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
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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
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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.
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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
ON ROOF PACKHORIZONTAL 2
PANEL0020078868 ON ROOF PACK
HORIZONTAL 3PANEL
0020078869
ON ROOF PACKVERTICAL 1
PANEL0020078855 ON ROOF PACK
VERTICAL 2PANEL
0020078856 ON ROOF PACKVERTICAL 3
PANEL0020078857
HORIZONTAL ORVERTICAL
ROOF TYPEONTILE
CYLINDERSELECTION
ONON ROOF PACKHORIZONTAL 1
PANEL0020078864
ON ROOF PACKVERTICAL 1
PANEL0020078852
ON ROOF PACKVERTICAL 2
PANEL0020078853
ON ROOF PACKVERTICAL 3
PANEL0020078854
ON ROOF PACKHORIZONTAL 2
PANEL0020078865 ON ROOF PACK
HORIZONTAL 3PANEL
0020078866
SOLAR EQUIPMENT SELECTOR
SOLAR EQUIPMENT SELECTOR
HORIZONTAL ORVERTICAL
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SOLAR EQUIPMENT SELECTOR
Solar system selector guide
ROOF TYPEIN
CYLINDERSELECTION
IN
IN ROOF PACKHORIZONTAL 1
PANEL0020078870
IN ROOF PACKHORIZONTAL 2
PANEL0020078871
IN ROOF PACKHORIZONTAL 3
PANEL0020078872
IN ROOF PACKVERTICAL 1
PANEL0020078858 IN ROOF PACK
VERTICAL 2PANEL
0020078859 IN ROOF PACKVERTICAL 3
PANEL0020078860
HORIZONTAL ORVERTICAL
A-FRAME
CYLINDERSELECTION
A-FRAME
A FRAME PACKHORIZONTAL 1
PANEL0020078873
A FRAME PACKVERTICAL 1
PANEL0020078861
A FRAME PACKVERTICAL 2
PANEL0020078862
A FRAME PACKVERTICAL 3
PANEL0020078863
HORIZONTAL ORVERTICAL
A FRAME PACKHORIZONTAL 2
PANEL0020078874
A FRAME PACKHORIZONTAL 3
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
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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
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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
Panel Pack Options: Part No. 1 Panel Pack
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
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
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Straightforward ordering INSTALLER Step 1
Straightforward ordering INSTALLER Step 1
Panel Pack Options: Part No. 1 Panel Pack
2 Panel Pack
3 Panel Pack
Tile packs: Vertical 0020078852 0020078853 0020078854
This pack contains
Vertical Flat Plate collector 0010006294 1 2 3
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
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
Panel Pack Options: Part No. 1 Panel Pack
2 Panel Pack
3 Panel Pack
A-Frame packs: Vertical 0020078861 0020078862 0020078863
This pack contains
Vertical Flat Plate collector 0010006294 1 2 3
A-frame vertical installation
0020060312 2 3 4
Mounting bar set Vertical 0020060308 1 2 3
Easy fi t Hydraulic connection-set
0020060207 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
Panel Pack Options: Part No. 1 Panel Pack
2 Panel Pack
3 Panel Pack
A-Frame packs: Horizontal 0020078873 0020078874 0020078875
This pack contains
Horizontal Flat Plate collector
0010006295 1 2 3
A-frame horizontal installation
0020060311 2 3 4
Mounting bar set Horizontal
0020060307 1 2 3
Easy fi t Hydraulic connection-set
0020060207 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 profi led tile packs
Step 1: Horizontal profi led tile packs
Panel Pack Options: Part No. 1 Panel Pack
2 Panel Pack
3 Panel Pack
Tile packs: Horizontal 0020078864 0020078865 0020078866
This pack contains
Horizontal Flat Plate collector
0010006295 1 2 3
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 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 A-frame packs
Step 1: Horizontal A-frame packs
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Straightforward ordering DEVELOPER Step 1
Straightforward orderingINSTALLER & DEVELOPER Step 2&3
Panel Pack Options: Part No. 1 Panel Pack
2 Panel Pack
3 Panel Pack
Developer pack A: Vertical 0020078876 0020078877 0020078878
This pack contains
Vertical Flat Plate collector 0010006294 1 2 3
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
Easy fi t Hydraulic connection-set
0020065271 1 1 1
Easy fi t Hydraulic extension-set
0020059909 1 2
Clearly Solar controller 0020054960 1 1 1
Pack Options: Part No.Flurocyl₂ Pack Codes
This pack contains Article No.
