Bosch Appliances Boiler 100 Combi Boiler User Manual
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!  
Gas Condensing Boiler  
Bosch  
100, 151 Combi Boiler  
57, 100, 131, 151 Heating Boiler  
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Table of Contents  
1 Information about the appliance  
1.1 Boiler types and sizes  
4
4
5
6
7
8
1.2 FW200 Boiler Energy Management  
1.3 FB100 Remote Control & Room Sensor  
1.4 IPM2 Space Heating Module  
1.5 ISM2 Solar Module  
2 Applications  
9
9
Legend  
List of most common applications  
Boiler pump capacity in single zone systems  
10  
11  
Single Zone Baseboard Systems:  
2.1 System 1: Greenstar Heating Boiler in a  
single zone system  
13  
17  
21  
2.2 System 2: Greenstar Combi Boiler in a  
single zone system  
2.3 System 3: Greenstar Heating Boiler in a single  
zone system with DHW tank loading  
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  
33  
37  
2.6 System 6: Greenstar Combi Boiler in a  
single zone system  
2.7 System 7: Greenstar Heating Boiler in a single  
zone system with DHW tank loading  
2.8 System 8: Greenstar Heating Boiler in a single  
zone system with room thermostat and DHW  
tank loading  
41  
45  
2.9 System 9: Greenstar Heating Boiler in a single  
zone system with solar thermal DHW and  
boiler backup  
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  
57  
2.12 System 12: Greenstar Heating Boiler with  
zone valves and room thermostats  
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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  
Data subject to change  
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Bosch Greenstar | 5  
Scope of delivery  
1.2 FW200 Boiler Energy Management  
System  
The Boiler Energy Management System includes the  
FW200 user programming interface with integrated  
outdoor reset control.  
2
3
In connection with the IPM2 module the FW200 offers  
an outdoor reset control for two heating zones and  
DHW generation with time programs:  
8
1
—
Central heating  
: Six weekly heating  
programs with six programmable switch points  
per day (one program is active).  
5
4
—
—
DHW  
points per day.  
: weekly DHW program with six switch  
DHW Recirculation pump program.  
Options:  
2x  
2x  
—
—
Remote control and room sensor FB100  
provides status information and a programming  
interface in each zone.  
Fig. 1 FW200 Energy Management System  
1 Controls top section  
2 Base for wall-mounting  
Module ISM2 for solar DHW heating and solar  
space heating support.  
3 Top cover  
4 Installation and operating instructions  
Programs and settings are stored in a permanent  
memory and remain even during power outages.  
5 Outdoor temperature sensor with mounting kit  
Installation options:  
—
—
In the boiler  
Wall-mounted as a remote room sensor  
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Scope of delivery  
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.  
3
2
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.  
8
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).  
1
4
Maximum of four FB100 in a heating system with  
FW200.  
Fig. 2 FB100 Remote Control & Room Sensor  
1 Upper part of remote control  
2 Base for wall-mounting  
In case of power failure, the display will be off. All  
settings are saved.  
3 Top cover  
4 Installation and operating instructions  
Data subject to change  
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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  
FW200  
and primary room sensor  
Remote control for  
FB100  
additional zones  
2 mixed heating zones  
1 mixed heating zone  
+ 1 unmixed heating zone  
+ 1 DHW recirculation pump  
2 unmixed heating zones  
Available  
systems  
+ 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.  
Data subject to change  
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Bosch Greenstar | 9  
2 Applications  
Legend  
Flow check valve  
pipe  
pipe  
Greenstar  
Greenstar boiler  
Greenstar  
Greenstar combi-boiler  
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.  
Bosch Thermotechnology Corp.  
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Bosch Greenstar  
Applications Manual  
List of most common applications  
Single Zone Baseboard Systems:  
System 1: Greenstar Heating Boiler in a single zone  
system (page 13-16).  
System 2: Greenstar Combi-Boiler in a single zone  
system (page 17-20).  
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).  
Data subject to change  
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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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Applications Manual  
Pump curve of heating boiler  
Pump curve of combi boiler (heating side)  
25  
20  
15  
10  
5
25  
20  
15  
10  
5
4
4
3
6
2
4
1
3
2
5
1
0
0
0
1
2
3
4
6
7
8
0
1
2
3
5
7
8
.
.
V / gpm  
V / gpm  
7
6
7
6
5
4
3
2
1
0
5
4
4
4
3
3
2
1
0
2
1
3
2
1
0
400  
800  
1200  
1600  
0
200 400 600 800 1000 1200 1400 1600  
.
.
V / l/h  
V / l/h  
6 720 641 933-59.1O  
6 720 641 933-61.1O  
Fig. 4  
Greenstar boiler pump curves  
Key to Fig. 4  
4
H
V
Head pressure of the boiler pump by itself (at speed 3)  
Head pressure in feet of head (m)  
Circulating water volume in gallons per minute (l/h)  
1
2
3
Residual head pressure at speed 1  
Residual head pressure at speed 2  
Residual head pressure at speed 3 (default setting)  
Data subject to change  
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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  
Data subject to change  
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System 1 - Wiring Diagram  
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16  
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System 1: Setup and Programming  
When done, ensure the mode selector is set to AUTO.  
The room temperature will be displayed.  
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.  
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).  
Initial setup:  
The boiler will always attempt to run at its highest  
efficiency in low fire for as long as necessary.  
See the installation instructions for description of buttons  
and displays, and for details on setup and programming.  
The boiler will shut down when the target temperature  
is reached followed by a 3 minute post purge by the  
pump.  
Power up the boiler.  
When commissioning for the first time set the display  
language, date and time.  
—
The boiler and the pump will start again when  
the supply water temperature drops 18°F (10°C)  
below the set point.  
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.  
Data subject to change  
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Bosch Greenstar | 17  
2.2 System 2: Greenstar Combi Boiler in a  
single zone system  
Summary:  
Additional instructions:  
See manufacturer’s installation and operating instructions.  
