High Efficiency Fixed-Plate Air-To-Air

Heat and Moisture Exchanger (Version 2.0)

2

Energy WallTM

Catalog Contents

Contact Info ................................................................................................................... 2

Product Key – Rated Per Square Foot Frontal Area ................................................... 3

Energy WallTM Features and Benefits .......................................................................... 4

Energy Wheel vs. Energy WallTM

.............................................................................................................. 6

The Principle of the Wall ........................................................................................................................... 7

Counterflow Design ................................................................................................................................... 8

Ceramic Membrane Infused with Salt Crystals ......................................................................................... 9

Bi-Axial Oriented Poly Spacer ................................................................................................................. 10

Antimicrobial ............................................................................................................................................ 11

Washable ................................................................................................................................................ 12

Frost and Freeze Protection.................................................................................................................... 13

Performance Testing ................................................................................................... 14

Installation ................................................................................................................... 15

Product Directory ........................................................................................................ 16

Square Series (Wheel Replacement) ..................................................................................................... 17

Contact Info

Energy Wall LLC

1002 New Holland Ave.

Lancaster, PA 17601

Tel.: 717-814-5365

Fax: 717-406-1918

e-mail: info@energywall.com

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Product Key – Rated Per Square Foot Frontal Area

Energy Wall is composed of an exchanger and integrated manifold. The published rating for the

assigned values of those performance characteristics are based on a square foot of frontal area

of the exchanger (A unit multiple of one base square foot). This value applies to all exchangers

as the depth size of eight (8) inches and plate spacing distance of 1/16” is universal. For sizes

greater than one (1) square foot, the number of layers in the width direction and the number of

layers in the height direction simply increase. The term Published Rating includes the rating of

all performance characteristics shown on the unit or published in specifications, advertising or

other literatures controlled by Energy Wall, at stated Rating Conditions.

Model Number Options

Example EW8 7 24 24 T

Type Area (ft2) Width (inch) Height (inch) Airflow Direction

EW – Energy WallTM 7 ft2

Multiple Over Base Unit of 1 ft2

Any 3” Interval Any 3” Interval S – Straight

HW – Heat WallTM T - Transverse

8 inch Depth 1/16” Plate Spacing

Note: Center Divide Length = Height

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Energy WallTM

Features and Benefits

Energy WallTM

Heat and Moisture Recovery For Applications <110F Operating Temperature

An Energy WallTM

Energy Recovery Wall is a superior alternative to (or replacement for)

an Energy Recovery Wheel, to significantly reduce the operating and maintenance costs

of a new (existing) commercial HVAC system.

Heat Wall

Heat Recovery For Applications <110F Operating Temperature

General...

Compatible Geometry: Counter-flow Design provides an economical plate style

alternative to Energy Wheels.

Improved Air Quality: Antimicrobial – Kills more than 80% of Airborne Bacteria

(Bacterial Killing Properties Equivalent to Having MERV 12 Filter). Salt-infused

membrane inhibits mold growth.

Efficient Energy Transfer: Transfers Heat and Moisture at efficiency ratings highest in

the market. The New Standard.

Low Resistance Air Flow: Patented Bi-axially oriented Poly Spacer increases

transfer area enhancing air flow.

Air Purity: Selectively-permeable membrane minimizes cross contamination.

Adaptable: Readily sized to meet all applications. Largest Size Range in Market.

Dependable: Resists particle build-up. No micron-sized pores to clog. Moisture

transfer unaffected by particulate loading.

Reliable: Design life exceeds 10 years.

Maintainable: Passive -- Minimal maintenance required.

Available: Minimal service downtime.

Flexible: Supports either Straight or Traverse Air Flow pattern.

Safe: Passes UL 900 Fire and Smoke Test.

Economical: Costs comparable to quality energy wheel.

Environment: Lowest Operating Temperature of any Air-to-Air exchanger; operates in

99% RH Humidity Without Deliquescing

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Manufacturing…

Ultrasonically welded seams – No glue or tape used in core.

Only Enthalpy Exchanger built from one (1) continuous membrane.

Design…

Components: (1) Core Membrane, (2) Core Spacer, (3) Integrated Manifold.