Flurocyl₂ Cylinder 200 l 0010010915
Flurocyl₂ Cylinder 250 l 0010010916
Flurocyl₂ Cylinder 300 l 0010010917
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
Panel Pack Options: Part No. 1 Panel Pack
2 Panel Pack
3 Panel Pack
Developer pack B 0020078882 0020080375 0020080376
This pack contains
Clearly Solar pump station 0020129143 1 1 1
Expansion vessel 18 l 0020054963 1
Expansion vessel 25 l 0020054992 1
Expansion vessel 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 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
Panel Pack Options: Part No. 1 Panel Pack
2 Panel Pack
3 Panel Pack
Developer pack A: Horizontal 0020078879 0020078880 0020078881
This pack contains
Horizontal Flat Plate collector
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
Easy fi t Hydraulic connection-set
0020065271 1 1 1
Easy fi t Hydraulic extension-set
0020059909 1 2
Clearly Solar controller 0020054960 1 1 1
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
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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
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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.
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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
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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
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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
Part Description Qty
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
Part Description Qty
6 Piping coupling 2
7 Securing clip 4
Hydraulic extension kit
Hydraulic connection kit
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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
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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
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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
thermostat with programmer
2 port valve 2 port valve
3.5
Third party -Room
thermostat with programmer
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
2 port valve 2 port valve
3.7Wired -
Glow-worm eBus room thermostat
3.8Wired -
Glow-worm eBus room thermostat
Wiring using only NTC sensors
3.9Wired -
Glow-worm eBus room thermostat
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
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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
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37
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 Expansion 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 3.4
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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
7 Domestic hot water cylinder 19 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
Solar control, terminal block, third partyRoom thermostat with programmer, 3 port valve wiring though a cylinder stat
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1 Boiler 13 NTC sensor pocket (TAC 1)
2 Solar gain NTC 14 Smart Wiring Centre
3 Solar collector 15 NTC sensor pocket (TAC 2)
4 Collector NTC (Black cable) 16 Heating circuit
5 Solar expansion & protection vessel 17 DHW 2 port zone valve
6 Solar pump station 18 CH 2 port zone valve
7 Domestic hot water cylinder 19 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 Systempro F Cylinder circuit return
11 Room thermostat (Ebus) G Solar circuit return
12 Electrical switch H Solar circuit flow
Solar Control, Smart Wiring Centre, WiredGlow-worm Ebus room thermostat, 2x2 port valves, wiring through a cylinder stat
diagram 3.6
42
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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
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 Systempro F Cylinder circuit return
11 Room thermostat RF (Ebus) G Solar circuit return
12 Electrical switch H Solar circuit flow
13 NTC sensor pocket (TAC 1)
Solar Control, Smart Wiring Centre, WirelessGlow-worm Ebus room thermostat, 2x2 port valves, wiring through a cylinder stat
diagram 3.7
44
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45
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 A Boiler circuit return
7.1 Immersion heater with thermal safety B Boiler circuit flow
7.2 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 Systempro F Cylinder circuit return
11 Room thermostat (Ebus) G Solar circuit return
12 Electrical switch H Solar circuit flow
13 NTC sensor pocket (TAC 1)
Solar Control, Smart Wiring Centre, WirelessGlow-worm Ebus room thermostat, 2x2 port valves, wiring using only NTC sensors
diagram 3.8
46
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47
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
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
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49
1 Solar gain NTC 10 NTC sensor pocket (TAC 1)
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
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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
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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)
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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