Potterton Apollo Installation & Service Instructions Manual
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Potterton Apollo Installation & Service Instructions Manual

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

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Summary of Contents for Potterton Apollo

  • Page 1 You can rely on Installation & Service Instructions Apollo Condensing Combination Boiler These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2012...
  • Page 2 Natural Gas Building Regulations and the Benchmark Commissioning Checklist Potterton Apollo 25 G.C.N 47-393-38 Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Potterton Apollo 30 G.C.N 47-393-37 Authority Building Control Department. From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly.
  • Page 3 Installer Notification Guidelines Choose Building Regulations Notification Route Competent Person's Building Control Self Certification Scheme Install and Commission this Contact your relevant Local appliance to manufacturer's Authority Building Control instructions (LABC) who will arrange an inspection or contact a government approved inspector Complete the Benchmark Checklist...
  • Page 4 Legislation IMPORTANT - Installation, Commissioning, Service & Repair This company declare that no substances harmful to health are contained in the appliance or used during appliance This appliance must be installed in accordance with the manufacturer’s instructions and manufacture. the regulations in force. Read the instructions fully before installing or using the appliance.
  • Page 5 Safe Manual Handling General The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance. Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands. Health &...

  • Page 6: Table Of Contents

    CONTENTS Section Page Introduction General Layout Appliance Operation Technical Data Dimensions and Fixings System Details Site Requirements Flue Options Plume Displacement 10.0 Installation 11.0 Commissioning 12.0 Completion 13.0 Servicing 14.0 Changing Components 15.0 Setting the Gas Valve 16.0 Electrical 17.0 Short Parts List 18.0 Fault Finding...

  • Page 7: Introduction

    1.0 Introduction Description 1. The Potterton Apollo is a fully automatic gas fired wall mounted condensing combination boiler. It is room sealed and fan assisted, and will serve central heating and mains fed Case Front Panel domestic hot water. 2. The boiler is set to give a maximum output of :- 25 models - 25.94 kW DHW...

  • Page 8: General Layout

    2.0 General Layout Layout Expansion Vessel Diverter Valve Motor DHW Plate Heat Exchanger Circulation Pump Automatic Air Vent Pressure Relief Valve Selector Switch Central Heating System Pressure Gauge Control Box Condensate Trap Heat Exchanger Air Vent Electrode Assembly Primary Heat Exchanger Fan Assembly On/Off/Reset Selector Switch Central Heating Temperature Control...

  • Page 9: Appliance Operation

    3.0 Appliance Operation Central Heating Mode (Fig. 2) Boiler Schematic 1. With a demand for heating, the pump circulates water through the primary circuit. 2. Once main burner ignites the fan speed controls the gas rate to maintain the heating temperature measured by the temperature sensor.

  • Page 10: Technical Data

    4.0 Technical Data Potterton Apollo 25 & 30 Appliance Type NO x Class Inlet Pressure (Natural Gas - G20) mbar Appliance Category CAT I Central Heating Primary Circuit Pressures Injector (Natural Gas - G20) Heat Input CH (Net) 6.0mm 25 model 26.06...

  • Page 11: Dimensions And Fixings

    5.0 Dimensions and Fixings Dimensions A 780mm At Least 1.5 B 345mm C 450mm D 116mm Ø Min. F 145mm G 132mm H 225mm 360° Orientation Tube Ø 100mm Gas Inlet Heating Domestic Hot Cold Water Heating Flow Water Outlet Inlet Return 95mm...

  • Page 12: System Details

    6.0 System Details Information 1. The Potterton Apollo Condensing Combination Boiler is a ‘Water Byelaws Scheme - Approved Product’. To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes (IRN). a) IRN 001 - See text of entry for installation requirements and notes.
  • Page 13 6.0 System Details System Filling and Pressurising (Fig. 4) 1. A filling point connection on the central heating return Double Stop Stop Check pipework must be provided to facilitate initial filling and Valve Valve Valve pressurising and also any subsequent water loss replacement/refilling.
  • Page 14 6.0 System Details Domestic Hot Water Circuit (Fig. 7) 1. All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply regulations. Other Tap Outlets 2. Your attention is drawn to: for GB: Guidance G17 to G24 and recommendation R17 to Boiler Expansion R24 of the Water Regulations Guide.

