Installation and Servicing
Flurocyl
Solar Hot Water Cylinder
200 l
250 l
300 l
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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
4
5
6
Important Information
Statutory Requirements
Safety Instructions
INTRODUCTION
Product Specifications
Installation
Commissioning
1
ꢁ
3
6
ꢀꢀ
ꢀ8
INSTALLATION
MAINTENANCE
Inspection and Maintenance
Fault Finding
4
5
ꢀ9
ꢁ0
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WARNINGS
SAFETY
The flurocyl 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
Testing and Certification
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.
This product is tested and certificated for safety and
performance. It is, therefore, important that no alteration is
made to the product, without permission, in writing, by Glow-
worm.
Control of Substances Hazardous to Health
Any alteration not approved by Glow-worm, could invalidate
the certification, warranty and may also infringe the current
issue of the statutory requirements.
Under Section 6 of The Health and Safety at Work Act
ꢀ974, we are required to provide information on substances
hazardous to health.
CE Mark
The adhesives and sealants used in this product are cured
and give no known hazard in this state.
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.
Manual Handling
With regards to the “Manual Handling Operations, ꢀ99ꢁ
Regulations”, the appliance exceeds the recommended
weight for a one man lift.
“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.
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 767ꢀ.
In IE, this is the current edition of ETCI rules.
The product MUST be connected to a permanent ꢁ30V 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 ꢀ363, 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 0.75mmꢁ (ꢁ4/0.ꢁ0mm).
4
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Statutory Requirements
IMPORTANT:
Domestic Hot Water
Where no British Standards exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.
All domestic hot water circuits, connections, fittings must be
in accordance with the relevant standards and water supply
regulations.
The installation of this product must be carried out by a
competent person in accordance the rules in force in the
countries of destination.
GB: Guidance Gꢀ7 to Gꢁ4 and recommendation Rꢀ7 to Rꢁ4
of the Water Regulations Guide.
IE: The current edition of I.S.8ꢀ3 “Domestic Gas Installations”.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
Heating System
In GB, it is necessary to comply with the Water Supply (Water
Fittings) Regulations ꢀ999 (for Scotland, the Water Byelaws
ꢁ000, Scotland).
Statutory Requirements
In GB, the installation of the product must be carried out by a
competent person as described in the following regulations:
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.
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).
In IE, the requirements given in the current edition of I.S.8ꢀ3
“Domestic Gas Installations” and the current Building
Regulations must be followed.
The Water Fittings Regulations or Water byelaws in Scotland.
Solar cylinder and cylinder installation
The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).
Pressure equipment directive 97/23/EC Directive of the
European Parliament and Council from ꢁ9th May, ꢀ997 for
the approximation of the laws on pressure equipment of the
Member States
The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
EN 12977-3 Thermal solar systems and components; Custom
built systems, Part 3: Performance characterisation of stores
for solar heating systems
In IE, the installation must be carried out by a competent
person and installed in accordance with the current edition
of I.S.8ꢀ3 “Domestic Gas Installations”, the current Building
Regulations and reference should be made to the current
ETCI rules for Electrical Installation.
EN 12897 Water supply - specification for indirectly heated
unvented (closed) storage water heaters
EN 806-1 Specifications for installations inside buildings
conveying water for human consumption - Part ꢀ: General
GB: the following Codes of Practice apply:
BS48ꢀ4, BS6798, BS5440 Part ꢀ and ꢁ, BS5546 Part ꢀ,
BS5449, BS689ꢀ, BS6700, BS7074 Part ꢀ and ꢁ, BS7593,
BS767ꢀ.
EN 1717 Protection against pollution of potable water
installations and general requirements of devices to prevent
pollution by backflow
IE: I.S.8ꢀ3, BS5546, BS 5449, BS 7074, BS 7593.
EN 60335-2-21 Safety of household and similar electrical
appliances; Part ꢁ: 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, modified)
NOTE: For further information, see the current issue of the
Building Regulations, approved document Lꢀ ( in the UK) and
the following current issues of:
1) Central heating system specification (CheSS)
Regulations in Great Britain
and
Building Regulation, dating from ꢀ99ꢀ (England and Wales)
ꢁ) Controls for domestic central heating system and hot water.
BRECSU.
Requirement G3, Lꢀ and Regulation 7
BS 7671 Requirements for electrical installations (IEE Wiring
Regulations, ꢀ6th edition)
BS 6759-1 Directive for the usage of the safety assembly for
hot water cylinders
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Safety Instructions
Safety instructions
Frost protection of the twin coil solar cylinder
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.
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.
IMPORTANT: A thermostatic mixing valve must be fitted 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.
Also drain all heat exchangers which are not filled with solar
fluid.
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 flowing out of the temperature and pressure
relief valve, switch off the boiler and the immersion heater and
contact Glow-worm or your installer.
1 Product Specifications
Unit
Flurocyl 200 l Flurocyl 250 l
Flurocyl 300 l
Cylinder:
Size
l
ꢁ00
ꢁ50
300
Maximum water supply pressure
Operating pressure
bar
bar
bar
bar
bar
°C/bar
kg
ꢀ0
3.5
Pressure limiting valve
Expansion relief valve
Hot water expansion vessel admission pressure
Temperature and pressure relief valve
Net weight
3.5
6.0
4.0
95 / 7.0
39
44
49
Weight (full)
kg
ꢁ45
ꢀ499
3ꢀ0
340
ꢁꢀ09
Height
mm
ꢀ789
Cylinder connections:
Cold water supply
ꢁꢁ mm pressure pipe
ꢁꢁ mm pressure pipe
ꢁꢁ mm pressure pipe
G 3/4
Hot water connection
Pressure-controlled cold water outlet
Secondary return
Inches
Flow (boiler/solar circuit)
Return (boiler/solar circuit)
Electrical connections:
3 kW immersion heater (according to ENBS 60335)
Length of the immersion heater
Motorised ꢁ port valve
Cylinder thermostat
ꢁꢁ mm pressure pipe
ꢁꢁ mm pressure pipe
ꢁ30/ꢁ40 V, 50 Hz
430
mm
ꢁ30/ꢁ40 V, 50 Hz
ꢁ30/ꢁ40 V, 50 Hz
ꢁ30/ꢁ40 V, 50 Hz
Thermal cut out for solar pump
Heating coil:
Heat loss
kW/ꢁ4 h
mins
ꢀ.9
ꢁꢀ
ꢀ3
ꢁ.ꢀ
ꢁ6
ꢀ6
ꢁ.4
Heat up time (boiler part)
Recovery (boiler part)
30
mins
ꢁꢀ
Table ꢀ.ꢀ Technical data
6
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1 Product Specifications
45
40
300 l
30
25
20
35
30
250 l
200 l
15
10
25
20
12
15
20
25
30
35 38
Heat input to cylinder (kW)
Flurocyl cylinder heat-up times (boiler part)
Diagram ꢀ.ꢀ
Mixed water of 40 °C, mixed from
60 % hot water of 60 °C and
40 % cold water of 10 °C
8 bar
4 bar
8 bar
4 bar
3 bar
2 bar
3 bar
2 bar
40
30
20
10
40
30
20
10
1 bar
1 bar
0
0
10
20
30
40
10
20
30
40
Flow available (litres/min) at entry to system
Flow available (litres/min) at entry to system
Flurocyl DHW flow rates at 60°C
Flurocyl mixed water flow rates
Diagram ꢀ.ꢁ
Diagram ꢀ.3
NOTE: The heat-up time is based on a primary flow rate of 9
l/min at 80 °C. Temperature rise from ꢀ5 °C to 65 °C
Static operating pressure of the cold water supply
The displayed flow 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 ꢀ bar.
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1 Product Specifications
1.1 Intended use
1.7 Solar Cylinder Charicteristics
The Glow-worm Flurocyl ꢁ00 l, Flurocyl ꢁ50 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.
Flurocyl solar cylinders are available in three sizes: ꢁ00, ꢁ50
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
ꢁ port valve.
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 specifications of the water ordinance.
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 ꢁꢁ mm
diameter. A cold water supply of appropriate pressure and
flow rate is required to operate the solar cylinder ideally, refer
to section ꢁ.6.
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.
Temperature control
The solar water heating control thermostat is part of the solar
control with sensor attached to the Flurocyl solar cylinder.
1.2 Data badge
The cylinder includes the boiler and imersion heater control
thermostats that are factory fitted and set.
The data badge has been applied to the top of the solar
cylinder by the manufacturer.
A themostatic mixing valve must be fitted to the outlet of the
cylinder and must be adjusted to the desired domestic hot
water temperature.
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.
The cylinder also includes the solar, boiler and immersion
heater thermal cut outs that are factory fitted 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.
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.
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.
Thermal cut out of the immersion heater
Thermal cut out set to 90°C, connected to the motorised ꢁ
port valve, in order to isolate the primary heat source in the
event of failure of the domestic water thermostat.
NOTE: In the event of a replacement, only the right immersion
heater equipped with a thermal cut out fur overheating
protection may be used.
1.4 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 modified in any way whatsoever.
It should be installed by a qualified 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.
1.5 Contents
Check the contents of the pack, see diagram ꢁ.ꢀ.
Make sure the cylinder is stored in an upright position in a dry
environment prior to its installation.
CARRYING
HANDLE
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
Diagram ꢀ.4
8
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1 Product Specifications
Hot water connection
Temperature
and pressure
relief valve
Immersion
heater
Boiler Flow
Boiler Return
Solar circuit Flow
Cold water supply
Solar circuit Return
45°
Dimensions
Diagram ꢀ.5
A
B
C
D
E
F
G
H
I
Flurocyl
ꢁ00 l
ꢀ468
ꢀ499
454
384
3ꢀ4
589
ꢀꢀꢀ8
8ꢀ3
953
Flurocyl
ꢁ50 l
ꢀ758
ꢁ078
ꢀ789
ꢁꢀ09
454
454
384
384
3ꢀ4
3ꢀ4
589
589
ꢀ408
ꢀ648
9ꢁ4
ꢀ064
ꢀꢁ4ꢀ
Flurocyl
300 l
ꢀꢀ0ꢀ
Table ꢀ.ꢁ Dimensions
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1 Product Specifications
Flurosorb
Solar Pump Unit
Protection
Vessel (optional)
Solar Expansion Vessel
Flow
Return
DHW
Flurocyl
Immersion
Heater
2 Port Valve
M
Drinking Water
Expansion Vessel
Automatic Air
Separator System
Boiler
Flow
Return
M
2 Port Valve
Diagram ꢀ.6
ꢀ0
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2 Installation
A
B
2
3
4
5
6
7
8
9
10
1
Diagram ꢁ.ꢀ
Flurocyl pack contents
Item Description
Qty.
Qty.
Qty.
ꢀ
Flurocyl solar cylinder
ꢁ00 l
ꢁ50 l
300 l
307 ꢁ06
307 ꢁ07
307 ꢁ08
Part no.
ꢁ
Cold water control pack with tundish
Motorised ꢁ port valve
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
3
4
DHW expansion vessel ꢀ8 l
DHW expansion vessel ꢁ5 l
DHW Expansion vessel mounting bracket
Carrying handle
5
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
6
ꢀ
ꢀ
ꢀ
ꢀ
ꢀ
7
8
Compression Fittings
9
Drain valve
ꢀ0
Thermostatic Mixing Valve
Table ꢁ.ꢀ Flurocyl pack contents
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2 Installation
Solar pump thermal
cut out
Domestic hot water
outlet connection
Immersion heater
thermal cut out
Immersion heater
thermostat
Legionella loop
return connection
Temperature and
Immersion
heater
switch
Pressure relief valve
Expansion
vessel
65°
REAR VIEW
65°
Flow (boiler)
Pressure controlled
cold water outlet
Expansion vessel
connection
Cold water
supply
Pressure
limiting
valve
Return
(boiler)
Expansion
relief
valve
Cylinder
thermostat
Cylinder thermostat
thermal cut out
Immersion
heater
Tundish
Flow (solar circuit)
Return
(solar circuit)
Cylinder drain valve
Temperature sensor immersion sleeve
Adjustable feet
Diagram ꢁ.ꢁ
2.1 Locating the cylinder
2.4 Domestic hot water pipework
Locate the solar cylinder at an appropriate place in the
building, while observing the following:
Connect the hot water outlet to the ꢁꢁmm hot water
connection of the solar cylinder.
The discharge pipe from the tundish must be installed at a
minimum slope of ꢀ:ꢁ00 and end at a safe and visible point,
refer to section ꢁ.9.
Lay a further 22mm pipe to the first T-piece.
A pipe of 15mm diameter should then be sufficient.
If the pipe is very long or several outlets are supplied,
continue with another ꢁꢁmm pipe.
The installation surface must be level and able to bear the
weight of the full cylinder, refer to table ꢀ.ꢀ.
The installation site may not be prone to frost. A frost
protection thermostat must be installed if necessary.
2.5 Thermostatic mixing valve
A hot water thermostatic mixing valve ensures the hot water
from the cylinder is mixed with cold water to a desired
maximum temperature between 30°C and 60°C.
There must be sufficient space to install, check and
repressurise the expansion vessel.
Set the thermostatic mixing valve to the desired maximum
temperature during the solar system commissioning.
Floor unevenness should not be greater than the
compensation offered by the adjustable feet of the solar
cylinder.
IMPORTANT: Risk of scalding, Set the thermostat mixer to
60°C or below and check the temperature at a hot water tap
to ensure effective protection against scalding.
2.2 Boiler heating circuit piping
Copper pipes with a minimum diameter of ꢁꢁmm should be
used for the pipes in the reheating circuit between the boiler
and the solar cylinder.
Larger pipe diameters may be necessary for relatively large
distances between the boiler and the cylinder.
2.3 Motorised 2 port valve
To prevent the Flurocyl cylinder from overheating the ꢁ port
motorised valve supplied must be fitted to the primary flow to
the indirect coil.
ꢀꢁ
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2 Installation
THERMOSTAT
MIXER
PUMP
HOT
WATER
LEGIONNELLA
LOOP (optional)
CONNECTION
TEMPERATURE
AND PRESSURE
RELIEF VALVE
(95 °C, 7 BAR)
BOILER
EXPANSION
VESSEL
FLOW
RETURN
EXPANSION
COLD
WATER
SUPPLY
RELIEF
VALVE
(6.0 BAR)
PRESSURE
LIMITING VALVE
(3.5 BAR)
WITH LINE
STRAINER
MOTORISED
2 PORT VAVE
MOTORISED
2 PORT VAVE
TUNDISH
FLUROCYL
DRAIN VALVE
Diagram ꢁ.3
Example: The available flow rate of mixed water at 40°C is 25
l/min (ꢀ5 l/min hot water of 60°C from the solar cylinder mixed
with ꢀ0 l/min cold water of ꢀ0°C) if the measured static cold
mains water pressure is ꢁ bar.
2.6 Mains water supply
The performance of unvented cylinders depends on the
available mains water pressure and the pipe size.
The solar cylinder operates satisfactorily at a mains water
pressure of below 2 bar, but at a reduced flow rate.The
unvented solar cylinder should not be installed if the mains
water pressure is below ꢀ bar.You can obtain information on
alternative hot water supply systems from Glow-worm.
In order for the performance of the Flurocyl solar cylinder to
be ideal, an appropriate cold water supply must be available.
The measured static pressure must be at least ꢁ.0 bar. A
corresponding flow rate of at least 20 - 25 l/min should be
available.
To keep the friction losses at a minimum, a minimum diameter
of ꢁꢁmm is recommended for the cold water supply in the
building, satisfactory performances can also be achieved with
ꢀ5mm pipes however.
NOTE: The mains water pressure is reduced during periods of
high water consumption.Make sure you take measurements
during these periods.
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2 Installation
2.7 Cold water inlet controls and pipework
PRESSURE LIMITING
VALVE WITH LINER
STRAINER
Connect both parts of the water control pack.
BALANCED
HOT WATER
EXPANSION
VESSEL
When installing the valves, make sure they are aligned in
such a way that the ꢀ5mm connection of the expansion relief
valve can be connected to the tundish.
PRESSURE
COLD WATER
CONNECTION
CONNECTION
Install the assembled water control pack in the cold water
supply at an appropriate place next to the solar cylinder.
Make sure there is sufficient space for maintenance and the
connection of the discharge pipe from the expansion relief
valve.
Install the drain valve in the cold water supply at the lowest
point between the solar cylinder and the water control pack.
LEGIONELLA
COLD
We recommend applying a hose, which reaches about ꢀm
under the base of the cylinder, to the outlet of the drain valve.
FLUROCYL
CONNECTION
LOOP
WATER
SUPPLY
CONNECTION
IMPORTANT: Risk of bursts for the solar cylinder! No stop
valve may be installed between the cold water control pack
and the cylinder.
EXPANSION
RELIEF VALVE
Install the water pack so that a discharge pipe of the
expansion relief valve can be fitted with constant outward
slope which can end at a safe, visible point where there is no
risk of freezing.
Diagram ꢁ.4
2.8 Discharge pipework
The outlet connections of both the temperature / pressure
relief valve and expansion relief valve should be connected in
ꢀ5mm copper pipe to the tundish supplied. The tundish should
be installed vertically, as close to the Flurocyl as possible and
within 500mm of the temperature and pressure relief outlet. It
must be positioned away from any electrical components and
installed in the same space as the Flurocyl cylinder, so that
it is visible to the user. The Dꢀ discharge pipe from the T&P
Valve/Expansion valve can be teed together upstream of the
tundish.
IMPORTANT: Risk of the solar cylinder bursting due to
overpressure! The outlet of the expansion relief valve must
not be covered or closed.
Test the expansion relief valve regularly to avoid calcification.
To ensure an optimum performance of the solar cylinder, in
particularly buildings in which a pressure controlled cold water
is used, copper pipes with a diameter of at least ꢁꢁmm should
be used for the pipe from the main stop valve of the building
to the solar cylinder.
The discharge pipework must be installed using minimum
ꢁꢁmm copper pipework from the ꢁꢁmm connection on the
tundish to a safe and visible discharge point.
If the discharge pipes are all together, the expansion relief
valve may not be installed more than 500 mm away from the
temperature and pressure relief valve.
There must be a vertical section of pipe at least 300mm
long, below the tundish before any bends or elbows in
the pipework. Increase the diameter of the pipework if the
total resistance of the discharge pipework exceeds the
figures shown in table 2.2. The installation of the discharge
pipework must be in accordance with G3 refer to Statutory
Requirements.
The Flurocyl solar cylinder is supplied with an external hot
water expansion vessel (DW EV).
Connect this expansion vessel to the installed water control
pack as follows:
Screw the expansion vessel directly onto the water control
pack, via the connection intended for this purpose or
Connect the expansion vessel to the water control pack with a
copper pipe or an appropriate hose. Make sure the expansion
vessel is supported sufficiently.
Use the supplied mounting bracket if the expansion vessel is
to be mounted on the wall.
Connect thermostatic mixing valve cold supply to the pressure
controlled cold water connection of the water control pack (if
convenient).
NOTE: In areas with high water pressure (4 bar or more), a
bath or shower mixer valve could also be connected to the
pressure-controlled cold water connection of the water control
pack. This is to ensure the pressure of the hot and cold water
supply to the mixer valve is about the same. Any second
cold water supply connection should be installed between
the water control pack and the solar cylinder by means of a
T-piece.
ꢀ4
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2 Installation
Minimum diameter Maximum
Resistance due
to each elbow
or bend (straight
length equivalent)
SAFETY DEVICE
(E.G. TEMPERATURE
RELIEF VALVE
VENTIL)
of the discharge
pipe from the
tundish
permissible
total resistance,
expressed as
straight pipe
METAL DISCHARGE PIPE FROM
TEMPERATURE RELIEF VALVE
TO TUNDISH
length (without
elbows or bends)
ꢁꢁmm
ꢁ8mm
35mm
Up to 9m
Up to ꢀ8m
Up to ꢁ7m
0.8m
DISCHARGE
500 MM
MINIMUM
BELOW
FIXED
ꢀ.0m
TUNDISH
ꢀ.4m
GRATING
300 MM
MINIMUM
Table ꢁ.ꢁ Resistance
FIXED
GRATING
Examples:
ꢁꢁmm discharge pipe with 4 elbows and of 7m length from the
tundish to the discharge point:
METAL DISCHARGE PIPE
FROM TUNDISH WITH
CONTINUOUS FALL
Resistance for 4 elbows per 0.8m
Resistance for discharge pipe
Total resistance
=
=
=
3.ꢁm
7.0m
ꢀ0.ꢁm
TRAPPED GULLY
The total resistance of the discharge pipe is higher than the
maximum permissible value for ꢁꢁmm pipes (9m). Base your
calculations therefore on the next largest pipe diameter.
Diagram ꢁ.5
ꢁ8mm discharge pipe with 4 elbows and of 7m length from the
tundish to the discharge point:
Resistance for 4 elbows per ꢀ.0m
Resistance for discharge pipe
Total resistance
=
=
=
4.0m
7.0m
ꢀꢀ.0m
TUNDISH
DISCHARGE
PIPE
The total resistance of the discharge pipe is lower than the
maximum permissible value for ꢁ8mm pipes (ꢀ8m),which
means this pipe diameter can be used.
300 MM
MINIMUM
Water which is almost boiling may escape from the discharge
pipe in the event of an error.
IMPORTANT: Risk of being scalded by escaping hot water!
Make sure the discharge pipe ends at a safe point inside or
outside the building (safe and visible), where there is no risk
of anyone coming in contact with hot water.
METAL
HOPPER
HEAD
A suitable point is, for example, under a fixed grating above
the trap of a trapped gully. Low discharge pipes, for example
up to ꢀ00mm above external surfaces, such as parking
spaces, grasslands etc., can be used, provided they are
secured by a wire fence or something similar to prevent
children from coming in contact with the waste water, and the
system is visible. No valves or taps may be installed in the
discharge pipe.
Diagram ꢁ.6
The possibility, taking into account wind effect, that someone
may be in the path of the water being discharged and if so,
whether the temperature of the discharge water will have
been sufficiently reduced to not be dangerous. Thermal
conductivity of the structure's surface, climatic conditions and
location and orientation of the discharge pipe may or may not
have an effect on reducing the temperature of the discharge
water.
Make sure the discharge pipe is at a constant slope of at least
ꢀ:ꢁ00 from the tundish to the discharge point.
The discharge pipe from the pressure relief valve of the boiler
(if applicable) can be connected to the horizontal discharge
pipe of the solar cylinder behind the tundish with a T-piece.
The location of windows and similar openings.
2.9 High level discharge termination
The likelihood of a pram being left beneath the point of
discharge.
Providing that the point of termination is such that persons
in or around the building will not be endangered should
discharge take place, this method of termination is
satisfactory. Points to consider when deciding whether a
location for the high level of discharge is suitable are:
The ability of structures surface to withstand near boiling
water.
The possibility of ice formation if water is discharged onto
pedestrian walkways.
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2 Installation
2.10 Electrical installation
IMMERSION HEATER
THERMAL CUT OUT
WITH RESET BUTTON
IMMERSION HEATER
Remove the front fascia panel.
THERMOSTAT
Wiring should be performed by a competent person in
accordance with the building regulations, Part P of the
current IEE regulations and further applicable regulations and
directives.
(FACTORY SET)
65°
IMMERSION
HEATER
CONNECTION
230V AC 3 kW
The discharge pipes of the tundish, drain valves, motorised
valves etc. should be laid at a safe distance to electrical
components.
65°
IMPORTANT: Danger of death from electric shock! You must
earth the solar cylinder for potential equalisation.
230V
AC
3 kW
2.11 Immersion heater
The Flurocyl solar cylinders incorporate an immersion heater.
REHEAT
THERMAL
IMPORTANT: Danger of death from electric shock! You must
CUT OUT WITH
RESET BUTTON
REHEAT
earth the immersion heater for potential equalisation.
THERMOSTAT
(FACTORY SET)
Install a separate electrical power supply line for the
immersion heater in accordance with current IEE regulations
(BS 767ꢀ).
TEMPERATURE SENSORS
IN IMMERSION SLEEVES
Diagram ꢁ.7
You must lay a heat-resistant line (3 x ꢁ.5 mmꢁ) from a double
pole isolating switch for the immersion heater. The circuit must
be protected by a ꢀ3 A fuse.
SOLAR THERMAL
CUT-OUT WITH
RESET BUTTON
The connection of the immersion heater is illustrated in detail
in diagram ꢁ.7.
DOMESTIC
IMPORTANT: Risk of damage! The immersion heater
is equipped with a thermal cut out and may under no
circumstance be replaced by a standard immersion heater.
65°
HOT WATER
DEMAND
WIRING
Only correct original Glow-worm spare parts are permitted.
REHEAT
CONTROL
THERMOSTAT
(FACTORY SET)
2.12 Thermostat setting
The entire inner wiring has been pre-assembled at the factory.
65°
IMPORTANT: Risk of damage! Switch off the power supply
before resetting the thermal cut out or making any other
changes to the temperature setting of the cylinder thermostat.
The cylinder thermostats for the regulation of the hot water
temperature are factory set at 65°C as the Domestic Hot
Water temperature is controlled by the adjustable thermostatic
mixing valve.Ensure both control thermostats are adjusted
fully clockwise.
Diagram ꢁ.8
Actuate the reset buttons, to reset the thermal cut outs if
necessary, see diagram ꢁ.7.
UPPER
TEMPERATURE
SENSOR
IMPORTANT: Risk of damage! If the immersion heater is not
connected, you must connect the earth wire to terminal E
on the terminal strip of the immersion heater. You can find a
wiring sheme on the inside of the cylinder cover.
TEMPERATURE
SENSOR
GAIN
2.13 Thermostat and sensor wiring
Connect the domestic hot water demand wiring to the reheat
control thermostat as shown in diagram ꢁ.8 and ꢁ.ꢀ0.
Connect the solar pump live via the solar thermal cut out and
ensure this thermal cut out is earthed, as shown in diagram
ꢁ.8. and ꢁ.ꢀ0.
Install the two temperature sensors in the solar cylinder, see
diagram ꢁ.9, and connect to the solar control, see diagram
ꢁ.ꢀ0.
Attach the solar gain sensor to the solar circuit return, see
diagram ꢁ.9.
LOWER
TEMPERATURE
SENSOR
Replace the front fascia panel.
