PowerStar AE-12 Use and Care Manual
Contents
1. Cable side entry Hi temp thermal cut out manual re set Neon Light How the Powerstar works Water comes in through the inlet tube The flow switch senses water has passed through the unit If it detects more than the pre set level the units heating the elements switch on This is shown by the neon light glowing The water is heated instantly as it passes through the copper heat exchanger tube The unit is Thermostatic i e it will switch the elements on and off in order to maintain a constant outlet temperature The temperature of the water conning out of the unit depends on The voltage of the electrical supply The temperature of the incoming water The setting of the temperature dial A badly set flow rate can also have a negative effect on the temperature Diagram 7 Thermal cut out Depending on the region of the country the temperature of the water supply can vary from 40 F in winter to about 70 F in the summer with an average of about 50 F Extreme weather conditions can cause the inlet temperature to go outside these boundaries making it necessary to adjust the Temperature Adjustment Spindle and or the inlet water flow The unit has one double pole thermal cut out which is mounted on the heat exchanger tube When tripped the cut out needs to be reset manually inside the unit The cut out will trip only in exceptional circumstances Diagram 7 Call your service person2. a A green terminal or wire connector marked G GR GROUND or GROUNDING is provided within the control box To reduce the risk of electric shock connect this terminal or connector to the grounding terminal of the electric service of supply panel with a continuous copper wire in accordance with the Canadian Electrical Code Part 1 b This product shall be protected by a Class A ground fault circuit interrupter Contents Using the Powerstar Installing the Powerstar Spare parts Starting up the Powerstar How the Powerstar works Trouble shooting 8 Warranty Back Cover NDALU Save these instructions Keep this guide in a safe place once your Powerstar unit has been installed You mayneed to refer to it for general instructions or future maintenance 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 it has completely thawed out before you switch it on Sink e Check that the power is switched on at the circuit breaker panel Turn on the hot tap FULLY If you do not turn the tap full on you will find that the temperature of the water may vary The hot water can be adjusted by altering the temperature dial and correctly setting the flow rate Refer to appendix on page 10 correct flow vs temperature If the unit has been used recently run the water through for a few seconds to let the temperature settle
3. rubber sleeve diagram 2 Diagram 2 Side of unit e If it is going through the back of the unit cut through the grommet on the backplate with a sharp knife Make sure that you do not remove the grommet from the backplate diagram 3 Feed the cable through the grommet before you mount the unit to the wall If you are using an approved cable fitting remove the grommet Diagram 3 Back of unit Fixing holes Grommet Mounting on the wall e Undo the retaining screws on the cover and take the cover of the unit Hold the backdate in position against the wall while you mark the four mounting holes e Drill the holes and secure the unit to the wall using the four no 8 wood screws supplied WARNING IMPORTANT Do not install a non return check valve within 6 feet of the inlet Plumbing in the unit Fitting the pipes e The unit should be connected directly to the main cold water supply and not to pre heated water The unit should be installed with service valves on both the inlet and outlet We recommend that you use 1 2 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 In some cases it may be worth fitting a second unit to serve an additional fixture Tf the unit is to supply more than one sink a similarly flow restricted aerator should be used at each tap If not the highest flow
4. down You may initially get a short burst of very hot water from the unit It a second tap connected to the unit is also turned on the hot water will be shared between the two therefore the flow and or the temperature of the water will decrease Diagram 1 Examples of installations Installing the Powerstar Warning Do not install the Powerstar 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 Sink Min 20psi 1 4 bar Max 150psi 10 3 bar Securing the unit to the wall Deciding the position If being used in a public place position the unit out of reach to discourage vandalism e Mount the unit onto a flat section of wall well away from any potential splashes of water or spray e Position the unit lengthways diagram 1 Remember to keep the length of hot water pipe to a minimum in order to save energy e If the unit is to supply a sink you can It it either above or below the sink Warning Unit must be mounted as shown Lengthways with plumbing connection pointing down Under no circumstances should the unit be mounted differently Deciding the wiring route e You have a choice of whether to feed the electric cable through the side or through the back of the unit e If it is gong to be through the side of the unit cut out the plastic lug to expose the