  • Page 15: Site Requirements

    7.0 Site Requirements 5mm Min 450mm 5mm Min Location 1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to 200mm Min atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply.
  • Page 16 7.0 Site Requirement Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. Gas Service Cock 2. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation.
  • Page 17 Examples are shown of the following methods of termination:- 7.0 Site Requirements i) to an internal soil & vent pipe ii) via an internal discharge branch (e.g. sink waste) downstream of the trap iii) to a drain or gully iv) to a purpose made soakaway Condensate Drain v) pumped into an internal discharge branch (e.g.
  • Page 18 7.0 Site Requirement Condensate Drain (cont.) iii) Termination to a drain or gully 11. When discharging condensate into a soil stack or waste Boiler pipe the effects of existing plumbing must be considered. If soil pipes or waste pipes are subjected to internal pressure Pipe must terminate above fluctuations when WC's are flushed or sinks emptied then water level but below...
  • Page 19 v) pumped into an internal discharge branch 1.0 Introduction (e.g. sink waste) downstream of the trap Pipe must terminate above Sink Condensate Drain (cont.) water level but below surrounding surface. Cut end at 45° 12. A boiler discharge pump is available, ‘MULTIFIT’ part no.
  • Page 20 Terminal Position with Minimum Distance (Fig. 18) (mm) 7.0 Site Requirements Directly below an opening, air brick, opening windows, etc. Above an opening, air brick, opening window etc. Horizontally to an opening, air brick, opening window etc. Flue (Figs. 17 & 18) Below gutters, soil pipes or drain pipes.

  • Page 21: Flue Options

    8.0 Flue Options Horizontal Flue Systems 1. The standard flue is suitable only for horizontal termination applications. (ii) 2. Maximum permissible equivalent flue lengths are:- Horizontal Concentric 10 metres 3. Any additional “in line” bends in the flue system must be taken into consideration.
  • Page 22 8.0 Flue Options Vertical Flues Vertical Flue Systems 1. Maximum permissible equivalent flue lengths are:- (ii) Vertical Concentric 10 metres 2. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:- Concentric Pipes: 135°...
  • Page 23 8.0 Flue Options Flue Accessories Accessory Size Code No FLUE GROUP A Concentric Flue System 100mm diameter Telescopic Internal Flue Kit 315-500mm 5119654 Telescopic Flue (incl elbow) 5118069 Horizontal Flue Terminal (incl elbow) 5118489 Flue Extension 1000mm 5111074 Flue Bend 93°...
  • Page 24 8.0 Flue Options For Roof Terminals 1. In the case of a pitched roof 25 - 50 degrees, position the lead Approx tile to replace/flash over existing roof tiling. Make an aperture in 1425mm the roof suitable for the lower tube of the roof terminal and ensure the integrity of the roof cover is maintained.

  • Page 25: Plume Displacement

    93° Elbow/Plume 9.0 Plume Displacement Outlet Assembly 60Ø Support Plume Displacement Kit (Fig. 23) O Ring Bracket FLUE GROUP K Kit No 5118638 0.9 metres Content of kit 0.9m 60/100 Concentric Flue 60Ø Exhaust 1m 60 Dia Exhaust Flue Pipe Flue Pipe Adaptor 60 Dia Support Brackets...
  • Page 26 9.0 Plume Displacement Determining Permissible Lengths In the graph the solid line diagonal represents the relationship between the concentric flue assembly (and any extensions) and the 60Ø exhaust (and any extensions or additional bends). Example 1 - Not Permissible If, for instance, a concentric length of 5 metres was required and the 60Ø...
  • Page 27 9.0 Plume Displacement General Fitting Notes 1. Cut a hole in the external wall which the concentric flue assembly will pass through. The hole should allow the flue to fall back to the boiler at an angle of at least 1.5°. 2.
  • Page 28 9.0 Plume Displacement Plume Outlet Elbow General Fitting Notes (cont.) 15. For aesthetic purposes it is permissible to route the 60Ø exhaust in an enclosed box, but the air inlet and plume outlet MUST remain in free air. 16. It is also possible to separate the plume outlet from the 93°...

  • Page 29: Installation

    10.0 Installation 10.1 Unpacking & Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). 1. Remove staples, open flaps and remove cardboard sheet. Remove the polystyrene side pieces and literature. Two people can then lift out the boiler (Fig.
  • Page 30 10.0 Installation Wall Plate 10.3 Fitting The Boiler 1. Lift the boiler using the Lifting Points as shown by the shaded areas (Fig. 43) The boiler should be lifted by TWO PEOPLE. Engage the slots at the top rear of the boiler on the wall plate (Fig.
  • Page 31 10.0 Installation 10.6 Fitting The Flue HORIZONTAL FLUE 1. The standard flue is suitable for lengths between 100mm Fig. 45 minimum and 685mm maximum, as measured from the edge of the flue elbow outlet to the joint between the terminal and air duct (Fig. 45). 2.
  • Page 32 10.0 Installation Inner Flue Support Bracket 10.6 Fitting the Flue (Cont) 6. The inner flue duct support bracket may be in the waste portion of the flue. In this case retrieve the bracket before discarding the waste. 7. Take the inner flue support bracket (if not already fitted) Fig.
  • Page 33 10.0 Installation 10.7 Making The Electrical Connections NOTE: Both the Live and Neutral connections are fused. To connect an external control proceed as follows:- 1. Slacken the facia panel securing screws and lift the outercase panel so that its securing tabs are clear of the facia.

  • Page 34: Commissioning

    Heat Exchanger 11.0 Commissioning Automatic Air Vent Fig. 58 11.1 Commissioning the Boiler 1. Reference should be made to BS:EN 12828 & 14336 when commissioning the boiler. 2. At the time of commissioning, complete all relevant sections of the Benchmark Checklist at the rear of this publications.
  • Page 35 11.0 Commissioning 11.2 Check the Operational (Working) Gas Inlet Pressure 1. Ensure that all controls are calling for heat, and the selector switch is in the central heating and hot water position ( The current boiler temperature is shown on the display. Central Heating Domestic Hot Water Temperature Control...

  • Page 36: Completion

    12.0 Completion Case Front Panel 12.1 Completion 1. Instruct the user in the operation of the boiler and system, explaining the operational sequence. 2. Set the central heating and hot water temperature control knobs to the requirements of the user. 3.

  • Page 37: Servicing

    13.0 Servicing 13 .1 Annual Servicing 1. For reasons of safety and economy, it is recommended that Case Front Panel the boiler is serviced annually. Servicing must be performed by a competent person in accordance with B.S. 7967-4. 2. After servicing, complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication.
  • Page 38 Injector 13.0 Servicing Gas/Air Inlet 13.2 Annual Servicing - Inspection (Cont) 6. Undo the nut on the gas pipe at the gas/air inlet (Fig. 72) and the gas valve. Remove the pipe, taking care not to lose the sealing washers. Also remove the injector. Gas Pipe 7.

  • Page 39: Changing Components

    14.0 Changing Components Igniter IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are Igniter Feed Plug isolated before any work is started. When the component has been changed turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler before recommissioning.
  • Page 40 14.0 Changing Components Injector Gas/Air Inlet 14.3 1. Undo the nut on the gas pipe at the gas/air inlet (Fig. 79) and the gas valve. Remove the pipe, taking care not to lose the sealing washers. Also remove the injector. 2.
  • Page 41 14.0 Changing Components 14.5 Burner (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 disconnect the lead.
  • Page 42 14.0 Changing Components 14.7 Safety Thermostat (Fig. 65) 1. Pull the plug off the thermostat. 2. Remove the screws securing the thermostat to the mounting plate on the flow pipe. Safety Thermostat 3. Reassemble in reverse order, ensuring that the plug is pushed fully on.
  • Page 43 14.0 Changing Components Heat Exchanger Air Vent 14.11 Heat Exchanger Automatic Air Vent (Fig. 86 ) 1. Drain the boiler primary circuit and unscrew the automatic air vent from the pump body. 2. Examine the ‘O’ ring seal, replacing if necessary, and fit it to the new automatic air vent.
  • Page 44 14.0 Changing Components 14.15 Pressure Gauge (Figs. 90 & 91) Gauge Retaining Bracket 1. Drain the boiler primary circuit and remove the clip securing the pressure gauge capillary. 2. Undo the screws securing the gauge retaining bracket to the facia. 3.
  • Page 45 14.0 Changing Components 14.18 Plate Heat Exchanger (Fig. 94) 1. Drain the boiler primary circuit and remove the gas valve Plate Heat Exchanger as described in Section 14.23. 2. Remove the clip securing the expansion vessel braided hose to the hydraulic assembly. 3.
  • Page 46 14.0 Changing Components 14.21 P.C.B. (Figs. 97 & 98) 1. Note the settings of the temperature control knobs, rotate them fully anticlockwise and carefully pull them off the drive pins. 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 hinge pin.
  • Page 47 Venturi Inlet 14.0 Changing Components Pipe Gas Valve 14.23 Gas Valve (Fig. 99) IMPORTANT: After replacing the valve the CO must be checked and adjusted as detailed in Section 15.0 Setting Sensing Pipe the Gas Valve. Only change the valve if a suitable calibrated combustion analyser is available, operated by a competent person - see section 13.1.

  • Page 48: Setting The Gas Valve

    15.0 Setting the Gas Valve 15.1 Setting the Gas Valve (CO check) IMPORTANT: The CO must be only be checked and adjusted to set the valve if a suitable calibrated combustion analyser is available, operated by a competent Central Heating person - see Section 13.1 Domestic Hot Water Temperature Control...

  • Page 49: Electrical

    16.0 Electrical 16.1 Illustrated Wiring Diagram Central Heating NTC Sensor gr gr NTC Sensor Overheat Stat Hall Effect Sensor Water Pressure Switch X400 X401 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 Optional Integral Timer Control PCB X501...

  • Page 50: Short Parts List

    17.0 Short Parts List Short Parts List G.C. Description Manufacturers Part No. NTC Sensor CH 5130291 Burner 5130292 Electrode Assembly 5130293 5121447 Gas Valve 720301001 Plate Heat Exchanger 720776401 Pump 720063001 Water Pressure Microswitch 720063201 DHW Hall Effect Sensor 720061801 Overheat Thermostat 5114729 NTC Sensor DHW...

  • Page 51: Fault Finding

    18.0 Fault Finding 18.1 Initial Fault Finding Checks NOTE: When instructed to turn the 1. Check that gas, water and electrical supplies are available selector to the reset position turn the at the boiler. selector switch fully anticlockwise against the spring pressure to the reset position 2.
  • Page 52 18.0 Fault Finding Refer to Section 16.0 “Illustrated Wiring Diagram” for position of terminals and components Central Heating - Follow operational sequence (do Turn selector switch to Go to section ‘A’ The display illuminates If the error 110 is still flashing. Turn the selector switch to Error 110 flashing reset position for 5 seconds...
  • Page 53 18.0 Fault Finding Domestic Hot Water - Follow operational sequence Turn selector switch to Go to section ‘A’ The display illuminates If the error 110 is still flashing. Turn the selector switch to Error 110 flashing reset position for 5 seconds Go to section ‘J’...
  • Page 54 18.0 Fault Finding Fault Finding Solutions Sections Is there 230V at: Main terminals L and N Check electrical supply Main terminal fuse Replace fuse Display Replace PCB illuminated Check wiring PCB - X1 connector terminals 1,2 Is there 230V at: Pump If pump jammed, release Replace pump...
  • Page 55 18.0 Fault Finding E20 or E50 - Temperature sensors faulty. Cold resistance approximately 10kΩ @ 25° C (DHW and CH sensors) Replace sensor or PCB (E28) 20kΩ @ 25° C (Flue sensor) (resistance reduces with increase in temp.) E28 - Incorrect PCB fitted Check and correct the connection of the tube between the venturi and gas valve Gas at burner...
  • Page 56 18.0 Fault Finding Check supply pressure at the gas valve:- Minimum 17 mbar Check and correct if necessary 1. The mechanical set of the gas valve (CO2 values - see instruction) 2. Flame sensing electrode and lead connections 3. Flame sensing electrode position 4.
  • Page 57 19.0 Notes © Baxi Heating UK Ltd 2012...

  • Page 58: Benchmark Checklist

    GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty.

  • Page 59: Service Record

    Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.

  • Page 60: Baxi Heating Uk Ltd

    A T r a d i n g D i v is i o n o f B a xi H e at i ng U K L td (3 87 91 56 ) 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 7209286 - 02 (7/12)

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