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.

4

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

4 Electrical Installation

SOLAR COLLECTOR

BOILER

SOLAR COLLECTOR
CIRCUIT PUMP

AUTO AIR

SEPARATOR

MOTORISED
2 PORT VALVE

MOTORISED
2 PORT VALVE

FLOW

FLOW

HOT
WATER
CONNECTION

TUNDISH

THERMOSTAT
MIXER

FLUROCYL
DRAIN VALVE

RETURN

RETURN

EXPANSION
RELIEF
VALVE
(6.0 BAR)

PRESSURE
LIMITING VALVE
(3.5 BAR)
WITH LINE
STRAINER

COLD
WATER
SUPPL

Y

PUMP

EXPANSION
VESSEL

TEMPERATURE
AND PRESSURE
RELIEF VALVE
(95 °C, 7 BAR)

LEGIONNELLA
LOOP (optional)

4.1 Hydraulic plan

IMPORTANT: Reference cylinder instructions for wiring to

cylinder thermostats and thermal cut-outs.
(NOTE: The Glow-worm Flurocyl cylinder is fitted with a solar
thermal cut-out - other manufacturers cylinders may not be
fitted with this device).

IMPORTANT: To simplify the system wiring, two hydraulic
plans are stored in the Fluropro solar control.

Hydraulic Plan 1 includes one collector array and
Hydraulic Plan 2 includes two collector arrays,

(separate circuits and pump stations). The relevant plan must
be selected within the Fluropro installer menu.

14213

10

Hydraulic Plan 1

4 Electrical Installation

Collector arrays setup for East / West orientation

14212

N

SOLAR
COLLECTOR

SOLAR
COLLECTOR
CIRCUIT PUMP

HOT
WATER
CONNECTION

SOLAR
COLLECTOR

LEGIONNELLA
LOOP (optional)

W

S

THERMOSTAT
MIXER

PUMP

TEMPERATURE
AND PRESSURE
RELIEF VALVE
(95 °C, 7 BAR)

E

BOILER

MOTORISED
2 PORT VALVE

MOTORISED
2 PORT VALVE

AUTO AIR

SEPARATOR

FLOW

RETURN

FLOW

RETURN

EXPANSION
VESSEL

EXPANSION
RELIEF
VALVE
(6.0 BAR)

PRESSURE
LIMITING VALVE
(3.5 BAR)
WITH LINE
STRAINER

TUNDISH

FLUROCYL
DRAIN VALVE

Hydraulic Plan 2

COLD
WATER
SUPPLY

11

4 Electrical Installation

Boiler

Flexicom hx / sx,

Ultracom hxi / sxi,

old hxi / sxi

3rd party ov / sys

Ultracom hxi / sxi

with

options board

Wiring

11 way terminal

block

11 way terminal

block

Solar Circuit

Control

Fluropro

Fluropro

DHW

programming

Fluropro

3rd party

programmer

Internal

programmer

Fluropro

CH

programming

3rd party

programmer

3rd party

programmer

Internal

programmer

Internal

programmer

Climapro or

Climapro RF

Diagram

4.1

4.2

4.3

4.4

4.5

Installer interface options for Glow-worm boilers

4.6

12

4 Electrical Installation

FLUROCYL

E N

L

3rd PARTY

EXTERNAL

PROGRAMMER

FOR CH

COMMON 230V

MAINS TERMINAL

BLOCK

ROOM

THERMOSTAT

L

or

E

N

NOC

L

TERMINAL BLOCK

230V~50Hz
MAINS SUPPLY

L

N

E

Double

pole

isolator

RETURN PIPE

AT 16A

FUSED
AT 3A

COLLECTOR

PUMP

SOLAR
COLLECTOR

DAO

LN

E N L E N 2 1 L

or g g

b b

g/y g/y br br

br

bl

g/y

N L

E

H

3 4 5 6 7 8 9

LINK E N L

10

ADDITIONAL
TERMINAL
BLOCK

DHW
VALVE

CH
VALVE

FLUROPRO
CONTROLLER

230v~ PCSA

NTCA

TAC1

TAC2

GAIN R

L

BROWN br
BLUE b
BLACK bl
ORANGE or
WHITE w
PURPLE p
GREEN gn
GREY g
GREEN
/YELLOW g/y

KEY

REFER TO BOILER WIRING
INTERFACE, PAGE 17.

