Raypak 181/182 Manual

INSTALLATI N & PERATING

INSTRUCTI NS

CATA OG NO. 6000.57G Effective: 05-27-10 Replaces: 12-12-08 P/N 241086 Rev. 8

WARNING: If these instructions are not followed exactly, a fire or explosion may

result causing property damage, personal injury or death.

F R Y UR SAFETY: Do not store or use gasoline or other flammable vapors and

liquids or other combustible materials in the vicinity of this or any other appliance. To

do so may result in an explosion or fire.

WHAT T D IF Y U SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas

supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or

the gas supplier.

This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for

future reference.

For 181/182, 260/261, 330/331 &

400/401 – Boilers & Water Heaters

D-2

Power

Vent

Rev. 8 reflects the following:

Changes to: Fig. 2 on page 5, Fig. 4 on page 7, Fig, 5 on page 8, Dimensional Drawing on page 13, Illustrated Parts ist

on page 15

Additions: Note on page 4, Wiring Diagrams on pages 11-12

Warnings 3

Pay Attention to These Terms 3

Receiving Equipment 4

General Specifications 4

Installation 4

Mounting the Assembly 4

Wiring a Power Vent Assembly to

an Appliance with IID Ignition 7

Venting 7

Wiring Diagrams 9

182-260 H4/WH1 (Atmospheric) 9

181-261 H4/WH1 ( ow NOx) 10

330-400 H4/WH1 (Atmospheric) 11

331-401 H4/WH1 ( ow NOx) 12

Sequence of peration 14

Start Up Procedures 14

Draft Proving Switch 14

Illustrated Parts List 15

C NTENTS

DANGER: Indicates the presence of immediate hazards which will cause severe

personal injury, death or substantial property damage if ignored.

WARNING: Indicates the presence of hazards or unsafe practices which could cause

severe personal injury, death or substantial property damage if ignored.

CAUTI N: Indicates the presence of hazards or unsafe practices which could cause

minor personal injury or product or property damage if ignored.

N TE: Indicates special instructions on installation, operation, or maintenance which

are important but not related to personal injury hazards.

WARNINGS

Pay Attention to These Terms

N TE: Minimum 18 AWG, 105°C, stranded wire

must be used for all low voltage (less than 30 volts)

external connections to the unit. Solid conductors

should not be used because they can cause

excessive tension on contact points. Install conduit

as appropriate. All high voltage wires must be the

same size (105°C, stranded wire) as the ones on the

unit or larger.

Receiving Equipment

On receiving your equipment, check the carton visual-

ly for external damage. If the carton is damaged, make

anote on the Bill of ading when signing for the equip-

ment. Remove the complete assembly from the carton

if it is damaged, and report the damage to the carrier

immediately. Be sure that you receive the number of

packages indicated on the Bill of ading. Claims for

shortages and damages must be filed with the carrier

by consignee.

Purchased parts are subject to replacement only

under the manufacturer's warranty. Debits for defec-

tive replacement parts will not be accepted and

defective parts will be replaced in kind only per our

standard warranties.

When ordering parts, you must specify Model and

Serial Number of the unit. When ordering under war-

ranty conditions, you must also specify date of

Installation.

Raypak recommends that this manual be reviewed

thoroughly before installing the D-2 Power Vent. If

there are any questions which this manual does not

answer, please contact your local Raypak

Representative.

THIS MANUA SHOU D BE MAINTAINED IN EGI-

B E CONDITION AND KEPT ADJACENT TO THE

UNIT.

General Specifications

The D-2 Power Vent Assembly is tested and certified

to the latest edition of the American National Standard

ANSI Z21.56. standard for pool heaters, Z21.10.3 for

water heaters and Z21.13 for boilers.

The Power Vent Assembly is a fan assisted combus-

tion system designed for application to Raypak Heater

Models 181-401. The unit, when installed as directed,

is capable of operating in applications such as through

the wall venting and reduced horizontal and vertical

vent pipe sizes in new and existing installations.

The D-2 Power Vent assembly includes a blower with

a 120/240 volt 60 Hz 1.0/1.95A 3200 RPM motor, a

plenum complete with a draft proving switch and a

motor relay. When provided for field mounting the

assembly is equipped with a wire harness.

