Glow-worm Clearly Solar System Hydraulics User Manual
Clearly Solar
Installation and Servicing
System Hydraulics
including
Solar Pump Station
and Accessories
www.glow-worm.co.uk
1
Guarantee Registration
Thank you for installing a new Glow-worm solar system.
Glow-worm products 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 the guarantee, from the beginning of the 13th month onwards after installation
or manufacture, is conditional upon the product having been serviced by a competent person
(i.e. clear skies registered engineer), in accordance with the manufacturer’s recommendations.
We strongly recommend regular servicing of your product, but where the condition is not met, any
chargeable spare parts or components issued within the applicable guarantee period still benet
from a 12 month warranty from the date of issue by the manufacturer.
The “Benchmark” Installation, Commissioning and Service Record must be completed on
installation and kept up to date.
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 596510.
Customer Service:
01773 596510
Technical Helpline:
01773 828300
General and Sales enquiries:
Tel. 01773 824639
Fax: 01773 820569
To register your Glow-worm product 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, Servicing, Fault Finding. The instructions
are an integral part of the product and must be handed to the user on completion of the
installation.
CONTENTS DESCRIPTION SECTION PAGE
Warnings 4
Important Information 4
INTRODUCTION
Statutory Requirements 5
Notes on the Documentation 6
Safety Instructions 6
System Specications 1 7
Product Specications 2 8
Component Specications 3 9
INSTALLATION
Installation 4 11
Commissioning 5 16
Commissioning Checklist 6 18
Commissioning Data 6 19
MAINTENANCE
Inspection and Maintenance 7 21
Fault Finding 8 22
Solar Fluid Safety Data 9 25
3
WARNINGS
SAFETY
The system 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 Information
Installation and Use Regulations
In your own interests and that of safety, it is the LAW that this
product is installed by a competent person in accordance
with the current issue of these regulations.
Local authority planning permission may be required for the
installation. The local authority should be notied.
Control of Substances Hazardous to Health
Under Section 6 of The Health and Safety at Work Act
1974, we are required to provide information on substances
hazardous to health.
The adhesives and sealants used in this product are cured
and give no known hazard in this state.
Solar uid safety data, see section 9.
Manual Handling
With regards to the “Manual Handling Operations, 1992
Regulations”, the appliance exceeds the recommended
weight for a one man lift, refer to section 9 for more
information.
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.
CE Mark
The CE mark on this product 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.
Testing and Certification
This product is tested and certicated 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 certication, warranty and may also infringe the current
issue of the statutory requirements.
4
Statutory Requirements
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 product must be carried out by a
competent person in accordance 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 product must be carried out by a
competent person as described in the following regulations:
The manufacturer’s instructions supplied.
The appropriate Buildings Regulations either The Building
Regulations, The Building Regulations (Scotland),The
Building Regulations (Northern Ireland).
The Water Fittings Regulations or Water byelaws in Scotland.
The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).
The Current I.E.E. Wiring Regulations.
Where no specic 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 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.
Solar system in general
EN ISO 9488 Thermal solar system and components,
terminology (ISO/DIS 9488; 1995)
EN 12975-1 Thermal solar systems and components;
Collectors, Part 1: General requirements
EN 12975-2 Thermal solar systems and components;
Collectors; Part 2: Test methods
ENV 1991-2-3 Eurocode 1 – Basis of design and actions on
structures, Part 2–3: Actions on structures - Snow loads
EN 12976-1 Thermal solar systems and components; Factory
made systems - Part 1: General requirements
EN 12976-2 Thermal solar systems and components; Factory
made systems - Part 2: Testing methods
ENV 12977-1 Thermal solar systems and components;
Custom built systems, Part 1: General requirements
ENV 12977-2 Thermal solar systems and components;
Factory made systems, Part 2: Testing methods
ISO 9459-1: 1993 Solar heating – Domestic water heating
systems – Part 1: Performance rating procedure using indoor
test methods
ISO/TR 10217 Solar energy – Water heating systems – Guide
to material selection with regard to internal corrosion
Collectors and collector assembly
ENV 1991-2-4 Eurocode 1 – Basis of design and actions on
structures - Part 2–4: Actions on structures - Wind actions
Solar cylinder and cylinder installation
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 stores
for solar heating systems
EN 12897 Water supply - specication for indirectly heated
unvented (closed) storage water heaters
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 (hot water cylinders and hot water boilers) (IEC 335-
2-21: 1989 and supplements 1; 1990 and 2; 1990, modied).
