NovelAire ECW Instrucciones de funcionamiento

Energy Conservation Wheel

Operating and Maintenance Manual

CONTENTS 
SECTION I: Introduction and Definitions....3 
Introduction................................................................3 
Definitions .................................................................3 
SECTION 2: Receiving and Inspecting........4 
Receiving...................................................................4 
Lifting and Handling..................................................4 
Storage.......................................................................4 
Figure 1- Cassette Components ..........................................4 
Section 3: I
nstallation
............................5 
Identification Markers................................................5 
Installing ....................................................................5 
Figure 2- Cabinet Installation Guide ...................................5 
Section 4: Controls and Wiring....................6 
Drive Motor ...............................................................6 
Variable Speed Control..............................................6 
Frost Prevention Measures.........................................6 
Section 5: Startup and Operation................7 
Prestartup Checks ......................................................7 
Seal Checks................................................................7 
Variable Frequency Drive (VFD)..............................7 
Adjustable Purge........................................................7 
Section 6: Maintenance ................................8 
Bearings.....................................................................8 
Drive Motor ...............................................................8 
Drive Belts.................................................................8 
Seals...........................................................................8 
Wheel Cleaning ..........................................................8 
Basic Cleaning .....................................................................8 
Wheel Washing within Cabinet: .........................................8 
Wheel Washing Removed from Cabinet: ...........................8 
Variable Frequency Drive..........................................9 
Section 7 –Belt Installation........................10
Sheet Metal Cassette Belt Installation .....................10 
Welded Box Tube Belt Installation..........................13 
Section 8: Troubleshooting........................15
Appendix 1 –Powertwist Belt...........................................16 
Appendix 2 –External Pillow Block Bearing......................17 
Appendix 3 –External Flange Bearing ..............................18 
Appendix 4 –Internal Insert Bearing................................18 
Appendix 4 –ECW General Arrangements .......................19 
 
 

Page | 3 2/25/2021

SECTION I: INTRODUCTION AND DEFINITIONS

INTRODUCTION

Your NovelAire Technologies energy conservation wheel (ECW)

cassette comes complete and ready to run. The ECW cassette is

built to provide many years of trouble-free service. With proper

installation and performance of the minimal maintenance

requirements, your ECW should operate problem free.

Please review these instructions carefully before installing the

unit. Most damage occurs due to improper installation. NovelAire

is not responsible for a unit that has been improperly installed.

The rotor media can be torn or crushed by mechanical means if

the unit is improperly treated.

This document covers operating and maintenance instructions for

both the total heat wheels (ECW) and sensible only wheels (SEW).

For questions, please contact NovelAire Technologies at:

Ph: (800) 762-1320 or (225) 924-0427

Fx: (225) 930-0340

Email: info@novelaire.com

DEFINITIONS

Bearing, external - Flanged or pillow block bearing used with

rotating shaft models in larger, welded units.

Bearing, internal - Sealed ball bearing used with fixed shaft

models in smaller, sheet metal units.

Brush seal - The seal used for both the perimeter seal and the face

seal in the NovelAire ECW cassettes. They are constructed of nylon

brushes and seal against the wheel band in the case of the

perimeter seal and are siliconized and positioned against the

wheel surface in the case of the face seal. These seals are

noncontact in that there is a slight gap between seal and sealing

face to allow the wheel to turn at high RPMs without over-

torquing motor or causing seal damage. These seals have an

integral clip and are clipped to the cassette face panel cutout

(perimeter) or to the post (face).

Cassette - The steel structure that houses the rotor. ECW cassettes

are of punched sheet metal panelized construction. Large

cassettes are of welded box tubing construction.

Energy Recovery Unit (ERV) - The unit that the ECW fits into. This

will typically include two blowers and the ECW cassette all

enclosed in a sheet metal housing.

Enthalpy wheel - A generic name for an energy conservation

wheel. The term enthalpy refers to an air stream's total energy

(temperature and humidity level).

