WARNING: Improper installation, setup, modifi cation, operation or

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WARNING: Improper installation, setup, modifi cation, operation or | Manualzz
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 Wall Hung & Floor Standing Boilers
Bosch
Greenstar & Greenstar FS 100, 151, 131 Combi Boiler
Greenstar & Greenstar FS 57, 79, 100, 131, 151 Regular Boiler
Applications Manual
2 | Bosch Greenstar
Data subject to change
Applications Manual
Bosch Thermotechnology Corp.
Applications Manual
Bosch Greenstar | 3
Table of Contents
Single Zone Systems
6
System # 1 Greenstar Combi Wall Boiler
Single Zone Baseboard with Standard Thermostat (drycontact only) and FW200 (optional)
6
System # 2 Greenstar Combi Wall Boiler
Single Zone Baseboard with Bosch CRC control
8
System # 3 Greenstar Combi Floor Boiler
Single Zone Baseboard with Standard Thermostat (dry contact only)
10
System # 4 Greenstar Combi Floor Boiler
Single Zone Baseboard with Bosch CRC control
12
System # 5 Greenstar Heat only Wall Boiler
Single Zone Baseboard with Standard Thermostat (dry contact only) and FW200 (optional)
14
System # 6 Greenstar Heat only Wall Boiler
Single Zone Baseboard with Bosch CRC control
16
System # 7 Greenstar Heat only Floor Boiler
Single Zone Baseboard with Standard Thermostat (dry contact only)
18
System # 8 Greenstar Heat only Floor Boiler
Single 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 standard zone relay (FW200 optional)
26
System # 12 Greenstar Combi Floor Boiler
Multi zone system using circulators and Bosch Comfort Zone Manager (CZM100)
28
System # 13 Greenstar Heat only Wall Boiler
Multi zone system using circulators with standard zone relay (FW200 optional) and indirect tank
30
System # 14 Greenstar Heat only Wall Boiler
Multi zone system using circulators and Bosch Comfort Zone Manager (CZM100) and indirect tank
32
System # 15 Greenstar Heat only Floor Boiler
Multi zone system using circulators with standard zone relay (FW200 optional) and indirect tank
34
System # 16 Greenstar Heat only Floor Boiler
Multi zone system using circulators and Bosch Comfort Zone Manager (CZM100) and indirect tank
36
Bosch Thermotechnology Corp.
Data subject to change
4 | Bosch Greenstar
Applications Manual
Multi Zone Systems using Zone Valves
38
System # 17 Greenstar Combi WallBoiler
Multi zone system using zone valves with standard zone relay (FW200 optional)
38
System # 18 Greenstar Combi Wall Boiler
Multi zone system using zone valves and Bosch Comfort Zone Manager (CZM100)
40
System # 19 Greenstar Combi Floor Boiler
Multi zone system using zone valveswith standard zone relay (FW200 optional)
42
System # 20 Greenstar Combi Floor Boiler
Multi zone system using zone valves and Bosch Comfort Zone Manager (CZM100)
44
System # 21 Greenstar Heat Only Wall Boiler
Multi zone system using zone valves with standard zone relay (FW200 optional) and indirect tank
46
System # 22 Greenstar Heat Only Wall Boiler
Multi zone system using zone valves and Bosch Comfort Zone Manager (CZM100) and indirect tank
48
System # 23 Greenstar Heat Only Floor Boiler
Multi zone system using zone valves with 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 Control
56
System # 27 Greenstar Heat Only Wall Boiler
Single zone baseboard with Bosch Control
58
System # 28 Greenstar Heat Only Floor Boiler
Single zone system with Bosch Control
60
System # 29 Greenstar Heat Only Wall Boiler
Single zone system with Bosch Control and indirect tank
62
System # 30 Greenstar Combi Wall Boiler
Multi zone system using circulators and Bosch Control with standard zone relay
64
Appendices
66
Appendix A Comfort Room Controller (CRC100) Quick set-up guide
66
Appendix B Primary/Secondary Piping requirements for Greenstar Wall Boiler
68
Appendix C FW200 Quick Set-up Guide
69
Appendix D Wiring of Hydro-Level Low Water Cut-off for Greenstar Wall Boiler
71
Appendix E Wiring of Hydro-Level Low Water Cut-off for Greenstar Floor Boiler
72
Data subject to change
Bosch Thermotechnology Corp.
Applications Manual
Bosch Greenstar | 5
Explanation Of Symbols
Key To Symbols
Warnings
Warnings in this document are identified by a
warning triangle printed against a grey background.
Keywords at the start of a warning indicate the
type and seriousness of the ensuing risk if measThe following 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 not related to
personal injury.
Important information
This symbol indicates important information where
there is no risk to people or property.
Bosch Thermotechnology Corp.
Data subject to change
Single Zone
Combi Wall Boiler
Baseboard
On/off Tstat
.
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, 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.
Created
Released
Changed
Bases
No.
State
Bosch
FW200
PRV
Relief piping
Purge
Drain
Room
Thermostat
Condensate
drain
Relief valve &
pressure gauge
Back-flow
preventer
Isolation
valve
Outdoor
air sensor
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Note:Greenstar Internal circulator
can support a single zone loop
not to exceed 4 gpm at 12 feet of
head. See pump curves in
manual for pump capacities at
alternate flow rates.
Domestic
Hot Water
Domestic
Cold Water
Gas
Supply
(Use of FW200 and
outdoor air sensor
is optional)
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
6 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 7
System #1
Heatronic Internal Wiring
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
B
Bosch Controls
B
Room Thermostat
4
Dry contacts
2
9
8
LWCO
1
Outdoor
Sensor
A
F
7
120 Vac Supply
Ground
Neutral
Outdoor Sensor
DHW Sensor
If using FW200 (Optional):
Ź install FW200 on front of
boiler (see manual)
Ź install outdoor air sensor
Ź Follow FW200 Quick
Set-up guide in Appendix C
L
L
N
Supply Sensor
N
red
storage
tank pump
white
mains
120v/60 hz
L
N
black
ch pump
for unmixed heating
(Not Used)
External Boiler Junction box
Wiring:
Low Voltage
Line Voltage
Ź Remove factory jumper from terminal #2 & #4
inside Heatronic control and connect non-power
robbing thermostat (dry contacts only)
Ź Wire Main power supply (120 v) to White molex
If using FW200 (Optional):
Ź install FW200 on front of boiler (see manual)
Ź install outdoor air sensor
Ź Follow FW200 Quick Set-up guide in Greenstar
Manual
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
approx. 167 °F (75 °C)
max
Approx. 194 °F (90°C)
Baseboard & convector system
1
4
3
5
2
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 104 °F (40 °C)
e
approx. 122 °F (50 °C)
max
approx. 140 °F (60 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Single zone
Combi wall boiler
Baseboard
NSC Controls
.
TK
02/20/15
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, 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.
Created
Released
Changed
Bases
No.
State
Bosch
Bosch
PRV
Relief piping
Purge
Drain
Comfort
Room
Controller
Condensate
drain
Relief valve &
pressure gauge
Back-flow
preventer
Isolation
valve
Outdoor
air sensor
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Note:Greenstar Internal circulator
can support a single zone loop
not to exceed 4 gpm at 12 feet of
head. See pump curves in
manual for pump capacities at
alternate flow rates.
Domestic
Hot Water
Domestic
Cold Water
Gas
Supply
Bosch
CRC100 or
CRC200
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
8 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 9
System #2
Heatronic Internal Wiring
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
CRC100 or CRC200
Bosch
B
Bosch Controls
B
4
Dry contacts
2
1
8
LWCO
9
Outdoor
Sensor
A
F
7
120 Vac Supply
Ground
Neutral
DHW Sensor
black
ch pump
for unmixed heating
(Not Used)
white
mains
120v/60 hz
Supply Sensor
N
L
N
L
External Boiler Junction box
Wiring:
Low Voltage
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:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 104 °F (40 °C)
e
approx. 122 °F (50 °C)
max
approx. 140 °F (60 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Single Zone
Combi floor boiler
Baseboard
On/off Thermostat
.
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, 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.
Created
Released
Changed
Bases
No.
State
Bosch
PRV
Relief piping
Purge
Drain
Room
Thermostat
Condensate
drain
Relief valve &
pressure gauge
Back-flow
preventer
Isolation
valve
Outdoor
air sensor
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Note:Greenstar Internal circulator
can support a single zone loop
not to exceed 4 gpm at 12 feet of
head. See pump curves in
manual for pump capacities at
alternate flow rates.
Note: additional expansion
tank shown – internal
expansion tank in combi boiler
models may be adequate for
standard systems -see boiler
manual for details.