Installation

The equipment must be installed in accordance with

local codes, or in the absence of local codes with the

latest edition of the National Fuel Gas Code, ANSI

Z223.1, the National Electrical Code, ANSI/NFPA 70.

The equipment shall be installed in accordance with

those installation regulations in force in the local area

where the installation is to be made. These shall be

carefully followed in all cases. Authorities having juris-

diction shall be consulted before installations are

made.

Mounting the Assembly

Follow these instructions if the Power Vent

venting system was purchased as an

optional assembly kit.

1. Remove existing pagoda top (outdoor units) or

drafthood (indoor units). To remove the pagoda top,

push the four brackets inward and pull up the pagoda

top. The pagoda may then be discarded.

2. Unscrew the four screws holding the outer top using

a phillips screw driver. Remove the jacket top.

3. Replace the inner stack adapter. If the heater had a

drafthood installed previously, remove the inner stack

adapter and replace it with the Power Vent stack

adapter. Otherwise, install the Power Vent stack

adapter.

4. Unscrew the access panel on the right side of the

appliance. Set aside the screws with the access panel.

5. Remove the knurled screw holding the front door

and set it aside with the door.

6. Mount the jacket top above the unit. Note: Do not

install at this point.

Table A: Draft Assembly Application and Kit umbers

Model o.

Minimum

Connection

Diameter

Kit

umber

Factory

Wired

181/182 4” 008757 120V

260/261 4” 008757 120V

330/331 4” 008758 120V

400/401 4” 008758 120V

N TE: The D-2 Power Vent comes factory-wired for

120V, but can be field-converted for 240V operation.

See wiring diagrams.

7. Mount the Power Vent on the outer top.

8. Route the conduit harness of the Power Vent thru

the outer top hole, around the adapter towards the

back of the unit. Continue routing the harness thru the

corner slot, which leads to open area behind the

access panel. Finally, route only the wire harness thru

the 7/8” grommet hole located on the sway brace.

Follow instructions on page 7 to wire the Power Vent.

Note: Newer units have a 7/8” grommet located on the

rain shield, which would eliminate routing the harness

around the back corner.

9. Re-mount the jacket top to its original position and

screw in the four screws holding it down to the appli-

ance.

10. If the appliance is a 181, 182, 330 or 331, remove

the tabs underneath the power vent using a 5/16” nut

driver and relocate them closer to the center of the

Power Vent as shown in Fig. 1.

11. Mount the Power Vent assembly bottom on the 6”

vent as shown below. Twist the assembly downward.

Snap the mounting brackets into their appropriate slot

to hold the Power Vent in position. Note: While twisting

you may notice some roughness, this is due to a tight

seal between the 6” vent and the Power Vent flue box.

12. Re-mount the access panel.

13. Re-mount the front door along with the knurled

screw on the heater.

TABS

BEFORE AFTER

Fig. 1: Reposition the Tabs as ecessary (see step 10)

Fig. 2: Draft Assembly

TOP VIEW

LEFT SIDE FRONT VIEWREAR VIEW

EXHAUST

OUTLET

Note: The 90° elbow may be used as a termination cap.

U.S. Installations1Canadian Installations2

AClearance above grade, veranda, porch,

deck, or balcony 1ft (30 cm) 1 ft (30 cm)

BClearance to window or door that may be

opened

4ft (1.2m) below or to side

of opening; 1 foot (30 cm)

above opening

3ft (91 cm)

C Clearance to permanently closed window **

Vertical clearance to ventilated soffit located

above the terminal within a horizontal dis-

tance of 2 ft (61cm) from the centerline of the

terminal

5ft (1.5m) *

EClearance to unventilated soffit **

FClearance to outside corner **

GClearance to inside corner 6ft (1.83m) *

HClearance to each side of center line ex-

tended above meter/regulator assembly *

3ft (91 cm) within a height

15ft above the me-

ter/regulator assembly

IClearance to service regulator vent outlet *6ft (1.83m)

