gledhill StainlessLite HP180IND, StainlessLite HP210IND, StainlessLite HP300IND, StainlessLite HP400IND, StainlessLite HP250IND Design, Installation & Servicing Instructions

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Design, Installation & Servicing Instructions

Models covered in this manual

Stainless Lite HP Direct 180-400 litres

StainlessLite HP

Unvented cylinders specifically designed to work with a heat pump

Page 2

Section Page

DESIGN

Description 3 Technical Information 5 System Design 6

INSTALLATION

Installation 7 Commissioning 18

USER INSTRUCTIONS 19

SERVICING AND MAINTENANCE

Servicing and Maintenance 20 Fault Finding 21 Short Parts List 23

APPENDIX

Appendix A 24 Appendix B 25

Benchmark Checklist 26 Benchmark Service Record 27

Notes 28

Terms & Conditions 30

ISSUE 3: 05-11

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 the W ater F itting Regulations (England and Wales) or Water Byelaws (Scotland). I t 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) T echnical Standar d P3 (Scotland) and Building Regulation P5 (Northern Ireland). Compliance can be achieved via a Competent Person Self Cer tiﬁ cation Scheme or notiﬁ caton of installation to the Local Authority Building Control Department.

It must be installed by a competent person as deﬁ 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 speciﬁ 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 speciﬁ cation, for the eff ectiveness of an installation or system containing one of our products unless speciﬁ 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 speciﬁ 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.

A KIWA product approved to comply with all relevant parts of the Building Regulations and Water Supply (Water Fittings) Regulations. Visit www.kiwa.co .uk f or more informa tion.

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 f or more information.

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 wat er 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 qualiﬁ 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 off and remove and clean the strainer element in the Pressure Reducing Valve.

4. Check the char ge pressure in the expansion vessel and repressurise if required

5. Re-ﬁ 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 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 ﬁ tted with a temperature & pressure relief valve that must not be used for any other purpose or removed.

The cylinder is factory ﬁ tted with immersion heaters with thermal cut outs. Immersions without thermal cut outs must not be ﬁ 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 4.75 bar Opening pressure of P & T Relief Valve 6 bar Opening temperature of P & T Relief Valve 95°C Energy cut-out thermostat setting 80°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

• Pressure and temperature relief valve

• Control thermostat

• Energy cut-out thermostat

• Energy cut-out motorised valve (indirects only)

• Tundish

• 3kW Immersion heater

• Expansion vessel/mounting bracket/ﬂ exible hose

• Technical/user product literature (Note: Two immersion heaters are supplied with the direct Stainless Lite)

In any situation where the volume of heated pipew ork (eg. secondary circulation pipes or manifold pipework for multiple units) exceeds 10 litres, then an additional expansion vessel must be ﬁ 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 f or slings, lifting beams etc.

A speciﬁ c manual handling assessment is shown in Appendix B at the rear of this manual.

DESIGN

DESCRIPTION

Page 4

DESCRIPTION

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 ﬁ 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 Heat Pump (HP) models:

The Stainless Lite HP is an unvented hot water storage cylinder ﬁ tted with two high efﬁ ciency internal primary heat exchangers especially designed for use with heat pump systems. These two heat exchangers can be connected in parallel to the heat pump circuit when a solar thermal system is not installed. When both heat pump and solar thermal systems are installed, the top heat exchanger is connected to the heat pump circuit and the bottom heat exchanger is connected to the solar circuit a shown in ﬁ gure 2.

All Stainless Lite HP models are ﬁ tted with 3kW (230Vac, 50Hz) immersion heater for raising the temperature of the stored water to about 60°C after the heat pump heating cycle if necessary. The technical details of the Stainless Lite HP models are listed in table 1.

Important notes:

1. All Stainless Lite HP models are suitable for both open vented and sealed primary systems.

2. When used with a sealed primary heating system, the heat pump must incorporate its own over heat thermostat.

3. Stainless Lite HP models must not be used with solid fuel boilers or steam as the heat source.

4. Heat pumps can normally only heat the domestic hot water to between 45 – 50°C, therefore provision should be made to periodically heat the cylinder to about 65°C to prevent growth of legionella.

5. The cold supply elbow c/w drain tapping must be ﬁ tted as shown in ﬁ gures 1 &

2. A ﬂ 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 content can be drained out by the symphonic action.

DESIGN

DESCRIPTION

Page 5

,00

45,00

0º

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 ﬁ ttings for direct connection to copper pipework.

1. Measured at 0.25 l/s primary ﬂ ow rate 2. Measured at 0.25 l/s primary ﬂ ow rate and at 82°C ﬂ ow temperature

Table 1

Stainless Lite HP Model HP180IND HP210IND HP250IND HP300IND HP400IND

Capacity - total volume litres 180 210 250 300 400 Volume heated by IH litres 113 135 160 195 270 Dedicated solar volume litres 65 75 90 105 130 Standing heat loss rate kWh/24h 1.40 1.60 1.75 1.93 3.33 Weight - empty/full kg 33/213 38/248 43/293 49/349 61/461 Pressure regulating valve setting bar 33333 Expansion relief valve setting bar 4.75 4.75 4.75 4.75 4.75 Temperature setting (P&T valve) °C 90 90 90 90 90 Pressure setting (P&T valve) bar 6.0 6.0 6.0 6.0 6.0 Expansion vessel size (volume) litres 18 24 24 35 2 x 24 Expansion vessel initial charge pressure bar 2.25 2.25 2.25 2.25 2.25 Height A mm 1295 1483 1733 2020 2040 Diameter B mm 550 550 550 550 630 22mm secondary return C mm - 1127 1377 1577 1592 22mm compression cold feed D mm 442 442 522 522 557 P & T valve E mm 1053 1241 1491 1777 1784 22mm solar return - bottom coil F mm 223 223 223 223 238 22mm solar ﬂ ow - bottom coil G mm 352 352 472 472 548 28mm primary return - top coil H mm 467 542 647 742 641 28mm primary ﬂ ow - top coil I mm 1072 1232 1467 1562 1791 Dual CT & OHT pocket - 1 top J mm 732 837 962 1092 1076 Dual CT & OHT pocket - 2 bottom K mm 419 419 539 539 651 Solar sensor pocket - 1 top L mm 882 1000 1180 1367 1382 Solar sensor pocket - 2 bottom M mm 203 203 262 262 334 3kW immersion heater height N mm 457 522 607 702 640 Surface area of solar heater coil m

0.68 0.68 0.97 0.97 1.27

Solar coil pressure loss

bar 0.191 0.191 0.241 0.241 0.31

Primary heat exchanger surface area m

1.36 1.56 1.94 2.04 2.91

Primary heat exchanger thermal rating

kW 24.3 26.2 27.5 34.2 47.2

Primary heat exchanger pressure loss

bar 0.048 0.054 0.060 0.019 0.027

Heat up time from 15°C to 60°C

min 33 41 44 48 49

Recovery time after 70% draw-off

min 21 26 30 32 38

DESIGN

TECHNICAL INFORMATION

Page 6

12 13

4 5

Stainless Lite HP

Basic Appliance

1. Hot water draw off (22mm) compression

2. Temperature & pressure relief valve 95°/6 bar

3. Hot water secondary return 22mm (not ﬁ tted to smaller sizes, see table 1)

4. Immersion heater 1¾” BSP 3kW

5. 22mm cold supply

6. Thermostat pocket (22mm)

7. Primary return (28mm)

8. Primary ﬂ ow (28mm)

9. Dual control/Overheat stat & solar thermostat pocket

10. Solar coil return to panel collector (22mm) compression

11.