Gas
Supply
Note: Internal Low Loss
Header in closed position
Domestic Domestic
Hot Water Cold Water
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
1 0 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 11
System #3
Low Voltage Wiring
BUS
TT
out sen
LWCO
1
2
3
4
Line Voltage Wiring
DHW sen
5
6
L
L
N
N
black
ch pump
for unmixed heating
(Not Used)
white
mains
120v/60 hz
Room
Thermostat
120 V Line
Note: For Low Water Cutoff Wiring see
Appendix E of this manual
Ground
Neutral
Wiring:
Low Voltage
Line Voltage
Ź Remove factory jumper from terminal #2 and
connect non-power robbing thermostat (dry contacts
only) to terminal #2
Ź Wire Main power supply (120 v) to White molex
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 104 °F (40 °C)
e
approx. 122 °F (50 °C)
max
approx. 140 °F (60 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Single Zone
Combi floor boiler
Baseboard
NSC Controls
.
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, 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.
Created
Released
Changed
Bases
No.
State
Bosch
Bosch
PRV
Relief piping
Purge
Drain
Supply
Sensor
Comfort
Room
Controller
Condensate
drain
Relief valve &
pressure gauge
Back-flow
preventer
Isolation
valve
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Note:Greenstar Internal circulator
can support a single zone loop
not to exceed 4 gpm at 12 feet of
head. See pump curves in
manual for pump capacities at
alternate flow rates.
Note: additional expansion
tank shown – internal
expansion tank in combi boiler
models may be adequate for
standard systems -see boiler
manual for details.
CRC100 or CRC200
Bosch
Gas
Supply
Note: Internal Low Loss
Header in closed position
Domestic Domestic
Hot Water Cold Water
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
1 2 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 13
System #4
Low Voltage Wiring
BUS
TT
out sen
LWCO
1
2
3
4
Line Voltage Wiring
DHW sen
5
6
L
L
N
N
black
ch pump
for unmixed heating
(Not Used)
white
mains
120v/60 hz
Bosch
CRC100 or CRC200
120 V Line
Note: For Low Water Cutoff Wiring see
Appendix E of this manual
Ground
Neutral
Wiring:
Low Voltage
Line Voltage
Ź Wire Comfort Room Controller (CRC100 or
CRC200) to Terminal # 1 on back of Greenstar FS
Boiler
Ź Wire Main power supply (120 v) to White molex
Ź See Appendix A for Room Controller Settings
Heatronic Settings:
Boiler
Heating
Dial
Typical supply
temperatures
Application
1
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
approx. 167 °F (75 °C)
max
Approx. 194 °F (90°C)
Baseboard & convector system
1
4
3
5
2
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 104 °F (40 °C)
e
approx. 122 °F (50 °C)
max
approx. 140 °F (60 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Single Zone
Heat only wall boiler
Baseboard
On/off Thermostat
.
TK
02/20/15
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, 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.
Created
Released
Changed
Bases
No.
State
Bosch
PRV
Relief piping
Purge
Drain
Room
Thermostat
Condensate
drain
Relief valve &
pressure gauge
Back-flow
preventer
Isolation
valve
Outdoor
air sensor
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Note:Greenstar Internal circulator
can support a single zone loop
not to exceed 4 gpm at 12 feet of
head. See pump curves in
manual for pump capacities at
alternate flow rates.
Gas
Supply
(Use of FW200 and
outdoor air sensor
is optional)
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
1 4 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 15
System #5
Heatronic Internal Wiring
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
B
Bosch Controls
B
Room Thermostat
4
Dry contacts
2
9
8
LWCO
1
Outdoor
Sensor
A
F
7
120 Vac Supply
Ground
Neutral
Outdoor Sensor
DHW Sensor
If using FW200 (Optional):
Ź install FW200 on front of
boiler (see manual)
Ź install outdoor air sensor
Ź Follow FW200 Quick
Set-up guide in Appendix C
L
L
N
Supply Sensor
N
red
storage
tank pump
white
mains
120v/60 hz
L
N
black
ch pump
for unmixed heating
(Not Used)
External Boiler Junction box
Wiring:
Low Voltage
Line Voltage
Ź Remove factory jumper from terminal #2 & #4
inside Heatronic control and connect non-power
robbing thermostat (dry contacts only)
Ź Wire Main power supply (120 v) to White molex
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Single Zone
Heat only wall boiler
Baseboard
NSC Controls
.
TK
02/20/15
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, 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.
Created
Released
Changed
Bases
No.
State
Bosch
Bosch
PRV
Relief piping
Purge
Drain
Comfort
Room
Control
Condensate
drain
Relief valve &
pressure gauge
Back-flow
preventer
Isolation
valve
Outdoor
air sensor
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Note:Greenstar Internal circulator
can support a single zone loop
not to exceed 4 gpm at 12 feet of
head. See pump curves in
manual for pump capacities at
alternate flow rates.
Gas
Supply
Bosch
CRC100 or
CRC200
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
1 6 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 17
System #6
Heatronic Internal Wiring
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
CRC100 or CRC200
B
Bosch
Bosch Controls
B
4
Dry contacts
2
9
8
LWCO
1
Outdoor
Sensor
A
F
7
120 Vac Supply
Ground
Neutral
DHW Sensor
L
L
N
Supply Sensor
N
red
storage
tank pump
white
mains
120v/60 hz
L
N
black
ch pump
for unmixed heating
(Not Used)
External Boiler Junction box
Wiring:
Low Voltage
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:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Single Zone
Heat only floor boiler
Baseboard
On/Off Thermostat
.
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, 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.
Created
Released
Changed
Bases
No.
State
Bosch
PRV
Relief piping
Purge
Drain
Room
Thermostat
Condensate
drain
Relief valve &
pressure gauge
Back-flow
preventer
Isolation
valve
Outdoor
air sensor
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Note:Greenstar Internal circulator
can support a single zone loop
not to exceed 4 gpm at 12 feet of
head. See pump curves in
manual for pump capacities at
alternate flow rates.
Gas
Supply
Note: Internal Low Loss
Header in closed position
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
1 8 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 19
System #7
Low Voltage Wiring
BUS
TT
out sen
LWCO
1
2
3
4
Line Voltage Wiring
DHW sen
5
6
L
L
N
L
N
N
black
ch pump
for unmixed heating
(Not Used)
red
storage
tank pump
white
mains
120v/60 hz
Room
Thermostat
120 V Line
Note: For Low Water Cutoff Wiring see
Appendix E of this manual
Ground
Neutral
Wiring:
Low Voltage
Line Voltage
Ź Remove factory jumper from terminal #2 and
connect non-power robbing thermostat (dry contacts
only) to terminal #2
Ź Wire Main power supply (120 v) to White molex
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Single Zone
Heat only floor boiler
Baseboard
NSC Controls
.
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, 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.
Created
Released
Changed
Bases
No.
State
Bosch
PRV
Relief piping
Purge
Drain
Room
Thermostat
Condensate
drain
Relief valve &
pressure gauge
Back-flow
preventer
Isolation
valve
Outdoor
air sensor
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Note:Greenstar Internal circulator
can support a single zone loop
not to exceed 4 gpm at 12 feet of
head. See pump curves in
manual for pump capacities at
alternate flow rates.
CRC100 or CRC200
Bosch
Gas
Supply
Note: Internal Low Loss
Header in closed position
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
2 0 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 21
System #8
Low Voltage Wiring
BUS
TT
out sen
LWCO
1
2
3
4
Line Voltage Wiring
DHW sen
5
6
L
L
N
L
N
N
black
ch pump
for unmixed heating
(Not Used)
red
storage
tank pump
white
mains
120v/60 hz
Bosch
CRC100 or CRC200
120 V Line
Note: For Low Water Cutoff Wiring see
Appendix E of this manual
Ground
Neutral
Wiring:
Low Voltage
Line Voltage
Ź Wire Comfort Room Controller (CRC100 or
CRC200) to Terminal # 1 on back of Greenstar FS
Boiler
Ź Wire Main power supply (120 v) to White molex
Ź See Appendix A for Room Controller Settings
Heatronic Settings:
Boiler
Heating
Dial
Typical supply
temperatures
Application
1
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Combi wall boiler
Circulators
Zone Relay
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
FW200
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Room
Thermostat
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
Supply
Sensor
Outdoor
Sensor
T
T
T
...
T
T
T
Note: Larger heating systems
may require an additional
expansion tank external to the
boiler – see manual for details.
