WESPAK 5.05 Manual

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Installation and maintenance manual
Manuel d’installation et de maintenance
WESPAK
4.05, 5.05 & 6.05
Belt drive compact air handling units
Centrales compactes de traitement d'air à entraînement par courroies
IOM WPKBD-N.2GBF/09.08
Part number / Code : Q3NSTE864
Supersedes / Annule et remplace : IOM WPKBD-N1GBF/06.05

II

1
English
1 - Introduction
The purpose of this manual is to provide the installation, start-up, operating and maintenance rules to the users of the compact
air handling units.
It does not give a full description of all maintenance works assuring the long life and reliability of this type of equipment. Only
the services of qualified personnel, member of a registered maintenance company, can guarantee a reliable and durable
running of the machine.
2 - Safety Precaution
Before installing the unit, please read the following safety precautions carefully.
Warning
All wiring must not touch the heat source or any moving
parts of fan motor.
Warning
The unit must be GROUNDED to prevent possible hazards
due to insulation failures.
Warning
Ensure the rated voltage of the unit corresponds to the
name plate before carrying out wiring according to the
supplied wiring diagram.
Warning
All field wiring must be installed in accordance with the
national wiring regulations.
Warning
Installation, operation and maintenance must be
performed by qualified personnels who are familiar with
local codes and regulations and experienced with this
type of equipment.
Warning
Confirm the unit is switched OFF before installing or
servicing the unit.
Caution
When undertaking water connection, make sure that any
foreign matters will not be introduced into water piping.
Caution
It is forbidden to undertake any work on electrical
components of the unit, if there is presence of water and
humidity.
Caution
It is forbidden to undertake any work on electrical
components of the unit before disconnecting the power
supply.
Caution
Handling of the unit must be done by using the systems
designed to support its weight.
The manufacturer warranty will not be applied, if all installation instructions stated in
this manual have not been followed.

2
3 - Inspection and Storage
When the equipment is received, all items must be carefully
checked against the bill of lading to be sure all crates and
cartons have been received.
The units are shipped on pallet. Inspect all units for visible
or concealed damages.
In case of deterioration, formulate the precise reserves
on the transport document and send immediately a
registered letter to the forwarder, mentioning clearly
the occured damages and a copy of the letter to the
manufacturer or its representative.
4.1 - Operating limits
Water piping system
Maximum operating pressure 10 bar
Minimum entering temperature +4 °C
Maximum entering temperature +90 °C
Room air temperature Minimum temperature 5 °C
Maximum temperature 32 °C
Supply voltage 400 V ± 10% / 3 ph / 50 Hz
4.2 - Physical data
MODELS 4.05 5.05 6.05
Air flow range m3/h 4000 - 6000 5500 - 7500 7000 - 9000
Nominal air flow m3/h 5000 6500 8000
Fan static pressure Pa 400 400 400
Nominal cooling capacity (tot. / sens.) (1) kW 25.9 / 19.6 36.0 / 26.5 43.2 / 32.0
Chilled water flow l/h 4441 6172 7409
Nominal heating capacity (2) kW 21.3 29.9 35.8
Hot water flow l/h 1223 1716 2056
FAN
Type Double wheel centrifugal
Model DA 9/9 N2T DA 9/9 N2T DA 10/10 N2T
Drive Adjustable pulley - Belt
MOTOR
Type IP55 - PTO - Class F - 400 V / 3 Ph / 50 Hz
Power kW 1.5 2.2 2.2 3.0 3.0
Current A 3.45 4.8 4.8 6.48 6.48
Rotational speed rpm 1420 1430 1430 1430 1430
Do not stand or transport the unit on its end. Temporary
storage must be indoor, completely sheltered from rain,
snow, etc.
Change in the weather (high and low temperatures) should
not damage the unit. Excessively high temperature (60 °C or
more) may deteriorate certain plastic materials and cause
permanent damages. In addition, some electric components
and electronic boards may not operate correctly.
4 - Technical features

