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Bosch Appliances Boiler manual

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Table of contents for the manual

  • Page 1

    Gas Condensing Boiler Bosch 100, 151 Combi Boiler 57, 100, 131, 151 Heating Boiler W ARNING: Improper installation, setup, modi fi cation, operation or maintenance of the heating syst em can cause personal injury and proper ty damage. F ollow each appliances' instructions precisely . F or assistance or further information, contact a trained a[...]

  • Page 2

    2 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange[...]

  • Page 3

    Applications Manual Bosch Gr eenstar | 3 Bosch Thermot echnology Corp. Data subject to c hange T able of Contents 1 Information about the appliance 4 1.1 Boiler types and sizes 4 1.2 FW200 Boiler Energy Management 5 1.3 FB100 Remot e Control & Room Sensor 6 1.4 IPM2 Space Heating Module 7 1.5 ISM2 Solar Module 8 2 Applications 9 Legend 9 List o[...]

  • Page 4

    4 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange 1 Information about the appliance 1.1 Boiler types and sizes Greenstar Heating boilers  Greenstar 57: ZBR 16-3, 54,600btu (16kW) output  Greenstar 100: ZBR 28-3, 95,500btu (28kW) output  Greenstar 131: ZBR 35-3, 119,400btu (35kW) output  Greens[...]

  • Page 5

    Applications Manual Bosch Gr eenstar | 5 Bosch Thermot echnology Corp. Data subject to c hange 1.2 FW200 Boiler Energy Management Syst em  The Boiler Energy Management Syst em includes the FW200 user programming int er face with integrat ed outdoor reset contr ol.  In connection with the IPM2 module the FW200 offers an outdoor reset contr ol [...]

  • Page 6

    6 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange 1.3 FB100 Remote Contr ol & Room Sensor The FB100 can only be connect ed to sy stems with FW200 and a boiler with BUS-enabled Heatronic 3.  The FB100 is a remot e room sensor and user interface that is used t o display de vice and syst em informatio[...]

  • Page 7

    Applications Manual Bosch Gr eenstar | 7 Bosch Thermot echnology Corp. Data subject to c hange 1.4 IPM2 Space Heating Module The IPM2 module operates pum ps and mixing valves of 2 heating zones. Each zone is run independently based on the programming and f eedback from the FB100 room sensor (if installed). Instead of a second zone a DHW recirculati[...]

  • Page 8

    8 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange 1.5 ISM2 Solar Module The ISM2 module controls the com ponents of a solar thermal syst em. Integration of solar thermal with a boiler and central heating syst em for backup brings additional bene fi ts as it allow s minimizing boiler r un time and reduces[...]

  • Page 9

    Applications Manual Bosch Gr eenstar | 9 Bosch Thermot echnology Corp. Data subject to c hange 2 Applications Legend Greenstar boiler Greenstar combi-boiler Greenstar Greenstar pipe pipe Flow check valve Fig. 3 Legend NOTICE: All drawings in t his manual are conceptual in natur e and only depict components r elevant f or the syst ems shown. It is t[...]

  • Page 10

    10 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange List of most common applications Single Zone Baseboard Syst ems:  Syst em 1: Greenstar Heating Boiler in a single zone syst em (page 13-16).  Syst em 2: Greenstar Combi-Boiler in a single zone syst em (page 17-20).  Syst em 3: Greenstar Heating B[...]

  • Page 11

    Applications Manual Bosch Gr eenstar | 11 Bosch Thermot echnology Corp. Data subject to c hange Boiler pump capacity in single zone syst ems When installing the boiler in a single zone application without primar y/secondar y piping, it is critical not to overload t he pump. Use the Greenstar Heating or Combi Boiler in this setup only in lo w pressu[...]

  • Page 12

    12 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange 02 5 7 8 14 36 15 20 25 10 5 0 H / ft . V / gpm 1 2 3 4 400 800 1200 1600 200 600 1000 1400 7 0 6 5 4 3 2 1 0 H / m . V / l/h 6 720 641 933-59.1O 1 2 3 4 02 13 5 46 8 7 15 20 25 10 5 0 H / ft . V / gpm 1 2 3 4 400 800 1200 1600 7 0 6 5 4 3 2 1 0 H / m . V[...]

  • Page 13

    Applications Manual Bosch Gr eenstar | 13 Bosch Thermot echnology Corp. Data subject to c hange 2.1 Syst em 1: Greenstar Heating Boiler in a single zone syst em Summar y: Single boiler supplying one baseboard heating zone equipped with FW200 outdoor rese t controller with built-in room sensor in the living space. This sy st em is using the boiler p[...]

  • Page 14

    14 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 1 - Piping Diagram[...]

  • Page 15

    Applications Manual Bosch Gr eenstar | 15 Bosch Thermot echnology Corp. Data subject to c hange System 1 - Wiring Diagram[...]

  • Page 16

    16 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 1: Setup and Pr ogramming In this single zone syst em the FW200 is installed in the living space in a location that repr esents the conditions of the entire zone. Av oid locations exposed to dir ect or indirect sunlight, heat sources, draft, etc. t[...]

  • Page 17

    Applications Manual Bosch Gr eenstar | 17 Bosch Thermot echnology Corp. Data subject to c hange 2.2 Syst em 2: Greenstar Combi Boiler in a single zone syst em Summar y: Single combi-boiler supplying one baseboard heating zone equipped with FW200 outdoor rese t controller with built-in room sensor in the living space. DHW generation directly off the[...]

  • Page 18

    18 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 2 - Piping diagram[...]

  • Page 19

    Applications Manual Bosch Gr eenstar | 19 Bosch Thermot echnology Corp. Data subject to c hange System 2 - Wiring diagram[...]

  • Page 20

    20 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 2: Setup and Pr ogramming In this single zone syst em the FW200 is installed in the living space in a location that repr esents the conditions of the entire zone. Av oid locations exposed to dir ect or indirect sunlight, heat sources, draft, etc. t[...]

  • Page 21

    Applications Manual Bosch Gr eenstar | 21 Bosch Thermot echnology Corp. Data subject to c hange 2.3 Syst em 3: Greenstar Heating Boiler in a single zone syst em with DHW tank loading Summar y: Single boiler supplying one baseboard heating zone equipped with FW200 outdoor rese t controller with built- in room sensor in the living space. This sy st e[...]

  • Page 22

    22 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 3 - Piping diagram[...]

  • Page 23

    Applications Manual Bosch Gr eenstar | 23 Bosch Thermot echnology Corp. Data subject to c hange System 3 - Wiring diagram[...]

  • Page 24

    24 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 3: Setup and Pr ogramming In this single zone syst em the FW200 is installed in the living space in a location that repr esents the conditions of the entire zone. Av oid locations exposed to dir ect or indirect sunlight, heat sources, draft, etc. t[...]

  • Page 25

    Applications Manual Bosch Gr eenstar | 25 Bosch Thermot echnology Corp. Data subject to c hange 2.4 System 4: Greenstar Heating Boiler in a single zone syst em with solar thermal DHW and boiler backup Summar y: Single boiler supplying one baseboard heating zone equipped with FW200 outdoor rese t controller with built- in room sensor in the living s[...]

  • Page 26

    26 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 4 - Piping diagram R1[...]

  • Page 27

    Applications Manual Bosch Gr eenstar | 27 Bosch Thermot echnology Corp. Data subject to c hange System 4 - Wiring diagram R1[...]

  • Page 28

    28 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 4: Setup and Pr ogramming In this single zone syst em the FW200 is installed in the living space in a location that repr esents the conditions of the entire zone. Av oid locations exposed to dir ect or indirect sunlight, heat sources, draft, etc. t[...]

  • Page 29

    Applications Manual Bosch Gr eenstar | 29 Bosch Thermot echnology Corp. Data subject to c hange 2.5 System 5: Greenstar Heating Boiler in a single zone syst em Summar y: Single boiler with primar y/secondar y piping con fi guration supplying one heating zone. Outdoor rese t with FW200 controller with built-in r oom sensor mounted in t he living sp[...]

  • Page 30

    30 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 5 - Piping diagram[...]

  • Page 31

    Applications Manual Bosch Gr eenstar | 31 Bosch Thermot echnology Corp. Data subject to c hange System 5 - Wiring diagram[...]

  • Page 32

    32 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 5: Setup and Pr ogramming In this single zone syst em the FW200 is installed in the living space in a location that repr esents the conditions of the entire zone. Av oid locations exposed to dir ect or indirect sunlight, heat sources, draft, etc. t[...]

  • Page 33

    Applications Manual Bosch Gr eenstar | 33 Bosch Thermot echnology Corp. Data subject to c hange 2.6 System 6: Greenstar Combi Boiler in a single zone syst em Summar y: Single combi-boiler supplying one heating zone. Outdoor reset wit h FW200 controller with built-in r oom sensor mounted in t he living space for r oom feedbac k. DHW generation direc[...]

  • Page 34

    34 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 6 - Piping diagram[...]

  • Page 35

    Applications Manual Bosch Gr eenstar | 35 Bosch Thermot echnology Corp. Data subject to c hange System 6 - Wiring diagram[...]

  • Page 36

    36 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 6: Setup and Pr ogramming In this single zone syst em the FW200 is installed in the living space in a location that repr esents the conditions of the entire zone. Av oid locations exposed to dir ect or indirect sunlight, heat sources, draft, etc. t[...]

  • Page 37

    Applications Manual Bosch Gr eenstar | 37 Bosch Thermot echnology Corp. Data subject to c hange 2.7 System 7: Greenstar Heating Boiler in a single zone syst em with DHW tank loading Summar y: Single boiler with primar y/secondar y piping con fi guration supplying one heating zone. Outdoor rese t with FW200 controller with built-in r oom sensor mou[...]

  • Page 38

    38 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 7 - Piping diagram[...]

  • Page 39

    Applications Manual Bosch Gr eenstar | 39 Bosch Thermot echnology Corp. Data subject to c hange System 7 - Wiring diagram[...]

  • Page 40

    40 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 7: Setup and Pr ogramming In this single zone syst em the FW200 is installed in the living space in a location that repr esents the conditions of the entire zone. Av oid locations exposed to dir ect or indirect sunlight, heat sources, draft, etc. t[...]

  • Page 41

    Applications Manual Bosch Gr eenstar | 41 Bosch Thermot echnology Corp. Data subject to c hange 2.8 System 8: Greenstar Heating Boiler in a single zone syst em with room thermostat and DHW tank loading Summar y: Single boiler with primar y/secondar y piping con fi guration supplying one heating zone. Outdoor rese t with FW200 controller mount ed o[...]

  • Page 42

    42 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 8 - Piping diagram[...]

  • Page 43

    Applications Manual Bosch Gr eenstar | 43 Bosch Thermot echnology Corp. Data subject to c hange System 8 - Wiring diagram[...]

  • Page 44

    44 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 8: Setup and Pr ogramming In this single zone syst em the FW200 is installed in the boiler for pur e outdoor reset wit hout room in fl uence. Install a suitable 3rd party thermostat in the living space in a location that repr esents the entire zon[...]

  • Page 45

    Applications Manual Bosch Gr eenstar | 45 Bosch Thermot echnology Corp. Data subject to c hange 2.9 System 9: Greenstar Heating Boiler in a single zone syst em with solar thermal DHW and boiler backup Summar y: Single boiler with primar y/secondar y piping con fi guration supplying one heating zone. Outdoor rese t with FW200 controller with built-[...]

  • Page 46

    46 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 9 - Piping diagram R1[...]

  • Page 47

    Applications Manual Bosch Gr eenstar | 47 Bosch Thermot echnology Corp. Data subject to c hange System 9 - Wiring diagram R1[...]

  • Page 48

    48 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 9: Setup and Pr ogramming In this single zone syst em the FW200 is installed in the living space in a location that repr esents the conditions of the entire zone. Av oid locations exposed to dir ect or indirect sunlight, heat sources, draft, etc. t[...]

  • Page 49

    Applications Manual Bosch Gr eenstar | 49 Bosch Thermot echnology Corp. Data subject to c hange 2.10 System 10: Greenstar Heating Boiler with zone pumps and room thermostats Summar y: Single boiler with primar y/secondar y piping con fi gura- tion supplying multiple heating zones. Outdoor rese t with FW200 controller mount ed on the boiler . 3rd p[...]

  • Page 50

    50 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 10 - Piping diagram[...]

  • Page 51

    Applications Manual Bosch Gr eenstar | 51 Bosch Thermot echnology Corp. Data subject to c hange System 10 - Wiring diagram[...]

  • Page 52

    52 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 10: Setup and Pr ogramming In this dual zone syst em the FW200 is installed in the boiler for pur e outdoor reset wit hout room in fl uence on the heating cur ve. Install suitable 3rd party thermostats in each zone in a location that best repr ese[...]

  • Page 53

    Applications Manual Bosch Gr eenstar | 53 Bosch Thermot echnology Corp. Data subject to c hange 2.11 System 11: Greenstar Heating Boiler with zone pumps, rela y panel, room thermostats and DHW tank loading Summar y: Single boiler with primar y/secondar y piping con fi guration supplying three heating zones contr olled by individual zone thermostat[...]

  • Page 54

    54 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 11 - Piping diagram[...]

  • Page 55

    Applications Manual Bosch Gr eenstar | 55 Bosch Thermot echnology Corp. Data subject to c hange System 11 - Wiring diagram[...]

  • Page 56

    56 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 11: Setup and Pr ogramming In this multi zone syst em the FW200 is installed in the boiler for pur e outdoor reset wit hout room in fl uence on the heating cur ve. Install suitable 3rd party thermostats in each zone in a location that best repr es[...]

  • Page 57

    Applications Manual Bosch Gr eenstar | 57 Bosch Thermot echnology Corp. Data subject to c hange 2.12 System 12: Greenstar Heating Boiler with zone valves and room thermostats Summar y: Single boiler with primar y/secondar y piping con fi gura- tion supplying three heating zones contr olled by 3rd par ty room thermostats with zone valv es. Outdoor [...]

  • Page 58

    58 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 12 - Piping diagram[...]

  • Page 59

    Applications Manual Bosch Gr eenstar | 59 Bosch Thermot echnology Corp. Data subject to c hange System 12 - Wiring diagram[...]

  • Page 60

    60 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange System 12: Setup and Pr ogramming In this multi zone syst em the FW200 is installed in the boiler for pur e outdoor reset wit hout room in fl uence on the heating cur ve. Z one control is handled b y a zone valve panel with r oom thermostats in each zone[...]

  • Page 61

    Applications Manual Bosch Gr eenstar | 61 Bosch Thermot echnology Corp. Data subject to c hange[...]

  • Page 62

    62 | Bosch Greenstar Applications Manual Bosch Thermot echnology Corp. Data subject to c hange[...]

  • Page 63

    Applications Manual Bosch Gr eenstar | 63 Bosch Thermot echnology Corp. Data subject to c hange[...]

  • Page 64

    United Stat es and Canada Bosch Thermotechnology Corp. 50 Wentw orth Avenue Londonderry, NH 03053 T el: 603-552-1100 F ax: 603-584-1681 www.bosch-climat e.us BTC 436001101 A / 07.2011[...]