Glow-worm Clearly Hybrid User Manual

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Installation and Servicing

Hydraulic module HB

TABLE OF CONTENTS

INTRODUCTION

1 Instructions guidance .........................................................................................................................2

1.1 Product documentation...........................................................................................2

1.2 Associated documents ..........................................................................................2

1.3 Explanation of symbols...........................................................................................2

1.4 Guarantee registration ............................................................................................2

2 Appliance description .........................................................................................................................2

2.1 Safety devices ........................................................................................................ 2

2.2 Data label ...............................................................................................................2

2.3 Hydraulic schematic ...............................................................................................3

3 Safety instructions and regulations ....................................................................................................3

3.1 Safety instructions .................................................................................................. 3

3.2 Regulations.............................................................................................................4

4 Recycling ...........................................................................................................................................4

4.1 Appliance ................................................................................................................4

4.2 Packaging ...............................................................................................................4

INSTA L L ATION

5 Appliance location ..............................................................................................................................5

6 Appliance installation ........................................................................................................................5

6.1 Scope of delivery ....................................................................................................5

6.2 Recommendations before installing .......................................................................5

6.3 Dimensions .............................................................................................................6

6.4 Mounting .................................................................................................................6

7 Hydraulic connection ..........................................................................................................................8

8 Electrical connections ........................................................................................................................9

9 Commissioning ..................................................................................................................................9

10 Specic adjustment ...........................................................................................................................9

11 Assembly of the casing ....................................................................................................................10

12 User information ...............................................................................................................................10

MAINTENANCE

13 Trouble-shooting .............................................................................................................................. 11

14 Servicing ........................................................................................................................................ 11

15 Replacement of Parts ......................................................................................................................11

16 Technical Data .................................................................................................................................11

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INTRODUCTION

1 Instructions guidance

1.1 Product documentation

The instructions are an integral part of the appliance and must be handed to the user on completion of the installation in order to comply with the current regulation.

• Carefully read the manual, to understand all the information to enable safe installation, use and servicing. No liability can be accepted in the event of damage for not complying with the guidance in this instruction manual.

1.2 Associated documents

- 1 Instructions for use

- Instructions for other system components

1.3 Explanation of symbols

We recommend you complete and return as soon as possible your guarantee registration card. If your guarantee registration card is missing you can obtain a copy or record your registration by telephoning the Glow-worm Customer Service number 01773 828100.

2 Appliance description

2.1 Safety devices

This appliance is equipped with a safety valve.

- The safety valve opens when the pressure in the heat pump circuit exceeds 3 bars.

2.2 Data label

The data label certies the country where the appliance is

intended to be installed.

Data label location:

a e b i

DANGER: Risk of injuries.

DANGER: Risk of electric shock.

ATTENTION: Risk of damage to the appliance or to its surroundings.

IMPORTANT: Important information.

1.4 Guarantee registration

Thank you for installing a new Glow-worm appliance in your home. Glow-worm appliances are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive Guarantee.

This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture, whichever is the shorter, for parts and labour.

The second year of guarantee, from the beginning of the 13th month onwards after installation or manufacture, is conditional upon the appliance having been serviced by a competent person approved at the time by the Health and Safety Executive, in accordance with the manufacturer’s recommendations. We strongly recommend regular servicing of your gas appliance, but where the condition is not met, any chargeable spare parts or components issued within

the applicable guarantee period still benet from a 12 month

warranty from the date of issue by the manufacturer.

Key 1 Data label

The data label contains the following data:

- The name of the manufacturer

- The commercial name of the appliance and its serial number

- The maximum pressure in the heating circuit

- The maximum pressure in the heat pump circuit

- The type and voltage of electricity supply

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INTRODUCTION

2.3 Hydraulic schematic

Key 1 Flow control valve 2 Safety valve

3 3-wayvalvewithshut-offvalveforlling 4 3-wayvalvewithshut-offvalveforlling

5 Manometer 6 Plate to plate heat exchanger 7 Pump

8 Boilerowcircuitisolatingvalve

9 Boiler return circuit isolating valve

10 Boilerowcircuitnon-returnvalve

11 Heat exchanger output non-return valve

12 Heatingowthermistor

13 Heating return circuit isolating valve

14 Heatingowcircuitisolatingvalve

A B

D CG F

3 Safety instructions and regulations

3.1 Safety instructions

Incorrect installation can cause electric shock or

• Never disable security devices and do not try to adjust them.

