Glowworm Lighting 250 I Water Heater User Manual
Contents
1. TIU x i N s THERMOSTAT 6 O PUMP LEGIONNELLA LOOP optional optional t AND PRESSURE RELIEF VALVE 95 C 7 BAR EXPANSION VESSEL EXPANSION edie RELIEF WATER VALVE SUPPLY 6 0 BAR PRESSURE LIMITING VALVE N 3 5 BAR WITH LINE T STRAINER TUNDISH DN A FLUROCYL DRAIN VALVE Diagram 2 3 2 6 Mains water supply The performance of unvented cylinders depends on the available mains water pressure and the pipe size 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 2 0 bar corresponding flow rate of at least 20 25 I min should be available NOTE The mains water pressure is reduced during periods of high water consumption Make sure you take measurements during these periods Example The available flow rate of mixed water at 40 C is 25 l min 15 l min hot water of 60 C from the solar cylinder mixed with 10 I min cold water of 10 C if the measured static cold mains water pressure is 2 bar 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 1 bar You can obtain information on alternative hot water supply systems from Glow worm To keep the friction losse2. Carrier handle Diagram 1 4 1 Product Specifications Hot water connection Temperature and pressure relief valve Immersion heater Boiler Flow L pud Return mi 0 m e m LL x _ Solar circuit Flow Cold water supply Solar circuit Return O a 1 ry Dimensions Diagram 1 5 Pa p Ta Table 1 2 Dimensions 1 Product Specifications 14162 NS Flurosorb Solar Pump Unit PTA L amp Protection L Vessel optional Flow Solar Expansion Vessel Return lY A PX DHW Flurocyl P Immersion 2 Port Valve NEL Heater Drinking Water Expansion Vessel e k H lt V LN Automatic Air P L Separator System Lor H B Boiler Flow E Return P 2 Port Valve gt Diagram 1 6 2 Installation Flurocyl pack contents Description 1 Flurocyl solar cylinder i DHW l e DHW Expansion vessel mounting bracket s Compression Fitings Danae C j Thermostatic Mixing Valve Table 2 1 Fl
3. Q COMMON 230V MAINS TERMINAL BLOCK JN J I Double pole 7 isolator AT 3A 230V 50Hz MAINS SUPPLY Wiring diagram EG L L LINK TERMINAL 9 BLOCK 14238 BROWN BLUE BLACK ORANGE WHITE PURPLE GREEN GREY GREEN YELLOW ADDITIONAL bl FLUROCYL RETURN PIPE Diagram 2 10 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 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 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 Close the hot water taps 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 Set the hot water thermostatic mixing valve with the adjusting knob to ma
4. 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 The location of windows and similar openings The likelihood of a pram being left beneath the point of discharge The ability of structures surface to withstand near boiling water The possibility of ice formation if water is discharged onto pedestrian walkways 2 Installation 2 10 Electrical installation Remove the front fascia panel 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 The discharge pipes of the tundish drain valves motorised valves etc should be laid at a safe distance to electrical components IMPORTANT Danger of death from electric shock You must earth the solar cylinder for potential equalisation 2 11 Immersion heater The Flurocyl solar cylinders incorporate an immersion heater IMPORTANT Danger of death from electric shock You must earth the immersion heater for potential equalisation Install a separate electrical power supply line fo
5. 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 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 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 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 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 contr
6. reheat control thermostat as shown in diagram 2 8 and 2 10 Connect the solar pump live via the solar thermal cut out and ensure this thermal cut out is earthed as shown in diagram 2 8 and 2 10 Install the two temperature sensors in the solar cylinder see diagram 2 9 and connect to the solar control see diagram 2 10 Attach the solar gain sensor to the solar circuit return see diagram 2 9 Replace the front fascia panel IMMERSION HEATER duc 5 THERMOSTAT THE CUT OU FACTORY d WITH RESET BUTTON IMMERSION CONNECTION 230V AC 3 kW REHEAT THERMAL RESET BUTTON THERMOSTAT TEMPERATURE SENSORS FACTORY SET IN IMMERSION SLEEVES Diagram 2 7 9 SOLAR THERMAL x CUT OUT WITH RESET BUTTON TN DOMESTIC HOT WATER DEMAND WIRING REHEAT CONTROL THERMOSTAT FACTORY SET O af id gt Diagram 2 8 UPPER TEMPERATURE SENSOR TEMPERATURE SENSOR GAIN T a SENSOR Diagram 2 9 2 Installation 230v PCSA IENLEN L Kod TAC1 2 GAIN FUSED AT bog FLUROPRO CONTROLLER TERMINAL BLOCK L 3 4 5 6 7 8 9 10 Q Q Q