Single combi-boiler supplying one baseboard heating  
zone equipped with FW200 outdoor reset controller with  
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.  
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 “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.  
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.  
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.  
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Bosch Greenstar  
Applications Manual  
System 2 - Piping diagram  
Data subject to change  
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System 2 - Wiring diagram  
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20  
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Applications Manual  
System 2: Setup and Programming  
Enter the installer menu to configure the heating zone.  
In this single zone system the FW200 is installed in the  
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.  
—
—
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.  
DHW is generated directly by the combi-boiler without the  
need for a storage tank.  
Set up the weekly program for DHW generation.  
For additional features of the combi boiler see the  
installation manual.  
Initial setup:  
See the installation instructions for description of buttons  
and displays, and for details on setup and programming.  
When done, ensure the mode selector is set to AUTO.  
The room temperature will be displayed.  
Power up the boiler.  
When commissioning for the first time set the display  
language, date and time.  
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).  
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.  
The boiler will always attempt to run at its highest  
efficiency in low fire for as long as necessary.  
Set up the weekly heating program for the three avail-  
able temperature levels:  
The boiler will shut down when the target temperature  
is reached followed by a 3 minute post purge by the  
pump.  
—
—
Comfort  
Economy  
The boiler and the pump will start again when the  
supply water temperature drops 18°F (10°C) below  
the set point.  
—
Frost (Frost protection)  
Take advantage of using one of the preset programs  
from the list or enter a custom program.  
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.  
—
—
—
—
—
—
—
—
—
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.  
Data subject to change  
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Bosch Greenstar | 21  
2.3 System 3: Greenstar Heating Boiler in a  
single zone system with DHW tank loading  
Summary:  
Single boiler supplying one baseboard heating zone  
equipped with FW200 outdoor reset controller with built-  
in room sensor in the living space. This system is using the  
boiler pump for zone water circulation and DHW tank load-  
ing. A diverter valve is used to switch between space heat-  
ing and tank loading. This system is identical to System 1  
with an added indirect fired DHW 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.  
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.  
Ensure to select a DHW tank with a coil pressure drop that  
does not exceed the capacity of the boiler pump.  
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.  
Indirect Fired DHW Tank.  
Diverter valve 120VAC, 3-way, spring return.  
Additional instructions:  
See manufacturer’s installation and operating instructions.  
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Applications Manual  
System 3 - Piping diagram  
Data subject to change  
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Bosch Greenstar | 23  
System 3 - Wiring diagram  
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24  
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Applications Manual  
System 3: Setup and Programming  
Set up the weekly program for DHW tank loading and  
the DHW recirculation pump (if installed). Separate  
individual programs can be set up or the hours of op-  
eration can be linked to the heating program.  
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.  
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.  
Initial setup:  
See the installation instructions for description of buttons  
and displays, and for details on setup and programming.  
—
Set the room influence followed by the  
remaining parameters as applicable.  
Power up the boiler.  
When done, ensure the mode selector is set to AUTO.  
The room temperature will be displayed.  
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.  
Additional information  
With outdoor reset the boiler will provide the water  
temperature according to the heating curve adjusted by  
level of room influence (if enabled).  
Set up the weekly heating program for the three  
available temperature levels:  
The boiler will always attempt to run at its highest  
efficiency in low fire for as long as necessary.  
—
—
Comfort  
Economy  
The boiler will shut down when the target temperature  
is reached followed by a 3 minute post purge by the  
pump.  
—
Frost (Frost protection)  
Take advantage of using one of the preset programs  
from the list or enter a custom program.  
The boiler and the pump will start again when the  
supply water temperature drops 18°F (10°C) below  
the set point.  
—
—
—
—
—
—
—
—
—
Program A  
Program F  
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.  
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.  
Data subject to change  
Bosch Thermotechnology Corp.  
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Applications Manual  
Bosch Greenstar | 25  
2.4 System 4: Greenstar Heating Boiler in a  
single zone system with solar thermal  
DHW and boiler backup  
Summary:  
Required components:  
Single boiler supplying one baseboard heating zone  
equipped with FW200 outdoor reset controller with built-  
in room sensor in the living space . This system is using  
the boiler pump for zone water circulation and DHW tank  
loading. A diverter valve is used to switch between space  
heating and tank loading. This system is identical to Sys-  
tem 3 with an added solar thermal DHW heating system.  
Greenstar combi-boiler.  
FW200 controller in the room.  
ISM2.  
DHW solar tank with 2 coils.  
Bosch solar thermal system complete.  
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.  
Diverter valve 120VAC, 3-way, spring return.  
Additional instructions:  
See manufacturer’s installation and operating instructions.  
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.  
The Bosch Greenstar boiler and ISM2 offer many different  
solar thermal applications including space heating sup-  
port and pool heating. Please consult the installation and  
operating instructions for details.  
Ensure to select a solar tank with a boiler coil pressure  
drop that does not exceed the capacity of the boiler pump  
(see pages 11 & 12 for details).  
Solar thermal provides renewable energy to heat DHW year  
round, and if sized properly reduce energy consumption  
significantly. Bosch offers plug and play components  
that are designed to work together with a boiler backup  
system. Bosch solar thermal systems are qualified for  
government and utility incentives reducing the upfront  
investment cost significantly. Bosch solar thermal  
collectors work even in the winter and under cloudy skies  
preheating water, and reducing boiler run time and burner  
starts.  
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.  
The control of the solar thermal system is integrated with  
the FW200 boiler control, and reduces boiler run time and  
burner starts significantly compared to independent sys-  
tems. The solar pump will run whenever the collectors are  
16°F (9°C) warmer than the bottom of the solar tank.  
It is recommended to double the volume of the solar  
thermal DHW tank compared to an equivalent conventional  
indirect fired DHW tank. This allows sufficient backup  
volume ("comfort zone") maintained by the boiler without  
sacrificing capacity for solar harvesting.  
