gledhill Stainless Lite Direct 90-300 litres User guide

Design, Installation
& Servicing Instructions
Models
Stainless Lite Direct 90-300 litres
Stainless Lite Indirect 90-300 litres
Stainless Lite Solar Direct 180-300 litres
Stainless Lite Solar Indirect 180-300 litres
An unvented hot water storage unit complying
with the requirements of Building Regulations
Approved Document G3 and manufactured in
accordance with BS EN 12897,the specification
for the unvented water storage vessels.

Page 2
Section Page
DESIGN
Description 3
Technical Information 6
System Design 8
INSTALLATION
Installation 10
Commissioning 19
USER INSTRUCTIONS 20
SERVICING AND MAINTENANCE
Servicing and Maintenance 21
Fault Finding 22
Short Parts List 25
ADDENDIX
Addendix A 26
Addendix B 27
Service Record 28
Notes 29
Terms & Conditions 30
ISSUE 9:05-09
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
SafetyRegulations,BuildingRegulations,I.E.E.WiringRegulationsandtheWaterFitting
Regulations (England and Wales) or Water Byelaws (Scotland). It should be read in
accordance with the relevant recommendations of the following:
BS 6798;BS 5549;BS 5546;
BS 5440:1;BS 5440:2;CP 331:3
BS 6700:BS 5258 and BS 7593:1992
Stainless Lite is covered by Section G3 of the Building Regulations (England and
Wales)TechnicalStandardP3(Scotland)andBuildingRegulationP5(NorthernIreland.
Compliance can be achieved via a Competent Person Self Certification Scheme or
notificaton of installation to the Local Authority Building Control Department.
It must be installed by a competent person as defined 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.
Responsibilityforselectionandspecificationofourequipmentmusthoweverremainthat
ofour customerand anyexpertsor consultantsconcernedwith the installation(s).
PLEASE NOTE: THAT WE DO NOT THEREFORE ACCEPT ANY RESPONSIBILITY FOR
MATTERS OF DESIGN SELECTION OR SPECIFICATION, FOR THE EFFECTIVENESS
OF AN INSTALLATION OR SYSTEM CONTAINING ONE OF OUR PRODUCTS UNLESS
SPECIFICALLY REQUESTEDTO DO SO INWRITING.
AllgoodsaresoldsubjecttoourConditionsofSalewhicharesetoutattherearofthis
specification. IntheinterestofcontinuouslyimprovingtheStainlessLiterange,Gledhill
BuildingProductsLimitedreservetherighttomodifytheproductwithoutnotice,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.
AKIWAPRODUCTAPPROVEDTOCOMPLYWITHALLRELEVANTPARTSOFTHEBUILDING
REGULATIONS AND WATER SUPPLY (WATER FITTINGS) REGULATIONS.
StainlessLiteISPRODUCEDUNDERANISO9001:2008QUALITYMANAGEMENTSYSTEM
APPROVED BY BSI.
Aspartoftheindustrywide“benchmark”initiativeallGledhillStainlessLiteappliancesnow
includeaBenchmarkInstallation,CommissioningandServiceRecordLogBook.Pleaseread
carefullyandcompleteallsectionsrelevanttotheapplianceinstallation. Carryingoutthe
workrequiredandcompletingtheLogBookwillsatisfytherequirementsoftheBuilding
RegulationsforcommissioningassetoutintheDomesticHeatingComplianceGuide.The
detailsoftheLogBookwillberequiredintheeventofanywarrantyworkbeingrequired.
There is also a section to be completed after each regular service visit. The completed
LogBookandtheseinstructionsshouldbeleft with the cylinder.

