terminals, and auxiliary output.
These controls allow you to adjust the airflow as
needed to maintain a comfortable level of fresh air. The
“check filter” indicator light is designed to let you know
when to check and/or clean/replace your pre-filters
and energy transfer/filtration material. For systems in
which constant ventilation is not required, a remote
on/off switch, timer, and/or furnace inputs can be
wired directly to the unit.
Frost Control
Programmed to regulate heat exchange automatically
to prevent frost build-up down to approximately 10˚F.
During this mode, the Wall Dials green light will flash.

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 

We strongly recommend a licensed HVAC technician install this product,
because of complex considerations such as airflow dynamics and condensation
issues. Read these instructions carefully before beginning any installation
procedure. Failure to follow them closely may reduce ventilation effectiveness,
cause a hazardous condition, and/or invalidate your warranty. Installation by
non-licensed HVAC personnel may void the warranty.
Unpack your RecoupAerator and check to make sure that the following are
included and undamaged:
UltimateAir RecoupAerator 200DX Energy Recovery Ventilator with four (4)
starter collars packaged inside the RecoupAerator.
Literature package with maintenance guide, parts list, registration card, and
warranty.
Wall mountable control dial (pre-wired for test run, and shipped inside the
RecoupAerator).
Control options if ordered.

1. Test Run the RecoupAerator by plugging into a power outlet
and adjust the blower speed with the included Wall Dial.
Familiarize yourself with the intake and outlet duct configuration and
installation dimensions. Decide how you will mount the unit. We
recommend ACCA’s manuals D & J for proper load calculations and duct
sizing.
2. After installation is complete, fill in contractor’s name and phone
number on the last page of this manual, and be sure to complete the
Warranty Registration to validate the installation.

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 
CAUTION
Always disconnect the power supply before wiring to prevent
electrical shock and/or equipment damage.
The RecoupAerator is equipped with a grounding plug for your
protection against shock hazards and should be plugged directly into
a properly grounded, 230V, wall receptacle. If only a two-pronged
outlet is available, it must be replaced with a properly grounded
three-pronged receptacle in accordance with the local codes and
ordinances. A qualified electrician should do this work. Use proper
circuit protection. If you have any doubts about the grounding in
your building, contact a qualified electrician.

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 

Vertical Installation Horizontal Installation
_______________________________________________________________________
Connect to the Inside Connect to the Outside
FRONT
BACK

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 

Option 1: Dedicated Ventilation Ducting
This is the most complete installation option and is ideal for new construction.
Use option 1 when a home or business is especially concerned with health
issues (e.g., when an occupant has asthma or severe allergies). Option 1 is the
only option for homes and businesses without existing forced air ductwork.
Option 1 is also used for homes employing radiant heat flooring or geothermal
heating.
The more rooms to which ductwork is run, the more effective the system will
be. Dedicated ductwork is installed for the exhaust intake and the fresh air
delivery. The kitchen, laundry room, and 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, and a good installation will feature supply vents in these locations.
As a general note, fresh air is generally supplied at floor level, and stale air is
removed at ceiling level.
A simpler but somewhat less effective version of this system uses one exhaust
and one or more delivery registers located strategically to encourage
circulation throughout the house.

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 
Option 2: Shared Forced Air Supply, Dedicated Stale-Return
This method partially uses the existing HVAC duct system. Fresh Air IN from
the RecoupAerator® gets ducted into the cold air return side, or the supply
side of the furnace. Stale Air Out thru the RecoupAerator® is ducted separately
to strategically located points throughout the house from which you’d like to
remove stale air (e.g., the kitchen, bathroom, open stairwell). This method
allows for independent control between the HVAC air handler and the
RecoupAerator® (i.e., the air handler and the RecoupAerator® are not
interlocked and run independent of each other).

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 
Option 3: Shared Forced Air Supply, Shared Return
This method uses the existing HVAC duct system completely.
Fresh Air IN from the RecoupAerator® is ducted to the main
supply duct to the house. The Stale Air Out thru the RecoupAerator®
is ducted into the cold air return duct of the furnace. If you use this
method, we recommend that you wire your RecoupAerator® and
your air handler to run simultaneously (i.e., they will be interlocked) to
prevent recirculation shorting thru back past the furnace air handler.
Option 4: Shared Forced Air Return
This method uses the existing HVAC duct system
completely. Both the Stale Air Out and the Fresh Air
IN from your RecoupAerator® are attached to the
cold air return duct of your HVAC system. Be sure to
keep at least three feet of space along the cold air
return duct between the two RecoupAerator ducts.
When using this method, your RecoupAerator® and
your air handler must be wired to run simultaneously
(i.e., they are interlocked).