bl

230V~50Hz
MAINS SUPPLY

L

N

E

Double

pole

isolator

AT 3A

14793

Diagram 4.1

13

4 Electrical Installation

FLUROCYL

3rd PARTY

EXTERNAL

PROGRAMMER

FOR CH

ROOM

THERMOSTAT

L

or

E

E

N

NOC

L

TERMINAL BLOCK

RETURN PIPE

FUSED
AT 3A

COLLECTOR

PUMP

SOLAR COLLECTOR

DAO

LN

E N L E N 2 1 L

or g g

b b

g/y g/y br br

br

N NL

L

E

H

NOHW

3 4 5 6 7 8 9

LINK E N L

10

ADDITIONAL
TERMINAL
BLOCK

DHW
VALVE

CH
VALVE

FLUROPRO
CONTROLLER

230v~ PCSA

NTCA

TAC1

TAC2

GAIN

R

L

BROWN br
BLUE b
BLACK bl
ORANGE or
WHITE w
PURPLE p
GREEN gn
GREY g
GREEN
/YELLOW g/y

KEY

bl

g/y

bl

COMMON 230V

MAINS TERMINAL

BLOCK

230V~50Hz
MAINS SUPPLY

L

N

E

Double

pole

isolator

AT 16A

REFER TO BOILER WIRING
INTERFACE, PAGE 17.

230V~50Hz
MAINS SUPPLY

L

N

E

Double

pole

isolator

AT 3A

14794

Diagram 4.2

14

4 Electrical Installation

FLUROPRO
CONTROLLER

14795

SOLAR COLLECTOR

FUSED
AT 3A

DHW
VALVE

orgg

NTCA

or

230v~ PCSA

ENL E N 21L

CH
VALVE

bb

g/yg/y br br

TAC2

TAC1

TERMINAL BLOCK

GAINR

COLLECTOR

PUMP

L

LINKE N L

ADDITIONAL
TERMINAL
BLOCK

bl

g/y

bl

KEY

BROWN br
BLUE b
BLACK bl
ORANGE or
WHITE w
PURPLE p
GREEN gn
GREY g
GREEN
/YELLOW g/y

E

Wiring for
boiler installer
interface
cartridge for

Ultracom hxi
ONLY

Wiring for
boiler installer
interface
cartridge for

Ultracom sxi
ONLY

BOILER
OPTIONS

N L 3 4 5 6 7 8 9

SYSTEM
PUMP

230V

4 ON TERMINAL
BLOCK

230V

4 ON TERMINAL
BLOCK

LN

ROOM
THERMOSTAT

EBUS

OV

24V

EBUS

OV
OTC1
OTC2

N
L

N
L
R
F

N

L
R
F

10

br

L DAO

FLUROCYL

RETURN PIPE

COMMON 230V
MAINS TERMINAL
BLOCK

HW ON

HEATING

X12

HW OFF

X40a

OPTIONS BOARD

X40b

Double

pole

isolator

AT 3A

230V~50Hz
MAINS SUPPLY

15

LNE

Double

pole

isolator

AT 16A

230V~50Hz
MAINS SUPPLY

LNE

Diagram 4.3

4 Electrical Installation

FLUROPRO
CONTROLLER

14796

SOLAR COLLECTOR

FUSED
AT 3A

DHW
VALVE

orgg

NTCA

or

230v~ PCSA

ENL E N 21L

CH
VALVE

bb

g/yg/y br br

E

N L 3 4 5 6 7 8 9 10

TAC2

TAC1

TERMINAL BLOCK

GAINR

COLLECTOR

PUMP

LINKE N LL

BROWN br
BLUE b
BLACK bl
ORANGE or
WHITE w
PURPLE p
GREEN gn
GREY g
GREEN
/YELLOW g/y

ADDITIONAL
TERMINAL
BLOCK

bl

g/y

bl

KEY

Wiring for
boiler installer
interface
cartridge for

Ultracom hxi
ONLY

Wiring for
boiler installer
interface
cartridge for

Ultracom sxi
ONLY

BOILER
OPTIONS

X12

X40a

PUMP

EBUS

OV

24V

EBUS

OV
OTC1
OTC2

N
L

N
L

4 ON TERMINAL

R

BLOCK

F

N

L
R
F

X40b

SYSTEM
PUMP

230V

230V

4 ON TERMINAL
BLOCK

LN

L DAO

ROOM
THERMOSTAT

Double

pole

isolator

AT 3A

br

br

L

E

N

RETURN PIPE

COMMON 230V
MAINS TERMINAL
BLOCK

Double

pole

isolator

AT 16A

FLUROCYL

L

N

E

HW ON

HEATING

HW OFF

OPTIONS BOARD

230V~50Hz
MAINS SUPPLY

16

230V~50Hz
MAINS SUPPLY

Diagram 4.4

4 Electrical Installation

FLUROPRO
CONTROLLER

14797

SOLAR COLLECTOR

FUSED
AT 3A

DHW
VALVE

orgg

NTCA

or

230v~ PCSA

ENL E N 21L

CH
VALVE

bb

g/yg/y br br

TAC2

TAC1

TERMINAL BLOCK

GAINR

COLLECTOR

PUMP

LINKE N LL

ADDITIONAL
TERMINAL
BLOCK

bl

g/y

bl

KEY

BROWN br
BLUE b
BLACK bl
ORANGE or
WHITE w
PURPLE p
GREEN gn
GREY g
GREEN
/YELLOW g/y

