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).

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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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02 5781436
15
20
25
10
5
0
H / ft
.
V / gpm
123
4
400 800 1200 1600200 600 1000 1400
7
0
6
5
4
3
2
1
0
H / m
.
V / l/h 6 720 641 933-59.1O
1
23
4
0213546 87
15
20
25
10
5
0
H / ft
.
V / gpm
12
3
4
400 800 1200 1600
7
0
6
5
4
3
2
1
0
H / m
.
V / l/h 6 720 641 933-61.1O
12
3
4
Pump curve of heating boiler Pump curve of combi boiler (heating side)
Fig. 4 Greenstar boiler pump curves
Key to Fig. 4
1Residual head pressure at speed 1
2Residual head pressure at speed 2
3Residual head pressure at speed 3 (default setting)
4Head pressure of the boiler pump by itself (at speed 3)
HHead pressure in feet of head (m)
VCirculating water volume in gallons per minute (l/h)

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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 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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System 1 - Piping Diagram

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System 1 - Wiring Diagram

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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 tem-
perature 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.

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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 circu-
lation.
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 inter-
nal 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.

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System 2 - Piping diagram

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System 2 - Wiring diagram

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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 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.
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 tem-
perature 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.