Raypak 181/182 User's Manual
Contents
1. D JILDE INPUTS 181 000 THRU 264 000 BTUH jr 9 BURNER TRAY CHG E O 3885 WIRING DIAGRAM ID ECONO LOW NOX POWER VENT 10 13 06 FIRING MODE ON OFF r OPTIO VENT ii I I OPTIONAL W 10 I I 357 a EAT I MOTOR I l BL I b R W l I l V BK I l D die L2 I AIR 120 VOLTS PRESS Sw BK H l 240V OPERATON TNO V W p LE L R UNE J Ch GAS PV PV MV Y Y SOLID STATE ECONOMASTER MAME DEVICE p lt D Y BK G BK FLOW 1 O KEY 24V 105 C 24N 150 C 120V 105 C O WIRE NUT GROUND BLACK ouw W AA YELLOW GREEN BLUE VIOLET WHITE Uo SIZE 181 261 r H4 W1 WH1 li 10 Wiring Diagrams 330 400 H4 WH1 Atmospheric PUMP DATA FACTORY r POWER VENT OPTIONAL V BK AIR PRESS SW R W li 120 VOLTS 240V OPERATION Y LINE w NO V W O Ipu ss RUNE u Z BK w SOLID STATE 120V ECONOMASTER DEMCE lt w GAS Pv Pv MV VALVE G BK TEST SWITCH a HIGH y V TENSION fe dom 9 BURNER TRAY sa L1 HOT w BK 120V L2 COMM ze En O D L1 GRO ND TEMP MANUAL LOW HIGH AUTO R U 2 BK SWITCH RESET LIMIT GAS PRESSURE GAS RESET LIMIT a BK R BR R E KEY ROLL OUT NC NO2. 8 17 00 CHG E O 3771 05 04 06 Rupak un ak R NC Ene NO NOTES USE GROUND CONNECTION PROVIDED FAILURE TO PROVIDE PROPER GROUND MAY RESULT IN LOCK OUT ALL GROUND TERMINATE AT 9 PUMP USED MUST BE RATED 10 AMPS MAX OR 3 4 HP MAX PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES A E CONNECTIONS FOR OPTIONAL E 4 ALARM PANEL Y CHECK CONTROLS PROVIDED WIRED AS SHOWN REPLACE WIRING WITH 105 C WIRE ONLY WIRING DIAGRAM IID ECONO LOW NOX POWER VENT FIRING MODE ON OFF 554 000 THRU 399 000 BTUH NC VALVE BK BURNER TRAY FIELD WIRE O WIRE NUT GROUND BLACK m C A YELLOW GREEN BLUE VIOLET WHITE z UO0 onxuu IS H4 W1 WH1 SEE TABLE D FOR DIMENSIONAL DATA Ne js fe e e o ENEN KEN KEN er ms wm KAN eoo 400 so preme 7e eoo EN KEN KEN Table D Dimensional Data 13 12 95 gt gt Jor lt Nr NS SS 9 S S S S Sequence of Operation On call for heat the D 2 Power Vent fan and appli ance pump start When the flow switch circuits close the ignition system consisting of an electronic spark module pilot gas system and flame sensor are ener gized When draft proving switch closes and all safety circuits are proven the automatic main g
3. NC NC ____ 150 C NOTES USE GROUND CONNECTION PROVIDED FAILURE TO PROVIDE m PROPER GROUND MAY RESULT LOCK OUT ALL GROUND TERMINATE AT CHECKED BY APPROVED BY ORIG E O 3311 CHECK CONTROLS PROVIDED WIRED AS SHOWN 08 17 00 REPLACE WIRING WITH 105 C WIRE ONLY CHG EO 3771 WIRING DIAGRAM IID ECONO POWER VENT 05 04 06 FIRING MODE ON OFF INPUTS 334 000 THRU 399 000 BTUH PUMP USED MUST BE RATED 10 AMPS MAX OR 3 4 HP MAX PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES lt A gt e CONNECTIONS FOR OPTIONAL E 4 ALARM PANEL 24V 120V 120V FIELD WIRE WIRE NUT GROUND BLACK OWN D ANGE YELLOW GREEN BLUE VIOLET WHITE SIZE 330 400 11 TYP E H4 W1 WH1 331 401 H4 WH1 Low NOx m q POWER VENT I I OPTIONAL LD I I eR CAN l MOTOR I l BL I 3 R W l I l V BK I I AIR R W L2 159 vocrs PRESS Sw H I 240V OPERATION NO VW B lt E AA EE NE RUNS Lc TEST L Yoav V PROBE L1 HOT BK KLO m SWITCH L2 cow GROUND SWITCH POWER CHECKED BY APPROVED BY ORIG E O 3311 TRANS 120V MANUAL LOW HIGH RESET LIMIT gas PRESSURE GAS HIGH TENSION O O AUTO RESET LIMIT NC
4. 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 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 dr
5. Clearance to outside corner Clearance to inside corner 6 ft 1 83m 3 ft 91 cm within a height 15 ft above the me ter regulator assembly l Clearance to service regulator vent outlet bi 6 ft 1 83m Clearance to non mechanical air supply inlet 4 ft 1 2m below or to side to building or the combustion air inlet to any of opening 1 ft 30 cm 3 ft 91 cm other appliance above opening r 3 ft 91 cm above if within Clearance to mechanical air supply inlet 10 ft 3m horizontally 6 ft 1 83m Clearance above paved sidewalk or paved 7 ft 2 13m 7 ft 2 13m t driveway located on public property Clearance to each side of center line ex tended above meter regulator assembly Clearance under veranda porch deck or Saten 12 in 30 cm TT In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code In accordance with the current CAN CGA B149 Installation Codes t Vent 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 minimum of 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 Table B Vent Air Inlet Termination Clearances Wiring a Power Vent Assembly to an Applian
