Bosch FS 100 User manual

Gas Condensing Wall Hung & Floor Standing Boilers
Bosch
Greenstar & Greenstar FS 100, 151, 131 Combi Boiler
Greenstar & Greenstar FS 57, 79, 100, 131, 151 Regular Boiler
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!
Applications Manual

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|Bosch Greenstar Applications Manual
Bosch Thermotechnology Corp.Data subject to change

Applications Manual Bosch Greenstar | 3
Bosch Thermotechnology Corp. Data subject to change
Table of Contents
Single Zone Systems 6
System # 1 Greenstar Combi Wall Boiler
Single Zone Baseboard with Standard Thermostat (drycontact only) and FW200 (optional) 6
System # 2 Greenstar Combi Wall Boiler
Single Zone Baseboard with Bosch CRC control 8
System # 3 Greenstar Combi Floor Boiler
Single Zone Baseboard with Standard Thermostat (dry contact only) 10
System # 4 Greenstar Combi Floor Boiler
Single Zone Baseboard with Bosch CRC control 12
System # 5 Greenstar Heat only Wall Boiler
Single Zone Baseboard with Standard Thermostat (dry contact only) and FW200 (optional) 14
System # 6 Greenstar Heat only Wall Boiler
Single Zone Baseboard with Bosch CRC control 16
System # 7 Greenstar Heat only Floor Boiler
Single Zone Baseboard with Standard Thermostat (dry contact only) 18
System # 8 Greenstar Heat only Floor Boiler
Single Zone Baseboard with Bosch CRC control 20
Multi Zone Systems using Circulators 22
System # 9 Greenstar Combi Wall Boiler
Multi zone system using circulators with standard zone relay (FW200 optional) 22
System # 10 Greenstar Combi Wall Boiler
Multi zone system using circulators and Bosch Comfort Zone Manager (CZM100) 24
System # 11 Greenstar Combi Floor Boiler
Multi zone system using circulators with standard zone relay (FW200 optional) 26
System # 12 Greenstar Combi Floor Boiler
Multi zone system using circulators and Bosch Comfort Zone Manager (CZM100) 28
System # 13 Greenstar Heat only Wall Boiler
Multi zone system using circulators with standard zone relay (FW200 optional) and indirect tank 30
System # 14 Greenstar Heat only Wall Boiler
Multi zone system using circulators and Bosch Comfort Zone Manager (CZM100) and indirect tank 32
System # 15 Greenstar Heat only Floor Boiler
Multi zone system using circulators with standard zone relay (FW200 optional) and indirect tank 34
System # 16 Greenstar Heat only Floor Boiler
Multi zone system using circulators and Bosch Comfort Zone Manager (CZM100) and indirect tank 36

