IMMERGAS 3.027849 Recessed Kit with Outflow Frame Instruction Manual

IMMERGAS 3.027849 Recessed Kit with Outflow Frame

Product Information

Specifications:

• Product Name: Recessed Kit with Outflow Frame for Flat-Plate Thermal Solar Manifold
• Vertical Installation: CP4 XL (Code: 3.027735), CP4 M (Code: 3.027768)
• Horizontal Installation: CP4 XL/M (Code: 3.027769), Extension Kit (Code: 3.027736, 3.027849)

Product Usage Instructions

Vertical Installation:

Foreword: This instruction booklet provides technical information for installing the Immergas kit for the vertical installation of solar manifolds. It does not cover other installation-related issues like workplace safety.

Description: The following components allow for the roof installation of recessed solar manifolds. This system isolates the solar panel on the roof, eliminating the need for additional sealing or adjustments as outflows occur above the panel.

Composition of the Recessed Kit:

Composition of Extension Kit for Recessed Kit:

FAQ:

• Q: Can the recessed kit be used for horizontal installations?
  A: Yes, there are specific codes for horizontal installations: CP4 XL/M (Code: 3.027769), and Extension Kit (Code: 3.027849).

• Q: How many wood screws are included in the extension kit?
  A: The extension kit contains 2 wood screws (5×70) and 12 screws (4×35) along with other components.

WARNING
THIS KIT MUST BE INSTALLED FROM LEFT TO RIGHT

VERTICAL INSTALLATION

General recommendations
This kit must be installed in compliance with the regulations in force, according to the instructions of the manufacturer, and by professionally qualified personnel, having specific technical skills in the plant sector. The appliance must only be used for that, expressly foreseen. Any other use must be considered improper and therefore dangerous.
If errors occur during installation, operation and maintenance, due to noncompliance with the technical laws in force, standards or instructions contained in this manual (or however supplied by the manufacturer), the manufacturer accepts no contractual and extra-contractual liability for any damages and the appliance warranty is invalidated.

Foreword: this instruction booklet contains only technical information to install the Immergas kit and does not involve other issues linked to the kit installation (e.g. safety in workplaces, etc.).

DESCRIPTION.
The structure described below allows roof installation of recessed solar manifolds.
This recessed system isolates the solar panel on the roof, therefore no additional sealing/adjustments are required as the bad weather outflows above the panel itself.

COMPOSITION OF THE RECESSED KIT

COMPOSITION OF EXTENSION KIT FOR RECESSED KIT

OVERALL DIMENSIONS
The table below indicates the clearance dimensions, excluding the sheath, to install the 1 to 6 manifold kit (Fig. 1) using the extension kit.

LONG SIDE MULTIPLE INSTALLATION (CP4 XL AND CP4 M) (FIG. 1)

In the event of single installation (manifolds side by side but hydraulically independent) consider the overall dimensions of a single kit, for convenience and space requirements you can mount the various independent manifolds, putting them side by side.

GENERAL RECOMMENDATIONS:

• Caution: to prevent any infiltration of water, it is essential to seal the roof attachment holes by means of suitable materials according to the principles of good practice and according to the type of roof (for example, use mastics or bituminous / silicone sealants).
• Ventilated roofs: especially with ventilated roofs, cement roofing, or in any case wherever it is necessary to minimise the total no. of direct anchoring points on the roofing, place a plywood board or other suitable material (not supplied) under the installation area. This support must be suitably attached to the roof, according to the principles of good practice.

LONG SIDE SINGLE MANIFOLD INSTALLATION
For installation of the long-side single manifold, follow the same instruc- tions for long side multiple manifold installations described below, without installing the extension kit.

LONG SIDE MULTIPLE MANIFOLD INSTALLATION

1. Remove the roof covering (e.g. slates, tiles, etc.) (Fig. 2).

2. Position the adhesive sheath (Fig. 3) for the required length (see the “X” measurement shown in the previous table).
   NOTE: the adhesive sheaths (Fig. 3) must be folded by approximately 50 mm on the upper long side (without crushing them), to prevent rainwater backflow.

