Rheem Raypak D-2 182 User manual

E󰀨ective: 11-30-2020
Replaces: 06-01-2017
P/N 241086 Rev. 11
INSTALLATION AND
OPERATION MANUAL
For Sizes 182, 260, 330,
400, Types H and WH –
Boilers & Water Heaters
WARNING: If these instructions are not followed exactly, a re or explosion may
result causing property damage, personal injury or death.
FOR YOUR SAFETY: Do not store or use gasoline or other ammable 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 re.
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 re department.
Installation and service must be performed by a qualied installer, service agency or
the gas supplier.
D-2 Power
Vent
This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for
future reference.

2
Revision 11 reects the following changes:
Obsolete models 181, 261, 331 and 401 removed from text, gures and table throughout. Text added to "General Specications" on
page 4. Dimension table moved to page 5. Figures 1 and 2 revised on page 5. "Venting" text revised on page 7. Figure 4 revised on
page 8. "Start Up Procedures" point 1 text revised on page 12. Figure in "Illustrated Parts List" revised on page 14.

3
CONTENTS
1. WARNINGS ............................................................ 3
Pay Attention to these Terms .................................. 3
2. RECEIVING EQUIPMENT ..................................... 4
3. GENERAL SPECIFICATIONS .............................. 4
4. INSTALLATION....................................................... 4
Mounting the Assembly ........................................... 4
5. WIRING (IID IGNITION) ......................................... 7
6. VENTING ................................................................. 7
7. WIRING DIAGRAMS .............................................. 9
182-260 WH1 (Atmospheric)................................... 9
182-260 H4/W1 (Atmospheric).............................. 10
330-400 H4/WH1 (Atmospheric) ........................... 11
8. SEQUENCE OF OPERATION............................. 12
9. START UP PROCEDURES ................................. 12
10. DRAFT PROVING SWITCH ................................ 12
11. ILLUSTRATED PARTS LIST............................... 13
1. WARNINGS
Pay Attention to these Terms
ADANGER Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial
property damage if ignored.
AWARNING Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or
substantial property damage if ignored.
ACAUTION Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product
or property damage if ignored.
CAUTION CAUTION used without the warning alert symbol indicates a potentially hazardous condition which could
cause minor personal injury or product or property damage if ignored.
NOTE 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.

4
2. RECEIVING EQUIPMENT
On receiving your equipment, check the carton visually for
external damage. If the carton is damaged, make a note on
the Bill of Lading when signing for the equipment. 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
led with the carrier by consignee.
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 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.
3. GENERAL
SPECIFICATIONS
The D-2 Power Vent Assembly is tested and certied to
the latest edition of the American National Standard ANSI
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
182 - 400. 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 ue gases are at a temperature that does not promote
condensation and is under higher pressure than the
ambient air; this denes venting category III. Vent material
certied for cat III usage must be used. Please note that
B-vent does not meet this requirement.
The D-2 Power Vent assembly includes a blower with
a 120/240 volt 60 Hz 1.95/1.0A 3200 RPM motor, a
plenum complete with a draft proving switch and a motor
relay. When provided for eld mounting the assembly is
equipped with a wire harness.
Model No. Discharge
Collar Size
Kit
Number
Factory
Wired
182 4" 008757 120V
260 4" 008757 120V
330 4" 008758 120V
400 4" 008758 120V
Table A. D-2 Kits
NOTE: The D-2 Power Vent comes factory-wired for
120V, but can be eld-converted for 240V operation.
See wiring diagrams from page 9.
4. 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.
Adding the D-2 power vent to the unit does not change
the service clearance requirements. Consult the manual
for the unit.
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.
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.