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26  
Bosch Greenstar  
Applications Manual  
System 4 - Piping diagram  
R1  
Data subject to change  
Bosch Thermotechnology Corp.  
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Applications Manual  
Bosch Greenstar | 27  
System 4 - Wiring diagram  
R1  
Bosch Thermotechnology Corp.  
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28  
Bosch Greenstar  
Applications Manual  
System 4: Setup and Programming  
Set up the weekly program for DHW tank loading and  
the DHW recirculation pump (if installed). Separate  
individual programs can be set up or the hours of op-  
eration can be linked to the heating program.  
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.  
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.  
Initial setup:  
See the installation instructions for description of buttons  
and displays, and for details on setup and programming.  
—
Set the room influence followed by the  
remaining parameters as applicable.  
Power up the boiler.  
Proceed in the installer menu to configure the solar  
thermal system. The solar system requires manual  
configuration.  
Use the FW200 for programming the heating system.  
When commissioning for the first time, set the display  
language, date and time.  
—
—
Run solar system: Yes  
Solar system parameters: Standard system.  
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 options A2 to E as required.  
It is recommended to keep the factory default  
solar system parameters.  
Exit the installer menu.  
Set up the weekly heating program for the three  
available temperature levels:  
When done, ensure the mode selector is set to AUTO.  
The room temperature will be displayed.  
—
—
Comfort  
Economy  
—
Frost (Frost protection)  
Additional information  
Take advantage of using one of the preset programs  
from the list or enter a custom program.  
The solar thermal system will start harvesting energy once  
the collector temperature is at least 16°F (9°C) warmer  
than the bottom of the solar tank. The upper half of the  
solar tank ("comfort zone") is maintained at temperature  
as set in the DHW programming. The lower half is available  
for solar harvesting.  
—
—
—
—
—
—
—
—
—
Program A  
Program F  
AM weekday worker  
PM weekday worker  
All day  
With outdoor reset the boiler will provide the water  
temperature according to the heating curve adjusted by  
the level of room influence (if enabled).  
All day, lunch  
Family  
The boiler will always attempt to run at its highest  
efficiency in low fire for as long as necessary.  
All day, early shift  
All day, late shift  
The boiler will shut down when the target temperature  
is reached followed by a 3 minute post purge by the  
pump.  
—
Seniors  
The boiler and the pump will start again when the  
supply water temperature drops 18°F (10°C) below  
the set point.  
Set the room temperatures for the three specified  
temperature levels.  
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.  
Data subject to change  
Bosch Thermotechnology Corp.  
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Applications Manual  
Bosch Greenstar | 29  
2.5 System 5: Greenstar Heating Boiler in a  
single zone system  
Summary:  
Single boiler with primary/secondary piping configuration  
supplying one heating zone. Outdoor reset with FW200  
controller with built-in room sensor mounted in the living  
space for room feedback.  
Use this design where System 1 cannot be used due to too  
great a system pressure drop. Primary/secondary piping is  
also required for radiant floor and panel radiator applica-  
tions.  
Primary/secondary piping isolates the system flow from  
the boiler flow and prevents the system from influencing  
boiler performance.  
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  
as a room sensor, it uses room temperature to adjust the  
heating curve and modify boiler supply temperature ac-  
cordingly.  
FW200 provides warm weather shutdown.  
For temperature sensitive radiant floor applications, install  
a thermostatic tempering valve for overheat protection.  
Required components:  
Greenstar heating boiler.  
FW200 controller in the room.  
Primary/secondary piping and system pump.  
Thermostatic mixing valve (optional - overheat  
protection for temperature sensitive floors).  
Additional instructions:  
See manufacturer’s installation and operating instructions.  
Bosch Thermotechnology Corp.  
Data subject to change  
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30  
Bosch Greenstar  
Applications Manual  
System 5 - Piping diagram  
Data subject to change  
Bosch Thermotechnology Corp.  
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Applications Manual  
Bosch Greenstar | 31  
System 5 - Wiring diagram  
Bosch Thermotechnology Corp.  
Data subject to change  
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32  
Bosch Greenstar  
Applications Manual  
System 5: Setup and Programming  
Enter the installer menu to configure the heating zone.  
In this single zone system the FW200 is installed in the  
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.  
—
Set heating circuit to the type of heat  
distribution system used.  
—
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.  
Initial setup:  
See the installation instructions for description of buttons  
and displays, and for details on setup and programming.  
Set up the weekly program for DHW generation.  
When done, ensure the mode selector is set to AUTO.  
The room temperature will be displayed.  
Power up the boiler.  
When commissioning for the first time set the display  
language, date and time.  
Additional information  
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.  
With outdoor reset the boiler will provide the water  
temperature according to the heating curve adjusted by  
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.  
Set up the weekly heating program for the three  
available temperature levels:  
The boiler will shut down when the target temperature  
is reached followed by a 3 minute post purge by the  
pump.  
—
—
Comfort  
Economy  
—
Frost (Frost protection)  
The boiler and the pump will start again when the  
supply water temperature drops 18°F (10°C) below  
the set point.  
Take advantage of using one of the preset programs  
from the list or enter a custom program.  
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.  
—
—
—
—
—
—
—
—
—
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.  
Data subject to change  
Bosch Thermotechnology Corp.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Applications Manual  
Bosch Greenstar | 33  
2.6 System 6: Greenstar Combi Boiler in a  
single zone system  
Summary:  
Additional instructions:  
See manufacturer’s installation and operating instructions.  
Single combi-boiler supplying one heating zone. Outdoor  
reset with FW200 controller with built-in room sensor  
mounted in the living space for room feedback. DHW  
generation directly off the boiler through the tankless heat  
exchanger. This system is using the boiler pump for zone  
water circulation.  
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 “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.  
