Raypak 181, 400, 330, 260, 182 User Manual
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INSTALLATION & OPERATING
INSTRUCTIONS
D-2
Power
Vent
For 181/182, 260/261, 330/331 &
400/401 – Boilers & Water Heaters
WARNING: If these instructions are not followed exactly, a fire or explosion may
result causing property damage, personal injury or death
FOR YOUR 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 TO DO IF YOU 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.
CATALOG NO. 6000.57G Effective: 05-27-10 Replaces: 12-12-08 P/N 241086 Rev. 8
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 List
on page 15
Additions: Note on page 4, Wiring Diagrams on pages 11-12
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CONTENTS
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 (Low NOx) 10
330-400 H4/WH1 (Atmospheric) 11
331-401 H4/WH1 (Low NOx) 12
Sequence of Operation 14
Start Up Procedures 14
Draft Proving Switch 14
Illustrated Parts List 15
WARNINGS
Pay Attention to These Terms
DANGER:
WARNING:
CAUTION:
NOTE:
NOTE: 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.
Indicates the presence of immediate hazards which will cause severe
personal injury, death or substantial property damage if ignored.
Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.
Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.
Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
3
Receiving Equipment
On receiving your equipment, check the carton visually for external damage. If the carton is damaged, make
note on the Bill of Lading when signing for the equip-
a
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 Lading. Claims for
shortages and damages must be filed with the carrier
by consignee.
Minimum
Model No.
181/182 4” 008757 120V
260/261 4” 008757 120V
330/331 4” 008758 120V
400/401 4” 008758 120V
Table A: Draft Assembly Application and Kit Numbers
Connection
Diameter
Kit
Number
Factory
Wired
Purchased parts are subject to replacement only
under the manufacturer's warranty. Debits for defective 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 warranty 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 MANUAL SHOULD BE MAINTAINED IN LEGIBLE 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 combustion 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.
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 jurisdiction 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.
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.
NOTE: The D-2 Power Vent comes factory-wired for
120V, but can be field-converted for 240V operation.
See wiring diagrams.
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.
4
7. Mount the Power Vent on the outer top.
TABS
BEFORE AFTER
TOP VIEW
LEFT SIDE FRONT VIEWREAR VIEW
EXHAUST
OUTLET
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 appliance.
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.
Fig. 1: Reposition the Tabs as Necessary (see step 10)
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.
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
13. Re-mount the front door along with the knurled
screw on the heater.
Note: The 90° elbow may be used as a termination cap.
Fig. 2: Draft Assembly
5
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