5
TABS TABS
BEFORE AFTER
FRONT
REAR
Figure 1. Position of Mounting Tabs
Figure 2. D-2 Power Vent Assembly
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 182 or 330, 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 Figure 1.
11. Mount the Power Vent assembly bottom over the flue
collar 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 flue collar 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.
D
12.95" (32.9 cm)
B
C
1.88"
(4.78 cm)
OFFSET
4.38"
(11.13 cm)
OFFSET
LEFT SIDE FRONT
FRONT
OF UNIT
FLUE COLLAR
ON THE UNIT,
SIZE 6" - 9"
BACK OF
UNIT
DISCHARGE COLLAR,
FOR 4" CAT III
METALLIC FLUE
Model
No.
A
in. (cm)
B
in. (cm)
C
in. (cm)
D
in. (cm)
182 18.13
(46.05)
12.38
(31.45)
7.88
(20.02)
4.25
(10.80)
260
330 17.50
(44.45)
15.75
(40.01)
7.63
(19.38)
6.00
(15.24)
400
Table B. Dimensions

6
U.S. Installations
1
Canadian Installations
2
AClearance above grade, veranda, porch,
deck, or balcony 1 ft (30 cm) 1 ft (30 cm)
BClearance to window or door that may be
opened
4 ft (1.2 m) below or to side
of opening; 1 foot (30 cm)
above opening
10 ft (328 cm)
C Clearance to permanently closed window * *
D
Vertical clearance to ventilated soffit located
above the terminal within a horizontal dis-
tance of 2 ft (61 cm) from the centerline of the
terminal
5 ft (1.5 m) *
E Clearance to unventilated soffit * *
F Clearance to outside corner* *
G Clearance to inside corner 6 ft (1.83 m) *
HClearance to each side of center line ex-
tended above meter/regulator assembly *
3 ft (91 cm) within a height
15 ft above the me-
ter/regulator assembly
I Clearance to service regulator vent outlet *6 ft (1.83 m)
J
Clearance to non-mechanical air supply inlet
to building or the combustion air inlet to any
other appliance
4 ft (1.2 m) below or to side
of opening; 1 ft (30 cm)
above opening
3 ft (91 cm)
K3 ft (91 cm) above if within
10 ft (3 m) horizontally 6 ft (1.83 m)
LClearance above paved sidewalk or paved
driveway located on public property
Slip hazard due to frozen
condensate
Slip hazard due to frozen ⁴
condensate
MClearance under veranda, porch, deck or
balcony*12 in. (30 cm) ³
1In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code
2In accordance with the current CAN/CSA-B149 Installation Codes
³Permitted 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
4Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that
serves both dwellings
Figure 3. Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations
Table C. Vent/Air Inlet Termination Clearances

7
5. WIRING (IID IGNITION)
AWARNING: 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.
6. VENTING
The D-2 Power Vent is capable of 360-degree discharge
rotation and operates with a positive vent static pressure
and with a vent gas temperature less than 400°F (204°C).
Use of 4" cat III-certied stainless steel vent material is
mandatory. The total length of horizontal run shall
not exceed an equivalent of 40 ft (12.2 m) including
termination cap. For all cases, each 90-degree elbow
reduces the maximum horizontal vent run by 10 ft (3
m) and each 45-degree elbow in the vent run reduces
the maximum vent run by 5 ft (1.5 m). See Table D for
maximum vent lengths using 90-degree and 45-degree
elbows.
90-Degree Elbows 45-Degree Elbows
Quantity
Maximum
Length
ft. (m)
Quantity
Maximum
Length
ft. (m)
1 30 (9.1) 1 35 (10.7)
2 20 (6.1) 2 30 (9.1)
3 10 (3.0) 3 25 (7.6)
Table D. E󰀨ects of Flue Elbows
The vent size must not be reduced to less than 4" cat III.
It is mathematically possible to increase the vent size, but
such a system is outside Raypak's certication and must
be handled as an Engineered Vent System, approved by
a Professional Engineer.
The D-2 Power Vent uses positive pressure to push ue
gases through the vent pipe to the outside. The vent must
be installed to prevent ue 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
recommended that:
1. The vent be installed with a slight downward slope
of not more than 1/4" per foot of horizontal run to the
vent terminal.
2. The vent be insulated through the length of horizontal
run.
For appliances installed in extreme cold climate, it is
recommended that:
1. 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.
2. The vent be insulated through the length of the
horizontal run.
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 vertical
vent of su󰀩cient 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 vent pipes and
breeching smaller than the standard collar for that size of
atmospheric heater.
The D-2 Power Vent assembly includes a wire harness,
shown in Figure 5, which provides quick connections
with the respective controls in the heater control box. The
harness is of su󰀩cient length to t the appliance for which
it is sized.
The wiring diagrams that follow are for basic on/o󰀨 units.
The same basic connection logic will apply to staged or
modulating units. Reference the wiring diagram supplied
with each appliance for actual connections.

