clearly solar technical guide€¦ · nottingham road belper derbyshire de56 1jt head offi ce:...

Clearly SolarTechnical Guide

Glow-worm

Nottingham Road

Belper

Derbyshire

DE56 1JT

www.glow-worm.co.uk

Head Offi ce:

01773 824 639

Literature:

01773 596 105

Aft er Sales Service:

01773 596 510

Technical Advice:

01773 828 300(Boiler)

08447 361 143(Renewables)

Training:

01773 596 156

www.glow-worm.co.uk

2

Visit www.glow-worm.co.uk to view and download technical data

3

ContentsContents

Clearly Solar 4-5

Solar system selector guide 6-9

System sizing

Specifi c system sizing calculations 10-12

Straightforward ordering

Installer step 1 13-15

Developer step 1 16

Developer and Installer step 2 & 3 17

Specifi cations 18

Dimensions

Clearly Solar flat plate collector 19

Flurocyl2 solar hot water cylinders 20

Thermal stratifi cation of Clearly Solar twin coil cylinder 21

Dimensions

Clearly Solar controller and pump station 22

Collector siting options 23

Arrangement, fi xings and clearances

On roof brackets 24

In roof 25-27

Disclaimer

This Technical Guide is intended as a guide only, and should not be used as an

alternative to the manufacturers instructions provided at purchase. The information

in this guide was correct at the time of going to print. Glow-worm reserve the right

to make any modifi cations to product specifi cations, or any other details, without

prior notifi cation. For further clarifi cation, please enquire in writing to the head offi ce

address on the reverse of this brochure.

A-frame 28

A-frame dimensions & In roof expansion vessel guide 29

Wiring

Clearly Solar controller DHW programme 30

Wiring table 32-33

Solar control, thermal block, third party 34-39

Solar control, Smart Wiring Centre, Wired 40-41

Solar control, Smart Wiring Centre, Wireless 42-47

Electric only, Solar control, additional terminal block 48-49

Anti-legionella option 50

DWH circulation loop option 47

Wiring diagrams 48-49

System set-up

Hydraulics 54

Clearly Solar Controller 55

Clearly Solar technical data 56-57

Notes 58-59

Useful notes 60-61

4


5

Clearly Solar

Features and benefi ts

• One provider, one solution, one warranty for all items

• A range of packs to suit every type of installation, in-roof,

on roof, or flat roof (mounted on A-frames)

• Easy to order packs 1, 2 and 3 panel packs – One article number

with everything you need in it

• Vertical and Horizontal orientation possible

• Developer packs available enabling a 2-stage delivery, minimising

space and security requirements on site

• Twin coil cylinders available in 200, 250, and 300 litres

• Intelligent controller minimizes the boiler re-heat reliance,

maximizing efficiency

• Lightweight panel - Only 38kgs dry weight

• Simple to fit on roof brackets – no frames or rails to construct

• Unique tool free fitting of hydraulic connections

• Flow and return connections made by the installer to maximise

siting flexibility

• Optional pipework kit for easy piping of the system

• A host of accessories to complement the installation, and aid

the installer

All Clearly Solar packs contain:

• Collectors

• Type P / Type S / A-frames / In-roof kit

• Hydraulic Connection Set

• Hydraulic Extension Set (if more than 1 collector)

• Controller

• Pump Station

• Solar Fluid

• Expansion Vessel

• Protection Vessel

• Automatic Air Separator

The straightforward Solar Thermal Solution

Designed specifi cally for use on UK homes, Clearly Solar has everything

you need to look for in a flat plate solar thermal solution. Glow-worm’s

Clearly Solar system can deliver between 50 and 60% of your domestic

hot water every year. In the summertime it can be as high as 100%

which means that your boiler may never have to fi re up, saving energy

and money.

Robust and subtle design

Clearly Solar comes in a simple pack solution ensuring that you have

everything you need for your solar thermal installation. The flat plate

collectors are made from black anodised aluminium which makes them

hard wearing, robust and very subtle, neatly fi tting into or onto a roof.

Alternatively, if the inclination or aspect of the roof is not perfectly suited

for a solar installation, Clearly Solar can also be installed on A-frames

which are extremely easy to construct and site on a flat roof or in a garden.

Total compatibility

Clearly Solar is a pressurised system, meaning that it is completely

full of heat transfer fluid and sealed from the atmosphere (a similar

concept to a sealed heating system). Clearly Solar is fully compatible

with all new and existing open vent and sealed system boilers

(including the complete Glow-worm range) or immersion heaters in

non-gas areas.

