Glow-worm Clearly Solar Cylinders User Manual
Instructions for use
Installation
and Servicing
Solar Hot Water Cylinders/
Flurocyl
200
250
300
2
TABLE OF CONTENTS
INTRODUCTION
1 Instructions guidance ................................................................................................................... 3
1.1 Product documentation .......................................................................................3
1.2 Associated documents ........................................................................................3
1.3 Storage of documents .........................................................................................3
1.4 Explanation of symbols .......................................................................................3
1.5 Benchmark .........................................................................................................3
2 Safety instructions and regulations ............................................................................................... 3
2.1 Intended use ......................................................................................................3
2.2 General safety information ..................................................................................4
2.3 Cylinder safety information ..................................................................................4
2.4 Cylinder identication plate .................................................................................4
2.5 Regulation and statutory requirements .................................................................4
3 Introducing your appliance ........................................................................................................... 5
3.1 Appliance description .........................................................................................5
READ CAREFULLY BEFORE U S I N G
4 Operation .................................................................................................................................... 6
4.1 Adjusting the hot water temperature ....................................................................6
4.2 Switching o hot water ........................................................................................6
4.3 Frost protection ..................................................................................................6
4.4 Cleaning the cylinder ..........................................................................................6
4.5 Fault nding .......................................................................................................7
5 Inspection and Maintenance ......................................................................................................... 7
TECHNICAL DATA
6 Technical data .............................................................................................................................. 8
INSTALLAT I O N
7 Hydraulic and electrical schematics ............................................................................................. 10
8 Description of the components ................................................................................................... 12
8.1 Flurocyl2 solar cylinder ......................................................................................12
8.2 Solar pump safety thermostat ............................................................................12
9 Cylinder installation ................................................................................................................... 13
9.1 Cylinder device description ................................................................................13
9.2 Installation site .................................................................................................15
9.3 Installing of discharge pipe ...............................................................................15
9.4 Pipes for the reheating circuit ............................................................................17
9.5 Installing hot water pipes ..................................................................................18
9.6 Installation of cold water pipe ............................................................................18
9.7 Electrical installation .........................................................................................20
10 Commissioning ......................................................................................................................... 21
10.1 Filling the cylinder ............................................................................................21
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TABLE OF CONTENTS
MAINTENANCE
11 Inspection and maintenance ....................................................................................................... 23
11.1 Maintenance checklist .......................................................................................23
11.2 Draining the cylinder .........................................................................................23
11.3 Fault diagnosis .................................................................................................24
12 Recycling and disposal ............................................................................................................... 25
12.1 Cylinder disposal ..............................................................................................25
12.2 Disposal of packaging .......................................................................................25
13 Customer service and manufacturer's warranty ............................................................................ 26
13.1 Glow-worm service ............................................................................................26
13.2 Glow-worm warranty .........................................................................................26
14 Spare parts ................................................................................................................................ 27
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INTRODUCTION
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
When installing and maintaining the solar system, you must
observe all of the installation and maintenance instructions
for system parts and components as well as those for other
accessories which are used in the system.
These installation and maintenance manuals are provided with
the relevant system parts, components, and accessories.
1.3 Storage of documents
Pass this installation manual and all other applicable documents
and, if necessary, any required aids to the system operator.
The system operator will be responsible for storing them so that
the instructions and aids are available when required.
1.4 Explanation of symbols
a
DANGER: Risk of injuries.
installed, commissioned and serviced in accordance with the
manufacturer’s instructions by competent persons and that it
meets the requirements of the appropriate Building Regulations.
The Benchmark Checklist must be used to demonstrate
compliance with Building Regulations and must be provided to
the customer for future reference.
Installers are required to carry out installation, commissioning
and servicing work in accordance with the Benchmark Code
of Practice which is available from the Heating and Hotwater
Industry Council who manage and promote the Scheme.
• Visit www.central heating.co.uk for more information.
2 Safety instructions and regulations
2.1 Intended use
Glow-worm cylinders are constructed using state-of-the-art
technology in accordance with recognised safety regulations.
Nevertheless, there is still a risk of injury or death to the user or
others or of damage to the unit and other property in the event of
improper use or use for which the unit is not intended.
Glow-worm cylinders are not intended for use by persons who
have inadequate experience and/or knowledge, unless they are
supervised by a person responsible for their safety or have been
given instructions by this person regarding the operation of the
unit. Children must be supervised to ensure that they do not play
with the unit.
Glow-worm Flurocyl
indirectly heated domestic hot water cylinders designed for use
with gas-red boilers as per GB standards for hot water supply
systems. The cylinders work with the pressure of the water supply
line and do not need a cold water tank for their supply.
They are used only to supply potable water heated up to 80°C
in solar systems with a collector array. They may only be used
for this purpose. The cylinders can be used in combination
with a downstream gas-red boiler for hot water generation in
accordance with GB standards.
domestic hot water cylinders are unvented,
2
e
DANGER: Risk of electric shock.
ATTENTION: Risk of damage to the appliance or to its
vicinity.
IMPORTANT: Useful information.
1.5 Benchmark
Benchmark places responsibilities on both manufacturers
and installers. The purpose is to ensure that customers are
provided with the correct equipment for their needs, that it is
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Any other use or extended use is considered to be improper.
Improper use of any kind is prohibited.
The manufacturer/supplier is not liable for any damage resulting
from improper use. The user alone bears the risk. Intended use
also includes observing the operating and installation manuals
and all other applicable documents, as well as complying with the
inspection and maintenance conditions.
At the end of this manual there is a commissioning report which
you must ll in and hand over to the operator. All installers
should have a current ID card and registration number. The
cylinder must be installed by a competent person approved at
the time by the Health and safety Executive to the prevailing
standards, installation book and building regulations at the time
of installation.
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INTRODUCTION
2.2 General safety information
Installation and adjustment as well as service, maintenance
and repair must be carried out by a competent person approved
at the time by the Health and Safety Executive and be in
accordance with the relevant requirements of the Local Authority,
Building Regulations, Building Regulations (Scotland), Building
Regulations (Northern Ireland), and the bye-laws of the local
Water Undertaking.
2.3 Cylinder safety information
This product has been assessed and found to comply with the
requirements of the Building Regulations for unvented hot water
storage systems and must not be altered or modied in any way.
In the event of parts replacement, use only genuine spare parts
supplied by Glow-worm.
The installation is subject to Building Regulation approval.
Notify the Local Authority of intention to install.
As stipulated in the manual "Handling Operations
Regulations 1992", the weight of the unit exceeds that
which should be lifted by one person.
Without potential equalisation, life-threatening voltage from
the electric immersion heater can reach the piping and water
taps.Earth the electric immersion heater. If the solar cylinder is
connected with pipes made of non-metallic materials and is not
earthed, corrosion damage can occur.
Earth the solar cylinder for potential equalisation and to protect
against overvoltage.
If using non-metallic pipes on the water route, make sure that
they are designed by the manufacturer for continuous operation
at 70°C and operation by the hour at temperatures of up to 95°C
Always use a suitable open-end spanner to tighten or undo
threaded connections. Do not use pipe wrenches, extensions,
etc. If the water does not meet the requirements of the UK water
quality standards with a maximum chloride level of 250 mg/l,
corrosion damage may occur to the cylinder.
Only use the cylinder to heat potable water.
2.3.1 Electric potential equalisation
If you use an electric immersion heater in the cylinder, the
external voltage may build up electrical potential in the water
which can result in the electrochemical corrosion of the electric
immersion heater. Make sure that both the hot water and cold
water pipes are connected to the earth line by means of earth
cable directly on the cylinder. You must also make sure that the
electric immersion heater is connected to the earth line via the
earthing terminal.
2.3.2 Preventing frost damage
You should not turn the gas-red boiler o completely so that
you can still use all of the safety functions for your heating
installation. If you want to take the unit out of operation for a
relatively long period of time in an unheated room at risk from
frost, you must completely drain the Flurocyl2.
2.3.3 Avoiding damage caused by leaks
If there are leaks in the pipe network, close o the cold water stop
valve on the safety assembly and notify an engineer qualied to
work on unvented systems to rectify the leaks.
2.3.4 Avoiding burns and scalds
For scald protection, install a hot water thermostat mixer in the
system.
If the system is in stagnation then hot steam can discharge from
the expansion relief valve of the solar pump unit. This may be
visible in the receptor canister. Should this occur contact your
installer for advice.
The temperature of the stored water could reach high
temperatures after solar charging and your Glow-worm solar
installer will have tted a tempering valve so as to prevent this
reaching the hot water taps. Should excessively hot water reach
your hot taps contact your installer immediately.
2.3.5 Preventing damage due to unauthorised
changes to the unit
Changes to the supply lines, relief valve termination, and
expansion relief valve may only be carried out by an engineer
qualied to work on unvented systems.
Never shut o the expansion relief valve or relief valve
termination.
Never bypass any of the security devices.
2.4 Cylinder identication plate
The identication plate is attached to the middle of the cylinder
at the factory.
2.5 Regulation and statutory requirements
2.5.1 Cylinder and cylinder assembly
Pressure equipment directive 97/23/EC
Directive of the European Parliament and Council from 29th May,
1997 for the approximation of the laws on pressure equipment of
the Member States
EN 12977-3
Thermal solar systems and components; Custom built systems,
Part 3: Performance characterisation of domestic hot water
cylinders
EN 12897:2006
Water supply - specication for indirectly heated unvented
(closed) domestic hot water cylinders
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INTRODUCTION
EN 806-1
Specications for installations inside buildings conveying water
for human consumption - Part 1: General
EN 1717
Protection against pollution of potable water installations and
general requirements of devices to prevent pollution by backow
EN 60335-2-21
Safety of household and similar electrical appliances; Part 2:
Particular requirements for storage water heaters (domestic hot
water cylinders and hot water boilers) (IEC 335-2-21: 1989 and
supplements 1; 1990 and 2; 1990, modied)
2.5.2 CE Mark
CE labelling shows that the appliance according to the model
overview comply with the basic requirements of the applicable
directives.
The CE declarations of conformity can be viewed at the
manufacturer's premises and can be supplied if necessary.
3 Introducing your appliance
3.1 Appliance description
3.1.2 Hot water temperature regulation
You can set the hot water temperature and reheating times in the
upper half of the cylinder on the controller.
One of the following controllers may be used depending on the
design of your system:
- Glow-worm Fluropro
- Climapro
Refer to the operating manual for the installed controller or timer.
in conjunction with a timer
2
3.1.3 Electric immersion heater
The cylinder is equipped with an additional electric immersion
heater (3) with a heating output of 3 kW. The electric immersion
heater is designed for use in unvented cylinders and has a
thermostat with a temperature controller (2) and a safety
thermostat (TCO) with a reset button (1).
3.1.4 Functional elements of cylinder
1
2
3
The Flurocyl2 solar cylinder is available in three sizes: 200, 250
and 300 litres. The containers are made from stainless steel with
EPS with additional infared absorbing insulation. The cylinder
works with the pressure of the water supply line and does not
need a cold water tank for its supply. To enable the cylinder to
work as well as possible, a cold water supply with an appropriate
pressure and ow rate is required.
3.1.1 Safety devices
The solar cylinder has been provided with all safety and control
devices for operation of the unvented domestic hot water supply:
- Temperature/pressure relief valve (90 °C, 7 bar)
- Pressure limiting valve (3.5 bar) with line strainer
- Expansion relief valve (one-way valve, 6.0 bar)
- Solar pump safety thermostat, set to 80 °C, connected with
the solar pump in order to isolate this heat source if there is a
malfunction in the solar control.
- Safety thermostat for electric immersion heater (85 °C).
- Solar cylinder safety thermostat, set to 80 °C, to be connected
to the 2-port motorised valve in order to isolate the primary
heat source if a domestic water supply thermostat malfunction
occurs.
4
Key
1 Reset button for reheating circuit
2 Cylinder thermostat
3 Electric immersion heater
4 Reset button for solar circuit
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READ CAREFULLY BEFORE USING
4 Operation
Risk of scalding and bursts due to inappropriate
a
a
4.1 Adjusting the hot water temperature
The hot water temperature is set to the required value by the
engineer qualied to work on unvented systems during the
cylinder commissioning. If an external controller is installed
for hot water temperature control, you can adjust the hot water
temperature and reheating times using this controller.
For information on making settings, see the operating manual for
the controller.
If no controller for hot water temperature control is installed,
you can set the required hot water temperature on the cylinder
thermostat (2). You can set the reheating times on the installed
hot water timer. Refer to the operating manual for the hot water
timer.
alterations!
There is a risk of escaping steam, bursting, and
damage to the system if you make any changes to
the cylinder, control system, supply lines for water
and power (if present), relief valve termination, or
expansion relief valve for the cylinder water.
Do not make any improper changes.
Risk of scalding!
The output temperature of the draw-o points can
reach 85 °C if the mixing valve is set incorrectly.
- Do not adjust the mixing valve.
- If the output temperature at a draw-o point is too
high or low, Contact an engineer qualied to work on
unvented systems to adjust the temperature.
Always make sure that there is clear access to the
cylinder to enable the use of the hot water thermostat
controller and the thermostat mixer.
4.2 Switching o hot water
• Switch o the immersion heater and the gas-red boiler (see
the operating manual for the gas-red boiler) to temporarily
switch o the heating and hot water system.
4.3 Frost protection
Risk of damage due to frost!
If the cylinder is placed out of operation for a
relatively long period of time in an unheated room
(e.g. during a winter holiday), the cylinder must be
completely drained.
- Contact an engineer qualied to work on unvented
systems to drain the cylinder.
If you are absent during a relatively long period when there is a
risk of frost, make sure that you leave the central heating on and
that the temperature in the cylinder room and in all other rooms
are kept above freezing.
4.4 Cleaning the cylinder
• Clean the outside of the cylinder only with a damp cloth, using
soapy water if it is especially dirty.
Do not use abrasive cleaning agents or solvents (any type of
scouring agent, petroleum etc.) since they can damage the
cladding and the cylinder xtures.
• Set the desired cylinder hot water temperature on the cylinder
thermostat (2).
• For optimum eciency, choose a setting of 45 °C.
• Use the operating manual for the gas-red boiler to make sure
that the unit is ready for operation.
We recommend the cylinder is set to 60 °C
periodically, to provide protection against the
proliferation of harmful bacteria.
If you are heating up water for the rst time or after a
long switch-o period, the full cylinder performance is
only available following a waiting period.
If the Flurocyl2 is installed in a cupboard, make sure
that clothing and other objects are not placed on
the cylinder, control devices, pipes, or other system
components.
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READ CAREFULLY BEFORE USING
4.5 Fault nding
Fault Remedy
Fluid is dripping from the system? If possible, collect the uid in a bucket and contact an engineer qualied to
The controller issues a message telling me the sensor is faulty or
there is a cable break?
The cylinder is not providing sucient hot water? Check that the hot water temperature is set correctly on the controller
A safety thermostat trips? Contact an engineer qualied to work on unvented systems.
Water escapes from the expansion relief valve? Contact an engineer qualied to work on unvented systems.
5 Inspection and maintenance
An annual inspection/maintenance run by an engineer qualied
to work on unvented systems is a prerequisite for ensuring that
the cylinder is permanently ready for operation, reliable, and has
a long service life.
work on unvented systems.
Contact an engineer qualied to work on unvented systems.
(recommended value of approx. 45 °C, however, set periodically to 60 °C to
provide protection against the proliferation of harmful bacteria) and
that the gas-red boiler is working. If the settings are
correct, the cylinder may be calcied. Then: contact an engineer qualied to
work on unvented systems.
It is important that your hot water cylinder is serviced annually.
We recommend entering into a maintenance agreement.
After servicing, the servicing engineer must complete the relevant
Service Interval Record section of the Benchmark Checklist
located on the inside back pages of this document.
Risk of death from electric shock.
e
a
Improperly executed work on the cylinder can result in
a risk to life and limb.
- Never try to rectify cylinder malfunctions yourself.
- Contact an engineer qualied to work on unvented
systems to rectify all malfunctions.
Risk of injury resulting from improper maintenance or
repair.
Failure to arrange for the system to be maintained
and repaired and improper maintenance and repair
can impair the operational safety of the unit, leading
to injuries and damage to property
- Never attempt to perform maintenance work or
repairs on the cylinder yourself.
- Always employ an engineer qualied to work on
unvented systems.
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TECHNICAL DATA
TECHNICAL DATA
6 Technical data
Unit Flurocyl2 200 Flurocyl2 250 Flurocyl2 300
Total capacity l 200 250 300
Actual capacity l 209.4 254.4 297.2
Hot water capacity (upper coil) l 104.8 142 144.2
Hot water capacity (solar coil) l 203.3 246.1 271.1
Dedicated solar volume l 104.6 112.4 153.0
Maximum supply pressure to pressure reducing valve bar 12
Maximum operating pressure of cylinder bar 7
Maximum operating pressure of heating coil bar 3.5
Maximum operating pressure of solar coil bar 6
Operating pressure bar 3.5
Pressure limiting valve bar 3.5
Expansion relief valve bar 6.0
Temperature and pressure relief valve bar 7.0
Charge pressure of hot water expansion vessel bar 4.0
Maximum temperature of heating circuit oC 85
Maximum temperature of potable hot water oC 85
Maximum temperature of solar uid oC 85
Standing heat loss kW/24h 2.05 2.20 2.40
Heat up time according to EN 12897 mins 22 29 30
Recovery time (70% capacity) mins 16 21 22
Primary heat exchanger performance kW 14.9 15.3 15.0
Flow rate for primary heat exchanger performance l/min 23.3 23.3 23.3
Primary heat exchanger pressure drop mbar 79 78 79
Primary heat exchanger volume l 2.37 2.37 2.37
Primary heat exchanger surface area m2 0.5 0.5 0.5
Solar heat exchanger performance kW 18.7 18.5 16.5
Flow rate for solar heat exchanger performance l/min 23.3 23.3 23.3
Solar heat exchanger pressure drop mbar 97 95 98
Solar heat exchanger volume l 2.94 2.94 2.94
Solar heat exchanger surface area m2 0.62 0.62 0.62
Heat up time according to EN12897 (solar) mins 34 42 51
Temperature and pressure relief valve oC/bar 90 / 7.0
Dimensions
Height mm 1593 1843 2153
Height with hot water draw o mm 1625 1875 2185
Topple measure mm 1680 1918 2217
Diameter mm 554.5
Depth mm 624
Net weight kg 40 43 50
Weight (lled) kg 249 298 347
Connections
Cold water inlet 22mm compression joint
Hot water draw-o 22mm compression joint
Balanced pressure cold water outlet 22mm compression joint
Secondary return 15 mm compression joint
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