Bosch Thermotechnology Corp. BoschThermotechnology Corp.
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. This appliance must be grounded. 3. Disconnect this product from the electrical supply before cleaning, servicing or removing the cover. 4. To reduce the risk of injury, close supervision is necessary when the product is used near children or elderly persons. 5.
Specifications Voltage supply Amperage Maximum output Temperature control range Pressure range Minimum flow rate Maximum flow rate Dimensions (excl. water couplers) Weight (without water) AE115 Unit AE125 Unit 2 x 240V AC (Canada 240VAC) 2 x 40 A (Canada 80 A) 17.25 kW 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 3 x 240V AC (Canada 240VAC) 3 x 40 A (Canada 120 A) 26.85kW 95°F to 131°F 15 psi to 150 psi 0.
Mounting the Powerstar WARNING: The heater 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 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.
• 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.
Diagram 2 AE115 Terminal Block Connection 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.
Canada wiring – auxiliary terminal block and connections Fitting the auxiliary terminal block (see diagram below). AE115 AE125 NOT FOR U.S.A. • 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).
Starting up the PowerStar Checking for leaks and purging air • Verify all circuit breakers supplying power to the water heater are turned off. • Open all hot water taps supplied by the water heater and inspect all water connections for leaks. • 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.
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 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.
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 during installation). 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. • • • • • 10 Check that the power is switched on at the circuit breaker panel.
Spare Parts Part Number 93 93 93 93 93 93 93 93 93 93 93 93 93 93 93 93 93 93 793770 793771 793772 793773 793842 793774 793775 793776 793843 793844 793779 793845 793846 793784 793847 793848 793849 793850 Description (Refer to Diagram 1, Page 4) 4 way term. block (for AE115) 6 way term.
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. Cold water only – Neon light off Flow rate is too low Verify the flow rate out of fixture is at or above the minimum activation rate required for the unit to activate. (Activation rates: AE115 = 0.6 GPM, AE125 = 0.8 GPM).
Water too cold – Neon light on Temperature dial is turned too low Turn the temperature dial located on the bottom of the water heater clockwise for hotter temperatures. Refer to Graph 1 for outlet temperature vs. flow rate variance. Water flow is too high Adjust water flow to stay within the water heater’s specifications. See Graph 1 on Page 8 of this manual.
Using an Ohmmeter to check for Premature element failure LEFT MODULE Top View Meter probes Outer to Outer Middle to Middle Inner to Inner RIGHT MODULE Top View Ohm Reading 10.5 ± 0.5 Ohms 11.5 ± 0.5 Ohms 15.0 ± 1 Ohms Meter probes Outer to Outer Middle to Middle Inner to Inner Ohm Reading 10.5 ± 0.5 Ohms 11.5 ± 0.5 Ohms 21.0 ± 1 Ohms Note: On AE115 model, there is no middle element.
Water Temperature Too Hot Temperature dial set too high Turn the temperature knob located on the bottom of the water heater counterclockwise for cooler temperatures. There are restrictions in the plumbing Obstructions in the water path can restrict the flow of water through the heater causing overheating. Verify the heater’s inlet filter screen, faucet aerators, showerheads and whole house filters are clear of debris.
(…Continued) comparable model. 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 oper ation. 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. 3.
