McQuay WCA Installation Manual
Installation and Maintenance Data
Group: WSHP
Part Number: 667691801
Date: March 2010
IM 1072
Water to Water Source Heat Pumps 3 to 35 Tons with R-410A
WRA - Heating and Cooling Models
WHA - Heating Only Models
WCA - Cooling Only Models
©2010 McQuay International
Table of Contents
Nomenclature ..........................................................................2
Safety Information ..................................................................3
Electrical Data .........................................................................4
Installation ........................................................................... 4-7
Pre Installation and Code Requirements ..........................4
Applications ................................................................. 5-6
Start Up ...................................................................................7
Maintenance Procedures ..................................................7
Dimensional Data .............................................................. 8-10
WRA, WCA, WHA, Size 036-072, 60Hz .......................8
WRA, WCA, WHA, Size 120-180, 60Hz .......................9
WRA, WCA, WHA, Size 240-420, 60Hz .....................10
Physical Data .......................................................................1 1
Cooling Mode Operating Pressure (PSIG)
WRA and WCA Models ................................................11
Heating Mode Operating Pressures
WRA and WHA Models ................................................ 11
Antifreeze Correction Factors ........................................11
Wiring Diagrams ............................................................. 12-14
208-230/60 Hz - 1 Phase, Sizes 036, 048, 060 & 072 ...1 2
3-Phase, Unit Sizes 036, 048, 060 & 072 ......................1 3
3-Phase, Unit Sizes 120, 150, 180, 240, 300,
360 & 420 ......................................................................14
Circuit Diagrams ............................................................. 15-17
WHA Circuit Diagram ...................................................1 5
WRA Circuit Diagram ...................................................1 6
WCA Circuit Diagram ...................................................1 7
Check, Test & Start Form .....................................................18
General Service Guide ..........................................................19
Replacement Parts List .........................................................20
McQuay WSHP Product Model Nomenclature
W WRA 1 036 E F T F YY FS A C Y A PVM
Product Category
W = WSHP
Product Identier
WRA = Heating and Cooling Models
WHA = Heating Only Models
WCA = Cooling Only Models
Design Series
1 = 1st Design
2 = 2nd Design
3 = 3rd Design
4 = 4th Design
Nominal Capacity
036 = 36,000 Btuh Nominal Cooling
048 = 48,000 Btuh Nominal Cooling
060 = 60,000 Btuh Nominal Cooling
072 = 72,000 Btuh Nominal Cooling
120 = 120,000 Btuh Nominal Cooling
150 = 150,000 Btuh Nominal Cooling
180 = 180,000 Btuh Nominal Cooling
240 = 240,000 Btuh Nominal Cooling
300 = 300,000 Btuh Nominal Cooling
360 = 360,000 Btuh Nominal Cooling
420 = 420,000 Btuh Nominal Cooling
Controls
E = Electromechanical
T = Temperature
Control System
Voltage
E = 208-230/60/1
F = 208-230/60/3
K = 460/60/3
L = 575/60/3
Source Water to Refrigerant
Heat Exchanger Construction
C = Copper Inner Tube Steel Outer Tube
S = Cupro-Nickel Inner Tube Steel Outer Tube
Y = None
Construction Type
A = Standard
Refrigerant
A = R-410A
Desuperheater
Y = None
D = Waste Heat Recovery
Water Heater
Cabinet Electrical
YYY = None
PVM = Phase Monitor
Monitors Voltage
and Phase Loss
Water Piping Location
F = Front
T = Top
L = Left Hand Side
R = Right Hand Side
Status Lights
YY = None
SL = Three Lights-Compressor-1,
Compressor-2, Compressor fault
The information in this manual supersedes and replaces previous manuals with regard to McQuay products. Illustrations cover the general appearance of McQuay prod-
ucts at the time of publication and McQuay reserves the right to make changes in design and construction at anytime without notice.
Page 2 of 20 / IM 1072 Water to Water Source Heat Pumps
Control Box Location
F = Front
L = Left Side Control Box
R = Right Side Control Box
NOTE: For illustration purposes only. Not all options available with all models.
PleaseconsultyourlocalMcQuayRepresentativeforspecicavailability.
Freezestat
YY = None
FS = Adjustable for Geothermal and
Boiler/Tower Application
Safety Information
Safe Operation Rules
Installation and maintenance are to be performed only by
qualied personnel who are familiar with and in compliance with
state, local and national codes and regulations, and experienced
with this type of equipment.
Please take a few minutes to read the instructions before
you install the heat pump. This will help you obtain the full
value from this unit. It will also help you avoid needless costs
that result from incorrect installation and are not covered in
the warranty.
Follow these instructions carefully. Failure to do so could
cause a malfunction of the heat pump, resulting in injury, death
and/or property damage.
