Bosch 100 User Manual

WARNING: Improper installation, setup, modiﬁ cation, 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 certiﬁ ed installer, service provider, or the gas supply company.

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

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 ofﬁ cials, 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

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Bosch Greenstar Applications Manual

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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

2.4 System 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

2.8 System 8: Greenstar Heating Boiler in a single zone system with room thermostat and DHW tank loading 41

2.9 System 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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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

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1.2 FW200 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

programs with six programmable switch points per day (one program is active).

— DHW

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.

: weekly DHW program with six switch

: Six weekly heating

Scope of delivery

2

5

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

3

8

1

4

 Installation options:

— In the boiler

— Wall-mounted as a remote room sensor

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Bosch Greenstar Applications Manual

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

1

4

Fig. 2 FB100 Remote Control & Room Sensor

1 Upper part of remote control

2 Base for wall-mounting

3 Top cover

3

8

4 Installation and operating instructions

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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 and primary room sensor

Remote control for additional zones

Available systems

Max. number of Modules per system

Tab. 1

FW200

FB100

2 mixed heating zones

1 mixed heating zone + 1 unmixed heating zone + 1 DHW recirculation pump

2 unmixed heating zones + 1 DHW recirculation pump

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. 5 IPM2

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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 beneﬁ ts as it allows minimizing boiler run time and reduces burner starts signiﬁ cantly compared to a non- integrated 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.

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2 Applications

Legend

Flow check valve

pipe

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.

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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 53-

56).

 System 12: Greenstar Heating Boiler with zone valves

and room thermostats ( page 57-60).

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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 ﬂ oor, 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 ﬂ ow rate of 4.0 gpm. This allows sufﬁ cient 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 ﬂ ow 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

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

and 65°F Room Temperature

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 ﬂ ow 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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Bosch Greenstar Applications Manual

Pump curve of heating boiler Pump curve of combi boiler (heating side)

25

20

15

H / ft

10

5

0

02 5781436

7

6

5

4

3

H / m

2

1

0

2

1

.

V / gpm

2

1

400 800 1200 1600200 600 1000 1400

.

V / l/h

4

3

4

3

6 720 641 933-59.1O

Fig. 4 Greenstar boiler pump curves

Key to Fig. 4

1 Residual head pressure at speed 1 2 Residual head pressure at speed 2 3 Residual head pressure at speed 3 (default setting)

25

20

15

H / ft

10

5

0

0213546 87

7

6

5

4

3

H / m

2

1

0

1

.

V / gpm

1

400 800 1200 1600

.

V / l/h

4

3

2

4

3

2

6 720 641 933-61.1O

4 Head pressure of the boiler pump by itself (at speed 3) H Head pressure in feet of head (m) V Circulating water volume in gallons per minute (l/h)

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Applications Manual Bosch Greenstar | 13

2.1 System 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 ﬂ oors, 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 ﬂ ow 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 inﬂ uence. 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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Bosch Greenstar Applications Manual

System 1 - Piping Diagram

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Applications Manual Bosch Greenstar | 15

System 1 - Wiring Diagram

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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

 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 inﬂ uence (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.

— 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.

Bosch Thermotechnology Corp.Data subject to change

Applications Manual Bosch Greenstar | 17

2.2 System 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 efﬁ ciency 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 ﬂ oors, 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 ﬂ ow rate of 4.0 gpm plus the necessary supply and return piping..

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 sufﬁ cient capacity for the application or if an additional expansion vessel is needed.

In detail:

The FW200 is an outdoor temperature based controller with room temperature inﬂ uence. 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.

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Bosch Greenstar Applications Manual

System 2 - Piping diagram

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Applications Manual Bosch Greenstar | 19

System 2 - Wiring diagram

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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.

 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 inﬂ uence (if enabled).

 The boiler will always attempt to run at its highest

efficiency in low fire for as long as necessary.

 Set up the weekly heating program for the three avail-

able 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.

 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.

Bosch Thermotechnology Corp.Data subject to change