5. or Bosch Water Heating if this happens frequently WARNING Always switch off the electrical supply to the unit before you remove the cover FOR THE INSTALLER SYMPTOM CAUSE WHAT TO DO Cold water Electricity not on Check electrical supply only neon The water supply is connected to Reconnect the water supply to the light off the OUTLET of the unit INLET marked in blue The high temperature thermalcut Reset it by opening the unit and out has tripped pushing the button on the cutout diagram 7 Before you do this you must find the cause of the problem The flow switch is not Turn off the power and observe if the working flow switch activates when the water is turned on If not contact BBT 866 330 2729 www boschhotwater com Water too Water flow too high for unit to Adjust water flow to cold neon control recommended flow rate light on One element is not working Switch off the electricity and check the resistance of the elements The power supply voltage has dropped Check the supply voltage to the heater Temperature is turned too low Ensure that the temperature dial is in the correct position for the flow of water Water flow too low or temperature too high There are restrictions in the plumbing Check the plumbing Only use Teflon tape for sealing pipe joints FOR THE USER SYMPTOM CAUSE WHAT TO DO Little or no water The water sup
6. 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 OR MERCHANT ABILITY AND FITNESS FOR A PARTICULAR PURPOSE Manufacturer shall not be liable for incidental consequential special or contingent damages or expenses arising directly o indirectly from any defect in the water heater or the use of the water heater Manufacturer shall not be liable for any water carnage 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 accident or freeze or 12 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 neater has not been installed in accordance with the printed manufacturers instructions or d 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 charges for labour 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 prod
7. For Service amp Installation BBT NORTH AMERICA Bosch Group Bosch Water Heating c 340 Mad River Park Waitsfield VT 05673 TOLL FREE 866 330 2729 www boschhotwater com Thermostatic m PewerStar electric tankless water heaters a MODEL AE12 240V IMPORTANT This booklet should be given to the customer after installation and demonstration 1 Important Safety Instructions When using this electrical equipment basic safety precautions should always be followed including the following Read and follow all instructions This appliance must be grounded Disconnect this product from the electrical supply before cleaning servicing orremoving the cover 4 lo reduce the risk of injury close supervision is necessary when the product is usednear children or elderly persons Warning Do not install the heater in a location where it may be subject to freezing 6 Warning Do not install a check valve or any other types of back flow preventer within six feet of the cold water inlet 7 The electrical insulation must conform to current National Electrical Codes Warning Do not switch the heater on if you suspect that it may be frozen Wait until youare sure that it has completely thawed cut 9 The Powerstar is designed to heat potable cold water for domestic purposes Contact Bosch Water Heating before specifying or installing the appliance in any other application 10 Additional Canadian Safety Instructions
8. ing outlet will take all the water under dual usage After the unit has been plumbed in 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 e The inlet and outlet are clearly marked on the unit They each have a2 NPT connector e 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 e If the unit is to supply a sink we recommend that you use aerators which you can get from your local distributor dealer As a condition of installing this product in the Commonwealth of Massachusetts a pressure relief valve must be installed on the cold water side by a licensed plumber MGL 42 Section 19 WARNING The unit must be installed by a qualified electrician The unit must be grounded Connecting the unit to power Making the electrical connections Rated Rated Recommended Voltage Current Wire Size Model V A AWG AE12 240 50 6 Strip back the insulation on the power wires about Any insulation on the ground should be stripped back about a Feed the cable through the side or rear entry grommets as appropriate e Connect the cables to the terminal block and ground stud diagram 4 Diagram 4 Cable termination Rubber Sleeve When the Powerstar is not within sight of
9. mperature Adjustment Spindle and or the flow rate may be required 2 We recommend the flow rate through the heater is set to the Winter Maximum temperature see graph above The heater will then maintain the set temperature in the summer months reducing the power automatically 10 11 Powerstar Limited 5 Year Warranty APPLIED ENERGY PRODUCTS LTD THROUGH ITS U S DISTRIBUTION BOSCH WATER HEATING here in after BBT guarantees this water heat at the original installation location against defects in material and workmanship for the periods specified below Warranty Period 1 The Heat Exchange Element if the original heat exchanger leaks or the heating element fails within five 5 years from the date of the original installation of the water heater because of a defect in material or workmanship BBT will furnish to such Owner a replacement heater of the then prevailing comparable model Any Component Part Other than the Heat Exchanger Element If any other component part other than the Heat Exchanger Element proves to be defective n material or workmanship within one 1 year from the date of original installations 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
10. ove leak performance Adjusting the flow IMPORTANT Turn the service valves on then Before leaving the site the installer should 5 demonstrate the unit to the user and give Turn on the hot tap fully at the sink him her this guide e Adjust the outlet service valve till the water cones out of the tap at the recommended flow rate for the required temperature Refer to Appendix on page 10 Correct flow vs Temperature If the required temperature is different from the factory setting 113 F 45 C turn the Adjustment Spindle Diagram 5 until the outlet temperature is correct Diagram 5 Temperature adjustment spindle e Check that the unit works correctly when the sink tap is closed and then opened again if not adjust the service valve slightly The outlet shut off valve can be used to regulate temperature or flow of water from the unit When using the hot water open the tap fully so that the water temperature is always the Remove nameplate in direction of Arrow A same If hotter water is desired adjust the Adjust the temperature setting using a screwdriver on the spindle as shown by arrow B Replace the Nameplate temperature dial and flow rate as recommended in the Appendix on page 10 Diagram 6 E Heat exchanger Control Inside view Fixing hole tube P C B Heating elements Terminal block Cover fixing screw Cable rear entry Ground stud Cable clamp
11. ply is turned off Turn on the main supply fully at the flows stop valve Cold water The flow is not high enough to Open the inlet service valve fully only neon activate Cold water The water flow rate is too high Adjust the flow rate only neon 3 The flow rate is correct Adjust the temperature dial on the light on front of the cover The inlet water temperature has Adjust the flow rate dropped Water flow rate too The hot tap is not fully open Adjust the stop ball valve so that low or temperature water is at the right temperature with too high the tap fully open Always turn the hot tap fully on If the problem persists The person who initially installed the unit is probably the best one to contact for help You can also call BBT at 866 330 2729 or visit www boschhotwater com Please have this guide with you when you call Appendix Flow vs Temperature Setting Guide The following graph Indicates the water temperatures the Thermostatic Powerstar canachieve at different flow rates The graph shows the maximum and minimum temperatures achievable for the 12 kW unit with the inlet water temperature set to an average ambient temperature 12kW Powerstar Incoming water temperature 50 F 140 5 t Maximum Setting 130 Minimum Setting 120 110 Temperature F 0 5 1 1 5 2 Flow Rate US gpm NOTE 1 As water temperature varies throughout the year adjustments to the Te
12. 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 e Make sure that all the terminal block screws are tightened securely Loose connections can cause wires to neat up e Make sure that the ground wire is wrapped around its terminal stud and into the saddle washer The nut should be tightened securely e Attach the front cover and tighten the retaining screws Spare Parts 93793749 12 kW Heat Exchanger Thermostatic 93793701 Backplate 93793703 Terminal Block 93793811 Front Cover White Thermostatic 93793765 Thermal Cut cut 93793751 Wiring Assembly Thermostatic 937937C9 Cable Clamps amp Rubber Boot 93793752 Cover Retaining Screws 93793753 12 kW Printed Circuit Board Thermostatic 93793754 93793755 Nameplate Brass Inlet Assembly For further information ask your local dealer FOR SERVICE AND INSTALLATION QUESTIONS CALL TOLL FREE 866 330 2729 www boschhotwater com Bosch Water Heating 340 Mad River Park Waitsfield VT 05673 Starting up the Powerstar Note Checking for leaks If the unit is servicing a single lever faucet you e Lot the water run through the unit for a may need to restrict the cold water supply to the few seconds Check that no pipe joints faucet to balance water pressure and impr
13. uct 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 THE 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 HOW THE OWNER CAN SECURE SERVICE OR MAKE A CLAIM 1 Owner should contact the dealer who sold the water heater covered by the warranty or Owner should submit the warranty claim directly to BBT at the address listed below and they will arrange for the handling on the claim Whenever any inquiry or service request s made be sure to include the water heater model number the date of manufacture date of installation Dealers name and the watts and voltage When returning the water heater or component part s they must be individually tagged and identified with the Returned Goods Authorisation issued by BBT and shipped prepaid to BBT at the address below Bosch Water Heating 340 Mad River Park Waitsfield VT 05673 866 330 2729 BBT NORTH AMERICA Bosch Group www boschhotwater com 12 14 05 2005 Bosch Water Heating 559234310A Waitsfield VT all rights reserved
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