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SIRIUS FS
Eurocondense four
Floor standing boiler
Direct Fired High Efficiency Boiler
Manufactured to the latest ISO standards, the
Eurocondense four uses tried and tested technology
to provide efficient heating for buildings of all sizes.
Models
A range of controls are available, for easy integration
with new or existing heating systems.
SIRIUS FS400
SIRIUS FS525
Features
Lightweight aluminium heat exchanger.
Top hydraulic and flue connections.
Compact dimensions and small footprint.
Built in boiler control.
Controls can be programmed to work with solar thermal,
biomass and buffer tanks.
This manual must be kept with the appliance
Installation & Servicing Instructions
Benefits
For reliable, highly efficient heat transfer.
Easier to connect and less space needed for
working access.
Requires less space for installation.
User friendly control panel includes operation status,
Benefits
weather compensation, timer for heating and DHW,
fault diagnostics and, where relevant, cascade operation.
Benefits
Sustainable, energy efficient, solution for a wide range
For reliable, highly efficient heat transfer.
of applications.
For reliable, highly efficient heat transfer.
Easier to connect and less space needed for
working access.
Easier to connect and less space needed for
Requires less space for installation.
working access.
Requires less space for installation.
User friendly control panel includes operation status,
weather compensation, timer for heating and DHW,
User friendly control panel includes operation status,
fault diagnostics and, where relevant, cascade operation.
weather compensation, timer for heating and DHW,
Sustainable, energy efficient, solution for a wide range
fault diagnostics and, where relevant, cascade operation.
of applications.
Sustainable, energy efficient, solution for a wide range
of applications.
Works every time.
Technical Specification
Works every time.
Works every time.
Technical Specification
Technical Specification
www.pottertoncommercial.co.uk
M7248
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Table of Contents
Related Manuals for Potterton SIRIUS FS
Summary of Contents for Potterton SIRIUS FS
- Page 1 Works every time. Technical Specification SIRIUS FS Installation & Servicing Instructions Eurocondense four Works every time. Works every time. Technical Specification Eurocondense four Floor standing boiler Technical Specification Direct Fired High Efficiency Boiler Eurocondense four Manufactured to the latest ISO standards, the Eurocondense four uses tried and tested technology to provide efficient heating for buildings of all sizes.
- Page 2 Whichever model you choose you can depend on: Reliability Efficiency Engineering quality Our boilers are all factory Our modulating boilers All of our products are tested before sale and we will meet the variable manufactured using tried will commission them for heating requirements of and tested technology, you to make sure they work...
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Page 3: Table Of Contents
Switching on ....................Engineers tools (Siemens) and use of Controller stop mode ..Checking and adjusting CO2 levels ............Decomissioning and Disposal ..............Controls and basic settings ..............Error messages ..................... Final checks & User handover ............... Sirius FS GB/IE... -
Page 4: Ref Subject Page
Component illustrations ..............Recommended parts list ..............Fault code table .................. 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. -
Page 5: General Information
The FS400 or FS525 model is a gas fired, 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 configured to control space heating, hot water, Solar and Primary circuits. -
Page 6: Symbols Used In This Guide
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 GB/IE... -
Page 7: Safety
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. -
Page 8: Regulations And Standards
- 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 GB/IE... -
Page 9: Ce Marking
- Protection requirements (04/108/EG) is only guaranteed when operating the boiler for its correct purpose. 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. Sirius FS GB/IE... -
Page 10: Technical Data
3.0 TECHNICAL DATA 3.1 DIMENSIONS AND CONNECTIONS - FS400 Sirius FS GB/IE... - Page 11 3.1 DIMENSIONS AND CONNECTIONS - FS525 Sirius FS GB/IE...
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Page 12: Performance Data
0.1 (24) Maximum power consumption A (W) 1.1 (253) 1.4 (322) Fuse rating on mains supply A (W) Flue Flue connection single flue Flue volume Max flue resistance permitted Other Gas connection Male 2“ Male 2” Condensate connection Dimensions & Weights Weight, (unpacked) Weight (packed) Height 1605 1605 Width Depth 1405 1620 Service clearance, rear Service clearance, right & top Service clearance, left Service clearance, front Sirius FS GB/IE... -
Page 13: Sensor Values
Resistance (Ohms) (Ohms) 7578 1690 5861 1621 4574 1555 3600 1492 3435 1433 3279 1375 3131 1320 2990 1268 2857 1218 2730 1170 2610 1125 2496 1081 2387 1040 2284 1000 2186 2093 2004 1920 1840 1763 Sirius FS GB/IE... -