8
LEFT SIDE
RAYPAK DISCHARGE
ELBOW (SUPPLIED
WITH D-2)
SCREENED
FACE
CAT III VENT, 4",
STAINLESS
FIELD-SUPPLIED VENT ADAPTER
FIELD-SUPPLIED
12" MIN.
(30.5 cm)
Figure 4. Through-the-Wall Vent
PRESSURE
SWITCH
GAS
VALVE
RELAY
Y/BK
Y/BK
V/BK
V/W
Y/BK V/BK
V/BK
V/W
Figure 5. Wire Harness
Note: The 90° elbow must be used as the termination cap.
The D-2 Power Vent assembly includes a wire harness, shown in Figure 5, which provides quick connections with the respective controls in the heater
control box. The harness is of su󰀩cient length to t the appliance for which it is sized.
The wiring diagrams that follow are for basic on/o󰀨 units. The same basic connection logic will apply to staged or modulating units.

9
Note: Use the wiring diagram provided with the heater.
7. WIRING DIAGRAMS 182-260 WH1

10
182-260 H4/W1

11
Note: Use the wiring diagram provided with the heater.
330-400 H4/WH1

12
8. SEQUENCE OF
OPERATION
On call for heat, the D-2 Power Vent fan (and appliance
pump) start. When the ow switch circuits close, the
ignition system consisting of an electronic spark module,
pilot gas system and ame sensor, are energized. When
draft proving switch closes and all safety circuits are
proven, the automatic main gas valves will open and the
heater will operate. When the operating limit circuit is
satised, the heater will shut down.
9. 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.
2. Check power connections.
3. Close heater power switch.
4. Set operating control to call for heat.
a. Fan motor starts, draft proving switch closes.
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 shutoff
valve is energized.
a. Main burners will ignite.
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
sections outlined in the heater manual.
EMERGENCY SHUTDOWN: SHUT OFF ALL POWER
AND GAS, CALL GAS UTILITY.
10. 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
Figure 6. Draft Proving Switch

13
1
2
3
5
6
7
8
9
10
11
12
13
14
15
16
17
4" GASKET-TO-GASKET VENT
ADAPTER, FIELD-SUPPLIED
4
CAT III VENT, 4" STAINLESS
FIELD-SUPPLIED
11. ILLUSTRATED PARTS LIST
Call Out Description 182-260 330-400
1 Relay 008784F 008784F
2 Blower 008156F 008156F
15 Blower Cooling Fan 011549F 011549F
17 Gasket 016000F 016000F
3 NO Pressure Switch 008062F 008135F
4 Elbow 4"-90° with Screen 010827F 010827F
5 Combustion Flue Box
Green 008682F 008683F
Cool Dark Grey 013854F 013855F
6 Base Assembly 008684F 008685F
7 Flue Collar 008686F 008686F
8 Flue Adapter 008687F 008688F
9 4" Flange 008689F 008689F
16 Seal Gasket 015040F 015040F
10 Blower Adapter
Green 008690F 008690F
Cool Dark Grey 013858F 013858F
11 Control Cover
Green 008691F 008691F
Cool Dark Grey 013856F 013856F
12 Control Swaybrace 008692F 008692F
13 Silicone Hose 008693F 008693F
14 Front Panel
Green 008694F 008694F
Cool Dark Grey 013857F 013857F

14
NOTES

15
NOTES

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 [phone] Fax [phone]
ISO 9001
REGISTERED QUALITY MANAGEMENT SYSTEM
www.raypak.com