The Greenstar combi boiler is equipped with an internal  
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.  
Single boiler with primary/secondary piping configuration  
supplying one heating zone. Outdoor reset with FW200  
controller and room sensor mounted in the living space for  
room feedback.  
Use this design where System 2 cannot be used due to too  
great a system pressure drop. Primary/secondary piping is  
also required for radiant floor and panel radiator applica-  
tions.  
Primary/secondary piping isolates the system flow from  
the boiler flow and prevents the system from influencing  
boiler performance.  
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  
as a room sensor, it uses room temperature to adjust the  
heating curve and modify boiler supply temperature ac-  
cordingly.  
FW200 provides warm weather shutdown.  
For temperature sensitive radiant floor applications, install  
a thermostatic tempering valve for overheat protection.  
Required components:  
Greenstar combi-boiler.  
FW200 controller in the room.  
Primary/secondary piping and system pump.  
Thermostatic mixing valve (optional - overheat  
protection for temperature sensitive floors).  
Bosch Thermotechnology Corp.  
Data subject to change  
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34  
Bosch Greenstar  
Applications Manual  
System 6 - Piping diagram  
Data subject to change  
Bosch Thermotechnology Corp.  
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Applications Manual  
Bosch Greenstar | 35  
System 6 - Wiring diagram  
Bosch Thermotechnology Corp.  
Data subject to change  
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36  
Bosch Greenstar  
Applications Manual  
System 6: Setup and Programming  
Enter the installer menu to configure the heating zone.  
In this single zone system the FW200 is installed in the  
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.  
—
Set heating circuit to the type of heat  
distribution system used.  
—
Set the minimum outdoor temperature, building  
storage capacity, design day temperature, and  
maximum supply temperature.  
DHW is generated directly by the combi-boiler without the  
need for a storage tank.  
—
Set the room influence followed by the  
remaining parameters as applicable.  
Set up the weekly program for DHW generation.  
Initial setup:  
For additional features of the combi boiler see the  
installation manual.  
See the installation instructions for description of buttons  
and displays, and for details on setup and programming.  
When done, ensure the mode selector is set to AUTO.  
The room temperature will be displayed.  
Power up the boiler.  
When commissioning for the first time set the display  
language, date and time.  
Additional information  
With outdoor reset the boiler will provide the water  
temperature according to the heating curve adjusted by  
the level of room influence (if enabled).  
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.  
The boiler will always attempt to run at its highest  
efficiency in low fire for as long as necessary.  
Set up the weekly heating program for the three  
available temperature levels:  
The boiler will shut down when the target temperature  
is reached followed by a 3 minute post purge by the  
pump.  
—
—
Comfort  
Economy  
The boiler and the pump will start again when the  
supply water temperature drops 18°F (10°C) below  
the set point.  
—
Frost (Frost protection)  
Take advantage of using one of the preset programs  
from the list or enter a custom program.  
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.  
—
—
—
—
—
—
—
—
—
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.  
Data subject to change  
Bosch Thermotechnology Corp.  
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Applications Manual  
Bosch Greenstar | 37  
2.7 System 7: Greenstar Heating Boiler in a  
single zone system with DHW tank loading  
Summary:  
Single boiler with primary/secondary piping configuration  
supplying one heating zone. Outdoor reset with FW200  
controller with built-in room sensor mounted in the living  
space for room feedback.  
Use this design where System 3 cannot be used due to  
too great a system pressure drop. Primary/secondary  
piping is also required for radiant floor and panel radiator  
applications.  
Primary/secondary piping isolates the system flow from  
the boiler flow and prevents the system from influencing  
boiler performance.  
This system is identical to System 5 with an added indirect  
fired DHW tank.  
Use this system over System 6 where the combi-boiler  
does not have the required DHW volume flow capacity;  
keep in mind however that the tank capacity is not endless  
compared to that of the combi-boiler.  
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  
as a room sensor, it uses room temperature to adjust the  
heating curve and modify boiler supply temperature ac-  
cordingly.  
FW200 provides warm weather shutdown.  
For temperature sensitive radiant floor applications, install  
a thermostatic tempering valve for overheat protection.  
Required components:  
Greenstar heating boiler.  
FW200 controller in the room.  
Primary/secondary piping and system pump.  
Thermostatic mixing valve (optional - overheat  
protection for temperature sensitive floors).  
Indirect Fired DHW Tank.  
Tank loading pump of sufficient capacity.  
Additional instructions:  
See manufacturer’s installation and operating instructions.  
Bosch Thermotechnology Corp.  
Data subject to change  
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38  
Bosch Greenstar  
Applications Manual  
System 7 - Piping diagram  
Data subject to change  
Bosch Thermotechnology Corp.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Applications Manual  
Bosch Greenstar | 39  
System 7 - Wiring diagram  
Bosch Thermotechnology Corp.  
Data subject to change  
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40  
Bosch Greenstar  
Applications Manual  
System 7: Setup and Programming  
Enter the installer menu to configure the heating zone.  
In this single zone system the FW200 is installed in the  
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.  
—
Set heating circuit to the type of heat  
distribution system used.  
—
Set the minimum outdoor temperature, building  
storage capacity, design day temperature, and  
maximum supply temperature.  
DHW is generated directly by the combi-boiler without the  
need for a storage tank.  
—
Set the room influence followed by the  
remaining parameters as applicable.  
Set up the weekly program for DHW generation.  
When done, ensure the mode selector is set to AUTO.  
The room temperature will be displayed.  
Initial setup:  
See the installation instructions for description of buttons  
and displays, and for details on setup and programming.  
Power up the boiler.  
Additional information  
When commissioning for the first time, set the display  
language, date and time.  
With outdoor reset the boiler will provide the water  
temperature according to the heating curve adjusted by  
the level of room influence (if enabled).  
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.  
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.  
