Bosch Heatronic 4000 Instructions for use

Wiring and Drawing Diagrams for:
Bosch Heatronic 4000 Controls
Applications Manual
US
C
®

2 |Bosch Heatronic 4000 Controls Applications Manual
Bosch Thermotechnology Corp.Data subject to change

Applications Manual Bosch Heatronic 4000 Controls | 3
Bosch Thermotechnology Corp. Data subject to change
Table of Contents
1 Introduction 4
2 Controls Description & Specifications 5
2.1 Brief description 5
2.2 Heatronic 4000 Outdoor Sensor 6
2.3 Heatronic 4000 Universal Sensor 7
3 Applications 8
3.1 Common Boiler Piping/Wiring 8
3.2 Boiler Connections 9
3.3 Application 1 10
3.4 Application 2 12
3.5 Application 3 14
3.6 Application 4 16
3.7 Application 5 18
3.8 Application 6 20
4 Burner Wiring Diagrams 22
4.1 Riello RS Modulating Burner Wiring: 22
4.2 Riello Dual Fuel Burner (2 Stage Oil & Modulating Gas) Wiring 23
4.3 Becket CG Burner Wiring: 24
4.4 Power Flame Burner Wiring: 25
4.5 Riello RS Lo/Hi/Lo Burner Wiring: 26
5 Recommended Specifications 27

4 |Bosch Heatronic 4000 Controls Applications Manual
Bosch Thermotechnology Corp.Data subject to change
1 Introduction
This manual is intended to address some of the many
applications that are possible using the Bosch Heatronic
4000 control. 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. Auxiliary
equipment depicted in this manual does not necessarily
represent any one particular manufacturer or specific model
number. There are a wide variety of techniques, practices
and piping arrangements possible with hydronic heating
systems and it is the responsibility of the system engineer
or the installing contractor to determine which of these
is best suited for a specific application. Information for
wiring of burners can be found in section 4 of this manual.
Refer to control Installation Manual for additional detailed
information. Should you encounter an application that is not
covered in this manual or have questions regarding any of
its content, we encourage you to contact us here at Bosch
Thermotechnology Corp. Bosch Thermotechnology Corp.
reserves the right to make changes without notice due to
continuing engineering and technological improvements.

Applications Manual Bosch Heatronic 4000 Controls | 5
Bosch Thermotechnology Corp. Data subject to change
2 Controls Description &
Specifications
2.1 Brief description
The Heatronic 4000 is designed to operate up to four
boilers to produce and maintain a target temperature.
The Heatronic 4000 operates both condensing and non-
condensing boilers that have modulating, single stage, two
stage, or dual fuel burners to provide a more flexible, cost
effective mixed plant solution with better system control,
energy efficiency and overall performance.
Fig. 1
Specifications Table 1
Description Value
Literature I/O Manual 7738003455, App Manual 7738003456, Building Integration 7738003457, ESS 7738003458
Control Microprocessor control. This is not a safety (limit) control (part# 7738003450)
Packaged weight 5.5 lb. (2490 g)
Dimensions 8-1/16” H x 11-1/8” W x 2-15/16” D (204 x 282 x 74 mm)
Enclosure Grey PC+ABS plastic with metal top and bottom conduit connection walls, NEMA type 1
Approvals
CSA C US, meets class B: ICES & FCC Part 15, BTL Listed
Ambient conditions Indoor use only, 32 to 122°F (0 to 50°C), < 90% RH non-condensing
Power supply 115 V (ac) ±10%, 60 Hz, 18 VA
Primary pump relays 230 V (ac) 10 A, 1/2 hp
Boiler & IDHW pump relays 230 V (ac) 5 A, 1/3 hp
Auxiliary & Alert Relays 230 V (ac) 5 A, 1/6 hp
Boiler Stage Relays 230 V (ac) 5 A
Modulating outputs 4 x 0-10 V (dc) 500 minimum load impedance / 4-20 mA 1 kmax load impedance
Calls 24 V (ac) or Short
Sensors NTC thermistor, 10 k@ 77°F (25°C ±0.2°C) ß=3892
–Included Outdoor Sensor (part #7738003452) and 5 Universal Sensors (part #7738003451)
–Optional Universal Sensor (part# 7738003451)
Warranty Limited 3 Year
Features:
Control and monitor up to 4 condensing, or
non-condensing boilers
BacNet® and Modbus® compatible
Programmable scheduling
DHW priority
Outdoor temperature reset
Compatible with modulating, single stage, two stage,
and dual fuel burners
Compatible with NG, LPG & oil burners
Programmed Bosch / Buderus boiler list
Pre-configured boiler default parameters
8-1/16"
(204 mm)
7/16" (11 mm)
CL
7/16"
(11 mm) Ø 3/16"
(5 mm)
1/2" Knock-out
(x 16 back) (x 8 top)
(x 8 bottom) (x 2 side)
12345
Temperatu re Sensors - Do Not Appl y Power tekmarNet Communication
C3C2C0 C1
H6106A
Boi ler 1
75 76
Pum p Boi ler 2
77 78
Pum p Boi ler 3
79 80
Pum p Boi ler 4
81 82
Pum p Po w e r I n
LN
45 46
Auxiliary
43 44
Pum p
47 48
P1 Pum p
Pri m ar y Pri m ar y
49 50
P2
85 8683 84
20V
11
dc 5V dc
Out In Out In In
Vdc
14
(+) (+ )
Gnd
15
(-) (-)
mA
12 13
(+) EM S
16 17
Pri m
Sup
18
Com
19
Pri m
Ret Bo il In
20
DHW
21
Com
22 23 24 25
Boi l 1
Out
26
Boi l 2
Out
27
ComCom
28
Com
31
Boil 3
Out
29
Boil 4
Out
30
tN4
32 33
Bus b tN4
34 35
Bus 1 tN4
36 37
Bus 2 tN4
38 39
Bus 3
Boiler Bo ile r Boi ler Bo iler
Pri m Pum p
1
2
Com b
34
AirProof CH
56
Call DHW
7
8
Tan k C al l Fu e l
910
Sw i t ch
Flo w
Sen so r Pre ssure Sen so r
BA
40 41
BACnet IP RS48 5 42
Gnd
Pri m Pum p Flo w Pro o f / O
Comb AirProof/ O
O /Exercise
Set b ac k / O
51 52
Mod Boil er 1
53 54
Stage1 Stage2
55 56
+
-
Mod Stage1 Stage 2
+
-
Mod Stage1 Stage 2
+
-
Mod Stage1 Stage 2
+
-
57 58
Boi ler 2
59 60 61 62 63 64
Boi ler 3
65 66 67 68 69 70
Boi ler 4
71 72 73 74
WARNING! Bef ore o pen ing
the c over d iscon nect f rom
powersupply
M eet s Class B: Can ad ian
ICES & FCCPart 1 5
4 bo iler co ntr ol, DHW, BACnet and Mod bus
MANUAL
OV ERRI D E
Home
Out
door Com Flu e Alert
Dry
Flo wPr oo f
Tan kDHW
Pum p
(+) (–)
Heatronic4000 158033
Type 1056-XX
tektra 1056-02
Designed and
assemble d i n Canada
by tekmarControlSystems
Sign al wirin g mu st be
rated at least 300 V.
Inp ut Pow er:
115 V (ac ) ±10%, 60 Hz ,1 8 VA
Pri m ar y Pu m p Rel ay s:
230 V (ac), 1 0 A , 1/2 h p
Boi ler & D HW Pu mp s:
230 V (ac), 5 A , 1/3 h p
Boiler Stage, Au xili ary &
Alert Relays:
230 V (ac), 5 A , 1/6 h p
Calls: 24 V (ac) o r Shor t
11-1/8"
(282 mm)
Side View
Front View
2-15/16"
(74 mm)
8-1/16"
(204 mm)