E

Wiring for
boiler installer
interface
cartridge for

Ultracom hxi
ONLY

Wiring for
boiler installer
interface
cartridge for

Ultracom sxi
ONLY

BOILER
OPTIONS

X12

N L 3 4 5 6 7 8 9 10

CLIMAPRO
or
CLIMAPRO
RF

SYSTEM
PUMP

TO CLIMASTAT
OR CLIMAPRO
IF FITTED

230V

4 ON TERMINAL
BLOCK

TO CLIMASTAT
OR CLIMAPRO
IF FITTED

230V

4 ON TERMINAL
BLOCK

X40b

Double

pole

isolator

AT 3A

EBUS

EBUS

OTC1
OTC2

X40a

OV

24V

OV

N

L

N
L
R
F

N

L
R
F

br

br

COMMON 230V
MAINS TERMINAL
BLOCK

L

E

N

RETURN PIPE

Double

pole

isolator

AT 16A

FLUROCYL

L

E

N

HW ON

HEATING

HW OFF

OPTIONS BOARD

230V~50Hz
MAINS SUPPLY

17

230V~50Hz
MAINS SUPPLY

Diagram 4.5

Main supply

3 Amp fused

LN

bl blE

TCO

Collector

Pump

Flurocyl

Cylinder

4 Electrical Installation

LEG/BYPPCSB/PCPCSA230 V~

E LNE LNLN

Pump East

L N

4 763

Relay

14839

V3VR

E LNE 12LN

EL N

Collector

EL N

Collector

Pump West

Diagram 4.6

4.2 Additional wiring for East/West
installations.

To maintain compliance with G3 regulations when using
an East/West arrangement with independant pump station
control, it is necessary to install an additional external relay.
(Drayton RBI shown, see diagram 4.6, but any suitable double
pole relay or 2 separate relays could be used).

Wiring for boiler installer

interface cartridge for

Glow-worm XI hxi ONLY

24V

EBUS

OV
OTC1
OTC2

N

230V

L
R
F

4 ON TERMINAL
BLOCK

N

L

N

L

4 ON TERMINAL

R

BLOCK

F

SYSTEM
PUMP

230V

4.3 Using Third party heating appliances
in conjunction with the Glow-worm solar
system solution.

It is possible to use a non Glow-worm boiler with the Glow­worm solar system solution which is controlled by the
Fluropro.
In order to achieve this, consult your boiler installation manual
to determine the switched live connection to the boiler. The
switched live input is the 230v input voltage to the boiler which
makes a heating demand.
The heating demand to your non Glow-worm boiler will be
provided from the Fluropro or a third party programmer at
terminal 4 of the wiring centre.

14277

4 ON TERMINAL
BLOCK

BOILER CONNECTIONS
230V CONTROLS INTERFACE

230V SWITCHED LIVE
FROST THERMOSTAT

230V SWITCHED LIVE

r

HEATING CONTROLS

DO NOT CONNECT

w

r

gr

Wiring for boiler installer
interface cartridge for

New Flexicom sx
Ultracom sxi ONLY

Wiring for boiler installer

interface cartridge for

New Flexicom hx

Ultracom hxi ONLY

BOILER OPTIONS

EBUS

OV

N
L

SYSTEM
PUMP

N

F

4 ON TERMINAL

R
L

BLOCK

If there are no system controls available
the red link will allow the boiler to run
continuously. REMOVE the red link if
fitting system controls

230V

INSTALLER INTERFACE OPTIONS FOR

GLOW-WORM BOILERS

Diagram 4.7

18

5 Commissioning

1

Display

User Control Panel

14722

Button

Button

Display overview Display symbols

13

12

11

10

8

2
3

5

4

6

9

7

Timer programs:

Cylinder reheat

Not used

Operating modes:

Cylinder reheat function in timed mode

Cylinder reheat function in constant mode

Button

Button

Diagram 5.1

Key

1 Programming menu
2 Service/diagnostic menu
3 Cylinder reheat
4 Not used
5 Info menu
6 Solar gain (blinks if solar gain is available)
7 Units
8 Cursor
9 Multifunction display
10 Days of the week
11 Target/actual value
12 Operating modes
13 Special functions

No cylinder reheat

Solar pump(s) not activated

No cylinder reheat

Special functions:

Party

Advanced cylinder reheat

Holiday function

Diagram 5.2

19

Changing the hydraulic plan

1, 2, 3

1

Setting the flow rate

0 – 165 litres/min

0

Resetting the solar gain.

