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Bosch Greenstar

Applications Manual

Bosch Thermotechnology Corp.

Data subject to change

Multi Zone Systems using Zone Valves

System # 17 Greenstar Combi WallBoiler

Multi zone system using zone valves with standard zone relay (FW200 optional)

System # 18 Greenstar Combi Wall Boiler

Multi zone system using zone valves and Bosch Comfort Zone Manager (CZM100)

System # 19 Greenstar Combi Floor Boiler

Multi zone system using zone valveswith standard zone relay (FW200 optional)

System # 20 Greenstar Combi Floor Boiler

Multi zone system using zone valves and Bosch Comfort Zone Manager (CZM100)

System # 21 Greenstar Heat Only Wall Boiler

Multi zone system using zone valves with standard zone relay (FW200 optional) and indirect tank

System # 22 Greenstar Heat Only Wall Boiler

Multi zone system using zone valves and Bosch Comfort Zone Manager (CZM100) and indirect tank

System # 23 Greenstar Heat Only Floor Boiler

Multi zone system using zone valves with standard zone relay (FW200 optional) and indirect tank

System # 24 Greenstar Heat Only Floor Boiler

Multi zone system using zone valves and Bosch Comfort Zone Manager (CZM100) and indirect tank

Single & Multi Zone Systems using Bosch Control

System # 25 Greenstar Combi Wall Boiler

Single zone baseboard with Bosch Control

System # 26 Greenstar Combi Floor Boiler

Single zone baseboard with Bosch Control

System # 27 Greenstar Heat Only Wall Boiler

Single zone baseboard with Bosch Control

System # 28 Greenstar Heat Only Floor Boiler

Single zone system with Bosch Control

System # 29 Greenstar Heat Only Wall Boiler

Single zone system with Bosch Control and indirect tank

System # 30 Greenstar Combi Wall Boiler

Multi zone system using circulators and Bosch Control with standard zone relay

Appendices

Appendix A Comfort Room Controller (CRC100) Quick set-up guide

Appendix B Primary/Secondary Piping requirements for Greenstar Wall Boiler

Appendix C FW200 Quick Set-up Guide

Appendix D Wiring of Hydro-Level Low Water Cut-off for Greenstar Wall Boiler

Appendix E Wiring of Hydro-Level Low Water Cut-off for Greenstar Floor Boiler

Summary of Contents for FS 100

Page 1: ...y 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...

Page 2: ...2 Bosch Greenstar Applications Manual Bosch Thermotechnology Corp Data subject to change ...

Page 3: ... Zone Baseboard with Bosch CRC control 20 Multi Zone Systems using Circulators 22 System 9 Greenstar Combi Wall Boiler Multi zone system using circulators with standard zone relay FW200 optional 22 System 10 Greenstar Combi Wall Boiler Multi zone system using circulators and Bosch Comfort Zone Manager CZM100 24 System 11 Greenstar Combi Floor Boiler Multi zone system using circulators with standar...

Page 4: ...standard zone relay FW200 optional and indirect tank 50 System 24 Greenstar Heat Only Floor Boiler Multi zone system using zone valves and Bosch Comfort Zone Manager CZM100 and indirect tank 52 Single Multi Zone Systems using Bosch Control 54 System 25 Greenstar Combi Wall Boiler Single zone baseboard with Bosch Control 54 System 26 Greenstar Combi Floor Boiler Single zone baseboard with Bosch Con...

Page 5: ...lowing keywords are defined and can be used in this document DANGER indicates a hazardous situation which if not avoided will result in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a hazardous situation which if not avoided could result in minor to moderate injury NOTICE is used to address practices n...

Page 6: ...te flow rates Purge Drain DISCLAIMER Application drawings in this manual are conceptual only and do not purport to address all design installation code or safety considerations The diagrams in this manual are for reference use by code officials designers and licensed installers It is expected that installers have adequate knowledge of national and local codes as well as accepted industry practices...

Page 7: ...upply 120 v to White molex Ź install FW200 on front of boiler see manual Ź install outdoor air sensor Ź Follow FW200 Quick Set up guide in Greenstar Manual If using FW200 Optional Heatronic Settings Ź Remove factory jumper from terminal 2 4 inside Heatronic control and connect non power robbing thermostat dry contacts only Outdoor Sensor Ź install FW200 on front of boiler see manual Ź install outd...