Set up the weekly heating program for the three  
available temperature levels:  
—
—
Comfort  
Economy  
The boiler and the pump will start again when the  
supply water temperature drops 18°F (10°C) below  
the set point.  
—
Frost (Frost protection)  
When a demand for DHW is sensed by the DHW tank  
temperature sensor, the boiler will go into DHW mode.  
When DHW is satisfied, or after one hour, the boiler  
will return to space heating mode.  
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.  
Data subject to change  
Bosch Thermotechnology Corp.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Applications Manual  
Bosch Greenstar | 41  
2.8 System 8: Greenstar Heating Boiler in a  
single zone system with room thermostat  
and DHW tank loading  
Required components:  
Summary:  
Single boiler with primary/secondary piping configuration  
supplying one heating zone. Outdoor reset with FW200  
controller mounted on the boiler. 3rd party room thermo-  
stat used to communicate heat demand.  
Greenstar heating boiler.  
FW200 controller in the room.  
Primary/secondary piping and system pump.  
This system is identical to System 7 except that it does not  
feature constant circulation. The system circulator runs  
only when a heat demand is communicated by the room  
thermostat and shut off when the heat demand goes away.  
Thermostatic mixing valve (optional - overheat  
protection for temperature sensitive floors).  
3rd party room thermostat ; self powered with dry  
contact closure.  
Use this design where Systems 1 through 4 cannot be  
used due to too great a system pressure drop. Primary/  
secondary piping is also required for radiant floor and  
panel radiator applications.  
Indirect Fired DHW Tank.  
Tank loading pump of sufficient capacity.  
Primary/secondary piping isolates the system flow from  
the boiler flow and prevents the system from influencing  
boiler performance.  
Additional instructions:  
See manufacturer’s installation and operating instructions.  
This system is designed for installations with other  
heat sources, e.g. wood stoves or significant solar gain.  
Compared to systems with the FW200 installed in the  
room that will throttle down the boiler output when the  
room reaches its set point, in this setup the thermostat  
will shut the boiler off.  
This system can also be used with a combi boiler (see  
system 6) instead of the indirect fired DHW tank.  
In detail:  
This system runs on pure outdoor reset without room  
feedback on the heating curve. The FW200 installed  
in the boiler adjusts the heating curve (boiler supply  
temperature) according to outdoor temperature. The 3rd  
party room thermostat turns the boiler on and off based  
on the conditions in the living space.  
FW200 provides warm weather shutdown.  
For temperature sensitive radiant floor applications, install  
a thermostatic tempering valve for overheat protection.  
Bosch Thermotechnology Corp.  
Data subject to change  
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42  
Bosch Greenstar  
Applications Manual  
System 8 - Piping diagram  
Data subject to change  
Bosch Thermotechnology Corp.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Applications Manual  
Bosch Greenstar | 43  
System 8 - Wiring diagram  
Bosch Thermotechnology Corp.  
Data subject to change  
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44  
Bosch Greenstar  
Applications Manual  
System 8: Setup and Programming  
Additional information  
In this single zone system the FW200 is installed in the  
boiler for pure outdoor reset without room influence.  
With outdoor reset the boiler will provide the water  
temperature according to the heating curve. There is no  
Install a suitable 3rd party thermostat in the living space in room influence on the heating curve in this system. When  
a location that represents the entire zone. Avoid locations  
exposed to direct or indirect sunlight, heat sources, draft,  
etc. that can lead to malfunctioning.  
the zone is satisfied the boiler and pump will shut off.  
The boiler will always attempt to run at its highest  
efficiency in low fire for as long as necessary.  
DHW is generated by the boiler loading the indirect fired  
DHW tank following the DHW program.  
The boiler will shut down when the target temperature  
is reached followed by a 3 minute post purge by  
the pump unless the 3rd party room thermostat is  
satisfied prior.  
Initial setup:  
When a demand for DHW is sensed by the DHW tank  
temperature sensor, the boiler will go into DHW mode.  
When DHW is satisfied, or after one hour, the boiler  
will return to space heating mode.  
Program the 3rd party room thermostat according to the  
manufacturer's instructions. it is recommended to set up a  
day and night heating program with reduced temperatures  
at night and when the home is unoccupied.  
Boiler and FW200 programming:  
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 the boiler for permanent day mode by switching  
the dial on the FW200 to  
—
Comfort  
Enter the installer menu to configure the heating zone.  
—
—
Set heating circuit to the type of heat  
distribution system used.  
Set the minimum outdoor temperature, building  
storage capacity, design day temperature, and  
maximum supply temperature.  
Set up the weekly program for DHW generation.  
When done, ensure the mode selector is set to AUTO.  
The room temperature will be displayed.  
Data subject to change  
Bosch Thermotechnology Corp.  
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Applications Manual  
Bosch Greenstar | 45  
2.9 System 9: Greenstar Heating Boiler in a  
single zone system with solar thermal  
DHW and boiler backup  
Required components:  
Summary:  
Single boiler with primary/secondary piping configuration  
supplying one heating zone. Outdoor reset with FW200  
controller with built-in room sensor mounted in the living  
space for room feedback.  
Greenstar heating boiler.  
FW200 controller in the room.  
Primary/secondary piping and system pump.  
Use this design where System 4 cannot be used due to too  
great a system pressure drop. Primary/secondary piping is  
also required for radiant floor and panel radiator applica-  
tions.  
Thermostatic mixing vavle (optional - overheat  
protection for temperature sensitive floors).  
ISM2.  
Primary/secondary piping isolates the system flow from  
the boiler flow and prevents the system from influencing  
boiler performance.  
DHW solar tank with 2 coils.  
Bosch solar thermal system complete.  
Tank loading pump of sufficient capacity.  