6 |Bosch Heatronic 4000 Controls Applications Manual
Bosch Thermotechnology Corp.Data subject to change
2.2 Heatronic 4000 Outdoor Sensor
The Outdoor Sensor is designed to provide accurate
sensing of the outdoor temperature for display and control
operation. Controls that operate based on Outdoor
Temperature Reset use this product to provide outdoor
reset operation.
F
Front View
Base Front View
Ø 1/2" (12 mm)
Knock-out
Bottom View Base Bottom View
(plug removed)
Ø 7/8" (22 mm)
Conduit connection
2–5/8"
(67 mm)
1–9/16"
(40 mm)
1–9/16"
(40 mm)
1–11/16"
(43 mm)
ig. 2
Specifications Table 2
Description Value
Literature Heatronic 4000 Engineering Submittal Sheet 7738003458
Packaged weight 0.17 lb. (77 g)
Dimensions 2-5/8” H x 1-9/16” W x 1-11/16” D (67 x 40 x 43 mm)
Enclosure
White PVC plastic, NEMA type 2
Approvals CSA C US
Operating range -60 to 140°F (-51 to 60°C)
Sensor NTC thermistor, 10 k@ 77°F (25°C ±0.2°C) ß=3892 (part# 7738003452)
Warranty Limited 3 Year
Temperature vs. Resistance Table 3
Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance
°F °C °F °C °F °C °F °C
-50 -46 490,813 20 -7 46,218 90 32 7,334 160 71 1,689
-45 -43 405,710 25 -4 39,913 95 35 6,532 165 74 1,538
-40 -40 336,606 30 -1 34,558 100 38 5,828 170 77 1,403
-35 -37 280,279 35 2 29,996 105 41 5,210 175 79 1,281
-30 -34 234,196 40 4 26,099 110 43 4,665 180 82 1,172
-25 -32 196,358 45 7 22,763 115 46 4,184 185 85 1,073
-20 -29 165,180 50 10 19,900 120 49 3,760 190 88 983
-15 -26 139,402 55 13 17,436 125 52 3,383 195 91 903
-10 -23 118,018 60 16 15,311 130 54 3,050 200 93 829
-5 -21 100,221 65 18 13,474 135 57 2,754 205 96 763
0 -18 85,362 70 21 11,883 140 60 2,490 210 99 703
5-1572,918752410,501145632,255215102648
10 -12 62,465 80 27 9,299 150 66 2,045 220 104 598
15 -9 53,658 85 29 8,250 155 68 1,857 225 107 553
Features:
10K thermistor
UV resistant enclosure
Mounts directly to a wall
Sensor built right into enclosure

Applications Manual Bosch Heatronic 4000 Controls | 7
Bosch Thermotechnology Corp. Data subject to change
2.3 Heatronic 4000 Universal Sensor
The Universal Sensor is a 10 ktemperature sensor designed
to be strapped onto a pipe. It can be used with any control
sensor input, but is most commonly used to monitor supply
and return water temperatures. This product has a brass
sleeve for fast response, a wide operating range, an indent
to allow pipe strap on installation, and 1 ft. (300 mm) of
2-conductor wire.
300 mm (12”)
9.5 mm (3/8”)
diameter
19 mm
(3/4”)
Fig. 3
Specifications Table 4
Description Value
Literature Heatronic 4000 Engineering Submittal Sheet 7738003458
Packaged weight 0.1 lb (50 g)
Dimensions 3/8" OD x 3/4" (9.5 OD x 19 mm)
Enclosure
Brass sleeve, 12" (2438 mm) 20 AWG, 300V PVC insulated zipcord
Approvals CSA C US
Operating range -60 to 221°F (-51 to 105°C)
Sensor NTC thermistor, 10 k@ 77°F (25°C ±0.2°C) ß=3892 (part# 7738003451)
Warranty Limited 3 Year
Temperature vs. Resistance Table 5
Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance
°F °C °F °C °F °C °F °C
-40° -40° 336,479 68° 20° 12,493 176° 80° 1,255 284° 140° 235
-31° -35° 242,681 77° 25° 10,000 185° 85° 1,070 293° 145° 208
-22° -30° 176,974 86° 30° 8,057 194° 90° 915 302° 150° 186
-13° -25° 130,421 95° 35° 6,531 203° 95° 786 311° 155° 166
-4° -20° 97,081 104° 40° 5,326 212° 100° 678 320° 160° 148
5° -15° 72,957 113° 45° 4,368 221° 105° 587 329° 165.° 133
14° -10° 55,329 122° 50° 3,602 230° 110° 510 338° 170° 119
23° -5° 42,327 131° 55° 2,986 239° 115° 445 347° 175° 107
32° 0° 32,650 140° 60° 2,488 248° 120° 389 356° 180° 97
41° 5° 25,392 149° 65° 2,083 257° 125° 341 365° 185° 87
50° 10° 19,901 158° 70° 1,752 266° 130° 301 374° 190° 79
59° 15° 15,712 167° 75° 1,480 275° 135° 265 383° 195° 72
Features:
10K thermistor
Very fast temperature response
Thermistor accuracy of +/-0.2°F
Corrosion resistant brass sleeve
CSA and C US Approved for use in USA and Canada

8 |Bosch Heatronic 4000 Controls Applications Manual
Bosch Thermotechnology Corp.Data subject to change
3 Applications
3.1 Common Boiler Piping/Wiring
Configurations
DISCLAIMER: 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.
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!
Application 1
Single Temperature System with two 2-Stage non-
condensing boilers for space heating and indirect
DHW loads. Installed with Primary/Secondary piping
arrangement. (pg 10)
Application 2
Single Temperature System with two modulating
condensing boilers for space heating and indirect DHW
loads. Installed with reverse / return piping arrangement.
(pg. 12)
Application 3
Single Temperature System with two modulating
condensing boilers for space heating and indirect
DHW loads. Installed with Primary/Secondary piping
arrangement. (pg. 14)
Application 4
Single Temperature System with four modulating
condensing boilers for space heating loads. The fourth
boiler also provides indirect DHW priority. Installed with
Primary/Secondary piping arrangement with near DHW
piping arrangement. (pg. 16)
Application 5
Single Temperature System with one Dual Fuel modulating
condensing gas / non condensing oil and one modulating
condensing gas boilers for space heating and indirect
DHW loads. Installed with reverse / return and injection
piping arrangement. (pg. 18)
Application 6
Two Temperature System with two 2-Stage non-
condensing boilers and two modulating condensing
boilers for space heating and indirect DHW loads. Installed
with unique high and low temperature return piping
arrangement. (pg. 20)

Applications Manual Bosch Heatronic 4000 Controls | 9
Bosch Thermotechnology Corp. Data subject to change
3.2 Boiler Connections
The SB Series condensing boilers can utilize a variety
of fuel sources, natural gas, LP gas, oil, ultra low sulfer
diesel. Riello, Beckett and Powerflame Burner models are
available in single stage, two stage, modulating and dual
fuel type signals. SB Series Boilers have three connections
points all out the top. One connection is the heating flow
outlet (supply). The supply is near the front of the boiler.
Next looking from front to back is the heating return high
temperature connection, and the last is the heating return
low temperature connection.
In common single temperature heating systems applica-
tions the return low temperature connection is utilized
while the return high temperature connection is capped.
In multi-temperature applications, both returns are used to
take better advantage of the SB Series condensing tech-
nology. In Multi- temperatures systems, the low tempera-
ture return is seperated from the high. This configuration
requires that a minimum of 20% of the total heating system
load is split into the low temperature return connection.
The G Series boilers with Thermostream Technology are
conventional non-condensing boilers that utilize the same
burners as the SB Series. G Series boilers have one supply
and one return connection, both coming out the back cent-
er of the boiler, supply is the top connection and return is
the bottom connection.
The GB Series Boilers are gas only boilers. The GB142 and
GB162 are both wall hung gas condensing boilers with
heating supply and return connections out the bottom
of the unit. Same as for the gas connections.The supply
connection is on the left and the return conneciton is on
the right when facing the boiler, the gas connection is in
the middle. The GB312 is a floor standing gas condensing
boiler with the supply connection is the upper right corner
and the return in the lower left corner when facing the
front of the boiler.