Air Flow Pattern: Patented Counterflow Design provides an economical, efficient Plate-

Style alternative to Energy Recovery Wheels.

Core Membrane: Patented Ceramic Membrane ensures High Efficiency Energy

Transfer.

Core Spacer: Patented Bi-axially oriented Poly Spacer maximizes Energy transfer

area and air flow.

Integrated Manifold: Directs Air Flow. Sized to fit all applications.

HVAC Impact: Chiller and Boiler Capacity can be reduced (30-40%).

Sizing: Modular Components accommodates all design and retrofit sizing requirements.

Performance: Performance Testing based upon 200 SCFM Per Sq FT of exchanger

frontal area.

Installation…

Modular Stacking – No heavy equipment required.

Maintenance…

No Maintenance for most applications.

No Moving Parts.

Infinitely washable with manufacture supplied salt water without performance loss.

Less susceptible to clogging – Tapered inlets and salt-infused membrane.

Naturally Corrosion Proof – Ceramic Membrane and Polyethylene Manifolding.

Naturally Frost Proof – when occurring, not damaged by frost or ice build-up.

Question About Your Application? Contact Us.

Energy Wall LLC

1002 New Holland Ave. Lancaster, PA 17601 Tel.: 717-814-5365 e-mail: info@energywall.com

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Energy Wheel vs. Energy WallTM

Note on Depth

The 2008 ASHRAE Handbook-HVAC Systems

and Equipment states “Sufficient space should

be provided in front of and behind the filter to

make it accessible for inspection and service. A

distance of 20 to 40 in. is required (pg 28.12).”

Energy WallTM

does not require these lead-up

distances; an integrated manifold provides

space for necessary airflow distribution and for

inspection and servicing, if necessary. An

Energy Wall will adapt into any existing Wheel-

style Air Handling Unit which follows the

recommendations of ASHRAE. In existing OEM

applications that do not currently adhere to

recommended ASHRAE offset requirements, the

long-term benefits of an Energy WallTM

application justify any changes necessary to

accommodate increased space requirements. A

solution is also available for those applications

involving an angled wheel.

Performance Ratings Energy Wheel Energy WallTM

Supply Air Flow (SCFM) 2,200 2,113

Required Outside Air Flow (CFM) 2,728 (1.24 OACF) 2,218 (1.05 OACF)

Pressure Drop (inches) 1.0 1.1

Net Total Effectiveness 72% 70%

Motor Energy (Watts) 37-138 None

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The Principle of the Wall

Energy WallTM

can be configured to

accommodate either a “Straight Flow” Air Path

which matches that of a traditional Energy

Wheel or a “Transverse Flow” Air Flow which

matches that of existing plate-type exchangers.

Conventional wisdom associates Wheel-type

exchangers with large commercial air handler

applications due to cost and efficiency benefits,

and Plate Type exchangers with smaller

residential/commercial applications due to size

and maintenance benefits.

Energy Wall™ is the first product that can

successfully operate as a single core, replacing

existing Energy Plate- exchangers - OR as a

modular "energy wall", replacing Energy Wheel

exchangers. An Energy WallTM

is a simple,

reliable, and efficient means of enhancing indoor

air quality for both commercial and residential

applications.

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Counterflow Design

The innovative Energy WallTM

counter-flow

design has the same membrane area as the

conventional cross-flow design, but with

efficiency performances equal to or greater than

the traditional Hex and Z counter-flow designs.

An Energy Wall multiple opening counter-flow

design is more compact than conventional

energy exchanger designs. Energy WallTM

is

constructed in a fully automated process using

just one (1) continuous membrane strip and one

(1) continuous spacer strip, significantly

reducing the chance for cross-contamination.

All edge seams are ultrasonically welded giving

lasting performance.

Layer A Layer B Combined Layers

Energy WallTM

Layer Geometry Diagram

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Ceramic Membrane Infused with Salt Crystals

At the heart of Energy WallTM

technology is a

patented gamma alumina ceramic membrane

with re-enforcing fibers infused with salt crystals.

