Glowworm Lighting 200 I, 300 I, 250 I User Manual
Installation and Servicing
Flurocyl
Solar Hot Water Cylinder
14161
200 l
250 l
300 l
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
2
These instructions consist of, Installation, Servicing, Fault Finding and Replacement
of Parts. 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
Safety Instructions 6
INSTALLATION
MAINTENANCE
Product Specications 1 6
Installation 2 11
Commissioning 3 18
Inspection and Maintenance 4 19
Fault Finding 5 20
3
WARNINGS
SAFETY
The urocyl 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.
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.
Manual Handling
With regards to the “Manual Handling Operations, 1992
Regulations”, the appliance exceeds the recommended
weight for a one man lift.
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 identied 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).
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.
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.
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 Gas Safety (Installation and Use) Regulations.
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.
NOTE: For further information, see the current issue of the
Building Regulations, approved document L1 ( in the UK) and
the following current issues of:
1) Central heating system specication (CheSS)
and
2) Controls for domestic central heating system and hot water.
BRECSU.
Domestic Hot Water
All domestic hot water circuits, connections, ttings must be
in accordance with the relevant standards and water supply
regulations.
GB: Guidance G17 to G24 and recommendation R17 to R24
of the Water Regulations Guide.
IE: The current edition of I.S.813 “Domestic Gas Installations”.
Heating System
In GB, it is necessary to comply with the Water Supply (Water
Fittings) Regulations 1999 (for Scotland, the Water Byelaws
2000, Scotland).
To comply with the Water regulations your attention is drawn
to: The Water Regulations guide published by the Water
Regulations Advisory Service (WRAS) gives full details of the
requirements.
In IE, the requirements given in the current edition of I.S.813
“Domestic Gas Installations” and the current Building
Regulations must be followed.
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)
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
Safety Instructions
Safety instructions
NOTE: In the event of leaks in the water pipework close the
main cold water stop valve. This is often located under a
kitchen sink.
IMPORTANT: A thermostatic mixing valve must be tted to
the outlet of the cylinder and can be adjusted to the desired
domestic hot water temperature by an installation or service
engineer. Otherwise there is a risk of scalding as the cylinder
outlet temperature at the taps could be up to 85°C.
IMPORTANT: Risk of damage! Do not remove or modify any
components of the solar cylinder.
In the unlikely event of a malfunction occurring of the Flurocyl,
such as hot water owing out of the temperature and pressure
relief valve, switch off the boiler and the immersion heater and
contact Glow-worm or your installer.
Frost protection of the twin coil solar cylinder
You must drain the solar cylinder completely if it is to be shut
down in a room prone to frost. It is drained at the cold water
inlet with a T-piece with tap to be provided by the installer.
Also drain all heat exchangers which are not lled with solar
uid.
1 Product Specications
Unit Flurocyl 200 l Flurocyl 250 l Flurocyl 300 l
Cylinder:
Size l 200 250 300
Maximum water supply pressure bar 10
Operating pressure bar 3.5
Pressure limiting valve bar 3.5
Expansion relief valve bar 6.0
Hot water expansion vessel admission pressure bar 4.0
Temperature and pressure relief valve °C/bar 95 / 7.0
Net weight kg 39 44 49
Weight (full) kg 245 310 340
Height mm 1499 1789 2109
Cylinder connections:
Cold water supply 22 mm pressure pipe
Hot water connection 22 mm pressure pipe
Pressure-controlled cold water outlet 22 mm pressure pipe
Secondary return Inches G 3/4
Flow (boiler/solar circuit) 22 mm pressure pipe
Return (boiler/solar circuit) 22 mm pressure pipe
Electrical connections:
3 kW immersion heater (according to ENBS 60335) 230/240 V, 50 Hz
Length of the immersion heater mm 430
Motorised 2 port valve 230/240 V, 50 Hz
Cylinder thermostat 230/240 V, 50 Hz
Thermal cut out for solar pump 230/240 V, 50 Hz
Heating coil:
Heat loss kW/24 h 1.9 2.1 2.4
Heat up time (boiler part) mins 21 26 30
Recovery (boiler part) mins 13 16 21
Table 1.1 Technical data
6
1 Product Specications
Approximate cylinder heat up time 15 C to 45 C (minutes)
Reheat time for 70 % of cylinder contents (minutes)
10
15
20
25
30
20
25
30
35
40
45
12
Heat input to cylinder (kW)
15 20 25 30 3835
200 l
250 l
300 l
40
40
8 bar
4 bar
3 bar
2 bar
1 bar
30
30
20
20
Flow available (litres/min) at entry to system
Flow out (litres/min) of the system
10
10
0
8 bar
4 bar
3 bar
2 bar
1 bar
Flow available (litres/min) at entry to system
Flow out (litres/min) of the system
40
40
30
30
20
20
10
10
0
Mixed water of 40 °C, mixed from
60 % hot water of 60 °C and
40 % cold water of 10 °C
14177
Flurocyl cylinder heat-up times (boiler part)
14178
Flurocyl DHW flow rates at 60°C Flurocyl mixed water flow rates
NOTE: The heat-up time is based on a primary ow rate of 9
l/min at 80 °C. Temperature rise from 15 °C to 65 °C
Static operating pressure of the cold water supply
The displayed ow rates apply to installations in which the
cold water supply is of appropriate dynamic pressure.