Exhaust air - The air stream leaving an ECW that is exhausted to

the outside. Exhaust air is building return air that has been run

through the wheel.

Heat wheel - Synonymous with enthalpy wheel, energy

conservation wheel, or total energy recovery wheel. Some heat

wheels are sensible only wheels and should not be confused with

total energy recovery wheels.

Hub - The center support of an ECW.

Latent energy - Latent energy in the context of wheel discussions

is the work done by the wheel to transfer moisture from one air

stream to another. Latent work is accompanied by humidity

changes in the air streams.

Media - The chemical composite part of the wheel which performs

the latent and sensible exchange.

Outdoor air - The air stream entering an ECW that is brought in

from outside. Outdoor air becomes supply air after going through

the wheel.

Purge - A small segment of supply air defined by the gap between

the inner seal on the outdoor air edge of the center post and the

supply air edge of the center post. The purge angle is adjustable.

The purge captures the small amount of supply air captive in the

wheel when the wheel moves from return to supply and routes it

to thereturn air to minimize cross contamination.

Return air - The air stream entering an ECW that is returned from

the building. Return air becomes exhaust air after going through

the wheel.

Rotor - The part of an ECW that does the energy exchange and

consists of the wheel media, hub, spokes, and band.

Sensible heat - Sensible energy in the context of wheel discussions

is the work done by the wheel to transfer heat from one air stream

to another. Sensible work is accompanied by temperature

changes in the air streams.

Sensible wheel - A wheel that does only sensible work, i.e., where

only heat is transferred from one air stream to another and the

resultant moisture level remains essentially unchanged.

Spoke - Flat metal member used to support the wheel radially.

Supply air - The air stream leaving an ECW that is supplied to the

building space. Supply air is outdoor air that has been run through

the wheel.

Page | 4 2/25/2021

SECTION 2: RECEIVING AND INSPECTING

RECEIVING

Upon arrival of your ECW, please inspect cartons, pallets, and

packaging for any damage that may have occurred during

shipping. Neither NovelAire nor its customer is responsible for

shipping damage, and it is important to identify any such damage

before the unit is offloaded. Report any shipping damage

immediately to shipper and NovelAire Technologies so that the

proper remedies may be taken.

If the unit has come shipped on a pallet, please use proper forklift

procedures to offload the pallet. The media can be easily damaged

by the forks on the forklift.

LIFTING AND HANDLING

The ECW comes complete with lifting lugs. Lugs are located on top

of the unit housing. Large ECWs have 4 lift points and small ECWs

have 2. Use only the lifting lugs to off load an ECW that is not

palletized. If the unit is palletized, it may be lifted either by the

lifting lugs or with the forks placed underneath the pallet. In no

case should the unit be lifted by any other means.

Small ECW units do not typically come with lifting lugs and can be

lifted by hand.

STORAGE

The unit should be stored out of the weather. Make sure the unit

is covered to prevent dust and dirt collection on wheel face during

long periods of storage.

FIGURE 1- CASSETTE COMPONENTS

1. Cassette Housing

2. Drive Sheave

3. Drive Belt

4. Drive Motor Mount Bolts

5. Perimeter Seal

6. Spoke

7. Outer Band

Page | 5 2/25/2021

SECTION 3: I

NSTALLATION

IDENTIFICATION MARKERS

Look for any identification markers that have come with your

ECW. Rotational direction and/or air stream orientation will be

marked on your unit. The air flow orientation should be identical

to that of the general arrangement drawing which was provided

to you during initial placement of the order. Check to make sure

that air flow orientation is as requested. Consult the general

arrangement drawing provided earlier. It is important that the unit

be installed with the right rotational directions. It is also important

that air flows be oriented as designed to allow the purge to

function as designed.

Consult NovelAire Technologies if you have problems with any of

these instructions or if the unit is improperly marked.

INSTALLING

Make sure that the installation plan is consistent with

identification markers.