XX
Zone relay
Domestic
Hot Water
Domestic
Gas
Supply Cold Water
(Use of FW200 and
outdoor air sensor is
optional)
Note: See Appendix B for
Primary/Secondary piping
requirements
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
2 2 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 23
System # 9
Heatronic Internal Wiring
B
X X
B
( end switch )
Bosch Controls
4
120 Vac
Power
Dry contacts
2
Zone 1 Zone 2 Zone 3
Zone 1 Zone 2 Zone 3
9
8
LWCO
1
Outdoor
Sensor
TT TT TT
A
F
7
Outdoor Sensor
DHW Sensor
If using FW200 (Optional):
Ź install FW200 on front of
boiler (see manual)
Ź install outdoor air sensor
Ź Follow FW200 Quick
Set-up guide in Appendix C
External Boiler Junction box
L
N
L
Supply Sensor
N
black
ch pump
for unmixed heating
(Not Used)
white
mains
120v/60 hz
Supply Sensor
L GN
120 Vac Supply
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
Wiring:
Low Voltage
Line Voltage
Ź Remove factory jumper from terminal #2 & #4
and connect to End Switch of Mult-Zone relay (dry
contacts only)
Ź Wire Main power supply (120 v) to White molex
of Boiler external junction box
Ź Wire 120 Vac power supply to zone relay
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
reset
eco
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 59 °F (15 °C)
e
approx. 131 °F (55 °C)
max
approx. 158 °F (70 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Combi wall boiler
Circulators
NSC Controls
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Comfort
Zone
Manager
(CZM100)
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Room
Thermostat
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
Supply
Sensor
Comfort Room
Controller
T
Bosch
T
Bosch
T
...
T
Bosch
T
T
CRC100 or
CRC200
Note: Larger heating systems
may require an additional
expansion tank external to the
boiler – see manual for details.
CZM100
Domestic
Hot Water
Note: See Appendix B for
Primary/Secondary piping
requirements
Domestic
Gas
Supply Cold Water
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
2 4 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 25
System #10
CZM100
See CZM100
Manual for
additional
Wiring
information
Heatronic Internal Wiring
B
Bosch Controls
3
4 5
CRC100 or CRC200
6
2
1
1
2
3
Bosch
4
Bosch
Bosch
0
T0
VZ3
VZ2
VZ1
1 2 1 2
3 4 1 2 3 4 1
2 3
24VAC
4 1 2
B
120 VAC
4
120 VAC
Dry contacts
N L
2
PZ1
PZ2
N L
N L
PZ3
< 24 V
N L
BUS BUS BUS BUS
1 2 1 2 1
9
8
LWCO
1
Outdoor
Sensor
2
1 2
A
F
Supply Sensor
7
DHW Sensor
External Boiler Junction box
L
N
L
N
black
ch pump
for unmixed heating
(Not Used)
white
mains
120v/60 hz
Supply Sensor
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
L G N
120 Vac Supply
Wiring:
Low Voltage
Line Voltage
Ź Wire BUS terminal of CZM100 to Terminal BB of
Greenstar boiler
Ź Wire CRC controllers to BUS terminals of
CZM100
Ź See Appendix A for Room Controller Settings
Ź Wire Main power supply (120 v) to White molex
of Boiler (external junction box) and to 120 VAC
input of CZM100
Ź Wire 120 VAC ouputs of PZ1, PZ2 and PZ3 of
CZM100 to Zone Circulators
Ź Wire Supply Sensor to “TO” connection on CZM100
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
approx. 167 °F (75 °C)
max
Approx. 194 °F (90°C)
Baseboard & convector system
1
4
3
5
2
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 59 °F (15 °C)
e
approx. 131 °F (55 °C)
max
approx. 158 °F (70 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Combi floor boiler
Circulators
Zone Relay
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Room
Thermostat
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
T
T
T
...
T
T
T
Gas
Supply
Note: Larger heating systems
may require an additional
expansion tank external to the
boiler – see manual for details.
XX
Zone relay
Note: Internal Low Loss
Header in open position
Domestic
Hot Water
Domestic
Cold Water
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
2 6 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 27
System #11
Low Voltage Wiring
BUS
TT
out sen
LWCO
1
2
3
4
Line Voltage Wiring
DHW sen
5
6
L
L
N
N H
( end switch )
H N
N H
X1 X2
Zone 1
Zone 2
Zone 3
N
black
ch pump
for unmixed heating
(Not Used)
white
mains
120v/60 hz
120 V Line
Ground
Zone 1
Zone 2
Zone 3
T T
T T
T T
Neutral
Note: For Low Water Cutoff Wiring see
Appendix E of this manual
Wiring:
Low Voltage
Line Voltage
Ź Remove factory jumper from terminal #2 and
connect End Switch of Mult-Zone relay (dry contacts
only) to terminal #2
Ź Wire Main power supply (120 v) to White molex
of Boiler
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 104 °F (40 °C)
e
approx. 122 °F (50 °C)
max
approx. 140 °F (60 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Combi floor boiler
Circulators
NSC Controls
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Comfort Zone
Manager
(CZM100)
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Comfort
Room
Controller
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
T
Bosch
T
Bosch
T
...
T
Bosch
T
T
CRC100 or
CRC200
Note: Internal Low Loss
Header in open position
Gas
Supply
Note: Larger heating systems
may require an additional
expansion tank external to the
boiler – see manual for details.
CZM100
Domestic
Hot Water
Domestic
Cold Water
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
2 8 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 29
System #12
Low Voltage Wiring
BUS
TT
out sen
LWCO
1
2
3
4
Line Voltage Wiring
DHW sen
5
6
CZM100
3
2
1
See CZM100
Manual for
additional
Wiring
information
4 5
L
N
L
CRC100 or CRC200
6
1
2
3
Bosch
4
Bosch
N
black
ch pump
for unmixed heating
(Not Used)
white
mains
120v/60 hz
Bosch
0
T0
VZ1
1 2 1 2
VZ3
VZ2
3 4 1 2 3 4 1
2 3
24VAC
4 1 2
120 VAC
120 VAC
N L
PZ1
N L
PZ2
N L
PZ3
N L
< 24 V
BUS BUS BUS BUS
1 2 1 2 1
2
1 2
Neutral
Ground
120 V Line
Note: For Low Water Cutoff Wiring see
Appendix E of this manual
Wiring:
Low Voltage
Line Voltage
Ź Wire BUS terminal of CZM100 to Terminal #1 of
Greenstar FS boiler
Ź Wire CRC controllers to BUS terminals of
CZM100
Ź Wire Main power supply (120 v) to White molex
of Boiler and to 120 VAC input of CZM100
Ź Wire 120 VAC ouputs of PZ1, PZ2 and PZ3 to
Zone Circulators
Ź See Appendix A for Room Controller Settings
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
approx. 167 °F (75 °C)
max
Approx. 194 °F (90°C)
Baseboard & convector system
1
4
3
5
2
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 104 °F (40 °C)
e
approx. 122 °F (50 °C)
max
approx. 140 °F (60 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Heat only wall boiler
Circulators
Indirect Tank
Zone Relay
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
FW200
DHW
Thermistor
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Room
Thermostat
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
Supply
Sensor
Outdoor
Sensor
T
T
T
...
T
...
T
T
XX
Zone relay
Gas
Supply
(Use of FW200 and outdoor
air sensor is optional)
Note: See Appendix B for
Primary/Secondary piping
requirements
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
3 0 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 31
System # 13
N H
N H
N H
N H
Heatronic Internal Wiring
Zone 1
Zone 2
Zone 3
Priority
Zone
Zone 1
Zone 2
Zone 3
T T
T T
T T
Note: Only use
a priority zone
for DHW
indirect zone
when not using
the FW200
outdoor reset
control. If using
FW200 wire as
shown
X1 X2
end
switch
B
Bosch Controls
B
4
Dry contacts
2
1
8
LWCO
9
Outdoor
Sensor
Outdoor Sensor
120 Vac
Power
A
Priority
Zone
F
7
DHW Sensor
DHW Sensor
If using FW200 (Optional):
External Boiler Junction box
Ź install FW200 on front of
boiler (see manual)
Ź install outdoor air sensor
Ź Follow FW200 Quick
Set-up guide in Appendix C
L
N
L
Supply Sensor
N
red
storage
tank pump
white
mains
120v/60 hz
N
L
black
ch pump
for unmixed heating
(Not Used)
Supply Sensor
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
DHW
Circulator
L G N
120 Vac Supply
Wiring:
Low Voltage
Line Voltage
Ź Remove factory jumper from terminal #2 & #4
and connect to End Switch of Mult-Zone relay (dry
contacts only)
Ź Wire Main power supply (120 v) to White molex
of Boiler (external junction box)
Ź Wire 120 Vac power supply to zone relay
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 59 °F (15 °C)
e
approx. 131 °F (55 °C)
max
approx. 158 °F (70 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Heat only wall boiler
Circulators
Indirect Tank
NSC Controls
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Comfort
Zone
Manager
(CZM100)
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Room
Thermostat
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
Supply
Sensor
Comfort Room
Controller
T
Bosch
T
Bosch
T
...