Page 8: ...ual are for reference use by code officials designers and licensed installers It is expected that installers have adequate knowledge of national and local codes as well as accepted industry practices and are trained on equipment procedures and applications involved Drawings are not to scale Refer to the boiler control and module installer manuals for additional detailed information Domestic Cold W...

Page 9: ...Radiant floor heating Panel radiator system Cast Iron radiator system Baseboard convector system CRC100 or CRC200 Bosch Low Voltage Wiring Line Voltage Ź Wire Comfort Room Controller CRC100 or CRC200 to Terminals B B of Heatronic control Ź Wire Main power supply 120 v to White molex Ź See Appendix A for Room Controller Settings Heatronic Settings Heatronic Internal Wiring B B 4 2 1 A F 9 7 8 LWCO ...

Page 10: ...installers have adequate knowledge of national and local codes as well as accepted industry practices and are trained on equipment procedures and applications involved Drawings are not to scale Refer to the boiler control and module installer manuals for additional detailed information Domestic Cold Water Domestic Hot Water Gas Supply PRV Relief piping Note Internal Low Loss Header in closed posit...

Page 11: ... approx 140 F 60 C approx 153 F 67 C approx 167 F 75 C max Approx 194 F 90 C Application Frost protection Radiant floor heating Panel radiator system Cast Iron radiator system Baseboard convector system Neutral 120 V Line Ground Low Voltage Wiring Line Voltage Wiring Heatronic Settings Low Voltage Ź Remove factory jumper from terminal 2 and connect non power robbing thermostat dry contacts only to...

Page 12: ... have adequate knowledge of national and local codes as well as accepted industry practices and are trained on equipment procedures and applications involved Drawings are not to scale Refer to the boiler control and module installer manuals for additional detailed information Domestic Cold Water Domestic Hot Water Gas Supply PRV Relief piping Bosch Bosch CRC100 or CRC200 Note Internal Low Loss Hea...

Page 13: ...67 C approx 167 F 75 C max Approx 194 F 90 C Application Frost protection Radiant floor heating Panel radiator system Cast Iron radiator system Baseboard convector system Neutral 120 V Line Ground Low Voltage Wiring Line Voltage Wiring Bosch CRC100 or CRC200 Heatronic Settings Low Voltage Ź Wire Comfort Room Controller CRC100 or CRC200 to Terminal 1 on back of Greenstar FS Boiler Wiring Line Volta...

Page 14: ... 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 f...

Page 15: ...n power supply 120 v to White molex Ź Remove factory jumper from terminal 2 4 inside Heatronic control and connect non power robbing thermostat dry contacts only Heatronic Settings Room Thermostat Outdoor Sensor Ź install FW200 on front of boiler see manual Ź install outdoor air sensor Ź Follow FW200 Quick Set up guide in Appendix C If using FW200 Optional Heatronic Internal Wiring B B 4 2 1 A F 9...

Page 16: ...grams 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 informatio...

Page 17: ...ystem Baseboard convector system CRC100 or CRC200 Bosch Ź See Appendix A for Room Controller Settings Low Voltage Wiring Line Voltage Ź Wire Comfort Room Controller CRC100 or CRC200 to Terminals B B of Heatronic control Ź Wire Main power supply 120 v to White molex Heatronic Settings Heatronic Internal Wiring B B 4 2 1 A F 9 7 8 LWCO Supply Sensor DHW Sensor Dry contacts Bosch Controls Outdoor Sen...

Page 18: ...re 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 Supply PRV Relie...

Page 19: ... 194 F 90 C Application Frost protection Radiant floor heating Panel radiator system Cast Iron radiator system Baseboard convector system Neutral 120 V Line Ground Low Voltage Wiring Line Voltage Wiring Heatronic Settings Low Voltage Ź Remove factory jumper from terminal 2 and connect non power robbing thermostat dry contacts only to terminal 2 Wiring Line Voltage Ź Wire Main power supply 120 v to...

Page 20: ...ference 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 Supply PRV Relief piping ...

Page 21: ...otection Radiant floor heating Panel radiator system Cast Iron radiator system Baseboard convector system Neutral 120 V Line Ground Low Voltage Wiring Line Voltage Wiring Bosch CRC100 or CRC200 Heatronic Settings Low Voltage Wiring Line Voltage Ź Wire Main power supply 120 v to White molex Ź Wire Comfort Room Controller CRC100 or CRC200 to Terminal 1 on back of Greenstar FS Boiler Ź See Appendix A...

Page 22: ...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 T T T T T T Note Larger heating systems may ...

