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

The 90 degree elbow fitted on the hot draw off needs to be positioned and tightened 

by installer.

For the control thermostat set points of the immersion heaters for direct heating 

of our cylinders, please refer to page 16 of this manual. The control thermostat for 

indirect heat exchanger heat up of our cylinders are usually set at between 60°C - 65°C. 

During commissioning the actual temperature that the cylinder reaches when the 

thermostat(s) operate should be tested and adjusted so that it achieves a minimum 

of 60°C. This temperature needs to be achieved on a regular basis.  

Check the pressure on the air side of the expansion vessel = 3 bar.  This must be done 

when the water in the cylinder is free to expand in atmospheric pressure or the cylinder 

and relevant pipe work is empty.

Check that the drain cock is closed, and open all the cold and hot water taps and other 

terminal fittings.  Allow the system to fill with water, and to 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 overflowing at the tundish, and the valve should 

seat satisfactorily.

In line with good plumbing practice, use of excessive flux should be avoided.  When 

soldering above the cylinder, ensure flux/solder does not contaminate the cylinder 

below, since this can cause corrosion. Flushing should be done performed as per BS 

EN 806:4 2010 section 6.2. 

Allow the cylinder to heat to normal working temperature, then thoroughly flush 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 flats etc., the hot and cold water system will need to be 

disinfected in accordance with BS EB 806:4 2010 section 6.3 and the Water Regulations.

Because the StainlessLite Plus appliance is stainless steel,  the use of chlorine as the 

disinfection agent can cause damage unless the appliance is adequately flushed and 

refilled with the mains water immediately on completion of the disinfection procedure. 

Your StainlessLite Plus unvented 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 qualified to work on unvented cylinders. The checks/work needed 

are listed in the maintenance part of these Instructions.

For the control thermostat set points of the immersion heaters for direct heating 

of our cylinders, please refer to page 16 of this manual. The control thermostat for 

indirect heat exchanger heat up of our cylinders are usually set at between 60°C - 65°C. 

During commissioning the actual temperature that the cylinder reaches when the 

thermostat(s) operate should be tested and adjusted so that it achieves a minimum 

of 60°C,  in order to comply with the Legionella pasteurisation requirements.

When initially opening the taps, a small surge in flow may be experienced, which 

disappears as the pressure in the system stabilises. This is quite normal with these 

types of systems and does not indicate a fault.

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 flowing 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 registered installer / a suitably qualified, 

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 overheat thermostats/

wiring.

Damage caused through a failure to do this 

adequately will not be covered by the warranty.

For the reasons mentioned, we recommend the 

use of a non chlorine based disinfectant such as 

Fernox LP Sterox as manufactured by Cookson 

Electronics when carrying out disinfection of 

systems incorporating these appliances.

Remove the filter from the combination inlet 

group clean and replace.  Refill 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 or the P&T valve should not operate 

during the heating cycle. If the P&T valve 

operates before the pressure relief valve due to 

high pressure, check that the inlet control group 

is fitted correctly, and no valve is between the 

inlet control group and the cylinder.

The boiler/heating systems should be filled and 

commissioned in accordance with good practice 

following the guidance in BS 7593:2006/the 

boiler manufacturers instructions. This includes 

adequately flushing the system to remove any 

debris that may have been introduced during 

installation/maintenance.

NOTE

At the time of commissioning, complete all 

relevant sections of the Benchmark Checklist 

located on the inside back pages of this 

document.

This must be completed during commissioning 

and left with the product to meet the Warranty 

conditions offered by Gledhill.

IMPORTANT - DRAIN DOWN PROCEDURE

1  Switch off both the boiler and the immersion heater

2  Open the nearest hot tap and run all hot water until cold, then close it

3  Close the incoming cold main at the stop tap

Hold open the pressure and temperature relief valve until water stops 

discharging into the tundish and leave it open

5  Open the cold taps starting from the highest point and working down to 

the lowest tap, leaving them open

6  When the cold taps have stopped draining, open the hot taps starting from 

the highest and working down to the lowest tap

7  Open the drain cock and ensure the pressure and temperature relief valve 

is held open until the cylinder is empty

INSTALLATION

USER INSTRUCTIONS

COMMISSIONING

USER INSTRUCTIONS

Summary of Contents for StainlessLite Plus Direct D120

Page 1: ...WWW GLEDHILL NET ONE NAME EVERY SOLUTION STAINLESSLITE PLUS UNVENTED MAINS PRESSURE HOT WATER STORAGE INSTRUCTION MANUAL DESIGN INSTALLATION SERVICING ...

Page 2: ...faninstallationorsystem containing one of our products unless specifically 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 specification In the interest of continuously improving the StainlessLite Plus range Gledhill Building Products Limited reserve the right to modify the product without notice and in these circumstances th...

Page 3: ... designed for use with a gas or oil boiler and is suitable for both open vented and sealed pumped primary systems When used with a sealed heating system the boiler must incorporate its own energy cut out overheat thermostat StainlessLite Plus Indirect models are listed in Table 2 on Page 8 9 StainlessLite Plus DIRECT StainlessLite Plus INDIRECT StainlessLite Plus DIRECT SOLAR StainlessLite Plus IN...

Page 4: ...89 37 2698 62 15 91 18 106 3 12 976 475 750 n a n a 210 227 n a n a n a n a n a n a n a n a n a 90 n a D120 SL PLUDR120SL L C 47 1 13 37 2765 62 15 122 23 143 3 12 1248 475 1022 n a 680 210 227 53 2 n a n a n a n a n a n a n a n a 119 n a D150 SL PLUDR150SL M C 56 1 37 36 1425 62 15 152 27 176 3 18 1519 475 1293 n a 832 210 227 66 6 n a n a n a n a n a n a n a n a 150 n a D180 SL PLUDR180SL L C 67...

Page 5: ... n a n a n a n a n a 30 5 1 27 0 31 n a n a 41 n a Indirect Slimline IND60 SL PLUIN060SL A 27 0 66 62 16 75 3 12 704 475 478 n a 393 325 n a 24 3 253 n a 195 305 n a n a n a n a n a n a 15 0 49 0 165 n a n a 13 n a IND90 SL PLUIN090SL B 37 0 89 91 20 108 3 12 976 475 750 n a 453 365 n a 48 1 343 n a 195 345 n a n a n a n a n a n a 16 5 0 59 0 165 n a n a 17 n a IND120 SL PLUIN120SL B 47 1 13 122 2...

Page 6: ...Hot water draw off 22mm compression 2 Lift up temperature pressure relief valve 89 96 6 bar 3 Hot water secondary return 22mm not fitted to smaller sizes see table 1 4 Immersion heater 1 BSP 3kW normally on peak 5 22mm cold supply 6 Immersion heater 1 BSP 3kW normally off peak 7 Dual control Overheat stat pocket solar 8 Solar coil return to panel collector 22mm compression 9 Solar coil flow from p...

Page 7: ...ixing valve canbeusedaslongasboththehotandcoldsuppliesaremainsfed However allmains pressure systems are subject to dynamic changes particularly when other hot and cold taps showersareopenedandclosed whichwillcausechangesinthewatertemperature at mixed water outlets such as showers For this reason and because these are now no moreexpensivethanamanualshowerwestronglyrecommendtheuseofthermostatic show...

Page 8: ...orage systems are installed where discharges form safety devices may not be apparent i e in dwellings occupied by blind infirm or disabled people consideration should be given to the installation of an electronically operated device to warn when discharge takes place Safety The safety devices supplied or fitted on an StainlessLite Plus are selected for their suitability for the temperatures and pr...

Page 9: ... the central heating return may be required to reduce excessive flow rates and therefore any potential noise problems Schematic Open Vented Primary System Boiler Pump 150mm max Warming Overflow Pipe F E Cistern Minimum distance as required by boiler manufacturers instructions Motorised Valve Not supplied Motorised Valve Energy cut out Gate Valve Not supplied Schematic Sealed Primary System Boiler ...

Page 10: ...lding regulations part G3 3 63 This product can be supplied from Gledhill part number XC007 which has a inlet temperature limit of 100 C Suitable plumbing configurations for installing this valve are shown on page 19 of this manual NB Any fitted Overheat thermostats may require resetting in the winter months to enable backup heat sources to heat the cylinder Schematic Solar Indirect System Solar P...

Page 11: ...lator 230 VAC 5 Amps HTG VALVE HW VALVE Typical schematic wiring diagram for an unvented installation The electrical installation must comply with IEE requirements For electrical installation refer to BS7671 Note Do not attempt the electrical work unless you are competent to carry out to the above standard Blue Bl Brown Br Green Grey Green Yellow G Gr G Y WIRE COLOUR LEGEND Black Orange Yellow Whi...

Page 12: ...ements When initially opening the taps a small surge in flow may be experienced which disappears as the pressure in the system stabilises This is quite normal with these types of systems and does not indicate a fault 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 Ifwate...

Page 13: ...ning 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 one supplied by Gledhill and check that it works correctly before returning the system to full operation The Regist...

Page 14: ...d seat clean undamaged Is heater operating at less than 60ºC Re set temperature NO YES YES NO NO YES YES Is ERV TPRV discharging YES Recommission expansion vessel pressure NO NO FAULT No Hot Water Direct FAULT No Hot Water Indirect Switch on Re set Replace element START Is power on to elements Is control temperature set at 60ºC 65ºC Has high limit tripped Check wiring links continuity and Re set E...

Page 15: ...ed Regulators Aerator forscrewingontoTaps Mixerswithinternal orexternalthreadsontheirnoses AntiVandal models also available 2 MR05 T Range Internal Regulators Push fit 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 fitting the ...

Page 16: ...nual 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 Regulatio...

Page 17: ...e 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...

Page 18: ...o Comments Signature SERVICE 07 Date Engineer name Company name Telephone No Comments Signature SERVICE 09 Date Engineer name Company name Telephone No Comments Signature SERVICE 02 Date Engineer name Company name Telephone No Comments Signature SERVICE 04 Date Engineer name Company name Telephone No Comments Signature SERVICE 06 Date Engineer name Company name Telephone No Comments Signature SERV...

Page 19: ...3 474412 OR WWW GLEDHILL SPARES NET 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 It is an offence to copy or adapt this document without consent of t...

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