Potterton SIRIUS FS Release note

Technical Specication Eurocondense four
Eurocondense four
Floor standing boiler
Manufactured to the latest ISO standards, the
Eurocondense four uses tried and tested technology
to provide efcient heating for buildings of all sizes.
A range of controls are available, for easy integration
with new or existing heating systems.
Technical Specication
Works every time.
www.pottertoncommercial.co.uk
Features Benets
Lightweight aluminium heat exchanger. For reliable, highly efcient heat transfer.
Top hydraulic and ue connections. Easier to connect and less space needed for
working access.
Compact dimensions and small footprint. Requires less space for installation.
Built in boiler control. User friendly control panel includes operation status,
weather compensation, timer for heating and DHW,
fault diagnostics and, where relevant, cascade operation.
Controls can be programmed to work with solar thermal,
biomass and buffer tanks.
Sustainable, energy efcient, solution for a wide range
of applications.
Works every time.
sales 0345 070 1055
technical 0345 070 1057
web pottertoncommercial.co.uk
Registered ofce address: Baxi Heating UK, Coventry Road, Warwick, CV34 4LL
500403
ICOM
Energy Association
RS 33961
Technical Specication Eurocondense four
Eurocondense four
Floor standing boiler
Manufactured to the latest ISO standards, the
Eurocondense four uses tried and tested technology
to provide efcient heating for buildings of all sizes.
A range of controls are available, for easy integration
with new or existing heating systems.
Technical Specication
Works every time.
www.pottertoncommercial.co.uk
Features Benets
Lightweight aluminium heat exchanger. For reliable, highly efcient heat transfer.
Top hydraulic and ue connections. Easier to connect and less space needed for
working access.
Compact dimensions and small footprint. Requires less space for installation.
Built in boiler control. User friendly control panel includes operation status,
weather compensation, timer for heating and DHW,
fault diagnostics and, where relevant, cascade operation.
Controls can be programmed to work with solar thermal,
biomass and buffer tanks.
Sustainable, energy efcient, solution for a wide range
of applications.
Works every time.
sales 0345 070 1055
technical 0345 070 1057
web pottertoncommercial.co.uk
Registered ofce address: Baxi Heating UK, Coventry Road, Warwick, CV34 4LL
500403
ICOM
Energy Association
RS 33961
Technical Specication Eurocondense four
Eurocondense four
Floor standing boiler
Manufactured to the latest ISO standards, the
Eurocondense four uses tried and tested technology
to provide efcient heating for buildings of all sizes.
A range of controls are available, for easy integration
with new or existing heating systems.
Technical Specication
Works every time.
www.pottertoncommercial.co.uk
Features Benets
Lightweight aluminium heat exchanger. For reliable, highly efcient heat transfer.
Top hydraulic and ue connections. Easier to connect and less space needed for
working access.
Compact dimensions and small footprint. Requires less space for installation.
Built in boiler control. User friendly control panel includes operation status,
weather compensation, timer for heating and DHW,
fault diagnostics and, where relevant, cascade operation.
Controls can be programmed to work with solar thermal,
biomass and buffer tanks.
Sustainable, energy efcient, solution for a wide range
of applications.
Works every time.
sales 0345 070 1055
technical 0345 070 1057
web pottertoncommercial.co.uk
Registered ofce address: Baxi Heating UK, Coventry Road, Warwick, CV34 4LL
500403
ICOM
Energy Association
RS 33961
M7248
This manual must be kept with the appliance
Direct Fired High Efciency Boiler
Installation & Servicing Instructions
SIRIUS FS
Models
SIRIUS FS400
SIRIUS FS525

