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Bosch Greenstar 57 Manual

Gas combi/heating condensing boiler

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Gas Condensing Boiler
Bosch
100, 151 Combi Boiler
57, 100, 131, 151 Heating Boiler
Applications 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!

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Summary of Contents for Bosch Greenstar 57

  • Page 1 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...
  • Page 2 2 | Bosch Greenstar Applications Manual Data subject to change Bosch Thermotechnology Corp.
  • Page 3: Table Of Contents

    Applications Manual Bosch Greenstar | 3 Table of Contents 1 Information about the appliance 1.1 Boiler types and sizes 1.2 FW200 Boiler Energy Management 1.3 FB100 Remote Control & Room Sensor 1.4 IPM2 Space Heating Module 1.5 ISM2 Solar Module...
  • Page 4: Information About The Appliance

    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 ...
  • Page 5: Fw200 Boiler Energy Management

    Applications Manual Bosch Greenstar | 5 1.2 FW200 Boiler Energy Management Scope of delivery 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 ...
  • Page 6: Fb100 Remote Control & Room Sensor

    6 | Bosch Greenstar Applications Manual 1.3 FB100 Remote Control & Room Sensor Scope of delivery 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 ...
  • Page 7: Ipm2 Space Heating Module

    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.
  • Page 8: Ism2 Solar Module

    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 benefi ts as it allows minimizing boiler run time and reduces burner starts signifi...
  • Page 9: Applications

    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.
  • Page 10: List Of Most Common Applications

    1 0 | 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).
  • Page 11: Boiler Pump Capacity In Single Zone Systems

    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.
  • Page 12 1 2 | Bosch Greenstar Applications Manual Pump curve of heating boiler Pump curve of combi boiler (heating side) V / gpm V / gpm 1000 1200 1400 1600 1200 1600 V / l/h V / l/h 6 720 641 933-59.1O 6 720 641 933-61.1O...
  • Page 13: System 1: Greenstar Heating Boiler In A Single Zone System

    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.
  • Page 14 1 4 | Bosch Greenstar Applications Manual System 1 - Piping Diagram Data subject to change Bosch Thermotechnology Corp.
  • Page 15 Applications Manual Bosch Greenstar | 15 System 1 - Wiring Diagram Bosch Thermotechnology Corp. Data subject to change...
  • Page 16 1 6 | Bosch Greenstar Applications Manual System 1: Setup and Programming  When done, ensure the mode selector is set to AUTO. In this single zone system the FW200 is installed in the The room temperature will be displayed.
  • Page 17: System 2: Greenstar Combi Boiler In A Single Zone System

    Applications Manual Bosch Greenstar | 17 2.2 System 2: Greenstar Combi Boiler in a single zone system Summary: Additional instructions: See manufacturer’s installation and operating instructions. Single combi-boiler supplying one baseboard heating zone equipped with FW200 outdoor reset controller with Install an adequately sized Pressure Relief Valve (PRV) on built-in room sensor in the living space.
  • Page 18 1 8 | Bosch Greenstar Applications Manual System 2 - Piping diagram Data subject to change Bosch Thermotechnology Corp.
  • Page 19 Applications Manual Bosch Greenstar | 19 System 2 - Wiring diagram Bosch Thermotechnology Corp. Data subject to change...
  • Page 20 2 0 | Bosch Greenstar Applications Manual System 2: Setup and Programming Enter the installer menu to configure the heating zone.  In this single zone system the FW200 is installed in the — Set heating circuit type to Baseboard.
  • Page 21: System 3: Greenstar Heating Boiler In A Single Zone System With Dhw Tank Loading

    Applications Manual Bosch Greenstar | 21 2.3 System 3: Greenstar Heating Boiler in a single zone system with DHW tank loading 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 and DHW tank load- ing.
  • Page 22 2 2 | Bosch Greenstar Applications Manual System 3 - Piping diagram Data subject to change Bosch Thermotechnology Corp.
  • Page 23 Applications Manual Bosch Greenstar | 23 System 3 - Wiring diagram Bosch Thermotechnology Corp. Data subject to change...
  • Page 24 2 4 | Bosch Greenstar Applications Manual System 3: Setup and Programming Set up the weekly program for DHW tank loading and  the DHW recirculation pump (if installed). Separate In this single zone system the FW200 is installed in the...
  • Page 25: System 4: Greenstar Heating Boiler In A Single Zone System With Solar Thermal Dhw And Boiler Backup

