RED-RING PowerStar AE115 User manual

For questions contact:
Controlled Energy Corp.
340 Mad River Park
Waitsfield VT 05673
TOLL FREE
866-330-2729
www.ControlledEnergy.com/tech

2
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. 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 type of back flow preventer within ten feet of
the cold water inlet.
7. The electrical installation must conform to current National Electrical Codes.
8. Warning: Do not switch the heater on if you suspect that it may be frozen. Wait until you are sure
that it has completely thawed out.
9. The PowerStar is designed to heat potable cold water for domestic purposes. The maximum
inlet water temperature it can handle is 86 degrees F. Contact Controlled Energy before
specifying or installing the appliance in any other application.
10. Additional Canadian safety instructions:
a) A green terminal (or a wire connector marked “G,” “GR,” “GROUND” or “GROUNDING”) is
provided within the control. 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.
b) This product shall be protected by a Class A ground fault circuit interrupter.
Contents
Using the PowerStar.............................................................................................................................. 3
Installing the PowerStar......................................................................................................................... 3
Spare Parts............................................................................................................................................ 7
Starting up the PowerStar ..................................................................................................................... 7
How the PowerStar works ..................................................................................................................... 9
Specifications....................................................................................................................................... 10
If you have a problem .......................................................................................................................... 10
Warranty .............................................................................................................................................. 11
SAVE THESE INSTRUCTIONS
Keep this guide in a safe place once your unit has been installed.
You may need to refer to it for general instructions or future maintenance.

3
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.
• Check that the power is switched on at the circuit breaker panel.
• 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 95oF and 131oF. The factory sets the temperature dial at the lowest position.)
• There are internal safety thermal cut-outs which will operate if the unit overheats. If a thermal
cut-out trips, then it must be reset by a qualified electrician.
• If the unit has been used recently, run the water through for a few seconds to let the temperature
settle down.You may initially get a short burst of very hot water from the unit.
• If a second outlet connected to the unit is also turned on, the hot water will be shared between the
two.
Installing the PowerStar
WARNING IMPORTANT
Do not install the unit in a room where there Read entire instructions.
is a chance of freezing.
Check the pressure of the main water supply. To operate correctly, the unit needs the following
running pressures : Minimum: 15 psi (1 Bar) Maximum: 150 psi (10 Bar)
Securing the unit to the wall
Diagram 1
AE115 Unit AE125 Unit

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WARNING
The unit 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 unit. Under no circumstances should
the unit be mounted differently.
• 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 upright with all plumbing and electrical connections at the bottom of the unit.
Mounting on the wall
• Undo the retaining screws on the front cover and take the cover off the unit. Hold the back plate in
position against the wall and mark the four mounting holes.
• Drill the holes and secure the unit using the four wood screws supplied or an appropriate alternative
method.
Plumbing the unit
WARNING
Do not install a non-return check valve within 10 feet of the inlet. Do not apply heat or solder to
connections or pipes if they are already directly connected to the unit.
Fitting the pipes
• The unit should be connected directly to the main cold water supply and not to pre-heated water.
(The inlet water temperature must not be greater than 86oF.) The unit should be installed with
shut-off valves on both the inlet and outlet connections.
• It is recommended that you use 3/4inch or 1/2inch 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.
• After the unit has been plumbed, 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
• The inlet and outlet connections are clearly marked on the unit. They each have a 3/4inch 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.

5
Wiring to the unit
WARNING
The unit must be installed by a qualified electrician, in accordance with the current version of the
National Electrical Code. The unit must be grounded.
IMPORTANT
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.)
• The minimum recommended wire size is 8 AWG. (The terminal block will accept cables up to 6
AWG size.)
• The cable entry is via the 1 1/4inch cable entry hole on the bottom right hand edge of the
backplate.
• Strip back the insulation on the power wires about 1/2inch. Connect the live wires to the terminals
marked “L1” and “L2.” There are two pairs of live wires in the AE115 and three pairs of live wires in
the AE125.
• Any insulation on the ground wire should be stripped back about 3/4inch. The ground lead must be
connected to the pillar terminal marked “GR.” (See Diagrams 2 and 3 on Page 6.)
• The AE115 requires two independent 240V
AC circuits protected by two separate and
independent double pole breakers rated at
40 A each.
At the circuit breaker panel there will be two
independent double pole breakers as shown
below.
• The AE125 requires three independent 240V
AC circuits protected by three separate and
independent double pole breakers rated at
40 A each
At the circuit breaker panel there will be three
independent double pole breakers as shown
below.

6
Diagram 2 (AE115 unit)
Diagram 3 (AE125 unit)
• Make sure the terminal block screws are tightened securely. Loose connections can cause wires to
heat up.
• Make sure that the ground wire is wrapped around its terminal stud and into the saddle washer.
The nut should be tightened securely.
• Attach the front cover and tighten the retaining screws.
L1 L2 L1 L2
Supply 1 Supply 2
GR
L1 L2 L1 L2
Supply 1 Supply 2
L1 L2
Supply 3
GR

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Spare Parts
Part Number Description
(Refer to Diagram 1, Page 3)
93 793770 4 way term. block (for AE115)
93 793771 6 way term. block (for AE 125)
93 793772 Front cover
93 793773 Thermal cut-out
93 793774 Flow transducer
93 793775 PCB enclosure (lid)
93 793776 PCB enclosure (base)
93 793777 Control PCB (for AE115)
93 793778 Control PCB (for AE125)
93 793779 Adjustment knob
93 793784 3/4" Inlet filter
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 temperature dial
• The temperature adjustment is made using the dial on the bottom edge of the unit. The adjustment
is between approximately 95oF and 135oF. Turning the dial clockwise increases the temperature
setting as indicated by the marking on the unit.
Adjusting the flow
• 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) closest to the outlet connection.
• Adjust the outlet shut-off valve until the water flow rate from the hot faucet corresponds to the value
given in Graph 1 on Page 8.
For further information ask your
local dealer.
FOR SERVICE AND INSTALLATION
QUESTIONS CALL TOLL FREE:
866-330-2729 (Toll Free)
Fax: [phone]
www.ControlledEnergy.com/tech

8
Graph 1
For example:
• For the AE115 unit, using a ball valve, ensure the flow rate does not exceed 2.3 US
gallons / minute.
• For the AE125 unit, using a ball valve, ensure the flow rate does not exceed 3.5 US
gallons / minute.
Note: These figures are based on an inlet water temperature of 55oF and a supply voltage of 240
volts. If the inlet water temperature is lower than 55oF, or if the supply voltage is less than 240 volts,
then the outlet temperature will be lower than what is shown in Graph 1. If a higher outlet water
temperature is desired, then reduce the flow rate and/or supply the unit with 240 volts.
IMPORTANT
Before leaving the site, the installer should demonstrate the unit to the user and give them this guide.
Outlet Temperature (oF)
Outlet Temperature vs Maximum Flow Rate Setting
(based on incoming water temperature of 55oF)

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How the PowerStar works
• The PowerStar heats water instantaneously as it flows through the heater modules.
• The electronic control monitors the flow rate and the incoming water temperature and then switches
on the required number of heater modules to reach the temperature set by the adjustment dial.
• As the flow rate or the incoming water temperature changes, the electronics adjust the number of
heater modules used so that the outlet temperature is maintained.
• The outlet water temperature can change slightly as the flow rate changes due to the steps in
power as different heater modules are switched on and off.
• The outlet water temperature can also vary if the maximum flow rate is exceeded (see Graph 1) or if
the supply voltage changes.
• Each heater module is protected by an electro-mechanical thermal cut-out. If the temperature of
any of the heater modules gets too high, then the cut-out will trip and cut the power to that heater
module. If the cut-out operates, it must be reset by a qualified service person. This cut-out will only
trip in exceptional circumstances.
• The AE115 unit is supplied from two independent voltage supplies and the AE125 unit from three
independent voltage supplies. The unit may continue to work if one of these supplies is switched off
or fails, but the temperature control will be poor.
• Depending on the region of the country, the temperature of the water supply can vary between 40oF
in winter to 70oF in summer, with an average of 55oF.
Diagram 4: Internal wiring schematic for single phase AE125 unit.
(AE115 has two heater modules and two supplies.)
Thermistor

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Specifications
AE115 Unit AE125 Unit
Voltage supply 2 x 240V AC 3 x 240V AC
Amperage 2 x 40 A 3 x 40 A
Maximum output 17.25 kW 26.85kW
Temperature control range 95oF to 131oF95
oF to 131oF
Pressure range 15 psi to 150 psi 15 psi to 150 psi
Minimum flow rate 0.6 US gal / min 0.8 US gal / min
Maximum flow rate See Graph 1, Page 8 See Graph 1, Page 8
Dimensions (excl. water couplers) 151/2” H x 151/4”Wx4
1/2”D 15 1/2” H x 151/4”Wx4 1/2”D
Weight (without water) 20 lbs 22 lbs
Note: The unit will work at lower supply voltages but the following changes will apply:
Maximum output 15kW at 220V 22.5kW at 220V
13kW at 208V 20kW at 208V
Temperature control range 87oF to 116oF at 220V 87oF to 116oF at 220V
82oF to 108oF at 208V 82oF to 108oF at 208V
Maximum flow rate 84% of maximum at 220V 84% of maximum at 220V
(refer to Graph 1, Page 8) 75% of maximum at 208V 75% of maximum at 208V
WARNING
Always switch off the electricity supply to the unit before you remove the cover.
If you have a problem...
Service should only be performed by qualified personnel
Symptom
Cold water only –
neon light off.
Electricity not on or one of the
supplies has failed. Check electricity supply.
The water supply is connected
to the outlet of the unit.
Reconnect the water supply to
the inlet of the unit (marked
blue).
Turn off the power, open the unit
and reset by pushing the
button(s) on the top of the heater
module(s). Establish and fix the
cause of the overheating.
One or more of the heater
module cut-outs has tripped.
Test by turning cold water supply
off to heater, then open hot water
faucet(s). No pressurized water
flow should be evident. If it is
evident, then that plumbing
crossover needs to be corrected
for the heater to operate.
Plumbing crossover.
Turn off the power, open the unit
and observe if the flow
transducer "spins" when the
water is turned on. If not, contact
CEC toll free at 866-330-2729.
The flow transducer is not
working.
Cause What to do

11
PowerStar
LIMITED 10 YEAR WARRANTY
COVERAGE
APPLIED ENERGY PRODUCTS THROUGH ITS U.S. DISTRIBUTOR CONTROLLED ENERGY
CORP. (herein after CEC) guarantees this water heater to the original owner of the water heater at
the original installation location against defects in material and workmanship for the periods specified
below.
WARRANTY PERIOD
1. The Heat Exchanger - If the original heat exchanger leaks or fails within ten (10) years from the
date of original installation of the water heater because of a defect in material or workmanship,
CEC will furnish to such an owner a new heater of the then-prevailing comparable model.
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.
Symptom
Water flow is too high. Adjust the water flow (see
Graph 1 on Page 8).
One of the power supplies is
not on.
Check the supply voltages to the
heater and rectify if necessary.
Temperature dial is turned
too low.
Turn the temperature control dial
clockwise.
The inlet water temperature
has dropped.
Turn temperature knob up or
reduce the flow rate according to
Graph 1 on Page 8.
The power supply voltage
has dropped.
This is likely an issue with the
power supply. Compensate for
this by increasing the
temperature setting (turn dial
clockwise).
Water too cold –
neon light on
Water flow too low
Water temperature
fluctuates
If the problem persists
The person who initially installed the unit is the best one to contact for help.
You can also call CEC Toll Free 866-330-2729. Please have this guide with you when you call.
Cause What to do
There are restrictions in the
plumbing.
Check the plumbing. Use only
Teflon tape for sealing pipe
joints. Inspect and clean inlet
filter screen at heater.
Outlet shut-off valves are set
too low.
Adjust outlet shut-off valves as
described in the section
"Adjusting the Flow" (see Page 7).
Fluctuating water pressure or
changing flow rate.
Avoid several hot water outlets
being used at the same time as
this causes the temperature to
fluctuate.
Water supply pressure too
low.
Check that all inlet shut-off
valves are fully open.

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2. Any Component Part Other Than the Heat Exchanger - If any other component part (other than
the heat exchanger) proves to be defective in material or workmanship within one (1) year from
the date of original installation of the water heater, CEC 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 date of manufacture marked on the tag
affixed to the 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 shall not be liable for 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;
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 manufacturer’s
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 damages 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 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
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.
The person who initially installed the unit is the best one to contact for help.
You can also call CEC toll free at 866-330-2729. Please have this guide with you when you call.
555-2028-01F
www.ControlledEnergy.com/tech