Solar coil ﬂ ow from panel (22mm) compression

12. Solar thermostat pocket

13. Drain off

Component kit supplied separately

Combination inlet group incorporating pressure reducing valve, strainer, check valve, balance cold take off point, expansion relief valve and expansion vessel connection points.

B. Potable expansion vessels c/w ﬂ 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

Typical arrangement of component kit shown ﬁ tted to the appliance for clarity

Pipework to be supplied and ﬁ tted by installer.

DESIGN

SYSTEM DESIGN

Page 7

General Design Considerations

The cupboard footprint needs to be at least 650mm square for units up to 300 litres, 730mm for 400 litre 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 should be insulated and the unit should NOT be ﬁ xed in a location where the contents could freeze.

The pipe connecting the boiler ﬂ ow to the appliance must not be less than 22mm copper or equivalent.

Mains Water Supply

Existing properties with a 15mm supply will be satisfactory provided the local mains pressure is good, but should be confined to single bathroom properties. F or new properties where simultaneous demand is required to more than one bathroom or a bathroom and one or more en-suites, the communication and ser vice pipe into the dwelling should be a minimum of 22mm (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 ﬂ ow of at least 30 litres per minute or above available into the property . 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.

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 ﬁ tted on the same level.

Note: No valves must be ﬁ tted between the expansion vessel and the storage cylinder(s).

INSTALLATION

Page 8

INSTALLATION

Model Selection

The suggested model sizes shown in the table opposite are based on a typical daily hot water usage and on the assumption that the heat pump will heat the domestic hot water to about 50°C. F or higher speciﬁ cation, an increase of one model size should be considered.

When selecting a solar model, it is important to check the dedicated solar volume shown in table 1 is suitable for the total ﬂ oor area of the dwelling and/or net area of the solar collectors to ensure compliance with the Building Regulations.

When Stainless Lite HP is connected to both heat pump and solar thermal systems, then during the winter period the solar contribution will be negligible and the heat pump will only heat about 65% of the cylinder volume. This should be taken into account when selecting the model.

Stainless Lite HP Model Selection Guide

Dwelling type Suggested model

Number of

bedrooms

Number of

bathrooms and

shower rooms

Without solar

heating system

(1)

With solar heating

system

(2)

1-3 1 bathroom HP180IND HP180IND (FA=50m2) 2-3

1 bathroom +

1 shower room

HP180IND HP210IND (F

=65m2)

2-3

1 bathroom +

2 shower rooms

HP180IND HP250IND (F

=85m2)

2-4

2 bathrooms + 1 shower room

HP210IND HP300IND (F

=110m2)

2-4

2 bathrooms +

2 shower rooms

HP250IND HP400IND (F

=150m2)

3-5

2 bathrooms +

2 shower rooms

HP300IND –

4-5

2 bathrooms +

3 shower rooms

HP400IND –

Notes

1 Both top and bottom heat exchangers connected to heat pump circuit 2 Top heat exchanger connected to heat pump circuit and bottom heat exchanger connected to solar circuit. 3 FA = Maximum ﬂ oor area of the dwelling for compliance with the Building Regulations

INSTALLATION

Page 9

INSTALLATION

Stainless Lite HP/Heat Pump Selection Guide

The table above can be used to match heat pumps to heat pump cylinders. To use, first obtain the maximum flow rate from the heat pump manufacture’s

instructions, match this t o the ﬂ ow rates in section 1 and follow this ﬂ ow rate’s column down through the other sections.

Section 2 shows the velocity in the pipe work of different diameters at this ﬂ ow rate. A maximum ﬂ ow velocity of 1m/s has been chosen to limit ﬂ ow noise. U se this section to choose the correct pipe diameter.

Stainless Lite HP/Heat Pump Selection Guide

1 - Flow rates in various units for comparison with heat pump manufacturers data

m3/h 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 3.75 4.00 4.25 l/min 8.33 12.50 16.67 20.83 25.00 29.17 33.33 37.50 41.67 45.83 50.00 54.17 58.33 62.50 66.67 70.83 l/sec or kg/s 0.14 0.21 0.28 0.35 0.42 0.49 0.56 0.63 0.69 0.76 0.83 0.90 0.97 1.04 1.11 1.18

2 - Velocity in pipe (limited to 1 m/s maximum) for pipe sizing

m/s in 22mm 0.37 0.55 0.73 0.91 - - ---------m/s in 28mm 0.23 0.34 0.45 0.56 0.68 0.79 0.90 --------m/s in 35mm 0.14 0.22 0.29 0.36 0.43 0.51 0.58 0.65 0.72 0.79 0.87 0.94 - - - m/s in 42mm 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85

3 - Operating power of heat exchanger suitable for cylinder based on a 5 degree temperature difference

kW @ 5K dt 3-4 4-6 5.5-8 7-10 8-12 10-14 11-16 13-18 14-20 16-22 17-24 18-26 20-28 21-30 23-32 24-34 180HP ---------180HP + Sol -----210HP --------210HP + Sol ----250HP --------250HP + Sol ----300HP ----300HP + Sol 400HP ----400HP + Sol -

4 - Pressure loss (bar) for each ﬂ ow rate above in the available coil combinations

180HP 0.010 0.027 0.053 0.092 0.143 0.207 0.286 0.381 0.491 0.618 0.763 0.927 1.109 1.310 1.532 1.774 180HP + Sol 0.003 0.008 0.017 0.031 0.049 0.073 0.103 0.140 0.183 0.234 0.292 0.359 0.434 0.518 0.612 0.715 210HP 0.017 0.040 0.074 0.118 0.173 0.239 0.316 0.405 0.505 0.617 0.741 0.877 1.025 1.184 1.356 1.540 210HP + Sol 0.013 0.033 0.064 0.107 0.164 0.234 0.318 0.417 0.532 0.663 0.810 0.975 1.156 1.356 1.574 1.810 250HP 0.006 0.015 0.028 0.045 0.067 0.093 0.124 0.159 0.200 0.245 0.295 0.350 0.410 0.475 0.545 0.620 250HP + Sol 0.004 0.011 0.021 0.036 0.054 0.077 0.105 0.138 0.176 0.218 0.267 0.321 0.380 0.445 0.517 0.594 300HP 0.008 0.019 0.036 0.058 0.086 0.120 0.160 0.206 0.259 0.318 0.384 0.457 0.536 0.623 0.716 0.816 300HP + Sol 0.004 0.014 0.031 0.058 0.098 0.152 0.223 0.312 0.421 0.553 0.708 0.890 1.100 1.339 1.610 1.915 400HP 0.004 0.010 0.018 0.030 0.044 0.062 0.083 0.108 0.136 0.167 0.202 0.241 0.283 0.329 0.379 0.432 400HP + Sol 0.008 0.018 0.031 0.049 0.070 0.094 0.123 0.155 0.190 0.230 0.273 0.319 0.370 0.423 0.481 0.542

INSTALLATION

Section 3 shows the maximum operating power of the coils in the cylinder. Shaded squares show the range of operating powers suitable for a cylinder in either of its set ups.

