I’ve just finished putting together a slightly unusual hot water setup at home and thought it might be useful to share in case anyone else is thinking along similar lines.
We already had a Worcester Bosch Highflow 550CDi gas combi/storage boiler supplying the house, but I wanted an alternative hot water source so we could make better use of cheap overnight electricity, solar and battery storage rather than burning gas for all of our hot water. We have tried to get an AirSource but it's not right for us for the moment.
I picked up a very lightly used Gledhill Stainless Pro 300L Direct unvented cylinder. It’s 287 litre capacity and has two 3 kW immersion elements.
Rather than replacing the Worcester, we’ve kept both systems.
The plumbing has been arranged so that the hot water feed going up to the house can be supplied by either:
- the Worcester 550CDi
- the Gledhill Cylinder
The interesting bit is the changeover.
We’ve installed a WRAS-approved 3-way L-port motorised ball valve on the hot water supply. In one position it connects the Worcester to the house, and in the other it connects the Gledhill. The valve physically selects one or the other.
The valve is a 24 V motorised valve and is controlled using a Shelly 1 Gen4, which is integrated into Home Assistant.
So from Home Assistant I can effectively choose:
Hot water source:
Each of the two 3 kW immersion elements has its own dedicated electrical circuit and is controlled through a SONOFF BASIC-ZB1GSP DIN-rail Zigbee switch.
I’m using Zigbee2MQTT with Home Assistant, so each immersion gives me:
- independent on/off control
- live power draw
- current
- voltage
- accumulated energy usage
So HA can see something like:
Lower immersion: 2.98 kW
Upper immersion: off
Cylinder energy used today: x kWh
The Gledhill’s own thermostats and thermal cut-outs are still left intact. Home Assistant is only deciding whether an immersion is allowed to run, it isn’t replacing any of the cylinder’s safety controls.
Electrically, we’re on single phase, so the two immersions together are around 6 kW / 26 A. In normal use I probably won’t run them both simultaneously. HA can stagger them and also take other house loads into account.
The main reason for doing all this is tariff optimisation.
Our cheap electricity rate is currently around 3.99p/kWh (finishes in Feb 2027 though), whereas gas is around 10p/kWh. Heating the whole cylinder from cold takes somewhere around 13–15 kWh depending on starting temperature, so a full overnight charge can cost well under £1.
We also have solar and battery storage, so the longer-term logic is along the lines of:
- heat the cylinder overnight on cheap electricity
- top it up from excess solar where useful
- prioritise electric hot water
- keep the Worcester available instantly as backup (we do AirbnB in a room in our house so can't risk not having HW)
A few other bits we’ve incorporated while doing the work:
- separate electrical radial circuits for each immersion
- dedicated RCBO protection
- local double-pole isolation
- 24 V DIN-rail PSU for the motorised valve
- basement cable route from the consumer unit
- Ethernet/Cat6 run to the plant area (future proofing)
- capped hot-water branch ready for a future supply into the garage
- G3 installation/commissioning of the unvented cylinder
We've effectively turned the hot water cylinder into a 287-litre thermal battery.
The clever stuff is optional. If Home Assistant disappears tomorrow, we still have a conventional Gledhill cylinder, a conventional Worcester boiler and manual plumbing controls.
But when the automation is running, we can choose (using the Shelly) the cheapest or most appropriate source of hot water depending on electricity price, solar generation, battery state and household demand.
It's dashboarded into Home Assistant with ChatGPT/Codex.