REXENER PR200 Water Heater User Manual

REXENER PR200 Water Heater

• Thank you for purchasing a Rexener water heater. It is a powerful, easy-to-use and economical heater for heating the water in a hot tub or swimming pool.
• The Rexener water heater can be installed as the heating system of either a new or existing hot tub or swimming pool. It can also be installed in systems equipped with a circulation pump and filter.
• We recommend that you read the operating instructions carefully. Once you have read the user manual, ensure that it is stored in such a way that it is available to everyone using the heater.
• Study the safety instructions with particular care before using the heater.
• The conditions in northern countries have been taken into account in the design of the Rexener heater.
• If you take the heater abroad, check the mains voltage in that new country.
• This product comes with a three-year limited warranty.
• Due to active product development, the manufacturer reserves the right to make changes to the technical specifications and functional descriptions in this manual without separate notice.

GREETINGS FROM THE IMPORTER’S REPRESENTATIVE
Thank you for purchasing a high-quality Rexener water heater. It was developed in Finland over many years in close cooperation with the manufacturer Hephzibah Co., Ltd. During the development, a variety of technical solutions were sought to ensure that the water heater is easy to use and reliable in northern climates as well. The Rexener water heater utilises a number of circuits to monitor and ensure flawless operation. The highly-efficient and silent diesel burner ensures the safety of the heater, while the digital control panel guarantees ease of use. The Rexener water heater was designed to be easy to install as the heater of a new hot tub or swimming pool, or to replace the heating solutions of either traditional wood-heated hot tubs or swimming pools. Biodiesel is the recommended fuel for the Rexener water heater, but the device also works flawlessly with diesel or red diesel. The heater’s burner and control system require very little power. Rex Nordic’s swift and proficient maintenance service ensures the reliability of the Rexener water heater. We hope you enjoy many blissful moments in the warmth provided by the Rexener water heater Our warmest greetings Team Rex Nordic

OPERATING PRINCIPLE OF THE REXENER WATER HEATER

• The Rexener water heater’s diesel burner is well-protected under heater’s metal housing. Varied weather conditions were considered in the design of the diesel burner, controlling electronics and fuel tank.
• The diesel burner fan feeds air into the combustion chamber into which fuel is injected. The fuel is ignited with an ignition device controlled by electronics.
• The heat energy from the diesel is used to warm the water running in the pipes inside the heater. The efficient and finely-tuned combustion arrangement can take nearly full advantage of the energy contained by the diesel. It is mostly harmless carbon dioxide that is discharged from the exhaust pipe.
• The heat energy from the diesel is used to warm the water running in the pipes inside the heater. The efficient and finely-tuned combustion arrangement can take nearly full advantage of the energy contained by the diesel. The Rexener water heater produces practically no carbon monoxide. Only harmless carbon dioxide is discharged from the exhaust pipe.
• Since all of the energy in the diesel can be converted into heating power, the Rexener water heater boasts excellent efficiency, which means low fuel consumption.
• The long exhaust pipe assembly supplied with the heater ensures silence and safety, and the hot diesel burner flame is effectively protected inside the device.
• Due to its high power level, the Rexener water heater requires a circulation pump to ensure that water circulates through the device at a sufficient rate.

Exact water temperature control
You can set the desired water temperature for the Rexener heater between 0 and 45 degrees (°C). The heater will maintain the set temperature automatically. The thermostat can be adjusted so that the burner starts after the temperature has dropped by 2 or 4 degrees.

Powerful diesel burner
The powerful fan and high-pressure diesel injection ensure the reliability of the Rexener water heater’s diesel burner in all conditions.

Comprehensive safety systems
The electronically-controlled safety functions of the Rexener water heater ensure the safe usability of the heater in all conditions. The safety functions include two systems that prevent overheating, a flame de-tector, automatic shutdown and water level monitoring.

Overheat prevention systems
The diesel burner is switched off if the temperature of the water coming to the heater rises to 50°C and is switched off again if the temperature rises to 75°C (2nd safety device)

Water level monitoring system
If the heater contains insufficient water or there are air pockets in the water system, the device will not start. If the water level drops too low, the burner is switched off.

