Glow-worm 150 Instructions For Use Manual
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Glow-worm 150 Instructions For Use Manual

Unvented hot water cylinders/ hydracyl for boilers
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Instructions for use
Installation
and Servicing
Unvented Hot Water Cylinders/
Hydracyl
150
205
250
300

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Summary of Contents for Glow-worm 150

  • Page 1 Instructions for use Installation and Servicing Unvented Hot Water Cylinders/ Hydracyl 150 205 250...

  • Page 3: Table Of Contents

    Table of conTenTs In T RoD U cT I o n Instructions guidance ........................5 1.1 Product documentation ..................5 1.2 Associated documents ..................5 1.3 Storage of documents ..................5 1.4 Explanation of symbols ..................5 1.5 Benchmark ......................5 Safety instructions and regulations ....................5 2.1 Intended use ......................5 2.2 General safety information ..................6 2.3 Cylinder safety information ..................6 2.4 Cylinder identification plate .................6 2.5 Regulation and statutory requirements .
  • Page 4 M aI nTe n a n ce Inspection and maintenance ....................... 29 12.1 Maintenance checklist ..................30 12.2 Draining the cylinder ..................30 Fault finding ..........................30 13.1 Taking the cylinder out of service ...............32 Recycling and disposal ....................... 32 14.1 Cylinder disposal ....................32 14.2 Disposal of packaging ..................32 Customer service and manufacturer's warranty ................32 15.1 Glow-worm service ....................32 15.2 Glow-worm warranty ..................32 Spare parts ..........................33 - 4 -...

  • Page 5: Introduction

    Product documentation and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Indus- The instructions are an integral part of the appliance and must be try Council who manage and promote the Scheme. handed to the user on completion of the installation in order to • Visit www.central heating.co.uk for more information. comply with the current regulation. • Carefully read the manual, to understand all the information to enable safe installation, use and servicing. No liability can safety instructions and regulations be accepted in the event of damage for not complying with the guidance in this instruction manual. Intended use associated documents Glow-worm cylinders are constructed using state-of-the-art When installing the cylinder, you must pay attention to the technology in accordance with recognised safety regulations. installation instructions for parts and components of the system. Nevertheless, there is still a risk of injury or death to the user or others or of damage to the unit and other property in the event of These installation instructions are enclosed with the various improper use or use for which the unit is not intended. system parts and supplementary components. You must also observe all operating instructions included with the system Glow-worm cylinders are not intended for use by persons who components. have inadequate experience and/or knowledge, unless they are supervised by a person responsible for their safety or have been given instructions by this person regarding the operation of the storage of documents unit. Children must be supervised to ensure that they do not play...

  • Page 6: General Safety Information

    This product has been assessed and found to comply with the requirements of the Building Regulations for unvented hot water Changes to the supply lines, relief valve termination, and storage systems and must not be altered or modified in any way. expansion relief valve may only be carried out by an engineer In the event of parts replacement, use only genuine spare parts qualified to work on unvented systems. supplied by Glow-worm. The installation is subject to Building Regulation approval. Never shut off the expansion relief valve or relief valve termination. Notify the Local Authority of intention to install. As stipulated in the manual "Handling Operations Regulations 1992", the weight of the unit exceeds that Never bypass any of the security devices.

  • Page 7: Regulations For Great Britian

    Ige/UP1 Soundness testing and purging of industrial and commercial gas installation. lightning protection Ige/UP2 Gas installation pipework, boosters and compressors on enV 61024-1 industrial and commercial premises. Protection of structures against lightning – Part 1: General Ige/UP10 Installation of gas appliances in industrial and principles (IEC 1024-1: 1990; modified) BS 6651: Code of commercial premises. practice for protection of structures against lightning. bs. 6644 Installation of gas fired hot water boilers of rated inputs Regulations for great britain between 60 kW and 2 MW (2nd and 3rd family gases). bs. 5449 Forced circulation hot water central heating systems for 2.6.1 Technical guidance domestic premises. Note: only up to 45 kW. This appliance must only be installed and commissioned by a bs. 6880 Low temperature hot water heating systems of output suitably competent person. Please check with your installer that greater than 45 kW. he is able to carry-out all the necessary works including official Part 1 Fundamental and design considerations. notification of the works to the relevant body upon completion. Part 2 Selection of equipment. 0020115468_03 - 12/11 - Glow-worm - 7 -...

  • Page 8: Introducing Your Appliance

    2.7.3 ce Mark CE labelling shows that the appliance according to the model overview comply with the basic requirements of the applicable directives. The CE declarations of conformity can be viewed at the manufacturer's premises and can be supplied if necessary. Introducing your appliance 1 electric immersion heater 2 safety thermostat appliance description 3 cylinder thermostat The Glow-worm Hydracyl domestic hot water cylinder is available The following are premounted at the factory for the Hydracyl in four sizes: 150, 205, 250, and 300 litres. The cylinders are domestic hot water cylinder: made from stainless steel with EPS insulation. - Cylinder thermostat (3) and reheating circuit safety thermostat The unvented domestic hot water cylinder works with the (2). pressure of the water supply line and does not need a cold water tank for its supply. To enable the cylinder to work as well as - Electric immersion heater (1) with safety thermostat and possible, a cold water supply with an appropriate pressure and cylinder thermostat. flow rate is required. 3.1.1 safety devices...

  • Page 9: Read Carefully Before Using

    For information on making settings, see the operating manual for components. the controller. Always make sure that there is clear access to the cylinder to enable the use of the hot water thermostat controller and the thermostat mixer. 0020115468_03 - 12/11 - Glow-worm - 9 -...

  • Page 10: Switching Off Hot Water

    (e.g. during a winter holiday), the cylinder must be completely drained. - Contact an engineer qualified to work on unvented systems to drain the cylinder. If you are absent during a relatively long period when there is a risk of frost, make sure that you leave the central heating on and that the temperature in the cylinder room and in all other rooms are kept above freezing. 0020115468_03 - 12/11 - Glow-worm - 10 -...

  • Page 11: Fault Finding

    - Never attempt to perform maintenance work or repairs on the cylinder yourself. - Always employ an engineer qualified to work on unvented systems. 0020115468_03 - 12/11 - Glow-worm - 11 -...

  • Page 12: Technical Data

    TECHNICAL DATA TecHnIcal DaTa Technical data Unit Hydracyl 150 Hydracyl 205 Hydracyl 250 Hydracyl 300 Total capacity Actual capacity 149.1 211.2 250.3 299.1 Hot water capacity 136.7 203.9 247.5 270.5 Maximum supply pressure to pressure reducing valve Maximum operating pressure of cylinder Maximum operating pressure of heating coil Operating pressure Pressure limiting valve Expansion relief valve Temperature and pressure relief valve C/bar 90/7.0 Charge pressure of hot water expansion vessel Maximum temperature of heating circuit Maximum temperature of potable hot water Standing heat loss kW/24 h 1.61 1.98 2.17 2.37 Heating up time according to EN 12897...

  • Page 13: Installation

    Heating circuit flow 2.2 cylinder dual thermostat cold water supply electrical supply + protection (This must have it's own single Domestic hot water outlet isolation) cH & DHW time controller electrical switch Terminal block Room thermostat Heating circuit 0020115468_03 - 12/11 - Glow-worm - 13 -...
  • Page 14 Heating circuit flow 2.2 cylinder dual thermostat cold water supply electrical supply + protection (This must have it's own single Domestic hot water outlet isolation) cH & DHW time controller electrical switch Terminal block Room thermostat 0020115468_03 - 12/11 - Glow-worm - 14 -...
  • Page 15 + protection (This must have it's own single cold water supply isolation) Domestic hot water outlet electrical switch smart Wiring centre climapro Heating circuit DHW 2 port valve cH 2 port valve 10 nTc sensor 0020115468_03 - 12/11 - Glow-worm - 15 -...
  • Page 16 + protection (This must have it's own single isolation) electrical switch smart Wiring centre climapro Rf room thermostat Heating circuit DHW 2 port valve cH 2 port valve 10 nTc sensor 11 Rf receiver 0020115468_03 - 12/11 - Glow-worm - 16 -...
  • Page 17 Motorized 2 port valve zone 3 Heating circuit flow electrical switch cold water supply Domestic hot water cylinder Domestic hot water outlet 8.2 Immersion heater with thermal safety Room thermostat Rf zone 2 10 DHW 2 port valve 0020115468_03 - 12/11 - Glow-worm - 17 -...
  • Page 18 Motorized 2 port valve zone 3 Heating circuit flow electrical switch cold water supply Domestic hot water cylinder Domestic hot water outlet 8.1 Immersion heater with thermal safety 8.2 cylinder dual thermostat Room thermostat Rf zone 2 0020115468_03 - 12/11 - Glow-worm - 18 -...

  • Page 19: Description Of The Components

    17 2 port motorised valve 18 2-pole circuit breaker for electric immersion heater 19 electric immersion heater (20 °c to 65 °c) with thermostat and safety thermostat 20 Temperature and pressure relief valve (90 °c, 7 bar) 0020115468_03 - 12/11 - Glow-worm - 19 -...
  • Page 20 The cylinder is supplied along with all required cold and hot water control devices and a 2-way motorised valve. The cylinder works with the pressure of the water supply line and does not need a cold water tank for its supply. The cylinder has hot and cold water connections with a diameter of 22 mm. To enable the cylinder to work as well as possible, a cold water supply with an appropriately high pressure and flow rate is required. Typical applications: • Single bathroom property: Hydracyl 150 litre • Single bathroom property with an en-suite shower room: Hydracyl 150 litre • Two bathroom property: Hydracyl 150 or 205 litre • Two bathroom property with an en-suite shower room: Hydracyl 205 litre • Larger properties: Hydracyl 250 or 300 litre Key: 8.2.1 safety devices electric immersion heater cover cover cap for reset button for reheating circuit Tco...
  • Page 21 Always replace Climapro or Climapro RF. the immersion heater gasket whem parts are replaced. If weather compensation is required, the Climapro or Climapro RF Only use original replacement parts from Glow-worm. can be used with a Glow-worm outdoor sensor. If you are using a non-eBUS-capable Glow-worm gas-fired boiler Inspection access to the cylinder is available through or a third-party boiler, you can use room thermostats commonly the immersion heater boss.
  • Page 22 Temperature and pressure relief valve circulation line connection gas-fired boiler supply line electric immersion heater Primary heater immersion sleeve cold water inlet Primary heater return Hydracyl 1229 1197 1631 1599 1341 1158 1881 1849 1591 1346 2191 2159 1901 1578 0020115468_03 - 12/11 - Glow-worm - 22 -...

  • Page 23: Assembly

    This valve allows air to enter the cylinder if the and hot water expansion vessel) pressure becomes too low due to draining or thermal 2-way motorised valve contraction. 15mm compression cap for secondary return Tundish Assembly set for hot water expansion vessel Hot water expansion vessel: 12 l for Hydracyl 150 18 l for Hydracyl 205 25 l for Hydracyl 250 and 300 Installation and maintenance instructions, operating manual - Check the pack contents for completeness. cylinder transportation - At least two people should lift the cylinder to prevent injuries.

  • Page 24: Installation Of Discharge Pipe

    As the actual length is 7 m, a 28 mm (D2) copper pipe will be satisfactory. The discharge connections of the temperature/pressure relief valve and the expansion relief valve must be connected with A suitable place for the end of the discharge pipe is, for the supplied tundish via 15 mm copper piping. The tundish example, beneath a fixed grille above the odour seal in a gully should be attached so that it is vertical, as near to the cylinder with a siphon. Low discharge pipes, for example up to 100 mm as possible, and not more than 600 mm from the connection above external surfaces such as car and other parking spaces, of the temperature/ pressure relief valve. It must be mounted grasslands etc. can be used provided that they are secured by a in the same room as the cylinder at a sufficient distance from wire fence or something similar to prevent children from coming the electrical components. The discharge pipes from the into contact with the waste water and as long as the system is temperature/pressure relief valve and expansion relief valve can not visible. You must not install any valves or stop cocks in the be joined above the tundish using a T-piece. discharge pipe. The discharge pipe from the 22 mm connection of the drain • Make sure that the discharge pipe from the tundish to the funnel must be laid using copper piping with a diameter of at drain has a constant downward incline of at least 1:200. The least 22 mm to a safe and visible discharge point. discharge pipe from the pressure relief valve of the Glow-worm gas-fired boiler can be connected to the horizontal discharge There must be a vertical section of pipe at least 300 mm long pipe of the cylinder behind the tundish using a T-piece. beneath the tundish before any bends or elbows in the pipework. If the total resistance of the discharge pipe exceeds the values specified in table below, you must increase the diameter of the piping. When installing the discharge piping, you must observe Directive G3 (section 2.5). 0020115468_03 - 12/11 - Glow-worm - 24 -...

  • Page 25: 10 Cylinder Installation

    • Make sure that the pipes in the reheating circuit between the expansion vessel may be required. gas-fired boiler and cylinder are as short as possible. Use copper piping with a minimum diameter of 22 mm. If the installation of a secondary circulation line is required, keep circulation operations to a minimum by only using circulation If you are using the cylinder as per GB standards with a gas-fired mode when required for demand and temperature reasons. boiler without a heating pump, you may have to install a suitable heating pump in the reheating circuit. The cylinder has a connection with a 15 mm diameter for a secondary circulation line. 10.1.1 2-way motorised valve • Connect a WRAS-approved circulation pump (4) with a non- return valve to the circulation connection. • Connect the circulation line (3) to the hot water pipe (2). The 2-way motorised valve prevents the cylinder from overheating. • Install the 2-way motorised valve (1) supplied with the cylinder in the supply line of the gas-fired boiler. Do not install the valve with the head upside down 0020115468_03 - 12/11 - Glow-worm - 25 -...

  • Page 26: Installation Of Cold Water Pipe

    When the discharge pipes are connected, the expansion relief - Make sure that there is no stop valve installed valve may not be more than 600 mm away from the temperature/ between the safety assembly and the cylinder. pressure relief valve. 10.3.3 safety assembly 10.3.4 Mounting the expansion vessel The Glow-worm domestic hot water cylinder is delivered with an external expansion vessel. Connect this expansion vessel to the installed safety assembly as follows: • Connect the expansion vessel with the safety assembly via a copper pipe or suitable hose line. Make sure the expansion vessel is supported sufficiently. • Use the supplied wall bracket if you want to mount the expansion vessel to a wall. • If necessary, establish the connection to the cold water connection (3) with pressure compensation of the safety assembly.

  • Page 27: Electrical Installation

    230 V supply lines and bus cables must be laid separately above lengths of 10 m. The discharge pipes of the tundish, drain valves, and motorised valves etc. must be laid at a distance from electrical components. 10.4.1 Wiring Wiring can be accommodated via the Glow-worm Smart Wiring Centre or Systempro as a system solution. This enables Glow- worm dual-channel eBUS controllers (low-voltage) to be used along with 230 V valves to give control of Hot Water and Heating systems. Alternatively, a standard 230 V cabling box and controls can be used. Smart Wiring Centre will accomodate 1 CH plus 1 DHW zone. Systempro will accomodate up to 3 CH zones plus 1 DHW zone.

  • Page 28: 11 Commissioning

    (n) outer conductor terminal (l) • Close all of the draw-off points. electric immersion heater • Check the system for leaks. In particular, check the installed Without earthing, life-threatening voltage can reach electric immersion heater for leaks. the piping and water draw-off points. • Open two hot water draw-off points, one at the lowest point - Earth the cylinder. and one at the highest point of the pipe system, and allow water to run for at least 5 minutes. 0020115468_03 - 12/11 - Glow-worm - 28 -...

  • Page 29: Filling Out The Cylinder Commissioning Checklist

    We recommend the cylinder is set to 60 °C periodically, to provide protection against the proliferation of harmful bacteria. To ensure lasting operational safety, reliability, and a long life, the cylinder must be regularly inspected/maintained by an • Place the gas-fired boiler into operation until the cylinder engineer qualified to work on unvented systems. reaches the operating temperature and all radiators in the system are hot. The operational reliability of the cylinder may be impaired and material damage and personal injuries may result if the • Then drain the entire central heating system again to remove inspection and maintenance work is not carried out. any residue from the pipes. The essential maintenance work on the cylinder and the • Fill and bleed the central heating system again as described in corresponding maintenance intervals are specified in the table the installation manual of the gas-fired boiler. below. Inspection access to the cylinder is available through the immersion heater boss. After servicing, the servicing engineer must complete the relevant Service Interval Record section of the Benchmark Checklist located on the inside back pages of this document. 0020115468_03 - 12/11 - Glow-worm - 29 -...

  • Page 30: Maintenance Checklist

    - Malfunctions may only be rectified by an engineer qualified to work on unvented systems. Not all electric immersion heaters have a safety thermostat. - Only use Glow-worm electric immersion heaters with a safety thermostat as replacement parts. 0020115468_03 - 12/11 - Glow-worm - 30 -...
  • Page 31 MAINTENANCE When replacing parts, only use original replacement parts from Glow-worm. We recommend that the operator enter into a maintenance agreement. Malfunction cause solution cylinder The cylinder cools down at night. One-pipe circulation in the case of short Install an anti-siphon valve (as close as possible tube networks with low pressure loss. to the cylinder). Reheating is not working. The Gas-fired boiler 1. Air in the reheating heat exchanger Vent the reheating heat exchanger. runs for a short time, goes off and then back on again. This is repeated until the cylinder is at its 2. The cold and hot water connections Compare the data provided by the boiler target temperature. on the cylinder have been mixed up. manufacturer with the data for the cylinder. It may be possible to solve the problem by setting a higher flow temperature on the gas-fired boiler. 2. Hot water thermostat mixer set too low. Increase the setting. 3. Heating insufficient; gas-fired boiler does not Check whether the gas-fired boiler is working. reheat.

  • Page 32: Taking The Cylinder Out Of Service

    13.2 Temporarily taking the cylinder out of service 15.1 glow-worm service Risk of damage as a result of the cylinder freezing! Frost protection and monitoring devices are only To ensure regular servicing, it is strongly recommended that active while the boiler is connected up to the power arrangements are made for a Maintenance Agreement. Please...

  • Page 33: 16 Spare Parts

    MAINTENANCE 16 spare parts Key no. Part no. Description 0020010155 Tundish 0020010154 Temperature and pressure relief valve 0020012035 Hot water expansion vessel assembly 12ltr 0020012036 Hot water expansion vessel assembly 18ltr 0020012037 Hot water expansion vessel assembly 25ltr 0020127614 Cylinder thermostat 0020127613 Immersion heater seal 0020127611 Immersion heater 0020127609 Safety assembly 0020127610 Pressure relief valve 0020127608 2-way motorised valve 0020115468_03 - 12/11 - Glow-worm - 33 -...
  • Page 34 A installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme. A Building Regulations Compliance Certificate will then be issued to the customer. 0020115468_03 - 12/11 - Glow-worm - 34 - ©Heating and Hotwater Industry Council (HHIC)

  • Page 35: Service Record

    Engineer Name Company Name Company Name Telephone Number Telephone Number Comments Comments Signature Signature SERVICE 9 SERVICE 10 Date Date Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number Comments Comments Signature Signature 0020115468_03 - 12/11 - Glow-worm - 35 -...
  • Page 36 Nottingham Road, Because of our constant endeavour for Belper, Derbyshire. improvement, details may vary slightly DE56 1JT from those shown in these instructions. www.glow-worm.co.uk...

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