AE115 Powerstar Manual
AE115 Powerstar Manual
AE115 Powerstar Manual
When using this electrical equipment, basic safety precautions should always be followed, including the following:
10. The PowerStar is designed to heat potable cold water for domestic purposes. The maximum inlet water temperature it can handle is 86 degrees F. Contact Bosch Water Heating before specifying or installing the appliance in any other application. 11. Additional Canadian safety instructions: a) 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 (Kit Part N AE Canada Kit). (See Page 7). A green terminal (or a wire connector marked G, GR, GROUND or GROUNDING) is provided within the control. To reduce the risk of electrical shock, connect this terminal or connector to the grounding terminal of the electrical service of supply pane l with a continuous copper wire in accordance with the Canadian Electrical Code, Part I.
b)
Contents
Specifications Installing the PowerStar Starting up the PowerStar How the PowerStar works Using the PowerStar Spare Parts Maintenance Troubleshooting Warranty 3 3 8 9 10 11 11 12 15
Specifications
AE115 Unit
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 240V AC (Canada 240VAC) 2 x 40 A (Canada 80 A) 17.25 kW 95F to 131F 15 psi to 150 psi 0.6 US gal / min See Graph 1, Page 8 15 H x 151/4 W x 4 D 20 lbs
AE125 Unit
3 x 240V AC (Canada 240VAC) 3 x 40 A (Canada 120 A) 26.85kW 95F to 131F 15 psi to 150 psi 0.8 US gal / min See Graph 1, Page 8 15 H x 151/4 W x 4 D 22 lbs
Note: The unit will work at lower supply voltages but the following changes will apply: Maximum output 15kW at 220V 22.5kW at 220V 13kW at 208V 20kW at 208V Temperature control range 87F to 116F at 220V 87F to 116F at 220V 82F to 108F at 208V 82F to 108F at 208V Maximum flow rate 84% of maximum at 220V 84% of maximum at 220V (refer to Graph 1, Page 8) 75% of maximum at 208V 75% of maximum at 208V
DISCLAIMER:
In the Commonwealth of Massachusetts a licensed plumber or electrician must perform the installation. (Approval number: P1-09-25).
Should it be necessary to service the Powerstar, observe the following clearances. These are not required clearances, but would facilitate any service work. Recommended minimum clearances for servicing Top Sides 12 0 Bottom Front 6 12
Diagram 1
Water Connections
WARNING:
Do not install a non-return check valve within 10 feet of the inlet.
WARNING:
Do not apply heat or solder to connections or pipe if they are already connected to the unit.
DISCLAIMER:
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) The heater must be connected directly to the main cold water supply and not to pre-heated water. (The inlet water temperature must not be greater than 86F.) The heater must be installed with shutoff valves on both the inlet and outlet connections. It is recommended that you use inch or inch copper or high-pressure flex connections.
Do not use plastic piping within 3 feet on either side of heater. 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 heater has been plumbed, and before you wire it, flush it with water to remove any debris or loose particles. Heater must be full of water and air purged before power is turned on. Failure to do so may make the heater inoperable. The inlet and outlet connections are clearly marked on the heater. They each have a inch NPT connector. Check the pressure of the main water supply. To operate correctly, the heater needs the following running pressures: Recommended water pressures Min water pressure 15 psi (1 Bar) Max water pressure 150 psi (10 Bar)
Electrical connections
WARNING
The unit must be wired by a qualified electrician, in accordance with the current version of the National Electrical Code US) or Canadian Electric Code (Canada).
IMPORTANT
When the heater 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.)
IMPORTANT
As per the Canadian Electrical Code, C22.1-02 Section 26-744, an auxiliary terminal block must be fitted to the heater before connecting to the electrical supply. This is available as a kit from Bosch Water Heating, Part Number AE Canada Kit. (Contact 866-330-2729).
US wiring
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 inch cable entry hole on the bottom right hand edge of the back plate. Strip back the insulation on the power wires about 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. (See Diagrams 2 or 3 on page 6). Any insulation on the ground wires should be stripped back about inch. The ground leads must be connected to the pillar terminal marked GR. (See Diagrams 2 and 3, Page 6). Make sure the terminal block screws are tightened securely. Loose connections can cause wires to heat up. Make sure that the ground wires are 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.
The AE115 requires two independent 240V AC circuits protected by two separate and independent double pole breakers (as shown) rated at 40 A each. Diagram 3 AE125 Terminal Block Connection
The AE125 requires three independent 240V AC circuits protected by three separate and independent double pole breakers (as shown) rated at 40 A each.
Connecting the supply cable - Canada only - not for the USA.
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 inch cable entry hole on the bottom right hand edge of the backplate. Strip back the insulation on the power wires about inch. Connect the ungrounded conductors to the terminals L1 and L2 on the auxiliary terminal block. Any insulation on the ground wire should be stripped back about 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.
4.50
4.00
3.50
AE125 Heater
3.00
2.50
2.00
AE115 Heater
1.50
For example:
For the AE115 unit, using the outlet ball valve, ensure the flow rate does not exceed 2.3 gallons / minute. For the AE125 unit, using the outlet ball valve, ensure the flow rate does not exceed 3.5 gallons / minute. Note: These figures are based on an inlet water temperature of 55F and a supply voltage of 240 volts. If the inlet water temperature is lower than 55F, 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.
Diagram 4: Internal wiring schematic for single phase AE125 unit. (AE115 does not have Elt 5 & 6 fitted and uses two supplies). (In Canada an auxiliary terminal block is fitted durin g installation).
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Spare Parts
Part Number
93 793770 93 793771 93 793772 93 793773 93 793842 93 793774 93 793775 93 793776 93 793843 93 793844 93 793779 93 793845 93 793846 93 793784 93 793847 93 793848 93 793849 93 793850
Maintenance
Check inlet water filter screen once a year
Shut off the installer supplied cold water isolation valve to the heater. If one is not installed, install before proceeding. Open nearest hot water tap to relieve pressure in the plumbing lines. Position a bucket under the cold water inlet connection of the heater to catch any water that may drain. Loosen cold water plumbing connection (bottom right of heater) to access filter screen (See Diagram 1, Page 4). Remove filter, clean with water and inspect for damage. If the filter is at all damaged, it should be replaced.
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Troubleshooting
WARNING
Always switch off the electricity supply to the unit before you remove the cover.
IMPORTANT:
If you are unable to perform the tasks listed below, or need additional assistance please contact your original installer/licensed electrician.
To test for a plumbing crossover, turn off power supply to the heater. Close installer supplied cold water shut off valve (if none installed, install before proceeding). Open all hot water taps supplied by the heater. Wait 5 minutes and check all taps. Any water running is a sign of a plumbing crossover. Consult a local plumber or service person for help in correcting a plumbing crossover. To return the heater to service, reinstall cover, open the inlet water supply to the heater and open all hot water taps. Let all taps run until there is no air coming out of the fixtures. Shut off all hot water taps. Turn power supply on to the heater. Return heater to service. (This procedure will prevent the heating elements from burning out). Turn off the power supply to the heater and remove the cover. Observe if the flow transducer "spins" when the water is turned on. Please note the flow transducer spins at a high speed and can appear to be stopped when actually spinning. It is recommended to observe the flow transducer without water flowing, then turn on a hot water tap while observing the flow transducer. If the flow transducer is not spinning, remove and flush flow transducer. See the technical support section of www.boschhotwater.com for more detailed instruction on removing the flow transducer. Turn off the power to the heater, remove the cover and locate thermal cutouts on the top of each heating module. Try resetting each cutout by pushing the reset button located in the center of the cutout. Determine and fix the cause of the overheating. Obstructions in the water path can restrict the flow of water through the heater causing it to overheat. Verify the heaters inlet filter screen and all outlets served by the heater are clear of debris. Ensure the heater is not being fed preheated water. This water heater is designed for a cold water supply only. If thermal cut out does not reset, check for continuity through each cutout (less than 0.5 Ohms). If any cutout reads more than 0.5 Ohms or open, then it may be defective and should be replaced. Have a licensed electrician verify proper wiring and adequate voltage on the terminal block inside the water heater. See the Electrical connections section on Page 5 of this manual.
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Verify the heater is sized appropriately for its geographic location. Turn temperature knob located on the bottom of the water all the way clockwise for maximum temperature setting. Ensure flow rates are within the heaters specifications. Refer to Graph 1 on Page 8 of the manual. Use of an isolation valve on the hot water outlet to control flow rate is recommended. Have a licensed electrician verify adequate voltage on the terminal block inside the water heater. Verify circuit breakers serving the heater are not tripped. See the Electrical connections section on Page 5 of this manual. Shut off power to the unit and remove cover. Use an ohmmeter to verify correct resistance on each element. If readings are different than listed specifications on Page 14, contact Technical Support (866) 330-2729 for further instruction.
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Ohm Reading 10.5 0.5 Ohms 11.5 0.5 Ohms 15.0 1 Ohms
Ohm Reading 10.5 0.5 Ohms 11.5 0.5 Ohms 21.0 1 Ohms
Water supply pressure too low Outlet shut-off valves are set too low
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WARRANTY PERIOD
1. The Heating Modules If the original heating module 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. (Continued) 15
(Continued) However, if the water heater is installed in other than a single family dwelling this heating modules warranty is limited to two (2) years from the date of original installation and o peration. 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 Heating Modules If any other component part (other than the heating modules) 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). 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.
3.
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. 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. 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) The water heater or any of its component parts has been subject to misuse, alteration, neglect or accident, or; b) The water heater has not been installed in accordance with the applicable local plumbing and/or building code(s) and/or regulation(s), or; c) The water heater has not been installed in accordance with the printed manufacturers instructions, or; d) The water heater is not continuously supplied with potable water. 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.
2.
3. 4.
5.
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 must 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, model number, serial number and date of installation with you when you call. Bosch Water Heating 340 Mad River Park Waitsfield VT 05673 TOLL FREE: 866-330-2729 Fax: 802-496-6924 www.boschhotwater.com
11.22.06 2006 Bosch Water Heating, Waitsfield, VT all rights reserved