RenewAire CA SERIES ERV Energy Recovery Module Instruction Manual

CA SERIES ERV Energy Recovery Module
Instruction Manual CA3XRT shown.www.ahridirectory.org

CA SERIES ERV Energy Recovery Module

WARNING
RISK OF FIRE, ELECTRIC SHOCK, OR INJURY.
OBSERVE ALL CODES AND THE FOLLOWING:

1. Before servicing or cleaning the unit, switch the power off at the system disconnect the switch or service panel, and lockout/tag out to prevent power from being switched on accidentally. More than one disconnect switch may be required to de-energize the system for servicing.
2. This installation manual shows the suggested installation method. Additional measures may be required by local codes and standards.
3. Installation work and electrical wiring must be done by qualified professional(s) in accordance with all applicable codes, standards, and licensing requirements.
4. Any structural alterations necessary for installation must comply with all applicable building, health, and safety code requirements.
5. Electrical equipment connected to this unit must be properly grounded.
6. Sufficient air is needed for proper combustion and exhausting of gases through the flue (chimney) of fuel-burning equipment that might be installed in the area affected by this equipment. If this unit is exhausting air from a space in which chimney-vented fuel-burning equipment is located, take steps to assure that combustion air supply requirements are of applicable codes and standards.
7. Use the unit only in the manner intended by the manufacturer. If you have questions, contact the manufacturer.
8. This unit is intended for general ventilating only. Do not use it to exhaust hazardous or explosive materials and vapors. Do not connect this unit to range hoods, fume hoods, or collection systems for toxics.
9. This unit must be properly ducted to the outdoors. Outside air inlets must not be located where air may be contaminated, for example by vehicle or appliance exhausts.

CAUTION
Tape both inner and outer vapor barriers of insulated duct to collars on duct adapters. This is critical to prevent the migration of moisture into the insulation. The build-up of moisture can result in failure of the duct system and/or frost in the insulation. Make sure any tears in the inner and outer vapor barriers are sealed.
CAUTION
Provide Adequate Service Access for Maintenance
The CA-Series Rooftop cabinet will require regular filter and core inspections. Install the CA-Series Rooftop cabinet where you can remove the doors for cleaning the core and replacing the filters, and where you can get at the wiring for installation and service.
WARNING
The unit’s outside air inlet should be at least 10′ away from any exhaust, such as dryer vents, chimneys, furnaces, water heater exhausts, or other sources of contamination or carbon monoxide. Do not locate the outside air inlet where vehicles may be serviced or left idling. Never locate the unit inside a structure.
WARNING
The danger of damage or severe injury if high winds move this unit. Secure unit to structure. Observe local code requirements at a minimum.
WARNING
The danger of injury if the unit started unexpectedly. Switch power off at service disconnect. Lock-out/tag-out the disconnect.
CAUTION
Maximum Differential Pressure The maximum pressure differential between the two airstreams should not exceed 4 inches (H2O).
CAUTION
It is the installer’s responsibility to make sure that the screws or bolts used for securing the units are properly selected for the loads and substrates involved. Secure the CA2–4XRT so that it cannot fall or tip in the event of an accident, structural failure, or earthquake. See the Rigging Information section for unit weight.
RenewAire strongly recommends that you secure rooftop units properly to the building structure. Strong winds, tornados, and hurricanes can and do displace or remove rooftop equipment from rails or curbs. When this happens, the equipment, adjacent roof structure, and even vehicles parked near the building can be damaged, and rain typically enters the building. The equipment is put out of service and the collateral damage can be very expensive.
CAUTION
Filters must be used or the energy exchanger core will become blocked by dust and the unit will not do its job. In extreme cases, components may be damaged.
CAUTION
Do Not Wash the Energy Exchange Core.
Keep it away from water or fire to avoid damaging it. Always handle the core carefully.

