Potterton Apollo, Installation & Service Instructions Manual

Page 1: ... UK Ltd 2012 Installation Service Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Apollo Condensing Combination Boiler You can rely on ...

Page 2: ...only applies if the appliance is being installed in a dwelling or some related structure The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations Baxi Heating UK Ltd 2012 All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means or stored in any retrieval system of any nature incl...

Page 3: ...elevant LABC You must ensure that the certificate number issued by the Gas Safe Register is written onto the Benchmark Checklist Scheme Members only Call Gas Safe Register on 0800 408 5577 or log onto www gassaferegister co uk within 10 days If you notify via the Gas Safe Register the register will issue the Building Regulations certificate on members behalf Complete the Benchmark Checklist Instal...

Page 4: ...rd Code of Practice In IE the installation must be carried out by a competent Person and installed in accordance with the current edition of I S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation All systems must be thoroughly flushed and treated with inhibitor see section 6 2 The boiler meets the requi...

Page 5: ...s clear and unobstructed If possible avoid steps wet or slippery surfaces unlit areas etc and take special care on ladders into lofts Technique When handling or lifting always use safe techniques keep your back straight bend your knees Don t twist move your feet avoid bending forwards and sideways and keep the load as close to your body as possible Where possible transport the boiler using a sack ...

Page 6: ... Fixings 11 6 0 System Details 12 7 0 Site Requirements 15 8 0 Flue Options 19 9 0 Plume Displacement 23 10 0 Installation 27 11 0 Commissioning 32 12 0 Completion 34 13 0 Servicing 35 14 0 Changing Components 37 15 0 Setting the Gas Valve 46 16 0 Electrical 47 17 0 Short Parts List 48 18 0 Fault Finding 49 Benchmark Checklist 58 Section Page ...

Page 7: ...al number and Gas Council number It is visible when the case front panel is removed and the control box hinged down Fig 1 6 The boiler model name and serial number are also shown on the information label on the back of the facia door This is for user reference 7 The boiler is intended to be installed in residential commercial light industrial E M C environments on a governed meter supply only 8 Th...

Page 8: ...bly 15 Primary Heat Exchanger 16 Fan Assembly 17 On Off Reset Selector Switch 18 Central Heating Temperature Control 19 Hot Water Temperature Control 20 Water Pressure Sensor 21 Gas Air Inlet 22 Burner Mounting Panel 23 Igniter 24 Burner On Light 25 Central Heating Mode Light 26 Domestic Hot Water Mode Light 27 Display 28 Position of Optional Integral Timer 29 Safety Thermostat 30 Gas Valve 13 17 ...

Page 9: ...e electrical supply to the boiler is isolated The boiler will not operate and the integral timer will require resetting once the selector switch is set to either Position or Position 3 3 Frost Protection Mode 1 The frost protection mode is integral to the appliance and functions only with the selector switch see Section 2 1 in the domestic hot water and central heating position If the system tempe...

Page 10: ...vicing Front 5 mm Min In Operation L H Side 5 mm Min R H Side 5 mm Min In Operation Heat Input CH Net Max Min 25 model kW 26 06 7 82 30 model kW 29 32 8 8 Heat Output CH Non Condensing Max Min 25 model kW 25 94 7 61 30 model kW 28 63 8 56 Electrical Supply 230V 50Hz Appliance must be connected to an earthed supply Power Consumption 150W Electrical Protection IPX0D with timer IPX4D without timer In...

Page 11: ...m Ø Min F 145mm G 132mm H 225mm 360 Orientation Tube Ø 100mm D C B A G F At Least 1 5o H H 65mm 65mm 65mm 65mm Wall View from under the appliance Gas Inlet Heating Flow Domestic Hot Water Outlet Cold Water Inlet Heating Return 130mm 165 7mm 95mm Left Hand Side of Boiler 127mm Condensate Drain 40mm ...

Page 12: ...which can lead to damage of system components All systems must be thoroughly drained and flushed out using for example Sentinel X300 or X400 or Fernox F3 They should be used following the flushing agent manufacturer s instructions System additives corrosion inhibitors and flushing agents descalers should comply to BS7593 requirements e g Sentinel X100 and Fernox MB 1 which should be used following...