3. Position the bottom drains (Fig. 4) on the roof crosspiece (A) so that they overlap the sheath, as shown in Fig. 5. The drains will overlap each other to completely cover the “X” measurement shown in the previous table (Fig. 1).
   Refer to the overlapping measurements (K) shown in the table below when installing the bottom drains. No. of XL-M vertical collectors| K measurement
   ---|---
   2| 590
   3| 425
   4| 345
   5| 290
   6| 260

4. Position the manifold positioning brackets and fix them by screwing the 4×35 screws provided into the prepared holes following the measurements shown in Fig. 5; when the brackets are fixed, the drains previously positioned in Fig. 4 are automatically fixed.

5. Position the 1st manifold (Fig. 6) at 250 mm from the internal edge of the left drain; make sure it is properly resting on the manifold positioning brackets and fix it with the 6 brackets to the roof crosspieces by screwing the 4×35 screws provided into the prepared holes.

6. Insert the sleeves and connection fittings on the 1st manifold (Fig. 7).

7. Position the 2nd manifold and connect it to the 1st one, keeping a distance of 56 mm between them (Fig. 8); make sure the 2nd collector is properly resting on the manifold positioning brackets and then fix it on the side without brackets using the other 3 brackets with the 4×35 screws (Fig. 8).

8. Apply a bead of silicone along the two sides of the middle guard (at approximately halfway up the bend) (Fig. 9).
   Note: for the “M” version, cut the middle guard at a length of 1740 mm and bend the ends as shown in Fig. 9.
   Place the previously prepared middle guard (with silicone) between the manifolds and press down where the silicone beads have been applied to ensure it sticks properly to the manifolds (Fig. 9).

9. Close the middle guard on both the top and bottom sides with the relative guard closure, using the 4.2×13 self-tapping screws (Fig. 10).
   Connect the manifolds (3 ways, vents, plugs, etc.).

10. Apply a bead of silicone on the two left and right side guards along the entire side shown in Fig. 11.
    Note: there are some pre-sections (B) on the side guards in the bottom area to facilitate removal of the metal-sheet plate portion if required when the pipes pass through; it is recommended to seal them with the silicone provided, in case the metal-sheet plate portion is not removed.
    Place the guards next to the manifolds (they are shaped so as to be centred on the manifold) and make the newly applied silicone stick against the side of the manifold (Fig. 11).

11. Fix the side guards with the 6 guard fixing brackets (3 per side) to the roof crosspieces with the 4×35 screws (Fig. 12).

12. Apply a bead of silicone along the perimeter on the inside of the 4 inspection brackets (Fig. 13).
    Mount the 4 inspection closure brackets using the 4.2×13 self-tapping screws in all 4 of the inspection openings on the side guards (Fig. 13).

13. Mount the sticky mats on the upper part of the side guards (Fig. 14).

14. Place the support bases against the upper part of the manifolds (at approximately halfway up each manifold) (Fig. 15).

15. Fix each base to the roof crosspieces with 2 5×70 wood screws (C) (Fig. 16). Make sure the support bases are properly resting against the manifolds and the 5×70 wood screws can be screwed to the crosspiece of the underlying roof (Fig. 16).

16. Apply a bead of silicone on the left corner group along the edge indicated on the inner side (at about the centre line of the folded bend), place it on the wooden base, slotting it sideways inside the bend of the side guard and against the manifold at the front, making sure the silicone sticks to the upper part of the manifold (Fig. 17).

17. Apply a bead of silicone on the inner side (not in view) of the top exten-sion guard along the centre line of the folded bend and along the left side edge (Fig. 17), place it on the wooden base and against the manifold at the front, making it overlap the previously positioned left corner group (Fig. 17).
    Refer to the overlapping measurements shown in the table below when installing the top extension guards (Fig. 17). No. of XL-M vertical collectors| W measurement
    ---|---
    2| 590
    3| 425
    4| 345
    5| 290
    6| 260

18. Apply a bead of silicone on the right corner group along the edge indicated on the inner side (at about the centre line of the folded bend) and along the left side edge then place it on the wooden base (Fig. 17), slotting it sideways inside the bend of the side guard and against the manifold at the front, making sure the silicone sticks to the manifold and on the side to the extension guard (Fig. 17).
    Note: the corner pieces are designed so that the joint does not meet the pro-tection brackets on the corners of the manifold.
    Note: in any case, during the installation of the top extension guards against the manifolds, make sure the joint goes against the manifold and not against the protection brackets on the corners of the manifolds.