Solar thermal provides renewable energy to heat DHW year  
round, and if sized properly reduce energy consumption  
significantly. Bosch offers plug and play components  
that are designed to work together with a boiler backup  
system. Bosch solar thermal systems are qualified for  
government and utility incentives reducing the upfront  
investment cost significantly. Bosch solar thermal  
collectors work even in the winter and under cloudy skies  
preheating water, and reducing boiler run time and burner  
starts.  
Additional instructions:  
See manufacturer’s installation and operating instructions.  
The Bosch Greenstar boiler and ISM2 offer many different  
solar thermal applications including space heating sup-  
port and pool heating. Please consult the installation and  
operating instructions for details.  
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  
as a room sensor, it uses room temperature to adjust the  
heating curve and modify boiler supply temperature ac-  
cordingly.  
FW200 provides warm weather shutdown.  
The control of the solar thermal system is integrated with  
the FW200 boiler control, and reduces boiler run time  
and burner starts significantly compared to independent  
systems. The solar pump will run whenever the collectors  
are 16°F (9°C) warmer than the bottom of the solar tank.  
For temperature sensitive radiant floor applications install  
a thermostatic tempering valve for overheat protection.  
Bosch Thermotechnology Corp.  
Data subject to change  
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46  
Bosch Greenstar  
Applications Manual  
System 9 - Piping diagram  
R1  
Data subject to change  
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Applications Manual  
Bosch Greenstar | 47  
System 9 - Wiring diagram  
R1  
Bosch Thermotechnology Corp.  
Data subject to change  
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48  
Bosch Greenstar  
Applications Manual  
System 9: Setup and Programming  
Set up the weekly program for DHW tank loading and  
the DHW recirculation pump (if installed). Separate  
individual programs can be set up or the hours of op-  
eration can be linked to the heating program.  
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.  
Enter the installer menu to configure the heating zone.  
—
Set heating circuit to the type of heat  
distribution used.  
—
Set the minimum outdoor temperature, building  
storage capacity, design day temperature, and  
maximum supply temperature.  
Initial setup:  
See the installation instructions for description of buttons  
and displays, and for details on setup and programming.  
Proceed in the installer menu to configure the solar  
thermal system. (The solar system requires manual  
configuration).  
Power up the boiler.  
Use the FW200 for programming the heating system.  
—
—
Run solar system: Yes  
Solar system parameters: Standard system.  
When commissioning for the first time set the display  
language, date and time.  
—
—
Set options A2 to E as required.  
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.  
It is recommended to keep the factory default  
solar sys parameters.  
Exit the installer menu.  
When done, ensure the mode selector is set to AUTO.  
The room temperature will be displayed.  
Set up the weekly heating program for the three  
available temperature levels:  
—
—
Comfort  
Economy  
Additional information  
The solar thermal system will start harvesting energy  
once the collector temperature is at least 16°F (9°C)  
warmer than the bottom of the solar tank. The upper  
half of the solar tank ("comfort zone") is maintained at  
temperature by the boiler during DHW day mode as set in  
the DHW programming. The lower half is available for solar  
harvesting.  
—
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  
With outdoor reset the boiler will provide the water  
temperature 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.  
All day, lunch  
Family  
The boiler will shut down when the target temperature  
is reached followed by a 3 minute post purge by the  
pump.  
All day, early shift  
All day, late shift  
The boiler and the pump will start again when the  
supply water temperature drops 18°F (10°C) below  
the set point.  
—
Seniors  
Set the room temperatures for the three specified  
temperature levels.  
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.  
Data subject to change  
Bosch Thermotechnology Corp.  
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Applications Manual  
Bosch Greenstar | 49  
2.10 System 10: Greenstar Heating Boiler with  
zone pumps and room thermostats  
Summary:  
Required components:  
Single boiler with primary/secondary piping configura-  
tion supplying multiple heating zones. Outdoor reset with  
FW200 controller mounted on the boiler. 3rd party room  
thermostats are used to communicate zone heat demands.  
Greenstar heating boiler.  
FW200 controller in the boiler.  
Primary/secondary piping and system pump.  
This system is identical to System 8 expanded to multiple  
zones. The zone circulators run only when a heat demand  
is communicated by the room thermostat and shut off  
when the heat demand goes away.  
Thermostatic mixing vavle (optional - overheat  
protection for temperature sensitive floors).  
3rd party room thermostats with dry contact closure  
in each zone.  
Primary/secondary piping isolates the system flow from  
the boiler flow and prevents the system from influencing  
boiler performance.  
Indirect Fired DHW Tank.  
Tank loading pump of sufficient capacity.  
This system works particularly well for installations with  
other heat sources, e.g. wood stoves or significant solar  
gain. Compared to systems with the FW200 installed in the  
room that will throttle down the boiler output when the  
room reaches its set point, in this setup the thermostat  
will shut the boiler off.  
Additional instructions:  
See manufacturer’s installation and operating instructions.  
This system can also be used with a combi boiler (see  
system 6) instead of the indirect fired DHW tank.  
In detail:  
This system runs on pure outdoor reset without room  
feedback on the heating curve. The FW200 installed in the  
boiler adjusts the heating curve (boiler supply tempera-  
ture) according to outdoor temperature. The 3rd party  
room thermostats turn the boiler on and off based on the  
conditions in the living space.  
FW200 provides warm weather shutdown.  
For temperature sensitive radiant floor applications install  
a thermostatic tempering valve for overheat protection.  
Bosch Thermotechnology Corp.  
Data subject to change  
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|
50  
Bosch Greenstar  
Applications Manual  
System 10 - Piping diagram  
Data subject to change  
Bosch Thermotechnology Corp.  
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Applications Manual  
Bosch Greenstar | 51  
System 10 - Wiring diagram  
Bosch Thermotechnology Corp.  
Data subject to change  
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52  
Bosch Greenstar  
Applications Manual  
System 10: Setup and Programming  
Additional information  
In this dual zone system the FW200 is installed in the  
boiler for pure outdoor reset without room influence on  
the heating curve.  