T
Bosch
T
T
CRC100 or
CRC200
CZM100
Note: See Appendix B for
Primary/Secondary piping
requirements
Gas
Supply
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
3 2 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 33
System #14
CZM100
See CZM100
Manual for
additional
Wiring
information
Heatronic Internal Wiring
B
Bosch Controls
3
4 5
CRC100 or CRC200
6
2
1
1
2
3
Bosch
4
Bosch
Bosch
0
T0
VZ1
1 2 1 2
VZ3
VZ2
3 4 1 2 3 4 1
2 3
24VAC
4 1 2
B
120 VAC
4
120 VAC
Dry contacts
N L
2
PZ1
PZ2
N L
N L
PZ3
< 24 V
N L
BUS BUS BUS BUS
1 2 1 2 1
9
8
LWCO
1
Outdoor
Sensor
2
1 2
A
F
Supply Sensor
7
DHW Sensor
DHW Thermistor
External Boiler Junction box
L
L
N
N
red
storage
tank pump
white
mains
120v/60 hz
N
L
black
ch pump
for unmixed heating
(Not Used)
Supply Sensor
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
DHW
Circulator
L G N
120 Vac Supply
Wiring:
Low Voltage
Line Voltage
Ź Wire BUS terminal of CZM100 to Terminal BB of
Greenstar boiler
Ź Wire CRC controllers to BUS terminals of
CZM100 (See Appendix A for Room Controller Settings)
Ź Wire Greenstar Tank thermistor sensor to blue
molex adaptor in Greenstar boiler wire harness
Ź Wire Supply Sensor to “TO” connection of CZM100
Ź Wire Main power supply (120 v) to White molex
of Boiler (external junction box) and to 120 VAC
input of CZM100
Ź Wire 120 VAC ouputs of PZ1, PZ2 and PZ3 of
CZM100 to Zone Circulators
Ź Wire 120 VAC of Red Molex to DHW Circulator
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
approx. 167 °F (75 °C)
max
Approx. 194 °F (90°C)
Baseboard & convector system
1
4
3
5
2
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 59 °F (15 °C)
e
approx. 131 °F (55 °C)
max
approx. 158 °F (70 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Heat only floor boiler
Circulators
Indirect Tank
Zone Relay
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Purge Drain
DHW
Aquastat
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Room
Thermostat
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Relief
Valve
Domestic
Hot Water
Circulator
T
T
T
...
T
T
T
XX
Zone relay
Gas
Supply
Note: Internal Low Loss
Header in open position
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
3 4 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 35
System #15
Low Voltage Wiring
BUS
TT
out sen
LWCO
1
2
3
4
Line Voltage Wiring
DHW sen
5
6
L
L
N
N H
N H
N H
N H
Zone 1
Zone 2
Zone 3
Priority
Zone
L
N
N
black
ch pump
for unmixed heating
(Not Used)
red
storage
tank pump
white
mains
120v/60 hz
X1 X2
end
switch
120 V Line
Zone 1
Zone 2
Zone 3
T T
T T
T T
Priority
Zone
Ground
Neutral
Note: For Low Water Cutoff Wiring see
Appendix E of this manual
Tank
Aquastat
Wiring:
Low Voltage
Line Voltage
Ź Remove factory jumper from terminal #2 and
connect End Switch of Mult-Zone relay (dry contacts
only) to terminal #2
Ź Wire Main power supply (120 v) to White molex
of Boiler
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
reset
eco
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 59 °F (15 °C)
e
approx. 131 °F (55 °C)
max
approx. 158 °F (70 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Heat only floor boiler
Circulators
Indirect Tank
NSC Controls
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Comfort
Zone
Manager
(CZM100)
Purge Drain
DHW Sensor
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Comfort Room
Controller
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Relief
Valve
Domestic
Hot Water
Circulator
T
Bosch
T
Bosch
T
...
T
Bosch
T
T
CRC100 or
CRC200
Gas
Supply
CZM100
Note: Internal Low Loss
Header in open position
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
3 6 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 37
System #16
Low Voltage Wiring
BUS
TT
out sen
LWCO
1
2
3
4
Line Voltage Wiring
DHW sen
5
6
CZM100
3
2
1
See CZM100
Manual for
additional
Wiring
information
N
L
red
storage
tank pump
N
L
white
mains
120v/60 hz
CRC100 or CRC200
N
L
black
ch pump
for unmixed heating
(Not Used)
4 5 6
1
2
3
Bosch
4
Bosch
Bosch
0
T0
VZ1
1 2 1 2
VZ3
VZ2
3 4 1 2 3 4 1
2 3
24VAC
4 1 2
DHW
Pump
120 VAC
120 VAC
N L
PZ1
N L
PZ2
PZ3
N L
N L
< 24 V
BUS BUS BUS BUS
1 2 1 2 1
2
1 2
Neutral
Ground
120 V Line
Note: For Low Water Cutoff Wiring see
Appendix E of this manual
Wiring:
Low Voltage
Line Voltage
Ź Wire BUS terminal of CZM100 to Terminal #1 of
Greenstar FS boiler
Ź Wire CRC controllers to BUS terminals of
CZM100
Ź Wire Greenstar Tank sensor to Terminal #5 of
Greenstar FS boiler
Ź See Appendix A for Room Controller Settings
Ź Wire Main power supply (120 v) to White molex
of Boiler and to 120 VAC input of CZM100
Ź Wire 120 VAC ouputs of PZ1, PZ2 and PZ3 to
Zone Circulators
Ź Wire Red molex on back of Greenstar FS boiler
to DHW indirect tank pump
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
approx. 167 °F (75 °C)
max
Approx. 194 °F (90°C)
Baseboard & convector system
1
4
3
5
2
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 59 °F (15 °C)
e
approx. 131 °F (55 °C)
max
approx. 158 °F (70 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Combi wall boiler
Zone Valves
Zone Relay
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Supply
Sensor
Outdoor
Sensor
FW200
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Room
Thermostat
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
Zone
Valve
T
T
T
...
T
T
T
XX
Zone relay
Domestic
Hot Water
Note: Larger heating systems
may require an additional
expansion tank external to the
boiler – see manual for details.
(Use of FW200 and
outdoor air sensor is
optional)
Domestic
Gas
Supply Cold Water
Note: See Appendix B for
Primary/Secondary piping
requirements
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
3 8 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 39
System # 17
T T
Zone 1
T T
Zone 2
T T
Zone 3
Zone 4
priority
off
T T
Zone 4
on
24 VAC
Transformer
Heatronic Internal Wiring
Zone 4 relay
N/O Com N/C
End
switch
B
End
switch
1
Zone 1
2 3 4
1
Zone 2
2 3 4
1
Zone 3
2 3 4
1
Zone 4
2 3 4
Bosch Controls
B
4
Dry contacts
2
9
8
LWCO
1
Outdoor
Sensor
2-wire
Zone
valve
A
F
4-wire
Zone
valve
3-wire
Zone
valve
7
Outdoor Sensor
Neutral
120 VAC
Ground
If using FW200 (Optional):
Ź install FW200 on front of
boiler (see manual)
Ź install outdoor air sensor
Ź Follow FW200 Quick
Set-up guide in Appendix C
L
L
N
Supply Sensor
N
black
ch pump
for unmixed heating
(Not Used)
white
mains
120v/60 hz
Supply Sensor
External Boiler Junction box
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
Wiring:
Low Voltage
Line Voltage
Ź Remove factory jumper from terminal #2 & #4
and connect to End Switch of Mult-Zone relay (dry
contacts only)
Ź Wire Main power supply (120 v) to White molex
of Boiler external junction box
Ź Wire 120 Vac power supply to zone relay
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
approx. 167 °F (75 °C)
max
Approx. 194 °F (90°C)
Baseboard & convector system
1
4
3
5
2
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 104 °F (40 °C)
e
approx. 122 °F (50 °C)
max
approx. 140 °F (60 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Combi wall boiler
Zone Valves
NSC Controls
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Supply
Sensor
Comfort
Zone
Manager
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Comfort
Room
Controller
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
Zone
Valve
Bosch
T
T
Bosch
T
...
T
Bosch
T
T
CRC100 or
CRC200
Domestic
Hot Water
Note: Larger heating systems
may require an additional
expansion tank external to the
boiler – see manual for details.
CZM100
Domestic
Gas
Supply Cold Water
Note: See Appendix B for
Primary/Secondary piping
requirements
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
4 0 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 41
System # 18
CZM100
Heatronic Internal Wiring
3
2
1
See CZM100
Manual for
Detail wiring
B
Bosch Controls
B
4 5
6
1
2
3
4
24 VAC
Transformer
0
T0
4
VZ1
1 2 1 2
VZ3
VZ2
3 4 1 2
3 4 1
2 3
24VAC
24 Vac
120 Vac
4 1 2
Dry contacts
2
120 VAC
9
8
LWCO
1
Outdoor
Sensor
120 VAC
N L
A
PZ1
N L
PZ2
N L
PZ3
N L
< 24 V
BUS BUS BUS BUS
1 2 1 2 1
2
2-wire, 3 -wire and 4- wire zone valves
1 2
F
7
Bosch
Supply Sensor
Bosch
Bosch
CRC100 or CRC200
120 V Line
Neutral
Ground
L
L
N
N
black
ch pump
for unmixed heating
(Not Used)
white
mains
120v/60 hz
Supply Sensor
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
Wiring:
Low Voltage
Line Voltage
Ź Wire BUS terminal of CZM100 to Terminal BB of
Greenstar boiler Heatronic control
Ź Wire CRC controllers to BUS terminals of CZM100
(See Appendix A for Room Controller Settings)
Ź Provide 24 Vac from transformer to Terminals 1
and 2 of CZM100 labeled “24 VAC”
ŹWire zone valves to “VZ” terminals of CZM100 –
remove jumper from terminal 3 and 4 for 3-wire and
4-wire zone valves
Ź Wire Supply Sensor to “TO” connection of CZM100
Ź Wire Main power supply (120 v) to White molex
of Boiler (external junction box) and to 120 VAC
input of CZM100
Ź Wire 120 VAC ouput of PZ1 to system pump
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 104 °F (40 °C)
e
approx. 122 °F (50 °C)
max
approx. 140 °F (60 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Combi floor boiler
Zone Valves
Zone Relay
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Room
Thermostat
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
Zone
Valve
T
T
T
...
T
T
T
Note: Larger heating systems
may require an additional
expansion tank external to the
boiler – see manual for details.
XX
Zone relay
Gas
Supply
Note: Internal Low Loss
Header in open position
Domestic
Hot Water
Domestic
Cold Water
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
4 2 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 43
System # 19
Low Voltage Wiring
BUS
TT
out sen
LWCO
1
2
3
4
Line Voltage Wiring
DHW sen
5
6
L
Thermostats
L
N
T T
Zone 1
T T
Zone 2
T T
Zone 3
T T
Zone 4
N
black
ch pump
for unmixed heating
(Not Used)
white
mains
120v/60 hz
Zone 4
priority
off
on
24 VAC
Transformer
Zone 4 relay
N/O Com N/C
End
switch
End
switch
1
Zone 1
2 3 4
2-wire
Zone
valve
1
Zone 2
2 3 4
3-wire
Zone
valve
1
Zone 3
2 3 4
1
Zone 4
2 3 4
Note: For Low Water Cutoff Wiring see
Appendix E of this manual
Neutral
Ground
120 V Line
4-wire
Zone
valve
Wiring:
Low Voltage
Line Voltage
Ź Remove factory jumper from terminal #2 and
connect End Switch of Multi-Zone relay (dry
contacts only) to terminal #2
Ź Wire Main power supply (120 v) to White molex
of Boiler
Ź Wire System circulator to Zone Relay end switch
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
approx. 167 °F (75 °C)
max
Approx. 194 °F (90°C)
Baseboard & convector system
1
4
3
5
2
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 59 °F (15 °C)
e
approx. 131 °F (55 °C)
max
approx. 158 °F (70 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Combi floor boiler
Zone Valves
NSC Controls
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Comfort
Zone
Manager
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Comfort
Room
Controller
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
Zone
Valve
Bosch
T
T
Bosch
T
...
T
Bosch
T
T
CRC100 or
CRC200
Note: Larger heating systems
may require an additional
expansion tank external to the
boiler – see manual for details.
Gas
Supply
CZM100
Note: Internal Low Loss
Header in open position
Domestic
Hot Water
Domestic
Cold Water
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
4 4 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 45
System #20
Low Voltage Wiring
BUS
TT
out sen
LWCO
1
2
3
4
Line Voltage Wiring
DHW sen
5
6
CZM100
3
2
1
4 5
L
N
L
See CZM100
Manual for
Detail wiring
N
black
ch pump
for unmixed heating
(Not Used)
white
mains
120v/60 hz
6
1
2
3
4
24 VAC
Transformer
0
T0
VZ1
1 2 1 2
VZ3
VZ2
3 4 1 2 3 4 1
2 3
24VAC
24 Vac
120 Vac
4 1 2
120 VAC
120 VAC
N L
PZ1
N L
PZ2
N L
PZ3
N L
< 24 V
BUS BUS BUS BUS
1 2 1 2 1
2
1 2
Bosch
2-wire, 3 -wire and 4- wire zone valves
Bosch
Neutral
Ground
120 V Line
Bosch
CRC100 or CRC200
Note: For Low Water Cutoff Wiring see
Appendix E of this manual
Wiring:
Low Voltage
Line Voltage
Ź Wire BUS terminal of CZM100 to Terminal #1 of
Greenstar FS boiler
Ź Wire CRC controllers to BUS terminals of
CZM100
Ź Provide 24 Vac from transformer to Terminals 1
and 2 of CZM100 labeled “24 VAC”
ŹWire zone valves to “VZ” terminals of CZM100 –
remove jumper from terminal 3 and 4 for 3-wire and
4-wire zone valves
Ź See Appendix A for Room Controller Settings
Ź Wire Main power supply (120 v) to White molex
of Boiler and to 120 VAC input of CZM100
Ź Wire 120 VAC ouput of PZ1 to system pump
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
reset
eco
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 104 °F (40 °C)
e
approx. 122 °F (50 °C)
max
approx. 140 °F (60 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Heat only wall boiler
Zone Valves
Indirect Tank
Zone Relay
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Supply
Sensor
Outdoor
Sensor
FW200
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Room
Thermostat
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
Zone
Valve
T
T
T
...
T
T
T
XX
Zone relay
Gas
Supply
Note: See Appendix B for
Primary/Secondary piping
requirements
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
4 6 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 47
System # 21
Tank
Aquastat
Thermostats
Heatronic Internal Wiring
B
Zone 4
priority
off
Bosch Controls
B
T T
Zone 1
4
Dry contacts
T T
Zone 2
T T
Zone 3
T T
Zone 4
on
2
9
LWCO
1
Outdoor
Sensor
24 VAC
Transformer
A
8
F
7
Zone 4 relay
N/O Com N/C
End
switch
End
switch
1
Zone 1
2 3 4
1
2-wire
Zone
valve
Zone 2
2 3 4
Zone 3
2 3 4
1
1
Zone 4
2 3 4
4-wire
Zone
valve
3-wire
Zone
valve
Neutral
Ground
120 Vac
Supply Sensor
Supply Sensor
External Boiler
Junction box
N
L
N
L
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
red
storage
tank pump
white
mains
120v/60 hz
L
N
black
ch pump
for unmixed heating
(Not Used)
Wiring:
Low Voltage
Line Voltage
Ź Remove factory jumper from terminal #2 & #4
connect End Switch of Multi-Zone relay (dry
contacts only)
Ź Wire Main power supply (120 v) to White molex
of Boiler
Ź Wire System Circulator to end switch of Relay
Ź Wire DHW Circulator to Normally Open priority
contacts of Relay
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 59 °F (15 °C)
e
approx. 131 °F (55 °C)
max
approx. 158 °F (70 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Heat only wall boiler
Zone Valves
Indirect Tank
NSC Controls
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Supply
Sensor
Comfort
Zone
Manager
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Comfort
Room
Controller
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
Zone
Valve
Bosch
T
T
Bosch
T
...
T
Bosch
T
T
CRC100 or
CRC200
CZM100
Note: See Appendix B for
Primary/Secondary piping
requirements
Gas
Supply
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
4 8 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 49
System # 22
CZM100
Heatronic Internal Wiring
3
2
1
See CZM100
Manual for
Detail wiring
B
Bosch Controls
B
4 5
6
1
2
3
4
24 VAC
Transformer
0
T0
VZ1
1 2 1 2
VZ3
VZ2
3 4 1 2 3 4 1
2 3
24VAC
24 Vac
120 Vac
4 1 2
4
Dry contacts
120 VAC
2
PZ1
120 VAC
9
8
LWCO
1
Outdoor
Sensor
N L
N L
PZ2
N L
PZ3
N L
< 24 V
BUS BUS BUS BUS
1 2 1 2 1
A
2
2-wire, 3 -wire and 4- wire zone valves
1 2
F
7
Bosch
Supply Sensor
Bosch
Bosch
CRC100 or CRC200
120 V Line
Neutral
Ground
External Boiler
Junction box
L
Supply Sensor
L
N
N
red
storage
tank pump
white
mains
120v/60 hz
L
N
black
ch pump
for unmixed heating
(Not Used)
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
Wiring:
Low Voltage
Line Voltage
Ź Wire BUS terminal of CZM100 to Terminal BB of
Greenstar boiler Heatronic control
Ź Wire CRC controllers to BUS terminals of CZM100
(See Appendix A for Room Controller Settings)
Ź Provide 24 Vac from transformer to Terminals 1
and 2 of CZM100 labeled “24 VAC”
ŹWire zone valves to “VZ” terminals of CZM100 –
remove jumper from terminal 3 and 4 for 3-wire and
4-wire zone valves
Ź Wire Supply Sensor to “TO” connection of CZM100
Ź Wire Main power supply (120 v) to White molex
of Boiler (external junction box) and to 120 VAC
input of CZM100
Ź Wire 120 VAC ouput of PZ1 to system pump
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
reset
eco
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 59 °F (15 °C)
e
approx. 131 °F (55 °C)
max
approx. 158 °F (70 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Heat only floor boiler
Zone Valves
Indirect Tank
Zone Relay
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Tank
thermistor
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Room
Thermostat
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
Zone
Valve
T
T
T
T
...
...
T
T
XX
Zone relay
Gas
Supply
Note: Internal Low Loss
Header in open position
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
5 0 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 51
System # 23
Low Voltage Wiring
BUS
TT
out sen
LWCO
1
2
3
4
Line Voltage Wiring
DHW sen
5
6
Tank
Aquastat
Thermostats
L
T T
Zone 1
T T
Zone 2
T T
Zone 3
T T
Zone 4
L
N
L
N
N
black
ch pump
for unmixed heating
(Not Used)
red
storage
tank pump
white
mains
120v/60 hz
Zone 4
priority
off
on
24 VAC
Transformer
Zone 4 relay
N/O Com N/C
End
switch
End
switch
Zone 1
1 2 3 4
Zone 2
1 2 3 4
2-wire
Zone
valve
3-wire
Zone
valve
Zone 3
1 2 3 4
Note: For Low Water Cutoff Wiring see
Appendix E of this manual
Zone 4
1 2 3 4
Neutral
Ground
4-wire
Zone
valve
120 V Line
Wiring:
Low Voltage
Line Voltage
Ź Remove factory jumper from terminal #2 and
connect End Switch of Multi-Zone relay (dry
contacts only) to terminal #2
Ź Wire Main power supply (120 v) to White molex
of Boiler
Ź Wire System Circulator to end switch of Relay
Ź Wire DHW Circulator to Normally Open priority
contacts of Relay
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
reset
eco
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 59 °F (15 °C)
e
approx. 131 °F (55 °C)
max
approx. 158 °F (70 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Heat only floor boiler
Zone Valves
Indirect Tank
NSC Controls
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Tank
thermistor
Comfort
Zone
Manager
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Comfort
Room
Controller
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
Zone
Valve
T
Bosch
T
T
Bosch
T
...
...
Bosch
T
T
CRC100 or
CRC200
Gas
Supply
CZM100
Note: Internal Low Loss
Header in open position
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
5 2 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 53
System #24
Low Voltage Wiring
BUS
TT
out sen
LWCO
1
2
3
4
Line Voltage Wiring
DHW sen
5
6
See CZM100
Manual for
additional
Wiring
information
CZM100
3
2
1
4 5
6
1
2
3
4
0
T0
VZ1
1 2 1 2
VZ3
VZ2
3 4 1 2 3 4 1
2 3
24VAC
N
L
red
storage
tank pump
N
L
white
mains
120v/60 hz
N
L
black
ch pump
for unmixed heating
(Not Used)
24 VAC
Transformer
24 Vac
120 Vac
4 1 2
120 VAC
120 VAC
N L
PZ1
N L
PZ2
N L
PZ3
N L
< 24 V
BUS BUS BUS BUS
1 2 1 2 1
2
1 2
Bosch
2-wire, 3 -wire and 4- wire zone valves
Bosch
Neutral
Ground
120 V Line
Bosch
Note: For Low Water Cutoff Wiring see
Appendix E of this manual
CRC100 or CRC200
Wiring:
Low Voltage
Line Voltage
Ź Wire BUS terminal of CZM100 to Terminal #1 of
Greenstar FS boiler
Ź Wire CRC controllers to BUS terminals of
CZM100
Ź Provide 24 Vac from transformer to Terminals 1
and 2 of CZM100 labeled “24 VAC”
ŹWire zone valves to “VZ” terminals of CZM100 –
remove jumper from terminal 3 and 4 for 3-wire and
4-wire zone valves
Ź Wire Greenstar DHW sensor to Terminal 5 of Boiler
Ź See Appendix A for Room Controller Settings
Ź Wire Main power supply (120 v) to White molex
of Boiler and to 120 VAC input of CZM100
Ź Wire 120 VAC ouput of PZ1 on CZM 100 to
system pump
Ź Wire 120 VAC ouput of RED Molex on Greenstar
to DHW Circulator
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
reset
eco
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 59 °F (15 °C)
e
approx. 131 °F (55 °C)
max
approx. 158 °F (70 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Single zone
Combi wall boiler
Baseboard
Bosch Control
.
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, 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.
Created
Released
Changed
Bases
No.
State
Bosch
PRV
Relief piping
Purge
Drain
Bosch
Control
Condensate
drain
Relief valve &
pressure gauge
Back-flow
preventer
Isolation
valve
Outdoor
air sensor
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Note:Greenstar Internal circulator
can support a single zone loop
not to exceed 4 gpm at 12 feet of
head. See pump curves in
manual for pump capacities at
alternate flow rates.
Domestic
Hot Water
Domestic
Cold Water
Gas
Supply
Bosch
Control
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
5 4 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 55
System #25
Heatronic Internal Wiring
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
B
Bosch
Control
Bosch Controls
B
4
Dry contacts
2
1
8
LWCO
9
Outdoor
Sensor
A
F
7
120 Vac Supply
Ground
Neutral
DHW Sensor
black
ch pump
for unmixed heating
(Not Used)
white
mains
120v/60 hz
Supply Sensor
N
L
N
L
External Boiler Junction box
Wiring:
Low Voltage
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:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
reset
eco
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
3
2
6
approx. 167 °F (75 °C)
max
Approx. 194 °F (90°C)
Baseboard & convector system
1
4
3
5
2
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 104 °F (40 °C)
e
approx. 122 °F (50 °C)
max
approx. 140 °F (60 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Single Zone
Combi floor boiler
Baseboard
Bosch Control
.
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, 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.
Created
Released
Changed
Bases
No.
State
Bosch
PRV
Relief piping
Purge
Drain
Supply
Sensor
Bosch
Control
Condensate
drain
Relief valve &
pressure gauge
Back-flow
preventer
Isolation
valve
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Note:Greenstar Internal circulator
can support a single zone loop
not to exceed 4 gpm at 12 feet of
head. See pump curves in
manual for pump capacities at
alternate flow rates.
Note: additional expansion
tank shown – internal
expansion tank in combi boiler
models may be adequate for
standard systems -see boiler
manual for details.
Gas
Supply
Bosch
Control
Note: Internal Low Loss
Header in closed position
Domestic Domestic
Hot Water Cold Water
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
5 6 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 57
System #26
Low Voltage Wiring
BUS
TT
out sen
LWCO
1
2
3
4
Line Voltage Wiring
DHW sen
5
6
L
L
N
N
black
ch pump
for unmixed heating
(Not Used)
white
mains
120v/60 hz
Bosch
Control
120 V Line
Note: For Low Water Cutoff Wiring see
Appendix E of this manual
Ground
Neutral
Wiring:
Low Voltage
Line Voltage
Ź Wire Bosch Control to Terminal # 1 on back of
Greenstar FS Boiler
Ź Wire Main power supply (120 v) to White molex
Heatronic Settings:
Boiler
Heating
Dial
Typical supply
temperatures
Application
1
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
reset
eco
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 104 °F (40 °C)
e
approx. 122 °F (50 °C)
max
approx. 140 °F (60 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Single Zone
Heat only wall boiler
Baseboard
Bosch Control
.
TK
02/20/15
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, 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.
Created
Released
Changed
Bases
No.
State
Bosch
PRV
Relief piping
Purge
Drain
Bosch
Control
Condensate
drain
Relief valve &
pressure gauge
Back-flow
preventer
Isolation
valve
Outdoor
air sensor
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Note:Greenstar Internal circulator
can support a single zone loop
not to exceed 4 gpm at 12 feet of
head. See pump curves in
manual for pump capacities at
alternate flow rates.
Gas
Supply
Bosch
Control
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
5 8 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 59
System #27
Heatronic Internal Wiring
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
Bosch
Control
B
Bosch Controls
B
4
Dry contacts
2
9
8
LWCO
1
Outdoor
Sensor
A
F
7
120 Vac Supply
Ground
Neutral
DHW Sensor
L
L
N
Supply Sensor
N
red
storage
tank pump
white
mains
120v/60 hz
L
N
black
ch pump
for unmixed heating
(Not Used)
External Boiler Junction box
Wiring:
Low Voltage
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:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Single Zone
Heat only floor boiler
Baseboard
Bosch Control
.
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, 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.
Created
Released
Changed
Bases
No.
State
Bosch
PRV
Relief piping
Purge
Drain
Bosch
Control
Condensate
drain
Relief valve &
pressure gauge
Back-flow
preventer
Isolation
valve
Outdoor
air sensor
Baseboard
Expansion
Tank
Auto-Fill
Air
Eliminator
Note:Greenstar Internal circulator
can support a single zone loop
not to exceed 4 gpm at 12 feet of
head. See pump curves in
manual for pump capacities at
alternate flow rates.
Gas
Supply
Bosch
Control
Note: Internal Low Loss
Header in closed position
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
6 0 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 61
System #28
Low Voltage Wiring
BUS
TT
out sen
LWCO
1
2
3
4
Line Voltage Wiring
DHW sen
5
6
L
L
N
L
N
N
black
ch pump
for unmixed heating
(Not Used)
red
storage
tank pump
white
mains
120v/60 hz
Bosch
Control
120 V Line
Note: For Low Water Cutoff Wiring see
Appendix E of this manual
Ground
Neutral
Wiring:
Low Voltage
Line Voltage
Ź Wire Bosch Control to Terminal # 1 on back of
Greenstar FS Boiler
Ź Wire Main power supply (120 v) to White molex
Heatronic Settings:
Boiler
Heating
Dial
Typical supply
temperatures
Application
1
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Single Zone
Heat only wall boiler
Indirect Tank
Bosch Control
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Bosch
Control
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
DHW
Thermistor
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
Supply
Sensor
T
T
Bosch
Control
...
Note: See Appendix B for
Primary/Secondary piping
requirements
Gas
Supply
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
6 2 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 63
System #29
Heatronic Internal Wiring
Bosch
Control
B
Bosch Controls
B
4
Dry contacts
2
9
8
LWCO
1
Outdoor
Sensor
A
External Boiler Junction box
F
7
DHW Sensor
DHW Thermistor
L
N
L
N
red
storage
tank pump
white
mains
120v/60 hz
N
L
black
ch pump
for unmixed heating
Zone
Circulator
L GN
120 Vac Supply
Supply Sensor
Supply Sensor
DHW
Circulator
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
Wiring:
Low Voltage
Line Voltage
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 Greenstar Tank thermistor sensor to blue
molex adaptor in Greenstar boiler wire harness
Ź Wire 120 VAC of Black Molex to Zone Circulator
Ź Wire Supply Sensor to terminals in the Heatronic
control
Ź Wire 120 VAC of Red Molex to DHW Circulator
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
max
4
3
5
2
approx. 167 °F (75 °C)
Approx. 194 °F (90°C)
Baseboard & convector system
1
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 59 °F (15 °C)
e
approx. 131 °F (55 °C)
max
approx. 158 °F (70 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
Multi Zone
Combi wall boiler
Circulators
Bosch Control with
Zone Relay
...
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, 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.
Created
Released
Changed
Bases
No.
Date
Bosch
Bosch
Control
Purge Drain
Heating
zone
Auto-Fill
Air Eliminator
Flow Check
Condensate
drain
Room
Thermostat
Expansion Tank
PRV Relief
Piping
Back-flow
preventer
Shut-off
valve
Circulator
Supply
Sensor
T
T
T
XX
Zone relay
T
T
Locate the Bosch Control
in the zone with the
greatest heat loss. See
additional requirements
below.
Bosch
Control
Do not connect endswitch of relay to boiler
T
The pump supplying
the zone with the
Bosch control must
be wired to the
Greenstar Boiler
(see wiring diagram)
Note: Larger heating systems
may require an additional
expansion tank external to the
boiler – see manual for details.
Domestic
Hot Water
Requirements for the location of the Bosch Control in a multizone application :
The Bosch Control must be installed in the zone with the largest btu/hr heat
loss
The zone must also have the highest or same supply temperature
requirement as compared to all other zones in the system.
Thermostats located in all other zones will act as temperature limiters.
A higher room temperature request in these zones may not be able to be
achieved. Avoid large temperature setback due to potentially slow recovery
during occupied periods.
...
Note: See Appendix B for
Primary/Secondary piping
requirements
Domestic
Gas
Supply Cold Water
Bosch Thermotechnology Corp.
Data subject to change
Applications Manual
6 4 | Bosch Greenstar
Applications Manual
Bosch Greenstar | 65
System # 30
Heatronic Internal Wiring
Bosch
Control
B
X X
B
( end switch )
Bosch Controls
4
120 Vac
Power
Dry contacts
2
Zone 1 Zone 2 Zone 3
Zone 1 Zone 2 Zone 3
9
8
LWCO
1
Outdoor
Sensor
TT TT TT
A
F
7
DHW Sensor
External Boiler Junction box
black
ch pump
for unmixed heating
(Not Used)
white
mains
120v/60 hz
Supply Sensor
N
L
N
L
Supply Sensor
L G N
120 Vac Supply
Note: For Low Water Cutoff Wiring see
Appendix D of this manual
“Coldest Zone”
Circulator
Wiring:
Low Voltage
Line Voltage
Ź Wire BUS terminal of the Bosch Control to
Terminal BB of Greenstar boiler Heatronic control
Ź Wire Main power supply (120 v) to White molex
of Boiler external junction box
Ź Wire 120 Vac power supply to zone relay
Ź Wire “coldest zone” circulator to Black molex of
Greenstar boiler external junction box
Heatronic Settings:
Boiler
Heating
Dial
1
Typical supply
temperatures
Application
approx. 95 °F (35 °C)
Frost protection
2
approx. 109 °F (43 °C)
3
approx. 122 °F (50 °C)
Radiant floor heating
4
approx. 140 °F (60 °C)
Panel radiator system
5
approx. 153 °F (67 °C)
Cast Iron radiator system
reset
eco
3
2
6
approx. 167 °F (75 °C)
max
Approx. 194 °F (90°C)
Baseboard & convector system
1
4
3
5
2
6
max
DHW thermostat
Typical DHW temperatures
min
approx. 59 °F (15 °C)
e
approx. 131 °F (55 °C)
max
approx. 158 °F (70 °C)
Bosch Thermotechnology Corp.
1
4
e
6
max
Data subject to change
6 6 | Bosch Greenstar
Applications Manual
Appendix A: Quick Set-up Guide for Room Controllers
CRC100 - Operation
The following table shows how to
change a value in the service menu
of the CRC100
1
= Display
2
= Dial
1
67.0 °F
2
Open the service menu
1. press and hold dial until two dashes appear.
2. Release dial to displaythe first setting.
A.1
Changing the setting (e.g. heating zone H.C)
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.
H.C
3
3
2
2
H.C
Close the service menu
1. Press and hold idal until three dashes appear.
2. Release dial.
The display changes to the standard display, and the
user interface works with the changed setting.
Data subject to change
67.0 °F
Bosch Thermotechnology Corp.
Applications Manual
Bosch Greenstar | 67
Appendix A: Quick Set-up Guide for Room Controllers
Note: Please consult the installation manual for a complete overview of the controller settings and proper installation. The
following guide is not a substitute for the installation manual.
CRC100 control set-up:
For single zone application where CRC100 is connected directly to the boiler:
Ź Set A.1 value to “CO”
For a multi- zone application where CRC100 is connected to a CZM100:
Ź Set H.C on each CRC100 to the appropriate zone number (1 thru 8)
CRC200 control set-up:
For single zone application where the CRC200 is connected directly to the boiler:
ŹSet 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 system requirement
Ź Set “Max Supply Temp” to appropriate maximum temperature for the system
For a multi- zone application where CRC200 is connected to a CZM100:
Ź Set HC on each CRC200 to the appropriate zone number (1 thru 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 maximum temperature for the zone
Zone number and corresponding pump/Zone valve output on CZM100:
The CZM100 can support systems using Pumps or Zone valves but
not both. The maximum number of CZM100 in a system is 3. The
CZM100 address can be set by adjusting the potentiometer screw
on the front of the CZM100 (see image right). Address #1 thru #3
is for systems using pumps. Address #4 thru #6 is for systems
using zone valves. Charts below show the heating zone number
and the corresponding pump or zone valve contacts on the
CZM100.
-
Pumps
Coding and Connection to…..
Coding and Connection to…..
Heating
Zone
Number
CZM100 #1
CZM100 #2
CZM100 #3
1
1
-
2
1
-
Pump
contacts
Heating
Zone
Number
CZM100 #1
CZM100 #2
CZM100 #3
-
PZ1
1
4
-
-
VZ1
-
PZ2
2
4
-
-
VZ2
VZ3
Zone
Valve
Contacts
3
1
-
-
PZ3
3
4
-
-
4
-
2
-
PZ1
4
-
5
-
5
-
2
PZ2
5
-
5
6
-
2
-
PZ3
6
-
5
-
VZ3
7
-
-
3
PZ1
7
-
-
6
VZ1
8
-
-
3
PZ2
8
-
-
6
VZ2
Bosch Thermotechnology Corp.
-
-
VZ1
VZ2
Data subject to change
6 8 | Bosch Greenstar
Applications Manual
Appendix B: Primary/Secondary piping for Greenstar Wall Boiler
Gas
Supply
Boiler Supply
Boiler Return
System Supply
System Return
A
B
C
System Header Pipe
Piping Section
A
B
C
Description
Requirements
Minimum length of 4 x pipe diameter based
on System header pipe size
Maximum distance of 4 x pipe diameter
Closely Spaced Tees (center-to-center) based on System header
pipe size
Minimum length of 8 x pipe diameter based
System Return
on System header pipe
System Supply
System Supply/Return Header pipe diameter*
system ¨T of 20°
system ¨T of 10°
Boiler Input (btu/hr)
Boiler Supply/Return pipe diameter
57,000
1"
1"
1.25"
79,000
1"
1"
1.25"
100,000
1"
1.25"
1.5"
131,000
1"
1.25"
1.5"
151,000
1"
1.5"
2.0"
*based on 2 – 4 ft/sec flow velocity.
Data subject to change
Bosch Thermotechnology Corp.
Applications Manual
Bosch Greenstar | 69
Appendix C: FW200 Quick Set-up Guide
This is a quick reference to highlight the BASIC
programming of this control. For a more in depth
understanding or complete programming of the control,
please refer to the FW 200 Installation and Operating
manuals.
9
12 h
15
18
6
At any time, pressing the Menu button (Fig.1, pos.3) will
bring you back to the standard display.
3
24 h
21
3
4
The FW200 is sold separately, and is not compatible any
of the NSC components (CZM100, CRC100, CRC200).
5
2
6
1
Instructions for programming

Set Date and Time upon initial start-up
—
—

Fig. 1 Controller with front flap open
Turn dial (Fig.1, pos.1) to adjust time and date. Press
the dial to finalize your selection.
You will be asked about System configuration, which is
only necessary if you have added additional controls.
If you see this prompt, press and hold the menu
button (Fig.1, pos.3) until it disappears.
Set Date and Time after intitial programming
—
Push the menu button once and release. On the
display Vacation will be highlighted.

Set for constant heating (no night set back)
This can be done two ways:
1.
Turn selector (Fig.1, pos.2) to the Comfort Symbol (
2.
Or change programming.
To change programming:
—
Press and release menu button. Vacation will be
highlighted.
—
Turn dial one click counter-clockwise to highlight
Heating and push dial to select.
—
Program will be highlighted. Push dial to select.
Activate will be highlighted. Turn the dial one click
to highlight Edit and push dial to select.
—
Turn dial counter-clockwise until General Settings is
highlighted.
—
—
Push dial once and release. Time and Date will be
highlighted.
—
Program A will be highlighted. Push dial to select.
—
Push dial again and Time will be highlighted. Set time
by pushing dial and rotating. Once complete, push
again to lock in time setting.
—
Replace with preset program will be highlighted.
Turn the dial counter-clockwise to display All days
and push dial to select.
—
Turn dial until Date is highlighted. Set date by pushing
dial and turning to select. Push dial once to lock in
date setting.
—
P1 will be highlighted. Press the dial again and the
display will flash.
—
Turn dial one click clockwise to 12:00PM.
—
Press the dial and rotate it until Comf. appears.
The area around the display should fill in.
—
Press dial again to lock in your program.
—
Press the menu button to return to main display.
Bosch Thermotechnology Corp.
).
Data subject to change
7 0 | Bosch Greenstar
Applications Manual
Appendix C: FW200 Quick Set-up Guide
Set type of heating system
There are three seperate default presets: Baseboard,
Radiators, Radiant Floor. They have an approximate
basepoint of 75°F. With this basepoint, the heating
system will take some time to raise the room
temperature in warmer weather. Please see the FW 200
Installation and Operating Instructions, “Heating circuit
parameters” for more details on those presets. For a
custom preset, see below.
—
AT / °C
1
10
0
- 10
- 20
90
176
80
158
70
140
60
122
50
104
3
40
86
30
4
68
20
2 50
10
VL / °F
To open INSTALLER SETTINGS: press and hold
the menu button for approx. 5 seconds. System
Configuration will be highlighted.
194
20
VL / °C

68
50
32
14
-4
AT / °F
—
Turn dial one click counter-clockwise to highlight
Heating Parameters.
—
Press the dial, Heating Circuit 1 will be highlighted.
Fig. 2
—
Press dial and Heating circuit type will be highlighted.
Fig. 2 Legend
—
Press dial and Radiators will be highlighted.
[1]
Maximum Base Line Adjustment 186 °F (85 °C)
[2]
Minimum Base Line Adjustment 50 °F (10 °C)
6 720 806 992-07.1O
—
Press dial again and Radiators will flash.
[3]
Maximum Design Temperature Adjustment 186 °F (85 °C)
—
Turn the dial to choose Baseline/Design temp.
[4]
Minimum Design Temperature Adjustment 86 °F (30 °C)
—
Press the dial, Heating circuit type will be highlighted.
AT
Outdoor temperature
—
Turn the dial counter-clockwise. Base Line will be
displayed.
VL
Supply temperature
—
Press the dial and 78°F (25 °C) will flash. This is
the supply temperature at 65 °F (18 °C) outdoor
temperature.

Adjust warm weather shut down (WWSD)
—
Set accordingly (Fig. 2).
—
Press the dial to confirm the setting.
For hydroair systems, the minimum supply temperature
must be raised to the turn on temperature for that coil.
—
Turn the dial until Design Temp is highlighted. Press
the dial and 168°F (75°C) will flash. 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 button to return to main display.
Data subject to change
—
Press and hold the menu button for about 5 seconds.
System Configuration will be highlighted.
—
Turn dial one click counter-clockwise to highlight
Heating Parameters and push dial to select.
—
Heating Circuit 1 will be highlighted.
—
Turn the dial counter-clockwise until Heating OFF at
outdoor temperature is highlighted.
—
Press the dial and the display will flash. The default
value is 68 °F (20 °C) and is adjustable from 50 °F (10
°C) to 77 °F (25 °C). Turning above 77 °F (25 °C) will
move it to 210 °F (99 °C), which disables WWSD.
—
Press the dial to confi rm the setting.
To restore to factory defaults, hold the Delete button (Fig.1,
pos.5) and the Menu button simultaneously for about 10 seconds.
A count down display will appear. This will restore factory
defaults. The only program that will be held is the date and time.
Bosch Thermotechnology Corp.
Applications Manual
Bosch Greenstar | 71
Appendix D: Wiring Hydrolevel Safgard 1100 Low Water Cut-off
to Greenstar Wall Boiler
N
L
white
mains
120v/60 hz
Main Power
Supply
N
L
red
storage
tank pump
N
L
black
ch pump
for unmixed heating
120 V
Ground
Neutral
External Junction
Box on Bottom of
Greenstar Wall boiler
Heatronic Control
Green
B
Bosch Controls
B
Transformer
4
Dry contacts
2
Yellow
9
8
Outdoor
Sensor
A
F
7
Yellow
LWCO
White
1
Red
120 VAC
24 VAC
Supply Sensor
Hydrolevel Safgard 1100
Low 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 and #9 and connect the leads
labeled SWITCH CONTACT (yellow) to terminals #8 and #9
Bosch Thermotechnology Corp.
Data subject to change
7 2 | Bosch Greenstar
Applications Manual
Appendix E: Wiring Hydrolevel safgard 1100 Low Water Cut-Of
to Greenstar Floor Boiler
N
L
white
mains
120v/60 hz
Main Power
Supply
N
L
red
storage
tank pump
N
L
black
ch pump
for unmixed heating
External Junction
Box on back of
Greenstar Floor
boiler
Low Voltage Junction
Box on back of floor
boiler
120 V
Ground
Neutral
Green
BUS
TT
out sen
LWCO
1
2
3
4
DHW sen
5
6
Transformer
White
Red
120 VAC
24 VAC
Yellow
Yellow
Hydrolevel Safgard 1100
Low 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)
ŹAT the Low Voltage box on the rear of the boiler, remove the jumper acros the LWCO connections and
connect the leads labeled SWITCH CONTACT (yellow) to these connections.
Data subject to change
Bosch Thermotechnology Corp.
Applications Manual
Bosch Thermotechnology Corp.
Bosch Greenstar | 73
Data subject to change
7 4 | Bosch Greenstar
Data subject to change
Applications Manual
Bosch Thermotechnology Corp.
Applications Manual
Bosch Thermotechnology Corp.
Bosch Greenstar | 75
Data subject to change
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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