Section 4 shows the pressure loss across the coils at this ﬂ ow rate for all cylinders in both conﬁ gurations.

Page 10

INCOMING COLD SUPPLY

TO EXTERNAL TAP

SINK

WATER SOFTENER (IF NECESSARY)

WM or DWM

WHB

W.C.

DHW

WHB

WC BATH

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 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 Lit e should not be used wher e st eam 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 ﬁ ttings (other than a dual outlet type) is not taken

from the balanced supply the system will become over pr essurized 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 nec essary to ﬁ 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 ﬁ ttings with regard to ﬂ ow/

pressure are suitable.

Shower Fittings

Aerated taps are recommended to prevent splashing . Any type of shower mixing valv e 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 ﬁ ttings. It is important that a 22mm supply is brought to the appliance and a 22mm take-off is continued at least to the bath. If there are two baths, 28mm pipework should be considered. One metre of smaller diameter pipework, or ﬂ ow restrictors, should be provided on the ﬁ nal 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 manufacturer and is installed fully in accordance with their recommendations.

Secondary Hot Water Circulation

Some models are ﬁ tted with a secondary return tapping as standard (see table 1 for details). If fitted, an extra expansion vessel may be necessary. A non-return v alve MUST be FITTED near the return connection. No v alve or terminal ﬁ tting should be installed between the non return valve and the cylinder. (See schematic arrangement on page 13.)

INSTALLATION

Page 11

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

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 ﬁ 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 ﬁ tted as close as possible and within 500mm 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 ﬂ ow resistance. Refer to the table and the worked example.

An alternative approach for sizing

discharge pipes would be to follow BS6700 Speciﬁ 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 dischar ge pipe (D2) having 4 elbows and length of 7m from the tundish to the point of discharge.

From T able 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.

5.8m 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.

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 ﬁ 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

Page 12

d) It is preferable for the discharge to be visible at both the tundish and the ﬁ nal point

of discharge but where this is not possible or practically difﬁ cult there should be clear visibility at one or other of these locations. Examples of acceptable dischar ge arrangements are:

1. Ideally below the ﬁ 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 ar e 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 ser ves a number of discharges, such as in blocks of ﬂ 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 dw ellings occupied by blind, inﬁ rm or disabled people, consideration should be giv en to the installation of an electronically operated device to warn when discharge takes place.

Safety

The safety devices supplied or ﬁ tted on an Stainless Lite are selected for their suitability for the temperatures and pressures involv ed. 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. This includes the immersion heaters, which must incorporate an energy cut-out. All parts are available to approv ed installers from Gledhill Building Products Limited, Sycamore Estate, Squires Gate, Blackpool (Telephone 01253 474402).

Stainless Lite HP model without

solar heating system

P&T Relief Valve

Tundish

Hot Outlet

To Drain

PRV

ERV

NRV

Stop Tap

Kitchen

Cold Tap

Combination

Valve

Balanced

Cold

Outlets

Expansion

Vessel

Heat Pump

Return

Secondary

Return Circuit

Non Return

Valve

Pump

Stainless Lite HP model with

solar heating system

Secondary

Return Circuit

Heat Pump

Flow

P&T Relief Valve

Tundish

Hot Outlet

To Drain

PRV

ERV

NRV

Stop Tap

Kitchen

Cold

Tap

Combination

Valve

Balanced

Cold

Outlets

Expansion

Vessel

Heat Pump

Return

Solar Return

Solar Flow

Non Return

Valve

Pump

Heat Pump

Flow

Combination Inlet Group

Combines elements 1, 2 and 3 below.

1. Pressure Reducing Valve - This must be ﬁ 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 backﬂ ow of hot water towards cold water draw off points.

3. Cold Water Expansion Relief Valv e - T his safety device is preset at the factory and will relieve excess cold water pressure resulting from a fault condition.

INSTALLATION

Page 13

Safety

Cut-out

Thermostat

Immersion Heater Wiring

E L

Temperature/pressure 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 Heater

All stainless Lite HP models are ﬁ tted with a 3kW immersion heater so that the store temperature can be raised above that which the heat pump provides, to boost the hot water performance if necessary and to protect against legionella eg. once a day or once a week.

These are 3kW 240V AC heaters and incorporate a thermostat and a manually reset energy cut-out which operates at 80°C. They have incalloy elements to prolong their life expectancy in aggressive water conditions.

External wiring to the immersion heaters must be in accordance with the relevant IEE Wiring Regulations and the circuit must 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. The operation of the boost immersion heater can also be controlled by means of an

independent time switch as shown schematically below. The ‘ON’ time settings on the immersion heater should be between 30 - 60 minutes later than the ‘ON’ times set for the hot water programmer channel.

For example if the hot water is programmed to come on between 0600 - 0900 and 1700 - 2200 then the immersion heater setting should be 0640 - 0900 and 1740 - 2200. This will give hot water heating by heat pump a priority.

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 par t of the annual maintenance/service check.

Tundish

This is to allow the discharge from any Relief Valve to be seen. It must be ﬁ tted away from any electrical devices. See page 13 for discharge pipework details.

Typical schematic wiring diagram for the boost immersion heater

using immersion programmable immersion heater timer.

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 Dual Thermostats

Care must be taken to ensure that the solar probes are fully inserted into the pockets provided.

INSTALLATION

Page 14

Heating And Primary Systems

Although the heat pump and the primary heating system should be sized and installed in accordance with BS 5449 the following should also be taken into account during the design and installation phase.

The heat pumps normally operate at lower ﬂ ow temperatures; typically 45 – 55°C compared with 75 – 80°C for the boilers. Therefore if traditional radiators are used then, these should be oversized in accordance with the heat pump manufacturers recommendations.

For optimum efﬁ ciency (i.e. COP of a heat pump), low temperature under ﬂ oor heating system should be considered.

The heat pumps normally operate at lower temperature difference between flow and return compared with the traditional boilers and therefore when sizing the pipework heat pump manufacturers recommendations should be taken into account.

Safety

Stainless Lite HP is fitted with a combined temperature and pressure relief valve to cope with any increase in temperature and pressure in the cylinder above the design limits, when used with heat sources up to 45kW total output. This is the maximum heat input to the cylinder allowed by section G3 of the ‘ Appr oved Document G’ of the Building Regulations.

The heat supply to the cylinder and hence the temperature of the stored water should be controlled as outlined below: -

• Heat supply from the primary heat source i.e. heat

The 2-port spring return motorised valve

supplied should be ﬁ tted adjacent to the unit and controlled by the cylinder thermostat (combined control and overheat thermostat) supplied with the unit. The motorised valve and the thermostat must be wired so that the motorised valve switches off when either the control thermostat contact breaks when the set temperature is reached or the overheat thermostat contacts break when an overheat condition develops. The operation of the heat source should be controlled via the auxiliary switch of the motorised valve.

It is important to follow the wiring diagrams

in the wiring section of these instructions.