Diagram ꢁ.9
ꢀ6
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2 Installation
KEY
BROWN
br
b
BLUE
BLACK
ORANGE or
WHITE
PURPLE
GREEN
GREY
bl
w
p
gn
g
NTCA
TAC2
GAIN
230v~ PCSA
R
TAC1
ENL EN L
21
FUSED
AT 3A
GREEN
/YELLOW g/y
FLUROPRO
CONTROLLER
ADDITIONAL
TERMINAL
BLOCK
E
N
L
L LINK
bl
g/y
bl
TERMINAL BLOCK
E
N
L
3
4
5
6
7
8
9
10
br
COMMON 230V
MAINS TERMINAL BLOCK
Double
L
E
N
pole
isolator
AT 3A
FLUROCYL
230V~50Hz
MAINS SUPPLY
RETURN PIPE
Wiring diagram
Diagram ꢁ.ꢀ0
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3 Commissioning
3.1 Filling the secondary circuit
IMPORTANT: Risk of damage! Do not manually open the
temperature/pressure relief valve or the expansion vessel for
venting purposes. Any foreign matter in the pipework may
cause damage to the valve seats.
LEVER
A
B
Make sure the cylinder drain valve is closed.
Open all cold and hot water taps and the corresponding
outlets.
Open the mains water supply to the Flurocyl and fill it with
water until it flows freely out of the outlets. Make sure all air
bubbles have been removed.
Close the outlets and check the system for leaks. Check in
particular the immersion heater connection for leaks.
‘B’ PORT
‘A’ PORT
Diagram 3.ꢀ
Motorised 2 port valve
The system must now be flushed thoroughly.
Open the hot water taps at the opposite ends of the systems
and let the water flow out for at least 5 minutes.
GB: It is a requirement that the “Benchmark” Installation,
Commissioning and Service Record is completed and left with
the user.
Close the hot water taps.
IE: it is necessary to complete a “Declaration of Conformity” to
indicate compliance to I.S.8ꢀ3. An example of this is given in
the current edition of I.S.8ꢀ3.
3.2 Setting the thermostatic mixing valve
The hot water from the solar cylinder can be set to a desired
maximum temperature between 30 °C and 70 °C by mixing
hot and cold water.
3.5 Handing over to the householder
Set the hot water thermostatic mixing valve with the adjusting
knob to maintain the householders desired temperature at the
hot water taps.
l Hand over all manuals to the householder.
l Advise the householder to keep the manuals near to the
system.
IMPORTANT: Risk of being scalded by hot water! Set the
thermostat mixer to 60 °C or below and check the temperature
at a hot water tap to ensure effective protection against
scalding.
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
efficient 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.
3.3 Reheat circuit (boiler circuit)
NOTE: Do not use the pressure relief valve of the boiler (if
applicable) for bleeding.
Flush the entire primary central heating system with cold and
hot water. Fill and bleed the central heating system according
to the installation manual of the boiler.
Set the lever on the motorised ꢁ port valve to MANUAL and
lock it in this position, see diagram 3.ꢀ.
Fill and bleed the central heating system after draining it
completely.
Unlock the lever on the motorised ꢁ port valve by setting it
back to AUTO.
Start up the boiler, refer to section 3.4, until the solar cylinder
is at operating temperature and all radiators in the system
are warm. Then drain the entire central heating system again
to remove any residue from the pipes. Fill and bleed it again
afterwards as described above.
l Inform the householder that the boiler and solar cylinder
should be serviced by a qualified engineer annually.
Leave these instructions and the “Benchmark” Installation,
Commissioning and Service record document with the user.
3.4 Starting up the boiler
Switch on the main switch of the boiler.
Make sure the control device and the thermostats are set in
such a way that heating is necessary.
Check whether the boiler starts up and the water in the solar
cylinder and radiators is heated up according to the hot water
and room thermostat settings.
Perform the commissioning and testing procedures in
accordance with the installation manual for the boiler.
ꢀ8
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4 Inspection and Maintenance
4.1 Checking the temperature / pressure relief
valve and expansion relief valve
Actuate each valve manually by turning the valve cap and
check whether the water flows unhindered to the discharge
point via the tundish. Make sure both valves fit properly in idle
position.
4.2 Checking the charge pressure of the
expansion vessel
Block the water supply and open the nearest hot water tap to
reduce the pressure from the secondary water system.
Check the pressure of the expansion vessel at the
measurement point with a pressure gauge. If the pressure
is below 3.0 bar, increase it with an appropriate air pressure
pump.
NOTE: Only use original spare parts from Glow-worm for the
replacement of parts.