7. 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 1 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 2 Hot water thermostat mixer set too low Increase the setting 3 Solar heating insufficient boiler does Check whether the boiler is working not reheat 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 Check the thermal cut out and reset it Replace the cylinder thermostat Table 5 1 Fault Finding Cylinder temperature sensor defective 5 Fault Finding Wafuon Gmse O O Water flows out of the expansion relief Dirt on the valve seat of the expansion Check the expansion relief valve and valve only when heating up relief valve reset it manua
8. Glow worm Installation and Servicing Flurocyl Solar Hot Water Cylinder 2001 250 300 www glow worm co uk 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 benefit 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 Tech
9. accordance with the installation manual for the boiler 14184 B PORT Motorised 2 port valve A PORT Diagram 3 1 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 1 5 813 An example of this is given in the current edition of l S 813 3 5 Handing over to the householder Hand over all manuals to the householder Advise the householder to keep the manuals near to the system Draw special attention to the safety instructions which the householder must follow Review the user instructions with the householder and answer any questions Show the householder how to operate the solar control CH control and any separate DHW control Inform the householder that the cylinder temperature is factory set at 65 and that the DHW temperature can be adjusted using the TMV by the installer 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 Inform the householder that they are not permitted to change the settings made on the solar system 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 interval
10. between the water control pack and the solar cylinder by means of a T piece PRESSURE LIMITING 5 VALVE WITH LINER BALANCED STRAINER PRESSURE HOT WATER X COLD WATER EXPANSION CONNECTION VESSEL CONNECTION COLD LEGIONELLA WATER LOOP i FLUROCYL SUPPLY CONNECTION CONNECTION EXPANSION RELIEF VALVE Diagram 2 4 2 8 Discharge pipework The outlet connections of both the temperature pressure relief valve and expansion relief valve should be connected in 15mm 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 D1 discharge pipe from the T amp P Valve Expansion valve can be teed together upstream of the tundish The discharge pipework must be installed using minimum 22mm copper pipework from the 22mm connection on the tundish to a safe and visible discharge point 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 2 Installation Re
11. by the adjustable feet of the solar cylinder 2 2 Boiler heating circuit piping Copper pipes with a minimum diameter of 22mm 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 2 port motorised valve supplied must be fitted to the primary flow to the indirect coil 2 4 Domestic hot water pipework Connect the hot water outlet to the 22mm hot water connection of the solar cylinder 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 22mm pipe 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 Set the thermostatic mixing valve to the desired maximum temperature during the solar system commissioning 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 Installation HOT WATER CONNECTION BOILER MOTORISED 2 PORT VAVE MOTORISED 2 PORT VAVE
12. ctions 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 fitted to the outlet of the cylinder and can be adjusted to the desired 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 filled with solar fluid 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 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 tery 2007 2801 Flurocyl 3001 se m Jee o Weight fu 340 Cylinder connections Cold water supply 22 mm pressure pipe Ss REESE 22 mm pressure pipe EE 22 mm pressure pipe Gan 22 mm pressure pipe NK 22 mm pressure pipe Hot water connection Pressure controlled c
13. e 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 1 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 55449 BS6891 BS6700 BS7074 Part 1 and 2 BS7593 BS7671 IE 1 5 813 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 specification CheSS and 2 Controls for domestic central heating system and hot water BRECSU Domestic Hot Water All domestic hot water circuits connections fittings 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 1 5 813 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 de
14. ef valve annually Checking the expansion relief valve annually 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 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 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 Only cold or lukewarm water comes out of the taps 1 The gravity brake is blocked 1 Check the position of the blue handle 2 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 2 port valve which is switched on at the same time as the pump Install a gravity brake as close as possible to the cylinder 2 One pipe circulation in the event of short pipe networks with low pressure loss 1 Air in the reheating heat exchanger Bleed the reheating heat exchanger 2 Heat exchanger surface area too