Page 13: ...o 0 5 bar Therefore the minimum cold fill pressure is 0 5 bar The vessel is suitable for correct operation for system capacities up to 125 litres 25 155 litres 30 For greater system capacities an additional expansion vessel must be fitted For GB refer to BS 7074 Pt 1 For IE the current edition of I S 813 Domestic Gas Installations 6 7 Safety Pressure Relief Valve Fig 6 1 The pressure relief valve ...

Page 14: ...op cock water meter or water treatment device already fitted to the wholesome water supply connected to the boiler domestic hot water DHW inlet supply then a suitable expansion device may be required 5 If the hot water expansion is not provided for then high pressures can develop which may result in damage to fittings and devices on the system 6 The boiler s maximum working mains pressure is 8 bar...

Page 15: ...st be made to the relevant requirements In GB this is the current I E E Wiring Regulations and Building Regulations In IE reference should be made to the current edition of I S 813 Domestic Gas Installations and the current ETCI rules 4 If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publica...

Page 16: ...ns In IE reference should be made to the current edition of ETCI rules 2 The mains supply is 230V 50Hz fused at 3A NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance Connection may be via a fused double pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only 7 6 Bath S...

Page 17: ...diameter and must be supported using suitably spaced clips of the correct design to prevent sagging 6 It is advisable that the full length of condensate pipe is run internally and preferably be less than 3 metres 7 Internal runs greater than 3 metres or runs in cold areas should use 32mm waste pipe 8 External runs MUST be a MINIMUM of 32mm and fully insulated with material suitable for external us...

Page 18: ... emptied then back pressure may force water out of the boiler trap and cause appliance lockout Boiler 2 5 Minimum fall iii Termination to a drain or gully Boiler 500mm min 2 5 Minimum fall iv Termination to a purpose made soakaway Holes in the soak away must face away from the building 50mm per metre of pipe run 50mm per metre of pipe run Further specific requirements for soakaway design are refer...

Page 19: ... Heating Element is NOT a substitute for correct installation of the condensate drain ALL requirements in this section must still be adhered to Boiler vi pumped into an external soil vent pipe 2 5 Minimum fall 50mm per metre of pipe run Condensate Pump Unheated Location e g Garage Basement or similar heated Boiler 2 5 Minimum fall 50mm per metre of pipe run Pipe must terminate above water level bu...

Page 20: ... with the diagram below Terminal Position with Minimum Distance Fig 18 mm A1 Directly below an opening air brick opening windows etc 300 B1 Above an opening air brick opening window etc 300 C1 Horizontally to an opening air brick opening window etc 300 D2 Below gutters soil pipes or drain pipes 25 75 E2 Below eaves 25 200 F2 Below balconies or car port roof 25 200 G2 From a vertical drain pipe or ...

Page 21: ...al telescopic flue kit is not included in any equivalent length calculations NOTE Flue length is measured from point i to ii as shown IMPORTANT All flue systems must be securely supported at least once every metre Suitable pipe supports are available as accessories Horizontal Flues ii i Plume Displacement Kit 60 100 Ø 1M Extensions 45 93 elbows are also available see Section 9 0 NOTE Horizontal fl...

Page 22: ...ulations NOTE Flue length is measured from point i to ii as shown ii i C Roof Terminal A B This bend is equivalent to 1 metre Total Equivalent Length A B C 1x90 Bend All vertical and angled runs must be included measured from the boiler adaptor point i to the joint with the flue terminal point ii One 91 5 bend or two 135 bends can be included without reduction of the flue length If further elbows ...

Page 23: ...mm5119654 A2 Telescopic Flue incl elbow 5118069 A Horizontal Flue Terminal incl elbow 5118489 B Flue Extension 1000mm 5111074 C Flue Bend 93 5111075 D Flue Bend pair 135 5111085 U Pipe Support painted 100mmØ 5111080 P Wall Liner 5111067 S Flue Terminal Deflector 5111068 Vertical Flue Kits K1 Vertical Flue Terminal 5118576 L Pitch Roof Flashing 25 50 5122151 M Roof Cover Plate 246143 N Flat Roof Fl...

Page 24: ...cture with the clamp supplied IMPORTANT If the boiler is not fitted immediately after the flue system temporary precautions must be taken to prevent rain entry into the room of installation Any precautionary measures must be removed prior to commissioning the boiler 8 5 Flue Dimensions The standard horizontal flue kit allows for lengths between 100mm and 685mm from elbow to terminal Fig 19 The max...

Page 25: ...or increase with the addition of extensions the length of either or both the 60 100 concentric and 60Ø exhaust 5 Standard concentric flue extension kits may be added between the boiler elbow and the terminal assembly 6 The minimum length of the concentric flue is 100mm when measured from the edge of the flue elbow IMPORTANT The maximum equivalent length of concentric flue is 8 metres Additional be...

Page 26: ...Flue Lengths OK Where both lengths have been determined they can be applied to the graph to check that the installation is permissible For example if it was known that 2 metres of concentric flue and 4 metres of 60Ø exhaust were required the values could be applied to the graph as shown in Example 2 As the point of intersection of the dotted lines is below the solid diagonal line the combination o...

Page 27: ... that the concentric assembly and any extensions fall back to the boiler at an angle of at least 1 5 and that the external air inlet is to the bottom 8 Use suitable brackets to support the concentric assembly and any extensions and make good inside and outside 9 The 60Ø exhaust can now be fitted Slide the adaptor over the plain end of the 60Ø exhaust Fig 31 and engage the exhaust in the terminal S...

Page 28: ...the extension at 30mm as shown in two positions directly opposite each other Fig 36 20 Using a suitable bit e g 2mm drill through the extension and outlet Secure using two of the screws supplied 21 The remaining screw must be used to secure the adaptor to the concentric terminal 22 When the plume outlet is positioned under a balcony or other projection Fig 37 it must protrude at least 200mm it is ...

Page 29: ...lots 4 Mark the position of the centre of the flue hole rear exit For side flue exit mark as shown Fig 40 5 If required mark the position of the gas and water pipes Remove the template 6 Cut the hole for the flue minimum diameter 116mm 7 Drill the wall as previously marked to accept the wall plugs supplied Secure the wall plate using the fixing screws 8 Using a spirit level ensure that the plate i...

Page 30: ... continuously downwards to a discharge point outside the building See section 6 7 for further details 4 Utilising one of the sealing washers connect the discharge pipe to the adaptor and tighten the nut 5 Complete the discharge pipework and route it to the outside discharge point IMPORTANT Make all soldered joints before connecting to the pressure relief valve 10 5 Condensate Drain see section 7 7...

Page 31: ...s angled at 93 degrees to ensure a fall back to the boiler 3 Measure the distance from the outside wall face to the elbow This dimension will be known as X Fig 48 4 To dimension X add 50mm This dimension to be known as Y IMPORTANT Check all dimensions before cutting 5 Mark dimension Y on the flue as shown Fig 49 Carefully cut the waste material from the flue ensuring that the ducts are square and ...

Page 32: ...ect boiler operation and prevent water entering the flue 11 Make good between the wall and air duct outside the building 12 Fit the flue trim if required and if necessary fit a terminal guard see Section 8 8 8 9 CONCENTRIC VERTICAL FLUE 15 Once the length of the vertical concentric extension has been determined mark and carefully cut off the excess material The cut end MUST be square and free of b...

Page 33: ...e thermostat The switched output from the thermostat must be connected to terminal 2 Fig 57 If the room thermostat being used incorporates an anticipator it MUST be wired as shown in Fig 57 7 Ensure that the external control input cable s have sufficient slack to allow the control box to drop down Tighten the cable clamp on the boiler chassis 8 Replace the terminal block cover routing the external...

Page 34: ...1 5 bar Fig 60 then close and disconnect the filling loop 9 Turn the gas supply on and purge according to in GB BS 6891 and in IE I S 813 Domestic Gas Installations 10 Test for gas soundness 11 Hinge the facia panel upwards and refit the case front panel Tighten the securing screws IMPORTANT The combustion for this appliance has been checked adjusted and preset at the factory for operation on the ...

Page 35: ... can be obtained with all other gas appliances in the property working Measure the Gas Rate 8 With any other appliances pilot lights turned OFF the gas rate can be measured It should be 25 model 2 76 m3 h 30 model 3 17 m3 h 9 The Calibration Function is active for 20 minutes unless the maximum CH temperature is exceeded 10 The function can be disabled at any time by turning the DHW temperature kno...

Page 36: ...xchanger pipework within the boiler case and domestic hot water heat exchanger in anticipation of further demand at the same time on the next day 2 The feature works on a 24 hour basis E G if there is a demand for hot water at 7 00 AM on Monday the pre heat will operate at 6 50 AM on Tuesday for 1 hour Similarly if there is a demand at 9 25 PM the pre heat will operate at 9 15 PM the next day agai...