SAVE THIS MANUAL

UNIT INFORMATION
Record information as shown below.
In the unlikely event that factory assistance is ever required, information located on the unit label will be needed.
Locate the RenewAire unit label found on the outside of the unit.
NOTE: This information is for purposes of identifying the unit-specific option data from the Option Code.
NOTE: This page is to be completed by the installing contractor. The completed document is to be turned over to the owner after start-up.
OPTION CODE:
**
SERIAL NUMBER:

SO #:
**

CA OUTDOOR Energy Recovery Module
ROOFTOP UNITS
Modular Cabinets

SPECIFICATIONS

Ventilation Type:
Static plate, heat, and humidity transfer
Standard Features:
Insulated sheet metal cabinets with energy exchange cores and filters.
The blower is not included and must be specified to meet job requirements.
Insulation:
One inch, high density, FSK faced, fiberglass
Options:
Double wall construction
Exterior paint – white, custom colors
Accessories:
Roof curb – standard 14″
Filters – MERV 13, 2″ (shipped loose)

Download specification at:
renewaire.com/specifications

462-593 lbs.
Max. Shipping Dimensions & Weight (on a pallet)| 63″ L x 47″ W x 48″ H 400 lbs.| 60″ L x 90″ W x 48″ H 590 lbs.| 60″ L x 90″ W x 48″ H 700 lbs.
Filters: MERV 8: 20″ x 20″ x 2″| Total qty. 4| Total qty. 6| Total qty. 8

AIRFLOW PERFORMANCE

Note: Airfl ow performance includes the effect of clean, standard filter supplied with the unit.

CA2XRT Energy Recovery Module

UNIT MOUNTING & APPLICATION
Must be mounted as shown. Duct confi duration is field convertible. Weather hood can be moved in the field. RA/EA airstream can be switched with OA/FA airstream.
AIRFLOW CONFIGURATION
Available as shown in the dimension drawing.

CA3XRT Energy Recovery Module

UNIT MOUNTING & APPLICATION
Must be mounted as shown. Duct configuration is field convertible. Weather hood can be moved in the fi eld. RA/EA airstream can be switched with OA/FA airstream.
AIRFLOW CONFIGURATION
Available as shown in the dimension drawing.

CA4XRT Energy Recovery Module

UNIT MOUNTING & APPLICATION
Must be mounted as shown. Duct configuration is field convertible. Weather hood can be moved in the fi eld. RA/EA airstream can be switched with OA/FA airstream.
AIRFLOW CONFIGURATION
Available as shown in the dimension drawing.

MODEL NUMBER|
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DIGIT NUMBER
Digits 1 – 5:| Model
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“CA-2X” = Cabinet Applied 2 Cores
“CA-3X” = Cabinet Applied 3 Cores
“CA-4X” = Cabinet Applied 4 Cores
Digit 11:| Wall Type
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“S” = Single
“D” = Double
Digit 24:| Other Options
---|---
“-” = None
“W” = White Paint
“C” = Custom Paint
“X” = Custom Unit
Digit 25:| Safety Listing
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“N” = Non-Listed

OVERVIEW

1.1 CA-SERIES ROOFTOP OPERATION
The CA-Series Rooftop cabinets have one basic purpose: to transfer heating or cooling energy from an exhaust airstream to a fresh airstream.
The CA-Series Rooftop cabinets operate with no moving parts. The cores in the modules will transfer energy between the two airstreams as long as the two system blowers are moving air through the module. (These blowers are separate from the cabinets).
1.2 APPLICATION GUIDELINES
1.2.1 Purpose of CA-Series Rooftop
The CA-Series Rooftop cabinets are modular cases with 2, 3, or 4 energy recovery cores.
A variety of duct connection configurations are possible. Disposable filters are provided; they are of a common size and can easily be replaced.
1.2.2 General Layout
The CA-Series Rooftop cabinets are used to transfer energy from exhaust air leaving a building, into fresh air being brought in from the outside for ventilation. By recovering energy from the exhaust airstream, the benefits of ventilation can be enjoyed without the full energy cost to condition the outside air.
The CA-Series Rooftop cabinets do not contain blowers. Therefore, two blowers must be installed as part of the system. Several ducts must also be installed.

1.3 SERVICE ACCESS
1.3.1 Service Access
Install the ERV where you can open the door for cleaning the core and filter. Although there is no electrical connection to the cabinet, there should be a nearby system disconnect switch, so service people can shut off the blowers connected to the system when changing filters.
1.3.2 Connection to the HVAC System
In most cases, one or two ducts connect the CA-Series Rooftop cabinet to the building’s ducted HVAC system. A variety of connection approaches are possible, depending on the number of CSeries Rooftop cabinets in the installation, the purpose of the system, and available space.
The filters must cover the INLET FACES of the cores. Filter racks are provided at each face to handle all possible airflow configurations.

INSTALLATION

2.1 BLOWER ORIENTATION
Two blowers will be required: one for the air to be exhausted from the building, and another for the fresh air to be brought into the building. See the diagram for proper and improper blower locations.
CAUTION
The maximum pressure differential between the two airstreams should not exceed 4 inches (H2O).

2.1.1 Pull-Pull—RECOMMENDED
This is the recommended blower orientation for virtually every application. In “Pull-Pull” applications, both pull from the cabinet.
With Pull-Pull blower orientation, there is generally no need to review the static pressure differences between the two airstreams.
An “RA Push-FA Pull” blower orientation is unacceptable.
The advantage is that both blowers are on the “outside” of the cabinets, taking advantage of the acoustic attenuation offered by the cabinets. If outside airstream bypass airflow occurs, it additionally ensures no exhaust contaminants leak past seals into the fresh air.
The disadvantage is that both blowers must be sized to provide the additional bypass air, which in most cases is a needless waste of energy.
The higher overall static pressure tends to increase duct leakage.
NOTE: This bypass air volume is lower than in most competing technologies, such as heat wheels, and even some other plate-type exchangers.

2.2 BLOWER SIZING
Most “low airflow” problems in the field are caused by under-sized blowers. Systems can underperform if the designer does not make sufficient allowance for duct leakage, variations in duct layout from an ideal design, less-than- ideal blower outlet conditions, dirty filters, and the like.
In general, ventilation systems with energy-recovery components tend to need blowers with relatively high static pressure curves. In addition, parts of the duct system may be operating at higher static pressures than usual, and greater duct leakage may result. While these effects may be small, they may consume a large portion of the “safety factor” that a designer conventionally adds in every blower selection exercise.
Given all these concerns, it is prudent to select blowers and motors that can be operated at higher RPMs than required by the nominal design.
2.3 STATIC PRESSURE DROP THROUGH THE CABINET
The following chart is to be used when considering a Pull-Pull orientation of the blowers. The chart represents clean filters. It will be necessary to add an additional drop to allow for the build-up of dirt on the filters.

2.4 PLACEMENT OF THE CA-SERIES ROOFTOP
The CA-Series Rooftop cabinet is designed for installation on a roof or other outside location.
Select a location that is central to the inside duct runs, and close to any other air handler that might be part of the system.
WARNING
The unit’s outside air inlet should be at least 10′ away from any exhaust, such as dryer vents, chimneys, furnaces, water heater exhausts, or other sources of contamination or carbon monoxide. Do not locate the outside air inlet where vehicles may be serviced or left idling. Never locate the unit inside a structure.
WARNING
The danger of damage or severe injury if high winds move this unit. Secure unit to structure. Observe local code requirements at a minimum.
CAUTION
It is the installer’s responsibility to make sure that the screws or bolts used for securing the units are properly selected for the loads and substrates involved. Secure the CA-Series Rooftop cabinet so that it cannot fall or tip in the event of an accident, structural failure, or earthquake. See Rigging Information for unit weight.
RenewAire strongly recommends that you secure rooftop units properly to the building structure. Strong winds, tornados, and hurricanes can and do displace or remove rooftop equipment from rails or curbs. When this happens, the equipment, adjacent roof structure, and even vehicles parked near the building can be damaged, and rain typically enters the building. The equipment is put out of service and the collateral damage can be very expensive.
CAUTION
Provide Adequate Service Access for Maintenance
The CA-Series Rooftop cabinet will require regular filter and core inspections. Install the CSeries Rooftop cabinet where you can remove the doors for cleaning the core and replacing the filters, and where you can get at the wiring for installation and service.
The CA-Series Rooftop cabinet is available from the factory in one configuration where room air enters the bottom of the unit and fresh air exits the bottom of the unit. The relocatable patch pans allow different duct connection configurations.
2.5 RIGGING INFORMATION
There are lifting lugs at each upper corner of the unit. Use slings or shackles at all four corners. Spreader bars are recommended in order to avoid damage to the unit.