Page 23: ...Line Voltage Ź Wire Main power supply 120 v to White molex of Boiler external junction box Outdoor Sensor Ź install FW200 on front of boiler see manual Ź install outdoor air sensor Ź Follow FW200 Quick Set up guide in Appendix C If using FW200 Optional Heatronic Internal Wiring B B 4 2 1 A F 9 7 8 LWCO Supply Sensor DHW Sensor Dry contacts Bosch Controls Outdoor Sensor Supply Sensor end switch T T...

Page 24: ...ers 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 T T T T T T Note Larger heating systems may require an additional...

Page 25: ...Z2 PZ1 120 VAC L N L N L N L N 24 V BUS 1 2 1 2 1 2 1 2 BUS BUS BUS 120 VAC 1 4 5 6 0 3 2 1 2 3 4 See CZM100 Manual for additional Wiring information B B 4 2 1 A F 9 7 8 LWCO Supply Sensor DHW Sensor Dry contacts Bosch Controls Outdoor Sensor Supply Sensor Ź Wire BUS terminal of CZM100 to Terminal BB of Greenstar boiler Ź Wire Main power supply 120 v to White molex of Boiler external junction box ...

Page 26: ...iagrams 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 informat...

Page 27: ... max Approx 194 F 90 C Application Frost protection Radiant floor heating Panel radiator system Cast Iron radiator system Baseboard convector system Neutral 120 V Line Ground Low Voltage Wiring Line Voltage Wiring Heatronic Settings Low Voltage Ź Remove factory jumper from terminal 2 and connect End Switch of Mult Zone relay dry contacts only to terminal 2 Wiring Line Voltage Ź Wire Main power sup...

Page 28: ...e use by code officials designers and licensed installers It is expected that installers have adequate knowledge of national and local codes as well as accepted industry practices and are trained on equipment procedures and applications involved Drawings are not to scale Refer to the boiler control and module installer manuals for additional detailed information Domestic Cold Water Domestic Hot Wa...

Page 29: ...al 120 V Line Ground Low Voltage Wiring Line Voltage Wiring Heatronic Settings Low Voltage Ź Wire BUS terminal of CZM100 to Terminal 1 of Greenstar FS boiler Wiring Line Voltage Ź Wire Main power supply 120 v to White molex of Boiler and to 120 VAC input of CZM100 Bosch Bosch Bosch CRC100 or CRC200 Ź Wire CRC controllers to BUS terminals of CZM100 Ź Wire 120 VAC ouputs of PZ1 PZ2 and PZ3 to Zone C...

Page 30: ...ations 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 detai...

Page 31: ...If using FW200 Optional External Boiler Junction box 120 Vac Supply Heatronic Internal Wiring B B 4 2 1 A F 9 7 8 LWCO Supply Sensor DHW Sensor Dry contacts Bosch Controls Outdoor Sensor Supply Sensor Ź Wire 120 Vac power supply to zone relay end switch T T T T T T X1 X2 Zone 3 Zone 1 Zone 2 H N Zone 3 Zone 1 Zone 2 H N H N Priority Zone H N Priority Zone 120 Vac Power DHW Sensor Note Only use a p...

Page 32: ...agrams 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 informati...

Page 33: ... See CZM100 Manual for additional Wiring information B B 4 2 1 A F 9 7 8 LWCO Supply Sensor DHW Sensor Dry contacts Bosch Controls Outdoor Sensor Ź Wire BUS terminal of CZM100 to Terminal BB of Greenstar boiler Ź Wire Main power supply 120 v to White molex of Boiler external junction box and to 120 VAC input of CZM100 Ź Wire CRC controllers to BUS terminals of CZM100 See Appendix A for Room Contro...

Page 34: ...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 th...

Page 35: ...r system Neutral 120 V Line Ground Low Voltage Wiring Line Voltage Wiring Heatronic Settings Low Voltage Ź Remove factory jumper from terminal 2 and connect End Switch of Mult Zone relay dry contacts only to terminal 2 Wiring Line Voltage Ź Wire Main power supply 120 v to White molex of Boiler end switch T T T T T T X1 X2 Zone 3 Zone 1 Zone 2 H N Zone 3 Zone 1 Zone 2 H N H N Priority Zone H N Prio...

Page 36: ...n 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 man...