With outdoor reset the boiler will provide the water  
temperature according to the heating curve. There is no  
room influence on the heating curve in this system.  
The boiler will always attempt to run at its highest  
efficiency in low fire for as long as necessary.  
Install suitable 3rd party thermostats in each zone in  
a location that best represents its conditions. Avoid  
locations exposed to direct or indirect sunlight, heat  
sources, draft, etc. that can lead to malfunctioning.  
The boiler will shut down when the target temperature  
is reached followed by a 3 minute post purge by  
the pump unless the 3rd party room thermostat is  
satisfied prior.  
DHW is generated by the boiler loading the indirect fired  
DHW tank following the DHW program.  
During DHW day mode the boiler will charge the DHW  
tank when a demand is sensed by the DHW tank tem-  
perature sensor. When DHW is satisfied, or after one  
hour, the boiler will return to space heating mode.  
Initial setup:  
Program the 3rd party room thermostats according to the  
manufacturer's instructions. It is recommended to set up a  
day and night heating program with reduced temperatures  
at night and when the zone is unoccupied.  
Boiler and FW200 programming:  
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 the boiler for permanent day mode by switching  
the dial on the FW200 to  
—
Comfort  
Set the room temperatures for the three specified  
temperature levels.  
Enter the installer menu to configure the heating zone.  
—
Set heating circuit to the type of heat  
distribution used.  
—
Set the minimum outdoor temperature, building  
storage capacity, design day temperature, and  
maximum supply temperature.  
—
Set the remaining parameters as applicable.  
Set up the weekly program for DHW generation.  
When done, ensure the mode selector is set to AUTO.  
The room temperature will be displayed.  
Data subject to change  
Bosch Thermotechnology Corp.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Applications Manual  
Bosch Greenstar | 53  
2.11 System 11: Greenstar Heating Boiler  
with zone pumps, relay panel, room  
thermostats and DHW tank loading  
Summary:  
Required components:  
Single boiler with primary/secondary piping configuration  
supplying three heating zones controlled by individual  
zone thermostats and a pump relay panel. Outdoor reset  
with FW200 controller mounted on the boiler. 3rd party  
room thermostats used to communicate heat demands  
from the zones.  
Greenstar heating boiler.  
FW200 controller in the boiler.  
Primary/secondary piping and system pump.  
Thermostatic mixing valve (optional - overheat  
protection for temperature sensitive floors).  
This system does not feature constant circulation and the  
zone circulators runs only when a heat demand is com-  
municated by the room thermostat and shut off when the  
heat demand goes away. It is similar to Systems 8 and 10  
except that a pump relay panel is being used.  
3rd party room thermostats with dry contact closure  
in each zone.  
Zone pump relay panel, e.g. TACO SR503 or similar.  
Indirect fired DHW tank.  
Primary/secondary piping isolates the system flow from  
the boiler flow and prevents the system from influencing  
boiler performance.  
Tank loading pump of sufficient capacity.  
This system works particularly well for installations with  
other heat sources, e.g. wood stoves or significant solar  
gain. Compared to systems with the FW200 installed in the  
room that will throttle down the boiler output when the  
room reaches its set point, in this setup the thermostat  
will shut the boiler off.  
Additional instructions:  
See manufacturer’s installation and operating instructions.  
This system can also be used with a combi boiler (see  
system 6) instead of the indirect fired DHW tank.  
In detail:  
This system runs on pure outdoor reset without room  
feedback on the heating curve. The FW200 installed in the  
boiler adjusts the heating curve (boiler supply tempera-  
ture) according to outdoor temperature. The 3rd party  
room thermostats turn the boiler and the zone pumps on  
and off based on the conditions in the living space.  
FW200 provides warm weather shutdown.  
For temperature sensitive radiant floor applications install  
a thermostatic tempering valve for overheat protection.  
Bosch Thermotechnology Corp.  
Data subject to change  
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|
54  
Bosch Greenstar  
Applications Manual  
System 11 - Piping diagram  
Data subject to change  
Bosch Thermotechnology Corp.  
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Applications Manual  
Bosch Greenstar | 55  
System 11 - Wiring diagram  
Bosch Thermotechnology Corp.  
Data subject to change  
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|
56  
Bosch Greenstar  
Applications Manual  
System 11: Setup and Programming  
Additional information  
In this multi zone system the FW200 is installed in the  
boiler for pure outdoor reset without room influence on  
the heating curve.  
With outdoor reset the boiler will provide the water  
temperature according to the heating curve. There is no  
room influence on the heating curve in this system.  
The boiler will always attempt to run at its highest  
efficiency in low fire for as long as necessary.  
Install suitable 3rd party thermostats in each zone in  
a location that best represents its conditions. Avoid  
locations exposed to direct or indirect sunlight, heat  
sources, draft, etc. that can lead to malfunctioning.  
The boiler will shut down when the target temperature  
is reached followed by a 3 minute post purge by  
the pump unless the 3rd party room thermostat is  
satisfied prior.  
DHW is generated by the boiler loading the indirect fired  
DHW tank following the DHW program. This system can  
also be realized with a combi boiler eliminating the DHW  
tank if the capacity is sufficient for the DHW load.  
During DHW day mode the boiler will charge the DHW  
tank when a demand is sensed by the DHW tank tem-  
perature sensor. When DHW is satisfied, or after one  
hour, the boiler will return to space heating mode.  
Initial setup:  
Program the 3rd party room thermostats according to the  
manufacturer's instructions. It is recommended to set up a  
day and night heating program with reduced temperatures  
at night and when the zone is unoccupied.  
Boiler and FW200 programming:  
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 the boiler for permanent day mode by switching  
the dial on the FW200 to  
—
Comfort  
Set the room temperatures for the  
three specified temperature levels.  
Enter the installer menu to configure the heating zone.  
—
Set heating circuit to the type of heat  
distribution used.  