Lightning protection
ENV 61024-1 Protection of structures against lightning – Part
1: General principles (IEC 1024-1: 1990; modied) BS 6651
Code of practice for protection of structures against lightning.
Regulations in Great Britain
Building Regulation, dating from 1991 (England and Wales)
Requirement G3, L1 and Regulation 7
BS 7671 Requirements for electrical installations (IEE Wiring
Regulations, 16th edition)
BS 6759-1 Directive for the usage of the safety assembly for
hot water cylinders.
5
Notes on the Documentation
Notes on the documentation
Your solar system is a quality product from Glow-worm.
This manual covers the solar system, excluding the
cylinder and provides you with information on installation,
commissioning, maintenance and fault nding. It is
supplemented by the installation instructions of the individual
components.
Observe the manuals for each individual system component
in conjunction with this manual.
Look after this manual and pass it on to the user for safe
keeping.
Glow-worm accepts no liability for any damage caused by
failure to observe this manual.
Safety Instructions
Safety instructions
The entire solar system must always be installed and
operated in accordance with recognised technical standards.
IMPORTANT: Risk of falling! Make sure you adhere to the
valid work protection regulations, in particular when working
on the roof. Make absolutely sure you wear anti-fall devices
whenever there is a risk of falling. (We recommend Glowworm fall protection systems, item no. 0020054985.) Observe
the accident prevention regulations of the trade associations.
IMPORTANT: Risk of being burned or scalded by hot
components! Install and replace collectors or collector parts
on very cloudy days. Perform installation work on sunny days
only in the morning or evening or with the collector covered.
IMPORTANT: Risk of being burned or scalded by hot solar
uid or components! Fill and ush the solar
system when the collectors are cold. Cover the
collectors while doing so.
IMPORTANT: Risk of being burned or scalded by escaping
hot steam! Steam can escape from the expansion relief valve
of the solar pump unit if the system is shut down. To avoid
injuries, you must connect the expansion relief valve to a
collecting container with a hose line.
Other applicable documents
Collector installation instructions.
System hydraulic installation instructions.
System electrical installation instructions including Fluropro.
System user instructions including Fluropro.
Installation and user instructions for the boiler.
Installation instructions for all sub components and
accessories used.
Warranty card.
Please observe the safety instructions in this manual when
installing this solar system.
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 being burned or scalded by escaping
hot steam! Steam can escape from unblocked automatic
bleeders if the system is shut down. Therefore block all
automatic bleeders after bleeding.
We recommend using the automatic air separator system
supplied as part of Glow-worm optional pipework kit. It works
fully automatically and does not need to be subsequently
blocked. It must be installed in an area however, in which no
steam can enter, preferably in the return pipe nearby the solar
cylinder.
6
1 System Specications
1.1 Intended use
The solar system is used for the solar-supported supply of
DHW.
Any other use is considered to be improper. The manufacturer
/ supplier is not liable for any resulting damage. The user
alone bears the risk.
Intended use includes the observance of the system
description and all other applicable documents, as well as
adherence to the maintenance and inspection conditions.
IMPORTANT: We accept no liability for any damage or injuries
caused by failure to observe this manual.
At the end of this manual is a commissioning protocol, which
should be lled in by the installer and/or commissioning
engineer and handed over to the user.
1.2 Design and function of the solar system
The solar system consists of four main components:
The collectors, which absorb the solar radiation and utilise it.
The solar control, which monitors, displays and controls all
functions of the system.
The solar pump unit, which transports the solar heat.
The solar cylinder.
The solar collector transforms solar energy into heat and
transfers the heat energy to a frost-protected solar uid.
