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

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

L

H

K

N

D

F

J

A

I

G

M

C

E

40

,00

º

45,00

º

35

,

0

0º

2

5,

0

0º

1

5

,0

0

º

NOTES

1. Not all models - see
table 1.

2. Recovery times based
on Primary Coil/I.H. duty
(ie. assumes the boiler
output is adequate).

3. All connections
are supplied with
compression 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

2

0.68 0.68 0.97 0.97 1.27

Solar coil pressure loss

1

bar 0.191 0.191 0.241 0.241 0.31

Primary heat exchanger surface area m

2

1.36 1.56 1.94 2.04 2.91

Primary heat exchanger thermal rating

1

kW 24.3 26.2 27.5 34.2 47.2

Primary heat exchanger pressure loss

1

bar 0.048 0.054 0.060 0.019 0.027

Heat up time from 15°C to 60°C

2

min 33 41 44 48 49

Recovery time after 70% draw-off

2

min 21 26 30 32 38

DESIGN

TECHNICAL INFORMATION

Page 6

7

9

3

11

2

9

6

12
13

1

8

4
5

10

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

A.

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

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

A

=65m2)

2-3

1 bathroom +

2 shower rooms

HP180IND HP250IND (F

A

=85m2)

2-4

2 bathrooms +
1 shower room

HP210IND HP300IND (F

A

=110m2)

2-4

2 bathrooms +

2 shower rooms

HP250IND HP400IND (F

A

=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

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 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

INSTALLATION