    fl ow rate of 4.0 gpm plus the necessary supply and return piping. The Bosch Greenstar boiler and ISM2 offer many different solar thermal applications including space heating sup- Ensure to select a solar tank with a boiler coil pressure port and pool heating.
  • Page 26 2 6 | Bosch Greenstar Applications Manual System 4 - Piping diagram Data subject to change Bosch Thermotechnology Corp.
  • Page 27 Applications Manual Bosch Greenstar | 27 System 4 - Wiring diagram Bosch Thermotechnology Corp. Data subject to change...
  • Page 28 2 8 | Bosch Greenstar Applications Manual System 4: Setup and Programming Set up the weekly program for DHW tank loading and  the DHW recirculation pump (if installed). Separate In this single zone system the FW200 is installed in the...
  • Page 29: System 5: Greenstar Heating Boiler In A Single Zone System

    Applications Manual Bosch Greenstar | 29 2.5 System 5: Greenstar Heating Boiler in a single zone system Summary: Single boiler with primary/secondary piping confi guration supplying one heating zone. Outdoor reset with FW200 controller with built-in room sensor mounted in the living space for room feedback.
  • Page 30 3 0 | Bosch Greenstar Applications Manual System 5 - Piping diagram Data subject to change Bosch Thermotechnology Corp.
  • Page 31 Applications Manual Bosch Greenstar | 31 System 5 - Wiring diagram Bosch Thermotechnology Corp. Data subject to change...
  • Page 32 3 2 | Bosch Greenstar Applications Manual System 5: Setup and Programming Enter the installer menu to configure the heating zone.  In this single zone system the FW200 is installed in the — Set heating circuit to the type of heat living space in a location that represents the conditions distribution system used.
  • Page 33: System 6: Greenstar Combi Boiler In A Single Zone System

    Applications Manual Bosch Greenstar | 33 2.6 System 6: Greenstar Combi Boiler in a single zone system Summary: Additional instructions: See manufacturer’s installation and operating instructions. Single combi-boiler supplying one heating zone. Outdoor reset with FW200 controller with built-in room sensor Install an adequately sized Pressure Relief Valve (PRV) on mounted in the living space for room feedback.
  • Page 34 3 4 | Bosch Greenstar Applications Manual System 6 - Piping diagram Data subject to change Bosch Thermotechnology Corp.
  • Page 35 Applications Manual Bosch Greenstar | 35 System 6 - Wiring diagram Bosch Thermotechnology Corp. Data subject to change...
  • Page 36 3 6 | Bosch Greenstar Applications Manual System 6: Setup and Programming Enter the installer menu to configure the heating zone.  In this single zone system the FW200 is installed in the — Set heating circuit to the type of heat living space in a location that represents the conditions distribution system used.
  • Page 37: System 7: Greenstar Heating Boiler In A Single Zone System With Dhw Tank Loading

    Applications Manual Bosch Greenstar | 37 2.7 System 7: Greenstar Heating Boiler in a single zone system with DHW tank loading Summary: Single boiler with primary/secondary piping confi guration supplying one heating zone. Outdoor reset with FW200 controller with built-in room sensor mounted in the living space for room feedback.
  • Page 38 3 8 | Bosch Greenstar Applications Manual System 7 - Piping diagram Data subject to change Bosch Thermotechnology Corp.
  • Page 39 Applications Manual Bosch Greenstar | 39 System 7 - Wiring diagram Bosch Thermotechnology Corp. Data subject to change...
  • Page 40 4 0 | Bosch Greenstar Applications Manual System 7: Setup and Programming Enter the installer menu to configure the heating zone.  In this single zone system the FW200 is installed in the — Set heating circuit to the type of heat living space in a location that represents the conditions distribution system used.
  • Page 41: System 8: Greenstar Heating Boiler In A Single Zone System With Room Thermostat And Dhw Tank Loading

    Applications Manual Bosch Greenstar | 41 2.8 System 8: Greenstar Heating Boiler in a single zone system with room thermostat and DHW tank loading Summary: Required components: Single boiler with primary/secondary piping confi guration  Greenstar heating boiler. supplying one heating zone. Outdoor reset with FW200 FW200 controller in the room.
  • Page 42 4 2 | Bosch Greenstar Applications Manual System 8 - Piping diagram Data subject to change Bosch Thermotechnology Corp.
  • Page 43 Applications Manual Bosch Greenstar | 43 System 8 - Wiring diagram Bosch Thermotechnology Corp. Data subject to change...
  • Page 44 4 4 | Bosch Greenstar Applications Manual System 8: Setup and Programming Additional information In this single zone system the FW200 is installed in the With outdoor reset the boiler will provide the water boiler for pure outdoor reset without room infl uence.
  • Page 45: System 9: Greenstar Heating Boiler In A Single Zone System With Solar Thermal Dhw And Boiler Backup