GB, IE
page 5
Tried. Tested.
Trusted.
Sirius two WH
Wall hung
condensing boiler
Compact, lightweight,
industry leading
modulation.
Modulation ratio
9:1
Single boiler output
50kW to
110kW
Cascade output
Up to
660kW
Solid and dependable Sirius condensing boilers are designed for
maximum combustion performance and energy efciency.
Modulation ratio
9:1
Single boiler output
50kW to
110kW
Cascade output
Up to
440kW
Sirius two FS
Floor standing
condensing boiler
Ideal for replacement
projects, large domestic
and all commercial
premises.
Modulation ratio
10:1
Single boiler output
400kW and
525kW
Sirius FS
Floor standing
condensing boiler
Cost effective heating
solution for large projects,
such as schools, hotels,
nursing homes and
leisure facilities.
Whichever model you choose
you can depend on:
Genuine parts
We support parts for
all our boilers for up to
10 years after they have
stopped being sold,
so you know your boiler
will be supported.
Online support
Our website contains all
the information you need,
including BIM and CAD
les, brochures, technical
specication sheets, case
studies, installation manuals
and user guides.
Specication and
sales support
Our technical support
experts can guide
you through building
regulations, legislation and
building service engineering
standards. Our dedicated
sales team is never more
than a phone call away.
Reliability
Our boilers are all factory
tested before sale and we
will commission them for
you to make sure they work
reliably and efciently. We
also offer parts and labour
warranties for extra peace
of mind.
Efciency
Our modulating boilers
will meet the variable
heating requirements of
any building, optimising
energy efciency and
running costs.
Engineering quality
All of our products are
manufactured using tried
and tested technology,
and meet the latest ISO
standards.
Stainless Steel range of condensing boilers
page 4

Sirius FS 1 GB/IE
Table of Contents
Ref Subject        Page
1.0 GeneralInformation
1.1 Description of appliance ........................................................................... 3
1.2 Symbols used in this guide ...................................................................... 4
1.3 For whom is this manual intended? ....................................................... 4
2.0 Safety
2.1 Usage and competency ............................................................................. 5
2.2 General safety ............................................................................................... 5
2.3 Regulations and standards ...................................................................... 6
2.4 CE Marking ...................................................................................................... 7
3.0 TechnicalData
3.1 Dimensions and connections .................................................................. 8
3.2 Performance data ........................................................................................ 10
3.3 Sensor values ................................................................................................ 11
3.4 Wiring diagrams ............................................................................................ 12
4.0 PriortoInstallation
4.1 Unpacking the boiler .................................................................................. 14
4.2 Locating the boiler ...................................................................................... 14
4.3 Power connection requirements ............................................................ 16
4.4 Requirements for heating circuit water................................................ 16
4.5 Hydraulic pump requirements ................................................................. 18
4.6 Application examples ................................................................................ 20
5.0 Installation
5.1 Water connections to low temperature circuits ................................ 23
5.2 Condense connections ............................................................................... 23
5.3 Electrical connections ................................................................................ 24
5.4 Installing room and outside sensors .................................................... 29
5.5 Flue and ventilation .................................................................................... 33
5.6 Gas connections and tightness testing ............................................... 37
6.0 Commissioning
6.1 Switching on .................................................................................................. 38
6.2 Engineers tools (Siemens) and use of Controller stop mode ...... 38
6.3 Checking and adjusting CO2 levels ....................................................... 39
6.4 Decomissioning and Disposal ................................................................. 40
6.5 Controls and basic settings ...................................................................... 41
6.6 Error messages ............................................................................................. 44
6.7 Final checks & User handover ............................................................... 46

Sirius FS 2 GB/IE
Ref Subject        Page
7.0 Maintenance
7.1 Routine Inspection intervals & requirements ......................... 47
7.2 Preparation for component access ............................................. 50
7.3 Removing and changing components ....................................... 52
7.4 Component parts list ........................................................................ 61
7.5 Component illustrations .................................................................. 63
7.6 Recommended parts list .................................................................. 66
7.7 Fault code table .................................................................................. 69
Potterton Commercial’s policy is one of continuous improvement, and therefore the
information in this manual, whilst correct at the time of publication, may be subject
to revision without prior notice.