-

-

Resetting the operating hours.

-

-

Setting the max. temperature for cylinder 1

20 to 90 °C

75 °C

5 Commissioning

Installer menu

Access the installer menu by pressing the button for 3
seconds.
Press the

button for 3 seconds again to return to the
operating menu.
These parameters should only be adjusted by the installation

engineer.

5.1 Setting the system parameters

Certain system parameters have to be set in order to optimise
the system for the respective conditions. These parameters are
all together in the installer menu and should only be set by the
installation engineer.
Access the installer menu.

Display

Press + or - to adjust
Press PROG to accept

1. 1 collector array.

2. 2 collector arrays (East/West system).

3. Not used.

IMPORTANT:

l The hydraulic plan, ow rate and current date must be

entered.
l It is also recommended that the solar gain modulation and
cylinder reheat delay are activated.
l Ask the householder how long they normally program the
DHW to be on for before they actually require it. If one hour or
more, activate the cylinder reheat delay.
l It may not be necessary to change any other settings from
the factory defaults
Exit the installer menu.
The following table gives an overview of all system parameters
and their factory settings and range.

Setting range Factory setting

When setting the the required flow rate,
please observe the measurement units,
required for display of Solar gain.

The solar gain is reset to 0 by turning the dial
to 1.

The operating hours are reset to 0 by turning
the dial to 1.

Setting the activation difference for cylinder 1.
(The activation difference should always be 2
K greater than the deactivation difference)

2 – 15 K 7 K

Setting the deactivation difference for cylinder

1.
(The deactivation difference should always be
2 K less than the activation difference)

1 – 10 K 3 K

20

Not used.

20 - 90 °C

60 °C

Not used

.

5 – 12 K

7 K

Not used.

1 – 10 K

3 K

PRIO

1, 2

1

AGEL:

-5oC – 10oC; OFF

OFF

PROT

OFF, 110oC – 150oC

130oC

CST:

1, 2

1

LEG

OFF, 1, 2, 3, 4, 5, 6, 7, 1-7

OFF

LEGT:

00:00 - 23:50

04:00

5 Commissioning

Display Turn the dial to adjust Setting range Factory setting

Cylinder with highest priority

Frost protection function

Solar circuit safeguard

Collector type
1 = Flat collector
2 = Tubular collector

Anti-Legionella function

Start time for the anti-Legionella function

Table 1 System parameters (continued)

21

Cylinder reheat delay function

0=deactivated; 1=activated

0

Solar gain modulation function

0=off; 1=on

0

Setting the current day

1 - 31

0

Setting the current month

1 - 12

0

Setting the current year

2000 - 2159

2000

5 Commissioning

Display Turn the dial to adjust Setting range Factory setting

Table 1 System parameters (continued)

22

5 Commissioning

Adjust the solar water heating target tem­perature setting

Important: Set the solar water heating target temperature to

the maximum adjustment
Press and hold the button to increase the solar water
heating target temperature, or press and hold the button
to decrease the solar water heating target temperature.
Once or is pressed a cursor appears beside the

current target temperature. The temperature begins to ash

as it is being adjusted. Once the desired target temperature
is selected wait 5 seconds. The display returns to running
screen.

5.2 Resetting parameters to default

You can reset the system parameters and the timer programs
to the default settings by pressing the button for

ten seconds. Then the display ashes twice and all of the

parameters are reset to the factory defaults.

5.4 Hand over to the householder

l Hand over all manuals to the householder.
l Advise the householder to keep the manuals near to the

system.
l Draw special attention to the safety instructions which the
householder must follow.
l Review the user instructions with the householder and
answer any questions.
l Show the householder how to operate the solar control, CH
control and any separate DHW control.
l Inform the householder that the cylinder temperature is
factory set at 65°C and that the DHW temperature can be
adjusted using the TMV by the installer.
l Inform the householder that the immersion heater is
intended as a standby device and should not be used
simultaneously with the boiler to heat the cylinder.
l Inform the householder that they are not permitted to
change the settings made on the solar system.
l Inform the householder that to ensure the continued

efcient and safe operation of the solar system it is

recommended that it is checked and serviced at regular
intervals. The frequency of servicing will depend upon the
installation conditions and usage, but in general, once a year
should be enough.
l Inform the householder that the boiler and solar cylinder

should be serviced by a qualied engineer annually.