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 

Position the RecoupAerator in a location convenient to existing ducting and
furnace/forced air system. We don’t recommend that the RecoupAerator be
mounted in an unconditioned space, as this will affect the performance and
longevity of the unit. If possible, locate equipment away from the quiet rooms
(e.g., bedrooms) in 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 RecoupAerator.
Vertical Floor Mount. The RecoupAerator rests on four rubber feet when
mounted vertically. Set the machine on a flat, dry, level surface at least 20”x
24”which is able to support a minimum of 85 lbs. Allow 24”above for removal
of the top cover and pre-filters so they may be easily lifted away for service of
the heat recovery/filtration material. Allow 24”on the front side of the unit for
service and cleaning.

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 
Horizontal.Use a Ceiling Mounting Kit to suspend the RecoupAerator from the
“D” rings located on the four corners. Allow adequate space (12”) between
the ceiling and the unit to allow for servicing. Allow 24”below the unit for
servicing. Allow 24”on the filter access side of the unit.

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 
Ducting between the RecoupAerator and the outdoors must be
insulated and sealed with a vapor barrier to prevent condensation
on the ductwork.
Planning the Duct Work
Locate all four collars and attach to the unit at each of the four 6” holes. Peel
the backing from the double-sided tape on the collars and then attach them to
the unit with three self drilling screws each (provided).
Two duct holes are labeled Connect to Outside. The other two duct holes are
labeled Connect to Inside.
To ensure maximum airflow, use the largest practical duct for the installation.
Design and installation of ductwork must be in accordance with HVAC
standards and regulations to allow required quantities of fresh air to circulate
through the building. Under no circumstances should the trunk duct size be
less than six inches, as this will restrict the airflow considerably. Insulated flex
ducts tend to reduce air noise levels but add airflow resistance, and galvanized
ducts provide the least resistance to airflow, but may amplify noise. Duct
connections inside each building will vary. The outside duct connections are
the same for most installations and must be insulated..
Connect to
Outside
Connect to
Inside
Fresh Air In (1)
Stale Air Out (4)
Fresh Air In (2)
Stale Air Out (3)
FRONT

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 
General Duct Design Guidelines
1. Use a minimum of six-inch-diameter round duct or equivalent for all
connections to and from the RecoupAerator. Use of eight-inch ducts on
main trunks is recommended, especially for ducts running to the
outside. A licensed HVAC contractor should do the duct design
calculations.
2. To minimize backpressure: Make the intake and exhaust duct runs as
short and straight as possible. Always use 45-degree elbows instead of
90-degree where practical. Where flex duct is used, make sure that no
“crimping” or “collapsing” of the duct occurs. Stretch flex duct evenly
to avoid air restriction. Use “Y” connections instead of “T” connections
wherever possible.
3. Position outdoor 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 six to ten feet
apart, 40 inches from the corner of the building, and above the
projected snow plane (above 18 inches if possible).
4. Position inside grill/register vents so that fresh air does not blow
directly onto occupants or the thermostat.
5. Fasten joints between duct components with screws, sealant, and/or
rivets and wrap them with metal foil duct tape to ensure no leaks.
6. Minimize any noise transmission through the ducts by using a short run
(2-3 ft) of insulated flex duct on duct trunks coming from the unit and
going to the inside of the house. If this isn’t enough, you can install an
optional duct muffler.
7. If you install a RecoupAerator in an unconditioned space (not
recommended), you must insulate the section(s) of the inside ducts,
and possibly the unit itself, which are exposed to an unconditioned
environment.
8. Ensure that ducting to the outdoors is installed above anticipated snow
and flood lines, and is fitted with screened weather caps to prevent
animal, insect, and debris entry.
Final duct system should exhibit less than 0.6 in. wg total external static
pressure at maximum airflow. Lowering the static pressure will lessen the
electrical usage.