Page 14: Wiring Diagrams
3.4 WIRING DIAGRAM - PCB 1 Sirius FS GB/IE... - Page 15 3.4 WIRING DIAGRAM - PCB 2 Sirius FS GB/IE...
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Page 16: Prior To Installation
The floor on which the boiler is installed must be flat and level. Levelling feet are provided on the boiler. The floor must be of sufficient strength to withstand the weight of the boiler when filled with water, and should satisfy the requirements of the Local Authority & Building Regulations. Sirius FS GB/IE... - Page 17 4.2.1 Space Requirements Model Dimension 800mm 800mm 600mm 600mm 400mm 400mm 600mm 600mm 600mm 600mm Sirius FS GB/IE...
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Page 18: Power Connection Requirements
- The expansion vessels and associated fittings are correctly sized to absorb the total expansion of the system and in tested working order. - The circulation pump output, the head and flow direction are suitable. - The complete system has been cleaned of impurities and lime scale. Sirius FS GB/IE... - Page 19 X300 Sludge remover Protector, Restorer X400 Antifreeze Alphi 11 X500 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. Sirius FS GB/IE...
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Page 20: Hydraulic Pump Requirements
C at maximum output) : Model Minimum Water flow rate (m FS400 6.75 FS525 9.00 With the boiler firing at maximum rate the rT should not be less than 20 C (unless using a mixing header system) Sirius FS GB/IE... - Page 21 1400 1000 1300 1200 1100 1120 1000 1120 Flow rate (m3/h) Flow rate (m3/h) T= T= T= FS525 1400 T= T= T= 1300 1400 1200 1300 1100 1200 1000 1100 1000 Flow rate (m3/h) Flow rate (m3/h) Sirius FS GB/IE...
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Page 22: Application Examples
4.6 APPLICATION EXAMPLES Sirius FS GB/IE... - Page 23 Sirius FS GB/IE...
- Page 24 Sirius FS GB/IE...
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Page 25: Installation
It is important that the condensate flow must be maintained, even in freezing conditions. In the event that the condensate becomes blocked, the boiler will shutdown and not operate normally again until the flow has been restored. Sirius FS GB/IE... -
Page 26: Electrical Connections
5.3 ELECTRICAL CONNECTIONS THIS BOILER MUST BE EARTHED Isolate the mains electrical supply before starting any work and observe relevant safety precautions 5.3.1 Access to electrical wiring panel 1 Undo 1/4 turn fasteners and lift panel vertically upwards 2 Undo single screw and lift panel vertically upwards Sirius FS GB/IE... - Page 27 Module No QX21 0-10 VDC Output QX22 BX22 Sirius FS GB/IE QX23 BX21...
- Page 28 MUST operate during this process. Failure to provide adequate water circulation to the boiler, via operation of a pump, when the gas burners are in operation may result in heat exchanger damage and will invalidate the manufacturers warranty. Sirius FS GB/IE...
- Page 29 Web based system or BMS. Using a Siemens OZW672 Web-Server it is possible to establish remote communications with Siemens own software or free phone app. Connections to BMS protocols such as BACnet or Lon are also possible. Please contact Potterton Commercial for further details. Sirius FS GB/IE...
- Page 30 WEB SERVER OZW672.01 AND OZW672.04 (P/N 5142798 & 5142799) This web server can be connected directly to the SIRIUS FS and allows for remote plant control and monitoring via the web and Smartphone-App. A summary of the features available are as follows:- • Operate the appliance via web browser, using a PC or Smartphone-App through the “cloud”...
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Page 31: Installing Room And Outside Sensors
The base provides the power for QAA55 and QAA75. When the units are removed from their base, power is cut off (i.e. the units are out of operation). Connections: Terminal Designation QAA55 QAA75 BSB data BSB data BSB ground BSB ground Not used Power supply DC 12V Sirius FS GB/IE... - Page 32 QAA75, unit 2 Operating line 40 Room unit 1 Room unit 1 Operating line 42 Heating circuits 1 and 2 Heating circuit 2 Operating line 44 Independently Independently Operating line 46 Independently Independently Operating line 48 Commonly None Sirius FS GB/IE...
- Page 33 P2 = 0 OFF: All operating elements released (default setting). P2 = 1 ON: Following operating elements are locked: - Operating mode changeover heating circuit. - Readjustment of Comfort set point. - Changeover of operating level (occupancy button). Sirius FS GB/IE...
- Page 34 Define contact type H2 mod 1 Dependent on device (NO or NC) 6054 Define function input H2 mod 2 Setup as room thermostat HC2 6055 Define contact type H2 mod 2 Dependent on device (NO or NC) Sirius FS GB/IE...