6. E CONNECTIONS FOR OPTIONAL E 4 ALARM PANEL Y CHECK CONTROLS PROVIDED WIRED AS SHOWN REPLACE WIRING WITH 105 C WIRE OR ITS EQUIVALENT AND 150 C AS NOTED WIRING DIAGRAM ID ECONO POWER VENT FIRING MODE ON OFF 181 000 THRU 264 000 BTUH 24V 105 C 24N 150 C MAX 120V 105 C O WIRE NUT GROUND BLACK BROWN RED ORANGE YELLOW GREEN BLUE VIOLET WHITE E IDD INPUTS SIZE 182 260 TYPE H4 W1 WH1 181 261 H4 WH1 Low NOx LWCO TENSION L1 HOT POWER SWITCH ke mn md s an i R W L2 COMM T MET o n o GROUND TEMP TEMP MANUAL LOW HIGH AUTO BK SWITCH SWITCH RESET LIMIT Gas PRESSURE GAS RESET LIMIT fos force EE Faja ROLL OUT VENT NC NO NC NC NOTES USE GROUND CONNECTION PROVIDED FAILURE TO PROVIDE PROPER GROUND MAY RESULT IN LOCK OUT ALL GROUND TERMINATE AT 6 amp 9 PUMP USED MUST BE RATED 10 AMPS MAX OR 3 4 HP MAX PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES VENT TEMP SWITCH ONLY PROVIDED ON INDOOR BOILERS lt A E CONNECTIONS FOR OPTIONAL E 4 ALARM PANEL MY CHECK CONTROLS PROVIDED WIRED AS SHOWN REPLACE WIRING WITH 105 C WIRE OR ITS EQUIVALENT AND 150 C AS NOTED CHECKED BY APPROVI ORIG E O 3311 8 17 00 ED BY
7. Receiving Equipment General Specifications Installation Mounting the Assembly Wiring a Power Vent Assembly to an Appliance with IID Ignition 7 Venting 7 9 9 PP B W NEN Wiring Diagrams 182 260 H4 WH1 Atmospheric 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 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 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 Receiving Equipment On receiving your equipment check the carton visua
8. horizon tal run For appliances installed in extreme cold climate it is recommended that 8 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 90 Degree Elbows 45 Degree Elbows Maximum Maximum Quantity Length ft Quantity Length ft LoT NE EHE CEN LT JM qox Table C Reduced Maximum Equivalent Vent Run LA KA FA IS ES IY BS ES LEFT SIDE 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 lll 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 12 MIN 4 EXHAUST VENT LEFT SIDE Fig 5 Through the Wall Vent 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 b
9. 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 NOTE The D 2 Power Vent comes factory wired for 120V but can be field converted for 240V operation See wiring diagrams Factory Model No Wired Minimum Connection Diameter 008757 008757 181 182 260 261 330 331 400 401 120V 120V 120V 120V Table A Draft Assembly Application and Kit Numbers 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
10. INSTALLATION amp OPERATING INSTRUCTIONS D 2 Power Vent For 181 182 260 261 330 331 amp 400 401 Boilers amp Water Heaters CERTIFIED 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 e A Romak q Bie A Bheem Company 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 2 CONTENTS Warnings Pay Attention to These Terms
11. R AND GAS CALL GAS UTILITY Draft Proving Switch The draft proving switch insures that the blower is operating The switch is in the limit circuit and does not allow the ignition module to operate unless it is closed NEGATIVE PRESSURE CONNECTOR Fig 7 Draft Proving Switch Illustrated Parts List Call Out Description 181 261 330 401 008784F 008784F 008156F 008156F NO Pressure Switch 008062F 008135F Elbow 4 90 with Screen 010827F 010827F Flue Box 008682F 008683F Base Assembly 008684F 008685F Flue Collar 008686F 008686F Flue Adaptor 008687F 008688F 4 Flange 008689F 008689F Blower Adaptor 008690F 008690F Control Cover 008691F 008691F Control Swaybrace 008692F 008692F Silicone Hose 008693F 008693F Front Panel 008694F 008694F Blower Cooling Fan 011549F 011549F 15 Registered Quality Management System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A