Please contact Glow-worm if the static water pressure is
below 1 bar.
Diagram 1.2
7
Diagram 1.1
14179
Diagram 1.3
1 Product Specications
CARRYING
HANDLE
1.1 Intended use
The Glow-worm Flurocyl 200 l, Flurocyl 250 l and Flurocyl 300
l are unvented, indirectly heated hot water cylinders for use
with solar systems and boilers for the provision of domestic
hot water.
IMPORTANT: Risk of damage! The appliances may only
be used to heat up potable water. Damage to the appliance
due to corrosion cannot be excluded if the water does not
correspond to the specications of the water ordinance.
Any other use or extended use is considered to be improper.
The manufacturer/supplier is not liable for any resulting
damage.
Intended use includes the observance of the instructions and
the adherence to the servicing requirements.
1.2 Data badge
The data badge has been applied to the top of the solar
cylinder by the manufacturer.
1.3 Safety devices
The Flurocyl solar cylinder has been provided with all safety
and control devices suitable for operation as part of an
unvented domestic hot water supply system.
Temperature and pressure relief valve (95°C, 7 bar)
Pressure limiting valve (3.5 bar) with line strainer
Expansion relief valve (one port valve, 6.0 bar)
Thermal cut out set to 90°C, connected to the solar pump in
order to isolate this heat source in the event of failure of the
solar control.
Thermal cut out of the immersion heater
Thermal cut out set to 90°C, connected to the motorised 2
port valve, in order to isolate the primary heat source in the
event of failure of the domestic water thermostat.
1.4 Safety regulations
This product has been checked for adherence to the building
regulations for unvented hot water cylinder systems. It may
not be changed or modied in any way whatsoever.
It should be installed by a qualied specialist, who should
observe the applicable regulations of the local authorities, the
building regulations, the building regulations for Scotland, the
building regulations for Northern Ireland and the directives of
the local water supply companies. Only original spare parts
may be used for the replacement of parts.
1.7 Solar Cylinder Charicteristics
Flurocyl solar cylinders are available in three sizes: 200, 250
and 300 litres. The containers are made of stainless steel
and insulated with EPS.The cylinders are equipped with all
necessary cold and hot water control devices and a motorised
2 port valve.
The Flurocyl cylinders are operated at the pressure of the
water supply pipe and do not need a cold water tank for their
supply. They have hot and cold water connections of 22 mm
diameter. A cold water supply of appropriate pressure and
ow rate is required to operate the solar cylinder ideally, refer
to section 2.6.
Temperature control
The solar water heating control thermostat is part of the solar
control with sensor attached to the Flurocyl solar cylinder.
The cylinder includes the boiler and imersion heater control
thermostats that are factory tted and set.
A themostatic mixing valve must be tted to the outlet of the
cylinder and must be adjusted to the desired domestic hot
water temperature.
The cylinder also includes the solar, boiler and immersion
heater thermal cut outs that are factory tted and set.
The solar pump must be connected to the solar control via
the solar thermal cut out (TCO), It ensures the solar pump is
switched off if the hot water temperature in the cylinder rises
above 90°C.
Immersion heater
The Flurocyl solar cylinders are equipped with an additional
immersion heater of 3 kW, including the control thermostat
and thermal cut out. The immersion heater is situated behind
the front plate.
NOTE: In the event of a replacement, only the right immersion
heater equipped with a thermal cut out fur overheating
protection may be used.
1.5 Contents
Check the contents of the pack, see diagram 2.1.
Make sure the cylinder is stored in an upright position in a dry
environment prior to its installation.
1.6 Transport
A cylinder carrying handle is supplied to make the transport to
the installation site easier.
Fasten the carrying handle to the hot water outlet connection
of the solar cylinder.
Carrier handle
8
14180
Diagram 1.4
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