Flame detector and automatic shutdown system
Irregular operation of the diesel burner (poor combustion) activates the flame detector, which deactivates the diesel burner and fuel pump. This ensures the safety of the Rexener water heater in all situations.

Diagnostics function
The diagnostics function connected to the Rexener water heater’s control system checks all the heater functions before activation.

SAFETY INSTRUCTIONS

The purpose of these safety instructions is to ensure the safe use of the Rexener water heater. Adherence to these instructions minimises the risk of injury or death and damage to the heating device as well as other items or premises.
Please read the safety instructions with care. “The instructions feature three concepts: “Danger to life’, “Warning” and “Note”.

WARNING

• Only use 230 volt 50 Hz mains electricity. Incorrect voltage may cause a fire or electrical shock.
• The power cord of the device may only be connected to a grounded socket.
• Do not use this heater for any purpose other than heating a hot tub or swimming pool.
• Do not handle the heater’s power cord, electrical devices or control panel with wet hands. The moisture may cause a short circuit, failure, electrical shock and even fire.
• Do not clean the interior of the heater with a wet cloth. The moisture may cause a short circuit, failure, electrical shock and even fire.
• Do not place your hands or any objects inside a running heater. The current in the electrical cables be-tween the control panel and heater burner may cause an electrical shock.
• Ensure that the heater remains upright during operation. Do not bang or push the heater or cause it to fall over. Damage to the heater may cause an electrical shock or fire.
• Hot condensation water and steam may cause burns.
• Do not make any structural changes to the heater or attempt to repair the burner, water heating circuit or control panel.
• Never place electrical equipment or heavy objects on the heater.
• Do not cover the heater with any obstructions such as clothing, fabric or plastic bags. This may cause a fire.
• Do not wash the heater with a water hose or pressure washer. Water entering the heater’s protective housing may cause a short circuit, electrical shock and/or fire.
• Do not use petrol, thinner or other technical solvents to clean the heater. They may cause a short circuit, electrical and/or fire.
• Install the heater on a non-flammable surface.
• Protect the heater from water spatter.
• Always ensure the condition of the power cord. Do not bend the cord, and ensure that it is not crushed under or between anything. A damaged power cord or plug may cause a short circuit, electrical shock and even fire.
• If the Rexener water heater’s power cord is damaged, it must be immediately replaced with a new one at a maintenance shop authorised by the manufacturer or importer, or in some other authorised provider of electrical repair services.
• Do not extend the power cord by connecting additional lengths of cord to it or its connector plugs. Poorly-made connections may cause a short circuit, electrical shock and/or fire.
• If the plug gets dirty, clean it carefully before connecting it to the socket. A dirty plug may cause a failure and, as the dirt is heated, smoke, a short circuit and even fire may result.
• Before cleaning and maintaining the device, disconnect the power plug from the socket and allow the device to cool down sufficiently. Neglecting these instructions may lead to burns or an electrical shock.
• During thunder, deactivate the device and disconnect the power plug from the electrical grid.

CONTENT OF THE REXENER WATER HEATER

• Rexener Water Heater
• Fuel tank
• Rexener water heater’s water circuit connections for water hose (1.5 mm external thread, 2 pcs).
• Plugs for the Rexener water heater’s water circuit (2 pcs).
• Sealing tape for the threads of the water circuit connection (1 roll).
• Water heater drainage valve.
• Chimney pipe (1 pcs) and cap (1 pcs)
• Instruction manual
• Key for heater door

INSTALLING THE REXENER WATER HEATER

• The Rexener water heater must be installed in a visible location that can be easily monitored.
• Do not install the heater in a location where it is subjected to significant heat or continuous moisture.
• Ensure sufficient room around the heater for maintenance and operation.
• The manufacturer’s recommendation is 60 cm from fixed structures.
• Clear the immediate vicinity of the heater of flammable materials or structures, wood piles, wooden walls or roofs, piles of leaves or twigs, etc.
• In operating conditions, the Rexener water heater weighs approx. 43 kg. Prepare a sufficiently solid and strong foundation for the heater with concrete tiles, for example. Remember to counteract the effects of frost heave. Remove loose soil from under the tiles and replace it with gravel up to a depth of about 20cm.
• Do not position the heater on an unstable, inclined or wobbly foundation. The device tilting and / or falling over may cause malfunctions and lead to a fire.
• Install the heater on a non-flammable surface or otherwise ensure that the surface is fireproof.
• Install the heater on a non-flammable surface.
• The heater’s legs are adjustable. Use them to ensure that the heater is level.
• Before cleaning and maintaining the device, disconnect the power plug from the socket and allow the device to cool down sufficiently. Neglecting these instructions may lead to burns or an electrical shock.
• Prepare a separate and safe platform for the fuel tank. Ensure that fuel can be added easily.
• The fuel tank can be installed either at a higher or equal level with the heater. The distance between the fuel tank and heater should be no more than 5-7 m.
• If possible, secure a separate fixed electrical connection and plug for the heater. In the event that you need to use an extension cord, it should be continuous from the socket to the heater.
• Use a residual-current device in the electrical connection or extension cord.
• Obtain sufficiently long hoses, at least 38-50 mm in diameter and with a minimum heat resistance of 50°C, as well as suitable hose clamps (6 pcs) for heater installation. You can also order them for delivery with the heater.
• Measure the diameter of the water connections of the tub or pool to be heated. Obtain the requisite reducers for installing the water hoses.
• Ensure the discharge of condensate and steam so that they do not cause injuries or damage
  the heater’s surroundings. For this purpose, there is a condensate drain valve in the bottom of the heater, to which it is possible to attach a drain hose. Direct the hose from under the heater to either of its sides.

ADVICE FOR INSTALLING THE DEVICE

• The manufacturer and importer strongly recommend ordering the installation service for the heater.
• Place the Rexener water heater in the position reserved for it. Ensure that the heater is in the appropriate and stable position horizontally and vertically by using the adjustable legs.
• Screw in the water lines suitable for the heater’s water connections. Wind sealing tape around the threaded section of the pipe connections in the direction of the thread.
• Plug the water connections on the other side of the heater. Wind sealing tape around the threaded section of the plugs in the direction of the thread.
• Install the heating element drain tap included in the delivery in the lower section of the water heating element. Use sealing tape.
• Ensure the suitability of the hose connections of the water basin. Install any reducers that may be needed.
• Position the circulation pump in a suitable location between the water basin to be heated and the Rexener heater. Install the circulation pump in connection to the lower water hose.
• Shorten the water hoses to the appropriate length and install them. Remember to install the hose clamps but do not tighten them.
• Dimension the upper water lower and install it.
• Screw the water hose clamps closed.
• Thread the fuel supply hose through the designated hole at the bottom of the housing.
• Draw the fuel lines from the fuel tank to the heater.
• Install the fuel tank on the base you have reserved for it.
• Fill the fuel tank. Use biodiesel, red diesel or regular diesel.
• Connect the Rexener water heater’s power plug to the power socket.
• You can now begin to run water into the tub or pool to be heated.
• Install the chimney and the chimney cover in place. Secure the chimney to the heater with the indicated screws.

BLEEDING THE FUEL SUPPLY SYSTEM
The fuel supply system must be bled in conjunction with the initial start-up or when the fuel runs out, when necessary. First try to turn on the heater 2-3 times. If the heater does not start, bleed the fuel supply system according to the instructions below.

• Open the wing screw at the bottom of the fuel pump by 2–3 rotations.
• Connect the power cord to the power socket and press the Reset switch on the plug to connect power to the heater.
• Press the heater’s activation switch (Power).
• The fuel pump is activated, discharging fuel and air bubbles from the bleed opening. Close the bleeding screw.
• If the fuel hose contains a lot of air, you may need to repeat the above steps two or three times.
• If the burner shuts down due to a lack of fuel or there is another cause to suspect that air has entered the fuel supply circuit, you must repeat the bleeding in accordance with these instructions.
• Should you wish to avoid bleeding in the future, do not let the fuel tank drain fully at any point.

HEATER STRUCTURE

CONTROL PANEL

1. LIQUID CRYSTAL DISPLAY
   The display can be used to check temperature adjustments, error codes, etc.

2. The temperature on the left side of the display indicates the temperature of the water to be heated

3. The temperature on the right side of the display indicates the target temperature set for the water

4. ACTIVITY INDICATOR LIGHT
   This light is on when the water heater is running.

5. DIESEL BURNER INDICATOR LIGHT
   This light is on when the diesel burner is in operation.

6. OVERHEAT WARNING LIGHT
   This warning light is lit when the temperature of the water being heated exceeds 50°C or the overheating sensor in the heater detects a temperature higher than 75°C. The burner is switched off at the same time.

7. POWER BUTTON
   Switches the device power on and off.

8. TEMPERATURE CONTROL BUTTONS
   These buttons are used to set the desired water temperature. They can also be used to adjust the thermostat’s accuracy to 2 or 4 degrees.

9. LOW WATER WARNING LIGHT (W/L = Water Low)
   The warning light is lit when the water level of the heating system drops too low or if there are air bubbles in the device.

10. BURNER MALFUNCTION WARNING LIGHT (MISFIRE)
    This indicator light is lit if the burner has failed or shut down during operation

INSTALLING INSTRUCTIONS

1. Check the fuel and water levels.
2. Connect the power cord to the power socket and press the Reset switch on the plug to connect power to the heater.
3. Press the “Power” button. Once the heater has been activated, the “Burn” indicator (3) is lit.
4. Use the temperature control buttons (6) to set the desired temperature.
5. The diesel burner is deactivated once the desired temperature is reached. It is restarted once the water temperature drops 2 or 4 degrees below the set target temperature.
6. Turn off the heater using the POWER button.
7. Hold the DOWN and UP buttons simultaneously for 5 seconds.
8. Di F2 or F4 will flash on the screen.
9. Choose the amount of degrees the water temperature is allowed to drop before the heater restarts with the DOWN and UP buttons.
10. Finally, press the POWER button to lock your selection.
11. Deactivate the water heater by pressing the “Power” button again.

• WARNING! The heater must always be prevented from water splashing into the heater. Please take this into account during installation and use!
• NOTE! The heater operating voltage is 230 V~, 50 Hz. It is the responsibility of the user to connect the device to a power grid that supplies the appropriate voltage.
• NOTE! Do not turn off the heater by pulling the power plug out of the socket.
• NOTE! Always deactivate the heater before refuelling it.
• RECOMMENDATION : Use only high-grade biodiesel, diesel or red diesel in the heater. Always ensure the cleanliness of the containers used for refuelling the heater. Container impurities and the use of fuels other than diesel may cause malfunctions or excessive soot formation.
• RECOMMENDATION : When handling fuel, observe all relevant safety instructions

CIRCULATION PUMP
If a circulation pump has been acquired for the Rexener water heater, it is always on when the heater burner is active. When the heater is switched off, the circulation pump shuts down. The water heater requires a circulation pump to function.

Recommended circulation pump properties

• Operating voltage 230 V~, 50 Hz
• Flow speed 6100 L/h 6 m.c.H2O
• Highest flow rate 9,6 m.c.H2O
• Lowest flow rate 2 m.c.H2O

OVERHEAT PREVENTION SYSTEM
The overheat prevention system has two phases. The overheat warning light is lit when the temperature of the water being heated rises to 50 °C or the overheating sensor in the heater detects a temperature higher than 75°C. The heater burner is switched off at the same time. Once the water temperature has exceeded 50°C, the overheat prevention system deactivates the burner and turns on the warning light. As the temperature drops, the system will reset automatically, enabling heater operation. If the heater water exceeds 75°C, the overheat prevention system deactivates the burner and activates the warning light. In this case, it must be determined whether the overheating was caused by a failure in the heater or water circulation (e.g. pipe blockage).

DAILY INSPECTION POINTS

1. Check fuel level and the fuel hose connections to detect leaks. Repair any faults immediately.
2. Check the connections of the exhaust piping and their tightness. Remove soot and other dirt with a soft cloth.
3. Check the water circuit hoses for leaks. Repair any faults immediately.
4. When you start the heater, monitor burner operation and smoke formation. If a noticeable amount of black smoke is discharged from the exhaust pipe, the diesel burner is not operating correctly. Please contact the importer to determine the problem.

CLEANING AND MAINTENANCE

Maintenance should be done by guaranteed person reguarly. Cleaning the rexener water heater Regularly wipe the surface and exhaust pipe of the water heater with a dry and clean cloth. Mild cleaning agents may also be used where necessary. DO NOT WASH the heater with a water jet or pressure washer. Water entering the heater internals may cause malfunctions or electrical shocks.

Cleaning the flame detector

• If the flame detector’s sensor is covered in soot or other dirt, the heater power is reduced and its op-eration can be prevented entirely. In order to prevent operating failures, the flame detector must be checked regularly and cleaned as necessary
• Detach the flame detector from the burner by pulling it outwards. The flame detector is installed in the lower section of the burner.
• Clean the flame detector sensor with a soft and clean cloth.
• Reinstall the flame detector carefully. The protrusion (A) in the body of the detector must settle firmly in place.
• If the flame detector is extremely sooty, the heater may also require sweeping.

Sweeping
The Rexener PR200 heater requires occasional sweeping. Sweeping may only be performed by an import-er-authorised provider of maintenance services Sweeping is required if the heater produces smoke during operation.

ANNUAL MAINTENANCE
We recommend maintaining the water heater annually. Annual maintenance includes the replacement of the diesel filter, funnel and seal, as well as general cleaning and inspection. Replacement parts required for annual maintenance are included in a separately sold maintenance package. Ensure you use the correct maintenance set. Annual maintenance is also available as a paid, comprehensive service. Annual maintenance is required to retain the heater’s three-year warranty.

OPERATING FAILURES

If the safety systems of the device detect a fault, the message “Err” appears on the display and one of the warning lights is lit at the same time.

The heater burner has shut down “misfire”
The burner is probably not receiving fuel. In addition to this, the poor combustion may have caused soot or deposits to accumulate on the flame detector or nozzle. Fuel may be of poor quality..

1. Check the fuel quality and level, and refuel as necessary.
2. Try to start the heater.
3. Check the fuel filter and funnel, and replace them as necessary.
4. If the fuel tank contains impurities that block the filter, drain the tank and flush it with clean fuel until the impurities are discharged. If necessary, contact the importer to have the tank cleaned.
5. If the fuel tank contains water, drain it and fill it with suitable fuel. If water does not drain, buy a new tank.
6. Check the condition of the flame detector. Inspection and cleaning instructions. Start the heater.
7. If the heater does not start, contact the importer.

Advice and instructions for problem situations

• If the heater safety systems deactivate the heaters, determine the cause(s) of the shutdown and immediately remedy any faults detected and reported by the safety system and diagnostics.
• Try turning the device off and on again.
• If necessary, contact the importer.
• Once the fault diagnostics display is deactivated, the warning sounds will also stop.

Fault codes

• ER1 -> Check the flame detector for soot or damage.
• ER2 -> Fault caused by the water temperature sensor.
• ER3 -> Insufficient water level or air pockets in the water tank.

Heater repairs

• In the event that the basic maintenance parts of the Rexener water heater require replacing, please contact the importer.
• Perform periodic maintenance on the heater at least once a year. Periodic maintenance may be performed by an importer-authorised maintenance service, or you may perform the maintenance yourself with a service kit that is available to purchase from the importer.
• Heater repairs must be conducted by the importer.

DIAGNOSING AND REPAIRING

If the heater is not functioning, check the following: Is the power connected? Is there sufficient fuel?

DEVICE WILL NOT START

|

The device does not receive power, none of the signal lights are on.

|

The plug is not connected to the socket.

|

Connect the power cord plug to the socket.

The power grid does not supply current.

| Check the operation of the power grid and the on-site fuses.
| Replace the fuse.
The “Power” signal light is on but the heater is not running| The water temperature is higher than the set temperature.| Increase the set temperature or wait for the water to cool down.

The “MISFIRE” or “ERR,

ER1, ER2 or ER3” light is on

|

Fuel has run out.

| Refuel the heater and, if necessary, bleed the fuel supply system

The fuel has hardened.

| Change to fuel that is more resistant to low temperatures.

The fuel filter is blocked.

|

Replace the fuel filter.

There is air in the fuel pump.

|

Bleed the fuel supply system (see instructions on page10.)

The “OVERHEAT” or

“ERR” warning light is on

|

The overheat prevention function has been activated.

| Allow the water to cool. Clean any water circuit blockages and reset the overheat sensor (instructions on page14.)

The temperature sensor has failed.The circulation pump has failed.

|

Contact the importer to repair the sensor or pump.

The burner has failed.

|

Contact the importer.

The burner’s fan is activated but the burner is not ignited.

|

The burner’s igniter has failed.

|

Contact the importer to repair the igniter. Check the electrical wiring and connections.

NOISY BURNER

| |

The fuel filter is clogged.

|

Clean or replace the filter. Instructions on page15.

The fuel pump is noisy during operation.|

There is air in the fuel system.

|

Bleed the fuel supply system.

|

The burner has failed.

|

Contact the importer.

THE HEATER SHUTS DOWN SHORTLY AFTER ACTIVATION.

| | Incorrect fuel type|

Drain the fuel tank and fill it with high-grade diesel.

“ERR” / “Misfire”| The fuel contains water or other impurities.
“ERR” / “Misfire”| The flame detector is in the incorrect position.| Install the flame detector precisely in the correct position.
“ERR” / “Misfire”| The flame detector is dirty.| Clean the flame detector.
“ERR” / “Misfire”|

There is air in the fuel supply system.

| Bleed the fuel supply system. Instructions on page10.

THE BURNER PRODUCES SMOKE AND ACCUMULATES SOOT

| | Incorrect fuel type|

Drain the fuel tank and fill it with high-grade diesel.

| The fuel contains water or other impurities.

The burner is not receiving enough air.

|

The intake channel is blocked or damaged.

|

Check the intake channel. Contact an authorised maintenance service.

The exhaust pipe is blocked.

|

The exhaust gases may be flowing in the wrong direction.

|

Clean the exhaust pipe carefully or replace it.

|

The burner has failed

|

Contact the importer to repair the burner.

| The combustion chamber is sooty.| Contact the importer to have the heater swept.

THE WATER FAILS TO HEAT UP OR CIRCULATE.

|

The heater functions but the water does not heat up.

| The set temperature is too low.| Adjust the set temperature to the desired level.
There is air in the water pipes.| Ensure a sufficient water level and the operation of the circulation pump.
The circulation pump has failed.

The circulation pump is noisy.

|

There is air in the water pipes.

| Ensure a sufficient water level and the operation of the circulation pump.

The circulation pump has failed.

| Contact an authorised maintenance service to have the circulation pump repaired.

PRODUCT SPECIFICATIONS

Over heating protection
Heating efficiency rated is measured at supply temperature of 40 oC and return temperature of 25 oC.

TECHNICAL SPECIFICATIONS

gas side resistance and combustion chamber pressure for heaters operating with positive pressure in mbar| 0.14 mbar
exit flue gas temperature in oC| 140 oC
exit flue gas mass flow in kg/s| 0.0088 kg/s
emissions of nitrogen oxides NOx in mg/kWh| 119 mg/kWh
exit flue connection diameter in mm| 75 mm
water resistance in mbar| 20 K – 60 mbar

10 K – 80 mbar

maximum heat input in kW| 19.6 kW
nominal heat output in kW| 18.5 kW
30 % nominal heat output in kW| 5.6 kW
useful efficiency at rated heat output and high temperature regime in %| 96 %
useful efficiency at 30 % of rated heat output and high temperature regime in %| 98 %
standby heat loss in kW| 0.089 kW

auxiliary electricity consumption

| Initial burn| 75 W
While operating| 40 W
in standby mode| 6 W
gas volume of the heater| 0.023
range of temperature control in oC| (0 ~ 45) oC
fuel type| Diesel
combustion chamber type| Forced Exhaust
the combustion chamber dimensions and the combustion chamber volume| 0.015
direct flame operation or flame reversal| Direct flame
heater type: ON/OFF, modulating, multi stage| ON/OFF

MANUFACTURER : HEPHZIBAH CO.,LTD
(Juan-dong) 86, Gilpa-ro 71beon-gil, Michuhol-gu, Incheon, Korea Puh : +82-32-509-5834 Faksi : +82-32-502-5519 Sähköposti: sales@hdtek.com DISTRIBUTOR : Rex Nordic Oy

References

• Rex Nordic Group – Airrex

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