Bosch AE7.2 Technisches Dokument

Installation Manual and Operating Instructions

Electric water heaters

AE 3.4/7.2/9.5 kW

en Installation Manual and Operating Instructions 2

es Instrucciones de instalación y funcionamiento 18

fr Instructions d'installation et d'utilisation 33

6 720 800 537 (2011/09) US

IMPORTANT: This booklet should be given to the customer after installation and demonstration.

For Service & Installation contact:

BOSCH Thermotechnology Corp.

50 Wentworth Avenue, Londonderry

NH 03053

Phone: 866-330-2729

www.bosch-climate.us

Table of contents

6 720 800 537 (2011/09)

Table of contents

1 Explanation of Symbols and Important Safety

Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 Explanation of symbols . . . . . . . . . . . . . . . 3

1.2 Important Safety Instructions . . . . . . . . . . 3

2 Information about the heater . . . . . . . . . . . . . . . 4

2.1 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1.1 Approval number . . . . . . . . . . . . . . . . . . . . 4

2.2 Technical identification code . . . . . . . . . . 4

2.3 Package contents . . . . . . . . . . . . . . . . . . . 4

2.4 Model name and number identification . . 4

2.5 General description . . . . . . . . . . . . . . . . . . 5

2.6 Electrical diagram . . . . . . . . . . . . . . . . . . . 6

2.7 Function . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.1 Important information . . . . . . . . . . . . . . . . 9

4.1.1 Freeze prevention . . . . . . . . . . . . . . . . . . . 9

4.2 Installing the AE 3.4/7.2/9.5 . . . . . . . . . . . 9

4.3 Water connections . . . . . . . . . . . . . . . . . 10

4.3.1 Water quality . . . . . . . . . . . . . . . . . . . . . . 10

4.4 Electrical connections . . . . . . . . . . . . . . . 10

4.5 Securing the unit to the wall . . . . . . . . . . 12

4.5.1 Deciding the position . . . . . . . . . . . . . . . 12

4.5.2 Deciding the wiring route . . . . . . . . . . . . 12

4.5.3 Mounting on the wall . . . . . . . . . . . . . . . 12

5 Starting up the AE 3.4/7.2/9.5 . . . . . . . . . . . . . 14

5.1 Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.2 Adjusting the flow . . . . . . . . . . . . . . . . . . 14

6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 15

6.1 For the Installer . . . . . . . . . . . . . . . . . . . . 15

6.2 For the User . . . . . . . . . . . . . . . . . . . . . . 16

7 Interior components and parts list . . . . . . . . . 17

Explanation of Symbols and Important Safety Instructions

6 720 800 537 (2011/09)

1 Explanation of Symbols and Important Safety Instructions

1.1 Explanation of symbols

Warnings

Signal words at the beginning of a warning are used to

indicate the type and seriousness of the ensuing risk if

measures for minimizing damage are not taken.

•NOTE indicates that minor damage to property may

occur.

•CAUTION indicates possible minor to medium

personal injury.

•WARNING indicates possible severe personal injury.

•DANGER indicates that severe personal injury may

occur.

Important information

Additional symbols

1.2 Important Safety Instructions

When using this electrical equipment, basic safety

precautions should always be followed, including the

following:

BRead and follow all instructions.

BThis appliance must be grounded.

BDisconnect this product from the electrical supply

before cleaning, servicing or removing the cover.

BTo reduce the risk of injury, close supervision is

necessary when the product is used near children or

elderly persons.

BWarning: Do not install the heater in a location where

it may be subject to freezing.

BWarning: Do not install a check valve or any other

types of back flow preventer within six feet of the cold

water inlet.

BThe electrical installation must conform to current

National Electrical Codes.

BWarning: Do not switch the heater on if you suspect

that it may be frozen. Wait until you are sure that it

has completely thawed cut.

BThe AE 3.4/7.2/9.5 is designed to heat potable cold

water for domestic purposes. Contact Bosch

Thermotechnology before specifying or installing the

appliance in any other application.

Additional Canadian Safety Instructions

•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 I.

•This product shall be protected by a Class A ground

fault circuit interrupter.

Safe these instructions

BKeep this guide in a safe place once your AE 3.4/7.2/

9.5 unit has been installed.

BYou may need to refer to it for general instructions or

future maintenance.

Warnings are indicated in the text by a

warning triangle and a gray background.

In case of danger due to electric shock, the

exclamation point on the warning triangle is

replaced with a lightning symbol.

Important information that presents no risk

to people or property is indicated with this

symbol. It is separated by horizontal lines

above and below the text.

Symbol Meaning

BSequence of steps

→

Cross-reference to other points in this

document or to other documents

•Listing/list entry

–Listing/list entry (2nd level)

Table 1

Information about the heater

6 720 800 537 (2011/09)

2 Information about the heater

2.1 Disclaimer

2.1.1

Approval number

Commonwealth of Massachusetts

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).

2.2 Technical identification code

US Electronic Instantaneous

3Maximum output (kW)

MMechanical temperature control

WWall hung

IIndoor

HHorizontal installation

BWater connections

2.3 Package contents

•Electric water heater

•4 No. 8 wood screws

2.4 Model name and number

identification

US 3 - 1 M W I H B

US 7 - 1 M W I H B

US 9 - 1 M W I H B

Table 2

Model Name Model Number

AE 3.4/7.2/9.5 US 3-1 Pro

M W I H B

AE 3.4/7.2/9.5 US 7-1 Pro

M W I H B

AE 3.4/7.2/9.5 US 9-1 Pro

M W I H B

Table 3

Information about the heater

6 720 800 537 (2011/09)

2.5 General description

Fig. 1

1Mounting hole

2Heat exchanger tube

3Thermal cut-out (manual re-set)

4Heating elements

5Terminal block

6Cable rear entry

7Ground stud

8Cable clamp

9Filter and water pipe mounting

10 Cable side entry

11 Flow switch

12 Power selector

13 Cover fixing screw

14 Neon light

Outlet Inlet

Information about the heater

6 720 800 537 (2011/09)

2.6 Electrical diagram

Fig. 2 Internal wiring plan

DANGER: Risk of electric shock!

BAlways switch off the electrical supply to

the unit before removing cover or

performing any maintenance and service.

Heating elements

Electrical

supply

Manual reset Thermal cut-out

Neon

Power selector

and Flow switch

Information about the heater

6 720 800 537 (2011/09)

2.7 Function

How the water heater works:

•Water comes in through the cold water inlet.

•The flow switch senses how much water is passing

through the unit. If it detects more than the preset

level, the unit’s 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 voltage 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 between

40 °F in winter to 70 °F in summer, with an average of

50 °F.

Fig. 3

AManual reset thermal cut out

The table below shows the rise in water temperature you

can expect from the unit:

Manual reset thermal cut-out

The unit has a thermal cut-out (Fig. 1) which is mounted

on the heat exchanger tube. This will switch off the

heater elements if the water 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 (Fig. 3). Call your service person or Bosch

Water Heating if this happens frequently.

The heater is designed for cold water supply

only. Do not supply with pre-heated water.

Model Volts Amps

Element

Resistance

High

Setting

Low

Setting

Temperature Rise (deg F) at Flow Rate

(GPM)

0,5

GPM

0,75

GPM

1,0

GPM

1,5

GPM

2,0

GPM

2,5

GPM

US3 120-110 27 2x8 Ω3,4-

3,0kW

- 41F 28F 20F NA NA NA

US7 240-220 15 1x16 Ω- 3,6-

3,05kW

NA 32F 24F 16F 12F NA

US7 240-220 30 2x16 Ω7,2-

6,1kW

- NA 63F 48F 32F 24F NA

US9 208 18 1x12 Ω- 3,5kW NA 32F 24F 16F 12F NA

US9 208 35 2x12 Ω7,1kW - NA 64F 48F 32F 24F NA

US9 240 20 1x12 Ω- 4,75kW NA 42F 32F 21F 16F NA

US9 240 40 2x12 Ω9,5kW - NA 84F 64F 42F 32F NA

Table 4

Regulations

6 720 800 537 (2011/09)

3 Regulations

Any local by-laws and regulations pertaining to

installation and use of electric water heater appliances

must be observed. Please refer to the laws that should

be attended in your country.

•The electrical installation must conform to current

National Electrical Codes.

•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.

•This product shall be protected by a Class A ground

fault circuit interrupter.

•In the Commonwealth of Massachusetts a licensed

plumber or electrician must perform the installation.

(Approval number: P1-09-25).

•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 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.).

•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.

Installation

6 720 800 537 (2011/09)

4 Installation

4.1 Important information

Please follow these instructions. Failure to follow

instructions may result in:

•Damage or injury.

•Improper installation/operation.

•Loss of warranty.

4.1.1 Freeze prevention

Introduction

Please note that the installation manual states 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.

Freeze damage is not covered under the warranty.

Draining the heater

Due to the shape of the heat exchangers and connecting

pipe, it is extremely difficult to get all of the water out of

the heater. Follow the procedure below to best minimize

the chance of freezing:

BDisconnect electric supply.

BDisconnect cold and hot water pipes from fittings on

bottom of heater. Allow water to drain out (have a

catch basin ready).

BAfter allowing all water to drain out, the heater should

be blown out with low pressure compressed air to

remove as much water as possible from water heater

modules. Bursts of air work better than continuous

flow.

Remember, these suggestions are only made to help

minimize the potential for freeze damage and are not to

be construed as the guaranteed method for dealing with

freeze possibilities.

4.2 Installing the AE 3.4/7.2/9.5

To operate correctly the unit needs the following

running pressures:

Sink

•Min: 10 psi (0,7 bar)

•Max: 150 psi (10,3 bar)

DANGER: Risk of electric shock!

BFor safety reasons, disconnect the power

supply to the heater before any service or

testing is performed.

WARNING:

BThis heater must be electrically grounded

in accordance with the most recent

edition of the National Electrical Code.

NFPA 70. In Canada, all electrical wiring

to the heater must be in accordance with

local codes and the Canadian Electrical

Code, CSA C22.1 Part 1.

DANGER:

BThe installation must only be performed

by a qualified person in accordance with

these instructions.

BBosch Thermotechnology Corp. is not

responsible for improperly installed

appliances.

WARNING:

BThe heater must only be wall mounted

and positioned with the water

connections located either at bottom or

the right side of the unit see Fig. 6. Under

no circumstances should the heater be

mounted differently.

WARNING:

BELECTRICITY IS EXTREMELY

DANGEROUS. TAKE EXTRA

PRECAUTIONS AND ENSURE ALL

CIRCUIT BREAKERS ARE OFF BEFORE

PERFORMING ANY WORK TO THE

HEATER.

Use of agents like anti-freeze are not

allowed as they may cause damage to the

water heater’s internal components.

WARNING:

BDo not install the AE 3.4/7.2/9.5 in a

room where there is a chance of freezing.

NOTE:

BRead entire instructions.

BCheck the pressure of the main water

supply.

Installation

6 720 800 537 (2011/09)

4.3 Water connections

BThe 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. These valves 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.

BWe recommend that you use ½" copper or high

pressure flex connections.

BUse Teflon tape for sealing pipe threads. Do NOT use

pipe dope.

BRemember 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.

BThe inlet and outlet are clearly marked on the unit.

They each have a ½" NPT connector.

BIf the unit is to supply a sink, we recommend that you

use aerators, which you can get from your local

distributor/dealer.

BIf the unit is to supply more than one sink, the aerator

should be the same at each tap if they are to be used

at the same time. If not, one outlet will take all the

water.

BAfter 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.

4.3.1 Water quality

Water quality can have an impact on appliance longevity

and may not be covered under the manufacturer's

warranty.

BFor 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.

4.4 Electrical connections

Connecting the unit to power

BStrip back the insulation on the power wires about

3/8". Any insulation on the ground should be stripped

back about 3/4".

BFeed the cable through the cover bottom or backplate

rear entry grommets, as appropriate.

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.

Approval number: P1-09-25

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

Table 5

WARNING:

BThe unit must be installed by a qualified

electrician.

BThe unit must be grounded.

BConnect the unit to power.

Model

Rated

Voltage

(V)

Rated

Current

(A)

Recommen

d Wire Size

(AWG)

US3 110 30 10

US7 240 30 10

US9 208 35 8

US9 240 40 8

Table 6

NOTE:

When the AE 3.4/7.2/9.5 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)

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