Tubing and compressor contain high pressure refrigerant
and they must not be exposed to high temperature or be punctured.
To prevent electrical shock, disconnect electric power to
system at main fuse or circuit breaker box until installation
is complete.
Sharp edges and coil surfaces are injury hazards. Avoid
contact with them.
Safety and Signal Words
!
WARNING
!
CAUTION
Danger Label
White lettering on a black background except the word
DANGER which is white with a red background.
Electric Shock Hazard.
Turn Off All Power
Before Servicing.
Warning Label
White lettering on a black background except the word
WARNING which is white with an orange background.
Fire Hazard.
Use copper wire only.
Failure to observe
could result in property
damage, bodily injury
or death
The signal words DANGER, WARNING and CAUTION
are used to identify levels of hazard seriousness. The signal word
DANGER is only used on product labels to signify an immedi-
ate hazard. The signal words WARNING and CAUTION will
be used on product labels and throughout this manual and other
manuals that may apply to the product.
DANGER
Immediate hazards which WILL result in severe personal
injury or death.
WARNING
Hazards or unsafe practices which COULD result in severe
personal injury or death.
CAUTION
Hazards or unsafe practices which COULD result in minor
personal injury or product or property damage.
Caution Label
White lettering on a black background except the word
CAUTION which is white with a yellow background.
Cuts and Abrasion
Hazard.
Wear gloves and handle
with care.
Failure to observe could
result in bodily injury.
This unit contains HFC-(R-410A), a azeotropic mixture of
R-32(Diuoromethane)andR-125(Pentauoroethane).Do
Not Vent HFC-(R-410A) to the atmoshpere. The U.S. Clean
Air Act requires the recovery of any residual refrigerant. Do
not use R-22 service equipment or components on R-410A
systems.
!
WARNING
Water to Water Source Heat Pumps IM 1072 / Page 3 of 20
Electrical Data – WRA, WHA, WCA 036 – 420
Unit Size
Compressor Total Min./Max. Min. Circuit Max. Circuit Max. Fuse
036
048
060
072
120
150
180
240
300
360
420
Voltage-Hz-Phase
208-230/60/1
208-230/60/3
460/60/3
575/60/3
208-230/60/1
208-230/60/3
460/60/3
575/60/3
208-230/60/1
208-230/60/3
460/60/3
575/60/3
208-230/60/3
460/60/3
575/60/3
208-230/60/3
460/60/3
575/60/3
208-230/60/3
460/60/3
575/60/3
208-230/60/3
460/60/3
575/60/3
208-230/60/3
460/60/3
575/60/3
208-230/60/3
460/60/3
575/60/3
208-230/60/3
460/50/3
575/60/3
208-230/60/3
460/60/3
575/60/3
RLA (each) LRA (each)
16.7
10.4
5.8
3.8
23.1
16.1
7.1
5.6
30.2
20.6
9.7
7.7
22.5
10.6
7.7
20.1
9.7
7.7
22.5
10.6
7.7
25
12.2
9
30.2
16.7
12.2
48.1
18.6
14.8
51.3
22.5
19.9
55.8
27
23.8
79
73
38
36.5
134
91
46
37
158
155
75
54
149
75
54
155
75
54
149
75
54
164
100
78
225
114
80
245
125
100
300
150
109
340
173
132
Amps Volts Ampacity Breaker Size
16.7
10.4
5.8
3.8
23.1
16.1
7.1
5.6
30.2
20.6
9.7
7.7
22.5
10.6
7.7
40.2
19.4
15.4
45
21.2
15.4
50
24.4
18
60.4
33.4
24.4
96.2
37.2
29.6
102.6
45
39.8
111.6
54
47.6
197/253
187/253
414/506
517/632
197/253
187/253
414/506
517/632
197/253
187/253
414/506
517/632
187/253
414/506
517/632
187/253
414/506
517/632
187/253
414/506
517/632
187/253
414/506
517/632
187/253
414/506
517/632
187/253
414/506
517/632
187/253
414/506
517/632
187/253
414/506
517/632
20.9
13
7.3
4.8
28.9
20.1
8.9
7
37.8
25.8
12.1
9.6
28.1
13.3
9.6
46.4
21.8
17.3
50.6
23.9
17.3
56.3
27.5
20.3
68
37.6
27.5
108.2
41.9
33.3
115.4
50.6
44.8
125.6
60.8
53.6
35
20
15
15
50
35
15
15
60
45
20
15
50
20
15
60
30
25
70
30
25
80
35
25
90
50
35
150
60
45
150
70
60
175
80
70
35
20
15
15
50
35
15
15
60
45
20
15
50
20
15
60
30
25
70
30
25
80
35
25
90
50
35
150
60
45
150
70
60
175
80
70
Capacity Data
Installation
Pre-Installation and Code Requirements
After removing the unit from the carton, immediately remove
the panels and inspect for any damage that might have occurred
during shipment. Report concealed damage immediately to the
transportation company and request inspection.