Page 37: ...ing the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts 1 to 4 Check the Combustion Performance CO CO2 ratio 4 Set the boiler to operate at maxim...

Page 38: ...ion and gasket cleaning or replacing if necessary Clean any dirt or dust from the air box 12 Reassemble in reverse order DHW Filter Fig 76 13 If the flow of domestic hot water is diminished it may be necessary to clean the filter 14 Turn the DHW isolation cock Fig 75 off and draw off from a hot tap 15 Remove the retaining clip and extract the filter cartridge and rinse thoroughly in clean water Re...

Page 39: ...nnect the igniter feed plug earth wire and the electrode leads noting their positions 2 Undo the screws securing the igniter to the boiler top panel Remove the igniter 3 Fit the new igniter and reassemble in reverse order 14 2 Electrode Assembly Fig 78 1 Disconnect the electrode lead caps remove the strain relief clip from the sensing lead and disconnect the lead 2 Undo the extended nuts securing ...

Page 40: ...n Examine and replace the gasket if necessary 6 Remove the four nuts and separate the fan from the gas air inlet Note the position of the orifice plate and examine the gasket replacing if necessary Fig 81 7 Fit the new fan ensuring that the orifice plate is correctly fitted and that the gasket is in position 8 Examine the insulation around the burner and the heat exchanger gasket and replace if ne...

Page 41: ...t the new burner and gasket examine the insulation and heat exchanger gasket replacing if necessary 7 Reassemble in reverse order 14 6 Insulation Fig 82 1 Undo the nut on the gas pipe at the gas air inlet and the gas valve Remove the pipe taking care not to lose the sealing washers Also remove the injector 2 Disconnect the electrode lead caps remove the strain relief clip from the sensing lead and...

Page 42: ... 14 9 Water Pressure Switch Fig 84a 1 Drain the boiler primary circuit 2 Pull the two wires of the microswitch 3 Draw the securing clip forwards to release the assembly The clip is captive and does not need to be fully removed 4 Reassemble in reverse order 14 10 DHW Temperature Sensor NTC Fig 85 1 Turn off the mains water supply and draw off the residual domestic hot water 2 Ease aside the retaini...

Page 43: ...ctrical supply plug from the pump 2 Drain the boiler primary circuit and undo the three screws securing the body to the inlet assembly and pump flow pipe Draw the complete pump forwards 3 Pull off the securing clip and remove the Automatic Air Vent Transfer them to the new pump body 4 Examine the O ring seals replacing if necessary and reassemble in reverse order 14 14 Automatic Air Vent Fig 89 1 ...

Page 44: ...ull the sensor off the DHW inlet manifold 2 Disconnect the plug from the sensor and connect it to the new component 3 Fit the new sensor ensuring it is fully engaged over the manifold 14 17 Safety Pressure Relief Valve Fig 93 1 Drain the primary circuit 2 Disconnect the discharge pipe from the valve Pull off the clip retaining the valve and withdraw it from the outlet assembly 3 Fit the new valve ...

Page 45: ...e that the right hand location stud is offset towards the centre more than the left hand one 8 Reassemble in reverse order 14 19 DHW Flow Regulator Filter Fig 95 1 Pull out the securing clip and prise the regulator and filter assembly out of the hydraulic inlet block 2 Twist the body to unlock the bayonet connection and remove the regulator 3 Examine and clean the filter and reassemble in reverse ...

Page 46: ...e 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions 14 22 Selector Switch Figs 97 98 1 Note the setting of the selector switch knob and carefully pull it off the facia 2 Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots Disengage the rear of the cover from the control box hing...

Page 47: ...l setting use a suitable hexagon key to wind out the Throttle Adjustment Screw until it is flush with the valve body then turn the screw 4 full turns clockwise Fig 99a If the boiler will not light or the correct CO2 cannot be achieved contact the heateam technical helpline 14 24 Expansion Vessel Fig 100 1 Drain the boiler primary circuit and undo the nut on the vessel connection pipe 2 Remove the ...

Page 48: ...the correct reading is obtained Fig 108 Turning clockwise will reduce the CO2 Anticlockwise will increase the CO2 9 The CO2 must then be checked at minimum rate Turn the CH temperature knob fully anticlockwise As the knob is turned the display will change indicating the fan speed When the display reads 0 the boiler runs at minimum rate The CO2 should be 8 4 0 0 0 4 10 With the boiler on minimum th...

Page 49: ...rheat Stat Pump X400 X401 g g b b r r b b bk br b g b br g y b br b br br b b b br br br b b br r bk r bk Water Pressure Switch Spark Generator Ignition Electrode 9 8 7 6 5 4 3 2 1 9 10 8 7 6 5 4 3 2 1 Hall Effect Sensor r w b br bk b b bk br DiverterValve Optional IntegralTimer 1 2 3 4 1 2 3 4 bk br bk b N L br br 1 4 2 5 3 1 2 a b Link b g y br Mains Input br b bk bk bk grey gr gr gr bk E N L 16...

Page 50: ...ctrode Assembly 5130293 326 Fan 5121447 401 Gas Valve 720301001 403 Plate Heat Exchanger 720776401 408 Pump 720063001 411 Water Pressure Microswitch 720063201 413 DHW Hall Effect Sensor 720061801 420 Overheat Thermostat 5114729 421 NTC Sensor DHW 5114725 503 PCB 25 5131264 PCB 30 5131265 504 Pressure Gauge 720061901 313 326 401 403 408 503 504 320 304 421 420 413 411 ...

Page 51: ...preceded by the letter E For example code E133 will be displayed by E1 alternating with 33 E50 is shown as E then 50 E20 E28 E50 indicate faulty or incorrect components E110 shows overheat of the primary water E119 is displayed when the primary water pressure is less than 0 5 bar E133 indicates that the gas supply has been interrupted ignition has failed or the flame has not been detected E125 is ...

Page 52: ...3 flashing Burner does not stay alights after 5 seconds Error 133 flashing Go to section I Operation sequence successful If the error 110 is still flashing Go to section J Fan runs at correct speed YES YES NO NO NO YES YES YES YES YES YES YES YES NO YES YES YES YES NO NO NO NO NO Burner output modulates to maintain the temperature set Burner goes out Go to section C Ensure controls are set to dema...

Page 53: ...33 flashing Go to section I Operation sequence successful Turn the selector switch to reset position for 5 seconds If the error 110 is still flashing Go to section J Fan runs at correct speed YES YES NO NO NO YES YES YES YES YES YES YES YES NO YES YES YES YES NO NO NO NO NO Burner output modulates to maintain the temperature set DHW flow sensor senses no flow Burner goes out Go to section C DHW fl...

Page 54: ...onnector terminals 3 4 Replace PCB 2 NO Change pump supply cable YES B CH system pressure less than 0 5 bar Re pressurise system 1 YES Check the tap of the automatic air vent is opened Open the automatic air vent 2 NO C 1 NO YES Fan connections correct at fan PCB X2 connector is 230V AC across terminals 5 7 Fan jammed or faulty winding Replace PCB Replace fan YES D If pump jammed release NO NO Rep...

Page 55: ... Check and correct if necessary 1 Ignition electrode and lead 2 Electrode connection 3 Spark gap and position voltage at PCB X2 connector is 110V AC across terminals 2 5 Note from multimeter connect common to 2 volts to 5 Check wiring YES NO Replace igniter YES H YES 1 Ensure that the Hall Effect Sensor is in position Check the connection between the PCB X400 connector terminals 3 6 7 and the elec...

Page 56: ... continuity across thermostat terminals Allow to cool Continuity across thermostat terminals more than 1 5 ohm J L M Is there 230V at Motor 3 way valve Replace motor 3 way valve 1 YES PCB X3 connector terminals 5 6 central heating mode 5 7 domestic hot water mode Replace PCB 2 NO Change pump supply cable YES Fan connections correct at fan PCB X401 connector terminals 5 6 7 8 1 YES Replace fan Temp...

Page 57: ...57 19 0 Notes Baxi Heating UK Ltd 2012 ...

Page 58: ...em cleaner was used Gas Rate Burner Operating Pressure if applicable Central Heating Flow Temperature Central Heating Return Temperature Gas Rate Burner Operating Pressure at maximum rate Cold Water Inlet Temperature Hot Water has been checked at all outlets If required by the manufacturer record the following The heating and hot water system complies with the appropriate Building Regulations The ...

Page 59: ...er Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Operative ID No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments S...

Page 60: ... in our products which may affect the accuracy of the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request POTTERTON A Trading Division of Baxi Heating UK Ltd 3879156 Brooks House Coventry Road Warwick CV34 4LL After Sales Service 0844 871 1560 Technical Enquiries 0844 871 1555 Website www potterton co uk e oe ...