    Bosch offers plug and play components that are designed to work together with a boiler backup Additional instructions: system. Bosch solar thermal systems are qualifi ed for See manufacturer’s installation and operating instructions. government and utility incentives reducing the upfront investment cost signifi...
  • Page 46 4 6 | Bosch Greenstar Applications Manual System 9 - Piping diagram Data subject to change Bosch Thermotechnology Corp.
  • Page 47 Applications Manual Bosch Greenstar | 47 System 9 - Wiring diagram Bosch Thermotechnology Corp. Data subject to change...
  • Page 48 4 8 | Bosch Greenstar Applications Manual System 9: Setup and Programming Set up the weekly program for DHW tank loading and  the DHW recirculation pump (if installed). Separate In this single zone system the FW200 is installed in the...
  • Page 49: System 10: Greenstar Heating Boiler With Zone Pumps And Room Thermostats

    Applications Manual Bosch Greenstar | 49 2.10 System 10: Greenstar Heating Boiler with zone pumps and room thermostats Summary: Required components: Single boiler with primary/secondary piping confi gura- Greenstar heating boiler.  tion supplying multiple heating zones. Outdoor reset with ...
  • Page 50 5 0 | Bosch Greenstar Applications Manual System 10 - Piping diagram Data subject to change Bosch Thermotechnology Corp.
  • Page 51 Applications Manual Bosch Greenstar | 51 System 10 - Wiring diagram Bosch Thermotechnology Corp. Data subject to change...
  • Page 52 5 2 | Bosch Greenstar Applications Manual System 10: Setup and Programming Additional information In this dual zone system the FW200 is installed in the With outdoor reset the boiler will provide the water boiler for pure outdoor reset without room infl uence on temperature according to the heating curve.
  • Page 53: System 11: Greenstar Heating Boiler With

    Applications Manual Bosch Greenstar | 53 2.11 System 11: Greenstar Heating Boiler with zone pumps, relay panel, room thermostats and DHW tank loading Summary: Required components: Single boiler with primary/secondary piping confi guration  Greenstar heating boiler. supplying three heating zones controlled by individual zone thermostats and a pump relay panel.
  • Page 54 5 4 | Bosch Greenstar Applications Manual System 11 - Piping diagram Data subject to change Bosch Thermotechnology Corp.
  • Page 55 Applications Manual Bosch Greenstar | 55 System 11 - Wiring diagram Bosch Thermotechnology Corp. Data subject to change...
  • Page 56 5 6 | Bosch Greenstar Applications Manual System 11: Setup and Programming Additional information In this multi zone system the FW200 is installed in the With outdoor reset the boiler will provide the water boiler for pure outdoor reset without room infl uence on temperature according to the heating curve.
  • Page 57: System 12: Greenstar Heating Boiler With Zone Valves And Room Thermostats

    Applications Manual Bosch Greenstar | 57 2.12 System 12: Greenstar Heating Boiler with zone valves and room thermostats Summary: Required components: Single boiler with primary/secondary piping confi gura- Greenstar heating boiler.  tion supplying three heating zones controlled by 3rd party ...
  • Page 58 5 8 | Bosch Greenstar Applications Manual System 12 - Piping diagram Data subject to change Bosch Thermotechnology Corp.
  • Page 59 Applications Manual Bosch Greenstar | 59 System 12 - Wiring diagram Bosch Thermotechnology Corp. Data subject to change...
  • Page 60 6 0 | Bosch Greenstar Applications Manual System 12: Setup and Programming Set up the weekly program for DHW generation.  In this multi zone system the FW200 is installed in the  When done, ensure the mode selector is set to AUTO.
  • Page 61 Applications Manual Bosch Greenstar | 61 Bosch Thermotechnology Corp. Data subject to change...
  • Page 62 6 2 | Bosch Greenstar Applications Manual Data subject to change Bosch Thermotechnology Corp.
  • Page 63 Applications Manual Bosch Greenstar | 63 Bosch Thermotechnology Corp. Data subject to change...
  • Page 64 United States and Canada Bosch Thermotechnology Corp. 50 Wentworth Avenue Londonderry, NH 03053 Tel: 603-552-1100 Fax: 603-584-1681 www.bosch-climate.us BTC 436001101 A / 07.2011...

This manual is also suitable for:

Greenstar 100Greenstar 131Greenstar 151

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