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English
4.2 - Physical data (cont'd)
4 - Technical Features (continued)
MODELS 4.05 5.05 6.05
COOLING COILS
Type Copper tubes - Aluminium fins - 2.1 mm spacing
Finned length mm 1360 1800 1800
Number of tubes per row 15 15 17
Number of rows 4 6 4 6 4 6
Number of circuits 15 22 15 22 17 25
Number of empty tubes 0 2 0 2 0 2
Header diameter (inlet/outlet) mm 33 / 42 - 33 / 42 33 / 42 - 33 / 42 33 / 42 - 33 / 42
Condensate drain diameter inch 7/8" 7/8" 7/8"
Water content litres 8.4 16.1 10.5 20.7 11.6 23.2
HEATING COIL
Type Copper tubes - Aluminium fins - 2.1 mm spacing
Finned length mm 1360 1800 1800
Number of tubes per row 15 15 17
Number of rows 2 2 2
Number of circuits 15 15 17
Number of empty tubes 0 0 0
Header diameter (inlet/outlet) mm 33 / 42 - 33 / 42 33 / 42 - 33 / 42 33 / 42 - 33 / 42
Water content litres 5.2 6.2 6.8
ELECTRIC HEATER
Heating element type à ailettes lisse lisse
BE1 capacity kW 12 24 36
BE2 capacity kW 24 36 48 (1)
BE3 capacity kW 36 (1) 48 (1) 60 (1)
Supply voltage 400 V / 3 Ph / 50 Hz + Neutral + Earth
AIR FILTERS
Filter efficiency G2 G4 G2 G4 G2 G4
Media type Synthetic
Length mm 480 470 470
Height mm 445 445 500
Thickness mm 10 50 10 50 10 50
Quantity 3 4 4
DIMENSIONS AND WEIGHT (2)
Length mm 1150 1350 1350
Width mm 1550 1990 1990
Height mm 485 485 540
Weight kg 180 250 280
(1) To be imperatively installed in discharge electric heater casing.
(2) For double skin configuration : 50 mm thick panel filter + cooling coil + heating coil + fan.

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Dimensions (mm)
Fan only casing or
electric heater casing
Standard casing or
silencer casing
Sizes A B A B
4.05 670 1498 1110 1498
5.05 870 1940 1310 1940
6.05 870 1940 1310 1940
5 - Dimensions
5.1 - Fixation dimensions
a) By threaded rods only
b) By threaded rods and hanger rails
Dimensions (mm)
Sizes A B C D E F GH
G2 filter G4 filter
4.05 1498 750 1074 1150 633 1690 82 122 485
5.05 1940 750 1274 1350 833 2132 82 122 485
6.05 1940 852 1274 1350 833 2132 82 122 540
12-way mixing box
2Standard casing
3Silencer casing
4Electric heater casing

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English
5 - Dimensions (continued)
5.2 - Duct connections
98
F
A
C
G
J I
A
I
R
M
L
N
K
H
40 E
DB
285
Ø22
Ø33/42
42
Dimensions (mm)
Sizes A B C D EF G
G2 filter G4 filter
4.05 1438 424 1430 420 62 102 1646 1498
5.05 1880 424 1872 420 62 102 2088 1940
6.05 1880 479 1872 475 62 102 2088 1940
Dimensions (mm)
Sizes H I JK L M N
G2 filter G4 filter
4.05 485 1110 1252 1292 1150 1548 950 500
5.05 485 1310 1452 1492 1350 1990 1290 600
6.05 540 1310 1452 1492 1350 1990 1290 600
Side view Rear view
Front view
Top view
Bottom view
Remark : The dimensions of mixing box connection are identical to those of inlet duct collar connection (dimensions A & B).

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5 - Dimensions (continued)
a) Cooling and heating configuration in the direction of air flow
Installation with 4-row cooling and 2-row heating coils
Sizes A B C D E F G H I
4.05 339 57 356 62 485 89 119 247 185
5.05 339 57 356 62 485 89 119 247 185
6.05 390 57 407 66 540 89 119 247 185
RIGHT-HAND
AIR
I H
A
F
E
B67
42
C
D
G H
285
H
H G
LEFT-HAND
AIR
67
CA
F
E
B
D
42
I
285
Installation with 6-row cooling and 2-row heating coils
Sizes A B C D E F G H I
4.05 351 50 356 62 485 84 140 226 206
5.05 351 50 356 62 485 84 140 226 206
6.05 402 54 407 66 540 84 140 226 206
Installation with 4-row cooling and 2-row heating coils
Sizes A B C D E F G H I J
4.05 356 66 339 90 485 63 112 146 178 56
5.05 356 66 339 90 485 63 112 146 178 56
6.05 407 67 390 90 540 66 112 146 178 60
Installation with 6-row cooling and 2-row heating coils
Sizes A B C D E F G H I J
4.05 356 66 352 83 485 63 112 168 178 50
5.05 356 66 352 83 485 63 112 168 178 50
6.05 407 67 402 83 540 66 112 168 178 55
H G
LEFT-HAND
AIR
C
J
D
EA
F
B
H I
424
42
RIGHT-HAND
AIR
C
J
D
EA
F
B
HI
G H
424
42
Dimensions are in mm.
Dimensions are in mm.
b) Heating and cooling configuration in the direction of air flow
5.3 - Water connections

