Bosch Appliances Water Heater AE115 User Manual

BBT NORTH AMERICA  
Bosch Group  
Bosch Water Heating  
340 Mad River Park  
Waitsfield, VT 05673  
 
Using the PowerStar  
WARNING  
Do not use the unit if you think it may be frozen, as this could result in serious damage to the unit. Wait  
until you are sure that it has completely thawed out before you switch it on.  
Check that the power is switched on at the circuit breaker panel.  
Turn on the hot water faucet FULLY. The hot water temperature can be changed by adjusting the  
temperature dial on the bottom surface of the unit. (The dial adjusts the temperature typically  
between 95°F and 131°F. The factory sets the temperature dial at the lowest position.)  
There are internal safety thermal cut-outs which will operate if the unit overheats. If a thermal cut-  
out trips, then it must be reset by a qualified electrician.  
If the unit has been used recently, run the water through for a few seconds to let the temperature  
settle down. You may initially get a short burst of very hot water from the unit.  
If a second outlet connected to the unit is also turned on, the hot water will be shared between the  
two.  
Installing the PowerStar  
WARNING  
Do not install the unit in a room where there  
is a chance of freezing.  
IMPORTANT  
Read entire instructions.  
Check the pressure of the main water supply. To operate correctly, the unit needs the following running  
pressures : Minimum: 15 psi (1 Bar) Maximum: 150 psi (10 Bar)  
Securing the unit to the wall  
Diagram 1  
A E115 Unit  
AE125 Unit  
3
 
WARNING  
The unit must only be installed in the orientation shown in Diagram 1, i.e., mounted in a vertical position  
with the water fittings located at the bottom of the unit. Under no circumstances should the unit be  
mounted differently.  
If being used in a public place, position the unit out of easy reach to discourage vandalism.  
Mount the unit onto a flat section of wall, well away from any potential splashes of water or spray.  
Position the unit upright with all plumbing and electrical connections at the bottom of the unit.  
Mounting on the wall  
Undo the retaining screws on the front cover and take the cover off the unit. Hold the back plate in  
position against the wall and mark the four mounting holes.  
Drill the holes and secure the unit using the four wood screws supplied or an appropriate alternative  
method.  
Plumbing the unit  
WARNING  
Do not install a non-return check valve within 10 feet of the inlet. Do not apply heat or solder to  
connections or pipes if they are already directly connected to the unit.  
Fitting the pipes  
The unit should be connected directly to the main cold water supply and not to pre-heated water.  
(The inlet water temperature must not be greater than 86°F.) The unit should be installed with shut-  
off valves on both the inlet and outlet connections.  
It is recommended that you use ¾ inch or ½ inch copper or high-pressure flex connections.  
Use Teflon tape for sealing pipe threads. Do NOT use pipe dope.  
Remember to keep the hot water pipe runs as short as possible.  
After the unit has been plumbed, and before you wire it, flush it with water to remove any debris or  
loose particles. Failure to do so may make the unit inoperable.  
Connecting the unit to the pipes  
The inlet and outlet connections are clearly marked on the unit. They each have a ¾ inch NPT  
connector.  
Install a ball valve in the cold water line. This valve can be used to turn off the water supply to the  
unit if it needs servicing, or to reduce the water flow if it is too high.  
DISCLAIMER  
As a condition of installing this product in the Commonwealth of Massachusetts a pressure relief valve  
shall be installed on the cold water side, by a licensed plumber MGL 142 Section 19 Approval number:  
P1-09-25  
Wiring to the unit in the United States of America  
WARNING  
The unit must be installed by a qualified electrician, in accordance with the current version of the National  
Electrical Code. The unit must be grounded.  
4
 
IMPORTANT  
When the PowerStar is not within sight of the electrical circuit breakers, a circuit breaker lockout or  
additional local means of disconnection for all non-grounded conductors must be provided that is within  
sight of the appliance. (Ref NEC 422.31.)  
The AE115 requires  
two independent 240V  
AC circuits protected  
by two separate and  
independent double  
pole breakers (as  
shown) rated at 40 A  
each.  
The AE125 requires  
three independent 240V  
AC circuits protected  
by three separate and  
independent double  
pole breakers (as  
shown) rated at 40 A  
each.  
The minimum recommended wire size is 8 AWG. (The terminal block will accept cables up to 6  
AWG size.)  
The cable entry is via the 1 ¼ inch cable entry hole on the bottom right hand edge of the backplate.  
Strip back the insulation on the power wires about ½ inch. Connect the live wires to the terminals  
marked “L1” and “L2.” There are two pairs of live wires in the AE115 and three pairs of live wires in  
the AE125.  
Any insulation on the ground wire should be stripped back about ¾ inch. The ground lead must be  
connected to the pillar terminal marked “GR”. (See Diagrams 2 and 3 below).  
Make sure the terminal block screws are tightened securely. Loose c onnections can cause wires to  
heat up.  
Make sure that the ground wire is wrapped around its terminal stud and into the saddle washer. The  
nut should be tightened securely.  
Attach the front cover and tighten the retaining screws.  
5
 
Wiring to the unitin Canada  
WARNING  
The unit must be installed by a qualified electrician, in accordance with the current version of the  
Canadian Electrical Code. The unit must be grounded.  
IMPORTANT  
When the PowerStar is not within sight of the electrical circuit breakers, a circuit breaker lockout or  
additional local means of disconnection for all non-grounded conductors must be provided that is  
within sight of the appliance. (Ref NEC 422.31.)  
As per the Canadian Electrical Code, C22.1-02 Section 26-744, an auxiliary terminal block must be  
fitted to the unit before connecting to the electrical supply. This is available as a kit from BBT, Part  
Number "AE Canada Kit". (Contact 866-330-2729).  
Fitting the auxiliary terminal block (see diagram below).  
AE115  
AE125  
Connect the red wires from the left hand terminal of the new block to the L1 terminals in the unit.  
(There are two red wires required in the AE115 and three in the AE125).  
Connect the blue wires from the right hand terminal of the new block to the L2 terminals in the unit.  
(There are two blue wires required in the AE115 and three in the AE125).  
Push and click the auxiliary terminal block onto the louvered rail in the backplate.  
Connecting the supply cable  
The AE115 requires an 80A 240V AC  
single phase supply protected by an 80A  
double pole circuit breaker.  
The AE125 requires a 120A 240V AC  
single phase supply protected by a 120A  
double pole circuit breaker.  
The power cable size and the installation must be in accordance with the Canadian Electrical Code,  
C22.1-02.  
The incoming hole diameter on auxiliary terminal block can accept up to 1/0 AWG size cables.  
The cable entry is via the 1 ¼ inch cable entry hole on the bottom right hand edge of the backplate.  
Strip back the insulation on the power wires about ½ inch. Connect the ungrounded conductors to  
the terminals “L1” and “L2” on the auxiliary terminal block.  
6
 
Any insulation on the ground wire should be stripped back about ¾ inch. The ground lead must be  
connected to the pillar terminal marked “GR.”  
Make sure the terminal block screws are tightened securely. Loose connections can cause wires to  
heat up.  
Make sure that the ground wire is wrapped around its terminal stud and into the saddle washer. The  
nut should be tightened securely.  
Attach the front cover and tighten the retaining screws.  
Spare Parts  
Description  
(Refer to Diagram 1, Page 3)  
Part Number  
For further information ask your  
local dealer.  
93 793770  
93 793771  
93 793772  
93 793773  
93 793774  
93 793775  
93 793776  
93 793777  
93 793778  
93 793779  
93 793784  
4 way term. block (for AE115)  
6 way term. block (for AE 125)  
Front cover (white)  
FOR SERVICE AND INSTALLATION  
QUESTIONS CALL TOLL FRE:  
866-330-2729 (Toll Free)  
Fax: 802-496-6924  
Thermal cut-out  
Flow transducer  
PCB enclosure (lid)  
PCB enclosure (base)  
Control PCB (for AE115)  
Control PCB (for AE125)  
Adjustment knob  
BBT NORTH AMERICA  
Bosch Group  
¾” Inlet filter  
Starting up the PowerStar  
Checking for leaks  
Let the water run through the unit for a few seconds. Check that no pipe joints leak.  
Adjusting the temperature dial  
The temperature adjustment is made using the dial on the bottom edge of the unit. The adjustment  
is between approximately 95°F and 135°F. Turning the dial clockwise increases the temperature  
setting as indicated by the marking on the unit.  
Adjusting the flow  
Open fully both inlet and outlet shut-off valves at the heater, then :  
Turn on fully the highest flowing hot water faucet (e.g., bathtub) closest to the outlet connection.  
Adjust the outlet shut-off valve until the water flow rate from the hot faucet corresponds to the value  
given in Graph 1 on Page 8.  
7
 
Graph 1  
Outlet Temperature vs Maximum Flow Rate Setting  
(based on incoming water temperature of 55°F)  
5.00  
4.50  
4.00  
3.50  
3.00  
2.50  
2.00  
1.50  
1.00  
AE125 Heater  
AE115 Heater  
95  
100  
105  
110  
115  
120  
125  
130  
135  
Outlet Temperature (°F)  
For example:  
For the AE115 unit, using a ball valve, ensure the flow rate does not exceed 2.3 US gallons / minute.  
For the AE125 unit, using a ball valve, ensure the flow rate does not exceed 3.5 US gallons / minute.  
Note:These figures are based on an inlet water temperature of 55°F and a supply voltage of 240  
volts. If the inlet water temperature is lower than 55°F, or if the supply voltage is less than 240 volts,  
then the outlet temperature will be lower than what is shown in Graph 1. If a higher outlet water  
temperature is desired, then reduce the flow rate and/or supply the unit with 240 volts.  
IMPORTANT  
Before leaving the site, the installer should demonstrate the unit to the user and give them this guide.  
How the PowerStar works  
The PowerStar heats water instantaneously as it flows through the heater modules.  
The electronic control monitors the flow rate and the incoming water temperature and then switches  
on the required number of heater modules to reach the temperature set by the adjustment dial.  
As the flow rate or the incoming water temperature changes, the electronics adjust the number of  
heater modules used so that the outlet temperature is maintained.  
The outlet water temperature can change slightly as the flow rate changes due to the steps in power  
as different heater modules are switched on and off.  
8
 
The outlet water temperature can also vary if the maximum flow rate is exceeded (see Graph 1) or if  
the supply voltage changes.  
Each heater module is protected by an electro-mechanical thermal cut-out. If the temperature of any  
of the heater modules gets too high, then the cut-out will trip and cut the power to that heater  
module. If the cut-out operates, it must be reset by a qualified service person. This cut -out will only  
trip in exceptional circumstances.  
The AE115 unit is supplied from two independent voltage supplies and the AE125 unit from three  
independent voltage supplies. The unit may continue to work if one of these supplies is switched off  
or fails, but the temperature control will be poor. (In Canada the unit has just one voltage supply).  
Depending on the region of the country, the temperature of the water supply can vary between 40°F  
in winter to 70°F in summer, with an average of 55°F.  
Diagram 4: Internal wiring schematic for single phase AE125 unit. (AE115 has two heater modules and  
two supplies). (In Canada an auxiliary terminal block is fitted during installation).  
Wiring Diagram for AE125, 3 x 240V supply. PowerStar heater.  
For clarity  
The positions of  
terminals shown  
here do not  
correspond to  
CUTOUT  
CUTOUT  
CUTOUT  
their positions on  
the installer  
terminal blocks  
L2C  
L2B  
L2A  
L1A  
L1B  
L1C  
Flow  
transducer  
Brass inlet manifold and Triac heat sink  
Electronic PCB  
Temperature  
adjustment  
potentiometer  
Specifications  
AE115 Unit AE125 Unit  
2 x 240V AC (Canada 240VAC) 3 x 240V AC (Canada 240VAC)  
Voltage supply  
Amperage  
Maximum output  
Temperature control range  
Pressure range  
Minimum flow rate  
Maximum flow rate  
Dimensions (excl. water couplers)  
Weight (without water)  
2 x 40 A (Canada 80 A)  
17.25 kW  
95°F to 131°F  
3 x 40 A (Canada 120 A)  
26.85kW  
95°F to 131°F  
15 psi to 150 psi  
0.6 US gal / min  
See Graph 1, Page 8  
15½” H x 151/4” W x 4½” D  
20 lbs  
15 psi to 150 psi  
0.8 US gal / min  
See Graph 1, Page 8  
15½” H x 151/4” W x 4½” D  
22 lbs  
9
 
Note: The unit will work at lower supply voltages but the following chanwgeilsl apply:  
Maximum output  
15kW at 220V  
13kW at 208V  
22.5kW at 220V  
20kW at 208V  
Temperature control range  
87°F to 116°F at 220V  
82°F to 108°F at 208V  
84% of maximum at 220V  
75% of maximum at 208V  
87°F to 116°F at 220V  
82°F to 108°F at 208V  
84% of maximum at 220V  
75% of maximum at 208V  
Maximum flow rate  
(refer to Graph 1, Page 8)  
WARNING  
Always switch off the electricity supply to the unit before you remove the cover.  
If you have a problem...  
Service should only be performed by qualified personnel  
Symptom  
Cause  
What to do  
Electricity not on or one of the  
supplies has failed.  
The water supply is connected Reconnect the water supply to the inlet  
Check electricity supply.  
to the outlet of the unit.  
of the unit (marked blue).  
Turn off the power, open the unit and  
reset by pushing the button(s) on the  
top of the heater module(s). Establish  
and fix the cause of the overheating.  
Test by turning cold water supply off to  
heater, then open hot water faucet(s).  
No pressurized water flow should be  
evident. If it is evident, then that  
One or more of the heater  
module cut-outs has tripped.  
Cold water only–  
neon light off.  
Plumbing crossover.  
plumbing crossover needs to be  
corrected for the heater to operate.  
Turn off the power, open the unit and  
observe if the flow transducer “spins”  
when the water is turned on. If not,  
contact BBT toll free at 866-330-2729.  
The flow transducer is not  
working.  
Adjust the water flow (see Graph 1  
on Page 8).  
One of the power supplies is not Check the supply voltages to the  
Water flow is too high.  
on.  
heater and rectify if necessary.  
This is likely an issue with the power  
supply. Compensate for this by  
increasing the temperature setting  
(turn dial clockwise).  
The power supply voltage has  
dropped.  
Water too cold–  
neon light on  
Temperature dial is turned too  
low.  
Turn the temperature control dial  
clockwise.  
Turn temperature knob up or reduce  
the flow rate according to Graph 1  
on Page 8.  
The inlet water temperature has  
dropped.  
10  
 
Check the plumbing. Use only Teflon  
tape for sealing pipe joints. Inspect  
and clean inlet filter screen at  
heater.  
There are restrictions in the  
plumbing.  
Water flow too  
low  
Check that all inlet shut-off valves  
are fully open.  
Water supply pressure too low.  
Adjust outlet shut-off valves as  
described in the section “Adjusting  
the Flow” (see Page 7).  
Outlet shut-off valves are set  
too low.  
Water  
temperature  
fluctuates  
Avoid several hot water outlets being  
used at the same time as this  
causes the temperature to fluctuate.  
Fluctuating water pressure or  
changing flow rate.  
If the problem persists  
The person who initially installed the unit is the best one to contact for help.  
You can also call BBT toll free at 866-330-2729. Please have this guide with you when you call.  
PowerStar  
LIMITED 10 YEAR WARRANTY  
COVERAGE  
APPLIED ENERGY PRODUCTS THROUGH ITS U.S. DISTRIBUTOR BOSCH WATER HEATING  
(herein after BBT) guarantees this water heater to the original owner of the water heater at the original  
installation location against defects in material and workmanship for the periods specified below.  
WARRANTY PERIOD  
1.  
The Heat Exchanger – If the original heat exchanger leaks or fails within ten (10) years from the date  
of original installation of the water heater because of a defect in material or workmanship, BBT will  
furnish to such an owner a replacement heater of the then-prevailing comparable model.  
However, if the water heater is installed in other than a single family dwelling this heat exchanger  
warranty is limited to two (2) years from the date of original installation and operation.  
Note :Damage caused by exposure to freezing conditions is not covered by the warranty.  
Note :Damage caused by scale formation is not covered by the warranty.  
2.  
Any Component Part Other Than the Heat Exchanger – If any other component part (other than the  
heat exchanger) proves to be defective in material or workmanship within one (1) year from the date  
of original installation of the water heater, BBT will furnish the owner with a replacement of the  
defective part(s).  
11  
 
PowerStar  
LIMITED 10 YEAR WARRANTY(Continued from Page 11)  
3.  
Verification of Date of Original Installation – When owner cannot verify or document the original date  
of installation, the warranty period begins on the date of manufacture marked on the tag affixed to  
the water heater.  
EXCLUSIONS  
1.  
THIS LIMITED WARRANTY SHALL BE THE EXCLUSIVE WARRANTY MADE BY THE  
MANUFACTURER AND IS MADE IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR  
IMPLIED (WHETHER WRITTEN OR ORAL), INCLUDING, BUT NOT LIMITED TO, WARRANTIES  
OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.  
2.  
Manufacturer shall not be liable for incidental, consequential, special or contingent damages or  
expenses arising, directly or indirectly, from any defect in the water heater or the use of the water  
heater.  
3.  
4.  
Manufacturer shall not be liable for any water damage arising, directly or indirectly, from any defect  
in the water heater component part(s) or from its use.  
Manufacturer shall not be liable under this warranty if:  
a)  
b)  
c)  
d)  
The water heater or any of its component parts has been subject to misuse, alteration, neglect  
or accident, or;  
The water heater has not been installed in accordance with the applicable local plumbing  
and/or building code(s) and/or regulation(s), or;  
The water heater has not been installed in accordance with the printed manufacturer’s  
instructions, or;  
The water heater is not continuously supplied with potable water.  
5.  
The owner and not the manufacturer or his representative shall be liable for and shall pay for all field  
damages for labor or other expenses incurred in the removal and/or repair of the product or any  
expense incurred by the owner in order to repair the product.  
SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR  
CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO  
YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE  
OTHERS.  
IMPORTANT: OWNER SHALL KEEP THIS CERTIFICATE  
NOTE: A water heater should be installed in such a manner that if it should leak, the resulting flow of  
water will not cause damage to the area in which it is installed.  
The person who initially installed the unit is the best one to contact for help.  
You can also call BBT toll free at 866-330-2729. Please have this guide with you when you call.  
Bosch Water Heating  
340 Mad River Park  
BBT NORTH AMERICA  
Bosch Group  
Waitsfield, VT 05673  
TOLL FREE: 866-330-2729  
Fax: 802-496-6924  
12.14.05  
©
2005 Bosch Water Heating  
Waitsfield, VT all rights reserved  
555-2028-04 A  
12  
 

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