Clearance to non-mechanical air supply inlet

to building or the combustion air inlet to any

other appliance

4ft (1.2m) below or to side

of opening; 1 ft (30 cm)

above opening

3ft (91 cm)

KClearance to mechanical air supply inlet 3ft (91 cm) above if within

10 ft (3m) horizontally 6ft (1.83m)

LClearance above paved sidewalk or paved

driveway located on public property 7ft (2.13m) 7ft (2.13m) t

MClearance under veranda, porch, deck or

balcony *12 in. (30 cm) TT

1Inaccordance with the current ANSIZ223.1/NFPA54National Fuel Gas Code

2Inaccordance with the current CAN/CGA-B149 Installation Codes

tVent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves

both dwellings

TT Permitted only if veranda, porch, deck, or balcony is fully open on a minimumof two sides beneath the floor and top of terminal and

underside of veranda, porch, deck or balcony is greater than 1 ft(30cm)

*Clearances in accordance with local installation codes and the requirements of the gas supplier

Fig. 3: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations

Table B: Vent/Air Inlet Termination Clearances

Wiring a Power Vent Assembly

to an Appliance with IID

Ignition

Venting

The vent pipe must be the same size or one size larg-

er than what is indicated. The D-2 Power Vent is

capable of 360-degree discharge rotation and oper-

ates with a positive vent static pressure and with a

vent gas temperature less than 400°F. The total

length of horizontal run shall not exceed an equiv-

alent of 40 feet including termination cap. For all

cases, each 90-degree elbow reduces the maximum

horizontal vent run by 10 feet and each 45-degree

elbow in the vent run reduces the maximum vent run

by 5 feet. See the table below for maximum vent

lengths using 90-degree and 45-degree elbows.

The D-2 Power Vent uses positive pressure to push

flue gases through the vent pipe to the outside. The

vent must be installed to prevent flue gas leakage.

Care must be taken during assembly to ensure that all

joints are sealed properly and are airtight.

The vent must be installed to prevent the potential

accumulation of condensate in the vent pipes. It is rec-

ommended that:

a) The vent be installed with a slight downward slope

of not more than 1/4” per foot of horizontal run to the

vent terminal.

b) The vent be insulated through the length of horizon-

tal run.

For appliances installed in extreme cold climate, it is

recommended that:

a) The vent be installed with a slight upward slope of

not more than 1/4” per foot of horizontal run to the vent

terminal. In this case, an approved condensate trap

must be installed per applicable codes.

b) The vent be insulated through the length of the hor-

izontal run.

Fig. 4: Draft Assembly

The Raypak Power Vent operates with a positive vent

static pressure and with a vent gas temperature that

avoids excessive condensate production in the vent

and as such it is listed as a CATEGORY III appliance.

Exception: When a Power Vent is connected to a ver-

tical vent of sufficient height to generate a negative

draft in the system. Consult sizing guide or factory.

The D-2 Power Vent assembly is suitable for through

the wall venting, and for connection to smaller size

vent pipes and breeching other than the standard

atmospheric heater.

WARNING: Disconnect all electrical power to the

unit before servicing to avoid potential shock injury

or damage to the unit. To change voltages, follow

wiring diagram for correct voltage connections.

Improper wiring connections can burnout the relay

and blower motor.

90 Degree Elbows 45 Degree Elbows

Quantity Maximum

Length (ft) Quantity Maximum

Length (ft)

1 30 1 35

2 20 2 30

3 10 3 25

Table C: Reduced Maximum Equivalent Vent Run

LEFT SIDE

DIAMETER

LEFT SIDE

The D-2 Power Vent assembly includes a wire harness, shown in Fig. 6 below, which provides quick connec-

tions with the respective controls in the heater control box. The harness is of sufficient length to fit the appliance

for which it is sized.

Reference the wiring diagram supplied with each appliance for actual connections.

Fig. 5: Through the Wall Vent

PRESSURE

SWITCH

GAS

VALVE

RELAY

Y/BK

V/BK

V/W

Y/BK V/BK

V/BK

V/W

Fig. 6: D-2 Power Vent Wire Harness

Wiring Diagrams—182-260 H4/WH1 (Atmospheric)

181-261 H4/WH1 (Low N x)

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