Page 37: ...Ź Wire BUS terminal of CZM100 to Terminal 1 of Greenstar FS boiler Wiring Line Voltage Ź Wire Main power supply 120 v to White molex of Boiler and to 120 VAC input of CZM100 CRC100 or CRC200 Ź Wire CRC controllers to BUS terminals of CZM100 Ź Wire 120 VAC ouputs of PZ1 PZ2 and PZ3 to Zone Circulators Ź Wire Greenstar Tank sensor to Terminal 5 of Greenstar FS boiler DHW Pump Ź Wire Red molex on bac...

Page 38: ...fficials 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 T T T T T T Note Larger heating systems may requir...

Page 39: ...y dry contacts only Wiring Line Voltage Ź Wire Main power supply 120 v to White molex of Boiler external junction box Outdoor Sensor If using FW200 Optional Heatronic Internal Wiring B B 4 2 1 A F 9 7 8 LWCO Supply Sensor Dry contacts Bosch Controls Outdoor Sensor Supply Sensor External Boiler Junction box 120 VAC Ź Wire 120 Vac power supply to zone relay Zone 1 1 2 3 4 Zone 3 1 2 3 4 Zone 4 1 2 3...

Page 40: ...ficials 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 T T T T T T Note Larger heating systems may require...

Page 41: ...rotection Radiant floor heating Panel radiator system Cast Iron radiator system Baseboard convector system Heatronic Settings Low Voltage Wiring Line Voltage Heatronic Internal Wiring B B 4 2 1 A F 9 7 8 LWCO Supply Sensor Dry contacts Bosch Controls Outdoor Sensor Ź Wire BUS terminal of CZM100 to Terminal BB of Greenstar boiler Heatronic control Ź Wire Main power supply 120 v to White molex of Bo...

Page 42: ...ms 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 D...

Page 43: ...tronic Settings Low Voltage Ź Remove factory jumper from terminal 2 and connect End Switch of Multi Zone relay dry contacts only to terminal 2 Wiring Line Voltage Ź Wire Main power supply 120 v to White molex of Boiler Zone 1 1 2 3 4 Zone 3 1 2 3 4 Zone 4 1 2 3 4 Zone 2 1 2 3 4 T T Zone 1 T T Zone 2 T T Zone 3 T T Zone 4 End switch End switch Zone 4 relay N O Com N C off on Zone 4 priority 24 VAC ...

Page 44: ...use by code officials designers and licensed installers It is expected that installers have adequate knowledge of national and local codes as well as accepted industry practices and are trained on equipment procedures and applications involved Drawings are not to scale Refer to the boiler control and module installer manuals for additional detailed information Domestic Cold Water Domestic Hot Wate...

Page 45: ...M100 to Terminal 1 of Greenstar FS boiler Wiring Line Voltage Ź Wire Main power supply 120 v to White molex of Boiler and to 120 VAC input of CZM100 See CZM100 Manual for Detail wiring CRC100 or CRC200 CZM100 Ź Wire CRC controllers to BUS terminals of CZM100 Ź Wire 120 VAC ouput of PZ1 to system pump Bosch Bosch VZ3 VZ1 T0 24VAC VZ2 1 2 1 2 1 2 1 2 1 2 3 4 3 4 3 4 24 VAC Transformer 2 wire 3 wire ...

Page 46: ...on 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 ma...

Page 47: ...ly 120 v to White molex of Boiler Zone 1 1 2 3 4 Zone 3 1 2 3 4 Zone 4 1 2 3 4 Zone 2 1 2 3 4 T T Zone 1 T T Zone 2 T T Zone 3 T T Zone 4 End switch End switch Zone 4 relay N O Com N C off on Zone 4 priority 24 VAC Transformer 2 wire Zone valve 3 wire Zone valve 4 wire Zone valve Tank Aquastat Thermostats Ź Wire System Circulator to end switch of Relay Ź Wire DHW Circulator to Normally Open priori...

Page 48: ...rations 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 deta...

Page 49: ...oltage Wiring Line Voltage Heatronic Internal Wiring B B 4 2 1 A F 9 7 8 LWCO Supply Sensor Dry contacts Bosch Controls Outdoor Sensor Ź Wire BUS terminal of CZM100 to Terminal BB of Greenstar boiler Heatronic control Ź Wire Main power supply 120 v to White molex of Boiler external junction box and to 120 VAC input of CZM100 Ź Wire CRC controllers to BUS terminals of CZM100 See Appendix A for Room...

Page 50: ...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 mo...

Page 51: ...from terminal 2 and connect End Switch of Multi Zone relay dry contacts only to terminal 2 Wiring Line Voltage Ź Wire Main power supply 120 v to White molex of Boiler Zone 1 1 2 3 4 Zone 3 1 2 3 4 Zone 4 1 2 3 4 Zone 2 1 2 3 4 T T Zone 1 T T Zone 2 T T Zone 3 T T Zone 4 End switch End switch Zone 4 relay N O Com N C off on Zone 4 priority 24 VAC Transformer 2 wire Zone valve 3 wire Zone valve 4 wi...

Page 52: ...onsiderations 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 additiona...

Page 53: ...20 v to White molex of Boiler and to 120 VAC input of CZM100 CRC100 or CRC200 CZM100 Ź Wire CRC controllers to BUS terminals of CZM100 Ź Wire 120 VAC ouput of PZ1 on CZM 100 to system pump Bosch Bosch VZ3 VZ1 T0 24VAC VZ2 1 2 1 2 1 2 1 2 1 2 3 4 3 4 3 4 24 VAC Transformer 2 wire 3 wire and 4 wire zone valves 120 Vac 24 Vac PZ3 PZ2 PZ1 120 VAC L N L N L N L N 24 V BUS 1 2 1 2 1 2 1 2 BUS BUS BUS 12...

Page 54: ... are for reference use by code officials designers and licensed installers It is expected that installers have adequate knowledge of national and local codes as well as accepted industry practices and are trained on equipment procedures and applications involved Drawings are not to scale Refer to the boiler control and module installer manuals for additional detailed information Domestic Cold Wate...

Page 55: ...194 F 90 C Application Frost protection Radiant floor heating Panel radiator system Cast Iron radiator system Baseboard convector system Low Voltage Wiring Line Voltage Ź Wire Bosch Control to Terminals B B of the Heatronic control Ź Wire Main power supply 120 v to White molex Heatronic Settings Heatronic Internal Wiring B B 4 2 1 A F 9 7 8 LWCO Supply Sensor DHW Sensor Dry contacts Bosch Controls...

Page 56: ...rs have adequate knowledge of national and local codes as well as accepted industry practices and are trained on equipment procedures and applications involved Drawings are not to scale Refer to the boiler control and module installer manuals for additional detailed information Domestic Cold Water Domestic Hot Water Gas Supply PRV Relief piping Note Internal Low Loss Header in closed position Note...

Page 57: ...0 C 4 5 6 approx 140 F 60 C approx 153 F 67 C approx 167 F 75 C max Approx 194 F 90 C Application Frost protection Radiant floor heating Panel radiator system Cast Iron radiator system Baseboard convector system Neutral 120 V Line Ground Low Voltage Wiring Line Voltage Wiring Heatronic Settings Low Voltage Ź Wire Bosch Control to Terminal 1 on back of Greenstar FS Boiler Wiring Line Voltage Ź Wire...

Page 58: ...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 informa...

Page 59: ...anel radiator system Cast Iron radiator system Baseboard convector system Low Voltage Wiring Line Voltage Ź Wire Bosch Control to Terminals B B of Heatronic control Ź Wire Main power supply 120 v to White molex Heatronic Settings Heatronic Internal Wiring B B 4 2 1 A F 9 7 8 LWCO Supply Sensor DHW Sensor Dry contacts Bosch Controls Outdoor Sensor External Boiler Junction box 120 Vac Supply Ground ...

Page 60: ... 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 Supply PRV Relief pipi...

Page 61: ...ax Approx 194 F 90 C Application Frost protection Radiant floor heating Panel radiator system Cast Iron radiator system Baseboard convector system Neutral 120 V Line Ground Low Voltage Wiring Line Voltage Wiring Heatronic Settings Low Voltage Wiring Line Voltage Ź Wire Main power supply 120 v to White molex Ź Wire Bosch Control to Terminal 1 on back of Greenstar FS Boiler L N red storage tank pump...

Page 62: ...fety 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 add...

Page 63: ...LWCO Supply Sensor DHW Sensor Dry contacts Bosch Controls Outdoor Sensor Ź Wire BUS terminal of the Bosch Control to Terminal BB of Greenstar boiler Ź Wire Main power supply 120 v to White molex of Boiler external junction box Ź Wire 120 VAC of Black Molex to Zone Circulator Ź Wire Supply Sensor to terminals in the Heatronic control DHW Thermistor Ź Wire Greenstar Tank thermistor sensor to blue mo...

