Bosch 100 User Manual

WARNING:

Improper installation, setup, modification, operation or maintenance of the heating system can cause personal injury and property damage.

Follow each appliances' instructions precisely.

For assistance or further information, contact a trained and certified installer, service provider, or the gas supply company.

In Massachusetts, the boiler must be installed by a licensed plumber or gas fitter.

Application drawings in this manual are conceptual only and do not purport to address all design, installation, code, or safety considerations.

The diagrams in this manual are for reference use by code officials, designers and licensed installers. It is expected that installers have adequate knowledge of national and local codes, as well as accepted industry practices, and are trained on equipment, procedures, and applications involved. Drawings are not to scale.

Refer to the boiler, control and module installer manuals for additional detailed information!

Gas Condensing Boiler

Bosch

100, 151 Combi Boiler

57, 100, 131, 151 Heating Boiler

Applications Manual

2 | Bosch Greenstar	Applications Manual

Data subject to change

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Applications Manual	Bosch Greenstar | 3

Table 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 Remote Control & Room Sensor	6
1.4	IPM2 Space Heating Module	7
1.5	ISM2 Solar Module	8

2 Applications		9
Legend		9
List of most common applications		10
Boiler pump capacity in single zone systems		11
Single Zone Baseboard Systems:
2.1	System 1: Greenstar Heating Boiler in a
	single zone system	13
2.2	System 2: Greenstar Combi Boiler in a
	single zone system	17
2.3	System 3: Greenstar Heating Boiler in a single
	zone system with DHW tank loading	21

2.4System 4: Greenstar Heating Boiler in a single zone system with solar thermal DHW and

boiler backup

25

Single Zone Systems with Primary/Secondary Piping:

2.5	System 5: Greenstar Heating Boiler in a
	single zone system	29
2.6	System 6: Greenstar Combi Boiler in a
	single zone system	33
2.7	System 7: Greenstar Heating Boiler in a single
	zone system with DHW tank loading	37

2.8System 8: Greenstar Heating Boiler in a single zone system with room thermostat and DHW

tank loading

41

2.9System 9: Greenstar Heating Boiler in a single zone system with solar thermal DHW and

boiler backup	45
Multi-zone Systems with Primary/Secondary Piping:
2.10 System 10: Greenstar Heating Boiler with
zone pumps and room thermostats	49
2.11 System 11: Greenstar Heating Boiler with
zone pumps, room thermostats and DHW
tank loading	53
2.12 System 12: Greenstar Heating Boiler with
zone valves and room thermostats	57

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Data subject to change

4 | Bosch Greenstar	Applications Manual

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

Greenstar 151: ZBR 42-3, 143,000btu (42kW) output

Greenstar Combi-boilers

Greenstar Combi 100: ZWB 28-3, 95,500btu (28kW) output

Greenstar Combi 151: ZWB 42-3, 143,000btu (42kW) output

Data subject to change

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Applications Manual	Bosch Greenstar | 5

1.2FW200 Boiler Energy Management System

The Boiler Energy Management System includes the FW200 user programming interface with integrated outdoor reset control.

In connection with the IPM2 module the FW200 offers an outdoor reset control for two heating zones and DHW generation with time programs:

— Central heating : Six weekly heating programs with six programmable switch points per day (one program is active).

— DHW : weekly DHW program with six switch points per day.

—DHW Recirculation pump program.

Options:

—Remote control and room sensor FB100 provides status information and a programming interface in each zone.

—Module ISM2 for solar DHW heating and solar space heating support.

Programs and settings are stored in a permanent memory and remain even during power outages.

Installation options:

—In the boiler

—Wall-mounted as a remote room sensor

Scope of delivery

	2
		3
	8	1
5		4

2x 2x

Fig. 1 FW200 Energy Management System 1 Controls top section

2 Base for wall-mounting

3 Top cover

4 Installation and operating instructions

5 Outdoor temperature sensor with mounting kit

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1.3 FB100 Remote Control & Room Sensor

The FB100 can only be connected to systems with FW200 and a boiler with BUS-enabled Heatronic 3.

The FB100 is a remote room sensor and user interface that is used to display device and system information and to change the settings of that particular zone.

The FB100 is designed for wall mounting.

In connection with the IPM2 module, the FB100 controls the assigned heating circuit using a timer program. Three weekly heating programs with six switch points per day are available for a heating circuit (one program is active).

Maximum of four FB100 in a heating system with FW200.

In case of power failure, the display will be off. All settings are saved.