CA2-4XRT CABINET UNIT WEIGHTS (LBS)

MODELS| UNIT| Dim “A”| LF| LR| RR| RF
CA2XRT| 250| 39 3/8″| 71| 69| 54| 56
CA3XRT| 377| 59 1/4″| 107| 104| 81| 85
CA4XRT| 462| 79″| 131| 128| 99| 104

2.6 MOUNTING THE CA-SERIES ROOFTOP
2.6.1 On Roof Curbs: The base of the CA-Series Rooftop cabinets is designed for installation on our optional Roof Curb. See the Curb portion on Dimension Drawings. Before installing CA-Series Rooftop cabinets, apply roofing and counterflashing to the Roof Curb as per standard practice. Install appropriate gasket on top of Roof Curb. Set CA-Series Rooftop cabinet in place. We recommend bolting through the sides of the unit base into the Roof Curb to secure the unit against high winds. 2.6.2 On Equipment Rails: Review drawing of Roof Curb and specify Equipment Rail to fit. Before installing CA-Series Rooftop cabinets, apply roofing and counterflashing to Equipment Rails as per standard practice. Set CA-Series Rooftop cabinet in place. We recommend bolting through the sides of the unit base into the Equipment Rails to secure the unit against high winds.
NOTE: OA Hood provided, can be mounted on either side of the cabinet over the upper cabinet openings. See Duct Connection locations below depending on which side of the cabinet the OA hood is installed.
2.7 DUCTING
Before the unit is installed on the Curb:
Basic Requirements:
Always connect an RA and an FA duct to each Rooftop unit.
The RA and FA ducts can be interchanged depending on where you install the OA hood.
With standard configuration units, both ducts are inside the building. In another unit, that utilizes the optional configuration openings, at least one of the ducts is outside and must be weatherized.
Any weatherized duct must be thermally insulated to prevent condensation on the inside or outside of the duct. The duct lining must be vapor-sealed, and the duct exterior must be rain tight.
Duct(s) connected to the bottom of the CA-Series Rooftop cabinet are generally installed at this time. Install (2) ducts with CA-Series Rooftop cabinet standard configuration.
Drop duct(s) into openings at the top of the roof curb.
Install appropriate gasket on top of Roof Curb and edges of ducts.
CAUTION
Tape both inner and outer vapor barriers of insulated duct to collars on duct adapters. This is critical to prevent the migration of moisture into the insulation. The build-up of moisture can result in failure of the duct system and/or frost in the insulation. Make sure any tears in the inner and outer vapor barriers are sealed. 2.8 INSIDE DUCTWORK SYSTEM
Follow Engineer’s Ductwork Design:

• Ductwork should be designed by an engineer to allow the unit to provide the required airflow.
• Ducts should enter and exit the unit through smooth gradual transitions.
• If the inside ducts run through unconditioned spaces, they must be insulated, with a sealed vapor barrier on both inside and outside of the insulation.

See the drawings below for examples of some common installation approaches.