Locate the purge side of the unit. The purge should always be in

the supply air stream. The ECW accomplishes “purging” by

removing a small wedge of supply air and routing it to return air.

Thus, when the wheel is in rotation, the small amount of stale

return air that is trapped in the wheel section rotating from

building to outdoor air side is isolated and routed to the exhaust

air stream.

The installation requires ducting to 4 air streams.

It is good practice to include means for accessing the ECW

cassette on all sides. This can be done either using 4 access doors,

or 2 access doors with provisions for a removable section of front

and back duct. NovelAire recommends including a removable

plenum section (see Figure 2) in the front and back of the cassette

for expedient repair and/or wheel removal. Alternatively, the

cassettes can be installed on a slide-out track for easy access.

Access must be provided to the shaft and bearings for servicing.

Before installation, inspect the cassette for loose screws or bolts.

Tighten any loose connections.

Small units (under 60 inches) can be installed in either a horizontal

or vertical orientation. Larger units must be pre-engineered to run

in the horizontal position as they require thrust bearings and

additional supports. If the unit was not pre-ordered to run

horizontally, do not install the unit horizontally. Vertical units

should be supported from the bottom in the installed position.

Horizontally mounted units should be supported at all four comers

and in the center.

Before installing, turn the wheel by hand in the direction of

rotation to ensure that the wheel alignment was not altered in

shipping. If severe binding occurs, it could be due to excessive seal

contact. In this case, adjust the seals according to the instructions

given in theseal adjustment procedure in section 5.

The ECW seals were preadjusted before leavingthe factory.If upon

inspection excessive clearance between seals and sealing surfaces

is found, adjust the seals according to the procedure given in

section 5.

Inspect the drive belt and make sure that it is securely fastened

around the drive sheaves and wheel. Ifpossible, test run the wheel

before installation.

Install the unit. Once the unit is in place, secure the ductwork to

the cassette with sheet metal screws, bolts, welding, or alternate

method of attachment. Gasketing may be used at the joints, but it

must be installed securely so that it cannot detach and cause rotor

damage. The duct work should be securely fastened to the

cassette at all locations.

The wheel should be protected using an ASHRAE 30% filter

installed in both the outdoor air and return air streams.

FIGURE 2- CABINET INSTALLATION GUIDE

Suggested access doors and removable panels to facilitate wheel removal.

Page | 6 2/25/2021

SECTION 4: CONTROLS AND WIRING

DRIVE MOTOR

The ECW comes standard with a constant speed drive motor at a

voltage requested by the customer. The typical motor voltage

options are: 115/208-230v 1 phase, 208-230/460v 3 phase, or 575v

3 phase. ECW motors are standard motors and should be wired

like any standard motor. For multi-voltage motors, ensure to read

and follow the wiring schematic on the motor or manual for the

applicable voltage required in the unit.

Single phase motors come prewired for correct rotation direction,

but rotation direction should be verified. Three phase motors

must always be checked for correct rotation direction as the local

power determines which direction the wheel will rotate when

power is connected.

Follow the directions on the motor schematic accompanying the

motor. Once the motor is wired, test run the ECW and check for

proper rotation.

VARIABLE SPEED CONTROL

If the variable speed option has been supplied, the variable

frequency drive’s (VFD) power rating, power supply, and motor

selection have all been matched up by the manufacturer. The unit

can accept either a 4-20ma or 0-20ma control signal or a 0-5VDC

or 0-10VDC. The unit has also been programmed for the range of

wheel speed operation recommended by the manufacturer.

Typical wheel speed is 35 RPM, but the programming can allow for

wheel speeds above or below 35 RPM. Check all factory settings

to make sure they are consistent with the application. Consult

NovelAire for any help in achieving the right setup for the

application.

The VFD may have been shipped loose for flexibility in mounting.

Locate the VFD where it can be read and reached easily. Mount

the VFD where it is protected from the weather.

The control signal to the VFD is customer supplied, but typically it

will be either a temperature or a humidity reading. Typical wheel

speed will be controlled either by exhaust humidity or exhaust

temperature measurement. Some applications for sensible wheel

exchangers in desiccant cooling systems may call for wheel speed

controlled by supply temperature.

FROST PREVENTION MEASURES

During extremely cold wintertime conditions, frost formation

becomes a possibility. The stream that is under risk from frost

formation is the exhaust air stream. Frost formation will basically

act to plug or reduce air flow and will not hurt the wheel itself.

Wheel speed control works to limit frost formation by reducing

wheel performance to a level where the exhaust air temperature

is kept above the dew point. Proper dew point control of exhaust

air can be determined using a psychrometric chart by:

1. Locating the wintertime design return air condition and

outdoor air condition and connect the two points on a

psychrometric chart.

2. Determine the dry bulb temperature at which this line

intercepts the saturation curve.

3. Add 2 degrees and set dew point control at this point and

vary wheel speed downward to control at or above this

point.

4. Audit performance of the wheel during actual operation.

If frost formation is never evident, it may be because

design conditions are never reached in which case it may

be possible to gradually work dew point control down.

Some of the frost control methods (www.ahrinet.org) that can be

used for all types of exchangers are:

Exhaust only: When frost is indicated on the component, the

intake blower is de-energized for a period of time to allow exhaust

air to warm component, melt frost, and drain or evaporate

condensate. Alternatively, exhaust-only operation is determined

based on outside air temperature to avoid frosting.

Preheat: For outdoor air preheat, heat is provided in the outdoor

air intake to heat the air to a temperature above the exchanger

frost threshold before it enters the component. Alternatively, for

return air preheat, heat is provided in the return air before it

enters the exchanger to prevent frost from forming.

Re-circulation: When return air or exhaust air re-circulation is

used, return air or exhaust air is substituted, in whole or in part,

for outside air passing through the exchanger for defrost

purposes.

Bypass: A portion of the outdoor air is bypassed around the

exchanger until the frost threshold is avoided.

Page | 7 2/25/2021

SECTION 5: STARTUP AND OPERATION

PRESTARTUP CHECKS

Before starting up the unit, check the following:

1. Does the rotor rotate freely by hand? If not, recheck the

seal to determine whether it is binding and if so, adjust

seals following the instructions below.

2. Is the motor rotation correct? This can be checked by

detaching the belts from the drive sheave and bumping

the motor. The sheave should be rotating in the direction

such that the belt will result in rotation per the exterior

markings. If not, rewire the motor.

3. Does the air flow orientation match up to design? See the

identification markings on the cassette and/or refer to

the general arrangement drawing to check the four duct

connections to the unit.

4. Are the belts on correctly and sufficiently tight? Belt

length is set by the manufacturer. Consult NovelAire if

the belt appears too loose.

5. Is the VFD programmed to control the unit and to prevent

frost formation? If not, follow the instructions in the

manual accompanying the VFD and/or consult NovelAire.

SEAL CHECKS

The ECW is provided with a nylon brush seal which provides not

only an effective seal in both the peripheral and side-to-side

sealing directions but also one which is easily adjusted to

compensate for seal run- in, shipping misalignment, etc. The brush

seal is attached to a metal reinforced U-shaped neoprene grip. The

metal/neoprene grip allows for an expandable grip range which

can be moved closer or further from the sealing face as needed.

The perimeter brush seals against the wheel outer band and the

inner, siliconized brush, seals against the wheel face. With the

wheel stopped, move seals as close to the sealing surface as

possible but without exceeding grip range of brush seal and

without pressing the brushes down against the seal face. Bump

the motor. If the motor will not turn, the seal is too close and

should be nudged back where needed. The seal will seek its

equilibrium position based on the closest part of the sealing face.

Seal leakage is meant to be under 5% at 1 inch of differential

between supply and exhaust.

Some seal run-in is to be expected, so do not be alarmed by small

amounts of wear on the nylon brushes.

VARIABLE FREQUENCY DRIVE (VFD)

Check the power supply for proper rating. Make sure that the

proper jumper orientation is used for the specific control input.

Make sure that the unit is programmed for proper input voltage

and output voltage.

Always refer to the specific VFD documentation that is provided

with the ECW cassette or contact NovelAire for support.

ADJUSTABLE PURGE

The adjustable purge on the ECW is in the supply air stream and,

depending on configuration ordered, will be either vertical or

horizontal, left, or right side. It is set from factory at 0° and is

adjustable from 0° to 12° to reduce cross-contaminated air.

Purge sections minimize cross leakage by shunting a portion of the

supply air back into the exhaust air stream and can limit cross

leakage to less than 1%. Studies have shown that changing the

purge angle from 0° to 12° has only a small impact on the

effectiveness (energy transfer) of the energy conservation wheel

(2%-3%), while the reduction in gaseous carryover is substantial.

The degree to which the purge angle should be adjusted is

dependent on:

1. Differential pressure between supply and exhaust air

streams

2. Air velocity

3. Wheel design (diameter, thickness, & flute geometry)

4. Wheel rotation speed

To be able to set the purge correctly, the optimal angle can be

determined using our web-based ECW wheel software available

at: www.novelaire.com

The pressure differential between the supply out (So) and exhaust

in (Ei) side of the wheel has a significant impact on the cross

leakage and gaseous carryover. If the pressure differential (So–Ei)

is negative, the driving force for leakage is towards the supply side

resulting in carryover. This condition must be avoided through

proper design/configuration of the unit. Contact NovelAire for

support or review the ASHRAE ERV design guides.

(https://www.ashrae.org/technical-resources/energy-recovery)

Page | 8 2/25/2021

SECTION 6: MAINTENANCE

BEARINGS

Small ECWs (ECW726 and smaller) are provided with no

maintenance inboard bearings. These bearings should require no

maintenance during the life of the equipment. Larger ECWs come

equipped with an external flanged or pillow block bearing which

should be greased annually. Use a lithium-based lubricant.

DRIVE MOTOR

The drive motors should require no maintenance. Replacement

motors may be purchased from normal motor distributors such as

Grainger, or directly from NovelAire if preferred.

DRIVE BELTS

NovelAire ECW belts are multilink belts with individual links

constructed of a high-performance polyurethane elastomer

reinforced with multiple plies of polyester fabric. This belt

provides a strong, yet flexible belting. The multilink feature

provides quick, easy servicing or replacement. See Section 7 for

belt repair, replacement, & re-tensioning instructions.

SEALS

The seals are designed to be durable and require no maintenance

other than adjustment, but if seals become worn or damaged,

they may easily be replaced. The seals are made to clip on the

cassette or post metal easily.

Call NovelAire for servicing information.

WHEEL CLEANING

The wheel is designed to last the life of the equipment. It should

be protected by an ASHRAE 30% filter to keep dust and dirt from

the heat transfer surface. The wheel is somewhat self-cleaning

through its normal action of rotating in and out of countercurrent

air flow streams.

BASIC CLEANING - Requires access to both sides of the wheel

and can be cleaned within the unit using the following method:

1. Using a shop vac, vacuum any debris from both faces of the

wheel. Slowly work around the entire face of the wheel to

complete the procedure. Do not damage wheel face by

excessive pressure of the vacuum nozzle on the wheel face.

2. Using 20 psig clean, dry air, and a small air nozzle, blow air

through one face of the wheel. At a similar location on the

opposite side of the wheel, gently apply a shop vac to catch

any debris exiting the wheel.

If this method does not remove visual buildup or return pressure

drop to within normal parameters, a wheel washing procedure

may be done. NovelAire wheels can be washed thoroughly with

water without affecting the performance of the wheel. The wheel

will simply dry out following a washing procedure and resume

normal energy transfer performance.