The electric power source must be the same voltage and
phase as shown on the serial plate. Line and low voltage wiring must be done in accordance with local codes or the national
electric code.
Make a survey of the nal location for the unit before setting
it in place. The unit should be centrally located with respect to
the distribution system. Install the unit within a heated area.
Exposure to inclement weather conditions may cause freeze
damage that is not covered by the warranty.
Heating Cooling
Model
36 48,200 34,300
48 58,200 42,100
60 67,200 46,600
72 85,500 62,200
120 129,000 94,500
150 170,400 122,140
180 237,000 157,000
240 290,900 202,400
300 339,720 221,800
360 416,900 284,700
420 493,200 358,600
Note:
At standard rating conditions of:
Heating - 100°F entering load water, 70°F entering source water.
Cooling - 55°F entering load water, 85°F entering source water.
Page 4 of 20 / IM 1072 Water to Water Source Heat Pumps
Btuh Btuh
Installation
Mounting the Unit
The unit should be mounted level on a vibration absorbing
pad slightly larger than the base to provide isolation between
the unit and the oor. It is not necessary to anchor the unit to
the oor.
The electrical connections are accessible from the front. The
compressor can be accessed from either side. A minimum of 24"
clearance in front and sides of the unit should be provided to al-
low sufcient room to make water and electrical connections. If
the unit is located in a conned space such as a closet, provisions
must be made for unit servicing. Unit sizes 036 thru 072 may be
stacked vertically (2 high) in tight mechanical rooms.
Piping the Unit
Both source and load connections must be at least as large
as the unit connection on the unit. The unit may be furnished
with either copper or optional cupronickel coil on either source
or load coaxial heat exchanger. Cupronickel should always be
used when chlorinated water or ground water which is high in
mineral content is the load or source load uid. Never use exible hoses that are smaller (inside diameter) than that of the water
connection on the unit. Make sure hoses and pipes are suitable
for system water pressure and sized for proper ow rate.
The supply and the discharge pipes should be insulated to
prevent condensation damage caused by low water temperature
in the pipes.
If water hammer should occur during start-up or shut down,
slow closing diaphragm type solenoid valves should be used.
Placing the solenoid valve on the outlet side of the system helps
relieve this situation. Due to high pressure drop or poor throttling characteristics, globe and gate valves should not be used,
all ow valves should be ball type.
Domestic Hot Water Heat Recovery
The unit may have an optional factory installed waste heat
recovery feature. The heat recovery device is factory piped to
the refrigerant circuit of the unit. The plumbing to the water
tank and the power to the recovery pump are to be completed
in the eld as required.
Care should be exercised in plumbing water lines to and from
the water heater. Note: It is important that both water lines be
insulated. For run less than 50 feet one way, use 1/2" O.D. water
lines on models sizes 036 thru 072. A run over 50 feet should
be avoided. On models 120 thru 420 specic system data must
be matched to industry standard pipe sizing charts.
To make a connection to Hot Water Heat Recovery:
1. Turn off power or gas valves to the water heater.
2. Turn off water supply to the water heater.
3. Open hot water faucet and drain tank.
4. Connect tubing to “Heat Recovery Water Out” on the unit
and extend this line to the hot water heater. Attach to hot
water heater with ttings.
!
CAUTION
5. Connect tubing to “Heat Recovery Water In” on the unit
and extend this line to the water heater. Attach to cold water
supply. Place pump in this line.
6. Set water heater thermostat as follows:
Electric, Double element - Upper 12 5° F, Lowe r
minimum
Gas, Oil or Single element - 125°F
7. Wire according to single phase diagram (page 12) and three
phase diagram (pages 13 and 14).
8. The piping and wiring are now complete. Turn on water
supply to water heater. With an open hot water faucet, allow tank to ll. Bleed air from water lines. Check for water
leaks. Do not restore power to water heater until after you
have veried that the heat recovery unit is working and you
have hot water circulating back to the water heater. Restore
power to the water heater.
9. On start up of the unit, make the following operation
checks:
■ Pump runs only when the compressor is on. Pump is
turned on by thermostat on compressor discharge
line.
■ All air is purged from water lines.
■ Verify water circulation to and from water heater.
Applications
Cooling Tower/ Boiler Application Closed Loop
Cooling Tower and Boiler Loop System temperature is
usually maintained between 55°F and 90°F. In the cooling
mode, heat is rejected from the unit into the source water loop.
To reject excess heat from the water loop, the use of a closed
circuit evaporative cooler or an open type cooling tower with
a secondary heat exchanger between the tower and the water
loop is recommended. When utilizing open cooling towers
chemical water treatment is mandatory so that the water is free
from corrosive minerals. It is imperative that all air be removed
from the source closed loop side of the heat exchanger to protect
against fouling.
In the heating mode, heat is absorbed from the source water
loop. A boiler can be utilized to maintain the loop at the desired
temperature. In milder climates a “ooded tower” concept is
often used. This concept involves adding makeup water to the
cooling tower sump to maintain the desired loop temperature.
When making water connections to unit sizes 036 thru 072,
a Teon taped thread sealant is recommended to minimize fouling of the pipes. Sweat connections are used for unit sizes 120
thru 420. The water lines should be routed so as not to interfere
with access to the unit. The use of short lengths on high pressure
hose with a swivel type tting may simplify the connections and
prevent vibration transmission to the building.
Before nal connection to the unit, the supply and return
hose kits must be connected together and the system ushed
to remove dirt, piping chips and foreign material. Ball valves
should be installed in the supply and return lines for unit isola-
tion and unit water ow rate balancing. The return valve can
be adjusted to obtain the proper ow rate whenever the unit
heats or cools.
Improperwaterowinthesystemduetopiping,valvingor
improper pump operating will void the warranty.
Water to Water Source Heat Pumps IM 1072 / Page 5 of 20
Water piping exposed to outside may freeze.
!
CAUTION
Pressure/temperature ports recommended both supply and
return lines adjacent to the unit for system ow balancing. Flow
can be accurately set by measuring the refrigerant-to-water heat
exchangers water side pressure drop.
Well Water Application Open Loop
Water pressure must be maintained in the heat exchanger by
placing water control valves at the outlet of the unit. A bladder
type expansion tank may be used to maintain pressure on the
system. Pressure/temperature ports should be used to set ow
rates by checking pressure drop across the heat exchanger. Avoid
using low voltage (24 volt) solenoids, using them may overload
the unit transformer or interfere with the lockout impedance
circuit. Line voltage solenoids across the load side of compressor contactor are recommended. Normally residential systems
require about 2-gpm of ow rate per ton of cooling capacity is
needed in open loop systems.
Discharge water from a heat pump is not contaminated in
any manner and can be disposed of in various ways depending
on local building codes.
Disposal methods may be by recharge well, storm sewer,
drain eld, adjacent stream or pond. Most local codes forbid the
use of sanitary sewer for disposal. Consult the local building and
zoning department to determine compliance in your area.
Earth Coupled Application Closed Loop
Earth coupled closed loop systems should follow the same
International Ground Source Heat Pump Association guidelines
used for closed loop heat pump applications. Once piping is
completed between the loop pump kit and the earth loop, nal
purging and charging of the loop is required. A ush/purge
assembly capable of obtaining a velocity of 2 fps throughout
the entire system is required. Usually a pump of at least 1.5 hp
will be adequate to purge air and dirt particles from the loop
itself for most residential systems. Commercial systems must
be sized carefully using pump manufacturer pump curves and
system specic data. Flush the system adequately to remove as
much air as possible then pressurize the loop to a static pressure
of 20 to 30 psi. This is normally adequate for proper system
operation. Check for proper ow through the unit by checking
pressure drop across the heat exchanger and compare it to the
cooling and heating operating pressure tables on page 11. In
order to achieve proper cooling capacity in a earth coupled close
loop application, a rate of 3 gpm per ton is required. Antifreeze
solutions are required when low evaporating conditions are
anticipated. Always use pressure/temperature ports to provide
proper uid ow rates.
Typical Load Side Applications
There are many load side applications for which the uid to
uid liquid chiller heat pumps can be used. The most popular
used would include: Hydronic baseboard heating, hydronic inslab oor heating, forced air fan coil heating or cooling, ice and
snow removal, heating potable water, heating swimming pools
and spas, and process uid heating and cooling. When specify-
ing load side heat transfer surface it is important to consider the
heat pump output capacities and uid ow rates. Insufcient
load side heat transfer surface may cause unstable heat pump
operating. Pressure/temperature ports should always be used
to determine load side ow rates. Avoid contact of dissimilar
metals in the load side piping system.
The units can provide heating or cooling for pools and spas
without the use of a secondary heat exchanger. This application
would however require a cupronickel load side heat exchanger.
Automatic chemical feeders must never be installed upstream of
the heat pump. An external bypass should be installed to avoid
over owing the heat exchanger which could cause erosion.
Proper pool PH levels and chemical balances must be maintained
to avoid possible heat exchanger damage.
Page 6 of 20 / IM 1072 Water to Water Source Heat Pumps
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