The membrane “encourages” the transfer of

desirable Heat and Water Vapor while blocking

the transfer of undesirable gases, contaminants,

and odors. The Energy WallTM

membrane is

one of the most selectively permeable materials

on the market. It is manufactured economically

providing unprecedented value to the customer.

Rapid Water Vapor transport through the solid

membrane is achieved through a first-order

chemisorption process driven by the differences

in the partial pressure of water vapor. Efficient

Heat transport is achieved through high

membrane surface area and thermally

conductive materials.

High Latent Transfer – Vapor passes by

chemisorption (not by physical porosity) which

gives up to 85% moisture transfer efficiency.

High Sensible Transfer – Gamma alumina

ceramic particles offer better heat transfer than

aluminum by disrupting the boundary layer.

Long life – Testing has shown a long life

expectancy in excess of twenty-five (25) years

with no known failure mechanism if proper pre-

filters are in place. LiCl salt crystals are infused

into the gamma alumina porosity making them

highly resistant to dirt/particulate build-up.

Sticky airborne particles that pass by the pre-

filter tend to just ‘float’ on membrane surface.

Frost-Proof – The Eutectic point for LiCl

gamma membrane is -80F! The salt crystals

inhibit the formation of ice crystals by lowering

the freezing point of the condensation. The core

will operate in conditions well below 0F without

condensation or frost formation complications

(<40% Inside Relative Humidity).

Infinitely washable in salt water – Energy

WallTM

is designed to be fully submerged and

washed innumerable times without any loss in

performance efficiency, seal weakening, or

antimicrobial properties. The stackable block

design allows for easy removal for those

specialized applications that will require cleaning

(A typical application will not require any

maintenance or cleaning). Proper salt water for

cleaning can be economically purchased

through Energy WallTM

. We also offer a nominal

cleaning/re-charging service if preferred.

Passes Stringent UL 900 Fire Test – The

Energy WallTM

membrane is largely comprised of

incombustible gamma alumina particles and salt

crystals. The membrane will ‘char’ upon

exposure to direct flame, protecting the

remaining binder fibers from producing

excessive smoke. Energy Wall is classified as a

class 2 type filer under UL 900 testing.

Superior Tensile Strength – able to handle

greater than 4” wg pressure differentials.

Energy WallTM

Membrane

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Bi-Axial Oriented Poly Spacer

Conventional Spacer Technology

Energy Wall’s patent pending bi-axial oriented

poly spacer is superior to conventional spacer

technologies. Other spacer technologies make

use of solid aluminum corrugated substrates

which limit air flow to that of defined fluted

channels. Air is prohibited from moving in a

nonlinear path through the exchanger and is

kept further away from the membrane surface.

Conventional technologies employ rigid spacers

which pre-set layer spacing and provide

substrate structure. The spacer is typically glued

to the transferring substrate to minimize the

impacts of substrate expansion and contraction

when exposed to varying environmental

conditions. The gluing process inhibits portions

of the substrate from effectively transferring

moisture. The rigid nature of the spacer

prevents the Energy Exchanger from either

being compressed or stretched to optimize

efficiency vs pressure-drop performance.

Energy Wall’s ceramic membrane does not

expand or contract with changing environments;

consequently there is no need to glue the spacer

to the membrane. In addition, the Energy Wall

spacer is flexible; this enables layer spacing to

be set in such a manner as to optimize efficiency

vs pressure-drop performance.

Bi-Axial Poly Spacer

Energy WallTM

processes its own patent pending

poly spacer which allows for bi-directional air

flow. This poly spacer has significant

advantages over conventional spacers. No glue

is used in the manufacturing of an Energy Wall

heat and moisture exchanger. The spacer

maintains layer spacing for the life of the

product, The spacer permits bi-directional,

counter-air air flow.

The Bi-Axial Poly Spacer ensures low pressure

drop. Through the implementation of a more

open spacer material a lower pressure drop is

observed while eliminating unessential product

weight. Since the spacer is “floating” in the air

stream, not glued to the membrane, by simply

increasing the number of layers built into the

core, we can achieve custom layers per inch

with the same materials and manufacturing

process. There are no internal bonds or joints

associated with the construction of Energy

WallTM

Cores, giving them unprecedented

longevity.

