PowerStar AE-115 Instructions / Assembly
Contents
1. Regulations Instructions and Assembly 17 25 kW 2x240 Volt Point of Use Electric Water Heater Model AE 115 Regulations Any local by laws and regulations pertaining to installation and use of electric water heating appliances must be observed Please refer to the laws that should be attended in your country A The electrical installation must conform to current National Electrical Codes 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 A A green terminal or wire connection marked G GR GROUND or GROUNDING is provided within the control box Aditional Canadian safety instructions to reduce the risk of electrical shock connect this terminal or connector to the grounding terminal of the electrical service of supply panel with a continuous copper wire in accordance with the Canadian Electrical Code Part I A In Canada this product shall be protected by a Class A ground fault circuit interrupter A Inthe Commonwealth of Massachusetts a licensed plumber or electrician must perform the installation Approval number P1 09 25 A Inthe 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 P 1 09 25 A The unit must be wired by a qualified electrician in accordance with the cur2. at is shown in Fig 11 If a higher outlet water temperature is desired then reduce the flow rate and or supply the unit with 240 volts Operation instructions Before using the water heater 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 gt Check that the power is switched on at the circuit breaker panel gt 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 Alf the unit has been used recently run the water through for a few seconds to let the temperature cool down You may initially get a short burst of very hot water that was in the plumbing lines from previous use Alf a second outlet connected to the unit is also turned on the hot water will be shared between the two 6 720 800 414 2011 09 5
3. d purging air gt Verify all circuit breakers supplying power to the water heater are turned off gt Open all hot water taps supplied by the water heater and inspect all water connections for leaks gt With all hot water taps still open inspect each tap to ensure all air in the lines has been purged out With the air purged and taps still flowing turn on all circuit breakers supplying the water heater gt Close all hot water taps and proceed to the next section 6 720 800 414 2011 09 4 Troubleshooting Adjusting the temperature dial gt The temperature adjustment is made using the dial on the bottom edge of the unit The adjustment is between approximately 95 F and 131 F Turning the dial clockwise increases the temperature setting as indicated by the marking on the unit Adjusting the flow gt 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 served by the water heater For Example AFor the AE115 unit using the outlet ball valve ensure the flow rate does not exceed 2 3 gallons minute AFor the AE125 unit using the outlet ball valve ensure the flow rate does not exceed 3 5 gallons minute 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 wh
4. or to lower floors of the structure Please follow these instructions Failure to follow instructions may result in amage or injury mproper installation operation oss of warranty Selection of place of installation WARNING Risk of freezing Do not install the water heater in an area where there is a chance of freezing Damage to the water heater as a result of freezing will not be covered under warranty Alf being used in a public place locate the heater out of easy reach to discourage vandalism ount the unit onto a flat section of wall well away from any potential splashes of water or spray and away from areas where direct moist or wet contact could occur Anstall the heater in a place that provides easy access for any service or maintenance Freeze prevention WARNING ELECTRICITY IS EXTREMELY DANGEROUS TAKE EXTRA PRECAUTIONS AND ENSURE ALL CIRCUIT BREAKERS ARE OFF BEFORE PERFORMING ANY WORK TO THE HEATER WARNING Indoor installation only where it will NOT be exposed to freezing Introduction Please note that the water heater must not be installed in a location where it may be exposed to freezing temperatures If the heater must be left in a space that is likely to experience freezing temperatures all water must be drained from the heater See Use and Care pdf file Freeze damage is not covered under the warranty 6 720 800 414 2011 09 2 Troubleshooting Recommended minimum clearances for servicing Should i
5. ou use 34 inch or 2 inch copper or high pressure flex connections gt Do not use plastic piping within 3 feet on either side of heater gt Use Teflon tape for sealing pipe threads Do NOT use pipe dope gt 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 result in damage to the product that is not covered by warranty gt After flushing and filling the heater with water with power off disconnect the inlet connection and inspect the filter screen for any debris that may have been flushed through the system The inlet and outlet connections are clearly marked on the heater They each have a 34 inch NPT connector Check the pressure of the main water supply To operate correctly the heater needs the running pressures mentioned in the chart shown 6 720 800 414 2011 09 3 Troubleshooting Technical characteristics Units AE115 AE125 Voltage supply Vv 2 X 240VAC Canada 240V AC 3 X 240VAC Canada 240VAC Amperage A 2 X 40A Canada 80A 3 X 40A Canada 120A Maximum output kW 17 25kW 26 85kW Temperature control range 95 F to 131 F 95 F to 131 F Minimum water pressure psi 15psi 15psi Maximum water pressure psi 150psi 150psi Minimum flow rate gal min 0 6 US gal min 0 8 US gal min Weight without
6. rent version of the National Electrical Code US or Canadian Electric Code Canada A 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 A The power cable size and the installation must be in accordance with the Canadian Electrical Code C22 1 02 WARNING California Proposition 65 lists chemical substances known to the state to cause cancer birth defects death serious illness or other reproductive harm This product may contain such substances be their origin from fuel combustion gas oil or components of the product itself Troubleshooting Installation DANGER Risk of electric shock B For safety reasons disconnect the power supply to the heater before any service or testing is performed Important information The installation must only be performed by a qualified person in accordance with these instructions Bosch Thermotechnology Corp is not responsible for improperly installed appliances The heater must only be mounted in a vertical position with the water fittings located at the bottom of the heater Under no circumstances should the heater be mounted differently The appliance should be located in an area where leakage of the heater or connections will not result in damage to the area adjacent to the appliance
7. t be necessary to service the Powerstar electric water heater observe the following clearances These are not required clearances but would facilitate any service work Recommended minimum clearances AE 115 AE125 Top 120 120 Sides 00 00 Bottom 60 60 Front 120 120 Mounting the water heater WARNING The heater must only be installed in the orientation shown in Fig 6 i e mounted in a vertical position with the water fittings located at the bottom of the heater Under no circumstances should the heater be mounted differently Undo the retaining screws on the front cover and take the cover off the heater Hold the back plate in position against the wall and mark the four mounting holes Drill the holes and secure the heater using the four wood screws supplied 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 NOTICE 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 P 1 09 25 gt 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 86 F gt The heater must be installed with shutoff valves on both the inlet and outlet connections gt It is recommended that y
8. water Ibs 20 Ibs 22 Ibs The unit will work at lower supply voltages but the following changes will apply Maximum output 15kW at 220V 13kW at 208V 84 of maximum at 220V 75 of maximum at 208V 22 5kW at 220V 20kW at 208V 84 of maximum at 220V 75 of maximum at 208V Maximum power Water quality Water quality can have an impact on appliance longevity and may not be covered under the manufacturer s warranty For water analysis data call your local water department or if on a well have well water analyzed periodically If water quality exceeds one or more of the values specified below Bosch recommends consulting a local water treatment professional for water softening conditioning options Description Max Levels pH pH 6 5 8 5 TDS total Dissolved Solids mg l or ppm 500 Total hardness mg l or ppm 100 Aluminum mg l or ppm 2 0 Chlorides mg l or ppm 250 Copper mg l or ppm 1 0 Iron mg l or ppm 0 3 Manganese mg l or ppm 0 05 Zinc mg l or ppm 5 0 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 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 Starting Up Checking for leaks an
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