Glow-worm Clearly Solar System User Manual

Clearly Solar

Installation and Servicing

System Wiring

including

Fluropro

Solar Control

www.glow-worm.co.uk

1

Customer Service:

01773 596510

Technical Helpline:

01773 828300.

General and Sales enquiries:

Tel. [phone]

Fax: [phone]

To register your Glow-worm appliance

call:

0800 0732142

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 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 can be used to demonstrate compliance with Building Regulations and should 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.centralheating.co.uk for more information.

2

These instructions consist of, Installation, Commissioning, Service and Fault Finding.

The instructions are an integral part of the appliance and must be handed to the user on

completion of the installation.

CONTENTS DESCRIPTION SECTION PAGE

Regulations 4
Electrical Supply 4

Testing and Certication 4

CE Mark 4

GENERAL

INFORMATION

Safety Instructions 4
Intended Use 5
Documents 5
Servicing 5
Cleaning 5
Recycling 5

INSTALLATION

MAINTENANCE

Specication 1 5

Functions 2 6
Installation 3 7
Electrical Installation 4 9
Commissioning 5 19

Service / Diagnostics 6 24
Sensor Characteristics 7 26
Control - Fault Finding 8 27

3

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 qualied servicing company!

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.

Regulations

When installing and commissioning the system, the current
version of regulations below shall be observed.
The electrical installation must be installed by a competent

person and in accordance with the relevant standards

Electrical Supply

The product MUST be earthed.

All system components shall be of an approved type and all
wiring to current I.E.E. wiring regulations.
External wiring must be correctly earthed, polarised and in
accordance with the relevant standards.
In GB, this is BS 7671.
In IE, this is the current edition of ETCI rules.

The product MUST be connected to a permanent 230V ac,
50Hz supply.
Connection of the whole electrical system of the product,
including any heating controls, to the electrical supply MUST
be through one common isolator and must be fused 3 Amp
maximum.
Isolation should be by a double pole switched fused spur box,
with a minimum gap of 3mm for both poles. The fused spur
box should be readily accessible and preferably adjacent to

the product. It should be identied as to its use.

Alternatively connection can be made through an unswitched
shuttered socket and 3A fused 3-pin plug both to the current
issue of BS 1363, provided they are not used in a room
containing a bath or shower.
Wiring to the product must be PVC 85°C insulated cable, not
less than 0.75mm2 (24/0.20mm).

CE Mark

The CE mark on the Fluropro solar control indicates that
it complies with the basic requirements of the applicable
directives as stated on the data badge.

“Benchmark scheme”

Glow-worm support the Benchmark initiative. It is very
important that the service record is completed by the
installation engineer and handed over to the user.

Safety Instructions

The entire solar system must always be installed and
operated in accordance with recognised technical standards.
IMPORTANT: Danger of death by electric shock! All live parts
of the system may be installed, serviced and repaired only by

a qualied servicing company!

IMPORTANT: 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.

Testing and Certication

This product is tested and certicated for safety and

performance. It is, therefore, important that no alteration is
made to the product, without permission, in writing, by Glow­worm.
Any alteration not approved by Glow-worm, could invalidate

the certication, warranty and may also infringe the current

issue of the statutory requirements.

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General Information

Intended use

The Fluropro solar control is a temperature differential
controller for solar DHW provision with a cylinder reheat
programmer for a supplementary boiler.
The control is suitable for controlling solar systems with a
collector array and a storage cylinder.
The Fluropro solar control can be used for controlling a
second collector array
If a second collector array is connected, an additional
collector sensor (available as an accessory) must be installed.
It is possible to determine the solar gain by using an
additional gain sensor (supplied with Glow-worm Clearly Solar
sets).
The Fluropro solar control is a state-of-the-art control which
has been constructed in accordance with recognised safety
regulations. Nevertheless, improper use can cause serious
or fatal injury to the user or others, and the appliance or other
property can be damaged.
The manufacturer or supplier is not liable for any damage
resulting from improper use.
The control is not suitable for outdoor use and must be
installed in a dry room.

Documents

Please retain these instructions as well as any documents
enclosed, for future reference.
We accept no liability in case of damage due to the non­compliance of these instructions.

Servicing

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

You can clean the housing of the Fluropro solar control with a
damp cloth and a little soap.
NOTE: Do not use scouring or cleaning agents which could
damage the display.

Recycling

The Fluropro solar control comprises many recyclable parts.
The packaging and control shall not be disposed of with
domestic waste but according to the current regulations.

1 Specication

14276

5

2 Functions

2.1 Solar gain

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.

The installation engineer activates and congures the solar

gain function within the Fluropro installer menu.
The solar gain is determined from:

– The difference of temperature between the collector ow

and return.

– The ow rate setting of the ow rate adjuster.

– 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.

2.2 Solar gain modulation

The rate of solar gain can be modulated to ensure the solar

heat at the bottom of the cylinder has sufcient time to

dissipate to the top of the cylinder. This maintains demand for
solar energy and prevents excessive on and off periods that

are inefcient.

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.

2.3 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 insufcient. 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.

2.5 Legionella protection

The Legionella protection function is designed to kill germs in
the cylinder and pipes.
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 species

whether the thermal disinfection should take place at 3:30
p.m. or at 4:00 a.m., i.e. offset gain versus cheaper electricity.

2.6 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.

2.7 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.

2.8 Calendar

The controller is equipped with a calendar so that it can
automatically adjust the clock by 1hr between GMT and BST.
To activate, 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.

2.4 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.

6

3 Installation

11Fluropro

21Collector sensor
32Cylinder sensor

UPPER

SENSOR

3.1 Contents of sets

Using Table1, verify the contents of the Fluropro solar control
set.

Item Quantity Components

Table 1

The gain sensor is a separate item and is also supplied as
part of the Glow-worm Clearly Sets.

3.2 Installing cylinder sensors

The cylinder sensors are designed so that they can be used
as immersion sensors or surface sensors.
Install the two sensors in the solar cylinder, see diagram 3.1,
and connect to the wiring as shown in wiring diagram.
When used as a surface sensor, the sensor is secured to

the ow pipe or the return pipe as appropriate using the

supplied tension band, see diagram 3.2. In order to guarantee

good heat transfer, the sensor is at on one side. We also

recommend that the pipe with the sensor is insulated, in order
to enable the best possible measuring of temperature.
Refer to cylinder instructions for the location of sensors and

specic tting instructions.

14361

TEMPERATURE
SENSOR

TEMPERATURE
SENSOR
GAIN

LOWER
TEMPERATURE

Diagram 3.1

3.3 Accessories

If a second collector array is connected, it is necessary
to install a second collector sensor from the Glow-worm
accessory range.

3.4 Installing the Fluropro housing

The Fluropro solar control is designed to be mounted on
a wall. The wiring terminals within this control includes the
connectors. These connectors must be used for all wiring to
this control.
The cover consists of two parts, which can be removed
separately:

• As shown in diagram 3.3, pull the lower front cover off of the

controller housing.

• Mark the position of both holes and drill, see diagram 3.4.

• Select wall plugs to suit, and screw the controller housing on

tightly.

14261

Diagram 3.2

14260

Diagram 3.3

7

3 Installation

230230

Diagram 3.4

14260

14263

Diagram 3.5

• Lift up the control panel, see diagram 3.5.

• Wire the controller according to the selected hydraulic plan

(see Section 4 Electrical installation).

• Secure all cables with the accompanying cable clamps.

• Push the control panel back into place.

• Re-attach the lower front cover.

8

4 Electrical Installation

Electrical Supply

The product MUST be earthed.
All system components shall be of an approved type and all
wiring to current I.E.E. wiring regulations.
External wiring must be correctly earthed, polarised and in
accordance with the relevant standards.
In GB, this is BS 7671.
In IE, this is the current edition of ETCI rules.
The product MUST be connected to a permanent 230V ac,
50Hz supply.
Connection of the whole electrical system of the product,
including any heating controls, to the electrical supply MUST
be through one common isolator and must be fused 3 Amp
maximum.
Isolation should be by a double pole switched fused spur box,
with a minimum gap of 3mm for both poles. The fused spur
box should be readily accessible and preferably adjacent to
the product. It should be identified as to its use.
Alternatively connection can be made through an unswitched
shuttered socket and 3A fused 3-pin plug both to the current
issue of BS 1363, provided they are not used in a room
containing a bath or shower.
Wiring to the product must be PVC 85°C insulated cable, not
less than 0.75mm2 (24/0.20mm).
IMPORTANT: Risk of fatal electric shock from touching live
connections.
Before working on the system wiring, including the Fluropro,
isolate the power supply.
The circuit board can be damaged if short circuited through
the connection leads. For safety purposes, a max. of 30 mm
of insulation may be removed from the ends of 230 V leads
which will be connected to Fluropro wiring connectors. If more
insulation is removed, there is a risk of short circuiting the
circuit board.
When exchanging the solar controller in an existing
system, sensor-curve characteristics should be taken
into consideration and the sensors should be replaced if
necessary!
The immersion heater must be installed with an additional
relay or contactor with a circuit-breaking capacity of at least
16 A. Never operate an immersion heater in connection with
the Fluropro without an additional external relay or contactor.

9