PowerStar AE9.5 Installation Guide
Contents
1. each tap if they are to be used at the same time If not one outlet will take all the water 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 a 1 2 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 Ifthe unit is to supply a sink we recommend that you use aerators which you can get from your local distributor dealer 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 Making the electrical connections Voltage Current Wire Size ee 0 WARNING The unit must be installed by a qualified electrician The unit must be grounded 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 Connecting the unit to power Strip back the insulation on the power wires about 3 8 A2. installing the appliance in any other application Additional Canadian Safety Instructions a A green terminal or a 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 I 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 Troubleshooting 10 Warranty Back Cover SAVE THESE INSTRUCTIONS Keep this guide in a safe place once your Powerstar unit has been installed You may need to refer to it for general instructions or future maintenance ON DW Ww 2 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 Sink Check that the power is switched on at the circuit breaker panel Turn on the hot water tap FULLY If you do not tur the tap full on you will find that the temperature of the water will vary The hot water temperature can then be set by adjusting the flow If the unit has been used recently run the water through for a few s
3. FREDRING For Service amp Installation Bosch Thermotechnology UL US Corporation Bosch Thermotechnology Corp 340 Mad River Park Waitsfield VT 05673 TELEPHONE 866 642 3199 www boschhotwater com Handbook for PowerStar electric tankless water heaters ne MODELS AE9 5 AE3 4 AE 2 240V 120V 240V 208V 110V 220V pe ee IMPORTANT This booklet should be given to the customer after installation and demonstration important safety Instructions When using this electrical equipment basic safety precautions should always be followed including the following 1 READ AND FOLLOW ALL INSTRUCTIONS 2 3 10 This appliance must be grounded Disconnect this product from the electrical supply before cleaning servicing or removing the cover To reduce the risk of injury close supervision is necessary when the product is used near children or elderly persons Warning Do not install the heater in a location where it may be subject to freezing Warning Do not install a check valve or any other type of back flow preventer within six feet of the cold water inlet The electrical installation must conform to current National Electrical Codes Warning Do not switch the the heater on if you suspect that it may be frozen Wait until you are sure that it has completely thawed out The Powerstar is designed to heat potable water for domestic purposes Contact Bosch Thermotechnology before specifying or
4. e of manufacture marked on the tag affixed to 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 shail not be liable 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 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 4 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 freeze 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 5 The OWNER and not the Manufacturer or his representative shall be liable for and shall pay for all field charges for labor or other expenses incurred in the removal and or repair of the product or any expense incurred by the owner in o
5. econds to let the temperature settle down You may initially get a short burst of very hot water from the unit If 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 Cold Hot View from rear Hot Hot Installing 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 10 psi 0 7 bar Max 150 psi 10 3 bar Securing the unit to the wall Deciding the position 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 either upright or length ways diagram 1 whichever is most convenient for plumbing and wiring Remember to keep the lengths of hot water pipe to a minimum in order to save energy If the unit is to supply a sink you can fit it either above or below the sink Cold 3 Deciding the wiring route You have a choice of whether to feed the electric cable through the side or through the back of the unit If it is going through the side of the unit cut out the
6. hermal cut out manual re set Heating elements Terminal block Cable rear entry Ground stud Cable clamp Cable side entry How the Powerstar works Water comes in through the inlet tube The flow switch senses how much water is passing through the unit If it detects more than the preset level the units heating 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 temperature of the water coming out of the unit depends on the voitage of the electrical supply the temperature of the incoming water supply the setting of the power selector the flow rate the power rating of the unit 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 summer with an average of about 50 F The chart below shows the rise in water temperature you can expect from the unit The unit has a thermal cut out diagram 6 which is mounted on the heat exchanger tube This will switch off the heater elements if the water flow is reduced too much and the temperature goes above 194 F If the cut out trips it will need to be reset manually inside the unit This cut out will only operate in exceptional circumstances diagram 7 Call your service person or Bosch Thermotechnology Corp if this happens frequently V Diagram 7 Manual re set Thermal cu
7. ion must be fixed or the heater will not work properly ff the problem persists The person who initially installed the unit is probably the best one to contact for help You can also contact Bosch Thermotechnology on 866 642 3199 or visit www boschhotwater com Please have this guide with you when you call 11 POWERSTAR LIMITED 5 YEAR WARRANTY COVERAGE BOSCH THERMOTECHNOLOGY guarantees this water heater to the owner here in after Owner of the water heater at the original installation against defects in material and workmanship for the periods specified below WARRANTY PERIOD 1 The Heat Exchanger Element if the original heat exchanger leaks or the heating element fails within five 5 years from the date of original instaliation of the water heater because of a defect in material or workmanship Bosch Thermotechnology will furnish such Owner a replacement heater of the then prevailing comparable model 2 Any Component Part Other than The Heat Exchanger Element If any other component part other than the heat exchanger element proves to be defective in material or workmanship within one 1 year from the date of original installation of the water heater Bosch Thermotechnology will furnish the Owner with a replacement of the defective part s 3 Verification of Date of Original Installation When Owner cannot verify or document the original date of installation the warranty period begins on the dat
8. ny insulation on the ground should be stripped back about 3 4 Feed the cable through the side or rear entry grommets as appropriate Connect the cables to the terminal block and ground stud diagram 4 Diagram 4 gt Cable Termination Rubber Sleeve Make sure that all the terminal block screws are tightened securely Loose connections can cause wires to heat up Make sure that the ground wire is wrapped around it s terminal stud and into the saddle washer The nut should be tightened securely Set the Power Selector Screw diagram 5 on the desired setting If it is set to LO only one heating element will operate and the output will be half power See the table on page 8 for temperature rise at various flow rates If the element is set on HI both heating elements will operate and the output will be full power When setting the Power Selector Screw it is important that the screw be adjusted all the way to the end of the slot and that it be well tightened Attach the front cover and tighten the retaining screws Diagram 5 Power selector screw Spare Parts 93 793701 Backplate Heat Exchange Assy please quote loading voitage on rating plate when ordering 93 793703 Terminal Block 93 793798 Front Cover White 93 793773 Therma Cut Out Assembly Manual Re set 93 793818 Flow Switch 93 793707 Neon Light amp Clip Wiring Assy please quote loading voltage on rating plate when
9. oo low or There are restrictions in the Check the plumbing Only use Teflon tape temperature too high plumbing for sealing pipe joints 10 Little or no water flows The water supply is tumed off Tum on the main supply fully at the stop valve Cold water only The flow is not high enough to neon light off activate Open the inlet service valve fully Adjust the flow rate see page 7 The water flow rate is too high The inlet water temperature Adjust the flow rate see page 7 has dropped Water fiow too The main supply of water flow is too Increase the water flow fow or temperature low too high The hot tap is not fully open Adjust the stop ball valve so that water is at the right femperature with the tap fully open see page 7 Always tum the hot tap full on Fluctuating water pressure and or Increase the fiow rate fluctuates flow is causing the flow switch to Be sure that the isolation valves are cycle on and off properly adjusted Be sure that the inlet filter screen is clean Be sure that the outlet restrictors and aerators on showers and or faucets are clear Be sure that there is no plumbing crossover by shutting off the inlet isolation valve and opening all hot water outlets served by the Powerstar if there is a steady flow then cold water is flowing into hot water service lines and back pressuring the Powerstar This condit
10. ordering 93 793709 Cable Clamp amp Rubber Boot 93 793713 Cover Retaining Screws For further information ask your local dealer FOR SERVICE AND INSTALLATION QUESTIONS CALL 866 642 3199 www boschhotwater com Bosch Thermotechnology Corp 340 Mad River Park Waitsfield VT 05673 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 flow Turn the service valves on then turn on the hot water tap fully at the sink adjust the outlet service valve until the water comes out of the tap at the required temperature increase flow for cooler decrease for hotter V Diagram 6 Inside view Heat exchanger Fixing hole tube Cover fixing screw Power selector Flow switch outlet Check that the unit works correctly when the sink tap is closed and then opened again if not adjust the service valve slightly the inlet service valve should not be used to regulate temperature When using the hot water open the tap fully so that the water temperature is always the same If hotter water is desired decrease the flow Note If the unit is servicing a single lever faucet you may need to restrict the cold water supply to the faucet to balance water pressure and improve performance IMPORTANT Before leaving the site the installer should demonstrate the unit to the user and give him her this guide T
11. plastic lug to expose the rubber sleeve diagram 2 Diagram 2 Lug cut out v 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 clamp fitting or conduit fitting remove the grommet Diagram 3 Back of unit Grommet Fixing holes Mounting on the wali Undo the retaining screws on the cover and take the cover off the unit Hold the backplate in position against the wall while you mark the four mounting holes 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 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 a pipe dope Remember to keep the 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 If the unit is to supply more than one sink the aerator should be the same at
12. rder 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 OTHER 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 this warranty or 2 Owner should submit the warranty claim directly to Bosch Thermotechnology at the address listed below and they will arrange for the handling of the claim 3 Whenever any inquiry or service request is made be sure to include the water heater model number the date of manufacture date of installation Dealers name and the watts and voltage 4 When returning the water heater or component part s they must be individually tagged and identified with the Returned Goods Authorization issued by Bosch Thermotechnology and shipped prepaid to Bosch Thermotechnology at the address below Bosch Thermotechnology Corporation Bosch Thermotechnology Corp 340 Mad River Park Waitsfield VT 05673 866 642 3199 www boschhotwater com 06 17 08 2008 Bosch Thermotechnology Corp 579 2188 14 E Waitsfield VT all rights reserved
13. t out Diagram 9 intemal wiring plan Y Power selector and l Flow switch r l Heating elements Electrical supply Manual re set Thermal cut out Warning Always switch off the electricity supply to the unit before you remove the cover If you have a problem For the Installer Symptom Cause What to do Electricity not on Check electrical supply The water supply is connected Reconnect the water supply to the to the OUTLET of the unit INLET marked in blue The high temperature thermal Reset it by opening the unit and cut out has tripped pushing the bution on the cut out diagram 7 on page 8 Before you do this you must find the cause of the problem The flow switch is not working Tum off the power open the unit and observe if the flow switch activates when the water is turned on if not contact Bosch Thermotechnology 866 642 3199 or visit www boschhotwater com Water too cold Adjust water flow see chart on page 8 neon light on Water flow too high Change the power select screw to HI see page 6 The power selector screw not ail the way to HI One element is not working Switch off the electricity amp check the resistance of the elements See chart on page 8 The power supply Check the supply voltage to the heater voltage has dropped see chart on page 8 Water fiow t
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