Sirius FS 3 GB/IE
1.0GENERALINFORMATION
1.1DESCRIPTIONOFAPPLIANCE
1.1.1 General
The FS400 or FS525 model is a gas red, low NOx, dual burner boiler system, for the supply
of low temperature hot water for space heating and primary hot water. The Sirius FS range
of boilers have extensive user programmable controls which can be congured to control
space heating, hot water, Solar and Primary circuits.
Fully automatic electronic controls are integrated into the boiler, with a wide range of
control and sensor options available. An outside temperature sensor is included as standard
to support full temperature compensated heating circuits. The controls also provides volt
free inputs to control the activation of heating and hot water circuits, a 0-10v input to
control demand, and volt free outputs to indicate burner on and fault. All of which can be
used when connected to an external BMS system.
Each burner module consists of a stainless steel combustion chamber, premix burner,
modulating fan and gas valve, ignition and ame detection electrodes and common ow and
return NTC sensors for accurate boiler management control. Fully premixed, radiating,
modulating burner, integrated with gas valve to deliver precise gas/air mixture throughout
the full modulation range.
A common combustion air intake manifold, takes air from the boiler room (type B23). An air
non-return valve gas mixing system is integrated into the air/gas mixture supply of each
burner, to ensure that ue products cannot contaminate the air supply, when the other
burner is not in operation. A separate electronic management system, monitors the position
of this air ap to ensure safe operation during all stages of boiler operation.
The safety and operation functions of each burner are managed by micro processor
controlled circuit boards, one for each of the burners. The Master ontroller also acts as the
cascade controller, switching/modulating the burners according to the demand and readings
from the systems sensors. Control is performed using comparison parameters between the
requested temperature and the global ow temperature.
1.1.2 Control Logic
At full demand, each burner is ignited one at a time, until both burners are operating at full
output. As ow and return temperatures increase, both burners will begin to modulate down
together, until both are operating at minimum input rate.
As ow temperatures begin to approach the calculated set point, one of the burners will
stop, leaving the other operating at minimum input rate. This will continue until both
burners have stopped and temperature ow requirements have been fully satised.

Sirius FS 4 GB/IE
1.2SYMBOLSUSEDINTHISGUIDE
DANGER!
Indicates serious danger to personal safety and life
DANGER of electric shock!
Indicates serious danger from electricity to personal safety and life
CAUTION!
Indicates a potentially dangerous situation for the boiler and the
environment
INFORMATION
Suggestions to assist the user in implementing instructions in this
guide
ADDITIONAL READING
Reference to additional information in other documents
1.3FORWHOMISTHISMANUALINTENDED?
This manual is intended for the heating specialist who installs commercial/industrial heating
plant and equipment.

Sirius FS 5 GB/IE
2.1USAGEANDCOMPETENCY
2.1.1 Improper Use
This Potterton Commercial Heating product has been designed and manufactured
to comply with current European standards of safety. However, following an improper
use, dangers could arise concerning the safety and life of the user or of other people,
or damage could be caused to the boiler or other objects. The boiler is designed to be
used in a pumped hot water space heating system and indirect potable hot water
supply and storage. Any other use of this boiler will be considered improper.
Potterton Commercial declines any responsibility for any damage or injuries caused
by an improper use. In order to use the boiler according to its designed scope, it is
essential to carefully follow the instructions given in this guide.
2.1.2 User Competency
This boiler is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge,
unless they are given supervision or instruction concerning the use of it by a person
responsible for their safety. Children should be supervised to ensure they do not
play with the boiler.
2.1.3 Engineer Competency
The installation, adjustment & servicing of this boiler must be carried out by a
competent person (In the UK by a Gas Safe Registered Engineer and in IE by a
(RGII) Registered Gas Installer) and installed in accordance with current standards
and regulations. Failure to correctly install or maintain this boiler could cause
injury to persons or damage to property. The manufacturer shall not be held liable
for any such injury and/or damage.
2.2GENERALSAFETY
2.2.1 Smell of Gas
If you smell gas - follow these safety instructions:
- DoNOTturn o or on any electrical switches (including light switches)
- DoNOT smoke
- DoNOT use the telephone
- DO evacuate persons away from the source of the gas smell
- DO close the main gas shuto valve
- DO open all the windows and doors where the gas leakage has occurred
- DO inform the gas authority or a competent specialist as soon as possible
2.2.2 Flammable Substances
Do not store or use explosive or easily inammable material (such as petrol, paint or
paper) in the same room where this boiler has been installed.
2.0SAFETY