Note: If the wheel can be easily removed from the cassette or unit,

it is recommended to do so to facilitate the washing process.

However, in most cases, it is impractical to remove larger wheels,

and therefore, the washing procedure must take place within the

air handling unit.

WHEEL WASHING WITHIN CABINET: Ensure provisions are

made to collect the runoff water from the bottom of the unit or

collect the water by using a wet vac on the opposite side of the

wheel following the procedure below:

1. Lock out / Tag out the unit and disable the drive motor.

2. Shield all electrical components and bearings with plastic

sheeting.

3. Ensure that an adequate drainage system exists to collect

runoff water from the bottom of the unit. Alternatively, use a

wet vac with a wide nozzle on the opposite face of the wheel

to collect the water during the washing procedure.

4. Using standard pressure water (do not use a high-pressure

washer) and working from the one side of the wheel, wash

the wheel with a standard garden nozzle to flush any debris

trapped within the flutes of the wheel. A mild detergent (ie.

Simple Green) can also be used to enhance cleaning without

effecting the performance of the wheel. No need to drench

the wheel with water and must avoid getting the bearings,

belts, and motor wet.

5. After washing, blow out excess water with air (20 psig).

Vacuum up very lightly with a wet vac. Do not energize the

drive motor or begin rotating the wheel yet.

6. Start the fans on both sides blowing through the wheel with

the wheel stationary for a few hours to dry the wheel off.

7. Once the wheel is dry, start the wheel motor and resume

normal operation.

WHEEL WASHING REMOVED FROM CABINET: If feasible, the

wheel may be removed from the cassette and washed with water

following the procedure below:

1. Lock out / Tag out the unit.

2. Remove air handler plenum sections so that the front or back

of the cassette may be easily accessed and cleared.

3. Support the wheel from the bottom.

4. If the unit is equipped with an external flanged bearing,

loosen the allen screws in the bearing housing that keeps the

shaft affixed in the horizontal plane on both bearing, front

Page | 9 2/25/2021

and back. Remove the shaft clips at the face of the hub from

both sides of the shaft. Unbolt one post completely and

remove post with bearing completely out. Remove the shaft.

Roll the wheel carefully out.

5. If the unit is equipped with an internal bearing, unbolt the

shaft screw on both sides of the shaft. Unbolt one post

completely and remove post. Remove the shaft clips at the

face of the hub from both sides of the shaft. Remove the

shaft. Roll the wheel out carefully.

6. With the wheel out, wash the media carefully with standard

pressure water (do not use a pressure washer) and a mild

detergent (ie. Simple Green). Once clean, allow the media to

dry out for several hours or days if necessary.

7. Once the wheel is fully dried out, reinstall using the reverse

procedure. Run the unit.

VARIABLE FREQUENCY DRIVE

No maintenance should be required on the VFD. Should problems

with the VFD develop, consult the VFD service manual. that

accompanied your order or call NovelAire for service information.

Page | 10 2/25/2021

SECTION 7 –BELT INSTALLATION

SHEET METAL CASSETTE BELT INSTALLATION

The PowerTwist belt is a highly durable and adjustable belt for

rotating the wheel. Under typical operating conditions, the belt

will last several times longer than competitors V-belts. If there is

a requirement to replace or adjust the belt, follow the directions

below:

1. Determine direction of wheel rotation. Direction is

indicated by arrow label on face panel of cassette. Locate

directional arrow on belt.

Figure 1

2. Confirm that the arrow on the belt is same direction as the

arrow on the cassette. Take one end of belt and begin

feeding it around the perimeter of the wheel. Depending

on the wheel size, it might be beneficial to use duct tape to

hold the belt to the perimeter band and rotate the wheel by

hand to feed it fully around the wheel.

Figure 2

Figure 3

3. Feed the other end of the belt to meet up with the leading

end while ensuring the belt is not twisted.

Figure 4

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