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Page 35: Flue And Ventilation
The maximum draught permissible is 0.2 mbar (20 Pa), this should be checked with a warm flue and the boilers not firing. If the draught is greater than this, then the fitting of a flue stabiliser is advised. Sirius FS GB/IE... - Page 36 If the boiler is to be operated 100% of the time during the summer, an additional 2cm free-area per kW will be required at low and high level. Sirius FS GB/IE...
- Page 37 The effect of pressure resistance of the flue system on the output of the boiler is given in the following table: Jug 555 Jug 400 Flue resistance (Pa) FS525 FS400 Sirius FS GB/IE...
- Page 38 250 Pa, so this 200mm flue system would be acceptable. If the same calculation was applied to a 250mm diameter flue system, the total resistance would be 70.1 Pa, which equates to an output increase of 10kW, from a 180mm flue system. Sirius FS GB/IE...
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Page 39: Gas Connections And Tightness Testing
150mbar. The gas line has to be purged of air before commissioning following the guidelines set out in IGE/UP/1. Check for tightness of any disturbed joints using a leak detector fluid after purging. Sirius FS GB/IE... -
Page 40: Commissioning
When the boiler has finished these checks, it should be displaying the default screen “Cascade flow temperature”, on the left hand side HMI display screen. The right hand HMI display screen should be displaying “Boiler temperature”. 6.2 ENGINEERS TOOLS AND USE OF CONTROLLER STOP Sirius FS GB/IE... -
Page 41: Checking And Adjusting Co2 Levels
Note: There is a time delay between making an adjustment and the CO value changing on the gas analyser. Adjust in increments of 1/8 turn at a time and wait at least 1 minute before making further adjustments. NB 1/2 turn = 1.0% CO Sirius FS GB/IE... -
Page 42: Decomissioning And Disposal
Dispose of the appliance correctly according to the laws and regulations in force. The appliance and accessories cannot be discarded along with normal household waste and should be recycled where appropriate. More than 90% of the materials that make up the appliance are recyclable. Sirius FS GB/IE... -
Page 43: Controls And Basic Settings
Pressing this button steps through a number of parameters on the display, they can also be stepped by rotating the multifunctional selection tool. If a fault has been detected this will also appear in the screen list. Sirius FS GB/IE... - Page 44 Maintenance or special mode. If this symbol appears, a maintenance mes- sage is delivered or a special operation has been manually activated. Error message If this symbol appears for more than 30 seconds, an error in the appliance has occurred Sirius FS GB/IE...
- Page 45 6.5.3 Setting the Time and Date Sirius FS GB/IE...
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Page 46: Error Messages
Pressing the info button will provide details of the fault (see section 7.7). Press the RESET button and provided the fault condition has been corrected, the boiler will operate as normal and the fault symbol will disappear from the display, after a short delay. Sirius FS GB/IE... - Page 47 Page two of fault history records specific details about what the software and controls were indicating at the precise moment the fault occurred. Example screen: Prog 6805 No Fault SW diagnostic code 1 Burner control phase 1 3 A complete listing of displayed fault codes is given in the Operating and Programming guide. Sirius FS GB/IE...
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Page 48: Final Checks & User Handover
(subject to the boiler being in control of the pumps rather than an external BMS). Finally, these instructions should be handed over to the user for safe keeping. Sirius FS GB/IE... - Page 49 - With the boiler operating at a low return temperature (below 50 C) check that condensate flows freely from the condensate line. -Carry out analysis of system water to ensure good water quality (see section 4.4.3) Sirius FS GB/IE...
- Page 50 Inspect condition of seal around the interior of the air control valve and check operation of the valve. The valve should close securely on its magnet and open with a little resistance. Ignition electrode Air control valve Burner head Door insulation Door gasket Connecting gasket Ionisation electrode Sirius FS GB/IE...
- Page 51 6.4 (P40), for full details on how to check and adjust CO levels. Function Check Run the boiler through a full heating / DHW cycle and note any operational errors. Ensure that all errors are corrected before completing any maintenance / servicing. Sirius FS GB/IE...
- Page 52 4 Remove 4 screws from the top and 2 screws from the bottom of panel and pull outwards 5 Remove 2 screws on front of panel and loosen 2 screws at rear of panel and pull forwards Locking screw Access to electrical components Sirius FS GB/IE...
- Page 53 8 Remove four screws to reveal access to: Flue sample point & rear overheat protection fuse 9 Remove four screws to reveal access to: Rear overheat protection fuse 10 Remove two screws to reveal access to: Adjustable levelling feet Sirius FS GB/IE...
- Page 54 7.3.15 - Air control valve 7.3.16 - Burner head removal with fan removed 7.3.17 - Burner head removal with air control valve removed 7.3.18 - Combustion chamber inspection & cleaning 7.3.19 - Rear heat exchanger insulation replacement Sirius FS GB/IE...
- Page 55 - Release all 7 PCB supports by pinching the end of each pilar with a pair of pliers and slowly withdraw the board from the supports. - Replacement is the reverse. PCB Supports PCB Supports Follow instructions supplied with the PCB replacement, in order to ensure the correct parameter programming is used. Sirius FS GB/IE...
- Page 56 - Remove the relay by pushing the release bar upwards - Fit new relay (note pin alignment) by gently pushing the relay into the holder. When correctly fitted the release bar can be returned to its original position Sirius FS GB/IE...
- Page 57 Inspect the condition of the insulation at the rear of the affected heat exchanger chamber before attempting to operate the boiler again. Failure to do so could result in permanent damage. See section 7.3.18 for insulation replacement guidance. Sirius FS GB/IE...
- Page 58 - Unplug the power connector and ignition lead from unit - Remove screws fixing the generator to the metal back plate - Remove unit - Replacement is the reverse Ignition lead Power connector Fixing screws Sirius FS GB/IE...
- Page 59 - Unplug the two electrical connectors from the rear of the fan Bolts Connectors - Remove the six bolts connecting the fan to the venturi - Remove the four bolts connecting the fan to the air control valve / burner - Remove fan - Replacement is the reverse Sirius FS GB/IE...
- Page 60 - Inspect condition of rubber seal and replace if worn or damaged. Ensure that the seal is correctly located with its tab in alignment inside the aluminium cut out on the door. - Replacement is the reverse Sirius FS GB/IE...
- Page 61 Do not use a brush to clean the outside of the burner tube. - Access is now available for heat exchanger inspection (see section 7.3.18) - If necessary replace burner tube - Re-assembly is the reverse Sirius FS GB/IE...
- Page 62 7.3.19 Rear Heat Exchanger Insulation Replacement Specialist equipment is required to replace the rear insulation, contact the manufacturer on 0845 070 1055 for advice. Sirius FS GB/IE...
- Page 63 * The heat exchanger for this boiler weighs in excess of 150kg. In the interests of manual handling and personal safety, specialist lifting equipment is needed should a part change be required. Please contact our service team on 0845 070 1058 for support Sirius FS GB/IE...
- Page 64 7.5 COMPONENT ILLUSTRATIONS 38/39 38/39 42/43 23/24 23/24 Sirius FS GB/IE...
- Page 65 7.5 COMPONENT ILLUSTRATIONS (CONTINUED) Sirius FS GB/IE...
- Page 66 7.5 COMPONENT ILLUSTRATIONS (CONTINUED) Sirius FS GB/IE...
- Page 67 These items are available to order as a single item 5103929 (FS400) & 5103930 (FS525) from the manufacturer. All items in each First Aid Kit are listed in section 7.6.3 with photos of each item. 5103929 5103930 FS400 FS525 First Aid Kit First Aid Kit Sirius FS GB/IE...
- Page 68 Spark electrode lead 5142148 Spark electrode c/w gasket & screws 5142149 Spark generator 5142150 Water pressure transmitter 5142151 Din Rail Mounted Relay 230VAC c/w base 5142638 Din Rail Mounted Relay 12VDC c/w base 5142639 AGU 2.5 Clip-In Extension 5139793 Sirius FS GB/IE...
- Page 69 7.6.3 First Aid Kit Parts List (continued) Sirius FS GB/IE...
- Page 70 Gas pressure too low or front door overheat thermostat activated. Check incoming gas pressure and operation of overheat stat on the screwed into the burner door. Safety time exceeded Ignition unsuccessful after 5 ignition attempts. Check gas supply, gas valve operation, ignition generator, lead and electrodes. Sirius FS GB/IE...
- Page 71 (see 3.2) Water press 3 too low Water pressure inside boiler is too low for safe operation. Opera- tion will automatically resume once water pressure is at or above minimum levels (see 3.2) Sirius FS GB/IE...
- Page 72 Eurocondense four Technical Specification Works every time. Technical Specification Eurocondense four Floor standing boiler Manufactured to the latest ISO standards, the Eurocondense four uses tried and tested technology to provide efficient heating for buildings of all sizes. A range of controls are available, for easy integration with new or existing heating systems.