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 
Flexible Ducting Tips
1. Ensure that your duct installation follows the following standards:
a. Mechanical integrity The system will remain as built for the life of
the building, without developing leaks, obstructions, or insulation
failures.
b. Freedom from leaks All air moved by the air handler will be
drawn from and delivered to the intended conditioned spaces.
c. Proper insulation Conditioned air should not exchange heat with
unconditioned spaces.
2. Size ductwork according to recognized industry standards such as Manuals D
and J, published by the Air Conditioning Contractors of America (ACCA).
3. Follow guidelines and instructions provided with duct installation materials.
4. Tapes and sealants used on connections should be listed for UL 181B,
Closure Systems for Use with Flexible Air Ducts and Connectors.
5. Assemble the tools to install non-metallic flexible duct:
a. Knife or Scissors/Wire Cutter: Use knife or scissors to cut duct
wall. Use wire cutters to cut spiral wire helix.
b. Foil Tape: Use only tapes that have been listed and labeled to
Standard UL 181B and labeled “181B-FX”. Use two wraps of 1½”
minimum width.
c. Draw Band/Plastic Clamp/Clamp Tool: Use for low-pressure
systems up to four-inch wg (diameters of three to 10’) and up to
two-inch wg (diameters of 12”and over). To achieve proper
tensioning of clamp, set clamp to max tension setting.
6. Use the minimum length of flexible duct necessary to make connections.
7. Support hardware (e.g., terminal devices, couplings, and fittings)
independently of flexible duct using elbows or other devices.
8. Repair torn or damaged vapor barrier jacket. If internal core is penetrated,
replace or splice flexible duct.
9. Install duct fully extended along straightest path possible.
10. Flexible duct shall be supported at manufacturer’s recommended intervals,
but at no greater distance than five feet, and the maximum permissible sag
is ½”per foot of spacing between supports.
11. In no case will the hanger or saddle material supporting the flexible duct be
less than 1½”wide.

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 
Attaching flexible ductwork to RecoupAerator Collars
Pull insulation and vapor
barrier jacket over core
and snug against steel
case to completely
cover the duct fitting
Mechanically fasten the
vapor barrier jacket with
a draw band
Secure the inner core to
the fitting using a draw
band or three wraps of
pressure-sensitive tape
- apply additional mastic
over the connection.
Pull back the
insulation and
vapor barrier
jacket from core
Apply mastic over the
fitting and / or inside the
duct core before pulling
the inner lining at least
1-inch over the fitting.

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 


In some installations, the unit may be too noisy for the occupants. Here are
some options for correcting the situation:
1. When installing the unit, allow for a three-foot section of insulated
flexible duct to go from the starting collar on the unit to the rest of the
ductwork (on all four collars). This will help dampen noise being
transmitted from the unit into the home or business, at the source.
2. Locate the unit farther away from the source of the noise pollution area
(e.g., if the unit is close to a living room vent where the noise is too loud,
locate the unit farther away from this location). This will allow the noise
to dissipate in the longer duct length.
3. Wire the RecoupAerator to run only with the furnace air handler.
4. Run at the lowest flow setting necessary for fresh air requirements.



The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 

Note: The ducts to the outside must be insulated. The starting collars
labeled Connect to Outside must be ducted to the outside of the building, and
the following precautions should be taken.
1. The ends of the two ducts should be as far apart as practical (at least six
feet, either horizontally or vertically) to minimize re-circulation of the
exhaust air.
2. Terminate the ducts using exterior weather hoods. Ensure that the
exterior weather caps have wire mesh to keep out birds, small animals,
insects, and debris. Angle the weather caps down and away from each
other and place them away from exhaust vents for other appliances
such as dryers or hot water heaters. Avoid placing air intake vents near
exhaust vents from adjacent buildings or sources of automobile exhaust.
Never place an air intake in a garage, for instance.
3. Make sure that the joints between the termination vents and the walls
are sealed to prevent air and moisture penetration.


The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 


CAUTION
Before performing any service to your RecoupAerator, switch off the unit and
disconnect power from 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.
Basic Electrical Wiring
The RecoupAerator Model 200DX is supplied with two blower motors, one
energy recovery wheel drive motor, and a detached wall controller that can be
mounted near the unit or in a remote location. Follow all applicable electrical
codes.
The RecoupAerator can be wired in a number of different ways depending on
desired features. This section of the manual describes each benefit option and
shows the wiring procedure to accomplish them.
Factory Default Settings
Airflow. This unit contains two blower motors, each independently controlling
the airflow coming into the building (Blower 1, supply), and leaving the
building (Blower 2, exhaust). The unit has the capability of lowering the airflow
from the building going to the outside by a selectable set of offset jumpers on
the three-motor control board. Factory settings provide for “balanced”
airflow, that is, equal airflow both coming into the building and exiting the
building.
Input. The RecoupAerator comes equipped to handle several different types of
control input. From the factory, The RecoupAerator is wired with the North
American Wall Dial Control, unless otherwise specified at the time of order.
EconoCool. This unit comes with an economic ‘night’ flush feature. There is a
small silver toggle switch mounted next to the Main Power switch to turn
EconoCool ON and OFF. Please see the ‘econocool’ section in this manual for
further detail.

The UltimateAir® RecoupAerator® 200DX Manual and Installation Guide, March 2014 
Three-motor Main Control Board