Bosch Greenstar 57 User manual

Gas Condensing Boiler
Bosch
100, 151 Combi Boiler
57, 100, 131, 151 Heating 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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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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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 : 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
2x
2x
5
2
4
1
3
8
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
4
1
3
8
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

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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 FW200
Remote control for
additional zones FB100
Available
systems
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. number of Modules
per system max. 5 IPM2
Tab. 1

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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 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 Installa-
tion and Service Manual.

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2 Applications
Legend
Greenstar boiler
Greenstar combi-boiler
Greenstar
Greenstar
pipe
pipe
Flow check valve
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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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).