Schematic Open Vented Primary System

Heat Pump

Pump

150mm max.

Warming/Overflow

Pipe

F & E Cistern

Minimum

distance as

required by

heat pump

manufacturers

instructions

Motorised Valve

Motorised Valve (Energy cut-out)

Schematic Sealed Primary System

Motorised Valve

Motorised Valve (Energy cut-out)

Expansion

Vessel

Gauge

Safety Valve

Pump

Heat Pump

INSTALLATION

Page 15

Solar Heating System

Stainless Lite HP is suitable for use with combined heat pump and solar thermal heating systems. All components in a solar primary circuit must be marked or identiﬁ ed in such a way that their design pressure and temperature can be readily determined

A safety device (pressure relief valve) to control the risk of over-pressure in system components should be ﬁ tted. A termination from a safety pressure device should minimise the risk of damage to persons or materials. Suitable locations are a high temperature receptacle, an internal gully or else issue externally at ground lev el. 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 nondeformable construction, without any possibility of restric tion or disclosure by any other ﬁ tted component.

A more detailed diagram of our recommended arrangement for a typical solar system is shown on page 15.

This provides all the necessary controls and safety devices necessary for the solar system i.e. the tw o port zone valve is wir ed as an energy cut out and the pump/v alv e will only allow heat transfer as required under control of the solar controller.

Stainless Lite HP system configuration with solar thermal heating system

Solar

pumping

station

Solar circuit

zone valve

Central heating flow and return

Central heating zone valve

Heat pump

PRV

Expansion

vessel

Hot water zone valve

System pump

PRV

Primary circuit

sealed system kit

• Sealed heating system A heat pump selected must be suitable for use in a sealed heating system which

may have working pressure of up to 3.0bar and it must be ﬁ tted with an overheat temperature cut-out device.

Unvented (i.e. sealed primary circuits may be ﬁ lled or replenished by means of a

temporary connection between the circuit and a water supply pipe provided a WRC ‘Listed’ double check valve and ﬁ lling loop or some other no less effective backﬂ 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 ﬁ tted with an F&E cistern.

• Open vented heating system It is essential that the primary circuit

between the boiler and the Stainless Lite is pumped and that the cold feed and open vent connections are positioned to prevent pup over into the feed and expansion cistern and to ensure that the open vent is correctly sized.

A typical arrangement of the open vented

system is shown in ﬁ gure _.

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 ﬂ 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 ﬁ tted with suitable non-return valves in both flow and return pipes to prevent gravity circulation when the pump is not running.

INSTALLATION

Page 16

19876543210

12 34567 8

S1 S2 S3

201918171615141312

LNR1R2 NN

1 bar

Solar Pumping Station

Solar Coil

TWO PORT

ZONE VALVE

12C1

+ C

230 VAC 5 amp Mains Supply

Dual Thermostat

Gledhill Stainless Lite Unvented Cylinder

Anti 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)

Solar Controller

Schematic Showing Solar Wiring Requirements

INSTALLATION

Page 17

INSTALLATION

Page 18

Connections can come loose in transit, and all should be checked before installation.

Ensure that the immersion heater setting is 60°C and that the wiring is in accordance with the diagram.

Check the pressure on the air side of the expansion vessel = 3 bar. This must be done when the volume in the cylinder is cold.

Check that the drain cock is closed, and open all the cold and hot water taps and other terminal ﬁ ttings. Allow the system to ﬁ ll with water , and t o run until there is no air left in the system. Close the taps and inspect the system closely for leaks.

Manually open the Relief Valves one by one and check that water is discharged and run freely through the tundish and out at the discharge point. The pipework should accept full bore discharge without overﬂ owing at the tundish, and the valve should seat satisfactorily.

Allow the cylinder to heat to normal working temperature, then thoroughly ﬂ ush the 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 ﬂ ats etc., the hot and cold water system will need to be disinfected in accordance with BS6700 and the Water Regulations.

Because the Stainless Lite appliance is stainless steel, the use of chlorine as the disinfection agent can cause damage unless the appliance is adequately ﬂ ushed and reﬁ lled with the mains water immediately on completion of the disinfection procedure. 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 disinfec tant such as Fernox LP Sterox as manufactured by C ookson Electronics when carrying out disinfection of systems incorporating these appliances.

Remove the ﬁ lter from the combination inlet group clean and replace. Reﬁ ll the system and open all hot taps until there is no air in the pipe work. ENSURE CYLINDER IS

DRAINED PRIOR TO CHECKING OR REMOVING FILTER FROM THE COMBINATION INLET GROUP.

Allow the cylinder to heat to normal working temperature with whatever heat source is to be used, and check again for leaks. The Pressure Relief Valve should not operate during the heating cycle.

The boiler/heating systems should be filled and commissioned in accordance with good practice following the guidance in BS 5449/the boiler manufacturers instructions. This includes adequately ﬂ ushing the system to remove any debris that may have been introduced during installation/maintenance.

NOTE: This appliance is c overed by BENCHMARK and the service record must be completed after commissioning and after every maintenance/ service visit.

IMPORTANT - DRAIN DOWN PROCEDURE

1 Switch off both the heat pump 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 Hold open the pressure and temperature relief valve until water stops

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

INSTALLATION

COMMISSIONING

Page 19

Your Stainless Lite un vented cylinder is automatic in normal use , but requires routine maintenance which is normally carried out at least annually along with the boiler service. The maintenance must be carried out by a suitably competent tradesperson who is qualiﬁ ed to work on unvented cylinders. The checks/work needed are listed in the maintenance part of these Instructions.

The heat pump control thermostat should switch to the hot water zone valve before the heat pump starts to cycle on its internal thermostats. For example if the maximum primary ﬂ ow temperature available from the heat pump is 55°C, then the control thermostat should be set to 48°C. ( This setting should not be changed by the occupant.)

When initially opening the taps, a small surge in ﬂ ow 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.

In some areas the water will initially appear cloudy, but will quickly clear when left to stand. This is nothing to be concerned about and is due to aeration of the water.

WARNING - If water is seen ﬂ owing through the tundish, this indicates a fault condition which needs action.

If the discharge is hot and continuous, turn the boiler and/or the immersion heaters off, but do not turn off the cold water to the appliance until the discharge is cold.

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 , in both cases you must call the r egistered installer / a suitably qualiﬁ ed, competent tradesperson, advise them that you have an unvented cylinder and request a maintenance visit.

DO NOT , at any time , tamper in any way with the safety valves or o verheat thermostats/

wiring.

USER INSTRUCTIONS

Page 20

The Registered Installer is responsible for the safe installation and operation of the system. The installer must also make his customer aware that periodic maintenance of the equipment is essential for safety.

Maintenance periods will vary for many reasons. Gledhill Building Products Ltd recommend a maximum of 12 months to coincide with boiler maintenance. Experience of local water conditions may indicate that more frequent maintenance is desirable, eg, when water is particularly hard, scale-forming or where the water supply contains a high proportion of solids, eg, sand. Maintenance must include the following:

1. Check and clean ﬁ lter

2. Manually check the operation of the temperature relief valve.

3. Manually check the operation of the expansion relief valve.

4. Check discharge pipes fr om temperature and expansion relief valv es are free from obstruction and blockage and are not passing any water.