—
Set the minimum outdoor temperature, building  
storage capacity, design day temperature, and  
maximum supply temperature.  
—
Set the remaining parameters as applicable.  
Set up the weekly program for DHW generation.  
When done, ensure the mode selector is set to AUTO.  
The room temperature will be displayed.  
Data subject to change  
Bosch Thermotechnology Corp.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Applications Manual  
Bosch Greenstar | 57  
2.12 System 12: Greenstar Heating Boiler with  
zone valves and room thermostats  
Summary:  
Required components:  
Single boiler with primary/secondary piping configura-  
tion supplying three heating zones controlled by 3rd party  
room thermostats with zone valves. Outdoor reset with  
FW200 controller mounted on the boiler.  
Greenstar heating boiler.  
FW200 controller in the boiler.  
Primary/secondary piping and system pump.  
The zone circulator runs only when a heat demand is com-  
municated by the room thermostats and shut off when the  
heat demand goes away.  
Thermostatic mixing valve (optional - overheat  
protection for temperature sensitive floors).  
3rd party room thermostats with dry contact closure  
in each zone.  
Primary/secondary piping isolates the system flow from  
the boiler flow and prevents the system from influencing  
boiler performance.  
Zone valve panel (e.g. TACO ZVC403 or similar).  
Zone pump (ECM recommended).  
Indirect fired DHW tank.  
This setup allows the use of a low energy ECM pump (e.g.  
Grundfos Alpha) that adjusts the flow rate based on back  
pressure depending on the number of zones calling.  
This system works particularly well for installations with  
other heat sources, e.g. wood stoves or significant solar  
gain. Compared to systems with the FW200 installed in the  
room that will throttle down the boiler output when the  
room reaches its set point, in this setup the thermostat  
will shut the boiler off.  
Tank loading pump of sufficient capacity.  
Additional instructions:  
See manufacturer’s installation and operating instructions.  
This system can also be used with a combi boiler (see  
system 6) instead of the indirect fired DHW tank.  
In detail:  
This system runs on pure outdoor reset without room  
feedback on the heating curve. The FW200 installed in the  
boiler adjusts the heating curve (boiler supply tempera-  
ture) according to outdoor temperature.  
The 3rd party room thermostats turn the boiler and the  
zone pump on and off based on the conditions in the living  
space.  
FW200 provides warm weather shutdown.  
For temperature sensitive radiant floor applications install  
a thermostatic tempering valve for overheat protection.  
Bosch Thermotechnology Corp.  
Data subject to change  
Download from Www.Somanuals.com. All Manuals Search And Download.  
|
58  
Bosch Greenstar  
Applications Manual  
System 12 - Piping diagram  
Data subject to change  
Bosch Thermotechnology Corp.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Applications Manual  
Bosch Greenstar | 59  
System 12 - Wiring diagram  
Bosch Thermotechnology Corp.  
Data subject to change  
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|
60  
Bosch Greenstar  
Applications Manual  
System 12: Setup and Programming  
Set up the weekly program for DHW generation.  
When done, ensure the mode selector is set to AUTO.  
The room temperature will be displayed.  
In this multi zone system the FW200 is installed in the  
boiler for pure outdoor reset without room influence  
on the heating curve. Zone control is handled by a zone  
valve panel with room thermostats in each zone. Use of  
an ECM pump (e.g. Grundfos Alpha) for a zone pump  
recommended to reduce energy consumption, risk of noisy  
pipes, and to establish a constant delta T.  
Additional information  
With outdoor reset the boiler will provide the water  
temperature according to the heating curve. There is no  
room influence on the heating curve in this system.  
Install suitable 3rd party thermostats in each zone in  
a location that best represents its conditions. Avoid  
locations exposed to direct or indirect sunlight, heat  
sources, draft, etc. that can lead to malfunctioning.  
The boiler will always attempt to run at its highest  
efficiency in low fire for as long as necessary.  
DHW is generated by the boiler loading the indirect fired  
DHW tank following the DHW program. This system can  
also be realized with a combi boiler eliminating the DHW  
tank if the capacity is sufficient for the DHW load.  
The boiler will shut down when the target temperature  
is reached followed by a 3 minute post purge by  
the pump unless the 3rd party room thermostat is  
satisfied prior.  
Initial setup:  
During DHW day mode the boiler will charge the DHW  
tank when a demand is sensed by the DHW tank tem-  
perature sensor. When DHW is satisfied, or after one  
hour, the boiler will return to space heating mode.  
Program the 3rd party room thermostats according to the  
manufacturer's instructions. It is recommended to set up a  
day and night heating program with reduced temperatures  
at night and when the zone is unoccupied.  
Boiler and FW200 programming:  
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 the boiler for permanent day mode by switching  
the dial on the FW200 to  
—
Comfort  
Set the room temperatures for the three specified  
temperature levels.  
Enter the installer menu to configure the heating zone.  
—
Set heating circuit to the type of heat  
distribution used.  
—
Set the minimum outdoor temperature, building  
storage capacity, design day temperature, and  
maximum supply temperature.  
—
Set the remaining parameters as applicable.  
Data subject to change  
Bosch Thermotechnology Corp.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Applications Manual  
Bosch Greenstar | 61  
Bosch Thermotechnology Corp.  
Data subject to change  
Download from Www.Somanuals.com. All Manuals Search And Download.  
|
62  
Bosch Greenstar  
Applications Manual  
Data subject to change  
Bosch Thermotechnology Corp.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Applications Manual  
Bosch Greenstar | 63  
Bosch Thermotechnology Corp.  
Data subject to change  
Download from Www.Somanuals.com. All Manuals Search And Download.  
United States and Canada  
Bosch Thermotechnology Corp.  
50 Wentworth Avenue  
Londonderry, NH 03053  
Tel: 603-552-1100  
Fax: 603-584-1681  
www.bosch-climate.us  
BTC 436001101 A / 07.2011  
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