OPERATION

3.1 PRINCIPAL OF OPERATION
The CA-Series Rooftop cabinet has one basic purpose: to exhaust air from a structure and bring in fresh air from outside while transferring heating or cooling energy from the exhaust air to the fresh air.
The CA-Series Rooftop cabinet is a very simple device and will accomplish this purpose as long as the blowers for both airstreams are able to move air through the energy-exchange core.
3.2 CHECKING THAT UNIT IS OPERATING
3.2.1 Airflow
Airflow should be occurring in both airstreams. Sometimes the easiest place to confirm that air is moving in is at the weather hoods.
If exact airflow is critical, it may be desirable to permanently install flow measuring stations and manometers in the ductwork connected to the unit. These also can be used to determine when filters should be cleaned or changed.
3.2.2 Use Static Taps in Doors to Measure Airflow Rates
See “Cross-Core Static Drop” in the MEASURING AIRFLOW table. These may be used to directly measure airflow in the unit.
NOTE: Be sure to remove the cap from the pressure port before inserting the tubing. Ensure tubing is well seated in the pressure port.
NOTE: The tubing should extend in the pressure port approximately 1″.
NOTE: These ports have been carefully located on the unit to give you the most accurate airflow measurement.
NOTE: Do not relocate pressure ports.
NOTE: Be sure to replace the cap with the pressure port when airflow measuring is completed.
3.3 ENERGY EXCHANGE
Precise determination of installed sensible energy exchange effectiveness requires careful measurement of temperatures and air flows in all four airstreams, and in practice is somewhat difficult.
It is possible to confirm that energy is being exchanged simply by feeling the ducts. If the Fresh Air duct from the unit into the room is closer to room temperature than to the outside temperature, energy is being recovered.
3.4 CONTINUOUS OPERATION
Continuous operation is acceptable in virtually all conditions. The unit will not be damaged by continuous operation as long as airflow occurs. Blower motors may overheat if filters become completely blocked due to a lack of maintenance. With continuous operation, some external frosting may occur in very cold weather (see below).
3.5 OPERATION IN EXTREME COLD WEATHER
The unit is capable of operating at outside temperatures down to -10˚F, with indoor humidities below 40%, without any internal frosting. The unit can operate under more severe conditions occasionally with little or no impact on its performance. At lower humidities, it can operate at lower outside temperatures without freezing the energy-exchange core.
3.6 MEASURING AIRFLOW
3.6.1 Equipment Required

• A Magnehelic gauge or another device capable of measuring 0–1.5 inch water of differential pressure.
• Two pieces of natural rubber latex tubing, 1/8″ ID, and 1/16″ wall work the best.

3.6.2 Cross Core Static Pressure Measurement Instructions

• The individual differential static pressures (DSP) can be measured using the installed pressure ports located in the front of the unit’s core access doors.
• To read the SCFM of Fresh Air (FA), install the “high” pressure side (+) of your measuring device to the Outside Air (OA) port and the “low” pressure side (-) to the FA port.
• To read SCFM of Room Air (RA) install the “high” pressure side (+) of your measuring device to the RA port and the “low” pressure side (-) to the Exhaust Air (EA) port.
• Use the reading displayed on your measurement device to cross-reference the CFM output using the conversion chart.

FIGURE 3.6.0 PROPER OPERATING AIRFLOW RANGE

| | DSP| 0.20″| 0.25″| 0.30″| 0.35″| 0.40″| 0.45″| 0.50″| 0.55″| 0.60″| 0.65″| 0.70″| 0.75″
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---
CA2X| Fresh Air (FA)| CFM| 529| 662| 794| 926| 1058| 1191| 1323| 1455| 1588| 1720| 1852| 1985
Room Air (EA)| 567| 709| 851| 993| 1134| 1276| 1418| 1560| 1701| 1843| 1985| 2127
CA3X| Fresh Air (FA)| 818| 1023| 1227| 1432| 1636| 1841| 2045| 2250| 2454| 2659| 2863| 3068
Room Air (EA)| 732| 915| 1098| 1281| 1464| 1647| 1830| 2013| 2196| 2379| 2562| 2745
CA4X| Fresh Air (FA)| 1221| 1526| 1832| 2137| 2442| 2747| 3053| 3358| 3663| 3969| 4274| 4579
Room Air (EA)| 1130| 1412| 1695| 1977| 2260| 2542| 2825| 3107| 3390| 3672| 3955| 4237

FIGURE 3.6.2 DIFFERENTIAL STATIC ACROSS CORE DSP VS. CFM

MAINTENANCE

4.1 CHANGING THE FILTERS
Inspect and/or replace filters every 2–3 months when the unit is in regular use, or as needed.

• Turn off the unit completely! Lock-out and tag-out the system disconnect switch.
• Open the door. The door is secured with turn-type latches.
• Remove and dispose of all filters. Replace all filters.
• Close the door.