The solar pump of the solar pump unit ensures the heat is
transported from the collector to the twin coil solar cylinder via
a pipe system. The solar pump unit is controlled by the solar
control.
The solar control switches the solar pump on or off as soon
as the difference in temperature between the collector and
solar cylinder falls below or exceeds the preset value. If the
solar energy is insufcient, the control system switches on the
boiler so that the upper third of the cylinder is reheated to the
set value for the domestic hot water temperature. In addition
the solar cylinder can be reheated by the immersion heater
installed by the manufacturer.
The solar expansion vessel compensates pressure
uctuations in the solar circuit.
On days on which the solar radiation is insufcient to heat the
DHW in the cylinder, the stored water must be reheated by a
heating system. This can be done with boilers or electrically
with an immersion heater.
The optional protection vessel protects the expansion
vessel from increased temperatures in the solar circuit. We
recommend installing a protection vessel.
Local authority planning permission may be required for
the installation. The local authority should be notied
about the intended installation.
The solar system is a closed system and must be bled
carefully. We recommend the automatic air separator
system for this purpose (item no. 0020054969). It works fully
automatically and does not need to be subsequently blocked.
The automatic air separator system must be installed in an
area in which no steam can enter, preferably in the return pipe
between the solar pump unit and the solar cylinder.
7
2 Product Specications
Solar Pump Unit
Flow
Return
14162
Clearly Solar
Collector
Protection
Vessel
Solar Expansion Vessel
Automatic Air
Separator System
Boiler
Flow Return
DHW
2 Port Valve
M
Flurocyl
Immersion
Heater
Drinking Water
Expansion Vessel
M
2 Port Valve
2.1 Diagramatic view of the system installation
Refer to diagram 2.1
Diagram 2.1
8
3 Component Specications
358
120
Ø 22
Ø 22
Ø 22
Ø 22
Ø 22
Ø 22
250
1
5
6
2
3
4
CONTAINER
SOLAR
EXPANSION
VESSEL
7
Solar Pump Station part no. 0020054961
14829
Item Qty. Description
1 1 Flow tube with isolating valve with integrated
gravity brake and temperature display
2 1 Return tube with isolating valve with
integrated gravity brake and temperature
display, ow rate meter with ll/vent valve,
circulating pump
3 1 Safety valve with pressure gauge, ll valve
and corrugated tube DN16 including wall
bracket for solar expansion vessel
4 1 Wall bracket for expansion vessel with tting
5 1 Wall bracket for solar pump station
6 4
7 2 C-clips
22mm Compression nuts
22mm Brass olives
4
22-18mm Reducers (discard)
4
Solar Expansion Vessel
Diagram 3.1
18 litre Supplied with 1 collector pack
25 litre Supplied with 2 collector packs
35 litre Supplied with 3 collector packs
3.1 Solar pump station
Refer to diagram 3.1 for contents and description.
The solar pump unit is equipped with a three-speed solar
pump for the optimum adaptation of the required circulating
volume and the pump capacity in the solar circuit.
Select the pump capacity, depending on the solar system (e.g.
collector surface, pipe diameter, length of the solar circuit), so
that the actual ow rate is slightly higher than the nominal ow
rate. The ow rate meter is used for ne adjustment of the
ow rate.
The solar pump unit is delivered with a water control pack,
consisting of an expansion relief valve and a pressure gauge.
The ow rate meter installed in the return pipe is an essential
component of the solar system. To achieve optimum heat
transfer, you must achieve a certain ow rate, refer to section
5.2.
Upper deviations are not as serious as lower deviations.
Make the rough adjustments with the solar pump rst. You can
make the ne adjustments with the adjustment valve of the
ow rate meter. You can view the set value on the display of
the ow rate meter.
The ow rate meter has a ll/vent valve for lling and draining
the solar circuit.
NOTE: Do not under any circumstances set the ow rate
below the calculated ow rate. The collector efciency will be
considerably reduced.
If you would like to use the solar exible pipework (DN16
0020054964) from the pump station to the cylinder, please
order an additional two ttings packs, part No. 0020054965,
these contain the relevant ttings for this application.
9
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