Conventional Spacer Technology Energy Wall’s Bi-Axial Poly Spacer

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Antimicrobial

Antimicrobial Test

The Pennsylvania State University conducted an

independent and unprecedented study of the

antimicrobial effectiveness of Energy Wall in a

full scale ASHRAE 52.2 compliant test rig.

Testing was the most comprehensive study on

any such air-to-air exchangers in the open

literature including testing not only on the

membrane itself but also on the membrane’s

ability to reach out and deactivate spores from a

challenging airstream. The detailed report is

available for download at www.energywall.com

with a summary as follows:

Airborne Bacterial Effectiveness

Energy WallTM

removes 82% of viable spores in air stream

Energy WallTM

yielded the equivalent performance of a MERV 12 Type Filter

Challenging Bacteria Deposited on Membrane Average Deactivation

Bacillus Subtilis 79%

Pseuduomonas Aeruginosa 83%

Staphylococcus Aureus 53%

Penn State University Antimicrobial Test

Antimicrobial Testing Apparatus Component Diagram

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Washable

Energy Wall is designed to be a maintenance free product for ten (10) years or more with the proper pre-

filers in place. A vacuum to suction off particulate buildup on the front surface of exchanger is

recommended in applications where the pre-filter has been removed, not installed, or bypass around the

pre-filter is occurring.

The Energy WallTM

salt-infused ceramic membrane is more resilient to particle build-up than any

other energy recovery technology because there are no micron-sized pores to clog. However,

Energy WallTM

still recommends the use of a pre-filter commonly employed for other energy recovery

technologies for long life (MERV 6 or higher). Ensure bypass around pre-filters is minimal. Energy

WallTM

has been meticulously designed to be robust, long-lasting, and require little to no maintenance

over its lifetime.

Washing may be required for those special applications where (1 sticky particulate loading such as tar

and oil is high, (2) pre-filters are missing or improperly installed, or (3) proper controls have failed and

extensive sub-freezing condensation has occurred. Energy WallTM

can be washed with factory

supplied salt water innumerable times without loss of performance or reduction in anti-microbial

properties.

Corrosion - Energy WallTM

will operate in corrosive environments such as swimming pools, coastal

locations, and industrial processes without damage or reduced lifespan. All manifolding is made from

chemical resistant polyethylene. Ultrasonically welded core seams unaffected by moisture or chemicals.

Deliquescing – Energy WallTM

will not deliquesce in 99% Humidity Air Streams. Proper controls should

be in place to prevent the core from condensing (See Frost and Freeze Section).

Fouling - Energy WallTM

is composed of a ceramic gamma alumina membrane infused with salt crystals.

There are no micron-sized pores that can be blocked which are found on most other energy recovery

devices. The salt infused membrane is more resilient to particle buildup than any other membrane

commercially marketed. Ultrasonic welds create a tapered inlet which further resists build-up.

Energy WallTM

Ultrasonically Welded Inlets

Conventional Enthalpy Plate Inlets

Build-up more

likely on flat

leading edge

Tapered Inlets

Resist Particle

Build-up

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Frost and Freeze Protection

Energy WallTM

employs a membrane with infused lithium chloride salt with eutectic point of -80F. The

technology is naturally frost and freeze proof, enabling it to operate in lower temperatures than

any previous energy recovery wheel or plate exchanger. While Energy Wall has this inherent frost-

free protection built into it, we still recommend the same frost control strategies as employed with

energy wheels on commercial installations to avoid having to re-charge the product. Prolonged

sub-freezing conditions producing excessive condensation may weaken the bond between the lithium

chloride salt and gamma alumina ceramic particles. No damage will occur to the product, but it may have

to be re-charged to return the core to original manufacturer’s performance (See Washable Section). It

should be noted that extreme conditions causing recharging to be necessary would permanently damage

most, if not all, existing wheel and plate technologies beyond repair. The following table lists typical frost

threshold temperatures for Energy Wall over a wide range of indoor air temperatures and relative

humidity. Frost control is not required until outdoor air temperatures are below the threshold.

Frost Control Designs

In regions of extreme winter temperatures, Energy WallTM

ERV components are utilized effectively with

specific frost control techniques, such as:

Preheat frost control, a universally applicable strategy which meets all design requirements

Variable effectiveness with bypass, which can be used to advantage in a limited number of

applications.