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English
6 - Installation
6.1 - Unit handling
Be careful to avoid rough handling on the unit. Do not
lift the unit by the condensate outlet or by the water
connections. Use a lifting truck to facilitate the unit
installation.
Warning
Sharp edges and coil surfaces are a potential hazard.
Avoid contact with them.
6.2 - Installation location
1. The units are designed to be installed above the false
ceiling.
2. Install the unit in a position having sufficient strength to
carry the weight of the unit.
3. Install the unit in a position where ducts can be connected
to inlet and outlet sides of the unit.
4. Install the unit in a position from where condensate can
be run to waste easily.
5. Check the distance between the upper slab and false
ceiling to ensure the unit will suit the distance.
6. Ensure there is sufficient space around the unit to service
it (see table hereafter for minimum clearances on service
side of filters and fan-motor assembly access).
Warning
Do not install the unit in a machinery shop or kitchen
where vapour from oil or its mist flows into the unit.
6.3 - Minimum service clearances
Leave sufficient space on the bottom and the sides of the
unit to assure maintenance works or replacement of one or
several internal components.
Sizes 4.05 5.05 6.05
A (mm) 1600 2000 2000
B (mm) 500 500 600
C (mm) 500 500 500
C
B
A

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6.4 - Installation instructions
1. Prepare the fixing center distances at the ceiling for each casing (see section "Dimensions" for fixing center distances).
2. Fix the suspension kit (optional) composed of threaded rods only or threaded rods and hanger rails.
3. In the case that the suspension kit by threaded rods only is supplied, install the casing as indicated in the drawing below.
In the other case, fix the casing on the hanger rails with the aid of fixing screws, see drawing below.
4. On the double casing units, assemble the two casing with the help of factory fitted assembling clamps and screws.
5. Secure the unit in its final position and level it with a spirit level to assure proper drainage and operation.
6. Unit must be mounted in such a way that water will flow toward drain connection.
6 - Installation (continued)
Assembly of two casings
Suspension
kit hanger
rail
Factory fitted assembling
clamps and screws
Final assembly
Suspension kit by threaded rods only (optional)
1
2
3
4
5
2
1Lifting ring
2M10 nut
3M10 threaded rod
4Rubber isolator
5M10 washer
Suspension kit by threaded rods and hanger rails (optional)
1Lifting ring
2M10 nut
3M10 threaded rod
4Rubber isolator
5M10 washer
6Hanger rail
7Rail fixing screws
Threaded rod
M10
Weight 75 kg
Rubber isolator
Washer/nut
M10
1
2
3
4
5
2
6
7

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English
LEFT-HAND connection
RIGHT-HAND connection
RIGHT-HAND service side
LEFT-HAND service side
7 - Water Connections
7.1 - Definition of the service side
The service side, the side where coil connections are located,
is defined left-hand or right-hand, when observer looks at the
unit from above in the direction of air.
Caution
If the units are not equipped with control valves, the air
temperature must not exceed 50 °C.
Warning
To avoid any damage on coil, use two spanners to tighten
the water pipe fittings on each header.
7.2 - Water coil connections
Each water coil is equipped with headers having Ø33/42
male threaded type connection on water supply and water
return.
Air vent must be installed at highest point of the water
piping.
To ensure an optimum heat transfer efficiency, connections
of water supply and return should be arranged in such a
way that a counter flow configuration between air and
water is obtained.
Flexible hoses are recommended for coil connections.
Tighten normally the water connections. Note that an
excessive tightening can cause too strong material stresses
at the time of significant temperature changes.
All water lines should be insulated to prevent sweating and
heat loss.
Air outAir in
Air out Air in

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7.3 - Condensate drain connection
The condensate drain pan is supplied with 7/8" OD copper
tube outlet.
Ensure that water condensate will be properly drained out
from the drain pan which must be connected to the main
drain piping.
The drain line must be installed with a downward slope.
Ensure water trap is available on drain piping.
On completion, the drain line should be insulated.
Warning
All foreign material must be removed from the drain
pan.
Caution
Check that there is no counter-slope which would prevent
condensates from flowing.
B
AA
Trap for condensate evacuation
The height A must be equal to 2 times the value of the
negative pressure present in the condensate reception
zone (example : negative pressure = 40 mm, height A =
80 mm, height B = 160 mm).
7 - Water Connections (continued)
7.4 - Winterizing water coils
In winter, due to a general shutdown of the installation or
a failure of outdoor air damper control, coil freeze-up may
occur.
To avoid coil damage, it is recommended to drain
completely the non used coils or to fill them with an anti-
freeze solution.
The concentration of anti-freeze solution must be regularly
and carefully checked before each winter season.
It is highly advised to place a heating coil before a cooling
coil for an operation during winter season.
Caution
Carefully read instructions for mixing anti-freeze solution
used. Some products will have a higher freezing point in
its natural state than when mixed with water.
The freezing of coils is not the responsibility of the
manufacturer.

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English
Dual-voltage motors with
Y / ∆ connections
Skeleton
diagrams
External connection diagrams
D.O.L. starting Y / ∆ starting
- Voltage : U
- Connection : ∆ (at lower
marked voltage)
- E.G. : 230 V / ∆
- Voltage : U √3
- Connection : Y (at lower
marked voltage)
- E.G. : 400 V / Y
8.1 - Unit connection
Before undertaking any electrical connection, make sure
that the fan motor is suitable for electrical power supply.
All wiring must be done in accordance with applicable
electrical codes and regulations.
Earthing of unit is imperative.
The manufacturer or its representative will not be held
responsible for accidents caused by incorrect or non-existing
earthing.
The units are not supplied with electrical panel.
Wiring on the electric motors must be done at site. All
motors are designed and produced in accordance with the
standards in use.
The connection of these motors will be done according to the
indications affixed on the nameplate and on the diagram
located in the terminal box.
All motors are equipped, as standard, with a normally closed
internal overload protection sensor. This safety device shall
Caution
The electric heater must never operate without the
ventilation.
8 - Electrical connections
be imperatively connected to the control circuit of the motor.
The non-respect of this instruction will cancel compulsorily
the warranty on the motor.
Power supply cables entering into the unit, must be run
through cable glands mounted on unit panel.
All orifices for cable entry done on the panels must be sealed
to prevent leakage.
8.2 - Electric heater
The factory mounted electric heater is fitted with a manual
reset high temperature cut-out switch which de-energizes
the heater in case of fan motor failure.
For electrical connection, refer to wiring diagram sticked on
the unit.
W2
L1 L2 L3
U2 V2
U1 V1 W1
W2
L1 L2 L3
U2 V2
U1 V1 W1
W2
L1
L2L3
W1
V2 V1
U2
U1
Démarreur Y/
W2
L1 L2 L3
U2 V2
U1 V1 W1
W2
L1 L2 L3
U2 V2
U1 V1 W1
W2
L1
L2L3
W1
V2 V1
U2
U1
Démarreur Y/
W2
L1 L2 L3
U2 V2
U1 V1 W1
W2
L1 L2 L3
U2 V2
U1 V1 W1
W2
L1
L2L3
W1
V2 V1
U2
U1
Y/ Starter
W2
L1 L2 L3
U2 V2
U1 V1 W1
W2 V2
L1
L2L3
W1 V1
U2
U1
W2
L1 L2 L3
U2 V2
U1 V1 W1
W2 V2
L1
L2L3
W1 V1
U2
U1
(1) Diagrams valid for :
- 3-phase 230 ∆ / 400 Y V motors with power from 0.25 to 4.5 kW at 1500 rpm and from 0.25 to 5.5 kW at 3000 rpm,
- 3-phase 400 ∆V motors with power higher or equal to 5.5 kW at 1500 rpm, using Y / ∆ starter.
Single speed motors (1)

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9 - Preliminary Checks Before Start-up
When performing startup and service, thorough safety
precautions should always be taken.
Only qualified individuals should perform these functions.
1. Check that the unit is completely and properly installed
with ductwork connected.
2. Check that all construction debris are removed and
filters are clean.
3. Check that the electrical work is complete and properly
terminated.
4. Check that the electrical connections are tight and that
the proper voltage is connected.
Belt alignment
For a quick check,
make sure that
the small rope
touch each end
of the pulleys as
shown on drawing
opposite.
Belt tensioning
90˚
5 kg
10 mm maxi.
5. Check that all holes for cable entry are tightly sealed.
6. Check tightness of setscrews on motors, bearings and
fans.
7. Check alignment of fan and motor pulleys and belt
tension (see drawings below).
8. Check that coil and drain pan connections are properly
done.
9. Leak test thermal system to insure that connections are
tight.
10. Check that condensate drain is trapped.
11. Check that fans rotate freely.