Page 64: ...tems may require an additional expansion tank external to the boiler see manual for details Domestic Cold Water Domestic Hot Water Gas Supply Bosch Control Supply Sensor Note See Appendix B for Primary Secondary piping requirements Multi Zone Combi wall boiler Circulators Bosch Control with Zone Relay Bosch Control Zone relay X X Do not connect end switch of relay to boiler Locate the Bosch Contro...

Page 65: ...ntrol Wiring Line Voltage Ź Wire Main power supply 120 v to White molex of Boiler external junction box Heatronic Internal Wiring B B 4 2 1 A F 9 7 8 LWCO Supply Sensor DHW Sensor Dry contacts Bosch Controls Outdoor Sensor Supply Sensor end switch T T T T T T Zone 3 Zone 1 Zone 2 Zone 3 Zone 1 Zone 2 L N G X X External Boiler Junction box 120 Vac Supply 120 Vac Power Ź Wire 120 Vac power supply to...

Page 66: ...l to displaythe first setting 1 Turn the dial to select a setting 2 Press dial to show the current value 3 Press dial to change the value 4 Turn dial to set the required value 5 Press the dial to store the value 6 Press and hold dial until the setting is displayed again 1 Press and hold idal until three dashes appear 2 Release dial The display changes to the standard display and the user interface...

Page 67: ...ru 8 For CRC200 located in Zone 1 Ź Set DHW to yes pr pump if indirect tank is connected to the system Ź Set Heat System to High Temp or Low Temp depending upon zone requirement Ź Set Max Supply Temp to appropriate maximum temperature for the zone For CRC200 located in zones 2 thru 8 ŹSet Heat System to High Temp or Low Temp depending upon zone requirement ŹSet Max supply Temp to appropriate maxim...

Page 68: ...d Tees Maximum distance of 4 x pipe diameter center to center based on System header pipe size C System Return Minimum length of 8 x pipe diameter based on System header pipe Boiler Input btu hr Boiler Supply Return pipe diameter System Supply Return Header pipe diameter 57 000 1 1 79 000 1 1 100 000 1 1 25 131 000 1 1 25 151 000 1 1 5 System Header Pipe based on 2 4 ft sec flow velocity system T ...

Page 69: ...and release Time and Date will be highlighted Push dial again and Time will be highlighted Set time by pushing dial and rotating Once complete push again to lock in time setting Turn dial until Date is highlighted Set date by pushing dial and turning to select Push dial once to lock in date setting 1 2 3 4 5 6 9 12h 15 18 21 24h 3 6 Fig 1 Controller with front flap open Set for constant heating no...

Page 70: ...sh This is the supply temperature at 5 F 15 C outdoor temperature Set accordingly Fig 2 Press the dial to confirm the setting Refer to FW 200 Installation and Operating Instructions for more custom settings Turn the dial counter clockwise until Maximum heating supply temperature is highlighted Press the dial Turn the dial to set the desired value Press the dial to confirm the setting Press menu bu...

Page 71: ...ow Water Cut Off ŹInstall a 24VAC 20VA Transformer near the boiler ŹFollow LWCO manufacturer s instructions ŹConnect the lead labeled BOILER GROUND green to the ground wire of the white plug in the boiler junction box ŹConnect the leads labeled 24V HOT red and 24V COMMON white to the external 24VAC transformer field supplied ŹInside the Heatronic Control of the boiler remove jumper from terminal 8...

Page 72: ...ar the boiler ŹFollow LWCO manufacturer s instructions ŹConnect the lead labeled BOILER GROUND green to the ground wire of the white plug in the boiler junction box ŹConnect the leads labeled 24V HOT red and 24V COMMON white to the external 24VAC transformer field supplied ŹAT the Low Voltage box on the rear of the boiler remove the jumper acros the LWCO connections and connect the leads labeled S...

Page 73: ...Applications Manual Bosch Greenstar 73 Bosch Thermotechnology Corp Data subject to change ...

Page 74: ...74 Bosch Greenstar Applications Manual Bosch Thermotechnology Corp Data subject to change ...

Page 75: ...Applications Manual Bosch Greenstar 75 Bosch Thermotechnology Corp Data subject to change ...

Page 76: ...United States and Canada Bosch Thermotechnology Corp 50 Wentworth Avenue Londonderry NH 03053 Tel 866 642 3198 Fax 603 965 7581 www boschheatingandcooling com BTC 436001101 C 10 2015 ...

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