5. Check the condition and if necessar y descale the heat exchangers in hard water areas.

6. Check that water pressure downstream of pressure reducing valve is within the manufacturers limits.

7. Check operation of motorised valve.

8. Check the pressure on the air side of the expansion vessel. This must be done when the volume in the cylinders is cold.

9. Check and advise the householder not to place any clothing or other combustible materials against or on top of this appliance.

10. On completion of the work, ﬁ ll in the Benchmark Ser vice Record at towards the back of this manual.

IMPORTANT NOTE

When draining down the appliance for any reason, the instructions provided in the Commissioning Section MUST be followed to prevent potential damage to the cylinder.

SERVICING AND MAINTENANCE

Page 21

Scale

In hard water areas it is recommended that an in-line scale inhibitor is ﬁ tted. Reducing the temperature of the stored water will reduce the rate at which scale forms. If the recovery rate is badly affected, this is an indication that scaling may have occurred. In this event, follow the procedures as recommended by a reputable Water Treatment Company.

General

No water at the tap. Check that the mains water supply is turned ON. Check the line strainer is not blocked. Check that the combination valve has been ﬁ tted so that water is ﬂ owing in the correct direction. If the water at the tap is cold, ensure that the boiler has been switched ON and is working correctly. Check that there are no air locks in the primary system. ISOLATE THE UNIT AT THE MAINS ELECTRIC SUPPLY AND THEN CHECK THE FOLLOWING: i. The cylinder thermostat ii. The thermal cut-out, which can be re-set by pushing the red button iii. The motorised valve iv. The boiler thermostat v. The boiler thermostat cut-out (if ﬁ tted)

ANY ENERGY CUT-OUT MUST NEVER BE BY-PASSED UNDER ANY CIRCUMSTANCES. If the units are not getting hot and the heat source is electrical, ensure that the

immersion heaters are isolated from the mains before re-setting the energy cut-out. If the immersion heater(s) need replacing this should be done with the units supplied from Gledhill Building Products Limited. Same day despatch to approved installers can be arranged by telephoning 01253 474402.

Discharge From Relief Valves

If cold water is discharging from the expansion relief valve into the tundish check the pressure on the expansion vessel when cold and recharge if necessary.

If the fault continues and the problem cannot be stopped by operating the easing control a few times then either the Pressure Reducing Valve or the Relief Valve may be at fault. If the cold wat er pressure is too high, this would suggest that the Pressure Reducing Valve is at fault and the Gledhill approved replacement should be ﬁ tted. If the pressure is correct then the Relief Valve will require replacing with a Gledhill approved component.

See Commissioning for drain down procedure.

If there is an overheat fault and very hot water is being discharged, turn off the heat source, but not the water supply.

When the supply is cool, check thermostats and energy cut-outs in the boiler and immersion heaters and replace the faulty component with a unit supplied by Gledhill and check that it works correctly before returning the system to full operation.

SERVICING AND MAINTENANCE

Page 22

FAULT - No Hot Water

Switch on

Set programmer

Re-set, check wiring &

plumbing is correct

Re-set

Is all wiring to the

controls ok?

Replace thermostat

Re-wire

START

Is heat pump on?

Is hot water programmer

in ‘on’ position?

Is zone valve in

correct position?

Is control temperature

set at 45ºC - 50ºC?

Has high limit cut out?

Re-set

END

YES

NO NO

FAULT - Poor Water Flow at Hot Taps

Water service check by

supply company required

Clean or replace strainer

as appropriate

Service /replace PRV

as appropriate

START

END

Is incoming mains supply flow/pressure adequate?

Is in-line strainer

(in combination valve)

clean?

YES

Clear obstructions

Is system free from

restrictions/blockages?

YES

Is pressure reducing valve

(in combination valve)

working?

SERVICING AND MAINTENANCE

FAULT FINDING

Page 23

FAULT - Water Discharge Into Tundish

Clean or replace

as required

Is expansion vessel

charge pressure correct?

Replace ERV/TPRV

Replace PRV END

START

Is pressure downstream

of pressure reducing valve

correct?

Is valve seal and seat clean & undamaged?

Is heater operating at

less than 60ºC?

Re-set temperature

YES

Is ERV/TPRV

discharging?

YES

Recommission

expansion

vessel pressure

SERVICING AND MAINTENANCE

FAULT FINDING/SHORT PARTS LIST

SPARE PARTS LIST

Description Quantity Stock Code No.

1 3kW immersion element 1 SH001 2 22mm 90° compression elbow c/w/drain 1 SF003 3 Pressure and temperature relief valve 6 bar 95°C 1 SG001 4 Inlet group set at 3 bar c/w expansion relief valve set at 4.75 bar 1 SG010 5¾” ﬂ exible hose 1 SG003 6 18 litre expansion vessel 1 XG191 7 24 litre expansion vessel 1 XG192 8 Wall mounting bracket for 18/24 litre expansion vessel 1 XG184

9 35 litre expansion vessel 1 XG193 10 Wall mounting bracket for 35 litre expansion vessel 1 XG058 11 22mm 2 port valve (indirects only) 1 XG083 12 Junction wiring box (12 way) 1 XG129 13 Control and overheat limit thermostat 1 XG168 14 15mm x 22mm tundish 1 XG173

Page 24

Vast quantities of water are needlessly run off to waste due to Taps , Mixers and Showers discharging ﬂ ow rates far in excess of the rates required for them to perform their duties.

The contrasting ﬂ ow rates shown on this leaﬂ et clearly illustrate the savings that can be made whilst still providing a good performance.

British made Aquaﬂ ow Regulators provide constant ﬂ ow rates by automatically compensating for supply pressure changes between 1 bar & 10 bars.

To facilitate installation into the wide range of plumbing equipment which is

encountered in the U.K, Four Fixing Options are available:-

Options For Showers

1. MXF “DW” Range - F or ﬁ tting behind Fixed Shower Heads or onto Flexible Hoses for Handshowers (preferably onto the inlet end when lightweight hoses are used).

2. Compression Fitting Range. “In Line” regulators as in Option 4 for Taps & Mixers.

Information by courtesy of

AQUAFLOW REGULATORS LTD

Haywood House, 40 New Road, Stourbridge, West Midlands DY8 1PA

TELEPHONE (01384) 442611 FAX: (01384) 442612

Water Savings

Water Related Costs Can Be Reduced By Good Plumbing Practice

TAPS & MIXERS

SHOWERS

Unregulated

25 - 30 l/m

Regulated 10 - 12 l/m

Over

20 l/m

5, 6 or

8 l/m

2 tap

half open

Fitted with regulator

Unregulated

4 Fixing Options For Taps & Mixers

1. MK Range - Combined Regulators & Aerator for screwing onto T aps & Mixers with internal or external threads on their noses. Anti Vandal models also available.

2. MR05-T Range - Internal Regulators. Pushfit into Tap or Mixer seats. Produced in three sizes - 12.5mm (BS1010), 12mm & 10mm, Flangeless models also available for Taps with Low Lift washers.