• Be sure to consider the following handling techniques and

- Grip the appliance at its base

- Use safety clothing where appropriate, e.g. gloves, safety

• Ensure safe lifting techniques are used:

- Keep back straight.

- Avoid twisting at the waist.

- Avoid upper body/top heavy bending.

- Always grip using the palm of the hand.

- Use designated hand holds.

- Keep load as close to body as possible.

- Always use assistance if required.

• Under no circumstances must the user interfere with or

appliance damage.

precautions:

footwear.

adjust sealed parts.

A Boilerowcircuit

B Boiler return circuit C Heating return circuit

D Heatingowcircuit

E Safety valve discharge F Heat pump return circuit

G Heatpumpowcircuit

• When assembling the connections, correctly position the seals to avoid any leakage of water.

• This appliance contains metal parts (components) and care should be taken when handling and cleaning, with particular regard to edges.

The basic safety instructions must be followed before attempting to maintain or replace spare parts:

• Stop the appliance.

• Electrically isolate the appliance from the power supply.

• Hydraulically isolate the appliance using the isolation valves

if provided.

• Should you need to replace hydraulic components, drain the appliance.

• Protect all the electrical components from water while working on the appliance.

• Use only original spare parts.

• Use only new O-rings and gaskets.

• After having completed work on water carrying components,

check for their tightness.

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• When work on the appliance is completed, perform an operational test and check for safety.

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INTRODUCTION

3.2 Regulations

IMPORTANT

Where no British Standards exists, materials and equipment

should be t for their purpose and of suitable quality and

workmanship.

The installation of this appliance must be carried out by a competent person approved at the time by the Health and Safety Executive and in accordance with the rules in force in the countries of destination.

Manufacturer’s instructions must not be taken as overriding statutory requirements.

Statutory Requirements

In GB, the installation of the appliance must comply with the requirements of the current issue of BS6798 and be carried out by a competent person approved at the time by the Health and Safety Executive and as described in the following regulations:

- The manufacturer’s instructions supplied.

- The Gas Safety (Installation and Use) Regulations.

- The appropriate Buildings Regulations either The Building Regulations, The Building Regulations (Scotland), The Building Regulations (Northern Ireland).

- The Water Supply (water ttings) Regulations 1999 and water

byelaws 2000, Scotland.

- The Health and Safety at Work Act, Control of Substances Hazardous to Health (COSHH).

- The Current I.E.E. Wiring Regulations.

Domestic Hot Water

All domestic hot water circuits, connections, ttings must be

in accordance with the relevant standards and water supply regulations.

GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide. IE: The current edition of I.S.813 “Domestic Gas Installations”.

Heating System

In GB, it is necessary to comply with the Water Supply (Water Fittings) Regulations 1999 (for Scotland, the Water Byelaws 2000, Scotland). To comply with the Water regulations your attention is drawn to: The Water Regulations guide published by the Water Regulations Advisory Service (WRAS) gives full details of the requirements.

In IE, the requirements given in the current edition of I.S.813 “Domestic Gas Installations” and the current Building Regulations must be followed.

4 Recycling

The recycling of the packaging must be carried

out by the qualied professional who installed the

appliance.

Where no specic instructions are given, reference should be

made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a competent person approved at the time by the Health and Safety Executive 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.

GB: the following Codes of Practice apply: BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593, BS7671. IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.

NOTE: For further information, see the current issue of the Building Regulations, approved document L1 ( in the UK) and the following current issues of:

1) Central heating system specication (CheSS) and

2) Controls for domestic central heating system and hot water. BRECSU.

Gas Supply

The gas installation must be in accordance with the relevant standards.

In GB, this is BS6891. In IE, this is the current edition of I.S.813 “Domestic Gas Installations”.

4.1 Appliance

Most of the appliance is made of recyclable materials.

This symbol indicates that this appliance must not

be disposed of with household waste, that it should be selectively collected for energy recovery, reuse

or recycling.

• Take the appliance to an appropriate collection point.

By complying with this directive, you will contribute

to the preservation of natural resources and the protection of human health.

4.2 Packaging

We recommend that you recycle the packaging of the appliance in a responsible fashion.

• Sort the waste in order to separate those elements which can be recycled (cardboard, plastics ...) and those which cannot be recycled.

• Dispose of the waste in accordance with existing regulations.

The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler. On completion, test the gas installation for tightness using the pressure drop method and suitable leak detection

uid, purge in accordance with the above standard.

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INSTALLATION

5 Appliance location

• Before choosing a site for the appliance, carefully read the safety warnings and installation manual.

• Ensure that wall to which the appliance will be mounted on is structurally safe in order to support the weight of the appliance.

• Ensure there is sufcient space available for the appliance,

taking care that minimum clearances are adhered to ensure that the connections to the water can be accessed and inspected.

• The appliance must be installed in a room protected from freezing. Take all necessary precautions.

• Explain these requirements to the appliance user.

6 Appliance installation

6.1 Scope of delivery

3.1

3.2

3.3

3.3 Module instructions for use (x1)

3.4 Guarantee conditions (x1)

3.5 Guarantee card (x1)

4 Frame

5 Accessories bag (x1)

5.1 Flat seal ¾" (x6)

5.2 Frame screws (x4)

5.3 Flat seal 1 " (x4)

• Check the contents of the packages.

(x2)

6.2 Recommendations before installing

6.2.1 Heating circuit design

The heat transmitters may be low temperature (under-oor

heating, low-temp radiator ...) and high temperature (cast iron radiator ...).

The installation pipework should be calculated using a ow / pressure curve. The distribution will be determined by the ow

corresponding to the power actually required, regardless of the maximum power that can be provided by the installation’s generators.

The pipework should be designed and installed in such a way so as to make all provisions necessary to avoid air pockets and facilitate the permanent degassing of the installation. Venting valves must be placed at each high point of the tubes, as well as on all radiators.

3.4

3.5

5.3

5.2

Key 1 Hydraulic module cover (x1)

2 Hydraulic module (x1)

5.1

The total volume of water for the heating circuit depends, among other factors, on the cold static load of the boiler’s expansion tank. It is recommended that a drainage valve be installed at the lowest point of the installation.

If using thermostatic valves, do not equip all radiators with them, placing these valves at high demand sites and never at the sites in which the room thermostats are installed.

- In both new and existing installations, the radiator circuit

must be ushed prior to installing the new appliance in

accordance with BS:7593.

- If a system component is not put in place immediately, protect the different connections so that the plaster and paint does not spoil water tightness for later connecting.

6.2.2 Heat pump circuit design

The pipework should be designed and installed in such a way so as to make all provisions necessary to avoid air pockets and facilitate the venting of air from the installation. Bleed valves are to be installed at each of the pipes' highest points.

• In order to avoid the transmission of vibration to surrounding structures, use hoses for water connections.

Insulate the pipes with a UV- and high-

temperature-resistant insulation.

3 Documents bag (x1)

3.1 System installation manual (x1)

3.2 Module installation manual (x1)

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INSTALLATION

6.3 Dimensions

6.3.1 Hydraulic module

431

6.3.2 Frame

Appliance weight : 12,5 kg

284

137

470

122

157

414

6.4 Mounting

Depending on the installation, you may install the

• Make sure that the equipment used for implementing the

• Determine the assembly location. See the "Appliance

• The applications should be anchored in accordance with

frame supplied with the appliance.

installation is compatible with that of the appliance.

location" chapter.

the characteristics of the supporting wall and must take into account the weight of the appliance.

414

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476

200

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INSTALLATION

6.5.1 Attaching the appliance to a wall without a frame

385

375

Key 1 Hydraulic module 2 Frame 3 Screw

• Attach the frame (2) to the hydraulic module using the provided screws (3).

385

• Attach the appliance to the wall in accordance with the diagram shown above.

6.5.2 Attaching the appliance to a wall with a frame

Key 1 Cutting tool 2 Metallic component

Depending on the installation, you can cut the metal

• Attach the appliance to the wall in accordance with the

component (2) in order to pass the connections

along the side of the appliance.

diagram shown above.

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INSTALLATION

7 Hydraulic connection

A label located inside the cover enables the

identication of the module’s hydraulic connections.