Page 3
DESCRIPTION
DESIGN
Maintenance
Modifications should not be made to this
product. Replacement parts, including
immersion heaters,should be purchased from
Gledhill Building Products Limited, or agents
approvedbythem.Unventedhotwaterstorage
vessels need regular routine checks,and these
aredetailedbelow. Itisforthisreasonthatthis
manual must always be left with the Stainless
Lite.
It is essential that these checks be carried out
atthetimeofboilermaintenancebyaqualified
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 off and remove and
clean the strainer element in the Pressure
ReducingValve.
4. Checkthechargepressureintheexpansion
vessel and repressurise if required
5. Re-fill the system and ensure that all relief
valves have re-seated.
6. The Benchmark log book supplied should
be updated at each service.
7. Check the water pressure downstream of
the combination valve is 2.25 bar in static
condition.
8. Check and if necessary, descale the heat
exchanger in hard water areas ie. above
200ppm (mg/l).
Note:
Thecylinderisfactoryfittedwithatemperature
&pressurereliefvalvethatmustnotbeusedfor
any other purpose or removed.
The cylinder is factory fitted with immersion
heaters with thermal cut outs. Immersions
without thermal cut outs must not be fitted.
Manufacturer: GledhillBuildingProductsLtd
Maximum inlet pressure to
Pressure ReducingValve 12 bar
Operating pressure (PRV setting) 2.2 bar
Expansion ReliefValve setting 4.5 bar
Maximum primary working pressure 3.5 bar
Opening pressure ofT & P Relief Valve 6 bar
Opening temperature ofT & P ReliefValve 95°C
Energy cut-out thermostat setting 80°C
Immersion heater: Rating:3kW,240V AC
All cylinders are manufactured in accordance with the requirements of BS EN 12897
Thetundishmust bepositioned so that it isvisible totheoccupant and is awayfrom
electrical devices.
Components supplied with Stainless Lite:
• Cold water inlet combination valve
• Expansion relief/PRV combination valve
• Temperature and pressure relief valve
• Control thermostat
• Energy cut-out thermostat
• Energy cut-out motorised valve (indirects only)
• Tundish
• 3Kw Immersion heater
• Expansion vessel/mounting bracket/flexible hose
• Technical/user product literature
(Note:Two immersion heaters are supplied with the direct Stainless Lite)
Inanysituationwherethevolumeofheatedpipework(eg.secondarycirculation
pipes or manifold pipework for multiple units) exceeds 10 litres, then an
additionalexpansionvesselmustbefittedtoaccommodatetheextraexpansion
volume.
Handling Before Installation
StainlessLitemustbehandledwithcareandstoredthecorrectwayupinadryplace.
Anymanualhandling/liftingoperationswillneedtocomplywiththerequirementsof
the Manual Handling Operations Regulations issued by the H.S.E.The appliance can
bemovedusing a sack truckon the rearface although careshould be taken andthe
route should be even.Inapartment buildingscontaining anumber ofstoreys we would
recommendthattheappliancesaremovedverticallyin amechanicallift.If it is proposed
touseacrane,expertadviceshouldbeobtainedregardingtheneedforslings,lifting
beams etc.
A specific manual handling assessment is shown in Appendix B at the rear of this
manual.

Page 4
DESIGN
DESCRIPTION
Stainless Lite is a range of unvented hot water
storage cylinders, manufactured in the latest
high quality duplex stainless steel. They are
designedto provide mains pressure hot water
andaresupplied asa package whichcomplies
with Section G3 of the Building Regulations.
Theapplianceisextremelywellinsulatedusing
highdensityHCFCfreefoaminsulationwithan
ozone depleting potential (ODP) of zero and a
globalwarmingpotential(GWP)of1. Itisfitted
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
oroil boilers (Figure2). Unventedcylinders
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. StainlessLiteIndirectSolar -Forproviding
hotwaterbysolargainsandgasoroilboilers
(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,
unventedhotwaterstoragecylinderdesigned
primarily for use with off peak electrical
supplies.
It is supplied fitted with two 3kW immersion
heaterswhich are BEABapprovedfor safetyas
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 efficiency 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
boilermustincorporateitsownenergycut-out
overheat thermostat.
Stainless Lite indirect models are listed in
Table 1 on Page 6 & 7.
Stainless Lite
DIRECT Stainless Lite INDIRECT
Figure 1 Figure 2
Pipework is not supplied by manufacturer,
but to be supplied and fitted by installer.

Page 5
DESCRIPTION
DESIGN
Stainless Lite
DIRECT SOLAR Stainless Lite INDIRECT SOLAR
Figure 3 Figure 4
Pipework is not supplied by manufacturer,
but to be supplied and fitted by installer.
Stainless Lite Direct Solar
Stainless Lite direct is an electrically heated,
unventedhot water storagecylinder designed
primarily for use with off peak electrical
supplies.
It is supplied fitted with two 3kW immersion
heaters which are BEAB approved for safety as
recommended by the Electricity Council.
Ahighefficiencycoil is positionedin thelower
part of the Stainless Lite vessel to ensure
maximum benefit 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 efficiency 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
boilermustincorporateitsownenergycut-out
overheat thermostat.
Ahighefficiencysecondsolarcoilispositioned
below the primary coil to ensure maximum
benefit of solar gain energy.
Stainless Lite indirect models are listed in
Table 1 on Page 6 & 7.
Note:
The cold supply elbow c/w drain tapping
must be fitted as shown in figs 1,2,3 and 4.
Aflexiblehosecanthenbeconnectedtothe
drain tapping and,providing the hose runs
below the lowest level of the cylinder,then
allthewatercontentscanbedrainedoutby
syphonic action.