4.2 GENERAL CLEANING AND INSPECTION
Perform general cleaning and inspection when changing filters.

• Remove paper, leaves, etc. from inlet and outlet screens.
• Inspect for insect nests.

4.3 CLEAN THE ENERGY EXCHANGE CORE
Clean the core annually.

• Remove the filters.
• Vacuum the exposed faces of the energy exchanger core with a soft brush.
• Vacuum out dust from the rest of the unit case.
• Install new filters.

NOTE: See chart for information on the initial resistance of the filters originally supplied with this unit. If replacement filters have higher resistance, the airflow of the system will be lower.
IMPORTANT
Make sure all four lips of the core enter the receiver channels when re- inserting the core into the unit.
CAUTION
Filters must be used or the energy exchanger core will become blocked by dust and the unit will not do its job. In extreme cases, components may be damaged.
CAUTION
Do Not Wash the Energy Exchange Core. Keep it away from water or fire to avoid damaging it. Always handle the core carefully.
WARNING
ALWAYS DISCONNECT THE POWER SOURCE BEFORE SERVICING, TO ENSURE NO AIRFLOW IN THE SYSTEM.
The high volume of air in the case when operating! If you open an access door when the system is running, you may be exposed to as much as 8,000 CFM! Severe eye injury could result!
4.4 FILTERS
4.4.1 Filter Specifications

• 20″ x 20″ x 2″ (nominal) pleated filters
• Actual size: 19.5″ x 19.5″ x 1.75″

Units are shipped with MERV 8 Filters. The Minimum recommended effectiveness is MERV 6.
4.4.2 Filter Resistance
The initial resistance of filters supplied with this unit:

FIGURE 4.4.2 CA-4XRT INITIAL PRESSURE DROP 20″ X 20″ MERV 8 FILTERS

FACTORY ASSISTANCE

In the unlikely event that you need assistance from the factory for a specific issue, make sure that you have the information called for in the Unit Records page in the Owner Information section of this manual. The person you speak with at the factory will need that information to properly identify the unit and the installed options.
To contact RenewAire Customer Service:
Call800-627-4499
Email: RenewAireSupport@RenewAire.com
Remember that RenewAire Customer Service can only assist with the products sold by RenewAire, it cannot resolve engineering issues that result from air handling system design by others.

About RenewAire
For over 30 years, RenewAire has been a pioneer in enhancing indoor air quality (IAQ) in commercial and residential buildings of every size. This is achieved while maximizing
sustainability through our fifth-generation, static-plate, enthalpic-core Energy Recovery Ventilators (ERVs) that optimize energy efficiency, lower capital costs via load reduction and decrease operational expenses by minimizing equipment needs, resulting in significant energy savings. Our ERVs are competitively priced, simple to install, easy to use and maintain and have a quick payback. They also enjoy the industry’s best warranty with the lowest claims due to long-term reliability derived from innovative design practices, expert workmanship, and Quick Response Manufacturing (QRM).
As the pioneer of static-plate core technology in North America, RenewAire is the largest ERV producer in the USA. We’re committed to sustainable manufacturing and lessening our environmental footprint, and to that end, our Waunakee, WI plant is 100% powered by wind turbines. The facility is also one of the few buildings worldwide to be LEED and Green Globes certified, as well as having achieved ENERGY STAR Building status. In 2010, RenewAire joined the Soler & Palau (S&P) Ventilation Group in order to provide direct access to the latest in energy-efficient air-moving technologies. For more information, visit: renewaire.com

201 Raemisch Road
Waunakee, WI
53597 | 800.627.4499
RenewAire.com. Member of the S &P Group Family of Brands
2021 © RenewAire LLC
148051_003_JUN21

Documents / Resources

| RenewAire CA SERIES ERV Energy Recovery Module [pdf] Instruction Manual
CA SERIES ERV Energy Recovery Module, CA SERIES ERV, Energy Recovery Module, ERV, Recovery Module, Module, CA Module, CA2XRT, CA3XRT, CA4XRT
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References

• Resource Library - RenewAire
• Air-Conditioning, Heating, and Refrigeration Institute | AHRI
• RenewAire Energy Recovery Ventilation - ERVs

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