Scope of delivery

2 3

8

1 4

Fig. 2 FB100 Remote Control & Room Sensor 1 Upper part of remote control

2 Base for wall-mounting

3 Top cover

4 Installation and operating instructions

Data subject to change

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Applications Manual	Bosch Greenstar | 7

1.4 IPM2 Space Heating Module

The IPM2 module operates pumps and mixing valves of 2 heating zones. Each zone is run independently based on the programming and feedback from the FB100 room sensor (if installed). Instead of a second zone a DHW recirculation pump can also be controlled by the IMP-2.

	Combination overview
	Outdoor reset controls	FW200
	and primary room sensor
	Remote control for	FB100
	additional zones
		2 mixed heating zones
		1 mixed heating zone
		+ 1 unmixed heating zone
		+ 1 DHW recirculation pump
		2 unmixed heating zones
	Available	+ 1 DHW recirculation pump
	systems	1 mixed heating zone
		+ 1 storage tank
		+ 1 DHW tank loading pump
		1 unmixed heating zone
		+ 1 storage tank
		+ 1 DHW tank loading pump
	Max. number of Modules	max. 5 IPM2
	per system
	Tab. 1

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Data subject to change

8 | Bosch Greenstar	Applications Manual

1.5 ISM2 Solar Module

The ISM2 module controls the components of a solar thermal system. Integration of solar thermal with a boiler and central heating system for backup brings additional benefits as it allows minimizing boiler run time and reduces burner starts significantly compared to a nonintegrated system.

Combination overview

With the ISM2 module, it is possible to realize a variety of solar thermal systems.

Basic solar thermal systems

System 1 : Solar thermal DHW heating

System 2 : Solar thermal DHW heating and space heating support

System expansions

Option A : Two collector arrays (east/west orientation)

Option B : Reloading system with two single coil DHW tanks

Option C : First/second priority system with 2 tanks, realized with

—p-p : a separate pump for each tank

—p-v : common pump and diverter valve

Option D : External heat exchanger on the solar circuit

Option E : Thermal disinfection of the solar tank

Combine a basic system with one or several options to realize the desired solar system.

This manual shows basic solar thermal DHW systems only. For information on all options, please consult the Installation and Service Manual.

Data subject to change

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Applications Manual	Bosch Greenstar | 9

2 Applications

Legend

Flow check valve

pipe pipe

Greenstar

Greenstar

Greenstar boiler

Greenstar combi-boiler

Fig. 3 Legend

NOTICE: All drawings in this manual are conceptual in nature and only depict components relevant for the systems shown. It is the installer's responsibility to know national and local code and install safety devices as required. Install and size peripheral devices such as air purge, expansion vessel, feeder valve, mud separator, shutoff valves, etc. per best installation practices. Contact Bosch with installation related questions.

Bosch Thermotechnology Corp.

Data subject to change

10 | Bosch Greenstar	Applications Manual

List of most common applications

Single Zone Baseboard Systems:

System 1: Greenstar Heating Boiler in a single zone system (page 13-16).

System 2: Greenstar Combi-Boiler in a single zone system (page 17-20).

System 3: Greenstar Heating Boiler in a single zone system with DHW tank loading ( page 21-24).

System 4: Greenstar Heating Boiler in a single zone system with solar thermal DHW and boiler backup (page 25-28).

Single Zone Systems with Primary/Secondary Piping:

System 5: Greenstar Heating Boiler in a single zone system (page 29-32)

System 6: Greenstar Combi-Boiler in a single zone system (page 33-36).

System 7: Greenstar Heating Boiler in a single zone system with DHW tank loading (page 37-40)

System 8: Greenstar Heating Boiler in a single zone system with room thermostat and DHW tank loading (page 41-44).

System 9: Greenstar Heating Boiler in a single zone system with solar thermal DHW and boiler backup (page 45-48).

Multi-zone Systems with Primary/Secondary Piping:

System 10: Greenstar Heating Boiler with zone pumps and room thermostats (page 49-52).

System 11: Greenstar Heating Boiler with zone pumps, room thermostats, and DHW tank loading (page 5356).

System 12: Greenstar Heating Boiler with zone valves and room thermostats ( page 57-60).

Data subject to change

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Applications Manual	Bosch Greenstar | 11

Boiler pump capacity in single zone systems

When installing the boiler in a single zone application without primary/secondary piping, it is critical not to overload the pump. Use the Greenstar Heating or Combi Boiler in this setup only in low pressure baseboard applications. Radiant floor, panel radiator, or multi-zone applications require primary/secondary piping. Do not install zone valves with this system.

Recommended maximum: 70' (21 m) of 3/4" baseboard at a 20°F delta T and a flow rate of 4.0 gpm. This allows sufficient reserves for the necessary supply and return piping plus elbows.

Alternatively determine the system pressure drop on a case by case basis to verify that the boiler pump is capable of delivering the required flow rate. Table 2 provides as an example the pressure drop of 100’ of 3/4” baseboard and its relevant heat output.

Water Flow	Pressure Drop per 100'		MBH output per 100’ at shown Medium Water Temperature
				and 65°F Room Temperature
GPM	feet of head	110°F	120°F	130°F	140°F	150°F	160°F	170°F	180°F
4	4.375	16	12	26	32	38	46	54	61

Tab. 2 Pressure drop and heat output for ¾” baseboard

Add to that the pressure drop of supply and return piping plus elbows and other devices like check valves.

Use the pump curves on the following page to verify that the pump is capable of delivering the needed flow rate for the given pressure drop of the system.

In order to save as much energy as possible and keep water circulation noises to a minimum, select the lowest possible pump speed.

If the working pressure cannot be met, use primary/ secondary piping.

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Data subject to change

12 | Bosch Greenstar	Applications Manual

Pump curve of heating boiler

	25
	20
/ ft	15								4
H	10						3
			1		2
	5
	0
	0	1	2	3 .	4	5	6	7	8
				V / gpm
	7
	6
	5							4
H / m	4
	3				2		3
				1
	2
	1
	0
	0	200	400	600 .800 1000 1200 1400 1600
					V / l/h				6 720 641 933-59.1O

Pump curve of combi boiler (heating side)

	25
	20
H / ft	15							4
	10
	5						3
	0			1		2
	0	1	2	3 .	4	5	6	7	8
				V / gpm
	7
	6
	5								4
H / m	4
	3
	2							3
	1				1		2
	0
	0		400		.800		1200		1600
					V / l/h				6 720 641 933-61.1O

Fig. 4 Greenstar boiler pump curves
Key to Fig. 4
1	Residual head pressure at speed 1	4 Head pressure of the boiler pump by itself (at speed 3)
2	Residual head pressure at speed 2	H Head pressure in feet of head (m)
3	Residual head pressure at speed 3 (default setting)	V Circulating water volume in gallons per minute (l/h)

Data subject to change

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Applications Manual	Bosch Greenstar | 13

2.1System 1: Greenstar Heating Boiler in a single zone system

Summary:

Single boiler supplying one baseboard heating zone equipped with FW200 outdoor reset controller with built-in room sensor in the living space. This system is using the boiler pump for zone water circulation.

This design can only be used with a single loop baseboard system that has a low pressure drop. Radiant floors, panel radiator, or multi zone systems require primary-secondary piping. Do not install zone valves with this system.

The pump will run in constant circulation except when in warm weather shutdown.

Max. 70' (21 m) of 3/4" baseboard at a 20°F delta T and a flow rate of 4.0 gpm plus the necessary supply and return piping.

In detail:

The FW200 is an outdoor temperature based controller with room temperature influence. The controller adjusts the heating curve (boiler supply temperature) according to outdoor temperature. When the FW200 is wall mounted, it also uses room temperature to adjust the heating curve and modify boiler supply temperature.

FW200 provides warm weather shutdown.

Required components:

Greenstar heating boiler.

FW200 controller in the room.

Additional instructions:

See manufacturer’s installation and operating instructions.

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Data subject to change

14 | Bosch Greenstar	Applications Manual

System 1 - Piping Diagram

Data subject to change

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Applications Manual	Bosch Greenstar | 15

System 1 - Wiring Diagram

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Data subject to change

16 | Bosch Greenstar	Applications Manual

System 1: Setup and Programming

In this single zone system the FW200 is installed in the living space in a location that represents the conditions of the entire zone. Avoid locations exposed to direct or indirect sunlight, heat sources, draft, etc. that can lead to over compensation.

Initial setup:

See the installation instructions for description of buttons and displays, and for details on setup and programming.

Power up the boiler.

When commissioning for the first time set the display language, date and time.

Upon first commissioning the automatic system configuration starts. Wait 60 seconds and follow the instructions displayed. You have the option of using the factory settings or entering custom parameters to better match the individual requirements.

Set up the weekly heating program for the three available temperature levels:

—Comfort

—Economy

—Frost (Frost protection)

Take advantage of using one of the preset programs from the list or enter a custom program.

—Program A

—Program F

—AM weekday worker

—PM weekday worker

—All day

—All day, lunch

—Family

—All day, early shift

—All day, late shift

—Seniors

Set the room temperatures for the three specified temperature levels.

Enter the installer menu to configure the heating zone.

—Set heating circuit type to Baseboard.

—Set the minimum outdoor temperature, building storage capacity, design day temperature, and maximum supply temperature.

—Set the room influence followed by the remaining parameters as they apply to the system.