19. Fix the top guards to the wooden bases with the 4×35 screws (it is advisable to use at least 2 screws per guard and with a multiple kit, it is advisable to place them on the overlapped part, so one screw will fix 2 guards at a time) (Fig. 18).
    Note: It is recommended to apply a bead of silicone on the 4×35 screws.

20. Fix the corner pieces further with the remaining 2 guard fixing brackets to the crosspieces of the underlying roof with the 4×35 screws.
    Note: make sure the brackets are placed as shown in Fig. 19.

21. Mount the adhesive insulating strips on the sides of the kit (Fig. 20).

22. Reposition the roof tiles so as to overlap the kit guards and press sideways on the insulating strips (Fig. 21).

HORIZONTAL INSTALLATION

DESCRIPTION
The structure described below ensures horizontal installation of recessed solar manifolds in roofs. This recessed system isolates the solar panel on the roof, therefore no additional sealing/adjustments are required as the bad weather outflows above the panel itself.

COMPOSITION OF THE RECESSED KIT

COMPOSITION OF EXTENSION KIT FOR RECESSED KIT

OVERALL DIMENSIONS
The table below indicates the clearance dimensions, excluding the sheath, to install the 1 to 6 manifold kit (Fig. 22) using the extension kit.

SHORT-SIDE MULTIPLE INSTALLATION (CP4 XL AND CP4 M) (FIG. 1)

SHORT SIDE HORIZONTAL PANEL (XL)

no. of manifolds| Clearance area (mm) (excluding sheath) (X x Y)
1| 2620 x 1800
2| 4820 x 1800
3| 7020 x 1800
4| 9220 x 1800
5| 11420 x 1800
6| 13620 x 1800
SHORT SIDE HORIZONTAL PANEL (M)

no. of manifolds| Clearance area (mm) (excluding sheath) (X x Y)
1| 2200 x 1800
2| 3980 x 1800
3| 5760 x 1800
4| 7540 x 1800
5| 9320 x 1800
6| 11100 x 1800

In the event of single installation (manifolds side by side but hydraulically independent) consider the overall dimensions of a single kit, for convenience and space requirements you can mount the various independent manifolds, putting them side by side.

GENERAL RECOMMENDATIONS:

• Caution: to prevent any infiltration of water into the roofing, it is essential to seal the roof attachment holes using suitable materials according to the principles of good practice and according to the type of roof (for example, use mastics or bituminous / silicone sealants).
• Ventilated roofs: especially with ventilated roofs, cement roofing, or in any case wherever it is necessary to minimize the total no. of direct anchoring points on the roofing, place a plywood board or other suitable material (not supplied) under the installation area. This support must be suitably attached to the roof, according to the principles of good practice.

SHORT SIDE SINGLE MANIFOLD INSTALLATION
For installation of the short-side single manifold, follow the instructions for short-side multiple manifold installations described below, without installing the extension kit.

LONG SIDE MULTIPLE MANIFOLD INSTALLATION

1. Remove the roof covering (e.g. slates, tiles, etc.) (Fig. 23).

2. Position the adhesive sheath (Fig. 24) for the required length (see the “X” measurement shown in the previous table).
   NOTE: the adhesive sheaths (Fig. 24) must be folded by approximately 50 mm on the upper long side (without crushing them), to prevent rainwater backflow.

3. Position the bottom drains (Fig. 25) on the roof crosspiece (A) so that they overlap the sheath, as shown in Fig. 26. The drains will overlap each other to completely cover the “X” measurement shown in the previous table (Fig. 22).
   Refer to the overlapping measurements (K) shown in the table below when installing the bottom drains. No. of horizontal manifolds| K measurement (XL)| K measurement (M)
   ---|---|---
   2| 100| 375
   3| 350
   4| 340
   5| 330
   6| 325

4. Position the manifold positioning brackets (Fig. 26) and fix them by screwing the 4×35 screws into the prepared holes following the measurements shown in the table below:
   Type of installation| J measurement
   ---|---
   Horizontal XL| 1800
   Horizontal M| 1380

When the brackets are fixed, the previously positioned drains are automa- tically fixed (Fig. 25).

5. Position the 1st manifold (Fig. 27) at 250 mm from the internal edge of the left drain; make sure it is properly resting on the manifold positioning brackets and fix it with the 6 brackets to the roof crosspieces by screwing the 4×35 screws into the prepared holes.

6. Insert the sleeves and connection fittings on the first manifold (Fig. 27).

7. Position the 2nd manifold, keeping a distance of 56 mm between them (Fig. 28); make sure the 2nd collector is properly resting on the manifold positioning brackets and then fix it on the side without brackets using the other 3 brackets with the 4×35 screws (Fig. 28).

8. Insert the sleeves and connection fittings on the second manifold (Fig. 28).

9. Note: cut the middle guard at a length of 1175 mm and bend the ends as shown in Fig. 29.
   Apply a bead of silicone along the two sides of the middle guard (at approximately halfway up the bend) (Fig. 29).
   Place the previously prepared middle guard (with silicone) between the manifolds and press down where the silicone beads have been applied to ensure it sticks properly to the manifolds (Fig. 29).

10. Close the middle guard on both the top and bottom sides with the relative guard closure, using the 4.2×13 self-tapping screws (Fig. 30).
    Connect the two manifolds (Fig. 30).

11. Apply a bead of silicone on the two left and right side guards along the entire side shown in Fig. 31.
    Place the guards next to the manifolds (they are shaped so as to be centred on the manifold) and make the newly applied silicone stick against the side of the manifold (Fig. 31).

12. Fix the side guards with the 6 guard fixing brackets (3 per side) to the roof crosspieces with the 4×35 screws (Fig. 32).

13. Mount the sticky mats on the upper part of the side guards (Fig. 33).

14. Place the support bases against the upper part of the manifolds (Fig. 34).

15. Fix each base to the roof crosspieces with 2 5×70 wood screws (B) (Fig. 35). Make sure the support bases are properly resting against the manifolds and the 5×70 wood screws can be screwed to the crosspiece of the underlying roof (Fig. 35).

16. Apply a bead of silicone on the left corner group along the edge indicated on the inner side (at about the centre line of the folded bend), place it on the wooden base, slotting it sideways inside the bend of the side guard and against the manifold at the front, making sure the silicone sticks to the upper part of the manifold (Fig. 36).

17. Apply a bead of silicone on the inner side (not in view) of the top exten-sion guard along the centre line of the folded bend and along the left side edge (Fig. 36), place it on the wooden base and against the manifold at the front, making it overlap the previously positioned left corner group (Fig. 36).
    Refer to the overlapping measurements shown in the table below when installing the top extension guards (Fig. 36). No. of horizontal manifolds| W measurement (XL)| W measurement (M)
    ---|---|---
    2| 100| 375
    3| 350
    4| 340
    5| 330
    6| 325

18. Apply a bead of silicone on the right corner group along the edge indicated on the inner side (at about the center line of the folded bend) and along the left side edge then place it on the wooden base (Fig. 36), slotting it sideways inside the bend of the side guard and against the manifold at the front, making sure the silicone sticks to the manifold and on the side to the extension guard (Fig. 36).
    Note: the corner pieces are designed so that the joint does not meet the pro-tection brackets on the corners of the manifold.
    Note: in any case, during the installation of the top extension guards against the manifolds, make sure the joint goes against the manifold and not against the protection brackets on the corners of the manifolds.

19. Fix the top guards to the wooden bases with the 4×35 screws (it is advisable to use at least 2 screws per guard and with a multiple kit, it is advisable to place them on the overlapped part, so one screw will fix 2 guards at a time) (Fig. 37).
    Note: It is recommended to apply a bead of silicone on the 4×35 screws.

20. Fix the corner pieces further with the remaining 2 guard fixing brackets to the crosspieces of the underlying roof with the 4×35 screws.
    Note: make sure the brackets are placed as shown in Fig. 38.

21. Mount the adhesive insulating strips on the sides of the kit (Fig. 39).

22. Reposition the roof tiles so as to overlap the kit guards and press sideways on the insulating strips (Fig. 40).

During the service life of the products, performance is affected by external factors, e.g. the hardness of the DHW, atmospheric agents, deposits in the system and so on. The declared data refers to new products that are correctly installed and used by applicable regulations.
NOTE: correct periodic maintenance is highly recommended.

The instruction booklet is made of eco-friendly paper

immergas.com
Per richiedere ulteriori approfondimenti specifici, i Profession-isti del settore possono anche avvalersi dell’indirizzo e-mail: consulenza@immergas.com
Immergas S.p.A.
42041 Brescello (RE) – Italy
Tel. 0522.689011
Fax 0522.680617

References

• Immergas

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