Sirius FS 6 GB/IE
2.2.3 Boiler Installation and Maintenance
This boiler has been designed for use with G20 and G25 gasses and is manufactured
to give an ecient, safe and long service life. To ensure continued trouble-free
operation of the boiler at maximum eciency, it is essential that correct installation,
commissioning, operation and service procedures are carried out strictly in accordance
with the instructions given in this manual ( see section 7.0 )
Only original parts and accessories from the manufacturer may be used on this
boiler. Using non-approved parts may compromise the safety of the boiler and
invalidate any warranty.
In the event of failure and/or suspected faulty functioning of the boiler. Switch o
the boiler and contact suitable qualied technicians. Do not attempt to make any
repairs unless you are suitably qualied and competent to do so.
2.3REGULATIONSANDSTANDARDS
This boiler must be installed in accordance with relevant British Standard Specications,
Codes of Practice and current Building Regulations, together with any special regional
requirements of the Local Authorities, Gas undertaking and Insurance I.E.E. Regulations for
the Electrical Equipment of Buildings. The installation of the appliance must be in accordance
with the relevant requirements of:
- Health and Safety at Work act 1974
- Building Regulations 2010
- Electricity at Work Regulations 1989
- Management of Health and Safety at Work Regulations 1998
- Manual Handling regulations 1992
- Model Water By-Laws 1986
- BS 7671:1992 Requirements for Electrical Installations, IEE Wiring, Regulations 16th
Edition
- BS 5440:2000: Part 1 - Specication for the Installation of Flues
- BS 5440:2000: Part 2 - Specication for the Installation of Ventilation for Gas Appliances
- BS 6644:2005 - Installation of Gas Fired Hot Water Boilers for inputs between 60kW and
2 MW
- BS 7074:1989: Part 2 - Applications Selection and Installation of Expansion Vessels and
Ancillary Equipment for Sealed Water Systems.
- BS 6880:1988 - Codes of Practice for Low Temperature Hot Water Systems
- CP 342:2 - Centralised Hot Water Supply Gas Safety (Installation and Use) Regulations 1998
- IM/11 - Flues for commercial and Industrial Gas Fired Boilers and Air Heaters
- IGE/UP/1 - Soundness Testing and Purging Procedure for Non Domestic Installations
- IGE/UP/2 - Gas Installation Pipe work, Boosters and Compressors for Industrial and
Commercial Premises
These manufacturer’s notes must not be taken in any way as over-riding statutory obligations.