12. as valves will open and the heater will operate When the operating limit circuit is satisfied the heater will shut down Start Up Procedures The water system the gas system and the electrical system for the heater should be completed and checked as per the heater installation manual and associated documents 1 Turn on power to the heater with the manual main gas valve and pilot gas valve off The electric power supply requirements are a Dual voltage fan motor 120 240 volt 60Hz 1 0 1 95 Amp fan motor for models 181 401 2 Check power connections 3 Close heater power switch 4 Set operating control to call for heat a Fan motor starts draft proving switch clos es b Heater pump starts flow switch closes c Ignition module energized d Check for spark at gas pilot 5 Turn operating control to end call for heat 6 Wait a minimum of 60 seconds 7 Open pilot gas valve a Repeat procedure outlined in 4 above 8 After pilot gas is proven and main safety shut off valve is energized a Main burners will ignite 14 9 Heater will operate until call for heat is satisfied 10 Restart unit and visually check all components for proper operation 11 Check all vent connections and joints for leakage Correct if found 12 To restart unit after a failure follow the procedures outlined above and other subsequent or related sec tions outlined in the heater manual EMERGENCY SHUTDOWN SHUT OFF ALL POWE
13. ce with IID Ignition 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 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
14. iver 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 BEFORE 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 13 Re mount the front door along with the knurled screw on the heater EXHAUST OUTLET TOP VIEW REAR VIEW Note The 90 elbow may be used as a termination cap LEFT SIDE FRONT VIEW Fig 2 Draft Assembly 5 INSIDE CORNER DETAIL A ZN FIXED CLOSED Fig 3 Minimum Clearances from Vent Air Inlet Terminations Indoor and Outdoor Installations U S Installations Canadian Installations Clearance above grade veranda porch 1 ft 30 cm 1 ft 30 cm deck or balcony 4 ft 1 2m below or to side of opening 1 foot 30 cm 3 ft 91 cm above opening Clearance to window or door that may be opened 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 Clearance to unventilated soffit
15. l ly for external damage If the carton is damaged make a note on the Bill of Lading 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 Lading 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 MANUAL SHOULD BE MAINTAINED IN LEGI BLE 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
16. ox 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 RELAY Y BK V BK PRESSURE SWITCH Fig 6 D 2 Power Vent Wire Harness Wiring Diagrams 182 260 H4 WH1 Atmospheric PUMP DATA FACTORY r POWER VENT OPTIONAL AIR PRESS SW I I I I I I v ek I I I l I I I I I R W L2 129 voors L1 I I I l 240V OPERATION W LINE O BL BK PUMP jk sc CERE A BK SOLID STATE ECONOMASTER DEVICE Y GAS Pv PV MV VALVE G BK TEST gt SWITCH B jel iQ 3l C BURNER TRAY V PROBE L1 HOT BK 120V SWITCH i L2 COMM u D u TEMP TEMP MANUAL LOW HIGH AUTO BK SWITCH SWITCH RESET LIMIT GaAs PRESSURE GAS RESET LIMIT GROUND I BK BK E l R BR R E gt ROLL OUT VENT NC NO NC NC KEY NOTES CHECKED BY APPROVED BY ORIG E O 3311 08 17 00 Fo 3883 09 26 06 CHG di Use GROUND CONNECTION PROVIDED FAILURE TO PROVIDE ROPER GROUND MAY RESULT IN LOCK O ALL GROUND TERMINATE AT Se PUMP USED MUST BE RATED 10 AMPS MAX OR 3 4 HP PUMP DELAY ADJUSTIBLE BETWEEN 3 AND 10 MINUTES VENT TEMP SWITCH ONLY PROVIDED ON INDOOR BOILERS A
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