6


7

Solar system selector guide

PIPE WORK PACK00200806631

FROM ROOF AND PANEL TYPE SELECTOR

CYLINDERAND

PIPEWORK

200l0010010915

300l0010010917

CYLINDERTYPE

250l0010010916

ROOF TYPE ON

SLATE/ FLAT TILE

CYLINDERSELECTION

ON

ON ROOF PACKHORIZONTAL 1

PANEL0020078867


PANEL0020078868 ON ROOF PACK

HORIZONTAL 3PANEL

0020078869

ON ROOF PACKVERTICAL 1


VERTICAL 2PANEL

0020078856 ON ROOF PACKVERTICAL 3

PANEL0020078857

HORIZONTAL ORVERTICAL

ROOF TYPEONTILE

CYLINDERSELECTION

ONON ROOF PACKHORIZONTAL 1

PANEL0020078864


PANEL0020078852


PANEL0020078853


PANEL0020078854



HORIZONTAL 3PANEL

0020078866

SOLAR EQUIPMENT SELECTOR



8


9


Solar system selector guide

ROOF TYPEIN

CYLINDERSELECTION

IN

IN ROOF PACKHORIZONTAL 1

PANEL0020078870


PANEL0020078871


PANEL0020078872

IN ROOF PACKVERTICAL 1

PANEL0020078858 IN ROOF PACK

VERTICAL 2PANEL

0020078859 IN ROOF PACKVERTICAL 3

PANEL0020078860


A-FRAME

CYLINDERSELECTION

A-FRAME

A FRAME PACKHORIZONTAL 1

PANEL0020078873

A FRAME PACKVERTICAL 1

PANEL0020078861


PANEL0020078862


PANEL0020078863



PANEL0020078874


PANEL0020078875

1 Panel 2 Panel 2 Panel 3 Panel

Flurocyl₂ Size* 200 Litres 200 or 250 Litres 250 or 300 Litres 300 Litres

* Flurocyl₂ should be correctly sized

Minimum number of persons in household 1 Person 1 Person 2 People 3 People

Maximum number of persons in household 2 People 3 People 4 People 5 People

Household average daily hot water usage Up to 100 Litres 80 to 120 Litres 100 to 140 Litres 120 to 180 Litres

Note: This system sizing rule of thumb will deliver 60% of annual DHW assuming near optimum collector

orientation. For precise sizing please refer to the product installation manual or seek advice from

Glow-worm’s technical helpline.

Basic guide to solar system sizing

10


11

System sizing Specifi c system sizing calculationsSteps 2-4

Specifi c system sizing calculations

1 Panel 2 PanelOptions A

2 PanelOption B

3 Panel

Cylinder Size* 200l 200 / 250l 250 / 300l 300l

Minimum No. persons household

1 1 2 3

Maximum No. persons household

2 3 4 5

Average daily hot water usage

100l 80 - 120l 100 - 140l 120 - 180l

Typical usage per person

Daily energy requirement (kWh/d)

Low usage 20-30 l DHW (45°C) 0.8-1.2

Typical usage 30-50 l DHW (45°C) 1.2-2.0

High usage 50-70 l DHW (45°C) 2.0-2.8

Washing machine or dishwasher

120-180 l 0.8

* Cylinders should be correctly sized

Note: This system sizing rule of thumb will deliver 60% of annual DHW assuming near

optimum collector orientation. Please ensure you correctly size the system. For further

help, please contact Glow-worm's technical help line.

Notes

• Daily hot water usage typically 40 l per person

• Washing machine daily hot water usage typically 20 l (4 person)

• Dish washer daily hot water usage typically 20 l (4 person)

• Cold mains supplied at 10°C / hot water supplied at 45°C

• Cylinder volume 1.5 to 2 times the household daily hot water usage

• Approx 50 l cylinder volume per 1m2 of collector area under optimum

conditions

• On no account fall below 35 l of cylinder volume per m2 of collector

being used

• Do not signifi cantly oversize cylinder

To calculate specifi c system sizes, please follow steps 1 through to 6

Step 1

Work out your domestic hot water demand using the table below

Note: Multiply the usage per person by the number of people in the house.

This will then tell you how much hot water is required.

Step 2

Work out the cylinder size using the following rules

• Solar cylinder size should be 1.5 to 2 times the household daily hot

water usage

• Ensure that the Clearly Solar Cylinder size allows the minimum of

50 l per 1m2 of collector area under optimum conditions

• Do not signifi cantly oversize cylinder

• Please use the table on page 4 as a guide

Step 3

Work out the heat requirement for hot water demand

Qwater = V x ΔT x 0.4234

Where

Qwater = Annual heat requirement (kWh)

V = Daily volume of water (l)

ΔT = Temperature diff erence between cold mains in and

hot water out (K)

Step 4

Work out the annual solar radiation

Annual solar radiation (kWh/m2) = Qsolar

Use this map to estimate annual solar radiation

1000

1100

1200

900

55

65

Image supplied by Solar Trade Association

12


13

Specifi c system sizing calculationsSteps 5-6

Orientation Collector Inclination at 30˚

Collector Inclination at 50˚

Collector Inclination at 70˚

E 1.64 1.61 1.61

ESE 1.45 1.47 1.61

SE 1.17 1.15 1.34

SSE 1.04 0.98 1.14

S 1.00 0.94 1.11

SSW 1.03 0.97 1.13

SW 1.13 1.09 1.27

WSW 1.35 1.35 1.60

W 1.64 1.61 1.61

Step 5

Using this table to select the correction factor (f)

Correction factor

Step 6

Use the values calculated in steps 1 to 5 to work out the collector area

required

Collector area

A= f x C x Qwater

0.3 x Qsolar

A = Collector area (net m2)

f = Correction factor (See table opposite)

C = Required contribution of solar towards hot water (%÷100)

normally 40-60%

Qwater = Annual heat requirement (kWh)

Qsolar = Annual solar radiation (kWh/m2)

Rule of thumb 1m2 of collector area per person

Once you have calculated your specifi c system requirements you can

then:

• Select your required solar pack (See page 8)

• Select your required cylinder (See page 8)

Notes

• Recommended maximum of 2 collectors on 200/250 l and maximum

3 collectors on 300 l cylinders

• For east/west installations, please seek advice from a professional

design service

Straightforward ordering INSTALLER Step 1

Panel Pack Options: Part No. 1 Panel Pack

2 Panel Pack

3 Panel Pack

In roof pack: Vertical 0020078858 0020078859 0020078860

This pack contains

Vertical Flat Plate collector 0010006294 1 2 3

In-roof one collector kit - Vertical

0020060316 1

In roof two collectors kit - Vertical

0020060318 1 1

In roof kit - additional collector -Vertical

0020060327 1

Easy fi t Hydraulic connection set In-Roof

0020065271 1 1 1

Easy fi t hydraulic extension set, In-roof/A-frame

0020059909 1 2

Clearly Solar controller 0020054960 1 1 1

Clearly Solar pump station 0020129143 1 1 1

Expansion vessel 18 l 0020054963 1

25 l 0020054992 1

35 l 0020054993 1

Solar fluid 20 l 0020054968 1 2 2

Protection vessel 0020054966 1 1 1

Automatic air separator 0020054969 1 1 1

Step 1: Vertical In roof packs

Step 1: Horizontal In roof packs


2 Panel Pack

3 Panel Pack

In roof pack: Horizontal 0020078870 0020078871 0020078872

This pack contains

Horizontal Flat Plate collector

0010006295 1 2 3

In-roof one collector kit - Horizontal

0020060315 1

In roof two collector kit - Horizontal

0020060317 1 1

In roof additional collector kit - Horizontal

0020060326 1

Easy fi t Hydraulic connection - set In Roof

0020065271 1 1 1


0020059909 1 2




25 l 0020054992 1

35 l 0020054993 1

Solar fluid 20 l 0020054968 1 2 2



14


15




2 Panel Pack

3 Panel Pack

Tile packs: Vertical 0020078852 0020078853 0020078854

This pack contains


Roof brackets for concrete tiles x 4 (one collector) - Type P

0020060302 1 2 3

Easy fi t Hydraulic connection-set

0020060207 1 1 1

Easy fi t Hydraulic extension-set

0020055175 1 2




25 l 0020054992 1

35 l 0020054993 1

Solar fluid 20 l 0020054968 1 2 2




2 Panel Pack

3 Panel Pack

A-Frame packs: Vertical 0020078861 0020078862 0020078863

This pack contains


A-frame vertical installation

0020060312 2 3 4

Mounting bar set Vertical 0020060308 1 2 3


0020060207 1 1 1


0020059909 1 2




25 l 0020054992 1

35 l 0020054993 1

Solar fluid 20 l 0020054968 1 2 2




2 Panel Pack

3 Panel Pack

A-Frame packs: Horizontal 0020078873 0020078874 0020078875

This pack contains


0010006295 1 2 3

A-frame horizontal installation

0020060311 2 3 4

Mounting bar set Horizontal

0020060307 1 2 3


0020060207 1 1 1


0020059909 1 2




25 l 0020054992 1

35 l 0020054993 1

Solar fluid 20 l 0020054968 1 2 2



Step 1: Vertical profi led tile packs

Step 1: Horizontal profi led tile packs


2 Panel Pack

3 Panel Pack

Tile packs: Horizontal 0020078864 0020078865 0020078866

This pack contains


0010006295 1 2 3

Roof brackets for concrete tiles x 4

(one collector) - Type P 0020060302 1 2 3


0020060207 1 1 1


0020055175 1 1 2




25 l 0020054992 1

35 l 0020054993 1

Solar fluid 20 l 0020054968 1 2 2



Step 1: Vertical A-frame packs

Step 1: Horizontal A-frame packs

16


17

Straightforward ordering DEVELOPER Step 1

Straightforward orderingINSTALLER & DEVELOPER Step 2&3


2 Panel Pack

3 Panel Pack

Developer pack A: Vertical 0020078876 0020078877 0020078878

This pack contains


In roof one collectors kit - Vertical

0020060316 1

In roof two collectors kit - Vertical

0020060318 1 1

In roof kit - additional collector -Vertical

0020060327 1


0020065271 1 1 1


0020059909 1 2


Pack Options: Part No.Flurocyl₂ Pack Codes

This pack contains Article No.

Flurocyl₂ Cylinder 200 l 0010010915



Pack Options: Part No. PackArticle Number 0020080631

Parts available

System flexible pipe 1 x 15m DN16 0020054964 2

System fi ttings pack for DN16 pipe 0020054965 1


2 Panel Pack

3 Panel Pack

Developer pack B 0020078882 0020080375 0020080376

This pack contains





Solar fluid 20 l 0020054968 1 2 2



Step 1: Vertical developer pack A

Step 3: Clearly Solar twin coil cylinder pack

Step 2: Pipe work pack

Step 1: Developer pack B

or Step 1: Horizontal developer pack A


2 Panel Pack

3 Panel Pack

Developer pack A: Horizontal 0020078879 0020078880 0020078881

This pack contains


0010006295 1 2 3

In roof one collector kit - Horizontal

0020060315 1

In roof two collectors kit - Horizontal

0020060317 1 1

In roof additional collector kit - Horizontal

0020060326 1


0020065271 1 1 1


0020059909 1 2


Accessories Part No.

Thermostatic mixing valve* 0020054967

Safety belt set for roof working 0020054985

Solar fluid 10 l 0020054983

Filling pump 0020054986

Antifreeze test kit 0020054984

Collector sensor 0020065994

DN16 Fittings pack from pump station to cylinder 0020088208

Collector flexible pipe 2 x 1m DN16 0020055014

System flexible pipe “2-in-1” x 15m DN16 (insulated with sensor wire)

0020054994

Pipe clamps for flexible pipe “2-in-1” DN16 0020054990

In roof mounting set 15 - 22° low inclination x 2 collectors

0020059886

In roof mounting set 15 - 22° low inclination x 3 collectors

0020059888

System flexible pipe “2-in-1” x 15m DN20 (insulated with sensor wire)

0020054995

Gravel plate set small (2 pcs), G-w 0020060313

Gravel plate set big (3 pcs), G-w 0020060314

Pipe clamps for flexible pipe “2-in-1” DN20 0020055012

Expansion vessel 50 l 0020084958

Expansion vessel 80 l 0020084959

Protection vessel 12 l 0020054996

Protection vessel 18 l 0020054997

Floor-standing exp. vessel fi xing pack 0020077251

In-roof additional sealing kit (5 l) 0020080803

Cylinder sensor 0020059225

*A TMV must be used on all solar thermal installations

18


19

Panel Pack Options: Verticalcollector SRV 2.3

Horizontal collector SRH 2.3

Dimensions and weights

Orientation Vertical (Portrait) Horizontal (Landscape)

Height / Width / Depth (mm) 2035 / 1233 / 80 1233 / 2035/ 80

Overall collector area (mm) 2.51 2.51

Aperture area (m2) 2.35 2.35

Absorber area (m2) 2.32 2.32

Weight (empty) (kg) 38 38

Capacity (solar fluid) (l) 1.85 2.16

Performance

Solar glass transmission (%) 91 91

Solar radiation absorption (%) 95 95

Solar radiation emission (%) 5 5

Effi ciency η 0 (%) 79.0 80.1

Effi ciency coeffi cient a1 (W/M

2K)

2.41 3.32

Effi ciency coeffi cient a2 (W/M

2K

2)

0.049 0.023

Max operating pressure (bar) 10 10

Stagnation temperature ( ‹C) 210 210

Certifi cation CE 0036 & Solar Keymark CE 0036 & Solar Keymark

Materials & construction

Absorber Sheet Aluminium Aluminium

Absorber plate coating Sunselect (selective) Sunselect (selective)

Absorber tube Copper Copper

Absorber tube joints Laser welded Laser welded

Frame AluminiumExtruded sides / sheet

rearExtruded sides / sheet

rear

GlazingSafety glass (low iron),

3.2mmSafety glass (low iron),

3.2mm

Rear insulation 40mm 40mm

Solar fluid Water / propylene glycol Water / propylene glycol

Flow / return connections DN 16 (G3/4”) DN 16 (G3/4”)

Specifi cation

Clearly Solar Flat Plate Collector

NotesClearly Solar flat plate collector complies with BSEN 12975

European Testing Standards

DimensionsClearly Solar flat plate collector

Cross section of Clearly Solar flat plate collector

Glue line glass-frame

Novasil S49-VP6095-SP 6116

40mm

mineral wool

insulation

Aluminium

alloy back

sheet

Frame:

Aluminium

(black anodised)

80mm

80mm

79mm1233mm

1178mm 79mm

1875mm1978mm

2035mm

20


21

DimensionsFlurocyl₂ solar hot water cylinders

Thermal stratifi cationof Clearly Solar twin coil cylinder

1 Hot water draw off

2 Temperature and pressure relief valve connection

3 Secondary circulation return

4 Primary heater flow

5 Primary heating sensor pocket (SP 1)

6 Primary heater return

7 Electric immersion heater

8 Solar flow

9 Solar circuit sensor pocket (SP 2)

10 Cold mains inlet connection

11 Solar Return

Model A B C D E F G H I J K L

200l 1625 1593 1341 1158 1052 912 822 802 534 506 259 51

250l 1875 1843 1591 1346 1102 962 872 872 534 506 259 51

300l 2185 2153 1901 1578 1377 1237 1147 1127 534 506 259 51

A B C

1

2

3

4

5

6

7

8910

11

45˚25˚

624

ø 554,5

D E F G H I J K L

High Performance:• High recovery heating coil (for when no solar gain)

• High flow rates working at 3.5 Bar pressure

• High quality environmentally friendly Neopor EPS insulation.

• Insulation exceeds CHeSS Best Practice

• Immersion heater positioned below the upper coil to maximise

comfort levels where there is no boiler back up

Easy Installation:• Expansion vessel wall mounting bracket included

• Simple front connection of all main pipe work

• Compatible for use with all boilers

• Single 3 kW back up immersion heater on all models

• Dedicated 15mm secondary circulation return connection on

all cylinders.

Flexible Site location:• Diameter remains the same

for all models to fi t through

standard UK cupboard

door ways *

• Access only required to front

and water controls group for

servicing.

• Intelligent system solutions

when used with Glow-worm

appliances and controls

Quality and Reliability:• All seams laser welded

• 25 Year Guarantee on

cylinder shell. (Subject

to water quality, correct

installation and annual

servicing).

* additional space required for solar pipe work and components.

22


23

Display

Button

Button

Button

Button

275mm 55mm

200mm

Key features of the Clearly Solar Controller• Diff erential temperature control

• East / West system control (additional collector sensor and pump

station connection)

• Solar gain display

• Temperature sensors

• Two independent time channels: auxiliary hot water e.g. boiler,

and DHW circulation pump

• Easy wiring connections

• Solar gain counter

• Boiler heating delay function

Key features of the Clearly Solar pump station• 6m head pump

• Two isolation valves

• Two non-return valves

• Two temperature gauges

• Pressure gauge

• Pressure relief valve

• Expansion vessel connection

• Integrated flow adjuster

and meter

250mm

358mm

120mm

DimensionsClearly Solar controller & pump station

Clearly Solar controller

Clearly Solar pump station

Collector sensors : horizontal and vertical

Easy fi t hydraulic connections

Maximum of 5 collectors can be connected in a single array when

piping flow and return on the same side (diagram 1)

Maximum of 12 collectors can be connected in a single array when

piping flow return top bottom and opposite ends (diagram 2)

Collector siting options

Flow connection with collector sensor

Stop plug

Return connection

Vent plug

Vent plugFlow connection with collector sensor

Return connection

Stop plug

Diagram 1

Diagram 2

N.B. Horizontal collectors cannot be mounted on top of each other.

Mounting rail connection piece

used only on A-frame

installations

24


25

Arrangement & fi xingsOn roof brackets

Type P brackets

Type S brackets

For profi led concrete roof tiles

For slate / flat concrete tiles

Arrangement & fi xingsIn roof

Contents of in roof kit : 1 panel

4

7

2

12

6

4

11

3

5

1

10

8

9TX 25 SCREW

No.2

No.3

No.4

SCREW

No.1

1 collector in-roof kit for roof angle 22-75˚

Part Description Qty

1 Tile bar 1

2 Ridge plate 1

3 Right side section 1

4 Left side section 1

5 Profi le end 2

6 Lower flashing 1

7 Roof batten 3

8 Inner clamp 9

9

Screw No.1Screw No.2Screw No.3Screw No.4

161576

10 External clamp 10

11 Support plate 2

12 Support board 1

13 System connection kit (not illustrated) 1

26


27

Arrangement & fi xingsIn roof

Arrangement & fi xings clearancesIn roof

Notes• Important: Roof must have a pitch greater than or equal to 22°

• An alternative In-roof solution for low inclination roofs exists.

This kit is suitable for roofs between 15 and 22 degrees,

and is available for 2 collectors mounted vertically

(art number 0020059886), and 3 collectors vertically

(art number 0020059888)

• Additional battens are supplied with In-roof kits. If locally -

sourced battens are preferred, they must be of suffi cient size and

strength to withstand the load.

6

6 7

25

1

7

1

1

3

1

4

Connection of hydraulic sets

Number ofCollectors A B C

1 2725 1717 309 (min 280)

2 2725 3336 309 (min 280)

3 2725 4243 309 (min 280)

B

A

C

In roof clearances

Description Article No.

Hydraulic connection kit On Roof 0020060207

Hydraulic connection kit In Roof 0020065271


1 Securing clip 4

2 Flow connection 1

3 Return (inlet) 1

4 Lower plug 1

5 Upper plug (with ventilation) 1

Description Article No.

Hydraulic extension kit On Roof 0020055175

Hydraulic extension kit In Roof 0020059909


6 Piping coupling 2

7 Securing clip 4

Hydraulic extension kit

Hydraulic connection kit

28


29

Arrangement & fi xingsA-frame

Arrangement & fi xingsA-frame dimensions & In roof expansion vessel guide

Frames and gravel trays fi xings and dimensions

Selection of gravel trays

A-frames

Dimensions of A-frame

NB: Gravel trays are not supplied as a standard with A-frame packs, and must be

ordered separately, based on the table above. All other components are supplied with

the A-frame packs.

1

2

3

Collector assembling No. of Collectors

Description Part No. 1 2 3

Horizontal collectors

Gravel plate 0020060313 2 3 4

A-frame horizontal 0020060311 2 3 4

Mounting bar set horizontal 0020060307 1 2 3

Vertical collectors

Gravel plate 0020060314 2 3 4

A-frame vertical 0020060312 2 3 4

Mounting bar set vertical 0020060308 1 2 3

Inclination Height (cm) Minimum distancebetween arrays (cm)

Horizontal collectors

30˚ 72 321

45˚ 101 380

60˚ 124 413

Vertical collectors

30˚ 112 500

45˚ 158 592

60˚ 193 643

Using Glow-worm flexible pipes

Notes• The supplied protection vessel for the expansion vessel must

be fi tted.

• The solar pump station must be located below the collector

array.

• The sizing table shown above is only a guide

Installation location for automatic air separator

Number ofCollectors

10m pipework

(total)

15m pipework

(total)

20m pipework

(total)

25m pipework

(total)

30m pipework

(total)

1 18 18 18 18 25

2 18 25 25 25 35

3 25 25 35 35 35

In roof expansion vessel sizing guide

Using glow-worm flexible DN16 pipework pack

30


31

Wiring Clearly Solar ControllerDHW programme

• The Clearly Solar controller incorporates a 7 day programmer to

allow timed heating of the DHW cylinder

• Using this programmer ensures the boiler only fi res when

absolutely necessary

• This maximises solar gain and minimises gas consumption

• When using the solar controller DHW programmer, the domestic hot

water channel of any existing programmer is not used

Display

Button

Button

Button

Button

The Clearly Solar Controller will only signal a demand to the boiler if:• The cylinder is below the required temperature

• The Clearly Solar system is not operating

• The programme is in an ‘ON’ period

Alternative DHW programmer• It may not be appropriate to use the solar controller to time the

auxiliary heat source:

• If there are installation limitations or;

• The Clearly Solar system is not operating and;

• Where the householder prefers an existing DHW programmer

• In such cases an alternative external DHW programmer can be used

• Whenever possible, programme ‘ON’ periods when there is

unlikely to be any solar gain

32


33

Diagram Boiler Solar control Wiring Programming Programming Cylinder Values typeDHW Heating DHW circuit Heating circuit

3.3

Regular heat only (without

eBus) 1

Fluropro

Terminal block

Third party -Room

thermostat with programmer

Third party - Room thermostat with

programmer

Wiring through a cylinder stat

2 port valve 2 port valve

3.4 FluroproThird party - Room



3.5

Third party -Room


Third party - Room thermostat with

programmerOne x 3 port valve (Y-plan)

3.6

System(with eBus) 1

Smart Wiring Centre Fluropro

Wired - Glow-worm eBus room thermostat


3.7Wired -

Glow-worm eBus room thermostat

3.8Wired -


Wiring using only NTC sensors

3.9Wired -


3.10 All electric solution

Additional terminal block Fluropro - 2 port valve 2 port valve

Diagram Solar control Diagram Options available

3.3

Fluropro

3.123.133.14

DHW circulation loopCollector arrays setup for East/West orientationSolar gain display

3.4

3.113.123.133.14

Anti-legionella functionDHW circulation loopCollector arrays setup for East/West orientationSolar gain display

3.53.123.133.14

DHW circulation loopCollector arrays setup for East/West orientationSolar gain display

3.63.7

3.113.123.133.14

Anti-legionella function DHW circulation loopCollector arrays setup for East/West orientationSolar gain display

3.83.93.10

3.113.123.133.14

Anti-legionella function DHW circulation loopCollector arrays setup for East/West orientationSolar gain display

Use the table below to identify which wiring diagram is appropriate

for your specifi c installation

1 Flexicom hx/sx, Ultracom hxi, Ultracom2 cxi Ultracom

2 sxi, old hxi/sxi open

vent or system boiler by other manufacturers.

Wiring

34


35

1 Boiler 14 Terminal block

2 Solar gain NTC 15 Room thermostat

3 Solar collector 16 NTC sensor pocket (TAC 2)

4 Collector NTC (Black cable) 17 Heating circuit

5 Solar expansion & protection vessel 18 DHW 2 port zone valve

6 Solar pump station 19 CH 2 port zone valve

7 Domestic hot water cylinder 20 Automatic air separator

7.1 Cylinder dual thermostat A Boiler circuit return

7.2 Immersion heater with thermal safety B Boiler circuit flow

7.3 Solar pump thermal cut-out C Cold water supply

8 Additional terminal block D Domestic hot water flow

9 Electrical supply + protection E Cylinder circuit flow

10 Fluropro solar controller F Cylinder circuit return

11 CH & DHW time controller G Solar circuit return

12 Electrical switch H Solar circuit flow

13 NTC sensor pocket (TAC 1)

Solar control, terminal block, third partyRoom thermostat with programmer, 2x2 port valves wiring though a cylinder stat

diagram 3.3

36


37

1 Boiler 14 Terminal block

2 Solar gain NTC 15 Room thermostat



5 Expansion vessel 18 DHW 2 port zone valve












Solar control, terminal block, third partyRoom thermostat with programmer, 2x2 port valves wiring though a cylinder stat

diagram 3.4

38


39

diagram 3.5

1 Boiler 13 NTC sensor pocket (TAC 1)

2 Solar gain NTC 14 Terminal block

3 Solar collector 15 Room thermostat

4 Collector NTC (Black cable) 16 NTC sensor pocket (TAC 2)

5 Solar expansion & protection vessel 17 Heating circuit

6 Solar pump station 18 3 port mid position valve










Solar control, terminal block, third partyRoom thermostat with programmer, 3 port valve wiring though a cylinder stat

40


41

1 Boiler 13 NTC sensor pocket (TAC 1)

2 Solar gain NTC 14 Smart Wiring Centre



5 Solar expansion & protection vessel 17 DHW 2 port zone valve








10 Systempro F Cylinder circuit return

11 Room thermostat (Ebus) G Solar circuit return


Solar Control, Smart Wiring Centre, WiredGlow-worm Ebus room thermostat, 2x2 port valves, wiring through a cylinder stat

diagram 3.6

42


43

1 Boiler 14 Smart Wiring Centre

2 Solar gain NTC 15 NTC sensor pocket (TAC 2)

3 Solar collector 16 Heating circuit

4 Collector NTC (Black cable) 17 DHW 2 port zone valve

5 Solar expansion & protection vessel 18 CH 2 port zone valve

6 Solar pump station 19 Automatic air separator

7 Domestic hot water cylinder 20 Radio receptor







11 Room thermostat RF (Ebus) G Solar circuit return



Solar Control, Smart Wiring Centre, WirelessGlow-worm Ebus room thermostat, 2x2 port valves, wiring through a cylinder stat

diagram 3.7

44


45







7 Domestic hot water cylinder A Boiler circuit return






11 Room thermostat (Ebus) G Solar circuit return



Solar Control, Smart Wiring Centre, WirelessGlow-worm Ebus room thermostat, 2x2 port valves, wiring using only NTC sensors

diagram 3.8

46


47







7 Domestic hot water cylinder 20 Radio receptor

7.1 Immersion heater with thermal safety A Boiler circuit return

7.2 Solar pump thermal cut-out B Boiler circuit flow

8 Additional terminal block C Cold water supply

9 Electrical supply + protection D Domestic hot water flow

10 Systempro E Cylinder circuit flow

11 Room thermostat RF (Ebus) F Cylinder circuit return

12 Electrical switch G Solar circuit return

13 NTC sensor pocket (TAC 1) H Solar circuit flow

Solar Control, Smart Wiring Centre, WirelessGlow-worm Ebus room thermostat, 2x2 port valves, wiring using only NTC sensors

diagram 3.9

48


49


2 Solar collector 11 16A power relay

3 Collector NTC (Black cable) 12 NTC sensor pocket (TAC 2)

4 Solar expansion & protection vessel 13 Automatic air separator

5 Solar pump station C Cold water supply

6 Domestic hot water cylinder D Domestic hot water outlet

6.1 Immersion heater with thermal safety G Solar circuit return

6.2 Solar pump thermal cut-out H Solar circuit flow

7 Additional terminal block

8 Fluropro solar controller

9 Electrical supply + protection(must have it's own single isolation)

Electric only, solar control, additional terminal blockWiring using only NTC sensors

diagram 3.10

50


51

1 Domestic hot water cylinder E Cylinder circuit flow

2 Fluropro solar control F Cylinder circuit return

3 Thermostatic mixing valve G Solar circuit return

4 Anti-legionella pump H Solar circuit flow

5 Non-return valve

6 Safety unit (pressure reducing valve,pressure relief valve, check valve, Non-return valve)

Anti-legionella option

diagram 3.11 diagram 3.12

1 Domestic hot water cylinder E Cylinder circuit flow

2 Fluropro solar control F Cylinder circuit return

3 Thermostatic mixing valve G Solar circuit return

4 Anti-legionella pump H Solar circuit flow

5 Non-return valve

6 Safety unit (pressure reducing valve,pressure relief valve, check valve, Non-return valve)

DWH circulation loop option

5

34

5

5H

G

2

1

F

E

6

4

2

52


53

Wiring diagrams

Installer interface options for Glow-worm boilers

Wiring for G3 compliance on a east/west installation

1 Collector NTC to fi rst array (black cable)

7 Solar pump station to second array

2 First array 8 Solar pump station to fi rst array

3 Second array 9 External relay

4 Collector NTC to second array (black cable) - Additional sensor required

10 Thermostat cut out

5 Fluropro solar control G Solar circuit return

6 Solar expansion vessel and protection vessel

H Solar circuit flow

1 Solar Gain NTC (cylinder sensor type)

2 Solar pump station to fi rst array

3 Fluropro solar control

4 Solar pump station to second array

G Solar circuit return

H Solar curcuit flow

diagram 3.13

diagram 3.14

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55

• Access the installer menu by pressing the mode button for 3

seconds. Press the mode button for 3 seconds again to return

to the operating menu at any stage

• Certain system parameters must be set in order to optimise the

system for the installation

• hydraulic plan;

• flow rate;

• current date and time

• It is recommended that the solar gain counter and cylinder reheat

delay function is activated

• Ask the householder how long they normally program the DHW

to be on for before they actually require it. If one hour or more,

activate the cylinder reheat delay

• It may not be necessary to change any other settings from the

factory defaults

System set uphydraulics

The system should be carried out in accordance to the installation

manual. This includes full details over and above the guidance given

below. Do not remove the protective fi lm from the collectors until the

solar system has been fi lled and commissioned.

Commissioning the hydraulics

• Fill the system with solar fluid supplied by Glow-worm

• Tyfocor solar fluid - suitable for use between -25°C and 320°C

• Pressurise the system to (h x 0.1 + 0.5) bar (h is height between

solar expansion vessel and collector), but not less than 2 bar

• Maximum pressure must be no higher than 5.5 bar

• Set the pump speed to minimum and adjust later if necessary

• Adjust the flow rate using the regulator in the Clearly Solar pump

station

• Set the flow rate according to the table below, but always with a

minimum of 3.0 l/minutes.

0,5123

0,5123

456

456

L/m

in

L/min

1,1 l/min

Regulator

Meter

System set upClearly Solar Controller

Flat Plate collector Flow rate Minimum pipe size1

No. of collectors I/min I/hour 20m 50m

1 1.33 80 DN16 DN16

2 2.66 160 DN16 DN16

3 4.00 240 DN16 DN16

4 5.33 320 DN16 DN20

Pump speed:Minimumspeed (1)

Maximumspeed (3)

Calculating the correct flow rate of the system

Display

Button

Button

Button

Button

1 Minimum pipe size to be used in the solar circuit at a total system pipe length

Clearly Solar Controller

• Diff erential temperature

control East / West system

control (additional collector

sensor and pump station

connection)

• Solar gain display

• Temperature sensors

• Two channels-solar,auxiliary

heating (usually boiler)

• Programmable boiler &

auxiliary channels

• Easy wiring connections

• Solar gain modulation

• Boiler heating delay function

(similar to optimum start)

56


57

Clearly Solar technical data

Flurocyl₂ solar hot water cylinders Cont.

Flurocyl₂ 200 250 300

Installation

Cold water inlet22mm unprofi led pipe(compression joints)

Hot water draw off 22mm unprofi led pipe(compression joints)

Balanced pressure cold water outlet22mm unprofi led pipe(compression joints)

Secondary return22mm unprofi led pipe(compression joints)

Primary heater flow22mm unprofi led pipe(compression joints)

Primary heater return22mm unprofi led pipe(compression joints)

Solar heater flow22mm unprofi led pipe(compression joints)

Solar heater return22mm unprofi led pipe(compression joints)

Primary heating circuit immersionsleeve size (mm)

8

Solar heating circuit immersionsleeve size (mm)

8

Immersion heater (according to BS EN 60335) 2.7kW, 230 V, 50 Hz

Length of electric immersion heater (inch) 14

Two port motorised valve 2.7kW, 230 V, 50 Hz

Cylinder thermostat 2.7kW, 230 V, 50 Hz

Safety

Maximum supply pressure to pressurereducing valve (bar)

12

Maximum operating pressure of cylinder (bar) 7

Maximum operating pressure ofheating coil (bar)

3.5

Maximum operating pressure of solar coil (bar) 6

Operating pressure (bar) 3.5

Pressure limiting valve (bar) 3.5

Expansion relief valve (bar) 6

Temperature and pressure relief valve (bar) 7

Charge pressure of hot water expansion vessel 4

Maximum temperature of heating circuit °C 85

Maximum temperature of solar fluid °C 85

Flurocyl₂ 200 250 300

Size

Total capacity (l) 200 250 300

Actual capacity (l) 209.4 254.4 297.2

Hot water capacity (upper coil) (l) 104.8 142 144.2

Hot water capacity (solar coil) (l) 203.3 246.1 271.1

Dedicated solar volume (l) 104.6 112.4 153

Height (mm) 1593 1843 2153

Height with hot water draw off (mm) 1625 1875 2185

Diameter (mm) 554.5 554.5 554.5

Depth (mm) 633 633 633

Net weight (kg) 40 43 50

Weight full (kg) 249 298 347

Construction

Cylinder body material Stainless steel (1.4521)

Cylinder jacket material Polypropylene

Insulation material EPS with infrared absorber

Insulation thickness (mm) 50.0

Corrosion protection Stainless steel

Blowing agent for insulation material Pentane (GWP < 5)

ODP 0

Performance

Standing heat loss (kW/24 h) 2.05 2.2 2.4

Heating up time according to EN 12897 (mins) 22 29 30

Recovery time (70% capacity) (mins) 16 21 22

Primary heat exchanger performance (kW) 14.9 15.3 15

Flow rate for primary heat exchanger performance (l/min)

23.3 23.3 23.3

Primary heat exchanger pressure drop (mbar) 79 78 79

Primary heat exchanger volume (l) 2.37 2.37 2.37

Primary heat exchanger surface area (m2) 0.5 0.5 0.5

Solar heat exchanger performance (kW) 18.7 18.5 16.5

Flow rate for solar heat exchanger performance (l/min)

23.3 23.3 23.3

Solar heat exchanger pressure drop (mbar) 97 95 98

Solar heat exchanger volume (l) 2.94 2.94 2.94

Solar heat exchanger surface area (m2) 0.62 0.62 0.62

Heating up time according to EN 12897 (solar) 22 29 30

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