3. MXF Standard Range - Screw on tail

models for Taps & Mixers. Fix onto the tails

before ﬁ tting the tap connectors. Available in 3/8", 1/2", 3/4" and 1" BSP.

4. Compression Fitting Range - “In Line” regulators housed in 15mm & 22mm CXC Couplers & Isolating V alves. “ ”UK WFBS listed by the Wa ter Research Centre. Isolation valves available for slotted screwdriver operation or with coloured plastic handles. Now available also in plastic bodied push-ﬁ t couplers & valves.

APPENDIX

APPENDIX A

Page 25

APPENDIX

APPENDIX B

Description

Manual handling means any transporting or supporting of a load (including lifting,

putting down, pushing, pulling, carrying or moving) by hand or bodily force.

Scope

This assessment will cover the largest unit within each product range manufactured by Gledhill.

For speciﬁc weights and dimensions please refer to technical data section.

Main Hazards

Vision may not be clear due to the size of the products. Adopting an incorrect method of lifting may cause injury, attempting to lift these products will require help from others. ( Team lifts)

Control Measures

Manual lifting procedure

The lift, key factors in safe lifting are:

a. Balance b. Position of back c. Positioning of the arms and body d. The hold e. Taking the lead for team lifts

a. Balance - Since balance depends essentially upon the position of the feet,

they should be apart about hip breadth with one foot advanced giving full balance sideways and forward without tension. In taking up this position, lifting is done by bending at the knees instead of the hips and the muscles that are brought into use are those of the thigh and not the back.

b. Position of back - Straight - not necessary vertical. The spine must be

kept rigid, this coupled with a bent knee position, allows the centre line of gravity of the body to be over the weight so reducing strain.

c. Positioning of arms and body - The further arms are away from the side,

the greater the strain on the shoulders, chest and back. Keep elbows close to the body arms should be straight.

d. The hold - Before lifting ensure you have a good hold.

e. Taking the lead for team lifts- As

more than one person is required for these products ensure that one person is taking the lead. This may be you so ensure that each person that is helping is made aware of the weight and of the items listed within this assessment. Make sure you and any others helping know the route you intend to take that it is clear of any obstructions. Never jerk the load as this will add a little extra force and can cause severe strain to the arms, back and shoulders. If there are steps involved decide on where you will stop and take a rest period. Move smoothly and in unison taking care to look and listen to others helping with the lift. Where possible use a sack truck to move the product over long ﬂat distances, only lift the products when necessary. If in doubt stop and get more help.

Individual capability

Individual capability plays an important part in handling these products. Persons above average build and strength will ﬁnd it easier and should be in good health. Persons below average build and strength may require more rest periods during the handling process.

Pregnant women should not carry out this operation.

Persons who are not in good health should seek medical advice prior to commencing any lifting or manual handling operation.

Residual risk

Following the guidelines given above will reduce any risk to injury.

All persons carrying out this operation must be fully trained and copies of the speciﬁc risk assessment made available for inspection and use in their training process.

Further guidance on Manual Handling can be obtained from the Health and Safety Executive. Manual Handling Operations Regulations 1992.

MANUAL HANDLING OF APPLIANCE PRODUCTS

Page 26

BENCHMARK

Page 27

BENCHMARK

Page 28

NOTES

Page 29

NOTES

Page 30

TERMS AND CONDITIONS

Gledhill (Building Products) Ltd

AMD. SEPTEMBER 2010

CONDITIONS OF SALE & GUARANTEE TERMS

1. Gledhill (Building Products) Ltd (“We” or “Gledhills”) only do business upon the Conditions which appear below and no other. Unless we so agree in writing these Conditions shall apply in full to any supply of goods by us to the exclusion of any Conditions or terms sought to be imposed by any purchaser. These Conditions of Sale and Warranty Terms override those which are contained on the Invoice Forms and all Sales are now subject to these Conditions of Sale and Warranty terms only.

2. PRICE Once an order or call off has been accepted the price will be held for three months but if delivery is extended beyond that period at the customer’s request, then we reserve the right to amend the price when necessary.

The company reviews its pricing annually to adjust for changes in our cost base. We reserve the right to alter prices at any time for severe movements in raw materials (mainly copper and steel). If there is to be a change we will give customers at least four weeks notice but anything delivered after that date will be at the revised price. An order may not be cancelled or varied after acceptance without the written consent of the company. Such cancellation or variation shall be subject to such reasonable charges as may be appropriate.

3. SPECIFICATION

The goods are supplied in accordance with the Specifications (if any) submitted to the Purchaser and any additions and alterations shall be the subject of an extra charge. Any goods not so specified shall be in accordance with our printed literature or the literature of any of our component suppliers (subject to any modifications made since publication). If we adopt any changes in construction or design of the goods, or in the specification printed in our literature, the Purchaser shall accept the goods so changed in fulfilment of the order.

4. PAYMENT

The buyer shall make payment in full within thirty days from the end of the month in which the invoice is dated. If we receive payment in full on or before the due date we will allow an appropriate settlement discount except where we have quoted a special net price. If payment is not received in full on or before the due date we shall be entitled in addition to the invoice price to: (i) payment of a sum equal to any increase in the copper price supplement applicable to the particular goods

sold between the date of receipt of order and the date of receipt of payment in full; and

(ii) interest on any part of the invoice price unpaid after the due date at the rate of 3% per annum over the base

rate for the time being of HSBC Bank plc.

5. TIME

We give estimates of delivery dates in good faith and time of delivery is not nor shall be made of the essence of any contract nor shall we be liable for any loss or damage occasioned by delay in delivery.

6. DELIVERY

We deliver free normally by our own vehicles within 25 miles of any of our manufacturing depots. Delivery to any place more than 25 miles from one of our manufacturing depots may be subject to our quoted delivery charges. We reserve the right to make delivery of goods contained in one order by more than one consignment and at different times. Where a period is agreed for delivery and such period is not extended by our Agreement, the Purchaser shall take delivery within that period. If the Purchaser fails to take delivery, we shall be entitled at the Purchaser’s risk and expense to store the goods at the Purchaser’s premises or elsewhere and to demand payment as if they had been despatched. Off loading at point of delivery shall be the responsibility of and be undertaken by the Purchaser.

7. SHORTAGES OR DAMAGE

Goods must be inspected before signature of delivery note and any damage, shortage or discrepancy noted on the delivery note and the goods returned on the same vehicle. The buyer must also give us immediate written notice of the damage, shortage or discrepancy so that we may prompt investigation.

8. RETURN OF GOODS

Goods may not be returned to the Company except by prior written permission of an authorised officer of the Company and such return shall be subject to payment by the Purchaser of handling and re-stocking charges, transport and all other costs incurred by the Company.

9. COMPANY LIABILITY AND GUARANTEE

9.1. Subject to the terms of these Conditions of Sale and Guarantee Terms Gledhills provide Guarantees in respect of specific products as set out in this clause.

9.2. Each Guarantee is strictly conditional upon the following:-

9.2.1. Complaints must be given to us immediately, before any action is taken, as responsibility cannot be accepted if repairs or renewals are attempted on site without our written approval.

9.2.2. The unit has been installed in accordance with our installation and service instructions and all relevant codes of practice and regulations in force at the time of installation.