When done, ensure the mode selector is set to AUTO.

The room temperature will be displayed.

Additional information:

With outdoor reset the boiler will provide the water temperature according to the heating curve adjusted by the level of room influence (if enabled).

The boiler will always attempt to run at its highest efficiency in low fire for as long as necessary.

The boiler will shut down when the target temperature is reached followed by a 3 minute post purge by the pump.

—The boiler and the pump will start again when the supply water temperature drops 18°F (10°C) below the set point.

Data subject to change

Bosch Thermotechnology Corp.

Applications Manual	Bosch Greenstar | 17

2.2System 2: Greenstar Combi Boiler in a single zone system

Summary:

Single combi-boiler supplying one baseboard heating zone equipped with FW200 outdoor reset controller with built-in room sensor in the living space. DHW generation directly off the boiler through the tankless heat exchanger. This system is using the boiler pump for zone water circulation.

The “combi” or combination boiler is a high efficiency central heating boiler and water heater combined within one compact unit. Water is heated on demand directly from the water main eliminating the need for a hot water storage tank.

This design can only be used with a single loop baseboard system that has a low pressure drop. Radiant floors, panel radiator, or multi zone systems require primary-secondary piping. Do not install zone valves with this system.

The pump will run in constant circulation while in space heating mode except during a call for DHW or when in warm weather shutdown.

Max. 70' (21 m) of 3/4" baseboard at a 20°F delta T and a flow rate of 4.0 gpm plus the necessary supply and return piping..

In detail:

The FW200 is an outdoor temperature based controller with room temperature influence. The controller adjusts the heating curve (boiler supply temperature) according to outdoor temperature. When the FW200 is wall mounted, it also uses room temperature to adjust the heating curve and modify boiler supply temperature.

FW200 provides warm weather shutdown.

Required components:

Greenstar combi-boiler.

FW200 controller in the room.

Additional instructions:

See manufacturer’s installation and operating instructions.

Install an adequately sized Pressure Relief Valve (PRV) on the DHW outlet of the combi boiler.

To reduce the risk of scalding it is recommended to install a DHW tempering valve.

The Greenstar combi boiler is equipped with an internal 3.17 gal (12 liter) expansion vessel. The installation manual provides information on how to determine if it is

of sufficient capacity for the application or if an additional expansion vessel is needed.

Bosch Thermotechnology Corp.

Data subject to change

18 | Bosch Greenstar	Applications Manual

System 2 - Piping diagram

Data subject to change

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Applications Manual	Bosch Greenstar | 19

System 2 - Wiring diagram

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Data subject to change

20 | Bosch Greenstar	Applications Manual

System 2: Setup and Programming

In this single zone system the FW200 is installed in the living space in a location that represents the conditions of the entire zone. Avoid locations exposed to direct or indirect sunlight, heat sources, draft, etc. that can lead to over compensation.

DHW is generated directly by the combi-boiler without the need for a storage tank.

Initial setup:

See the installation instructions for description of buttons and displays, and for details on setup and programming.

Power up the boiler.

When commissioning for the first time set the display language, date and time.

Upon first commissioning the automatic system configuration starts. Wait 60 seconds and follow the instructions displayed. You have the option of using the factory settings or entering custom parameters to better match the individual requirements.

Set up the weekly heating program for the three available temperature levels:

—Comfort

—Economy

—Frost (Frost protection)

Take advantage of using one of the preset programs from the list or enter a custom program.

—Program A

—Program F

—AM weekday worker

—PM weekday worker

—All day

—All day, lunch

—Family

—All day, early shift

—All day, late shift

—Seniors

Set the room temperatures for the three specified temperature levels.

Enter the installer menu to configure the heating zone.

—Set heating circuit type to Baseboard.

—Set the minimum outdoor temperature, building storage capacity, design day temperature, and maximum supply temperature.

—Set the room influence followed by the remaining parameters as applicable.

Set up the weekly program for DHW generation.

For additional features of the combi boiler see the installation manual.

When done, ensure the mode selector is set to AUTO.

The room temperature will be displayed.

Additional information

With outdoor reset the boiler will provide the water temperature according to the heating curve adjusted by the level of room influence (if enabled).

The boiler will always attempt to run at its highest efficiency in low fire for as long as necessary.

The boiler will shut down when the target temperature is reached followed by a 3 minute post purge by the pump.

The boiler and the pump will start again when the supply water temperature drops 18°F (10°C) below the set point.

When the demand for hot water is sensed by the flow sensor, the boiler will change to DHW mode. When the DHW demand ends, the boiler will return to heating mode.

Data subject to change

Bosch Thermotechnology Corp.