On/Off System Fan Control

Indoor Air R.H. % Indoor Air Dry Bulb Temperature

70°F 72°F 75°F 80°F

20 -14 -13 -11 -8

30 -3 -2 -1 3

40 5 7 9 11

50 12 13 15 18

60 18 19 21 26

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Performance Testing

A modular system approach

Energy Wall is tested according to AHRI

Standard 1060-2005 Method of Testing Air-

to-Air Heat Exchangers. The entire Energy

Wall family product line is based on the

performance of model EW8. Face velocity,

efficiency, and pressure drop are common

across all option sizes. This design

dramatically simplifies the engineering and

minimizes the confusion often associated

with hundreds of different certification

documents and performances for various

model sizes from other vendors. All Energy

Wall cores are 8 inches in depth with 16

membrane layers per inch (1/16” plate

spacing), manufactured in an automated and

continuous line from one (1) membrane roll

and one (1) spacer roll.

EW8-1 Performance EW8-7 Performance

Supply Air Flow (SCFM) 200 SCFM 1400 SCFM

Return Air Flow (SCFM) 200 SCFM 1400 SCFM

CFM per sq ft 200 CFM per Square Foot 200 CFM per Square Foot

Face Velocity 400 FPM 400 FPM

Equivalent Wheel Face Velocity Approx. 600 FPM Approx. 600 FPM

Sensible Effectiveness 79% 79%

Latent Effectiveness 62% 62%

Total Effectiveness 72% 72%

Pressure Drop (inch wg) 1.1” wg 1.1” wg

Energy Wall’s Performance Ratings the Same For All Sizes

Energy WallTM

EW8 Exchanger Performance

Testing Based On:

200 CFM Supply and 200 CFM Return

Per Sq Ft Frontal Area

12 Inch

12 Inch

8 Inch

Depth

1 SQ FT

1/16 “ Plate Spacing

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Installation

Energy WallTM

can be quickly installed into an

Air Handling Unit or Ductwork with minimal

chances of cross-contamination or leakage.

Individual modules with a maximum height of

42” are stacked on top of or next to each other

to attain a complete wall. The modules are

lightweight and can be installed or removed by

one or two laborers without additional

equipment.

Energy WallTM

can be orientated and

positioned in any direction.

Vertical Divide Horizontal Divide

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Product Directory

Modular Design

Energy Wall’s modular design provides

unmatched design flexibility, allowing for greater

customization while simplifying shipment and

installation. All of Energy Wall’s products

exceeding a height of 42” are composed of a

number of stackable, more manageable,

modules. Each module includes our patented

ceramic membrane heat and moisture

exchanger as well as a configurable manifold

(Transverse or Straight). Various combinations

of Energy WallTM

modules will produce either a

Square Series Wall (width = height) or a

Rectangular Series Wall (width ≠ height).

Square Series

Energy Wall’s Square Wall Series are direct

replacements for energy wheels. Square Walls

match energy wheels in both cost and efficiency,

all while maintaining a comparable geometric

footprint. With little to no design changes,

engineers, OEM’s, and end use customers can

replace an undesirable energy wheel with a

maintenance free alternative. Energy Wall’s

Square Walls are perfect for retrofit applications

or current designs specifying energy wheels.

Rectangular Series

Energy Wall’s Rectangular Series provide a

unique design advantage in that they do not

require their height and width to be of the same

length. Rectangular Series Walls allow for a

natural design flow for installations with

rectangular air ducts. Each Series is delineated

by its width: the height of the final unit is chosen

by selecting a combination of modules, where

each module may possess either a unique or

equal height. Any combination of modules may

be stacked to achieve the design requirements.

Energy Wall’s Modular Exchangers

(Select Products)

Energy Wall Rectangular Series

(15”X60”)

Energy Wall’s Square Series

(78”X78”)

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Square Series (Wheel Replacement)

www.EnergyWall.com ● info@energywall.com

Energy Wall LLC ● 1002 New Holland Ave ● Lancaster PA 17601 ● 717.814.5365