9.2.3. All necessary inlet controls and safety valves have been fitted correctly.

9.2.4. The unit has only been used for the storage of potable water supplied from the public mains.

9.2.5 Where appropriate the unit has been regularly maintained as detailed in the installation and service instructions

9.2.6. Defects caused by corrosion or scale deposits are not covered by any Guarantee.

9.2.7. Where we agree to rectify any defect we reserve the right to undertake the work on our own premises.

9.2.8. We will not accept any labour charges associated with replacing the unit or parts for any of the following products listed.

9.3. Guarantees are provided in respect of specified goods supplied by Gledhills as follows:-

(a) Domestic and Commercial Open Vented Cylinders and Tanks.

The copper storage vessel is guaranteed for ten years and if it proves to be defective either in materials or

workmanship, we will either repair or supply replacement at our option with the closest substitute in the case of any obsolete product to any address in Great Britain.

(i) free of all charge during the first year after delivery by us. (ii) thereafter at a charge of one-tenth of the then current list price and any copper price supplement and

delivery charge during the second year after delivery by us and increasing by a further one-tenth on the second and subsequent anniversary of delivery by us.

(b) Domestic Mains Fed Products [Primary Stores]

The copper storage vessel is guaranteed for five years and if it or any integral pipework as part of the storage

vessel assembly proves to be defective either in materials or workmanship, we reserve the right to either repair or supply replacements or the closest possible substitute in the case of any obsolete product and will collect and deliver to any address in England, Wales and Scotland (excluding all Scottish Islands).

(i) free of all charge during the first year after delivery by us. (ii) thereafter at a charge of one-fifth of the then current list price or any copper price supplement and

delivery charge during the second year after delivery by us increasing by a further one-fifth on the second and subsequent anniversary of delivery by us.

Gledhill guarantee the components including

controls, valves and electrical parts for two years from the date of purchase. IT SHOULD BE NOTED THAT THE FACTORY FITTED TEMPERATURE AND PRESSURE RELIEF VALVE MUST NOT BE REMOVED OR ALTERED IN ANY WAY OR THE GUARANTEE WILL NOT BE VALID. GLEDHILL WILL NOT BE RESPONSIBLE FOR ANY CONSEQUENTIAL LOSS OR DAMAGE HOWEVER IT IS CAUSED.

The guarantee for the stainless steel vessel is for

twenty five years if the original unit is returned to us

AND PROVIDED THAT: (i) It has not been modified, other than by Gledhill. (ii) It has not been subjected to wrong or improper

use or left uncared for.

(iii) It has only been used for the storage of potable

water, max 200mg/litre chloride. (iv) It has not been subjected to frost damage. (v) The benchmark service record is completed after

each annual service. (vi) The unit has been serviced annually. (vii) Any disinfection has been carried out strictly in

accordance with BS6700.

If the stainless steel vessel proves to be defective

either in materials or workmanship we reserve the right to either repair or supply replacements or the closest possible substitute in the case of any obsolete product and will collect and deliver to any address in England, Scotland and Wales (excluding all islands):

(i) free of charge during the first year after delivery by

us. (ii) thereafter at a charge of one twenty fifth of the

then current list price during the second year

after delivery by us and increasing by a further

one twenty fifth on the second and subsequent

anniversary of delivery by us.

ACTION IN THE EVENT OF FAILURE If the stainless steel cylinder develops a leak we will

ask for a deposit against the supply of a new one. This will be refunded if the failure is within the terms of the warranty when it has been examined by us.

Please note:

- Installation must have been carried out by a

licensed specialized company (heating contractor

or plumber) following the version of installation

instructions in force.

- Gledhill or its representative was given the

opportunity to check complaints on site

immediately after any defect occurred.

- Confirmation exists that the system was

commissioned properly and that the system

was checked and maintenance was performed

annually by a specialised company licensed for

this purpose.

(d) Components of our products other than Storage Vessels and Integral Pipework.

We will either extend to the purchaser the same terms

of warranty as we are given by the manufacturer of the component or if the manufacturer does not give any warranty, replace free of charge any component which becomes defective within two years after the date of the delivery by us and is returned to us at the purchaser’s expense but we shall not meet the cost of removal or shipping or return of the component or any other cost charges or damages incurred by the purchaser.

9.4.

9.4.1. In respect of goods supplied by us and in respect of any installation work carried out by or on our behalf, our entire liability and the purchaser’s sole remedies (subject to the Guarantees) shall be as follows:-

(a) We accept liability for death or personal injury to

the extent that it results from our negligence or that of our employees

(b) Subject to the other provisions of this clause 9

we accept liability for direct physical damage to tangible property to the extent that such damage is caused by our negligence or that of our employees, agents or subcontractors.

Page 31

TERMS AND CONDITIONS

in contract or in tort including negligence) in respect of any one cause of loss or damage claimed to result from any breach of our obligations hereunder, shall be limited to actual money damages which shall not exceed £20,000 provided that such monetary limit shall not apply to any liability on the part of ourselves referred to in paragraph (a) above

(d) Except as provided in paragraph (a) above but otherwise not withstanding any provision herein contained

in no event shall we be liable for the following loss or damage howsoever caused and even if foreseeable

by us or in our contemplation: (i) economic loss which shall include loss of profits, business revenue, goodwill or anticipated savings (ii) damages in respect of special indirect or consequential loss or damage (other than death, personal

injury and damage to tangible property) (iii) any claim made against the purchaser by any other party (save as expressly provided in paragraph (b) above) (e) Except in respect of our liability referred to in paragraph (a) above no claim may be made or action

brought (whether in contract or in tort including negligence) by the purchaser in respect of any goods supplied by us more than one year after the date of the invoice for the relevant goods.

(f) Without prejudice to any other term we shall not be liable for any water damage caused directly or

indirectly as a result of any leak or other defect in the goods. We cannot control the conditions of use of the goods or the time or manner or location in which they will be installed and the purchaser agrees to be fully responsible for testing and checking all works which include the goods at all relevant times (up to, including and after commissioning) and for taking all necessary steps to identify any leaks and prevent any damage being caused thereby.

(g) Nothing in these Conditions shall confer on the purchaser any rights or remedies to which the purchaser

would not otherwise be legally entitled

10. LOSS OR INJURY

Notwithstanding any other provision contained herein the purchaser’s hereby agree to fully indemnify us against any damages losses costs claims or expenses incurred by us in respect of any claim brought against us by any third party for:(a) any loss injury or damage wholly or partly caused by any goods supplied by us or their use. (b) any loss injury or damage wholly or partly caused by the defective installation or substandard workmanship

or materials used in the installation of any goods supplied by us. (c) any loss injury or damage in any way connected with the performance of this contract. (d) any loss resulting from any failure by the purchaser to comply with its obligations under these terms as to

install and/or check works correctly. PROVIDED that this paragraph will not require the purchaser to indemnify us against any liability for our own acts of negligence or those of our employees agents or sub-contractors FURTHER in the case of goods supplied by us which are re-sold and installed by a third party by the purchaser it will be the sole responsibility of the purchaser to test the goods immediately after their installation to ensure that inter alia they are correctly installed and in proper working order free from leaks and are not likely to cause any loss injury or damage to any person or property.