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English
9 - Preliminary Checks Before Start-up (continued)
9.1 - Adjustable pulley adjustment
Mounting
1. The pulley must be mounted on the motor shaft with the
aid of the set screws "A".
2. Be sure that both driving and driven pulleys are in
alignment and that shafts are parallel (see paragraph
"Belt alignment").
3. Securely tighten the set screw "A" on the keyway of the
motor shaft.
Adjusting
1. Loosen the set screw "B" located in the pulley moving
sheave.
2. Adjust the sheave pitch diameter for a desired rotational
speed by opening the moving sheave by half turns or
full turns from the closed position.
Fan rotational
speed
(rpm)
Motor rotational
speed
(rpm)
= x Motor pulley diameter
Fan pulley diameter
3. Securely tighten the set screw "B" on the flat surface of
the pulley fixed sheave.
4. Put on the belt and adjust its tension. Do not force
the belt on the pulley sheaves (see paragraph "Belt
tensioning").
5. The future adjustments should be performed by
loosening the belt tension and by increasing or
decreasing the pulley pitch diameter by half turns or
full turns as required. Re-adjust the belt tension before
starting the motor.
6. Make certain that all parts are in place and that all set
screws are tight before starting the motor. Check set
screws and belt tension after a 24 hour operation.
Remark : The authorized maximum opening of the pulley
is 3.5 turns from the completely closed position. If this
maximum opening is not followed, there is a risk of early
breaking of the belt.
Screw "A"
Screw "B"
Screw "B"
Flat
surface
Flat
surface
Moving
sheave
Fixed
sheave

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Filter removal through the bottom
10 - Maintenance
10.1 - Air filter
Filters should be frequently cleaned to avoid clogging. They
should be inspected every 3 or 4 months under normal
operating conditions and be replaced if necessary.
Unit should never be run without filter.
The filters can be removed for cleaning or replacement,
through the bottom or the side of the unit (see drawings
below).
Note : In case the filters are to be removed from the bottom,
take off the clips on the filters in order to be able to remove
them from the casing.
Caution
Before performing any maintenance operation,
disconnect the unit main power supply.
10.2 - Condensate drain pan
The condensate pan must be checked periodically to make
sure that drain piping is not obstructed.
If required, it must be cleaned and rinsed.
The fan motor assembly bottom panel allows for easy
access, if there is no heating coil located downstream the
cooling coil, to condensate drain pan for cleaning.
10.3 - Coils
Check that coil fins are not clogged or damaged.
To avoid mouldiness of coils caused by an accumulation of
fine dusts, it is recommended to clean them frequently. If
necessary, comb the coil fins with an appropriate tool.
Care must be taken not to damage the fins while cleaning
them.
The coils can be removed for cleaning as shown on the
drawing below.
10.4 - Fan motor assembly
There is no particular maintenance on fan motor assembly.
The units are equipped with permanently lubricated fan
motor bearings. It is not necessary to add oil. However,
during periodic maintenance, check that fan wheel rotates
freely without any friction.
If the fan motor overload protection is tripped, wait for safety
automatic reset and try to find out the cause of overload
protection tripping.
Follow the instructions below to remove the motor and fans
for replacement :
Step 1 : Access panels removal
Disconnect the unit power supply. According to the access
condition, remove either the service side panel and the
opposite panel or the service side panel and the fan motor
assembly access panel.
Step 2 : Motor removal
Take away the drive belt, then the fixing screws from the
motor platform. Push this platform upward to take it from
the fans support rails.
It is recommended to proceed to the following maintenance
works in order to ensure a good operation of the unit.
Filter removal through the side
Coils removal
Clips

15
English
Step 1
Step 3 : Fans dismounting
Remove the first and the second support rails of the fans,
after releasing the 3 fixing screws of the rails to the vibration
isolators, and the 6 fixing screws of the fans to the support
rails.
Note : On sizes 5.05 and 6.05, it is not necessary to remove
the rails, since the set of fans and rails can go through the
service side access.
Step 4 : Fans removal
Pull backwards the fans before taking them out through the
service side access.
10.5 - Electrical connections
Re-tighten periodically the electrical connections.
10 - Maintenance (continued)
Step 2
Step 3
Step 4
10.6 - Water quality
It is not the manufacturer's policy to make recommendations
in terms of water treatment (please contact a specialised
water treatment company).
However, given the critical nature of this subject, particular
care should be taken to ensure that, if treatment is required,
it works effectively.
Using untreated or unsuitable water leads to excessive
clogging inside the coil tubes (earth and mud deposits,
corrosion, etc.) with major consequences on the thermal
efficiency of the unit and irreversible damage to the
equipment.
The manufacturer and its representative decline all
responsability in the event of untreated or incorrectly treated
water being used.
2 screws
per rail

16
Notes

III

As part of our ongoing product improvement programme, our products
are subject to change without prior notice. Non contractual photos.
Dans un souci d’amélioration constante, nos produits peuvent être
modifiés sans préavis. Photos non contractuelles.