5.3 Benchmark

GB: It is a requirement that the “Benchmark” Installation,

Commissioning and Service Record is completed and left with
the user.
IE: it is necessary to complete a “Declaration of Conformity” to
indicate compliance to I.S.813. An example of this is given in
the current edition of I.S.813.

Leave these instructions and the “Benchmark” Installation,
Commissioning and Service record document with the user.

23

6 Service / Diagnostics

Collector pump test (array 1)

Collector pump 1 on, all other actuators off

Collector pump test (array 2 if applicable)

Collector pump 2 on, all other actuators off

Cylinder reheat 230V demand test

Cylinder reheat 230V demand on, all other actua-

Cylinder reheat demand - volt free contacts test

Cylinder demand - volt free contacts - closed cir-

Upper cylinder sensor value

6 Service menu

Access the service menu by simultaneously pressing the

button and button for approx. 3 seconds. All
relays and sensors can be controlled and checked in this
menu (refer to the system wiring manual included with
Fluropro).

Display Relay check/sensor values Test procedure

The display returns to the main operating menu if you press
the
and sensors should be checked only by the installation and
service engineer.

button and button for 3 seconds. The relays

Switching valve test Switching valve on, all other actuators off

Legionella protection pump test Legionella protection pump on, all other actuators

off

tors off

cuit, all other actuators off

Table 1 Actuators and sensors

24

Collector sensor value (array 1)

Collector sensor value (array 2 if applicable)
Gain sensor value

6 Service / Diagnostics

Display Relay check/sensor values Test procedure

Low cylinder sensor value

Not used

Table 1 Actuators and sensors (continued)

You can check the visual display by pressing

Diagram 6.1 Check visual display

With another press, the current version of the controller’s
software is displayed.

Diagram 6.2 Controller software version

You can exit the service/diagnostic level by pressing the

and buttons simultaneously.

again.

Emergency mode

When the Fluropro detects an error, its basic display always
shows the error. If either the solar yield or reheating function
is possible, the controller carries out this function despite the
error.

25

Sensor values

Resistance value

0 °C

9191 Ohm

20 °C

3384 Ohm

25 °C

2692 Ohm

30 °C

2158 Ohm

50 °C

954 Ohm

60 °C

658 Ohm

70 °C

463 Ohm

120 °C

105 Ohm

Sensor values

Resistance value

-20 °C

97070 Ohm

0 °C

32650 Ohm

5 °C

25390 Ohm

10 °C

19900 Ohm

20 °C

12490 Ohm

25 °C

10000 Ohm

30 °C

8057 Ohm

40 °C

5327 Ohm

50 °C

3603 Ohm

60 °C

2488 Ohm

90 °C

918 Ohm

100 °C

680 Ohm

130 °C

301 Ohm

7 Sensor Characteristics

Cylinder sensors, type NTC 2.7 K

5 °C 7064 Ohm

10 °C 5214 Ohm

40 °C 1416 Ohm

80 °C 333 Ohm

Collector sensor, type NTC 10 K

-10 °C 55330 Ohm

-5 °C 42320 Ohm

15 °C 15710 Ohm

35 °C 6532 Ohm

70 °C 1752 Ohm

80 °C 1258 Ohm

110 °C 511 Ohm

120 °C 389 Ohm

26

8 Control - Fault Finding

Error messages

The Fluropro solar controller shows error messages in
the main operating menu if there is a problem with the
temperature sensor.

The sensor conguration will always be displayed when the
controller is switched on for the rst time, or if the power

has been switched off and on again. Depending on the set
hydraulic plan, the controller recognises whether there is a
problem, or if the sensor is not necessary for operation.
The following diagrams assume that the day is Monday
and that the timer is active for reheat but is not currently
reheating.

Error collector sensor (array 1)

This error occurs if the there is a problem with the collector
sensor, or if it is not connected.

Error collector sensor (array 2)

This error occurs if a sensor is connected for hydraulic plan

1. Alternatively for hydraulic plan 2 or 3, if there is a problem
with the connected sensor or it is not connected.

Error Upper cylinder sensor

This error occurs if there is a problem with the heating circuit
sensor connected.

Error Lower cylinder sensor

This error occurs if there is a problem with the solar circuit
sensor, or if it is not connected.

27

0020055002

Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT

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

28

0020055002-04 03.09