Sirius FS 7 GB/IE
`
MODEL: SIRIUS FS400
NG
1508000120
CATEGORY: I
FLUE TYPES: B23 0558
HEAT INPUT (net) Q = 36.0 - 380.0 kW
HEAT OUTPUT (50/30ºC) P = 38.0 - 400.9 kW
CO Min rate / Max rate 8.7% / 9.1% (+/- 0.5%)
Gas flow rate 3.5m/h
–
40.0m/h
This appliance may only be installed in a room which complies
with appropriate ventilation requirements. Read the technical
instructions before installing this appliance.
CONDENSING BOILER
NOx CLASS = 5
MAX WATER PRESSURE = 6 bar
MAX OPERATING TEMPERATURE = 90ºC
POWER SUPPLY = 230V ~ 50Hz, IP20 300W
P.I.N. CODE = 0558CP3771
COUNTRIES OF DESTINATION = GB, IE
Manufactured by : Malvern Boilers Limited
Year: Serial No:
2015
M7242
AD
J
USTED FOR G20
@
20 mbar
2H
MODEL: SIRIUS FS400
NG
1508000120
CATEGORY: I
FLUE TYPES: B23 0558
HEAT INPUT (net) Q = 36.0 - 380.0 kW
HEAT OUTPUT (50/30ºC) P = 38 – 400.9 kW
CO Min rate / Max rate 8.7% / 9.1% (+/- 0.5%)
Gas flow rate 3.50m/h
–
40.0m/h
This appliance may only be installed in a room which complies
with appropriate ventilation requirements. Read the technical
instructions before installing this appliance.
CONDENSING BOILER
NOx CLASS = 5
MAX WATER PRESSURE = 6 bar
MAX OPERATING TEMPERATURE = 90ºC
POWER SUPPLY = 230V ~ 50Hz, IP20 300W
P.I.N. CODE = 0558CP3771
COUNTRIES OF DESTINATION = GB, IE
Manufactured by : Malvern Boilers Limited
Year: Serial No:
2015
M7242
AD
J
USTED FOR G20
@
20 mbar
2H
2.4CEMARKING
There are two data plates located on the appliance . One is mounted on the inside of the
front LH side panel (which becomes visible when the front door panel is removed) and the
other is on the REAR panel casing.
The CE marking documents that the appliance complies with the essential requirements of
the following directives:
- Gas appliance directive (2009/142/EC)
- Electromagnetic compatibility directive (89/336/EEC)
- Low voltage directive (2006/95/EEC)
- Eciency requirements directive (Council Directive 92/42/EEC) for condensing boilers
- Protection requirements (04/108/EG) is only guaranteed when operating the boiler for its
correct purpose.
KEY
1 Type approval designation
2 Gas type and pressure
3 Model Name
4 Heat, gas ow & CO ² data
5 Technical data
6 Serial number and year
This manual is an integral and indispensable part of the boiler and it is suggested that
this manual is kept in a safe place for future reference.
1
2
2
3
4
5
6

Sirius FS 8 GB/IE
3.1DIMENSIONSANDCONNECTIONS-FS400
3.0TECHNICALDATA
829
295
Flue sample point
& Thermal Fuse Access panel
Condensate Drain Ø41mm Left, Right or Rear exit
Rear pallet truck opening
Flue Ø180mm
Low Voltage
Cable Entry
230V
Cable Entry
1550
1625
Wiring Centre Access panel
Remove Door to allow access
for pallet truck from front
Remove Base Trim (x2)
to allow access for pallet truck from side 1.5" BSP Female
(DN40)
0.5" BSP Female (x2)
(DN15)
1465
1405
692
1466
1506
258
356
1341
1405
86
561
1921011
346
590
Gas 2" BSPT (DN50) Male
Flow 2.5" (DN65) PN6 Return 2.5" (DN65) PN6
Thermal Fuse Access panel

Sirius FS 9 GB/IE
3.1DIMENSIONSANDCONNECTIONS-FS525
Flue sample point & Thermal Fuse Access panel
Flue Ø180mm
Thermal Fuse Access panel
Condensate Drain Ø41mm Left, Right or Rear exit
295
346
590 Rear pallet truck opening
230V
Cable Entry
Low Voltage
Cable Entry
2461173
566
1620
1557
356
Flow 3" (DN80) PN6 Return 3" (DN80) PN6
Gas 2" BSPT Male (DN50)
86
1.5" BSP Female (DN40) 0.5" BSP Female (x2)
(DN15)
Wiring Centre Access panel
Remove Door to allow access
for pallet truck from front
Remove Base Trim (x2)
to allow access for pallet truck from side
1474
1405
1466
1550
1625
692
1506
258

Sirius FS 10 GB/IE
3.2SPECIFICATIONDATA
GeneralperformanceUnitFS400FS525
NominalHeatInputnet(gross) kW 380 (421.7) 500 (554.9)
MinimumHeatInputnet(gross) kW 36.0 (39.9) 47.0 (52.2)
NominalHeatOutputat50/30oCkW 38.0 - 400.9 49.6 - 527.0
NominalHeatOutputat80/60oCkW 35.0 - 368.6 45.6- 485.5
GasConsumption(G20) m3/h 3.5 - 40.0 4.5 - 52.4
Fluegastemperatureat80/60oCoC 80.0 80.0
CO2atmaxoutput(minoutput) % 9.0 (8.7) 9.0 (8.7)
COatmaxoutput(minoutput) ppm 150 (10) 150 (10)
NOxValue(@0%O2)mg/kWh <40 <40
NOxClass Class 6 6
Soundlevelsatmaximumoutput(@1m) dB(A) 59 65
Heating
Eciencymaxheatoutput50/30oCnet % 105.5 105.4
Eciencymaxheatoutput80/60oCnet % 97.0 97.2
Eciency30%heatoutput net % 108.1 108.6
SeasonalEciency(partL2CV) gross % 97.0 97.3
Operatingpressure-min/normal/max bar 1.0 / 4.0 / 6.0 1.0 / 4.0 / 6.0
Maxpermittedowtemperature oC 90 90
Flow/Returnconnections Flange size DN65 PN6 DN80 PN6
Minimumowrate m3/h 6.75 9.0
Electrical
Electricalsupplyvoltage/Hz V/Hz 230 / 50 230 / 50
Minimumpowerconsumption A (W) 0.1 (24) 0.1 (24)
Maximumpowerconsumption A (W) 1.1 (253) 1.4 (322)
Fuseratingonmainssupply A (W) 5 5
Flue
Flueconnectionsingleue mm 180 180
Fluevolume m3/h 673 875
Maxueresistancepermitted Pa 200 250
Other
Gasconnection BSP Male 2“ Male 2”
Condensateconnection mm 40 40
Dimensions&Weights
Weight,(unpacked) kg 359 424
Weight(packed) kg 423 488
Height mm 1605 1605
Width mm 692 692
Depth mm 1405 1620
Serviceclearance,rear mm 600 600
Serviceclearance,right&top mm 600 600
Serviceclearance,left mm 400 400
Serviceclearance,front mm 800 800

Sirius FS 11 GB/IE
3.3SENSORVALUES
3.3.1 10K Sensors (all ow/return sensors):
Temperature
(oC) Resistance (Ohms) Temperature (oC) Resistance (Ohms)
-30 175203 50 3605
-25 129269 55 2989
-20 96360 60 2490
-15 72502 65 2084
-10 55047 70 1753
-5 42158 75 1481
0 32555 80 1256
5 25339 85 1070
10 19873 90 915
15 15699 95 786
20 12488 100 677
25 10000 105 586
30 8059 110 508
35 6535 115 443
40 5330 120 387
3.3.2 1K Sensor (outside temperature sensor):
Temperature
(oC) Resistance (Ohms) Temperature (oC) Resistance (Ohms)
-20 7578 12 1690
-15 5861 13 1621
-10 4574 14 1555
-5 3600 15 1492
-4 3435 16 1433
-3 3279 17 1375
-2 3131 18 1320
-1 2990 19 1268
0 2857 20 1218
1 2730 21 1170
2 2610 22 1125
3 2496 23 1081
4 2387 24 1040
5 2284 25 1000
6 2186 26 962
7 2093 27 926
8 2004 28 892
9 1920 29 859
10 1840 30 827
11 1763 35 687

Sirius FS 12 GB/IE
3.4WIRINGDIAGRAM-PCB1

Sirius FS 13 GB/IE
3.4WIRINGDIAGRAM-PCB2

Sirius FS 14 GB/IE
4.1UNPACKINGTHEBOILER
This boiler is delivered assembled and protected by a plastic bag, inside a strong wooden
crate. The packaging is designed to be handled by a forklift or narrow base pallet truck. The
complete crated boiler will t through a standard door of 1,970mm high by 750mm wide.
Remove screws xing crate sides to the base. Remove screws from one end of the crate.
Remove end of crate and slide the main body of the boiler o the opposite end. Remove
plastic wrapping once the boiler has reached its intended installation area.
Boiler is heavy (up to 450kg). Use only specialist lifting equipment to move the
boiler.

Dispose of plastic packaging carefully. Keep out of the reach of children and
animals. Recycle packing materials whenever possible.
4.2LOCATINGTHEBOILER

The location selected for installation of the boiler must allow the provision of a satisfactory
ue, an adequate air supply , a drain and be well illuminated. A purpose built plant room or
compartment is strongly recommended.
If a purpose built plant room is not available, measures should be taken to protect the boiler
from damage and prevent any extraneous matter from being stored on or around the boiler.
See BS 6644 Clauses 4, 5 and 6 for details. Any combustible material adjacent to the boiler
must be so placed and shielded as to ensure that it’s temperature does not exceed 66ºC .
There must be easy access to the plant room and boiler at all times. The boiler must be
located in an area where leakage from the water connections or the combined temperature
and pressure safety valve will not result in damage to the area adjacent to it.
When such locations cannot be avoided, a suitable drain tray must be installed under the
boiler. The drain tray must be no deeper than 38mm and must be 100mm wider and
longer than the boiler. It should be piped to an adequate drain using 20mm (0.75in)
diameter pipe, angled for proper drainage.
Access must be provided to the front of the boiler with adequate clearance for servicing
and operation. (see section 4.2.1 for details)
The oor on which the boiler is installed must be at and level. Levelling feet are provided
on the boiler. The oor must be of sucient strength to withstand the weight of the boiler
when lled with water, and should satisfy the requirements of the Local Authority &
Building Regulations.
4.0PRIORTOINSTALLATION

Sirius FS 15 GB/IE
4.2.1 Space Requirements
Model
Dimension 400 525
A800mm 800mm
B600mm 600mm
C400mm 400mm
D600mm 600mm
E600mm 600mm

Sirius FS 16 GB/IE
4.3POWERCONNECTIONREQUIREMENTS
All electrical work in connection with the installation must be carried out by a trained
electrician in accordance with current regulations in force. The point of connection
to the mains electricity supply should be readily accessible and adjacent to the
boiler, and should be connected to the mains supply as detailed below.
The boiler is designed to operate from a 230V 50Hz, single phase supply, fused at 5
amps. Mains input cable should be at least 1.0 mm2, and comply with BS6500.
The method of connection to the mains electricity supply should facilitate complete
electrical isolation of the boiler. A suitable isolator should switch o all poles and have
a contact opening width of at least 3mm, serving only the boiler.
A permanent live supply must be connected to the boiler. Automatic timed, remote operation
or 0-10V control of the boiler can be achieved by connecting optional expansion modules
inside the wiring centre. (see section 5.3.2 for guidance on expansion module setup)
4.4REQUIREMENTSFORHEATINGCIRCUITWATER
4.4.1 Connection into Existing Heating Systems.
  Before replacement of an existing boiler, it is necessary to thoroughly clean out the
old system rst. This is best achieved by using a suitable cleaning solution.
If cleansing of the existing system is not possible (e.g. very old or large systems), it is
recommended that this system water is separated from the boiler system by means
of a secondary heat exchanger.
Please ensure you have considered the following before installation of the new boiler:
- If you intend to use the existing ue, check that ue outlet is suitable for condensing
boilers, is the correct size, is correct for the temperature of the products of combustion
and is manufactured according to current regulations. It must be tested for soundness and
must not have any restrictions or defects. Also ensure that the ue outlet system has
sucient connections for the discharge of condensate.
- The boiler room has a suitable outlet for the discharge of condensate produced.
- The electrical connections comply with the current electrical standards and the work has
been carried out by a suitably qualied person.
- The gas supply pipe work is constructed to the current regulations in force.
- The expansion vessels and associated ttings are correctly sized to absorb the total
expansion of the system and in tested working order.
- The circulation pump output, the head and ow direction are suitable.
- The complete system has been cleaned of impurities and lime scale.

Sirius FS 17 GB/IE
4.4.2 Connection into new Heating Systems.
It is recommended to thoroughly clean out the new system with a system ush product,
before commissioning the boiler.
Whether connecting to an existing or a new heating system, a lter/strainer with
a size of 100 microns (with two isolation valves) must be tted in the return pipe.
During routine maintenance and service visits it can be removed and cleaned, which
will help protect the boiler from contaminants, inside the heating system.
4.4.3 Water Quality and System Inhibitors
It is essential, for the long life of the boiler that the following water quality limits are not
exceeded:-
If the system contains aluminium parts, the pH level must be less than 8.5. The pH
value inside the system should only be measured after a steady state has been
achieved (i.e. all lling and bleeding operations have been completed)
Chloride values of the system water and the supply water should be compared at
regular intervals. If the Chloride value of the system water is considerably higher
than the supply value, this would indicate that there is system leakage and water is
being lost to evaporation. This will result in Chloride concentration and premature
boiler failure if left untreated. If Chloride concentration levels have exceeded
200mg/l, the system should be ushed clean and relled with low Chloride water
and appropriate system treatments.
After cleaning and ushing of the system, it should be lled with an appropriate inhibitor
or antifreeze treatment to maintain water quality levels. The following system treatments
have been tested and are recommended for use in this boiler:
If a mixture of additives is required in the same system (e.g. sludge remover and inhibitor) it
is recommended that the same manufacturer of additive be used.
FERNOX SENTINEL
Inhibitors Protector/Alphi 11 X100, X500
Noise reducer X200
Universal cleaner Restorer X300
Sludge remover Protector, Restorer X400
Antifreeze Alphi 11 X500
Water Hardness <250ppm
Chloride levels <200mg/l
pH levels 7.5 to 9.5

Sirius FS 18 GB/IE
4.5HYDRAULICPUMPREQUIREMENTS
The size of the pumps must be determined by the installer or technical engineer
according to boiler data and system design (see notes below). If using the boiler
with a secondary heat exchanger, it is important to size the pumps on the secondary
side correctly, so that the correct rT can be achieved on the primary side.
The installer must ensure that when the boiler demand is turned on, the boiler
circulation pump and where applicable, the secondary system circulation pump must
be active at the same time. When the boiler demand is switched o the circulation
pump and where applicable, the secondary system circulation pump must continue to
run on for a minimum of three minutes after boiler operation has stopped. Failure to
ensure minimum water circulation when the burners of the boiler are in operation
may result in premature heat exchanger failure.
A system which proves the operation (by means of water ow or motor current) of
the boiler circulation pumps, before the burners of the boiler can operate is
recommended to ensure long service life
The use of a mixing header tted between the boiler circuit and system circuit is
recommended. This becomes essential if the system requires ow rates superior
to the maximum permitted boiler ow rates, (i.e. less than rT 200C)
4.5.1 Minimum Flow Requirements
The boiler pump must have a delivery head which can ensure the following minimum water
ow rates at all times (equivalent to a rT of 350C at maximum output) :




With the boiler ring at maximum rate the rT should not be less than 200C (unless using a
mixing header system)
Model Minimum
Water ow
rate (m3/h)
FS400 6.75
FS525 9.00