15. ght 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 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 insulated cable not less than 0 75 2 24 0 20 Testing and Certification 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 Any alteration not approved by Glow worm could invalidate the certification warranty and may also i
16. ication 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 22mm should be used for the pipe from the main stop valve of the building to the solar cylinder 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 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
17. intain the householders desired temperature at the hot water taps 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 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 2 port valve to MANUAL and lock it in this position see diagram 3 1 Fill and bleed the central heating system after draining it completely Unlock the lever on the motorised 2 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 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
18. l 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 Make sure the discharge pipe is at a constant slope of at least 1 200 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 2 9 High level discharge termination 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 SAFETY DEVICE RELIEF VALVE VENTIL METAL DISCHARGE PIPE FROM TEMPERATURE RELIEF VALVE TO TUNDISH 500 DISCHARGE Er BELOW MINIMUM r TUNDIS FIXED 300 MM MINIMUM GRATING METAL DISCHARGE FROM TUNDISH WITH E CONTINUOUS FALL TRAPPED GULLY Diagram 2 5 x Z TUNDISH DISCHARGE MINIMUM P B METAL HOPPER HEAD Diagram 2 6
19. lly 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 Ifthe pressure is normal replace the expansion relief valve Water comes out of the temperature and Dirt on the valve seat of the temperature Check the seat of the temperature pressure relief valve only when heating and pressure relief valve and pressure relief valve and reset it up manually Temperature control of the boiler Check the temperature control of the defective 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 Check the cylinder temperature sensor and the corresponding thermal cut outs and replace the temperature sensor and reset the thermal cut outs if necessary Two port valve defective Check whether the two port valve is working and replace it if necessary Temperature and pressure relief valve Replace the temperature and pressure defective relief valve if water only come
20. nfringe 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 Statutory Requirements IMPORTANT Where no British Standards exists materials and equipment should be fit 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 specific instructions are given reference should be mad
21. nical Helpline 01773 828300 General and Sales enquiries Tel 01773 824639 Fax 01773 820569 To register your Glow worm product call 0800 0732142 C The mark of quality for domestic heating 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 a Emm I 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 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 wei
22. ol devices and a motorised 2 port valve The Flurooyl 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 flow 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 fitted and set A themostatic mixing valve must be fitted 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 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 Immersion heater The Flurooyl 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 14180 CARRYING HANDLE
23. old water outlet Secondary return Flow boiler solar circuit Return boiler solar circuit Electrical connections 3 kW immersion heater according to ENBS 60335 1230 240 V 50 Hz Length of the immersion heater 430 Motorised 2potvave zmomowsonz cylinder thermostat 2020 Thermal out out for soarpump Heating coil Table 1 1 Technical data 1 Product Specifications s l nuluu sjuejuoo Jo 0 104 1e u zJ 10 I I 1 1 I I 1 I 3 Heat input to cylinder kW nn VnVF I r r r m VO 2 9 2 eum dn jeeu ejeuurxouddy Diagram 1 1 Flurocyl cylinder heat up times boiler part 65 t GG UG a OO CON Flow available litres min at entry to system Flurocyl mixed water flow rates Diagram 1 3 i ih 1 1 l 2 lt i gt i 1 o e t e N uu s s y JO uiu saJy _ OQ G GG oO Q Q a or ON A 40 1 4 uu l s s y JO uluu s ni JNO Flow available litres min at entry to system Flurocyl DHW flow rates at 60 C Diagram 1 2 NOTE The heat up time is based on a primary flow rate of 9 l min at 80 C Temperature rise from 15 C to 65 C Sta
24. r the immersion heater in accordance with current IEE regulations BS 7671 You must lay a heat resistant line 3 x 2 5 mm2 from a double pole isolating switch for the immersion heater The circuit must be protected by a 13 A fuse The connection of the immersion heater is illustrated in detail in diagram 2 7 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 Only correct original Glow worm spare parts are permitted 2 12 Thermostat setting The entire inner wiring has been pre assembled at the factory 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 Actuate the reset buttons to reset the thermal cut outs if necessary see diagram 2 7 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 2 13 Thermostat and sensor wiring Connect the domestic hot water demand wiring to the
25. s The frequency of servicing will depend upon the installation conditions and usage but in general once a year should be enough 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 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 reli
26. s at a minimum a minimum diameter of 22mm is recommended for the cold water supply in the building satisfactory performances can also be achieved with 15mm pipes however 2 Installation 2 7 Cold water inlet controls and pipework Connect both parts of the water control pack When installing the valves make sure they are aligned in such a way that the 15mm connection of the expansion relief valve can be connected to the tundish 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 We recommend applying a hose which reaches about 1m under the base of the cylinder to the outlet of the drain valve IMPORTANT Risk of bursts for the solar cylinder No stop valve may be installed between the cold water control pack and the cylinder 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 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 calcif
27. s 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 1 Fault Finding continued 0020055006 02 07 07 0020055006 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. sistance due to each elbow or bend straight length equivalent Minimum diameter Maximum of the discharge permissible pipe from the total resistance tundish expressed as straight pipe length without elbows or bends Table 2 2 Resistance Examples 22mm discharge pipe with 4 elbows and of 7m length from the tundish to the discharge point Resistance for 4 elbows per 0 8m 3 2m Resistance for discharge pipe 7 0m Total resistance 10 2m The total resistance of the discharge pipe is higher than the maximum permissible value for 22mm pipes 9m Base your calculations therefore on the next largest pipe diameter 28mm discharge pipe with 4 elbows and of 7m length from the tundish to the discharge point Resistance for 4 elbows per 1 0m 4 0m Resistance for discharge pipe 7 0m Total resistance 11 0 The total resistance of the discharge pipe is lower than the maximum permissible value for 28mm pipes 18m which means this pipe diameter can be used 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 A suitable point is for example under a fixed grating above the trap of a trapped gully Low discharge pipes for example up to 100mm above externa
29. tails of the requirements In IE the requirements given in the current edition of 1 5 813 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 specification for indirectly heated unvented closed storage water heaters EN 806 1 Specifications 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 backflow 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 modified 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 Safety Instru
30. tic 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 1 bar 1 Product Specifications 1 1 Intended use The Glow worm Flurocyl 200 Flurocyl 250 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 specifications 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 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
31. urocyl pack contents 2 Installation Solar pump thermal cut out Immersion heater thermal cut out Immersion heater thermostat Domestic hot water outlet connection 14174 Legionella loop Temperature and Immersion return connection heater switch boiler Cylinder Cylinder thermostat thermostat thermal cut out Immersion heater EL P d Flow solar circuit 9 Return solar circuit Adjustable feet ENS Pressure relief valve Expansion vessel REAR VIEW Pressure controlled cold water outlet Expansion vessel Cold water supply Pressure limiting Expansion valve relief valve Tundish D Cylinder drain valve Temperature sensor immersion sleeve Diagram 2 2 2 1 Locating the cylinder Locate the solar cylinder at an appropriate place in the building while observing the following The discharge pipe from the tundish must be installed at a minimum slope of 1 200 and end at a safe and visible point refer to section 2 9 The installation surface must be level and able to bear the weight of the full cylinder refer to table 1 1 The installation site may not be prone to frost A frost protection thermostat must be installed if necessary There must be sufficient space to install check and repressurise the expansion vessel Floor unevenness should not be greater than the compensation offered
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