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Bosch Thermotechnology Corp.Data subject to change
Multi Zone Systems using Zone Valves 38
System # 17 Greenstar Combi WallBoiler
Multi zone system using zone valves with standard zone relay (FW200 optional) 38
System # 18 Greenstar Combi Wall Boiler
Multi zone system using zone valves and Bosch Comfort Zone Manager (CZM100) 40
System # 19 Greenstar Combi Floor Boiler
Multi zone system using zone valveswith standard zone relay (FW200 optional) 42
System # 20 Greenstar Combi Floor Boiler
Multi zone system using zone valves and Bosch Comfort Zone Manager (CZM100) 44
System # 21 Greenstar Heat Only Wall Boiler
Multi zone system using zone valves with standard zone relay (FW200 optional) and indirect tank 46
System # 22 Greenstar Heat Only Wall Boiler
Multi zone system using zone valves and Bosch Comfort Zone Manager (CZM100) and indirect tank 48
System # 23 Greenstar Heat Only Floor Boiler
Multi zone system using zone valves with standard zone relay (FW200 optional) and indirect tank 50
System # 24 Greenstar Heat Only Floor Boiler
Multi zone system using zone valves and Bosch Comfort Zone Manager (CZM100) and indirect tank 52
Single & Multi Zone Systems using Bosch Control 54
System # 25 Greenstar Combi Wall Boiler
Single zone baseboard with Bosch Control 54
System # 26 Greenstar Combi Floor Boiler
Single zone baseboard with Bosch Control 56
System # 27 Greenstar Heat Only Wall Boiler
Single zone baseboard with Bosch Control 58
System # 28 Greenstar Heat Only Floor Boiler
Single zone system with Bosch Control 60
System # 29 Greenstar Heat Only Wall Boiler
Single zone system with Bosch Control and indirect tank 62
System # 30 Greenstar Combi Wall Boiler
Multi zone system using circulators and Bosch Control with standard zone relay 64
Appendices 66
Appendix A Comfort Room Controller (CRC100) Quick set-up guide 66
Appendix B Primary/Secondary Piping requirements for Greenstar Wall Boiler 68
Appendix C FW200 Quick Set-up Guide 69
Appendix D Wiring of Hydro-Level Low Water Cut-off for Greenstar Wall Boiler 71
Appendix E Wiring of Hydro-Level Low Water Cut-off for Greenstar Floor Boiler 72

Applications Manual Bosch Greenstar | 5
Bosch Thermotechnology Corp. Data subject to change
Explanation Of Symbols
Key To Symbols
Warnings
Warnings in this document are identified by a
warning triangle printed against a grey back-
ground.
Keywords at the start of a warning indicate the
type and seriousness of the ensuing risk if meas-
The following keywords are defined and can be used in
this document:
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if
not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation which, if not
avoided, could result in minor to moderate injury.
NOTICE is used to address practices not related to
personal injury.
Important information
This symbol indicates important information where
there is no risk to people or property.

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|Bosch Greenstar Applications Manual
Bosch Thermotechnology Corp.Data subject to change
Bosch
State Bases No. . Changed Released Created
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Isolation
valve
Back-flow
preventer
Relief valve &
pressure gauge
Condensate
drain
Outdoor
air sensor
Room
Thermostat
(Use of FW200 and
outdoor air sensor
is optional)
Note:Greenstar Internal circulator
can support a single zone loop not to exceed 4 gpm at 12 feet of head. See pump curves in manual for pump capacities at alternate flow rates.
Purge
Drain
DISCLAIMER: 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.
Domestic
Cold Water
Domestic
Hot Water
Gas
Supply
PRV
Relief piping
FW200
Single Zone Combi Wall Boiler Baseboard On/off Tstat

Applications Manual Bosch Greenstar | 7
Bosch Thermotechnology Corp. Data subject to change
System #1
reset
eco
1
2
34
5
6
max
1
2
34
e
6
max
DHW thermostat
min
e
max
Typical DHW temperatures
approx. 104 °F (40 °C)
approx. 122 °F (50 °C)
approx. 140 °F (60 °C)
Boiler
Heating
Dial
1
2
3
Typical supply
temperatures
approx. 95 °F (35 °C)
approx. 109 °F (43 °C)
approx. 122 °F (50 °C)
4
5
6
approx. 140 °F (60 °C)
approx. 153 °F (67 °C)
approx. 167 °F (75 °C)
max Approx. 194 °F (90°C)
Application
Frost protection
Radiant floor heating
Panel radiator system
Cast Iron radiator system
Baseboard & convector system
Room Thermostat
Low Voltage
Wiring:
Line Voltage
ŹWire Main power supply (120 v) to White molex
Źinstall FW200 on front of boiler (see manual)
Źinstall outdoor air sensor
ŹFollow FW200 Quick Set-up guide in Greenstar
Manual
If using FW200 (Optional):
Heatronic Settings:
ŹRemove factory jumper from terminal #2 & #4
inside Heatronic control and connect non-power
robbing thermostat (dry contacts only)
Outdoor Sensor
Źinstall FW200 on front of
boiler (see manual)
Źinstall outdoor air sensor
ŹFollow FW200 Quick
Set-up guide in Appendix C
If using FW200 (Optional):
Heatronic Internal Wiring
B
B
4
2
1
A
F
97
8
LWCO
Supply Sensor
DHW Sensor
Dry contacts
Bosch Controls
Outdoor
Sensor
LN
red
storage
tank pump
LN
black
ch pump
for unmixed heating
(Not Used)
LN
white
mains
120v/60 hz
External Boiler Junction box
120 Vac Supply
Ground
Neutral
Note: For Low Water Cutoff Wiring see
Appendix D of this manual

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|Bosch Greenstar Applications Manual
Bosch Thermotechnology Corp.Data subject to change
Bosch
State Bases No. . Changed Released Created TK
02/20/15
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Isolation
valve
Back-flow
preventer
Relief valve &
pressure gauge
Condensate
drain
Outdoor
air sensor
Comfort
Room
Controller
Purge
Drain
DISCLAIMER: 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.
Domestic
Cold Water
Domestic
Hot Water
Gas
Supply
PRV
Relief piping
Bosch
Bosch
CRC100 or
CRC200
Single zone Combi wall boiler Baseboard NSC Controls
Note:Greenstar Internal circulator
can support a single zone loop not to exceed 4 gpm at 12 feet of head. See pump curves in manual for pump capacities at alternate flow rates.

Applications Manual Bosch Greenstar | 9
Bosch Thermotechnology Corp. Data subject to change
System #2
reset
eco
1
2
34
5
6
max
1
2
34
e
6
max
DHW thermostat
min
e
max
Typical DHW temperatures
approx. 104 °F (40 °C)
approx. 122 °F (50 °C)
approx. 140 °F (60 °C)
Boiler
Heating
Dial
1
2
3
Typical supply
temperatures
approx. 95 °F (35 °C)
approx. 109 °F (43 °C)
approx. 122 °F (50 °C)
4
5
6
approx. 140 °F (60 °C)
approx. 153 °F (67 °C)
approx. 167 °F (75 °C)
max Approx. 194 °F (90°C)
Application
Frost protection
Radiant floor heating
Panel radiator system
Cast Iron radiator system
Baseboard & convector system
CRC100 or CRC200
Bosch
Low Voltage
Wiring:
Line Voltage
ŹWire Comfort Room Controller (CRC100 or
CRC200) to Terminals B B of Heatronic control
ŹWire Main power supply (120 v) to White molex
ŹSee Appendix A for Room Controller Settings
Heatronic Settings:
Heatronic Internal Wiring
B
B
4
2
1
A
F
97
8
LWCO
Supply Sensor
DHW Sensor
Dry contacts
Bosch Controls
Outdoor
Sensor
External Boiler Junction box
120 Vac Supply
Ground
Neutral
LN
black
ch pump
for unmixed heating
(Not Used)
LN
white
mains
120v/60 hz
Note: For Low Water Cutoff Wiring see
Appendix D of this manual

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|Bosch Greenstar Applications Manual
Bosch Thermotechnology Corp.Data subject to change
Bosch
State Bases No. . Changed Released Created
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Isolation
valve
Back-flow
preventer
Relief valve &
pressure gauge
Condensate
drain
Outdoor
air sensor
Room
Thermostat
Purge
Drain
DISCLAIMER: 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.
Domestic
Cold Water
Domestic
Hot Water
Gas
Supply
PRV
Relief piping
Note: Internal Low Loss
Header in closed position
Note: additional expansion
tank shown – internal
expansion tank in combi boiler
models may be adequate for
standard systems -see boiler
manual for details.
Note:Greenstar Internal circulator
can support a single zone loop not to exceed 4 gpm at 12 feet of head. See pump curves in manual for pump capacities at alternate flow rates.
Single Zone Combi floor boiler Baseboard On/off Thermostat