4.3 Maintenance Checklist
Reheating
Check the circulation pump annually.
Check the timer/time programme settings annually.
Reheating: does it deliver the desired deactivation
temperature? annually.
Solar cylinder
Bleed the heat exchanger if necessary annually.
Check the connections for leaks annually.
Check the temperature and pressure relief valve annually.
Checking the expansion relief valve annually.
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5 Fault Finding
The following tables provide information on possible
malfunctions during the operation of the solar cylinder as well
as their cause and remedy.
NOTE: Only use original spare parts from Glow-worm. for the
replacement of parts. We recommend making a maintenance
agreement.
Malfunction
Cause
Remedy
Solar cylinder
The cylinder cools down at night. The
flow and return temperatures vary after
switching off the pump. The collector
temperature is higher than the air
temperature at night.
ꢀ. The gravity brake is blocked.
ꢀ. Check the position of the blue handle.
ꢁ. Check the gravity brake for tightness
(jammed cuttings, particles of dirt in the
sealing face).
3. Do not connect the solar heat
exchanger directly, rather pull the supply
pipes downwards and then upwards to
the collector (syphon supports the gravity
brake) or install a ꢁ-port valve, which
is switched on at the same time as the
pump.
ꢁ. One-pipe circulation in the event of
short pipe networks with low pressure
loss.
Install a gravity brake (as close as
possible to the cylinder).
Reheating is not working. The boiler
runs for a short time, goes off and then
back on again. This is repeated until the
cylinder is at its target temperature.
ꢀ. Air in the reheating heat exchanger.
Bleed the reheating heat exchanger.
ꢁ. Heat exchanger surface area too small. Compare the specifications of the boiler
manufacturer with those of the cylinder
manufacturer. The problem may be able
to be solved by a higher setting of the
flow temperature at the boiler.
Only cold or lukewarm water comes out
of the taps.
ꢀ. Cold and hot water connections on the Turn off the cold water supply, then
cylinder have been mixed up.
let water flow out via the hot water
connection. Only a few litres of water
flow out if the connection is laid correctly.
The inlet of the hot water draw-off pipe
then rests in the air space; no further
emptying is possible. If the entire solar
cylinder runs empty via the hot water
connection, the connections have been
laid incorrectly. Change the connections!
ꢁ. Hot water thermostat mixer set too low. Increase the setting.
3. Solar heating insufficient; boiler does
not reheat.
Check whether the boiler is working.
External control device faulty.
Check whether the external control
device is working.
Check whether the two port valve is in the
hot water position.
Replace the two port valve.
Air in the reheating heat exchanger
Bleed the reheating heat exchanger.
Cylinder temperature sensor defective.
Check the thermal cut out and reset it.
Replace the cylinder thermostat.
Table 5.ꢀ Fault Finding
ꢁ0
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5 Fault Finding
Malfunction
Cause
Remedy
Water flows out of the expansion relief
valve (only when heating up).
Dirt on the valve seat of the expansion
relief valve.
Check the expansion relief valve and
reset it manually.
Pressure limiting valve defective.
Switch off the boiler and immersion
heater and check whether the pressure
behind the pressure limiting valve is lower
than 3.0 bar if water flows out only when
heating up. If so, replace the pressure
limiting valve.
Expansion vessel defective.
Check the pressure in the expansion
vessel. If the pressure is insufficient,
re-establish the pressure and check
whether the equalisation tank maintains
the pressure.
Expansion relief valve defective.
If the pressure is normal, replace the
expansion relief valve.
Water comes out of the temperature and
pressure relief valve (only when heating
up).
Dirt on the valve seat of the temperature
and pressure relief valve.
Check the seat of the temperature
and pressure relief valve and reset it
manually.
Temperature control of the boiler
defective.
Check the temperature control of the
boiler if water only comes out when
reheating with the boiler. Check whether
the two port valve switches to the heating
position after reaching the cylinder
temperature.
Cylinder temperature sensor defective.
Two port valve defective.
Check the cylinder temperature sensor
and the corresponding thermal cut outs
and replace the temperature sensor and
reset the thermal cut outs if necessary.
Check whether the two port valve is
working and replace it if necessary.
Temperature and pressure relief valve
defective.
Replace the temperature and pressure
relief valve if water only comes out when
heating up with the immersion heater.
Immersion heater defective.
Check the temperature sensor of the
immersion heater and the corresponding
thermal cut out and replace the
immersion heater if necessary.
Table 5.ꢀ Fault Finding (continued)
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ꢁꢁ
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Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 ꢀJT
Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.
ꢁ4
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