10 |Bosch Heatronic 4000 Controls Applications Manual
Bosch Thermotechnology Corp.Data subject to change
Features:
The boiler plant is sequenced to obtain maxi-
mum efficiency based on the boiler types &
target temperatures. For detailed information
about sequencing, rotation & staging, refer to
the Installation & Operation Manual.
Dual primary pumps with a flow proof provide
redundancy. Pumps can be sequenced with
equal run-time rotation. A pressure differential
switch is used to prove primary pump flow.
System includes combustion air (C.A.)
damper. Proving of C.A. damper via external
C.A. proof (motor end switch).
A pressure sensor is used for monitoring flow,
energy and gauge pressure.
Boiler T monitoring is available when using op-
tional boiler outlet sensors (S6 & S7) & boiler
inlet sensor (S5).
This schematic could also be used for a #2 oil
or ultra low sulfur diesel dual fuel application.
3.3 Application 1
Description:
Single temperature system with two two stage non-condensing
boilers are operated to provide a boiler target temperature
for space heating and indirect DHW loads. The boiler target
temperature for the space heating load is determined from outdoor
temperature reset. Piping schematic is primary/secondary.
Essential System Settings:
APP MODE = RSET
AUX RELAY = DMPR
PUMP 1 = AUTO
PUMP 2 = AUTO
IDHW MODE = ON
IDHW LOCATION = PRIM
IDHW SENSOR = ON
IDHW PRIM PUMP = OFF
FLOW SENSOR = ON
PRES SENSOR = ON
Application 1 Piping:
LEGEND:
P3 P4
P5
P1
X1
P2
S2
S4
S6 S7
F1 S8
S3
S5
S1
C.A. Damper
C.A.
Proof
S1 = Outdoor Sensor
S2 = Primary Supply Sensor
S3 = Primary Return Sensor
S4 = DHW Sensor
S5 = Boiler Inlet Sensor
S6, S7 =
Boiler Outlet Sensors
S8 = Pressure Sensor
P1, P2 =
Primary Pumps
P3, P4 = Boiler Pumps
P5, = IDHW Pump
X1 = Pressure Differential Switch
X2 = Comb Air Proof External Flow Proof
/ Off
External C.A. Proof
/ Off
G-SeriesG-Series
DIP Settings:
X2
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 o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!
ENABLE (1) = AUTO
BOSC BOILER (1) = YES
BOSC MODL (1) = “G-Series”
ENABLE (2) = AUTO
BOSC BOILER (2) = YES
BOSC MODL (2) = “G-Series”
ENABLE (3) = OFF
ENABLE (4) = OFF
Essential Source (#) Settings:

Applications Manual Bosch Heatronic 4000 Controls | 11
Bosch Thermotechnology Corp. Data subject to change
Application 1 Wiring:
L
NPrimary Pump 2(P2)
C.A. Proof Call (x2)
Pressure Sensor (S8)
Pressure Differential
Switch (X1)
C.A. Damper
R
C
L
N
L
N
Stage1
T
T
Boiler 1Pump (P3)
Boiler 2Pump (P4)
115 V (ac) Power Supply
Prim Pump
Flow Proof
Comb Air
Proof
CH
Call
DHW Tank
Call
Fuel
Switch
20V dc Out
5V dc Out
V dc (+) In
Gnd (-)
EMS(+)
Outdoor
Prim Sup
Prim Ret
DHW
Com
Com (-)
mA (+) In
1
2
3
4
Primary
Pump P1
Primary
Pump P2
47
48
49
50
5
6
7
8
Auxiliary
43
44
Bus b
Boiler
Boiler
Boiler
Boiler
tN4
C0
Bus 1tN4
C1
Bus 2tN4
C2
Bus 3tN4
C3
32
33
34
35
36
37
38
39
RS485 A
B
40
41
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Com Flue
Boil In
Com
Boil 1Out
Boil 2Out
Boil 3Out
Boil 4Out
Com
23
24
25
26
27
Gnd
42
28
29
30
Alert
Dry
45
46
Boiler 1
Pump
Boiler 2
Pump
75
76
77
78
Boiler 3
Pump
Boiler 4
Pump
Power
In
79
80
81
82
DHW
Tank Pump
85
86
53
54 Stage1
Stage2
Boiler 1
51
52
55
56
N
83
84
59
60Stage1
Stage2
Boiler 2
57
58
61
62
65
66 Stage1
Stage2
Boiler 3
63
64
67
68
71
72 Stage1
Stage2
Boiler 4
69
70
73
74
L
Com
31
Primary Pump 1(P1)
Primary Supply Sensor (S2)
Primary Return Sensor (S3)
DHW Sensor (S4)
Boiler 1Outlet Sensor (S6)
Boiler 2Outlet Sensor (S7)
Boiler Inlet Sensor (S5)
Outdoor
Sensor (S1)
Mod +
-
Mod +
-
Mod +
-
Mod +
-
Stage1
T
T
L
N
L
N
12345
Temperature Sensors - Do Not Apply Power tekmarNet Communication
C3C2C0 C1
H7019A
Boiler 1
75 76
Pump Boiler 2
77 78
Pump Boiler 3
79 80
Pump Boiler 4
81 82
Pump Pump
Power In
LNIDHW
Alert
45 46
Auxiliary
43 44
Pump
47 48
P1 Pump
Primary Primary
49 50
P2
85 8683 84
20V
11
dc 5V
dc
Out In Out
Flow Sensor
Pressure
Sensor
In In
Vdc
14
(+) (+)
Gnd
15
(-) (-)
mA
12 13
(+) EMS
16
Out
17
Prim
Sup
18
Com
19
Prim
Ret Boil In
20
DHW
21
Com
22
Com
Flue
23 24 25
Boil1
Out
26
Boil2
Out
27
ComCom
28
Com
31
Boil3
Out
29
Boil4
Out
30
tN4
32 33
Bus b tN4
34 35
Bus 1 tN4
36 37
Bus 2 tN4
38 39
Bus 3
Boiler Boiler Boiler Boiler
Flow Proof
1 2
Call C.A. Proof
34
Call CH
56
Call IDHW
7 8
Call Fuel
910
Switch AB
40 41
BACnet RS485 42 Gnd
External Flow Proof / Off
External C.A. Proof / Off
Off / Exercise
Setback / Off
51 52
Mod Boiler 1
53 54
Stage 1 Stage 2
55 56
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
57 58
Boiler 2
59 60 61 62 63 64
Boiler 3
65 66 67 68 69 70
Boiler 4
71 72 73 74
tektra 1056-01
Caution! Disconnect All
Power before Opening Designed and
assembled in Canada
Meets Class B: Canadian
ICES & FCC Part 15 Input Power:
115 V (ac) ±10% 60 Hz, 18 VA
Primary Pump Relays:
230 V (ac) 10 A, 1/2 hp
Boiler & IDHW Pumps:
230 V (ac) 5 A, 1/3 hp
Auxiliary & Alert Relays:
230 V (ac) 5 A, 1/6 hp
Boiler Stage Relays:
24 V (ac) 5 A
Calls: 24 V (ac) or Short
Signal wiring must be
rated at least 300 V.
Heatronic 4000
4 boiler control, DHW, BACnet and Modbus
Manual
Override
Home
L
NIndirect DHW Pump (P5)
Two
Stage
Boiler
Two
Stage
Boiler
Stage2
T
T
Stage2
T
T
Permanent
Call (Jumper)
12345
Temperat ure Sensor s - Do Not Appl y Pow er tekmarNet Communication
C3C2C0 C1
H6106A
Boiler 1
75 76
Pu m p Boiler 2
77 78
Pu m p Boiler 3
79 80
Pu m p Boiler 4
81 82
Pu m p Pow er In
LN
45 46
Auxiliary
43 44
Pu m p
47 48
P1 Pu m p
Prim ar y Pr im ar y
49 50
P2
85 8683 84
20V
11
dc 5V dc
Out In Out In In
Vdc
14
(+) (+)
Gnd
15
(-) (-)
mA
12 13
(+) EM S
16 17
Prim
Sup
18
Com
19
Prim
Ret Boil In
20
DHW
21
Com
22 23 24 25
Boil 1
Out
26
Boil 2
Out
27
ComCom
28
Com
31
Boil 3
Out
29
Boil 4
Out
30
tN4
32 33
Bus b tN4
34 35
Bus 1 tN4
36 37
Bus 2 tN4
38 39
Bus 3
Boiler Boiler Boiler Boiler
Prim Pu m p
1
2
Com b
34
Air Proof CH
56
Call DHW
7
8
Tan k Cal l Fuel
910
Sw i t c h
Flow
Sen sor Pressu re Sen sor
BA
40 41
BACnet IP RS48 5 42
Gnd
Prim Pu m p Flo w Pro o f / O
Comb Air Proof / O
O /Exercise
Se tb ack / O
51 52
Mod Boiler 1
53 54
Stage 1 Stage 2
55 56
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
57 58
Boiler 2
59 60 61 62 63 64
Boiler 3
65 66 67 68 69 70
Boiler 4
71 72 73 74
WARNING! Before opening
the cover disconnect from
powersupply
Meets Class B: Canadian
ICES & FCC Part 15
4 boiler control, DHW, BACnet and Modbus
MANUAL
OVERRI DE
Home
Out
door Com Flue Alert
Dry
FlowPro o f
Tan kDHW
Pu m p
(+) (–)
Heatronic4000 158033
Type 1056-XX
tektra 1056-02
Designed and
assemble d i n Canada
by tekmar Control Systems
Signal wiring m ust be
rated at least 300 V.
Inpu t Pow er:
115 V (ac) ±1 0%, 60 Hz, 18 VA
Prim ar y Pum p Relays:
230 V (ac), 10 A, 1/ 2 hp
Boiler & DHW Pum ps:
230 V (ac), 5 A, 1/ 3 h p
Boiler Stage, Auxiliary &
Alert Relays:
230 V (ac), 5 A, 1/ 6 h p
Calls: 24 V (ac) or Short