11. VARIATION OF WARRANTY AND EXCLUSION

Should our warranty and exclusion be unacceptable we are prepared to negotiate for variation in their terms but only on the basis of an increase in the price to allow for any additional liability or risk which may result from the variation. Purchasers are advised to insure against any risk or liability which they may incur and which is not covered by our warranty.

12. ADVICE

Any advice or assistance given by the Company is provided without charge and is in good faith without undertaking, representation or warranty, and we will not accept any liability, whether consequential or compensatory, for advice or assistance given.

13. RISK AND RETENTION OF TITLE

(a) goods supplied by us shall be at the Purchaser’s risk immediately upon delivery to the Purchaser or into

custody on the Purchaser’s behalf or to the Purchaser’s Order. The Purchaser shall effect adequate insurance

of the goods against all risks to the full invoice value of the goods, such insurance to be effective from the time

of delivery until property in the goods shall pass to the Purchaser as hereinafter provided. (b) property in the goods supplied hereunder will pass to the Purchaser when full payment has been made by the

Purchaser to us for :-

(i) the goods of the subject of this contract. (ii) all other goods the subject to of any other contract between the Purchaser and us which, at the time of

payment of the full price of the goods sold under this contract, have been delivered to the Purchaser but not paid for in full.

(i) the Purchaser shall hold the goods in a fiduciary capacity for us and shall store the same separately from any

other goods in the Purchaser’s possession and in a manner which enables them to be identified as our goods.

(ii) the Purchaser shall immediately return the goods to us should our authorised representative so request.

All the necessary incidents associated with a fiduciary relationship shall apply.

(d) the Purchaser’s right to possess the goods shall cease forthwith upon the happening of any of the following

events, namely :-

(i) if the Purchaser fails to make payment in full for the goods within the time stipulated in clause 4 hereof. (ii) if the Purchaser, not being a company, commits any act of bankruptcy, makes a proposal to his or her

creditors for a compromise or does anything which would entitle a petition for a Bankruptcy Order to be presented.

(iii) if the Purchaser, being a company, does anything or fails to do anything which would entitle an

administrator or an administrative receiver or a receiver to take possession of any assets or which would entitle any person to present a petition for winding up or to apply for an administration order.

(e) the Purchaser hereby grants to us an irrevocable licence to enter at any time any vehicle or premises owned

or occupied by the Purchaser or in the possession of the Purchaser for the purposes of repossessing and

recovering any such goods the property in which has remained in us under paragraph (2) above. We shall not

be responsible for and the Purchaser will indemnify us against liability in respect of damage caused to any

vehicle or premises in such repossession and removal being damaged which it was not reasonably practicable

to avoid. (f) notwithstanding paragraph (3) hereof and subject to paragraph (7) hereof, the Purchaser shall be permitted to

sell the goods to third parties in the normal course of business. In this respect the Purchaser shall act in the capacity of our commission agent and the proceeds of such sale :-

(i) shall be held in trust for us in a manner which

enables such proceeds to be identified as such, and :

(ii) shall not be mixed with other monies nor paid into

an overdrawn bank account.

We, as principal, shall remunerate the Purchaser as

commission agent a commission depending upon the surplus which the Purchaser can obtain over and above the sum, stipulated in this contract of supply which will satisfy us.

(g) in the event that the Purchaser shall sell any of the

goods pursuant to clause (6) hereof, the Purchaser shall forthwith inform us in writing of such sale and of the identity and address of the third party to whom the goods have been sold.

(h) if, before property in the goods passes to the

Purchaser under paragraph (2) above the goods are or become affixed to any land or building owned by the Purchaser it is hereby agreed and declared that such affixation shall not have the effect of passing property in the goods to the Purchaser. Furthermore if, before property in the goods shall pass to the Purchaser under paragraph (2) hereof, the goods are or become affixed to any land or building (whether or not owned by the Purchaser), the Purchaser shall:-

(i) ensure that the goods are capable of being

removed without material injury to such land or building.

(ii) take all necessary steps to prevent title to the

goods from passing to the landlord of such land or building.

(iii) forthwith inform us in writing of such affixation

and of the address of the land or building concerned.

The Purchaser warrants to repair and make good

any damage caused by the affixation of the goods to or their removal from any land or building and to indemnify us against all loss damage or liability we may incur or sustain as a result of affixation or removal.

(i) in the event that, before property in the goods

has passed to the Purchaser under paragraph (2) hereof, the goods or any of them are lost, stolen, damaged or destroyed :-

(ii) the Purchaser shall forthwith inform us in writing

of the fact and circumstances of such loss, theft, damage or destruction.

(iii) the Purchaser shall assign to us the benefit of any

insurance claim in respect of the goods so lost, stolen, damaged or destroyed.

14. NON-PAYMENT

If the Purchaser shall fail to make full payment for the goods supplied hereunder within the time stipulated in clause 4 hereof or be in default of payment for any other reason then, without prejudice to any of our other rights hereunder, we shall be entitled to stop all deliveries of goods and materials to the Purchaser, including deliveries or further deliveries of goods under this contract. In addition we shall be entitled to terminate all outstanding orders.

15. VALUE ADDED TAX

All prices quoted are exclusive of Value Added Tax which will be charged at the rate ruling at the date of despatch of invoice.

16. TRADE SALES ONLY

We are only prepared to deal with those who are not consumers within the terms of the Unfair Contract Terms Act 1977, the Sale of Goods Act 1979 and the Supply of Goods and Services Act 1982. Accordingly any person who purchases from us shall be deemed to have represented that he is not a consumer by so purchasing.

17. JURISDICTION

The agreement is subject to English law for products delivered in England and Scottish law for products delivered in Scotland and any dispute hereunder shall be settled in accordance therewith dependent upon the location.

18. PRODUCT DEVELOPMENT

Gledhill have a policy of continuous product development and may introduce product modifications from time to time.

Gledhill Building Products Limited

Sycamore Estate, Squires Gate, Blackpool FY4 3RL Tel: 01253 474550 Fax: 01253 474551 sales@gledhill.net

FM 2057

Gledhill cylinders are produced

under an ISO 9001:2008

Quality System accepted

by BSI

Due to a programme of continuous improvement Gledhill Building Products reserve the right to modify products without prior notice.

It is advisable to check the product technical detail by using the latest design and installation manuals available from our technical support team or on our website.

Gledhill Building Products produce cylinders for use with a wide range of heat sources including;

Gas and oil boilers Electricity Air source heat pumps

Ground source heat pumps Solar energy Wood burning stoves

For further information of Gledhill products can be found on the internet at www.gledhill.net

“Only the best

is acceptable”

Providing peace of mind

On expiry of your initial warranty period, Gledhill Response Limited would be

pleased to provide further customer support with a range of services including:

Low cost annual repair and maintenance contracts direct from Gledhill

Annual servicing and safety checks Expert response to ‘out of warranty’ breakdowns at fixed charges Please ring 08445 679898 or visit www.gledhill.net for further details

Issue 03 05/11

gledhill StainlessLite HP180IND, StainlessLite HP210IND, StainlessLite HP300IND, StainlessLite HP400IND, StainlessLite HP250IND Design, Installation & Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual