Glow-worm Clearly Solar Controller User Manual
Instructions for Use
To b e l e f t w i t h t h e u s e r
Clearly Solar System
including
Fluropro
Solar Differential Controller
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www.glow-worm.co.uk
WARNINGS
SAFETY
The uropro must be installed by a competent person, who is responsible for adhering to
the existing standards and regulations.
ALTERATIONS
Under no circumstances should you ever attempt to make alterations to these
components or any other part of the system
SEALED COMPONENTS
Under no circumstances must the user interfere with or adjust sealed parts.
IMPORTANT
Danger of death by electric shock! All live parts of the system may be installed, serviced and repaired only by a competent
person. Risk of overvoltage! Earth the solar circuit as potential equalisation and protection against overvoltage! Attach
earthing pipe clips to the solar circuit pipes and connect the clips to a potential rail with a 16mm2 copper cable.
Glow-worm service call: 01773 596510 Technical helpline: 01773 828300
General and Sales enquiries Tel: 01773 824639 Fax: 01773 820569
Glow-worm is a licensed member of the Benchmark Scheme which aims to
improve the standards of installation and commissioning of domestic heating and
hot water systems in the UK and to encourage regular servicing to optimise safety,
efciency and performance.
Benchmark is managed and promoted by the Heating and Hotwater Industry
Council. For more information visit www.centralheating.co.uk
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Important Information
Documents
Please retain these user instructions and all related documents in a safe place for future reference.
If you vacate the premises in which this system is installed,
please give the documents to the new owner.
Testing and Certication
These products are tested and certicated for safety and
performance. It is therefore, important that no alteration
is made to the products, without permission, in writing, by
Glow-worm.
CE Mark
The CE mark on the Fluropro solar control and Flurocyl
twin coil cylinder indicates that these products comply with
the basic requirements of the applicable directives.
General Note
Servicing/maintenance should be carried out by a competent person in accordance with the rules in force in the
countries of destination.
Servicing
To ensure the continued efcient and safe operation of the
product it is recommended that it is checked and serviced
at regular intervals. The frequency of servicing will depend
upon the site conditions and usage, but in general, once a
year should be enough.
To obtain service, please call your installer or Glow-worm’s
own service organisation using the telephone number on the
inside front cover of this booklet.
Cleaning
The Fluropro and Flurocyl can be cleaned using a mild liquid
detergent with a damp cloth.
Do not use any form of abrasive or solvent cleaner as you
may damage the surfaces.
Recycling
These products comprises many recyclable parts.
The packaging and the content of the package shall not be
disposed of with general domestic waste but according to
the current regulations.
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Contents
Description Page
System Design 6
System Functions 7
Control Functions 9
User Instructions 10
User Control Panel 11
Operation 12
Display 13
Display Modes 14
Settings 17
Servicing, Maintenance and Spare Parts 24
System - Fault Finding 25
Operation of the Solar Control 26
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System Design
These instructions are an integral part of the controller and
must, to comply with the current issue of the Gas Safety
(Installation and Use) Regulations, be left with the user.
Please ensure that the installer has fully completed the
Benchmark Checklist in the centre pages of the installation
instructions supplied with the product and that you have
signed it to say that you have received a full and clear
explanation of its operation. The installer is legally required
to complete a commissioning checklist as a means of
complying with the appropriate Building Regulations
(England and Wales).
All installations must be notied to Local Area Building
Control either directly or through a Competent Persons
Scheme. A Building Regulations Compliance Certicate
will then be issued to the customer who should, on receipt,
write the Notication Number on the Benchmark Checklist.
Please read these instructions and follow them carefully for
the safe and economical use of this product.
Solar system
The solar system is intended for the provision of solar heated domestic hot water. Any other use is considered to be
improper and the manufacturers / suppliers are not liable for
any resulting damage.
IMPORTANT: We accept no liability for any damage or injuries caused by improper use.
Flurocyl twin coil unvented cylinder
The Flurocyl is an unvented, indirectly heated hot water
cylinder for use with solar systems and suitable boilers.
This cylinder is intended to supply domestic hot water and
may only be used for this purpose.
Compartment or Cupboard Installations
Ventilation is not required for compartment or cupboard
installations. Do not use the compartment or cupboard for
storage.
Fluropro solar control
The Fluropro monitors the temperature within your cylinder
and solar panel and controls the solar system accordingly.
This control is also able to determine if the boiler is
required to provide further heat.
The Fluropro solar control works on the principal of
differential temperature control. The control always
switches on the collector pump when the difference in
temperature (collector temperature - cylinder temperature)
is greater than the programmed activation difference.
The controller switches off the collector pump when the
difference in temperature (collector temperature - cylinder
temperature) is less than the programmed deactivation
difference.
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System Functions
Solar gain
The installation engineer activates and congures the
solar gain function within the Fluropro installer menu.
The solar gain is determined from:
l The difference of temperature between the collector ow
and return.
l The ow rate setting of the ow rate adjuster.
l The operating time of the collector pump.
During installation the engineer sets the actual ow rate
and enters the setting into the solar control. The solar gain
is calculated and displayed by the solar control. The total
gain can be called up and reset in the installer menu.
Solar gain modulation
The rate of solar gain can be modulated to ensure the solar
heat at the bottom of the cylinder has sufcient time to
dissipate to the top of the cylinder. This maintains demand
for solar energy and prevents excessive on and off periods
that are inefcient.
The modulation is achieved by means of more frequent on
and off operations of the solar pump during solar demand.
The pump is switched on and off and the rate depends
upon the difference between the collector temperature
and lower cylinder sensor. When the activation difference
is reached, the function is started (if activated) with an
activation duration of 50 % - i.e., the pump is switched on
for 30 seconds and then switched off for 30 seconds. If the
difference in temperature increases, the activation duration
is prolonged (e.g., 45 sec. on, 15 sec. off). When the
difference in temperature decreases, the activation duration
is reduced (e.g., 20 sec. on, 40 sec. off). The period length
is always a minute.
Solar circuit protection function
If the solar heat exceeds the current heat requirement,
i.e. the cylinder is fully charged, the temperature in the
collector array can rise steeply.
To protect the solar circuit (solar pump, valves, etc.) from
overheating, if the protection temperature at the collector
sensor is exceeded, the collector pump is shut down and is
prevented from restarting even when there is a demand for
solar reheating. The solar pump is switched on again once
the system has cooled down. This function is performed
independently for each collector array. The control will
show “PROT” whilst this function is active.
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System Functions
Cylinder reheat
The cylinder reheat function allows the cylinder to heat up
to the required temperature during a set time window, even
if the solar gain is insufcient. In this case the water can be
reheated using an external boiler or the immersion heater.
You can set up times for reheating the solar cylinder, refer
to Settings section in Instructions for Use.
Reheat delay
To prevent unnecessary cylinder reheating by a boiler or
an immersion heater, the Fluropro solar control includes
a reheat delay function. This function delays the cylinder
reheat by up to 30 mins if solar gain is available.
If the solar pump is off and the desired cylinder
temperature is not reached after the delay period, the
cylinder will be reheated using an external boiler or the
immersion heater.
The reheat delay function is activated by an engineer within
the Fluropro installer menu.
Legionella protection
The Legionella protection function is designed to kill germs
in the cylinder system.
When the function is activated, the cylinder, the hot water
pipes, and the circulation pump (if installed), are brought to
a temperature of 70°C on the programmed day(s) and at
the programmed time.
In doing so, the cylinder temperature is raised to 70°C
and the corresponding circulation pump is switched on
(if installed). First, an attempt will be made using solar
gain alone to reach the target temperature over a 90 min.
period. If this is not successful, the Legionella protection is
carried out using an external boiler or an immersion heater,
whichever has been set up for this thermal protection. The
Legionella protection function will stop once a temperature
of at least 70°C has been maintained for a period of 30
minutes.
The installation engineer activates the Legionella protection
function within the Fluropro installer menu and species
whether the thermal disinfection should take place at 3:30
p.m. or at 4:00 a.m., i.e. mininal offset gain at 3:30 p.m.
versus cheaper electricity at 4:00 a.m.
Anti-seize protection for pumps
If no pumping has occurred for 23 hours, all installed
pumps are switched on for approx. 3 seconds to prevent
pumps from seizing.
Secondary recirculation
The Fluropro solar control includes a programmer channel
for a DHW secondary return. A secondary return should not
be used with Glow-worm twin coil unvented solar cylinders.
Calendar
The controller is equipped with a calendar so that it can
automatically adjust by 1 hr between GMT and BST. To
activate it, an engineer can simply enter the current date
within the Fluropro installer menu.
NOTE: In the event of a power failure, the controller only
has a power reserve of 30 minutes. After 30 minutes, the
internal clock stops and the calender will not automatically
resume function once power has been restored. In this
case the time and date will need to be reset.
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Control Functions
Special functions
Please refer to Settings section for information on how to
activate the following special functions.
l Party function
When the party function is activated, the cylinder reheat is
activated until the next programmed off period. This means
that the cylinder DHW temperature setting will be maintained by the auxiliary cylinder reheating if necessary.
l One-time cylinder reheat
When this function is activated, the cylinder is reheated to
DHW temperature setting ONCE ONLY.
l Holiday function
When this function is activated, the operating mode is
switched to “Off” for the set holiday period (1 to 99 days).
This deactivates both the solar heating and the cylinder reheat.
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User Instructions
General Note
We recommend declaring the solar system as an increase
in value to your insurance and insuring it against lightning.
Operation of the solar system
Once the solar system is commissioned it will work automa-
tically, you do not even need to make any adjustments when
you go on holiday.
IMPORTANT: The collectors and pipes can become very
hot – avoid touching them!
IMPORTANT: You must not make any changes to the Flu-
rocyl cylinder, Fluropro control, pipework, power supply, wiring, pressure relief valves or expansion relief valves. The
system operates automatically.
IMPORTANT: Do not switch off the solar system – even
when you go on holiday or assume an error has occurred,the
only exception is if, the solar panels have been damaged,
resulting in a pressure drop in the solar system or solar uid
escaping.
Do not take out the fuse or switch off the fuse box.
Operation of the solar cylinder
The unvented Flurocyl solar cylinder is provided with connections for a solar system as well as an auxiliary cylinder
reheat system.
How to control the solar system is described in the manuals
for each controller.
NOTE: In the event of leaks in the water pipework close the
main cold water stop valve. This is usually located under a
kitchen sink.
IMPORTANT: A thermostatic mixing valve must be tted to
the outlet of the cylinder and can be adjusted to the desired
domestic hot water temperature by an installation or service
engineer. Otherwise there is a risk of scalding as the cylinder outlet temperature at the taps could be up to 85°C.
IMPORTANT: Risk of damage! Do not remove or modify any
components of the solar cylinder.
In the unlikely event of a malfunction occurring of the Flu-
rocyl, such as hot water owing out of the temperature and
pressure relief valve, switch off the boiler and the immersion
heater and contact Glow-worm or your installer.
Do not under any circumstances empty or ll the solar circuit
yourself.
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