12 |Bosch Heatronic 4000 Controls Applications Manual
Bosch Thermotechnology Corp.Data subject to change
3.4 Application 2
Description:
Single temperature system with two modulating condensing boilers
operated to provide heat for space heating and indirect DHW
loads. The boiler target temperature for the space heating load is
determined from outdoor temperature reset. Piping schematic is
reverse / return with bypass.
Essential Source (#) Settings:
ENABLE (1) = AUTO
BOSC BOILER (1) = YES
BOSC MODL (1) = “SB-Series”
ENABLE (2) = AUTO
BOSC BOILER (2) = YES
BOSC MODL (2) = “SB-Series”
ENABLE (3) = OFF
ENABLE (4) = OFF
Essential System Settings:
APP MODE = RSET
PUMP 1 = AUTO
PUMP 2 = OFF
IDHW MODE = ON
IDHW LOCATION = PRIM
IDHW SENSOR = ON
IDHW PRIM PUMP = OFF
Application 2 Piping:
LEGEND:
S8
S2
S3
S6 P4
P1
S1
S7
S4
S1 = Outdoor Sensor
S2 = Primary Supply Sensor
S3 = Primary Return Sensor
S4 = DHW Sensor
S6, S7 = Boiler Outlet Sensors
S8 = Vent Sensor
P1 = Primary Pump
P4 = IDHW Pump
External Flow Proof
/ Off
External C.A. Proof
/ Off
SB Series
SB Series
DIP Settings:
S5
S5 = Boiler Inlet Sensor
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 o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!
Features:
The boiler plant is sequenced to obtain
maximum efficiency based on the boiler
types & target temperatures. For detailed
information about sequencing, rotation &
staging, refer to the Installation & Operation
Manual.
Outdoor Temperature Reset saves energy
by operating the boiler plant using the
lowest possible temperatures. Lower water
temperatures ensure modulating condensing
boilers operate at maximum efficiency.
Optional indirect DHW (IDHW) priority.
Boiler T monitoring is available when using
optional boiler outlet sensors (S6 & S7) and
boiler inlet sensor (S5).
The Common Flue Sensor (S8) is optional.

Applications Manual Bosch Heatronic 4000 Controls | 13
Bosch Thermotechnology Corp. Data subject to change
Application 2 Wiring:
IndirectDHW Pump (P4)
L
N
Vent Sensor (S8)
L
N
Mod
Stage1
T
T
+
-
Modulating
Boiler
115V (ac) Power Supply
Prim Pump
FlowProof
CombAir
Proof
CH
Call
DHW Tank
Call
Fuel
Switch
20V dcOut
5V dcOut
V dc(+) In
Gnd (-)
EMS(+)
Outdoor
Prim Sup
Prim Ret
DHW
Com
Com (-)
mA(+) In
1
2
3
4
Primary
Pump P1
Primary
Pump P2
47
48
49
50
5
6
7
8
Auxiliary
43
44
Bus b
Boiler
Boiler
Boiler
Boiler
tN4
C0
Bus 1tN4
C1
Bus 2tN4
C2
Bus 3tN4
C3
32
33
34
35
36
37
38
39
RS485A
B
40
41
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Com Flue
Boil In
Com
Boil 1Out
Boil 2Out
Boil 3Out
Boil 4Out
Com
23
24
25
26
27
Gnd
42
28
29
30
Alert
Dry
45
46
Boiler 1
Pump
Boiler 2
Pump
75
76
77
78
Boiler 3
Pump
Boiler 4
Pump
Power
In
79
80
81
82
DHW
Tank Pump
85
86
53
54Stage1
Stage2
Boiler 1
51
52
55
56
N
83
84
59
60Stage1
Stage2
Boiler 2
57
58
61
62
65
66 Stage1
Stage2
Boiler 3
63
64
67
68
71
72 Stage1
Stage2
Boiler 4
69
70
73
74
L
Com
31
Primary Pump 1(P1)
Modulating
Boiler
Primary Supply Sensor (S2)
Primary Return Sensor (S3)
DHW Sensor (S4)
Boiler 1Outlet Sensor (S6)
Boiler 2Outlet Sensor (S7)
Outdoor
Sensor (S1)
Mod +
-
Mod +
-
Mod +
-
Mod +
-
Mod
Stage1
T
T
+
-
L
N
L
NIndirectDHW Pump (P4)
Boiler Inlet Sensor (S5)
Permanent
Call (Jumper)
12345
Temperature Sensors - Do Not Apply Power tekmarNet Communication
C3C2C0 C1
H7019A
Boiler 1
75 76
Pump Boiler 2
77 78
Pump Boiler 3
79 80
Pump Boiler 4
81 82
Pump Pump
Power In
LNIDHW
Alert
45 46
Auxiliary
43 44
Pump
47 48
P1 Pump
Primary Primary
49 50
P2
85 8683 84
20V
11
dc 5V
dc
Out In Out
Flow Sensor
Pressure
Sensor
In In
Vdc
14
(+) (+)
Gnd
15
(-) (-)
mA
12 13
(+) EMS
16
Out
17
Prim
Sup
18
Com
19
Prim
Ret Boil In
20
DHW
21
Com
22
Com
Flue
23 24 25
Boil1
Out
26
Boil2
Out
27
ComCom
28
Com
31
Boil3
Out
29
Boil4
Out
30
tN4
32 33
Bus b tN4
34 35
Bus 1 tN4
36 37
Bus 2 tN4
38 39
Bus 3
Boiler Boiler Boiler Boiler
Flow Proof
1 2
Call C.A. Proof
34
Call CH
56
Call IDHW
7 8
Call Fuel
910
Switch AB
40 41
BACnet RS485 42 Gnd
External Flow Proof / Off
External C.A. Proof / Off
Off / Exercise
Setback / Off
51 52
Mod Boiler 1
53 54
Stage 1 Stage 2
55 56
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
57 58
Boiler 2
59 60 61 62 63 64
Boiler 3
65 66 67 68 69 70
Boiler 4
71 72 73 74
tektra 1056-01
Caution! Disconnect All
Power before Opening Designed and
assembled in Canada
Meets Class B: Canadian
ICES & FCC Part 15 Input Power:
115 V (ac) ±10% 60 Hz, 18 VA
Primary Pump Relays:
230 V (ac) 10 A, 1/2 hp
Boiler & IDHW Pumps:
230 V (ac) 5 A, 1/3 hp
Auxiliary & Alert Relays:
230 V (ac) 5 A, 1/6 hp
Boiler Stage Relays:
24 V (ac) 5 A
Calls: 24 V (ac) or Short
Signal wiring must be
rated at least 300 V.
Heatronic 4000
4 boiler control, DHW, BACnet and Modbus
Manual
Override
Home
12345
Temperat ure Sensor s - Do Not Appl y Pow er tekmarNet Communication
C3C2C0 C1
H6106A
Boiler 1
75 76
Pu m p Boiler 2
77 78
Pu m p Boiler 3
79 80
Pu m p Boiler 4
81 82
Pu m p Pow er In
LN
45 46
Auxiliary
43 44
Pu m p
47 48
P1 Pu m p
Prim ar y Pr im ar y
49 50
P2
85 8683 84
20V
11
dc 5V
dc
Out In Out In In
Vdc
14
(+) (+)
Gnd
15
(-) (-)
mA
12 13
(+) EM S
16 17
Prim
Sup
18
Com
19
Prim
Ret Boil In
20
DHW
21
Com
22 23 24 25
Boil 1
Out
26
Boil 2
Out
27
ComCom
28
Com
31
Boil 3
Out
29
Boil 4
Out
30
tN4
32 33
Bus b tN4
34 35
Bus 1 tN4
36 37
Bus 2 tN4
38 39
Bus 3
Boiler Boiler Boiler Boiler
Prim Pu m p
1
2
Com b
34
Air Proof CH
56
Call DHW
7
8
Tan k Cal l Fuel
910
Sw i t c h
Flow
Sen sor Pressu re Sen sor
BA
40 41
BACnet IP RS48 5 42
Gnd
Prim Pu m p Flo w Pro o f / O
Comb Air Proof / O
O /Exercise
Se tb ack / O
51 52
Mod Boiler 1
53 54
Stage 1 Stage 2
55 56
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
57 58
Boiler 2
59 60 61 62 63 64
Boiler 3
65 66 67 68 69 70
Boiler 4
71 72 73 74
WARNING! Before opening
the cover disconnect from
powersupply
Meets Class B: Canadian
ICES & FCC Part 15
4 boiler control, DHW, BACnet and Modbus
MANUAL
OVERRI DE
Home
Out
door Com Flue Alert
Dry
FlowPro o f
Tan kDHW
Pu m p
(+) (–)
Heatronic4000 158033
Type 1056-XX
tektra 1056-02
Designed and
assemble d i n Canada
by tekmar Control Systems
Signal wiring m ust be
rated at least 300 V.
Inpu t Pow er:
115 V (ac) ±1 0%, 60 Hz, 18 VA
Prim ar y Pum p Relays:
230 V (ac), 10 A, 1/ 2 hp
Boiler & DHW Pum ps:
230 V (ac), 5 A, 1/ 3 h p
Boiler Stage, Auxiliary &
Alert Relays:
230 V (ac), 5 A, 1/ 6 h p
Calls: 24 V (ac) or Short

14 |Bosch Heatronic 4000 Controls Applications Manual
Bosch Thermotechnology Corp.Data subject to change
3.5 Application 3
Description:
Single temperature system with two modulating condensing boilers
operated to provide heat for space heating and indirect DHW
loads. The boiler target temperature for the space heating load is
determined from outdoor temperature reset. Piping Schematic is
Primary /Secondary Piping.
Essential Source (#) Settings:
ENABLE (1) = AUTO
BOSC BOILER (1) = YES
BOSC MODL (1) = “SB-Series”
ENABLE (2) = AUTO
BOSC BOILER (2) = YES
BOSC MODL (2) = “SB-Series”
ENABLE (3) = OFF
ENABLE (4) = OFF
Essential System Settings:
APP MODE = RSET
PUMP 1 = AUTO
PUMP 2 = OFF
IDHW MODE = ON
IDHW LOCATION = PRIM
IDHW SENSOR = ON
IDHW PRIM PUMP = OFF
Application 3 Piping:
LEGEND:
S8
S2
S3
S6
P4
P1
S1
S7
S4
S1 = Outdoor Sensor
S2 = Primary Supply Sensor
S3 = Primary Return Sensor
S4 = DHW Sensor
S6, S7 = Boiler Outlet Sensors
S8 = Vent Sensor
P1 = Primary Pump
P4 = IDHW Pump External Flow Proof
/ Off
External C.A. Proof
/ Off
SB Series
SB Series
DIP Settings:
P3
P2
S5 = Boiler Inlet Sensor
S5
P2, P3 = Boiler Pump
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 o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!
Features:
The boiler plant is sequenced to obtain
maximum efficiency based on the boiler
types & target temperatures. For detailed
information about sequencing, rotation &
staging, refer to the Installation & Operation
Manual.
Outdoor Temperature Reset saves energy
by operating the boiler plant using the
lowest possible temperatures. Lower water
temperatures ensure modulating condensing
boilers operate at maximum efficiency.
Optional indirect DHW (IDHW) priority.
Boiler T monitoring is available when using
optional boiler outlet sensors (S6 & S7) and
boiler inlet sensor (S5).
The Common Flue Sensor (S8) is optional.

Applications Manual Bosch Heatronic 4000 Controls | 15
Bosch Thermotechnology Corp. Data subject to change
Application 3 Wiring:
IndirectDHW Pump (P4)
L
N
Vent Sensor (S8)
L
N
L
N
Mod
Stage1
T
T
+
-
Modulating
Boiler
Boiler 1Pump (P2)
Boiler 2Pump (P3)
115V (ac) Power Supply
Prim Pump
FlowProof
CombAir
Proof
CH
Call
DHW Tank
Call
Fuel
Switch
20V dcOut
5V dcOut
V dc(+) In
Gnd (-)
EMS(+)
Outdoor
Prim Sup
Prim Ret
DHW
Com
Com (-)
mA(+) In
1
2
3
4
Primary
Pump P1
Primary
Pump P2
47
48
49
50
5
6
7
8
Auxiliary
43
44
Bus b
Boiler
Boiler
Boiler
Boiler
tN4
C0
Bus 1tN4
C1
Bus 2tN4
C2
Bus 3tN4
C3
32
33
34
35
36
37
38
39
RS485A
B
40
41
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Com Flue
Boil In
Com
Boil 1Out
Boil 2Out
Boil 3Out
Boil 4Out
Com
23
24
25
26
27
Gnd
42
28
29
30
Alert
Dry
45
46
Boiler 1
Pump
Boiler 2
Pump
75
76
77
78
Boiler 3
Pump
Boiler 4
Pump
Power
In
79
80
81
82
DHW
Tank Pump
85
86
53
54Stage1
Stage2
Boiler 1
51
52
55
56
N
83
84
59
60Stage1
Stage2
Boiler 2
57
58
61
62
65
66 Stage1
Stage2
Boiler 3
63
64
67
68
71
72 Stage1
Stage2
Boiler 4
69
70
73
74
L
Com
31
Primary Pump 1(P1)
Modulating
Boiler
Primary Supply Sensor (S2)
Primary Return Sensor (S3)
DHW Sensor (S4)
Boiler 1Outlet Sensor (S6)
Boiler 2Outlet Sensor (S7)
Boiler Inlet Sensor (S5)
Outdoor
Sensor (S1)
Mod +
-
Mod +
-
Mod +
-
Mod +
-
Mod
Stage1
T
T
+
-
L
N
L
N
Permanent
Call (Jumper)
12345
Temperature Sensors - Do Not Apply Power tekmarNet Communication
C3C2C0 C1
H7019A
Boiler 1
75 76
Pump Boiler 2
77 78
Pump Boiler 3
79 80
Pump Boiler 4
81 82
Pump Pump
Power In
LNIDHW
Alert
45 46
Auxiliary
43 44
Pump
47 48
P1 Pump
Primary Primary
49 50
P2
85 8683 84
20V
11
dc 5V
dc
Out In Out
Flow Sensor
Pressure
Sensor
In In
Vdc
14
(+) (+)
Gnd
15
(-) (-)
mA
12 13
(+) EMS
16
Out
17
Prim
Sup
18
Com
19
Prim
Ret Boil In
20
DHW
21
Com
22
Com
Flue
23 24 25
Boil1
Out
26
Boil2
Out
27
ComCom
28
Com
31
Boil3
Out
29
Boil4
Out
30
tN4
32 33
Bus b tN4
34 35
Bus 1 tN4
36 37
Bus 2 tN4
38 39
Bus 3
Boiler Boiler Boiler Boiler
Flow Proof
1 2
Call C.A. Proof
34
Call CH
56
Call IDHW
7 8
Call Fuel
910
Switch AB
40 41
BACnet RS485 42 Gnd
External Flow Proof / Off
External C.A. Proof / Off
Off / Exercise
Setback / Off
51 52
Mod Boiler 1
53 54
Stage 1 Stage 2
55 56
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
57 58
Boiler 2
59 60 61 62 63 64
Boiler 3
65 66 67 68 69 70
Boiler 4
71 72 73 74
tektra 1056-01
Caution! Disconnect All
Power before Opening Designed and
assembled in Canada
Meets Class B: Canadian
ICES & FCC Part 15 Input Power:
115 V (ac) ±10% 60 Hz, 18 VA
Primary Pump Relays:
230 V (ac) 10 A, 1/2 hp
Boiler & IDHW Pumps:
230 V (ac) 5 A, 1/3 hp
Auxiliary & Alert Relays:
230 V (ac) 5 A, 1/6 hp
Boiler Stage Relays:
24 V (ac) 5 A
Calls: 24 V (ac) or Short
Signal wiring must be
rated at least 300 V.
Heatronic 4000
4 boiler control, DHW, BACnet and Modbus
Manual
Override
Home
12345
Temperat ure Sensor s - Do Not Appl y Pow er tekmarNet Communication
C3C2C0 C1
H6106A
Boiler 1
75 76
Pu m p Boiler 2
77 78
Pu m p Boiler 3
79 80
Pu m p Boiler 4
81 82
Pu m p Pow er In
LN
45 46
Auxiliary
43 44
Pu m p
47 48
P1 Pu m p
Prim ar y Pr im ar y
49 50
P2
85 8683 84
20V
11
dc 5V dc
Out In Out In In
Vdc
14
(+) (+)
Gnd
15
(-) (-)
mA
12 13
(+) EM S
16 17
Prim
Sup
18
Com
19
Prim
Ret Boil In
20
DHW
21
Com
22 23 24 25
Boil 1
Out
26
Boil 2
Out
27
ComCom
28
Com
31
Boil 3
Out
29
Boil 4
Out
30
tN4
32 33
Bus b tN4
34 35
Bus 1 tN4
36 37
Bus 2 tN4
38 39
Bus 3
Boiler Boiler Boiler Boiler
Prim Pu m p
1
2
Com b
34
Air Proof CH
56
Call DHW
7
8
Tan k Cal l Fuel
910
Sw i t c h
Flow
Sen sor Pressu re Sen sor
BA
40 41
BACnet IP RS48 5 42
Gnd
Prim Pu m p Flo w Pro o f / O
Comb Air Proof / O
O /Exercise
Se tb ack / O
51 52
Mod Boiler 1
53 54
Stage 1 Stage 2
55 56
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
57 58
Boiler 2
59 60 61 62 63 64
Boiler 3
65 66 67 68 69 70
Boiler 4
71 72 73 74
WARNING! Before opening
the cover disconnect from
powersupply
Meets Class B: Canadian
ICES & FCC Part 15
4 boiler control, DHW, BACnet and Modbus
MANUAL
OVERRI DE
Home
Out
door Com Flue Alert
Dry
FlowPro o f
Tan kDHW
Pu m p
(+) (–)
Heatronic4000 158033
Type 1056-XX
tektra 1056-02
Designed and
assemble d i n Canada
by tekmar Control Systems
Signal wiring m ust be
rated at least 300 V.
Inpu t Pow er:
115 V (ac) ±1 0%, 60 Hz, 18 VA
Prim ar y Pum p Relays:
230 V (ac), 10 A, 1/ 2 hp
Boiler & DHW Pum ps:
230 V (ac), 5 A, 1/ 3 h p
Boiler Stage,Auxiliary &
Alert Relays:
230 V (ac), 5 A, 1/ 6 h p
Calls: 24 V (ac) o r Sho rt

16 |Bosch Heatronic 4000 Controls Applications Manual
Bosch Thermotechnology Corp.Data subject to change
Features:
The boiler plant is sequenced to obtain
maximum efficiency based on the boiler
types & target temperatures. For detailed
information about sequencing, rotation &
staging, refer to the Installation & Operation
Manual.
Dual primary pumps with a flow proof provide
redundancy. Pumps can be sequenced with
equal run-time rotation.
Boiler T monitoring is available when using
optional boiler outlet sensors (S6 to S9) and
boiler inlet sensor (S5).
The boiler outlet sensor S9 is required for
indirect DHW operation.
3.6 Application 4
Description:
Single temperature system with four modulating condensing
boilers are operated to provide an outdoor temperature reset
boiler target for a space heating load. The fourth boiler also
operates to provide heat for an indirect DHW load with priority
over space heating. Piping schematic is primary/secondary with
DHW near piping.
Essential Source (#) Settings:
ENABLE (1) = AUTO
BOSC BOILER (1) = YES
BOSC MODL (1) = “SB-Series”
ENABLE (2) = AUTO
BOSC BOILER (2) = YES
BOSC MODL (2) = “SB-Series”
ENABLE (3) = AUTO
BOSC BOILER (3) = YES
BOSC MODL (3) = “SB-Series”
ENABLE (4) = AUTO
BOSC BOILER (4) = YES
BOSC MODL (4) = “SB-Series”
Essential System Settings:
APP MODE = RSET
PUMP 1 = AUTO
PUMP 2 = AUTO
IDHW MODE = ON
IDHW LOCATION = NEAR
IDHW SENSOR = ON
Application 4 Piping:
LEGEND:
P2
P1 Current Switch
Current Switch
S2
S3
S5
S8
S7
P3 P4 P5 P6
S9
S1
S6
P7
S1 = Outdoor Sensor
S2 = Primary Supply Sensor
S3 = Primary Return Sensor
S4 = DHW Sensor
S5 = Boiler Inlet Sensor
S6-S9= Boiler Outlet Sensors
P1, P2 =
Primary Pumps
P3-P6 = Boiler Pumps
P7 = IDHW Pump
External Flow Proof
/ Off
External C.A. Proof
/ Off
SB Series SB Series SB SeriesSB Series
DIP Settings:
S4
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 o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!

Applications Manual Bosch Heatronic 4000 Controls | 17
Bosch Thermotechnology Corp. Data subject to change
Application 4 Wiring:
IndirectDHW Pump (P4)
L
N
Vent Sensor (S8)
L
N
Mod
Stage1
T
T
+
-
Modulating
Boiler
115V (ac) Power Supply
Prim Pump
FlowProof
CombAir
Proof
CH
Call
DHW Tank
Call
Fuel
Switch
20V dcOut
5V dcOut
V dc(+) In
Gnd (-)
EMS(+)
Outdoor
Prim Sup
Prim Ret
DHW
Com
Com (-)
mA(+) In
1
2
3
4
Primary
Pump P1
Primary
Pump P2
47
48
49
50
5
6
7
8
Auxiliary
43
44
Bus b
Boiler
Boiler
Boiler
Boiler
tN4
C0
Bus 1tN4
C1
Bus 2tN4
C2
Bus 3tN4
C3
32
33
34
35
36
37
38
39
RS485A
B
40
41
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Com Flue
Boil In
Com
Boil 1Out
Boil 2Out
Boil 3Out
Boil 4Out
Com
23
24
25
26
27
Gnd
42
28
29
30
Alert
Dry
45
46
Boiler 1
Pump
Boiler 2
Pump
75
76
77
78
Boiler 3
Pump
Boiler 4
Pump
Power
In
79
80
81
82
DHW
Tank Pump
85
86
53
54Stage1
Stage2
Boiler 1
51
52
55
56
N
83
84
59
60Stage1
Stage2
Boiler 2
57
58
61
62
65
66 Stage1
Stage2
Boiler 3
63
64
67
68
71
72 Stage1
Stage2
Boiler 4
69
70
73
74
L
Com
31
Primary Pump 1(P1)
Modulating
Boiler
Primary Supply Sensor (S2)
Primary Return Sensor (S3)
DHW Sensor (S4)
Boiler 1Outlet Sensor (S6)
Boiler 2Outlet Sensor (S7)
Outdoor
Sensor (S1)
Mod +
-
Mod +
-
Mod +
-
Mod +
-
Mod
Stage1
T
T
+
-
L
N
L
NIndirectDHW Pump (P4)
Boiler Inlet Sensor (S5)
Permanent
Call (Jumper)
12345
Temperature Sensors - Do Not Apply Power tekmarNet Communication
C3C2C0 C1
H7019A
Boiler 1
75 76
Pump Boiler 2
77 78
Pump Boiler 3
79 80
Pump Boiler 4
81 82
Pump Pump
Power In
LNIDHW
Alert
45 46
Auxiliary
43 44
Pump
47 48
P1 Pump
Primary Primary
49 50
P2
85 8683 84
20V
11
dc 5V
dc
Out In Out
Flow Sensor
Pressure
Sensor
In In
Vdc
14
(+) (+)
Gnd
15
(-) (-)
mA
12 13
(+) EMS
16
Out
17
Prim
Sup
18
Com
19
Prim
Ret Boil In
20
DHW
21
Com
22
Com
Flue
23 24 25
Boil1
Out
26
Boil2
Out
27
ComCom
28
Com
31
Boil3
Out
29
Boil4
Out
30
tN4
32 33
Bus b tN4
34 35
Bus 1 tN4
36 37
Bus 2 tN4
38 39
Bus 3
Boiler Boiler Boiler Boiler
Flow Proof
1 2
Call C.A. Proof
34
Call CH
56
Call IDHW
7 8
Call Fuel
910
Switch AB
40 41
BACnet RS485 42 Gnd
External Flow Proof / Off
External C.A. Proof / Off
Off / Exercise
Setback / Off
51 52
Mod Boiler 1
53 54
Stage 1 Stage 2
55 56
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
57 58
Boiler 2
59 60 61 62 63 64
Boiler 3
65 66 67 68 69 70
Boiler 4
71 72 73 74
tektra 1056-01
Caution! Disconnect All
Power before Opening Designed and
assembled in Canada
Meets Class B: Canadian
ICES & FCC Part 15 Input Power:
115 V (ac) ±10% 60 Hz, 18 VA
Primary Pump Relays:
230 V (ac) 10 A, 1/2 hp
Boiler & IDHW Pumps:
230 V (ac) 5 A, 1/3 hp
Auxiliary & Alert Relays:
230 V (ac) 5 A, 1/6 hp
Boiler Stage Relays:
24 V (ac) 5 A
Calls: 24 V (ac) or Short
Signal wiring must be
rated at least 300 V.
Heatronic 4000
4 boiler control, DHW, BACnet and Modbus
Manual
Override
Home
12345
Temperat ure Sensor s - Do Not Appl y Pow er tekmarNet Communication
C3C2C0 C1
H6106A
Boiler 1
75 76
Pu m p Boiler 2
77 78
Pu m p Boiler 3
79 80
Pu m p Boiler 4
81 82
Pu m p Pow er In
LN
45 46
Auxiliary
43 44
Pu m p
47 48
P1 Pu m p
Prim ar y Pr im ar y
49 50
P2
85 8683 84
20V
11
dc 5V dc
Out In Out In In
Vdc
14
(+) (+)
Gnd
15
(-) (-)
mA
12 13
(+) EM S
16 17
Prim
Sup
18
Com
19
Prim
Ret Boil In
20
DHW
21
Com
22 23 24 25
Boil 1
Out
26
Boil 2
Out
27
ComCom
28
Com
31
Boil 3
Out
29
Boil 4
Out
30
tN4
32 33
Bus b tN4
34 35
Bus 1 tN4
36 37
Bus 2 tN4
38 39
Bus 3
Boiler Boiler Boiler Boiler
Prim Pu m p
1
2
Com b
34
Air Proof CH
56
Call DHW
7
8
Tan k Cal l Fuel
910
Sw i t c h
Flow
Sen sor Pressu re Sen sor
BA
40 41
BACnet IP RS48 5 42
Gnd
Prim Pu m p Flo w Pro o f / O
Comb Air Proof / O
O /Exercise
Se tb ack / O
51 52
Mod Boiler 1
53 54
Stage 1 Stage 2
55 56
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
57 58
Boiler 2
59 60 61 62 63 64
Boiler 3
65 66 67 68 69 70
Boiler 4
71 72 73 74
WARNING! Before opening
the cover disconnect from
powersupply
Meets Class B: Canadian
ICES & FCC Part 15
4 boiler control, DHW, BACnet and Modbus
MANUAL
OVERRI DE
Home
Out
door Com Flue Alert
Dry
FlowPro o f
Tan kDHW
Pu m p
(+) (–)
Heatronic4000 158033
Type 1056-XX
tektra 1056-02
Designed and
assemble d i n Canada
by tekmar Control Systems
Signal wiring m ust be
rated at least 300 V.
Inpu t Pow er:
115 V (ac) ±1 0%, 60 Hz, 18 VA
Prim ar y Pum p Relays:
230 V (ac), 10 A, 1/ 2 hp
Boiler & DHW Pum ps:
230 V (ac), 5 A, 1/ 3 h p
Boiler Stage,Auxiliary &
Alert Relays:
230 V (ac), 5 A, 1/ 6 h p
Calls: 24 V (ac) or Short

18 |Bosch Heatronic 4000 Controls Applications Manual
Bosch Thermotechnology Corp.Data subject to change
Features:
The boiler plant is sequenced to obtain
maximum efficiency based on the boiler
types & target temperatures. For detailed
information about sequencing, rotation &
staging, refer to the Heatronic 4000 Installa-
tion & Operation Manual.
Outdoor Temperature Reset saves energy by
operating the boiler plant using the lowest
possible temperatures. Lower water tem-
peratures ensure modulating condensing
boilers operate at maximum efficiency.
Optional indirect DHW (IDHW) priority.
Pump logic feature for protection against
low water temperatures for Bosch non-con-
densing boilers.
3.7 Application 5
Description:
Single temperature system with dual fuel condensing gas & non-
condensing oil boilers operated to provide heat for space heating
and indirect DHW loads. The boiler target temperature for the
space heating load is determined from outdoor temperature reset.
LEGEND:
X1
S2
S3
S6
P4
P1
S1
S7
S4
S1 = Outdoor Sensor
S2 = Primary Supply Sensor
S3 = Primary Return Sensor
S4 = DHW Sensor
S6, S7 = Boiler Outlet Sensors
P1 = Primary Pump
P4 = IDHW Pump
DIP Sett
i
ngs:
Prim Pump Flow Proof / Off
Comb Air Proof / Off
Off / Exercise
Setback/ Off
Dual
Fuel
Oil
Gas
SB Series
Dual Fuel Condensing Gas, Non Condensing Oil
P2
P2 = Boiler Pump
Boiler primary
System
Secondary
4 x O.D
of Primary
Loop Piping
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 o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!
Essential Source (#) Settings:
ENABLE (1) = AUTO
BOSC BOILER (1) = YES
BOSC MODL (1) = “SB-Series”
BOSC FUEL TYPE (1) = DUAL
ENABLE (3) = AUTO
BOSC BOILER (3) = YES
BOSC MODL (3) = “SB-Series”
ENABLE (4) = OFF
Essential System Settings:
APP MODE = RSET
PUMP 1 = AUTO
PUMP 2 = OFF
IDHW MODE = ON
IDHW LOCATION = PRIM
IDHW SENSOR = ON
IDHW PRIM PUMP = OFF
Application 5 Piping:

Applications Manual Bosch Heatronic 4000 Controls | 19
Bosch Thermotechnology Corp. Data subject to change
Application 5 Wiring:
L
N
T
T
T
T
IndirectDHW Pump (P4)
Dual Fuel
Boiler
Modulating
Boiler
Mod
Stage 1
T
T
+
-
Burner Switchover
ToOil
Permanent
Call (Jumper)L
N
Mod
Stage1
T
T
+
-
TwoStage
Oil Burner
Boiler 1Pump (P2)
115V (ac) Power Supply
Prim Pump
FlowProof
CombAir
Proof
CH
Call
DHW Tank
Call
Fuel
Switch
20V dcOut
5V dcOut
V dc(+) In
Gnd (-)
EMS(+)
Outdoor
Prim Sup
Prim Ret
DHW
Com
Com (-)
mA(+) In
1
2
3
4
Primary
Pump P1
Primary
Pump P2
47
48
49
50
5
6
7
8
Auxiliary
43
44
Bus b
Boiler
Boiler
Boiler
Boiler
tN4
C0
Bus 1tN4
C1
Bus 2tN4
C2
Bus 3tN4
C3
32
33
34
35
36
37
38
39
RS485A
B
40
41
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Com Flue
Boil In
Com
Boil 1Out
Boil 2Out
Boil 3Out
Boil 4Out
Com
23
24
25
26
27
Gnd
42
28
29
30
Alert
Dry
45
46
Boiler 1
Pump
Boiler 2
Pump
75
76
77
78
Boiler 3
Pump
Boiler 4
Pump
Power
In
79
80
81
82
DHW
Tank Pump
85
86
53
54Stage1
Stage2
Boiler 1
51
52
55
56
N
83
84
59
60Stage1
Stage2
Boiler 2
57
58
61
62
65
66 Stage1
Stage2
Boiler 3
63
64
67
68
71
72 Stage1
Stage2
Boiler 4
69
70
73
74
L
Com
31
Primary Pump 1(P1)
Modulating
Gas Burner
Primary Supply Sensor (S2)
Primary Return Sensor (S3)
DHW Sensor (S4)
Boiler 1Outlet Sensor (S6)
Boiler 2Outlet Sensor (S7)
Outdoor
Sensor (S1)
Mod +
-
Mod +
-
Mod +
-
Mod +
-
L
N
L
N
Stage1
Stage2
12345
Temperature Sensors - Do Not Apply Power tekmarNet Communication
C3C2C0 C1
H7019A
Boiler 1
75 76
Pump Boiler 2
77 78
Pump Boiler 3
79 80
Pump Boiler 4
81 82
Pump Pump
Power In
LNIDHW
Alert
45 46
Auxiliary
43 44
Pump
47 48
P1 Pump
Primary Primary
49 50
P2
85 8683 84
20V
11
dc 5V
dc
Out In Out
Flow Sensor
Pressure
Sensor
In In
Vdc
14
(+) (+)
Gnd
15
(-) (-)
mA
12 13
(+) EMS
16
Out
17
Prim
Sup
18
Com
19
Prim
Ret Boil In
20
DHW
21
Com
22
Com
Flue
23 24 25
Boil1
Out
26
Boil2
Out
27
ComCom
28
Com
31
Boil3
Out
29
Boil4
Out
30
tN4
32 33
Bus b tN4
34 35
Bus 1 tN4
36 37
Bus 2 tN4
38 39
Bus 3
Boiler Boiler Boiler Boiler
Flow Proof
1 2
Call C.A. Proof
34
Call CH
56
Call IDHW
7 8
Call Fuel
910
Switch AB
40 41
BACnet RS485 42 Gnd
External Flow Proof / Off
External C.A. Proof / Off
Off / Exercise
Setback / Off
51 52
Mod Boiler 1
53 54
Stage 1 Stage 2
55 56
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
57 58
Boiler 2
59 60 61 62 63 64
Boiler 3
65 66 67 68 69 70
Boiler 4
71 72 73 74
tektra 1056-01
Caution! Disconnect All
Power before Opening Designed and
assembled in Canada
Meets Class B: Canadian
ICES & FCC Part 15 Input Power:
115 V (ac) ±10% 60 Hz, 18 VA
Primary Pump Relays:
230 V (ac) 10 A, 1/2 hp
Boiler & IDHW Pumps:
230 V (ac) 5 A, 1/3 hp
Auxiliary & Alert Relays:
230 V (ac) 5 A, 1/6 hp
Boiler Stage Relays:
24 V (ac) 5 A
Calls: 24 V (ac) or Short
Signal wiring must be
rated at least 300 V.
Heatronic 4000
4 boiler control, DHW, BACnet and Modbus
Manual
Override
Home
12345
Temperat ure Sensor s - Do Not Appl y Pow er tekmarNet Communication
C3C2C0 C1
H6106A
Boiler 1
75 76
Pu m p Boiler 2
77 78
Pu m p Boiler 3
79 80
Pu m p Boiler 4
81 82
Pu m p Pow er In
LN
45 46
Auxiliary
43 44
Pu m p
47 48
P1 Pu m p
Prim ar y Pr im ar y
49 50
P2
85 8683 84
20V
11
dc 5V
dc
Out In Out In In
Vdc
14
(+) (+)
Gnd
15
(-) (-)
mA
12 13
(+) EM S
16 17
Prim
Sup
18
Com
19
Prim
Ret Boil In
20
DHW
21
Com
22 23 24 25
Boil 1
Out
26
Boil 2
Out
27
ComCom
28
Com
31
Boil 3
Out
29
Boil 4
Out
30
tN4
32 33
Bus b tN4
34 35
Bus 1 tN4
36 37
Bus 2 tN4
38 39
Bus 3
Boiler Boiler Boiler Boiler
Prim Pu m p
1
2
Com b
34
Air Proof CH
56
Call DHW
7
8
Tan k Cal l Fuel
910
Sw i t c h
Flow
Sen sor Pressu re Sen sor
BA
40 41
BACnet IP RS48 5 42
Gnd
Prim Pu m p Flo w Pro o f / O
Comb Air Proof / O
O /Exercise
Se tb ack / O
51 52
Mod Boiler 1
53 54
Stage 1 Stage 2
55 56
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
Mod Stage 1 Stage 2
+
-
57 58
Boiler 2
59 60 61 62 63 64
Boiler 3
65 66 67 68 69 70
Boiler 4
71 72 73 74
WARNING! Before opening
the cover disconnect from
powersupply
Meets Class B: Canadian
ICES & FCC Part 15
4 boiler control, DHW, BACnet and Modbus
MANUAL
OVERRI DE
Home
Out
door Com Flue Alert
Dry
FlowPro o f
Tan kDHW
Pu m p
(+) (–)
Heatronic4000 158033
Type 1056-XX
tektra 1056-02
Designed and
assemble d i n Canada
by tekmar Control Systems
Signal wiring m ust be
rated at least 300 V.
Inpu t Pow er:
115 V (ac) ±1 0%, 60 Hz, 18 VA
Prim ar y Pum p Relays:
230 V (ac), 10 A, 1/ 2 hp
Boiler & DHW Pum ps:
230 V (ac), 5 A, 1/ 3 h p
Boiler Stage,Auxiliary &
Alert Relays:
230 V (ac), 5 A, 1/ 6 h p
Calls: 24 V (ac) or Short

20 |Bosch Heatronic 4000 Controls Applications Manual
Bosch Thermotechnology Corp.Data subject to change
Modbus®/ BACnet®IP
S1
C.A. Damper
BAS
C.A. Proof
S1 = Outdoor Sensor
S2 = Primary Supply Sensor
S3 = Primary Return Sensor
S4 = DHW Sensor
S6-S9
= Boiler Outlet Sensors
F1 = Flow Sensor
P1, P2 = Boiler Pumps
P3 = IDHW Pump
LEGEND:
External Flow Proof
/ O
External C.A. Proof
/ O
DIP Settings:
S3
M
P3
S2
S9
S7
P1 S8
S4
F1
S6
SB Series G-Series
High Temp Return
SB Series G-Series
P2
Low Temp Return
Boiler primary
System
Secondary
4 x O.D
of Primary
Loop Piping
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 o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!
3.8 Application 6
Description:
Two temperature system with two two stage non-condensing boilers
& two modulating condensing boilers are operated to provide a
boiler target temperature for space heating & indirect DHW. The
boiler target temperature for the space heating load is determined
from outdoor temperature reset.
Essential Source (#) Settings:
ENABLE (1) = AUTO
BOSC BOILER (1) = YES
BOSC MODL (1) = “G-Series”
ENABLE (2) = AUTO
BOSC BOILER (2) = YES
BOSC MODL (2) = “G-Series”
ENABLE (3) = AUTO
BOSC BOILER (3) = YES
BOSC MODL (3) = “SB-Series”
ENABLE (4) = AUTO
BOSC BOILER (4) = YES
BOSC MODL (5) = “SB-Series”
Essential System Settings:
APP MODE = RSET
AUX RELAY = DMPR
PUMP 1 = OFF
PUMP 2 = OFF
IDHW MODE = ON
IDHW LOCATION = PRIM
IDHW SENSOR = ON
IDHW PRIM PUMP = OFF
SETP PRIM PUMP = OFF
Application 6 Piping:
Features:
The boiler plant is sequenced to obtain
maximum efficiency based on the boiler
types & target temperatures. For detailed
information about sequencing, rotation &
staging, refer to the Installation & Operation
Manual.
System includes a combustion air (C.A.)
damper. Proving of C.A. damper via external
C.A. proof (motor end switch).
Communication with a Building Automation
System (BAS) is available using BACnet®IP or
Modbus®.