D HeatingowcircuitØ¾"

E Safety valve discharge

F HeatpumpreturncircuitØ1" G HeatpumpowcircuitØ1"

• Take care to clean the pipes before assembly removing any debris or burrs. Grease and oils may need to be removed

they are not possible to remove by cleansing and ushing.

Foreign bodies in the system may enter the appliance and interrupt its operation.

• Do not use any solvent products, due to the risk of damaging the circuit.

Do not perform any 'hot work' directly under

• Only use original seals supplied with the appliance.

• Check that there are no leaks.

the appliance, this may cause damage to the appliance base. Heat may also damage the isolation valves.

Always pre-assemble pipes before tting them to

the appliance.

Key 1 Hydraulic connection label

Key

A BoilerowcircuitØ¾" B BoilerreturncircuitØ¾" C HeatingreturncircuitØ¾"

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INSTALLATION

REL1

8 Electrical connections

Incorrect installation can cause electric shock or

The external wiring must be earthed, with correct polarity and in accordance with current standards.

The manufacturer declines any responsibility for damages to persons or others caused by the incorrect installation of the appliance earthing. This includes failure to comply with current standards.

appliance damage. The electrical connection of

the appliance must be made only by a qualied

engineer.

NTC1

9 Commissioning

• Refer to the system’s installation manual in order to activate the installation.

Pump ow / pressure curve

Key 1 Speed 2

2 Speed 3 (Factory setting) A Available pressure (kPa) B Flow in the circuit (l / h)

300 600 900 1200

Key 1 Pump cable 2 Pump cable gland

3 Heatingowthermistorcable 4 Heatingowthermistorcablegland

Component Voltage (cable section)

Pump 230 V (3 x 0.75 mm ²)

Thermistor 3.3 V (2 x 0.34 mm ²)

Speed 1 is not applicable to this system.

10 Specicadjustment

• Refer to the system’s installation manual to adjust the

installation.

• Pass the pump cable (1) through the gland (2).

• Connect the cable (1) to the REL1 terminal in the Systempro.

• Tighten the gland (2).

• Pass the thermistor cable (3) through the gland (4).

• Connect the cable (3) to the NTC1 terminal in the Systempro.

• Tighten the gland (4).

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INSTALLATION

11 Assembly of the casing

1 2

Key 1 Hydraulic module cover 2 Hydraulic module

• Once the installations settings have been completed, t the

cover (1) to the hydraulic module (2).

12 User information

At the end of the installation, the installer must:

- explain the operation of the appliance and its safety devices to the user, if necessary provide a demonstration and answer any questions;

- hand over to the user all the required documentation,

- ll in the documents where necessary;

- advise the user of the precautions necessary to prevent damage to the system, appliance and the building;

- remind the user to service the appliance annually.

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MAINTENANCE

13 Trouble-shooting

The following checks should be performed before proceeding

onto specic diagnostics:

- Make sure that the electricity supply has not been interrupted and that the appliance is connected correctly.

• Ensure that the isolating valves are open.

• Check that all external controls are connected correctly.

14 Servicing

• See the "Safety instructions" chapter for a list of operations to be performed prior to the maintenance of the application.

• Once the maintenance operations have been completed, refer to the system’s installation manual to restart the installation.

Annual Maintenance

16 Technical Data

Description Unit Value

Maximum heating circuit pressure

Maximum heat pump circuit pressure

Pump supply voltage V/Hz 230 / 50

Thermistor supply voltage V 3.3

Dimensions

Height mm 476

Length mm 470

Depth mm 200

Lift weight kg 12,5

bar 3

Pa 3 x 10

bar 3

Pa 3 x 10

• Check the proper functioning of safety devices.

• Check the pressure of the circuits.

• Check the airtightness of the connections.

• Ensure that the appliance’s components are neither worn nor

broken.

15 Replacement of Parts

In order to guarantee the safe and prolonged life of the product, manufacturers genuine spare parts must be used.

Use only the manufacturer’s authorised, original,

• Ensure that spare parts are correctly mounted in the right

new spare parts.

position and direction. After tting any spare part or servicing,

the appliance must be tested for its safe operation.

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Glow-worm

Subject to engineering changes

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Nottingham Road, Belper, Derbyshire. DE56 1JT

www.glow-worm.co.uk

Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.

Glow-worm Clearly Hybrid User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual