gledhill StainlessLite D120 User guide

Design, Installation & Servicing Instructions
Models covered in this manual
Stainless Lite Direct 90-400 litres
Stainless Lite Indirect 90-400 litres
Stainless Lite Solar Direct 180-400 litres
Stainless Lite Solar Indirect 180-400 litres
Stainless Lite Slimline Direct 60-210 litres
Stainless Lite Slimline Indirect 60-210 litres
StainlessLite
Unvented mains pressure water storage in Duplex stainless steel

Page 2
Section Page
DESIGN
Description 3
Technical Information 6
System Design 10
INSTALLATION
Installation 12
Commissioning 22
USER INSTRUCTIONS 23
SERVICING AND MAINTENANCE
Servicing and Maintenance 24
Fault Finding 25
Short Parts List 28
APPENDIX
Appendix A 29
Appendix B 30
Notes 31
Terms & Conditions 32
Benchmark Checklist 34
Benchmark Service Record 35
ISSUE 23: MARCH 2016
These instructions should be read in conjunction with the installation/servicing
instructions issued by the manufacturer of the heat source being used.
Any installation must be in accordance with the relevant requirements of the Gas
Safety Regulations, Building Regulations, I.E.E.Wiring Regulations and theWater Fitting
Regulations (England and Wales) or Water Byelaws (Scotland). It should be read in
accordance with the relevant recommendations of the following:
BS 6798; BS EN 12828, BS EN 12831, BS EN 14336; BS 5546;
BS 5440:1; BS 5440:2; CP 331:3
BS EN 806-1 to 5, BS EN 8558:2011: BS EN 1458-1:2011 and BS 7593:2006
Stainless Lite is covered by Section G3 of the Building Regulations (England andWales)
Technical Standard P3 (Scotland) and Building Regulation P5 (Northern Ireland).
Compliance can be achieved via a Competent Person Self Certication Scheme or
noticaton of installation to the Local Authority Building Control Department.
It must be installed by a competent person as dened by the relevant regulations.
Manufacturers notes must NOT be taken as over-riding statutory obligations.
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge unless
they have been given supervision or instruction concerning use of the appliance by
a person responsible for their safety. Children should be supervised at all times to
ensure they do not play with the appliance.
This information is provided to assist generally in the selection of equipment.
Responsibility for selection and specication of our equipment must however remain
that of our customer and any experts or consultants concerned with the installation(s).
Please note: that we do not therefore accept any responsibility for matters of
design selection or specication, for the eectiveness of an installation or system
containing one of our products unless specically requested to do so in writing.
All goods are sold subject to our Conditions of Sale which are set out at the rear of this
specication. In the interest of continuously improving the Stainless Lite range, Gledhill
Building Products Limited reserve the right to modify the product without notice, and
in these circumstances this booklet, which is accurate at the time of printing, should
be disregarded. An updated set of Instructions will be produced and supplied with
new appliances and will be made available for other appliances on request.
Stainless Lite is produced under an ISO 9001:2008 Quality Management System
approved by BSI.
Benchmark places responsibilities on both manufacturers and installers.The purpose is to
ensure that customers are provided with the correct equipment for their needs, that it is
installed, commissioned and serviced in accordance with the manufacturers instructions
by competent persons and that it meets the requirements of the appropriate Building
Regulations. The Benchmark Checklist can be used to demonstrate compliance with
Building Regulations and should be provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work
in accordance with the Benchmark Code of Practice which is available from the
Heating and Hot Water Industry Council who manage and promote the Scheme.
Visit www.centralheating.co.uk for more information.
For further information on the HWA Charter Statement, please refer to the HWA website
hotwater.org.uk.

Page 3
Maintenance
Modifications should not be made to this
product. Replacement parts, including
immersion heaters, should be purchased from
Gledhill Building Products Limited, or agents
approved by them. Unvented hot water storage
vessels need regular routine checks, and these
are detailed below. It is for this reason that this
manual must always be left with the Stainless
Lite.
It is essential that these checks be carried out
at the time of boiler maintenance by a qualied
installer:
1. Manually open the relief valves in turn, and
check that water is discharged from the
valves and runs freely through the tundish
and out at the discharge point. Ensure that
the valves re-seat satisfactorily. (Note - the
water may be very hot).
2. It is important to check that the discharge
pipework is carrying the water away
adequately. Check for blockages etc. if it is
not.
3. Turn the mains water o and remove and
clean the strainer element in the Pressure
Reducing Valve.
4. Check the charge pressure in the expansion
vessel and repressurise if required
5. Re-ll the system and ensure that all relief
valves have re-seated.
6. The Benchmark Service Record should be
updated at each service.
7. Check the water pressure downstream of the
combination valve is 3 bar in static condition.
8. Check and if necessary, descale the heat
exchanger in hard water areas ie. above
200ppm (mg/l).
Note:
The cylinder is factory fitted with a lift up
temperature & pressure relief valve that must
not be used for any other purpose or removed.
The cylinder is factory tted with immersion
heaters with thermal cut outs. Immersions
without thermal cut outs must not be tted.
Manufacturer: Gledhill Building Products Ltd
Maximum inlet pressure to
Pressure reducing valve 12 bar
Operating pressure (PRV setting) 3 bar
Expansion vessel charge pressure 3 bar
Expansion relief valve setting 4.5 bar
Opening pressure of P & T Relief Valve 6 bar
Opening temperature of P & T Relief Valve 92-95°C
Energy cut-out thermostat setting 85°C
Max. working pressure - Primary heat exchanger (Indirect models) 6 bar
Max. working pressure - Solar heat exchanger (Solar models) 10 bar
Immersion heater rating 3kW, 240V AC
All cylinders are manufactured in accordance with the requirements of BS EN 12897
The tundish must be positioned so that it is visible to the occupant and is away from
electrical devices.
Components supplied with Stainless Lite:
• Cold water inlet PRV combination valve/expansion relief
• Lift up pressure and temperature relief valve
• Control thermostat
• Energy cut-out thermostat
• Energy cut-out motorised valve (indirects only)
• Tundish
• 3kW Immersion heater including control and cut out thermostats
• Expansion vessel/mounting bracket/exible hose
• Technical/user product literature
(Note: Please refer to tables 1 and 2 on pages 6-9 to conrm the quantity of immersion
heaters supplied with the unit)
In any situation where the volume of heated pipework (eg. secondary circulation
pipes or manifold pipework for multiple units) exceeds 10 litres, then an
additional expansion vessel must be tted to accommodate the extra expansion
volume.
Handling Before Installation
Stainless Lite must be handled with care and stored the correct way up in a dry place.
Any manual handling/lifting operations will need to comply with the requirements
of the Manual Handling Operations Regulations issued by the H.S.E. The appliance
can be moved using a sack truck on the rear face although care should be taken and
the route should be even. In apartment buildings containing a number of storeys we
would recommend that the appliances are moved vertically in a mechanical lift. If it is
proposed to use a crane, expert advice should be obtained regarding the need for
slings, lifting beams etc.
A specic manual handling assessment is shown in Appendix B at the rear of this
manual.
The Environment
This product has been manufactured using many recyclable materials, including the
approved HCFC/CFC free polyurethane foam insulation. At the end of its useful life, it
should be disposed of at a Local Authority Recycling Centre, to maximise the products
full environmental benets.
DESIGN
DESCRIPTION

Page 4
Stainless Lite is a range of unvented hot water
storage cylinders, manufactured in the latest
high quality duplex stainless steel. They are
designed to provide mains pressure hot water
and are supplied as a package which complies
with Section G3 of the Building Regulations.
The appliance is extremely well insulated using
high density HCFC free foam insulation with an
ozone depleting potential (ODP) of zero and a
global warming potential (GWP) of 1. It is tted
with all necessary safety devices and supplied
with all the necessary control devices to make
installation on site as easy as possible.
Stainless Lite is available in four basic
variants:
1. Stainless Lite Direct - For providing hot
water heated by electricity (Figure 1).
2. Stainless Lite Indirect - For use with gas
or oil boilers (Figure 2). Unvented cylinders
must not be used with solid fuel boilers or
steam as the energy source.
3. Stainless Lite Direct Solar - For providing
hot water by solar gains and electricity.
(Figure 3).
4. Stainless Lite Indirect Solar - For providing
hot water by solar gains and gas or oil boilers
(Figure 4). Unvented cylinders must not be
used with solid fuel boilers or steam as the
energy source.
Stainless Lite Direct
Stainless Lite direct is an electrically heated,
unvented hot water storage cylinder designed
primarily for use with off peak electrical
supplies.
It is supplied tted with two 3kW immersion
heaters which are BEAB approved for safety as
recommended by the Electricity Council.
Stainless Lite direct models are listed in
Table 1 on Page 6 & 7.
Stainless Lite Indirect
Stainless Lite indirect is an unvented hot
water storage cylinder and is provided with a
high eciency internal primary coil which is
designed for use with a gas or oil boiler and
is suitable for both open vented and sealed
pumped primary systems.
When used with a sealed heating system the
boiler must incorporate its own energy cut-out
overheat thermostat.
Stainless Lite indirect models are listed in
Table 2 on Page 8 & 9.
Stainless Lite
DIRECT
Stainless Lite
INDIRECT
Figure 1 Figure 2
Pipework is not supplied by manufacturer,
but to be supplied and tted by installer.
DESIGN
DESCRIPTION

Page 5
Stainless Lite
DIRECT SOLAR
Stainless Lite
INDIRECT SOLAR
Figure 3 Figure 4
Pipework is not supplied by manufacturer,
but to be supplied and tted by installer.
Stainless Lite Direct Solar
Stainless Lite direct is an electrically heated,
unvented hot water storage cylinder designed
primarily for use with off peak electrical
supplies.
It is supplied tted with two 3kW immersion
heaters which are BEAB approved for safety as
recommended by the Electricity Council.
A high eciency coil is positioned in the lower
part of the Stainless Lite vessel to ensure
maximum benet of solar gain energy.
Stainless Lite direct models are listed in
Table 1 on Page 6 & 7.
Stainless Lite Indirect Solar
Stainless Lite indirect is an unvented hot
water storage cylinder and is provided with a
high eciency internal primary coil which is
designed for use with a gas or oil boiler and
is suitable for both open vented and sealed
pumped primary systems.
When used with a sealed heating system the
boiler must incorporate its own energy cut-out
overheat thermostat.
A high eciency second solar coil is positioned
below the primary coil to ensure maximum
benet of solar gain energy.
Stainless Lite indirect models are listed in
Table 2 on Page 8 & 9.
Note:
The cold supply elbow c/w drain tapping
must be tted as shown in gs 1, 2, 3 and
4. A exible hose can then be connected to
the drain tapping and, providing the hose
runs below the lowest level of the cylinder,
then all the water contents can be drained
out by syphonic action. (The cold feed pipe
dips internally to the base of the cylinder.)
DESIGN
DESCRIPTION

Page 6
Table 1 - Direct Models
Model
Stock Code
Load Prole
Energy Eciency Class
Heat Loss
Energy Eciency %
Annual Consumption
Other Load Prole
Thermostat
Temperature Setting
Sound Power Level
O-Peak Available
Capacity (Total Volume)
Weight - Empty
Weight - Full
Pressure Regulator 3 bar inlet group c/w balance
cold supply, expansion vessel connection and
expansion valve set at 4.5 bar
Expansion Vessel size.
Pre-charged to 3 bar
Overall Height
Overall Diameter
Pressure & Temperature
Relief Valve 6bar 95°C
22mm Secondary
Return Tapping
On Peak Immersion
Heater - High Level
Cold Feed 22mm
Compression Connection
O Peak Immersion
Heater - Low Level
Volume of On Peak Water
Heated
22mm Solar Return
Compression Connection
22mm Solar Flow
Compression Connection
Dual Control & Overheat Stat
Solar Pocket Solar Pocket
Second O Peak Immersion
Heater - Low Level
Surface Area of
Solar Heater Coil
Pressure Loss Across Solar Heater
Coil
Heat Up Time from 15°C to 60°C
(applies to Primary Heat Source only)
Dedicated Solar Volume
Watts % kWh °C db Litres kg kg bar
Litres A=mm mm B=mm C=mm D=mm E=mm F=mm Litres K=mm L=mm M=mm N=mm P=mm R=mm m2bar min Litres
Direct
D90 ASL0001 M D 35 36 2320 - 62 15 Y 90 13 103 3
12 745 550 490 n/a n/a 367 223 n/a n/a n/a n/a n/a n/a n/a n/a n/a 90 n/a
D120 ASL0005 M D 44 35 2366 - 62 15 Y 120 18 138 3
12 930 550 678 n/a 487 367 223 55 n/a n/a n/a n/a n/a n/a n/a n/a 119 n/a
D150 ASL0010 L D 51 37 4522 M 62 15 Y 150 22 172 3
18 1120 550 865 n/a 587 442 223 70 n/a n/a n/a n/a n/a n/a n/a n/a 150 n/a
D180 ASL0015 L D 54 36 4537 M 62 15 Y 180 24 204 3
18 1305 550 1053 n/a 686 442 223 85 n/a n/a n/a n/a n/a n/a n/a n/a 179 n/a
D210 ASL0020 XL D 65 37 6939 L/M 62 15 Y 210 28 238 3
24 1495 550 1241 1127 786 442 223 90 n/a n/a n/a n/a n/a n/a n/a n/a 209 n/a
D250 ASL0025 XL D 75 37 6990 L/M 62 15 Y 250 32 282 3
24 1745 550 1491 1377 927 522 223 125 n/a n/a n/a n/a n/a n/a n/a n/a 249 n/a
D300 ASL0030 XL D 85 36 7042 L/M 62 15 Y 300 37 337 3
35 1992 550 1720 1577 1077 522 223 155 n/a n/a n/a n/a n/a n/a n/a n/a 299 n/a
D400 ASL0031 XL D 118 36 7213 L/M 62 15 Y 400 48 448 3
2 x 24 2030 630 1784 1592 1181 457 238 180 n/a n/a n/a n/a n/a 338 n/a n/a 398/198 n/a
Direct Slimline
D60-SL ASL475D60 M D 40 35 2341 - 62 15 Y 60 13 73 3
12 705 475 462 n/a n/a 348 197 n/a n/a n/a n/a n/a n/a n/a n/a n/a 60 n/a
D90-SL ASL475D90 M D 52 34 2407 - 62 15 Y 90 16 106 3
12 978 475 734 n/a n/a 348 197 n/a n/a n/a n/a n/a n/a n/a n/a n/a 90 n/a
D120-SL ASL475D120 L D 59 36 4561 M 62 15 Y 120 22 142 3
12 1250 475 1006 n/a 650 348 197 55 n/a n/a n/a n/a n/a n/a n/a n/a 119 n/a
D150-SL ASL475D150 L D 68 36 4609 M 62 15 Y 150 30 180 3
18 1520 475 1278 n/a 785 423 197 70 n/a n/a n/a n/a n/a n/a n/a n/a 150 n/a
D180-SL ASL475D180 L D 76 37 4522 M 62 15 Y 180 31 211 3
18 1790 475 1548 n/a 921 423 197 85 n/a n/a n/a n/a n/a n/a n/a n/a 179 n/a
D210-SL ASL475D210 XL D 84 36 7036 L/M 62 15 Y 210 32 242 3
24 1970 475 1706 1540 1147 503 197 90 n/a n/a n/a n/a n/a n/a n/a n/a 209 n/a
Solar Direct
SOL180d ASL0070 n/a B 54 n/a n/a n/a n/a n/a n/a 180 26 206 3
18 1305 550 1053 n/a 746 437 482 75 223 352 419 882 203 n/a 0.680 0.191 n/a 60
SOL210d ASL0075 n/a C 65 n/a n/a n/a n/a n/a n/a 210 30 240 3
24 1495 550 1241 1127 908 437 544 80 223 352 419 1000 203 n/a 0.680 0.191 n/a 70
SOL250d ASL0080 n/a C 75 n/a n/a n/a n/a n/a n/a 250 34 284 3
24 1745 550 1491 1377 1092 522 629 100 223 472 539 1180 262 n/a 0.970 0.241 n/a 84
SOL300d ASL0085 n/a C 85 n/a n/a n/a n/a n/a n/a 300 39 339 3
35 1992 550 1720 1577 1287 522 724 115 223 472 539 1367 262 n/a 0.970 0.241 n/a 100
SOL400d ASL0086 n/a D 118 n/a n/a n/a n/a n/a n/a 400 49 449 3
2 x 24 2030 630 1784 1592 1296 557 691 140 238 548 651 1383 334 n/a 1.270 0.310 n/a 150
Solar Direct Slimline
SOL 180d-SL ASL475D180SOL n/a C 51 n/a n/a n/a n/a n/a n/a 180 32 212 3
18 1790 475 1548 n/a 1090 423 640 75 179 329 678 1263 243 n/a 0.680 0.191 n/a 60
SOL 210d-SL ASL475D210SOL n/a C 84 n/a n/a n/a n/a n/a n/a 210 36 246 3
24 1970 475 1706 1540 1190 503 730 80 179 409 778 1363 273 n/a 0.680 0.191 n/a 70
A
C
Direct
D
F
E
B
R
A
Solar Direct
C
N
M
L
P
E
K
B
D
F
DESIGN
TECHNICAL INFORMATION

Page 7
Table 1 - Direct Models
Model
Stock Code
Load Prole
Energy Eciency Class
Heat Loss
Energy Eciency %
Annual Consumption
Other Load Prole
Thermostat
Temperature Setting
Sound Power Level
O-Peak Available
Capacity (Total Volume)
Weight - Empty
Weight - Full
Pressure Regulator 3 bar inlet group c/w balance
cold supply, expansion vessel connection and
expansion valve set at 4.5 bar
Expansion Vessel size.
Pre-charged to 3 bar
Overall Height
Overall Diameter
Pressure & Temperature
Relief Valve 6bar 95°C
22mm Secondary
Return Tapping
On Peak Immersion
Heater - High Level
Cold Feed 22mm
Compression Connection
O Peak Immersion
Heater - Low Level
Volume of On Peak Water
Heated
22mm Solar Return
Compression Connection
22mm Solar Flow
Compression Connection
Dual Control & Overheat Stat
Solar Pocket Solar Pocket
Second O Peak Immersion
Heater - Low Level
Surface Area of
Solar Heater Coil
Pressure Loss Across Solar Heater
Coil
Heat Up Time from 15°C to 60°C
(applies to Primary Heat Source only)
Dedicated Solar Volume
Watts % kWh °C db Litres kg kg bar
Litres A=mm mm B=mm C=mm D=mm E=mm F=mm Litres K=mm L=mm M=mm N=mm P=mm R=mm m2bar min Litres
Direct
D90 ASL0001 M D 35 36 2320 - 62 15 Y 90 13 103 3
12 745 550 490 n/a n/a 367 223 n/a n/a n/a n/a n/a n/a n/a n/a n/a 90 n/a
D120 ASL0005 M D 44 35 2366 - 62 15 Y 120 18 138 3
12 930 550 678 n/a 487 367 223 55 n/a n/a n/a n/a n/a n/a n/a n/a 119 n/a
D150 ASL0010 L D 51 37 4522 M 62 15 Y 150 22 172 3
18 1120 550 865 n/a 587 442 223 70 n/a n/a n/a n/a n/a n/a n/a n/a 150 n/a
D180 ASL0015 L D 54 36 4537 M 62 15 Y 180 24 204 3
18 1305 550 1053 n/a 686 442 223 85 n/a n/a n/a n/a n/a n/a n/a n/a 179 n/a
D210 ASL0020 XL D 65 37 6939 L/M 62 15 Y 210 28 238 3
24 1495 550 1241 1127 786 442 223 90 n/a n/a n/a n/a n/a n/a n/a n/a 209 n/a
D250 ASL0025 XL D 75 37 6990 L/M 62 15 Y 250 32 282 3
24 1745 550 1491 1377 927 522 223 125 n/a n/a n/a n/a n/a n/a n/a n/a 249 n/a
D300 ASL0030 XL D 85 36 7042 L/M 62 15 Y 300 37 337 3
35 1992 550 1720 1577 1077 522 223 155 n/a n/a n/a n/a n/a n/a n/a n/a 299 n/a
D400 ASL0031 XL D 118 36 7213 L/M 62 15 Y 400 48 448 3
2 x 24 2030 630 1784 1592 1181 457 238 180 n/a n/a n/a n/a n/a 338 n/a n/a 398/198 n/a
Direct Slimline
D60-SL ASL475D60 M D 40 35 2341 - 62 15 Y 60 13 73 3
12 705 475 462 n/a n/a 348 197 n/a n/a n/a n/a n/a n/a n/a n/a n/a 60 n/a
D90-SL ASL475D90 M D 52 34 2407 - 62 15 Y 90 16 106 3
12 978 475 734 n/a n/a 348 197 n/a n/a n/a n/a n/a n/a n/a n/a n/a 90 n/a
D120-SL ASL475D120 L D 59 36 4561 M 62 15 Y 120 22 142 3
12 1250 475 1006 n/a 650 348 197 55 n/a n/a n/a n/a n/a n/a n/a n/a 119 n/a
D150-SL ASL475D150 L D 68 36 4609 M 62 15 Y 150 30 180 3
18 1520 475 1278 n/a 785 423 197 70 n/a n/a n/a n/a n/a n/a n/a n/a 150 n/a
D180-SL ASL475D180 L D 76 37 4522 M 62 15 Y 180 31 211 3
18 1790 475 1548 n/a 921 423 197 85 n/a n/a n/a n/a n/a n/a n/a n/a 179 n/a
D210-SL ASL475D210 XL D 84 36 7036 L/M 62 15 Y 210 32 242 3
24 1970 475 1706 1540 1147 503 197 90 n/a n/a n/a n/a n/a n/a n/a n/a 209 n/a
Solar Direct
SOL180d ASL0070 n/a B 54 n/a n/a n/a n/a n/a n/a 180 26 206 3
18 1305 550 1053 n/a 746 437 482 75 223 352 419 882 203 n/a 0.680 0.191 n/a 60
SOL210d ASL0075 n/a C 65 n/a n/a n/a n/a n/a n/a 210 30 240 3
24 1495 550 1241 1127 908 437 544 80 223 352 419 1000 203 n/a 0.680 0.191 n/a 70
SOL250d ASL0080 n/a C 75 n/a n/a n/a n/a n/a n/a 250 34 284 3
24 1745 550 1491 1377 1092 522 629 100 223 472 539 1180 262 n/a 0.970 0.241 n/a 84
SOL300d ASL0085 n/a C 85 n/a n/a n/a n/a n/a n/a 300 39 339 3
35 1992 550 1720 1577 1287 522 724 115 223 472 539 1367 262 n/a 0.970 0.241 n/a 100
SOL400d ASL0086 n/a D 118 n/a n/a n/a n/a n/a n/a 400 49 449 3
2 x 24 2030 630 1784 1592 1296 557 691 140 238 548 651 1383 334 n/a 1.270 0.310 n/a 150
Solar Direct Slimline
SOL 180d-SL ASL475D180SOL n/a C 51 n/a n/a n/a n/a n/a n/a 180 32 212 3
18 1790 475 1548 n/a 1090 423 640 75 179 329 678 1263 243 n/a 0.680 0.191 n/a 60
SOL 210d-SL ASL475D210SOL n/a C 84 n/a n/a n/a n/a n/a n/a 210 36 246 3
24 1970 475 1706 1540 1190 503 730 80 179 409 778 1363 273 n/a 0.680 0.191 n/a 70
4
0
,0
0
º
4
5
,
00º
3
5
,00º
2
5,
0
0
º
1
5
,
0
0
º
NOTES
1. Not all models - see table 1.
2. Recovery times based on Primary
Coil/I.H. duty (ie. assumes the boiler
output is adequate).
3. All connections are supplied with
compression fittings for direct
connection to copper pipework.
4. The heat up times shown for
the D400 model indicate the
times when 1 or 2 immersions are
connected.
5. The diagrams shown are generic.
For exact product specification
refer to the table eg. the number
of immersion heaters varies
depending on model.
6. Heat up and recovery times based
on 0.25 l/s primary ow rate and at
82°C ow temperature.
DESIGN
TECHNICAL INFORMATION

Page 8
Table 2 - Indirect Models
Model
Stock Code
Energy Eciency Class
Heat Loss
Capacity (Total Volume)
Weight - Empty
Weight - Full
Pressure Regulator 3 bar inlet group c/w balance
cold supply, expansion vessel connection and
expansion valve set at 4.5 bar
Expansion Vessel size.
Pre-charged to 3 bar
Overall Height
Overall Diameter
Pressure & Temperature
Relief Valve 6bar 95°C
22mm Secondary
Return Tapping
On Peak Immersion
Heater - High Level
Cold Feed 22mm
Compression Connection
O Peak Immersion
Heater - Low Level
Volume of On Peak Water
Heated
Dual Control & Overheat Stat
Extra Stat Pocket
For Boiler Use If Required
22mm Primary Return Compression
Connection
(28mm tails for 400 litre model)
22mm Primary Flow Compression
Connection
(28mm tails for 400 litre model)
22mm Solar Return
Compression Connection
22mm Solar Flow
Compression Connection
Dual Control & Overheat Stat
Solar Pocket Solar Pocket
Second O Peak Immersion
Heater - Low Level
kW Rating of Primary Coil
Surface Area of
Primary Heater Coil
Pressure Loss Across
Primary Heater Coil
Surface Area of
Solar Heater Coil
Pressure Loss Across Solar Heater
Coil
Heat Up Time from 15°C to 60°C
(applies to Primary Heat Source only)
Dedicated Solar Volume
Watts Litres kg kg bar Litres A=mm mm B=mm C=mm D=mm
E=mm F=mm Litres G=mm H=mm I=mm J=mm K=mm L=mm M=mm N=mm P=mm R=mm kW m2bar m2bar min Litres
Indirect
IND90 ASL0035 B 35 90 19 109 3 12 745 550 490 n/a 352
367 n/a 40 367 367 223 312 n/a n/a n/a n/a n/a n/a 16.5 0.59 0.165 n/a n/a 17 n/a
IND120 ASL0040 B 44 120 22 142 3 12 930 550 678 n/a 352
367 n/a 67 367 367 223 312 n/a n/a n/a n/a n/a n/a 18 0.59 0.165 n/a n/a 21 n/a
IND150 ASL0045 B 51 150 26 176 3 18 1120 550 865 n/a 392
442 n/a 92 407 407 223 392 n/a n/a n/a n/a n/a n/a 18.5 0.68 0.191 n/a n/a 25 n/a
IND180 ASL0050 B 54 180 28 208 3 18 1305 550 1053 n/a 432
442 n/a 116 447 447 223 392 n/a n/a n/a n/a n/a n/a 19 0.78 0.216 n/a n/a 30 n/a
IND210 ASL0055 C 65 210 33 243 3 24 1495 550 1241 1127 432
442 n/a 145 482 482 223 392 n/a n/a n/a n/a n/a n/a 20.5 0.78 0.216 n/a n/a 32 n/a
IND250 ASL0060 C 75 250 38 288 3 24 1745 550 1491 1377 927
522 512 109 577 577 223 472 n/a n/a n/a n/a n/a n/a 21.5 0.97 0.241 n/a n/a 36 n/a
IND300 ASL0065 C 85 300 44 344 3 35 1992 550 1720 1577 1077
522 512 130 677 677 223 522 n/a n/a n/a n/a n/a n/a 25 0.97 0.241 n/a n/a 38 n/a
IND400 ASL0066 D 118 400 55 455 3 2 x 24 2030 630 1784 1577 1151
542 586 180 668 668 223 533 n/a n/a n/a n/a n/a n/a 30.5 1.27 0.310 n/a n/a 41 n/a
Indirect Slimline
IND60-SL ASL475IND60 B 40 60 14 74 3 12 705 475 462 n/a 352
348 n/a 28 242 242 179 329 n/a n/a n/a n/a n/a n/a 15 0.59 0.165 n/a n/a 13 n/a
IND90-SL ASL475IND90 C 52 90 19 109 3 12 978 475 734 n/a 392
348 n/a 54 359 359 179 329 n/a n/a n/a n/a n/a n/a 16.5 0.59 0.165 n/a n/a 17 n/a
IND120-SL ASL475IND120 C 59 120 23 143 3 12 1250 475 1006 n/a 432
348 n/a 75 423 423 179 329 n/a n/a n/a n/a n/a n/a 18 0.59 0.165 n/a n/a 21 n/a
IND150-SL ASL475IND150 C 68 150 28 178 3 18 1520 475 1278 n/a 462
423 n/a 102 514 514 179 409 n/a n/a n/a n/a n/a n/a 18.5 0.68 0.191 n/a n/a 25 n/a
IND180-SL ASL475IND180 C 76 180 31 211 3 18 1790 475 1548 n/a 512
503 n/a 125 604 604 179 449 n/a n/a n/a n/a n/a n/a 19.0 0.78 0.216 n/a n/a 30 n/a
IND210-SL ASL475IND210 C 84 210 34 244 3 24 1970 475 1706 1540 512
503 n/a 150 695 695 179 449 n/a n/a n/a n/a n/a n/a 20.5 0.78 0.216 n/a n/a 32 n/a
Solar Indirect
SOL180i ASL0090 B 54 180 30 210 3 18 1305 550 1053 n/a 680
437 n/a 80 825 n/a 715 935 223 352 419 882 218 n/a 18 0.59 0.165 0.680 0.191 28 96
SOL210i ASL0095 C 65 210 35 245 3 24 1495 550 1240 1127 723
437 n/a 95 888 n/a 758 1018 223 352 419 1000 233 n/a 18.5 0.68 0.191 0.680 0.191 35 101
SOL250i ASL0100 C 75 250 40 290 3 24 1745 550 1491 1377 785
522 n/a 115 970 n/a 820 1120 223 472 539 1180 294 n/a 19 0.78 0.216 0.970 0.241 38 107
SOL300i ASL0105 C 85 300 46 346 3 35 1992 550 1720 1577 910
522 n/a 140 1095 n/a 945 1245 223 472 539 1367 300 n/a 20.5 0.78 0.216 0.970 0.241 41 125
SOL400i ASL0110 D 118 400 59 459 3 2 x 24 2030 630 1784 1592 872
557 n/a 190 1060 1060 930 1190 238 548 651 1383 357 n/a 22 0.97 0.241 1.270 0.310 45 165
Solar Indirect Slimline
SOL180i-SL ASL475IND180SOL C 76 180 33 213 3 18 1790 475 1548 n/a 1044
423 n/a 75 897 n/a 619 1004 179 320 583 1232 243 n/a 18 0.59 0.165 0.680 0.191 28 60
SOL210i-SL ASL475IND210SOL C 84 210 37 247 3 24 1970 475 1706 1540 1130
503 n/a 85 1083 n/a 710 1095 179 409 673 1383 273 n/a 18.5 0.68 0.191 0.680 0.191 35 70
A
C
Indirect
D
H
F
E
I
J
B
G
D
Solar Indirect
N
G
P
I
E
K
J
A
B
M
L
C
DESIGN
TECHNICAL INFORMATION

Page 9
Table 2 - Indirect Models
Model
Stock Code
Energy Eciency Class
Heat Loss
Capacity (Total Volume)
Weight - Empty
Weight - Full
Pressure Regulator 3 bar inlet group c/w balance
cold supply, expansion vessel connection and
expansion valve set at 4.5 bar
Expansion Vessel size.
Pre-charged to 3 bar
Overall Height
Overall Diameter
Pressure & Temperature
Relief Valve 6bar 95°C
22mm Secondary
Return Tapping
On Peak Immersion
Heater - High Level
Cold Feed 22mm
Compression Connection
O Peak Immersion
Heater - Low Level
Volume of On Peak Water
Heated
Dual Control & Overheat Stat
Extra Stat Pocket
For Boiler Use If Required
22mm Primary Return Compression
Connection
(28mm tails for 400 litre model)
22mm Primary Flow Compression
Connection
(28mm tails for 400 litre model)
22mm Solar Return
Compression Connection
22mm Solar Flow
Compression Connection
Dual Control & Overheat Stat
Solar Pocket Solar Pocket
Second O Peak Immersion
Heater - Low Level
kW Rating of Primary Coil
Surface Area of
Primary Heater Coil
Pressure Loss Across
Primary Heater Coil
Surface Area of
Solar Heater Coil
Pressure Loss Across Solar Heater
Coil
Heat Up Time from 15°C to 60°C
(applies to Primary Heat Source only)
Dedicated Solar Volume
Watts Litres kg kg bar Litres A=mm mm B=mm C=mm D=mm
E=mm F=mm Litres G=mm H=mm I=mm J=mm K=mm L=mm M=mm N=mm P=mm R=mm kW m2bar m2bar min Litres
Indirect
IND90 ASL0035 B 35 90 19 109 3 12 745 550 490 n/a 352
367 n/a 40 367 367 223 312 n/a n/a n/a n/a n/a n/a 16.5 0.59 0.165 n/a n/a 17 n/a
IND120 ASL0040 B 44 120 22 142 3 12 930 550 678 n/a 352
367 n/a 67 367 367 223 312 n/a n/a n/a n/a n/a n/a 18 0.59 0.165 n/a n/a 21 n/a
IND150 ASL0045 B 51 150 26 176 3 18 1120 550 865 n/a 392
442 n/a 92 407 407 223 392 n/a n/a n/a n/a n/a n/a 18.5 0.68 0.191 n/a n/a 25 n/a
IND180 ASL0050 B 54 180 28 208 3 18 1305 550 1053 n/a 432
442 n/a 116 447 447 223 392 n/a n/a n/a n/a n/a n/a 19 0.78 0.216 n/a n/a 30 n/a
IND210 ASL0055 C 65 210 33 243 3 24 1495 550 1241 1127 432
442 n/a 145 482 482 223 392 n/a n/a n/a n/a n/a n/a 20.5 0.78 0.216 n/a n/a 32 n/a
IND250 ASL0060 C 75 250 38 288 3 24 1745 550 1491 1377 927
522 512 109 577 577 223 472 n/a n/a n/a n/a n/a n/a 21.5 0.97 0.241 n/a n/a 36 n/a
IND300 ASL0065 C 85 300 44 344 3 35 1992 550 1720 1577 1077
522 512 130 677 677 223 522 n/a n/a n/a n/a n/a n/a 25 0.97 0.241 n/a n/a 38 n/a
IND400 ASL0066 D 118 400 55 455 3 2 x 24 2030 630 1784 1577 1151
542 586 180 668 668 223 533 n/a n/a n/a n/a n/a n/a 30.5 1.27 0.310 n/a n/a 41 n/a
Indirect Slimline
IND60-SL ASL475IND60 B 40 60 14 74 3 12 705 475 462 n/a 352
348 n/a 28 242 242 179 329 n/a n/a n/a n/a n/a n/a 15 0.59 0.165 n/a n/a 13 n/a
IND90-SL ASL475IND90 C 52 90 19 109 3 12 978 475 734 n/a 392
348 n/a 54 359 359 179 329 n/a n/a n/a n/a n/a n/a 16.5 0.59 0.165 n/a n/a 17 n/a
IND120-SL ASL475IND120 C 59 120 23 143 3 12 1250 475 1006 n/a 432
348 n/a 75 423 423 179 329 n/a n/a n/a n/a n/a n/a 18 0.59 0.165 n/a n/a 21 n/a
IND150-SL ASL475IND150 C 68 150 28 178 3 18 1520 475 1278 n/a 462
423 n/a 102 514 514 179 409 n/a n/a n/a n/a n/a n/a 18.5 0.68 0.191 n/a n/a 25 n/a
IND180-SL ASL475IND180 C 76 180 31 211 3 18 1790 475 1548 n/a 512
503 n/a 125 604 604 179 449 n/a n/a n/a n/a n/a n/a 19.0 0.78 0.216 n/a n/a 30 n/a
IND210-SL ASL475IND210 C 84 210 34 244 3 24 1970 475 1706 1540 512
503 n/a 150 695 695 179 449 n/a n/a n/a n/a n/a n/a 20.5 0.78 0.216 n/a n/a 32 n/a
Solar Indirect
SOL180i ASL0090 B 54 180 30 210 3 18 1305 550 1053 n/a 680
437 n/a 80 825 n/a 715 935 223 352 419 882 218 n/a 18 0.59 0.165 0.680 0.191 28 96
SOL210i ASL0095 C 65 210 35 245 3 24 1495 550 1240 1127 723
437 n/a 95 888 n/a 758 1018 223 352 419 1000 233 n/a 18.5 0.68 0.191 0.680 0.191 35 101
SOL250i ASL0100 C 75 250 40 290 3 24 1745 550 1491 1377 785
522 n/a 115 970 n/a 820 1120 223 472 539 1180 294 n/a 19 0.78 0.216 0.970 0.241 38 107
SOL300i ASL0105 C 85 300 46 346 3 35 1992 550 1720 1577 910
522 n/a 140 1095 n/a 945 1245 223 472 539 1367 300 n/a 20.5 0.78 0.216 0.970 0.241 41 125
SOL400i ASL0110 D 118 400 59 459 3 2 x 24 2030 630 1784 1592 872
557 n/a 190 1060 1060 930 1190 238 548 651 1383 357 n/a 22 0.97 0.241 1.270 0.310 45 165
Solar Indirect Slimline
SOL180i-SL ASL475IND180SOL C 76 180 33 213 3 18 1790 475 1548 n/a 1044
423 n/a 75 897 n/a 619 1004 179 320 583 1232 243 n/a 18 0.59 0.165 0.680 0.191 28 60
SOL210i-SL ASL475IND210SOL C 84 210 37 247 3 24 1970 475 1706 1540 1130
503 n/a 85 1083 n/a 710 1095 179 409 673 1383 273 n/a 18.5 0.68 0.191 0.680 0.191 35 70
4
0
,0
0
º
4
5
,
00º
3
5
,00º
2
5,
0
0
º
1
5
,
0
0
º
NOTES
1. Not all models - see table 2.
2. Recovery times based on Primary
Coil/I.H. duty (ie. assumes the boiler
output is adequate).
3. All connections are supplied with
compression fittings for direct
connection to copper pipework.
4. The diagrams shown are generic.
For exact product specification
refer to the table eg. the number
of immersion heaters varies
depending on model.
5. Heat up and recovery times based
on 0.25 l/s primary ow rate and at
82°C ow temperature.
DESIGN
TECHNICAL INFORMATION

Page 10
Stainless Lite Direct
Basic Appliance
1. Hot water draw o (22mm) compression
2. Lift up temperature & pressure relief valve
92-95°/6 bar
3. Hot water secondary return 22mm
(not tted to smaller sizes, see table 1)
4. Immersion heater 1¾”BSP 3kW
(normally on-peak)
5. 22mm cold supply compression
6. Immersion heater 1¾”BSP 3kW
(normally o-peak)
7. Immersion heater 1¾”BSP 3kW
(normally o-peak - 400 litre model only)
Part G3 loose components supplied in a
separate box
A. Combination inlet group incorporating
pressure reducing valve, strainer, check
valve, balance cold take o point, expansion
relief valve and expansion vessel connection
points.
B. Portable expansion vessels c/w exible hose
and wall bracket
C. Tundish
Stainless Lite Indirect
Basic Appliance
1. Hot water draw o (22mm) compression
2. Lift up temperature & pressure relief valve
92-95°/6 bar
3. Hot water secondary return 22mm
(not tted to smaller sizes, see table 2)
4. Immersion heater 1¾” BSP 3kW
5. 22mm cold supply compression
6. Immersion heater 1¾” BSP 3kW
7. Dual control/overheat stat pocket (22mm)
8. Boiler control sensor pocket (spare)
9. Primary return (22mm)
- (28mm tails for 400 litre models)
10. Primary ow (22mm)
- (28mm tails for 400 litre models)
Part G3 loose components supplied in a
separate box
A. Combination inlet group incorporating
pressure reducing valve, strainer, check
valve, balance cold take o point, expansion
relief valve and expansion vessel connection
points.
B. Potable expansion vessels c/w exible hose
and wall bracket
C. Tundish
D. Dual control thermostat and combined
overheat thermostat
E. Two port (22mm) zone valve for
primary circuit
F. Wiring junction box for primary system
1
2
5
3
4
6
7
1
2
3
4
7
5
6
9
8
10
Typical arrangement of component kit shown tted to the appliance for clarity
Pipework to be supplied and tted by installer.
DESIGN
SYSTEM DESIGN

Page 11
7
9
3
11
6
12
12
1
2
8
4
5
10
Stainless Lite Direct Solar
Basic Appliance
1. Hot water draw o (22mm) compression
2. Lift up temperature & pressure relief valve
92-95°/6 bar
3. Hot water secondary return 22mm
(not tted to smaller sizes, see table 1)
4. Immersion heater 1¾” BSP 3kW
(normally on-peak)
5. 22mm cold supply
6. Immersion heater 1¾” BSP 3kW
(normally o-peak)
7. Dual control/Overheat stat pocket (solar)
8. Solar coil return to panel collector (22mm)
compression
9. Solar coil ow from panel (22mm) compression
10. Solar thermostat pocket
Part G3 loose components supplied in a
separate box
A. Combination inlet group incorporating
pressure reducing valve, strainer, check valve,
balance cold take o point, expansion relief
valve and expansion vessel connection points.
B. Portable expansion vessels c/w exible hose
and wall bracket
C. Tundish
D. Dual control thermostat and combined
overheat thermostat
Stainless Lite Indirect Solar
Basic Appliance
1. Hot water draw o (22mm) compression
2. Lift up temperature & pressure relief valve
92-95°/6 bar
3. Hot water secondary return 22mm
(not tted to smaller sizes, see table 2)
4. Immersion heater 1¾” BSP 3kW
5. 22mm cold supply
6. Dual control/Overheat stat pocket (solar)
7. Primary return (22mm)
- (28mm tails for 400 litre models)
8. Primary ow (22mm)
- (28mm tails for 400 litre models)
9. Dual control/Overheat stat pocket (boiler)
10. Solar coil return to panel collector (22mm)
compression
11. Solar coil ow from panel (22mm) compression
12. Solar thermostat pocket
Part G3 loose components supplied in a
separate box
A. Combination inlet group incorporating
pressure reducing valve, strainer, check valve,
balance cold take o point, expansion relief
valve and expansion vessel connection points.
B. Potable expansion vessels c/w exible hose
and wall bracket
C. Tundish
D. Dual control thermostat and combined
overheat thermostat (x2)
E. Two port (22mm) zone valve for
primary circuit
F. Wiring junction box for primary system
1
2
5
8
7
6
4
3
9
10
10
Typical arrangement of component kit shown tted to the appliance for clarity
Pipework to be supplied and tted by installer.
DESIGN
SYSTEM DESIGN

Page 12
General Design Considerations
The cupboard footprint needs to be at least 650mm square for standard units up to
300 litres, 730mm for 400 litre and 575mm for slimline units. The base chosen for the
cylinder should be level and capable of supporting the weight of the unit when full of
water as shown in General Data. The discharge pipework for the safety valves must have
a minimum fall of 1 : 200 from the unit to a safe discharge point. All exposed pipework
and ttings on the cylinder should be insulated, and the unit should NOT be xed in a
location where the contents could freeze.
In new systems, pipes should be insulated to comply with building regs, the maximum
permissible heat loss is indicated in the table opposite, and labelled accordingly as follows:
i. Primary circulation pipes for domestic hot water circuits should be insulated
through their length, subject only to practical constraints imposed by the need
to penetrate joists and other structural elements.
ii. All pipes connected to hot water storage vessels, including the vent pipe, should
be insulated for at least 1 metre from their points of connection to the cylinder (or
they should be insulated up to the point where they become concealed).
In replacement systems, whenever a boiler or hot water storage vessel is replaced in
an existing system, any pipes that are exposed as part of the work or are otherwise
accessible should be insulated as recommended for new systems, or to some lesser
standard where practical constraints dictate.
The pipe connecting the boiler ow to the appliance must not be less than 22mm
copper or equivalent.
Standard and Slimline Model Selection Guide
Max hot water demand
Max number
of bed spaces
(Bedrooms)
Indirect
litres
Direct
litres
1 shower room Bedsit (0) 90 120
1 bathroom 2 (2) 120 150
1 bathroom 4 (3) 120 180
1 bathroom + separate shower room 6 (4) 150 210
1 bathroom + 2 separate shower rooms
or 2 bathrooms 7 (5) 180 210
2 bathrooms + separate shower room 7 (5) 210 250
2 bathrooms + 2 separate shower rooms 7 (5) 250 300
3 bathrooms + 2 separate showers rooms 9 (6) 300 400
3 bathrooms + 3 separate showers rooms 9 (6) 400 -
Solar Model Selection Guide
Max hot water demand Bedrooms Indirect
litres
Direct
litres
1 shower room Bedsit - 180
1 bathroom 1-3 180 -
1 bathroom 1-3 210
1 bathroom + 1 shower room 1-3 210 -
1 bathroom + 1 shower room 1-3 - 250
1 bathroom + 2 shower rooms 2-4 250 -
1 bathroom + 2 shower rooms 2-4 - 300
2 bathrooms + 1 shower room 3-4 300 -
2 bathrooms + 1 shower room 4-5 - 400
2 bathrooms + 2 shower rooms 4-5 400 -
INSTALLATION
INSTALLATION
Further guidance on converting heat loss limits
to insulation thickness for specific thermal
conductivities is available in TIMSA “HVAC
guidance for achieving compliance with Part L
of the Building Regulations”.
Mains Water Supply
Existing properties with a 15mm supply will be
satisfactory provided the local mains pressure is
good, but should be conned to single bathroom
properties. Fornew propertieswheresimultaneous
demand is required to more than one bathroom
or a bathroom and one or more en-suites, the
communication and service pipe into the dwelling
should be a minimum of 22mm (usually in the
form of a 25mm MDPE supply). The optimum
performance is achieved if the inlet pressure is 3 bar
dynamic. However, the Stainless Lite will function
with lower inlet pressures, but this will reduce the
performance. For optimum performance, 30L per
minute incoming mains ow should be present,
however the Stainless Lite will work at lower ow
rates, although performance will be affected.
Normally Stainless Lite provides well in excess of
40 litres/min in most conditions. Flow rates for
ALL mains pressure systems are subject to district
pressures and system dynamic loss. Particularly on
larger properties with more than one bathroom,
the pipe sizes should be calculated in accordance
with BS EN 806-3:2006 and BS 8558:2011.
Model Selection
The suggested Direct model sizes, shown
opposite, are based on a typical days hot water
use assuming an Economy 7 tari is provided.
A reduction of one model size can normally
be made with an Economy 10 tariff. When
using the Direct models for high specication
developments an increase of one model size
should be considered.
Thesuggestedmodelsizesarebasedontypicalhot
water usage. For high specication dwellings an
increase of one model size should be considered.
Insulation of pipework
Pipe outside
diameter
Maximum
heat loss
15mm 7.89W/m
22mm 9.12W/m
28mm 10.07W/m
35mm 11.08W/m

Page 13
INCOMING COLD SUPPLY
M
DC
DC
DC
TO
EXTERNAL
TAP
SINK
WATER SOFTENER (IF NECESSARY)
WM or DWM
WHB W.C.
DC
DC
SH
DHW
WHB
WC BATH
SCV SCV
P&T
ERV/NRV
PRV
DCV
Note:
Cold supplies to single taps must be
taken from the mains cold water
system.
Cold supplies to mixer taps must be
taken from the balanced cold water
connection on the combination
valve.
General Restrictions
a. The highest hot or cold water draw o point should not exceed 10 metres above
the Pressure Reducing Valve.
b. An ascending spray type bidet or any other appliance with a Class 1 back-syphonage
risk requiring a type A air gap should not be used.
c. Stainless Lite should not be used where steam is the primary heating medium, or
in a situation where maintenance is likely to be neglected.
d. Unvented cylinders are not suitable for use with solid fuel boilers.
e. If the supply to the mixer ttings (other than a dual outlet type) is not taken from
the balanced supply the system will become over pressurized and cause the
pressure relief valve to discharge. Over time this could also cause the premature
failure of the appliance itself which will not be covered by the warranty.
f. In larger properties with a number of bathrooms/en-suites and long pipe runs
we would recommend that the balance cold supply is provided with its own
pressure reducing valve and is not taken from the balanced cold connection on
the combination valve. In this case it will also be necessary to t a small expansion
vessel on the balanced cold water system to accommodate the pressure rise caused
by the increase in temperature of the balanced cold water.
g. Check the performance requirements of the terminal ttings with regard to ow/
pressure are suitable.
h. In relation to potable water systems, expansion vessels shall be installed in a vertical
orientation and located so that the length of the connecting pipe work is kept to
a minimum.
Shower Fittings
Aerated taps are recommended to prevent splashing. Any type of shower mixing valve
can be used as long as both the hot and cold supplies are mains fed. However, all mains
pressure systems are subject to dynamic changes particularly when other hot and cold
taps/showers are opened and closed, which will cause changes in the water temperature
at mixed water outlets such as showers. For this reason and because these are now no
more expensive than a manual shower we strongly recommend the use of thermostatic
showers with this appliance. These must be used in 3 storey properties where the
impact on pressure/temperature of opening another tap in the system is greater than
normal. The shower head provided must also be suitable for mains pressure supplies.
Pipe Layout
In all mains pressure installations it is important
to remember that the incoming cold supply
must be shared between all terminal ttings. It
is important that a 22mm supply is brought to
the appliance and a 22mm take-o is continued
at least to the bath. If there are two baths, 28mm
pipework should be considered. One metre of
smaller diameter pipework, or ow restrictors,
should be provided on the nal connection to
all outlets so as to balance the water available.
In any event the distribution pipework should
generally be in accordance with BS EN806-1 to 5.
Plastic Pipework
This appliance is suitable for use with plastic
pipework as long as the material is recommended
for the purpose by the manufacturer and is installed
fully in accordance with their recommendations.
Secondary Hot Water Circulation
Some models are fitted with a secondary
return tapping as standard (see tables 1 and 2
for details). If tted, an extra expansion vessel
may be necessary. A non-return valve MUST be
FITTED near the return connection. No valve
or terminal tting should be installed between
the non return valve and the cylinder. (See
schematic arrangement on page 15.) All pipes
kept hot by the secondary circulation should
be insulated.
INSTALLATION
INSTALLATION

Page 14
15 mm
discharge
pipe
Expansion
relief valve
Typical Discharge Pipe Arrangement
Dotted line showing
alternative route with
single tundish being used
600 mm max.
P & T
Relief
Valve
300 mm
min.
22 mm metal pipe with continuous
fall up to 9m equivalent length (D2).
NOTES:
The discharge will consist of scalding
waterand steam. Asphalt, roong felt
and non-metallic rainwater goods may
be damaged by such discharges.
It is not acceptable to discharge straight
into a soil pipe.
Discharge below
xed grating
Fixed Grating
Trapped gully
Pressure & Temperature/expansion Relief
Valve Pipework
The relief valve should be installed to discharge
in accordance with G3 of the Approved
Document of the Building Regulations and
should be piped to where it is visible, but will
not cause danger to persons or damage to
materials.
The following information is taken from
Approved Document G3 of the Building
Regulations and is provided to assist with
the design and installation of the discharge
pipework. However, the information is not
exhaustive and reference should always be
made to Approved Document G3 of the Building
Regulations. The nal decision regarding any
arrangements rests with Building Control and
it is recommended that their advice is sought
if you have any concerns regarding this aspect
of the installation.
The two safety valves will only discharge
water under fault conditions. When operating
normally water will not be discharged.
The tundish should be vertical, located in the
same space as the unvented hot water storage
system and be tted as close as possible and
within 600mm of the safety device e.g. the
temperature relief valve.
The discharge pipe (D2) from the tundish should
terminate in a safe place where there is no risk
to persons in the vicinity of the discharge, be
of metal and:
a) Be at least one pipe size larger than the
nominal outlet size of the safety device unless
its total equivalent hydraulic resistance
exceeds that of a straight pipe 9m long
i.e. discharge pipes between 9m and 18m
equivalent resistance length should be at
least two sizes larger than the nominal outlet
size of the safety device, between 18 and
27m at least 3 sizes larger, and so on. Bends
must be taken into account in calculating
the ow resistance. Refer to the table and
the worked example.
An alternative approach for sizing discharge
pipes would be to follow BS EN 806-2:2005
Specication for design installation, testing
and maintenance of services supplying water
for domestic use within buildings and their
curtilages.
b) Have a vertical section of pipe at least
300mm long, below the tundish before any
elbows or bends in the pipe work.
c) Be installed with a continuous fall.
Worked Example
The example below is for G1/2 temperature relief valve with a discharge pipe (D2)
having 4 elbows and length of 7m from the tundish to the point of discharge.
From the table below:
Maximum resistance allowed for a straight length of 22mm copper discharge
pipe (D2) from a G1/2 temperature relief valve is: 9m subtract the resistance for
4 x 22mm elbows at 0.8m each = 3.2m.
Therefore the maximum permitted length equates to: 5.8m.
5.8m is less than the actual length of 7m therefore calculate the next largest size.
Maximum resistance allowed for a straight length of 28mm pipe (D2) from a G1/2
temperature relief valve equates to: 14m.
As the actual length is 7m, a 28mm (D2) copper pipe will be satisfactory.
Sizing of copper discharge pipe‘D2’ for a temperature relief valve
with a G1/2 outlet size (as supplied)
Size of discharge
pipework
Maximum length of
straight pipe
(no bends or elbows)
Deduct the gure
below from the
maximum length for
each bend or elbow in
the discharge pipe
22mm Up to 9m 0.8m
28mm Up to 18m 1m
35mm Up to 27m 1.4m
INSTALLATION
INSTALLATION

Page 15
d) It is preferable for the discharge to be visible at both the tundish and the nal point
of discharge but where this is not possible or practically dicult there should be
clear visibility at one or other of these locations. Examples of acceptable discharge
arrangements are:
1. Ideally below the xed grating and above the water seal in a trapped gulley.
2. Downward discharges at a low level; i.e. up to 100mm above external surfaces
such as car parks, hard standings, grassed areas etc are acceptable providing that
where children play or otherwise come into contact with discharges, a wire cage
or similar guard is positioned to prevent contact whilst maintaining visibility.
3. Discharges at a high level; e.g. into metal hopper and metal down pipe with the
end of the discharge pipe clearly visible (tundish visible or not) or onto a roof
capable of withstanding high temperature discharges of water and 3m from
any plastic guttering systems that would collect such discharges.
4. Where a single pipe serves a number of discharges, such as in blocks of ats,
the number served should be limited to not more than 6 systems so that any
installation can be traced reasonably easily. The single common discharge pipe
should be at least one pipe size larger than the largest individual discharge pipe
to be connected. If unvented hot water storage systems are installed where
discharges form safety devices may not be apparent i.e. in dwellings occupied by
blind, inrm or disabled people, consideration should be given to the installation
of an electronically operated device to warn when discharge takes place.
P&T Relief Valve
Tundish
Hot Outlet
To Drain
PRV
NRV
Stop
Tap
Kitchen
Cold
Tap Combination
Valve
Balanced
Cold
Outlets
Immersion Heater
Expansion Vessel(s)
Boiler
Return
Boiler
Flow
2 Port Valve
Secondary
Return Circuit
Schematic Diagram
Non Return
Valve
Pump
ERV
Combination Inlet Group
Combines elements 1, 2 and 3 below.
1. Pressure Reducing Valve - This must be xed
near the cylinder. The cold water supply to
any mixer taps/showers must be taken from
the cold water tapping of this valve to ensure
balanced hot and cold pressures. This valve
is factory set to ensure the correct operating
pressure for the Stainless Lite.
2. Non Return Valve - This is integral with the
pressure reducing valve to prevent backow of
hot water towards cold water draw o points.
3. Cold Water Expansion Relief Valve -This safety
device is preset at the factory and will relieve
excess cold water pressure resulting from a
fault condition.
2 expansion cylinders on 400 litre Models
All 400 litre models are supplied with two 24
litre expansion cylinders. These can be coupled
together and tted to the expansion cylinder
tapping on the combination inlet valve, or by
some other means on the cold/hot water inlet
pipework. There must be no valve on the pipe
work between the expansion cylinders and the
unvented cylinder which could prevent the
expansion of the water contained in the unvented
cylinder reaching the expansion cylinders.
INSTALLATION
INSTALLATION
Safety
The safety devices supplied or fitted on an
Stainless Lite are selected for their suitability for
the temperatures and pressures involved. They
must not be changed, removed or by-passed
and it is essential that only genuine replacement
parts supplied or approved by Gledhill Building
Products Limited are used. All parts are available
to approved installers from Gledhill Building
Products Limited, Sycamore Estate, Squires Gate,
Blackpool (Telephone [phone]).
Line Strainer
This is integral within the combination inlet
group to reduce the likelihood of contaminants
fouling the valve seat. Following installation this
line strainer must be cleaned and replaced. This
needs to be carried out on a regular basis. as part
of the annual maintenance/service check.
Tundish
This is to allow the discharge from any Relief
Valve to be seen. It must be tted away from
any electrical devices. See page 14 for discharge
pipework details.

Page 16
Lift Up Pressure & Temperature Relief Valve
This safety device is also pre-set at the factory and relieves before the temperature
reaches 100°C. It is also a Pressure Relief Valve, and is pre-set to 6 bar.
Immersion Heaters
The immersion heaters tted to our units are 3kW 240V ~AC. Check that the mains
supply conforms to this, and all external wiring conforms to the most recent
revision of the IEE wiring regulations. An Incoloy element is used on this product for
standard domestic use and water conditions, use our Titanium elements in all other
circumstances, part number SH002.
The immersion heater is tted into the hot water cylinder using an O-ring. After the
unit is lled with water check for leaks to determine if the O-ring has sealed and
tighten carefully using the appropriate tool. To prevent damage to the O ring do not
use excessive force to tighten the immersion heater.
The immersion heater is supplied with a thermostat which has been tested
for operation in the cylinder and complies with the European directives for
Electromagnetic compatibility and radio interference. It is Rated at 16 Amp 250V ~AC.
Immersion Heater Wiring
E
L
N
INSTALLATION
INSTALLATION
The immersion thermostat has two terminals
A and B. The Live (brown) wire should be
connected to terminal A and the Neutral (blue)
wire should be connected to terminal B. It has
been our experience that Crimp terminals make
better connections.The immersion heater must
be fully earthed (earth post) and connected via
a double pole isolator switch having a contact
separation at least 3mm, see diagram opposite.
Danger of electrocution: before making any
adjustments to the thermostat isolate the
immersion heater from the mains electricity
supply at the fuse spur unit.
The immersion heater thermostats incorporate
a manual reset safety/overheat cut out
thermostat. Should this operate, investigate the
cause for the operation cut out before pressing
the red reset button labelled safety. If there is no
apparent fault adjust the control setting down
slightly to prevent nuisance tripping.
If another heat source is used to heat the
cylinder and this is allowed to raise the water
temperature excessively then the overheat
thermostat will trip. This is likely on solar
thermal products when the solar thermostats
are set at high temperatures.
The Direct cylinder is intended to be heated
from an off peak supply using the lowest
immersion heater(s) and boosted via the upper
immersion heater from an on peak supply.
Suitable controllers are available to control this
operation eectively.
Solar Thermistors / sensors
Care must be taken to ensure that the solar probes
are fully inserted into the pockets provided.
Important
Failure to follow the drain down procedure will
invalidate the warranty. (see page 22)
NEVER drain the cylinder of hot water and
then close all cylinder inlets and
outlets.
REASON as the air remaining in the cylinder
cools the pressure inside the
cylinder will fall below atmospheric
and cause damage to the cylinder.
NEVER close the cold main and drain the
cylinder via any tap connected to it.
REASON as the water drains, the pressure
inside the cylinder may decrease
below atmospheric and this may
cause damage to the cylinder.
In line with good plumbing practice, use of
excessive ux should be avoided.
I.V.
Combination Valve
I.V.
If two Stainless Lites are coupled together the secondary inlet and outlet pipes must
be balanced. The units must be tted on the same level.
Note: No valves must be tted between the expansion vessel and the storage cylinder(s).
Thermostat Type TSR tted in the
Direct cylinders; is supplied set at
62°C ± 3°C. Position 4 is 55°C ± 3°C
and position 5 is 68°C ± 3°C.
ThermostatType TSE tted in the
indirect cylinders - is supplied set
in position 5 at 60°C ± 4°C.
When ordering a replacement
part the TSR thermostat type will
be supplied with the immersion
heater.

Page 17
Heating/primary Systems
The boiler and primary/heating systems should
be sized and installed in accordance with BS
EN 12828:2003, BS EN 12831:2003 & BS EN
14336:2004.
Safety
Stainless Lite is fitted with a Combined Lift
Up Temperature/Pressure Relief Valve to cope
with any increase in system temperature and
pressure above the design limitations, when
used with boilers up to 45kW output, which is the
maximum allowed by section G3 of the Building
Regulations. The primary water temperatures
should be controlled as outlined below.
Primary Circuit
It is essential that the circuit between the boiler
and the Stainless Lite is pumped. The motorised
zone valve supplied should be tted adjacent
to the unit and controlled by the cylinder
thermostat supplied. The thermostat and
motorised valve must be wired so that they both
switch o should an overheat situation develop.
It is important to follow the wiring diagram in
the Wiring Section of these instructions.
Sealed Primary Circuit
Any boiler used must be tted with an over
temperature cut-out. Unvented primary circuits
may be filled or replenished by means of a
temporary connection between the circuit and
a supply pipe provided a ‘Listed’ double check
valve or some other no less eective backow
prevention device is permanently connected
at the inlet to the circuit and the temporary
connection is removed after use.
Alternatively, a CA device can be used, which
will allow the system to be permanently
connected to the cold mains supply. The
primary system can then be topped up, when
required, in the same way as an open vented
system tted with an F&E Cistern.
Gate Valve
All our cylinders are tested to BS EN 12897 at
15 l/mim at which they exceed the minimum
requirements for heat up performance and reheat
in less time than the maximum reheat times.
In extreme situations where excessive flow
rates, above 25 l/min are present, then a gate
valve on the return from the cylinder to the
boiler, before it joins the central heating return,
may be required to reduce excessive ow rates
and therefore any potential noise problems.
Schematic Open Vented Primary System
Boiler
Pump
150mm max.
Warming/Overflow
Pipe
F & E Cistern
Minimum
distance as
required by
boiler
manufacturers
instructions
Motorised Valve
(Not supplied)
Motorised Valve
(Energy cut-out)
Gate Valve
(Not supplied)
Schematic Sealed Primary System
Boiler
Motorised Valve
(Energy cut-out)
Expansion
Vessel
Gauge
Safety Valve
Pump
Motorised Valve
(Not supplied)
Gate Valve
(Not supplied)
INSTALLATION
INSTALLATION

Page 18
Schematic Solar Direct System
Solar Pumping Station
Solar Panel
Expansion
Vessel
Solar
Controller
Motorised Valve
Energy cut-out
(Not supplied)
All components in a solar primary system must
be marked or identiable in such a way that
their design pressure and temperature can be
readily determined.
A pressure and temperature relief valve to
control the risk of over-pressure in system
components should be tted. A termination
from a pressure and temperature relief valve
should minimise the risk of damage to persons
or materials. Suitable locations are into a
high temperature receptacle, an internal
gully or externally at ground level. High level
termination from walls or on roofs could cause
injury to people or animals below if the valve
were to release scalding water and steam.
The pipe leading to the safety device and the
collector should be of rigid and non-deformable
construction, without any possibility of
restriction or disclosure by any other fitted
component.
A more detailed diagram of our recommended
arrangement for a typical solar system is shown
on page 20.
This provides all the necessary controls and
safety devices necessary for the solar system i.e.
the two port zone valve is wired as an energy
cut out and the pump/valve will only allow heat
transfer as required under control of the solar
controller.
The solar pocket provided accommodates an
8mm diameter sensor which, with the sensor
located in the solar collector (or in the ow
pipe immediately adjacent to the collector),
will provide the information required by the
solar controller.
Note: If the motorised valve is not used then
any factory built hydraulic station for solar
use MUST be tted with suitable non-return
valves in both flow and return pipes to
prevent gravity circulation when the pump
is not running.
If there is a possibility of the solar controller that
you install causing the cylinder temperature to
exceed 80°C, under normal working conditions,
then a Solar tempering valve must be tted to
the domestic hot water outlet of the cylinder.
This must limit the hot water temperature to a
maximum of 60°C.(ref building regulations part
G3 3.63). This product can be supplied from
Gledhill part number XC007 which has a inlet
temperature limit of 100°C. Suitable plumbing
configurations for installing this valve are
shown on page 19 of this manual. NB. Any tted
Overheat thermostats may require resetting
in the winter months to enable backup heat
sources to heat the cylinder.
Schematic Solar Indirect System
Solar Pumping Station
Solar Panel
Expansion
Vessel
Solar
Controller
Motorised Valve
Energy cut-out
(Not supplied)
Motorised Valve
Energy cut-out
(Not supplied)
INSTALLATION
INSTALLATION

Page 19
Mixed HW out
Mains CW in
Figure 1: Cold port of the blending valve connected to mains supply
NOT ALLOWED
Mixed HW out
Mains CW in
Figure 3: Cold port of the blending valve connected to mains supply
to the vessel after the inlet control group
Mixed HW out
Mains CW in
Non-Return Valve (must be fitted)
Figure 2: Cold port of the blending valve connected to balanced cold
supply - NON-RETURN VALVE MUST BE FITTED
Fitting Blending Valves To The Unvented
Stainless Lite Appliances
When tting a blending valve to the unvented
appliances, it is important that the installation
does not contravene the G3, WRC and Health
and Safety directives or the manufacturers
recommendations. If this is the case, then
the warranty should be null & void. The key
requirements to comply with these regulations
are: -
1. Any fitting or material in contact with
potable water (e.g. a blending valve) must
be approved by WRC or an equivalent body.
2. Connections or wiring arrangements must
not bypass any safety devices.
3. Any expansion due to heating must not be
allowed to expand back into the cold mains.
4. The settings of any safety devices must not
be tampered with or adjusted.
The diagrams opposite shows how the
blending valve can be piped onsite.
Figure 1 shows the cold water port of the
blending valve connected to the mains cold
water supply before the inlet control group.
This arrangement is completely unacceptable
and illegal because: -
• the water is allowed to expand in to mains
cold water supply.
• the vessel will be charged to the incoming
mains supply which may be considerably
higher than the working pressure of the
vessel.
If this arrangement is used then the Gledhill
warrant will not be valid.
Figure 2 shows the cold water port of the
blending valve connected to the balanced
cold water outlet. This arrangement will only
be acceptable if a WRAS approved non-return
valve is tted, otherwise: -
• during the heating cycle, the water will
expand back into the mains supply, as the
regulating valve must not be relied upon
to act as a check valve under all operating
conditions.
• depending upon the characteristics of the
blending valve, hot water may also ow from
the balanced cold water taps.
Figure 3 shows the cold port of the blending
valve connected to the cold water supply to the
vessel after the inlet control group. This should
be the preferred method. It is recommended
that the installer should ensure that there is no
gravity circulation in the pipework connected to
the cold port. If necessary, this can be achieved
by tting a non-return valve or using a thermal
trap.
INSTALLATION
INSTALLATION
✗

Page 20
1 98765432 10
1 2 3 4 5 6 7 8
S1 S2 S3
201918171615141312
LNR1R2 NN
T
S1
S1
1 bar
Solar
Pumping
Station
Solar Coil
TWO PORT
ZONE VALVE
AB
C1 2 C1
+ C
o
+ C
o
L N
230 VAC 5 amp
Mains Supply
Dual Thermostat
Gledhill Stainless Lite
Unvented Cylinder TAnti Gravity
Check Valve
Pressure
Relief Valve
Anti Gravity
Check Valve
Standard 10 way
wiring junction box
(Not supplied)
This valve must be tted on
the return to the solar panels
and be suitable for higher
temperatures operation
(Not
supplied)
No isolation valve
should be installed
between the solar
circuit and the safety
valve (pressure relief
valve)
Solar Controller
Schematic Showing Solar Wiring Requirements
INSTALLATION
INSTALLATION