Page 6
DESIGN
TECHNICAL INFORMATION
Table 1
Model
Weight - Empty
Weight - Full
Capacity (Total Volume)
Pressure Regulator 2.25bar inlet
group c/w balance cold supply,
expansion vessel connection and
expansion valve set at 4.5 bar
ExpansionVessel size.
Pre-charged to 2.25bar
Overall Height
Overall Diameter
Pressure &Temperature
ReliefValve 6bar 90°C
22mm Secondary
ReturnTapping
On Peak 1¾”Incalloy
Immersion 3kW
Cold Feed 22mm
Compression Connection
Lower 1¾”Incalloy
Immersion 3kW
Volume of On PeakWater
Heated
Dual Control & Overheat Stat
kg kg Litres bar Litres A=mm mm B=mm C=mm D=mm E=mm F=mm Litres G=mm
Direct
D90 13 103 90 2.25 12 732 550 490 n/a n/a 367 223 n/a n/a
D120 18 138 120 2.25 12 920 550 678 n/a 487 367 223 55 n/a
D150 22 172 150 2.25 18 1107 550 865 n/a 587 442 223 70 n/a
D180 24 204 180 2.25 18 1295 550 1053 n/a 686 442 223 85 n/a
D210 28 238 210 2.25 24 1483 550 1241 1127 786 442 223 90 n/a
D250 32 282 250 2.25 24 1733 550 1491 1377 927 522 223 125 n/a
D300 37 337 300 2.25 35 2020 550 1777 1577 1077 522 223 155 n/a
Indirect
IND90 19 109 90 2.25 12 732 550 490 n/a n/a 367 352 n/a 367
IND120 22 142 120 2.25 12 920 550 678 n/a n/a 367 352 n/a 367
IND150 26 176 150 2.25 18 1107 550 865 n/a n/a 442 392 n/a 407
IND180 28 208 180 2.25 18 1295 550 1053 n/a n/a 442 432 n/a 447
IND210 33 243 210 2.25 24 1483 550 1241 1127 n/a 442 432 n/a 482
IND250 38 278 250 2.25 24 1733 550 1491 1377 927 522 512 125 577
IND300 44 344 300 2.25 35 2020 550 1777 1577 1077 522 512 155 677
Solar Direct
SOL180d 26 206 180 2.25 18 1295 550 1053 n/a 746 437 482 75 n/a
SOL210d 30 240 210 2.25 24 1483 550 1241 1127 908 437 544 80 n/a
SOL250d 34 284 250 2.25 24 1733 550 1491 1377 1092 522 629 100 n/a
SOL300d 39 339 300 2.25 35 2020 550 1777 1577 1287 522 724 115 n/a
Solar Indirect
SOL180i 30 210 180 2.25 18 1295 550 1053 n/a n/a 437 717 80 732
SOL210i 35 245 210 2.25 24 1483 550 1241 1127 n/a 437 822 95 837
SOL250i 40 290 250 2.25 24 1733 550 1491 1377 n/a 522 947 115 962
SOL300i 46 346 300 2.25 35 2020 550 1777 1577 n/a 522 1042 140 1092
A
C
Direct
D
F
E
B
A
Solar Direct
C
N
M
L
P
E
K
B
D
F
A
C
Indirect
D
H
F
E
I
J
B
G

Page 7
TECHNICAL INFORMATION
DESIGN
Extra Stat Pocket
For Boiler Use If Required
22mm Primary Return
Compression Connection
22mm Primary Flow
Compression Connection
22mm Solar Return
Compression Connection
22mm Solar Flow
Compression Connection
Dual Control/Overheat Stat
& Solar Control
Thermostat Pocket
Solar Pocket Solar Pocket
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 UpTime from 15°C to 60°C
(applies to Primary Heat Source only)
RecoveryTime after 70% Draw Off
(applies to Primary Heat Source only)
Standing Losses kWhr/24hr
Dedicated SolarVolume
H=mm I=mm J=mm K=mm L=mm M=mm N=mm P=mm kW m2bar m2bar min min kWh Litres
n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 90 58 0.80 n/a
n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 119 90 1.00 n/a
n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 150 121 1.20 n/a
n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 179 157 1.40 n/a
n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 209 192 1.60 n/a
n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 249 224 1.75 n/a
n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 299 263 1.93 n/a
367 223 312 n/a n/a n/a n/a n/a 16.5 0.59 0.165 n/a n/a 21 16 0.80 n/a
367 223 312 n/a n/a n/a n/a n/a 18 0.59 0.165 n/a n/a 27 19 1.00 n/a
407 223 352 n/a n/a n/a n/a n/a 18.5 0.68 0.191 n/a n/a 28 19 1.20 n/a
447 223 392 n/a n/a n/a n/a n/a 19 0.78 0.216 n/a n/a 33 21 1.40 n/a
482 223 392 n/a n/a n/a n/a n/a 20.5 0.78 0.216 n/a n/a 41 26 1.60 n/a
577 223 472 n/a n/a n/a n/a n/a 21.5 0.97 0.241 n/a n/a 44 30 1.75 n/a
677 223 472 n/a n/a n/a n/a n/a 25 0.97 0.241 n/a n/a 48 32 1.93 n/a
n/a n/a n/a 223 352 419 882 203 n/a n/a n/a 0.680 0.191 n/a 90 1.40 60
n/a n/a n/a 223 352 419 1000 203 n/a n/a n/a 0.680 0.191 n/a 115 1.60 70
n/a n/a n/a 223 472 539 1180 262 n/a n/a n/a 0.968 0.241 n/a 139 1.75 84
n/a n/a n/a 223 472 539 1367 262 n/a n/a n/a 0.968 0.241 n/a 187 1.93 100
n/a 457 677 223 352 419 882 203 18 0.59 0.165 0.680 0.191 28 16 1.40 60
n/a 522 782 223 352 419 1000 203 18.5 0.68 0.191 0.680 0.191 35 16 1.60 70
n/a 607 907 223 472 539 1180 262 19 0.78 0.216 0.968 0.241 38 19 1.75 84
n/a 702 1002 223 472 539 1367 262 20.5 0.78 0.216 0.968 0.241 41 20 1.93 100
F
Solar Indirect
N
G
P
I
E
K
J
A
B
M
L
C
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.assumestheboiler
output is adequate).
3. All connections are supplied with
compression fittings for direct
connection to copper pipework.

Page 8
INSTALLATION
INSTALLATION
Stainless Lite Direct
Basic Appliance
1. Hot water draw off (22mm) compression
2. Temperature&pressurereliefvalve90°/6bar
3. Hotwater secondary return22mm capped
(not fitted 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 off-peak)
Component kit supplied separately
A. Combination inlet group incorporating
pressure reducing valve, strainer, check
valve,balancecoldtakeoffpoint,expansion
reliefvalveandexpansionvesselconnection
points.
B. Portableexpansionvesselsc/wflexiblehose
and wall bracket
C. Tundish
Stainless Lite Indirect
Basic Appliance
1. Hot water draw off (22mm) compression
2. Temperature&pressurereliefvalve90°/6bar
3. Hotwater secondary return22mm capped
(not fitted to smaller sizes,see table 1)
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)
10. Primary flow (22mm))
Component kit supplied separately
A. Combination inlet group incorporating
pressure reducing valve, strainer, check
valve,balancecoldtakeoffpoint,expansion
reliefvalveandexpansionvesselconnection
points.
B. Potableexpansionvesselsc/wflexiblehose
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
1
2
3
4
7
5
6
9
8
10
Typical arrangement of component kit shown fitted to the appliance for clarity
Pipework to be supplied and fitted by installer.

Page 9
INSTALLATION
INSTALLATION
7
9
3
11
6
12
12
1
2
8
4
5
10
Stainless Lite Direct Solar
Basic Appliance
1. Hot water draw off (22mm) compression
2. Temperature&pressurereliefvalve90°/6bar
3. Hotwatersecondaryreturn22mmcapped
(not fitted 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 off-peak)
7. Dual control/Overheat stat & solar
thermostat pocket
8. Solar coil return to panel collector (22mm)
compression
9. Solarcoil flowfrompanel (22mm) compression
10. Solar thermostat pocket
Component kit supplied separately
A. Combinationinletgroupincorporatingpressure
reducing valve, strainer, check valve, balance
cold take off point,expansion relief valve and
expansion vessel connection points.
B. Portableexpansionvesselsc/wflexiblehose
and wall bracket
C. Tundish
D. Dual control thermostat and combined
overheat thermostat
Stainless Lite Indirect Solar
Basic Appliance
1. Hot water draw off (22mm) compression
2. Temperature&pressurereliefvalve90°/6bar
3. Hotwatersecondaryreturn22mmcapped
(not fitted to smaller sizes,see table 1)
4. Immersion heater 1¾”BSP 3kW
5. 22mm cold supply
6. Thermostat pocket (22mm)
7. Primary return (22mm)
8. Primary flow (22mm)
9. Dual control/Overheat stat & solar
thermostat pocket
10. Solar coil return to panel collector (22mm)
compression
11. Solarcoil flowfrompanel (22mm) compression
12. Solar thermostat pocket
Component kit supplied separately
A. Combinationinletgroupincorporatingpressure
reducing valve, strainer, check valve, balance
cold take off point,expansion relief valve and
expansion vessel connection points.
B. Potableexpansionvesselsc/wflexiblehose
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 fitted to the appliance for clarity
Pipework to be supplied and fitted by installer.

Page 10
INSTALLATION
INSTALLATION
General Design Considerations
The cupboard footprint needs to be at least
650mm square.
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
dischargepipeworkforthesafetyvalvesmusthave
a minimum fall of 1 : 200 from the unit to a safe
discharge point. All exposed pipework should be
insulated and the unit should NOT be fixed in a
locationwherethecontentscouldfreeze.
The pipe connecting the boiler flow to the
appliancemustnotbelessthan22mmcopper
or equivalent.
MainsWater Supply
Existing properties with a 15mm supply will be
satisfactory provided the local mains pressure
is good, but should be confined to single
bathroomproperties. Fornewpropertieswhere
simultaneous demand is required to more than
one bathroom or a bathroom and one or more
en-suites,the communication and service pipe
intothedwellingshouldbeaminimumof22mm
(usually in the form of a 25mm MDPE supply).
The minimum recommended static pressure
to operate a Stainless Lite domestic system is 3
bar. There should be a flow of at least 30 litres
perminuteoraboveavailableintotheproperty.
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 BS6700.
Model Selection
The suggested Direct model sizes, shown
opposite,are based on a typical days hot water
use assuming an Economy 7 tariff is provided.
A reduction of one model size can normally be
made with an Economy 10 tariff.
When using the Direct models for high
specification developments an increase of one
model size should be considered.
Where selecting a solar model, it is important to
check the dedicated solar volume (shown in table
1 on page 7) is suitable for the total floor area of
the dwelling to ensure compliance with Building
Regulations.Themaximumfloorareaofthedwelling
permittedforthemodelsisshownopposite.
The suggested model sizes are based on
typical hot water usage. For high specification
dwellings an increase of one model size should
beconsidered.
I.V.
Combination Valve
I.V.
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 -
IftwoStainlessLitesare coupledtogetherthesecondaryinletand outlet pipesmust
be balanced.The units must be fitted on the same level.
Note:No valves must be fitted between the expansion vessel and the storage cylinder(s).
Solar Model Selection Guide
Max hot water demand Max floor
area (m2)Bedrooms Indirect
litres Direct litres
1 shower room 44 Bedsit - 180
1 bathroom 44 1-3 180 -
1 bathroom 66 1-3 210
1 bathroom + 1 shower room 66 1-3 210 -
1 bathroom + 1 shower room 84 1-3 - 250
1 bathroom + 2 shower rooms 84 2-4 250 -
1 bathroom + 2 shower rooms 113 2-4 - 300
2 bathrooms + 1 shower room 113 3-4 300 -

Page 11
INSTALLATION
INSTALLATION
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 off point should not exceed 10 metres above
the Pressure ReducingValve.
b. AnascendingspraytypebidetoranyotherappliancewithaClass1back-syphonage
risk requiring a type A air gap should not be used.
c. StainlessLite shouldnot be used where steam isthe primary heatingmedium,or
in a situation where maintenance is likely to be neglected.
d. Unvented cylinders are not suitable for use with solid fuel boilers.
e. Ifthe supply to the mixerfittings (other than a dual outlet type) is not taken
fromthebalancedsupplythesystemwillbecomeoverpressurizedandcause
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
thecombinationvalve. Inthiscaseitwillalsobenecessarytofitasmallexpansion
vesselonthebalancedcoldwatersystemtoaccommodatethepressurerisecaused
by the increase in temperature of the balanced cold water.
g. Checktheperformancerequirementsoftheterminalfittingswith regardtoflow/
pressure are suitable.
Shower Fittings
Aeratedtapsarerecommendedtopreventsplashing.Anytypeofshowermixingvalve
can be used as long as both the hot and cold supplies are mains fed. However, all
mainspressuresystems aresubject todynamic changesparticularlywhen other hot
andcoldtaps/showersareopenedandclosed,whichwillcausechangesinthewater
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
propertieswheretheimpactonpressure/temperatureofopeninganothertapinthe
system is greater than normal.The shower head provided must also be suitable for
mains pressure supplies.
Pipe Layout
Inallmainspressureinstallationsitisimportant
to remember that the incoming cold supply
mustbesharedbetweenallterminalfittings. It
isimportant that a 22mm supplyis brought to
theapplianceanda22mmtake-offiscontinued
atleasttothebath. Iftherearetwobaths,28mm
pipeworkshould be considered. Onemetre of
smaller diameter pipework,or flow restrictors,
should be provided on the final connection to
all outlets so as to balance the water available.
In any event the distribution pipework should
generally be in accordance with EN806:1.
Plastic Pipework
This appliance is suitable for use with
plastic pipework as long as the material
is recommended for the purpose by the
manufacturerandisinstalledfullyinaccordance
with their recommendations.
Secondary Hot Water Circulation
Somemodelsarefittedwithasecondaryreturn
tapping as standard (see table 1 for details).
If fitted, an extra expansion vessel may be
necessary. Anon-returnvalveMUSTbeFITTED
nearthereturnconnection. Novalveorterminal
fitting should be installed between the non
return valve and the cylinder. (See schematic
arrangement on page 13.)

Page 12
INSTALLATION
INSTALLATION
15 mm
discharge
pipe
Expansion
relief valve
Typical Discharge Pipe Arrangement
Dotted line showing
alternative route with
single tundish being used
500 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, roofing 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
fixed grating
Fixed Grating
Trapped gully
Pressure & Temperature/expansion Relief
Valve Pipework
Thereliefvalveshouldbeinstalledtodischarge
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
madetoApprovedDocumentG3oftheBuilding
Regulations.The final 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
samespace asthe unventedhot water storage
system and be fitted as close as possible and
within 500mm of the safety device e.g. the
temperature relief valve.
Thedischargepipe(D2)fromthetundishshould
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
nominaloutletsizeofthesafetydeviceunless
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
leasttwosizeslargerthanthenominaloutlet
size of the safety device, between 18 and
27mat least 3sizes larger,and so on. Bends
must be taken into account in calculating
the flow resistance. Refer to the table and
the worked example.
An alternative approach for sizing
discharge pipes would be to follow BS6700
Specification for design installation,testing
andmaintenanceofservicessupplyingwater
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
TheexamplebelowisforG1/2temperaturereliefvalvewithadischargepipe(D2)
having 4 elbows and length of 7m from the tundish to the point of discharge.
FromTable 1:
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.
5.8mis lessthan the actual length of 7mthereforecalculate the next largestsize.
Maximumresistanceallowedforastraightlengthof28mmpipe(D2)fromaG1/2
temperature relief valve equates to:14m.
As the actual length is 7m,a 28mm (D2) copper pipe will be satisfactory.
Table 1: 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 figure
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

Page 13
INSTALLATION
INSTALLATION
d) Itispreferableforthedischargetobevisibleatboththetundishandthefinalpoint
of discharge but where this is not possible or practically difficult there should be
clearvisibilityatoneorotheroftheselocations. Examplesofacceptabledischarge
arrangements are:
1. Ideally below the fixed 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
suchascarparks,hardstandings,grassedareasetcareacceptableprovidingthat
wherechildrenplayorotherwisecomeintocontactwithdischarges,awirecage
or similar guard is positioned to prevent contact whilst maintaining visibility.
3. Dischargesatahighlevel;e.g.intometalhopperandmetaldownpipewiththe
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 flats,
the number served should be limited to not more than 6 systems so that any
installationcanbetracedreasonablyeasily. Thesingle commondischargepipe
shouldbeatleastonepipesizelargerthanthelargestindividualdischargepipe
to be connected. If unvented hot water storage systems are installed where
dischargesformsafetydevicesmaynotbeapparenti.e.indwellingsoccupiedby
blind,infirmordisabledpeople,considerationshouldbegiventotheinstallation
of an electronically operated device to warn when discharge takes place.
Safety
ThesafetydevicessuppliedorfittedonanStainlessLiteareselectedfortheirsuitability
forthe temperaturesandpressuresinvolved. Theymustnotbechanged,removedor
by-passedanditisessentialthatonlygenuinereplacementpartssuppliedorapproved
by Gledhill Building Products Limited are used.This includes the immersion heaters,
whichmustincorporateanenergycut-out.Allpartsareavailabletoapprovedinstallers
from Gledhill Building Products Limited, Sycamore Estate, Squires Gate, Blackpool
(Telephone [phone]).
P&T Relief Valve
Tundish
Hot Outlet
To Drain
PRV
ERV NRV
Stop
Tap
Kitchen
Cold
Tap Combination
Valve
Balanced
Cold
Outlets
Immersion Heater
Expansion
Vessel
Boiler
Return
Boiler
Flow
2 Port Valve
Secondary
Return Circuit
Schematic Diagram
Non Return
Valve
Pump
Combination Inlet Group
Combines elements 1,2 and 3 below.
1. PressureReducingValve -This must be fixed
near the cylinder. The cold water supply to
anymixertaps/showersmustbetakenfrom
thecoldwatertappingofthisvalvetoensure
balancedhotandcoldpressures. Thisvalve
isfactorysettoensurethecorrectoperating
pressure for the Stainless Lite.
2. Non Return Valve - This is integral with the
pressurereducingvalvetopreventbackflow
of hot water towards cold water draw off
points.
3. ColdWaterExpansionReliefValve-Thissafety
deviceispresetatthefactoryandwillrelieve
excesscoldwater pressureresulting froma
fault condition.

Page 14
INSTALLATION
INSTALLATION
Safety
Cut-out
Thermostat
Immersion HeaterWiring
E
L
N
Temperature/pressure ReliefValve
This safety device is also pre-set at the factory and relieves before the temperature
reaches 100°C.It is also a Pressure ReliefValve,and is pre-set to 6 bar.
Immersion Heaters
These are 3kW 240V AC heaters and incorporate a thermostat and a manually reset
energycut-out whichoperatesat80°C. Theyhaveincalloyelementstoprolongtheir
life expectancy in aggressive water conditions.
Two immersion heaters are fitted to all direct models and the indirect 250 and 300
models.Allothermodelshaveoneimmersionheaterfitted. Whereitisintendedthat
unitsarefittedtooffpeakcircuits,thensuitablecontrollerssuchastheHorstmannoff
peakelectrictimecontrollerwillberequired. Externalwiringtotheimmersionheaters
mustbe in accordancewith therelevantIEEWiring Regulationsand the circuitmust
be protected by a suitable fuse and a double pole isolating switch.
The correct method of terminating the wiring to the immersion heater is shown
opposite.
Line Strainer
This is integral within the combination inlet group to reduce the likelihood of
contaminantsfoulingthe valveseat. Followinginstallation this linestrainer mustbe
cleaned and replaced. This needs to be carried out on a regular basis.as part of the
annual maintenance/service check.
Tundish
Thisisto allowthe discharge fromanyReliefValve tobeseen. Itmust be fitted away
from any electrical devices. See page 13 for discharge pipework details.
Safety
The immersion heaters must be earthed and they must be isolated from the mains
before the cover is removed on every occasion. Replacement immersion heaters
should be obtained from Gledhill Building Products Limited.
Control/overheat DualThermostats
Caremustbetakentoensurethatthesolarprobesarefullyinsertedintothepockets
provided.

Page 15
INSTALLATION
INSTALLATION
Heating/primary Systems
Theboilerandprimary/heatingsystemsshould
be sized and installed in accordance with BS
5449.
Safety
Stainless Lite is fitted with a Combined
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
Itisessentialthatthecircuitbetweentheboiler
andtheStainlessLiteispumped.Themotorised
zone valve supplied should be fitted adjacent
to the unit and controlled by the cylinder
thermostat supplied. The thermostat and
motorisedvalvemustbewiredsothattheyboth
switchoffshouldanoverheatsituationdevelop.
It is important to follow the wiring diagram in
theWiring Section of these instructions.
Sealed Primary Circuit
Any boiler used must be fitted 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 effective backflow
prevention device is permanently connected
at the inlet to the circuit and the temporary
connection is removed after use.
Alternatively,aCAdevicecanbeused,whichwill
allowthesystemtobepermanentlyconnected
to the cold mains supply.The primary system
can then be topped up,when required,in the
samewayasanopenventedsystemfittedwith
an F&E Cistern.
Schematic OpenVented Primary System
Boiler
Pump
150mm max.
Warming/Overflow
Pipe
F & E Cistern
Minimum
distance as
required by
boiler
manufacturers
instructions
Motorised Valve
Motorised Valve
(Energy cut-out)
Schematic Sealed Primary System
Boiler
Motorised Valve
Motorised Valve
(Energy cut-out)
Expansion
Vessel
Gauge
Safety Valve
Pump

Page 16
INSTALLATION
INSTALLATION
Schematic Solar Direct System
Solar Pumping Station
Solar Panel
Expansion
Vessel
Solar
Controller
Motorised Valve
Energy cut-out
(Not supplied)
Allcomponentsinasolarprimarysystemmust
be marked or identifiable in such a way that
their design pressure and temperature can be
readily determined.
Asafetydevice(pressurereliefvalve)tocontrol
theriskofover-pressureinsystemcomponents
should be fitted. A termination from a safety
pressure device should minimise the risk of
damage to persons or materials. Suitable
locationsareahightemperaturereceptacle,an
internalgullyor elseissueexternallyatground
level. High level termination from walls or on
roofs could cause injury to people or animals
belowifthevalveweretoreleasescaldingwater
and steam.
The pipe leading to the safety device and
the collector should be of rigid and non-
deformableconstruction,withoutanypossibility
of restriction or disclosure by any other fitted
component.
Amoredetaileddiagramofourrecommended
arrangementforatypicalsolarsystemisshown
on page 17.
This provides all the necessary controls and
safetydevicesnecessaryforthesolarsystemi.e.
the two port zone valve is wired as an energy
cutoutandthepump/valvewillonlyallowheat
transfer as required under control of the Delta
Sol controller.
The pocket provided for the Dual Thermostat
also includes the facility to accommodate an
8mm diameter sensor which, with the sensor
located in the solar collector (or in the flow
pipeimmediatelyadjacenttothecollector),will
provide the information required by the Delta
Sol BS controller.
Note:Ifthemotorisedvalveisnotusedthen
any factory built hydraulic station for solar
useMUST befittedwithsuitablenon-return
valves in both flow and return pipes to
prevent gravity circulation when the pump
is not running.
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)

Page 17
INSTALLATION
INSTALLATION
19876543210
12 3456 78
S1 S2 S3
201918171615141312
LNR1R2 NN
T
S1
S1
1 bar
Solar
Pumping
Station
Solar Coil
DeltaSol BS
TWO PORT
ZONE VALVE
AB
C12C1
+ C
o
+ C
o
LN
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 fitted 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)
Schematic Showing SolarWiring Requirements

Page 18
INSTALLATION
INSTALLATION
19876543210
11 12
NL1234
Clock OFF ON OFF ON
HW CHST6400
V4043A TWO PORT ZONE VALVE
AB
HTG
V4043A TWO PORT ZONE VALVE
AB
DHW
123 4
Room Thermostat T6360 T6360B1028
GLEDHILL HE BOILER
L
L_P
SL_B
E
N
N_P
E_P
C12C1
Dual Aqua Stat
Control Stat Overheat Stat
LNE
Boiler Pump
Mains Supply Fed Via Double Pole Isolator 230 VAC ~ 5 Amps
Danfoss WB12 Wiring Centre
SL-B
LNE
HTG VALVE
HW VALVE
Typical schematic wiring diagram for an unvented installation
The electrical installation must
comply with IEE requirements.
For electrical installation
refer to BS7671
Note: Do not attempt
the electrical work unless
you are competent to carry
out to the above standard
BlueBl BrownBr
Green Grey Green / Yellow
G Gr G/Y
WIRE COLOUR LEGEND
Black Orange Yellow White Red
B Or Y Wh R
Br Bl G/Y B Br Br Bl G/Y Or Gr
Br Bl G/Y
Br Bl G/Y Or Gr Br Bl G/Y Or Gr
5 Amps
Br Bl G/Y Br Br B B *Br Bl G/Y Br B
Bl Br Br Br
Br Bl B
G/Y G/Y Br *Br
* Blue core used from standard 3 core flex please ensure you use brown sleeving at both terminating ends to identify core potential.
3 core flex
4 core cable
LN
Br Bl G/Y BBr Bl G/Y 3 core flex
4 core cable
ISSUE No : 1
APPROVED
DRN. DATE
04-01-08
S. McGachie

Page 19
COMMISSIONING
INSTALLATION
Connections can come loose in transit, and all should be checked before
installation.
Ensurethattheimmersionheatersettingis60°Candthatthewiringis inaccordance
with the diagram.
Checkthepressureontheairsideoftheexpansionvessel=2.2bar. Thismustbedone
when the volume in the cylinder is cold.
Checkthatthedraincockisclosed,andopenallthecoldandhotwatertapsandother
terminalfittings. Allowthesystemtofillwithwater,andtorununtilthereisnoairleft
in the system. Close the taps and inspect the system closely for leaks.
Manually open the ReliefValves one by one and check that water is discharged and
runfreely through the tundish and out at the discharge point. Thepipework should
accept full bore discharge without overflowing at the tundish,and the valve should
seat satisfactorily.
Allowthecylindertoheattonormalworkingtemperature,thenthoroughlyflushthe
domestic hot and cold water pipework through each tap.
NOTE: If this appliance is to be installed in other than a single domestic dwelling ie.
in an apartment block or student flats etc.,the hot and cold water system will need
to be disinfected in accordance with BS6700 and theWater Regulations.
Because the Stainless Lite appliance is stainless steel, the use of chlorine as the
disinfectionagentcancausedamageunlesstheapplianceisadequatelyflushedand
refilledwiththemainswaterimmediatelyoncompletionofthedisinfectionprocedure.
Damage caused through a failure to do this adequately will not be covered by the
warranty.
For the above reasons we recommend the use of a non chlorine dased disinfectant
suchasFernoxLPSteroxasmanufacturedbyCooksonElectronicswhencarryingout
disinfection of systems incorporating these appliances.
Removethefilterfromthecombinationinletgroupcleanandreplace. Refillthesystem
and open all hot taps until there is no air in the pipe work. ENSURE CYLINDER IS
DRAINED PRIORTOCHECKING OR REMOVINGFILTER FROMTHE COMBINATION
INLET GROUP.
Allowthecylindertoheattonormalworkingtemperaturewithwhateverheatsource
isto beused,and checkagain forleaks. ThePressureReliefValve shouldnot operate
during the heating cycle.
The boiler/heating systems should be filled
and commissioned in accordance with good
practicefollowingtheguidanceinBS5449/the
boilermanufacturersinstructions.Thisincludes
adequatelyflushing the system to removeany
debris that may have been introduced during
installation/maintenance.
NOTE:ThisapplianceiscoveredbyBENCHMARK
and the log book must be completed after
commissioning and after every maintenance/
service visit.
IMPORTANT - DRAIN DOWN PROCEDURE
1 Switch off both the boiler and the immersion heater
2 Open the nearest hot tap and run all hot water until cold
3 Close the incoming cold main at the stop tap
4 Holdopenthepressureandtemperaturereliefvalveuntilwaterstops
discharging into the tundish
5 Open all the taps in the property
6 Open the drain cock and immediately hold open the pressure and
temperature relief valve again until the cylinder is empty

Page 20
YourStainlessLiteunventedcylinderisautomaticinnormaluse,butrequiresroutine
maintenance which is normally carried out at least annually along with the boiler
service.Themaintenancemust be carriedout bya suitablycompetenttradesperson
who is qualified to work on unvented cylinders.The checks/work needed are listed
in the maintenance part of these Instructions.
The temperature of the hot water is adjustable,but the control thermostat should
havebeen set to60˚C tomeet therelevantregulations/ensuresafe operation.Inthe
directpattern,thecontrolthermostatispartoftheimmersionheaterandshouldonly
be adjusted by a suitably competent tradesperson. A simple, manually adjustable
control thermostat is fitted to the indirect pattern units,but it is recommended that
this is left at 60˚C as hotter water will increase the risk of scalding.
When initially opening the taps, a small surge in flow may be experienced, which
disappears as the pressure in the system stabilises.This is quite normal with these
types of systems and does not indicate a fault.
Insomeareasthewaterwill initiallyappearcloudy,but willquickly clearwhenleft to
stand.This is nothing to be concerned about and is due to aeration of the water.
WARNING-Ifwaterisseenflowingthroughthetundish,thisindicatesafaultcondition
which needs action.
If the discharge is hot and continuous,turn the boiler and/or the immersion heaters
off,butdonotturnoffthecoldwatertotheapplianceuntilthedischargeiscold.Note:
The discharge may stop by itself as the discharge cools.
If the discharge is cold and intermittent, no immediate action is needed but this
indicates a problem with the expansion vessel.
However,inbothcasesyoumustcalltheregisteredinstaller/asuitablyqualified,
competent tradesperson,advise them that you have an unvented cylinder and
request a maintenance visit.
DONOT,atanytime,tamperinanywaywiththesafetyvalvesoroverheatthermostats/
wiring.
USER INSTRUCTIONS
USER INSTRUCTIONS