STI FKA270V, FKA240V, FKA 200V, FKA 200H, FKA240H Assembly Instructions Manual
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1
Assembly Instructions
Solar collectors FKA 200/240/270
console installation
2
Table of contents
Contents Page
Please read these instructions carefully before beginning the assembly.
Observe the warnings indicated by this sign.
They warn of dangers or possibly erroneous actions, which may result in the invalidation of the warranty.
The collectors FKA 200, FKA 240 and FKA 270 are monitored according to the CEN-Keymark program rules
Solarthermal Products and are certified with the registration numbers 011-7S1910 ... 1915 F.
The copyright of this instruction incl. graphical material remains in the property of the STI GmbH. The instruction can
only be duplicated completely or in parts with written authorisation of the STI GmbH. Subject to technical changes and
misprints.
The STI GmbH is obliged to take back with the environmental label RAL-UZ-73 for solar collectors ( „Blauer Engel“)
labeled products, and to consign it to recycling.
Safety regulations, instructions and guidelines 3
Product description 5
Hydraulic connections 7
Collector field dimensions 8
bottom support dimensions 9
Assembly bottom support on concrete block 11
Assembly bottom support with fixed dowel pin 12
Assembly collectors 13
Temperature sensor 15
Spacing roof hooks 16
Assembly base console on roof profile 17
Assembly roof-tile clamps 18
Assembly roof-tile clamps with lead 20
Assembly plain tile clamps without lead 22
Assembly plain tile clamps with lead 23
Assembly roof-tile clamp corrugated 25
Assembly mounting profiles/console 26
Wall console dimensions 27
Assembly wall console 28
Temperature sensor 31
Arrangement hydraulic connections 32
Hydraulic connection with manifold 33
Overview hydraulic connections / accessories 34
Assembly distance metal sheets 35
Pipe dimensions of the connecting pipe 36
Initial operation 38
Appendix 43
3
Safety regulations, instructions
and guidelines
Engineer standards and guidelines
• VBG 4 Unfallverhütungsvorschriften Elektrische
Anlagen und Betriebsmittel
• VBG 37 Unfallverhütungsvorschrift Bauarbeiten
• VBG 74 Leitern und Tritte
• ZVDH, Regelwerk (Stand Juni 2001)
• LBO’s Landesbauordnungen der Bundesländer
• DIN 18299 Allgemeine Regelung für Bauarbeiten
jeder Art
• DIN 18334 Zimmer- und Holzbauarbeiten
• DIN 18338 Dachdeckungs- und
Dachabdichtungsarbeiten
• DIN 18339 Klempnerarbeiten
• DIN 18351 Fassadenarbeiten
• DIN 18360 Metallbauarbeiten, Schlosserarbeiten
• DIN 18381 Gas-, Wasser- und Abwasser installationsanlagen
• DIN 18451 Gerüstarbeiten
• DIN 1055 Lastenannahme für Bauten Teil 1-5
• DIN 1988 Teil 1-8 Technische Regeln für die
Trinkwasserinstallation
• DIN 4708 Teil 3 Zentrale Brauchwasser-
erwärmungsanlagen
• DIN 4102 Brandverhalten von Baustoffen und
Bauteilen
• DIN 4109 Schallschutz im Hochbau
• HeizAnlVO Heizungsanlagenverordnung
• ZVH - Richtlinie 11.01 Einbindung solartechnischer
Anlagen in die Hauswärmeversorgung
• TRD 802 Dampfkessel der Gruppe III
• TRD 402 Ausrüstung von Dampfkesselanlagen mit
Heißwassererzeugern der Gruppe IV
• ENV 1991-2-3- 4 Grundlagen der Tragwerksplanung
und Einwirkung auf Tragwerke – Schneelasten und
Windlasten
• DIN EN 516 Einrichtungen zum Betreten des Daches
• EN 517 Sicherheitsdachhaken
• DIN 4751 Teil 1: Wasserheizungsanlagen:
Offene und geschlossene physikalisch
abgesichterte Wäremeerzeugungsanlagen bis 120°C
- Sicherheitstechnische Ausrüstung
Teil 2: Wasserheizungsanlagen: Geschlossene,
thermostatisch abgesicherte Wärmeerzeugungs anlagen mit Vorlauftemperaturen bis 120°C Sicherheitstechnische Ausrüstung
Teil 3: Wasserheizungsanlagen: Geschlossene,
thermostatisch abgesichter te
Wärmeerzeugungsanlagen mit 50 kW
Nennwärmeleistung mit Zwangumlauf Wärmeerzeugern und Vorlauftemperaturen bis 95°C
- Sicherheitstechnische Ausrüstung
• DIN 4753 Teil 1 Wassererwärmer und
Wassererwärmungsanlagen für Trink- und
Betriebswasser;Anforderungen, Kennzeichnung,
Ausrüstung und Prüfung
• DIN 4757 Teil 1: Sonnenheizungsanlagen mit Wasser
und Wassergemischen als Wärmeträger;
Anforderungen an die Sicherheitstechnische
Ausrüstung
Teil 2: Sonnenheizungsanlagen mit organischen Wärmeträgern;
Anforderungen an die sicherheitstechnische Ausrüstung
• DIN VDE 0100-510 Errichten von Starkstromanlagen mit
Nennspannungen bis 1000 V; Allgemeine Bestimmungen
• DIN VDE 0100-725 Errichten von Starkstromanlagen mit
Nennspannungen bis 1000 V; Hilfsstromkreise
• DIN VDE 0100-737 Errichten von Niederspannungsanlagen -
Feuchte und nasse Bereiche und Räume und Anlagen im
Freien
• DIN VDE 0105-100 Betrieb von elektrischen Anlagen
• DIN VDE 0185-1, DIN 57185-1 Blitzschutzanlage, Allgemeines
für das Errichten
• DIN VDE 0190 Einbeziehung von Gas- und Wasserleitungen in
den Hauptpotentialausgleich
• VDE 0855-1, DIN 57855-1 Errichtung und Betrieb (Erdung) von
Antennenanlagen
Connection of solar thermal systems
• DIN EN 12976: Thermische Solaranlagen und ihre Bauteile
(vorgefertigte Anlagen)
• DIN EN 12977: Thermische Solaranlagen und ihre Bauteile
(kundenspezifisch gefertigte Anlagen)
• DIN 1988: Technische Regeln für Trinkwasser-Installation
Notes before starting assembly
The installation and initial operation must be carried out by an expert
who is responsible for the correct installation and operation.
Before installing and putting the collectors into service, please inform
yourself about the local engineer standards and regulations.
Components of the collectors can reach temperatures over 200 °C,
there is a danger of burning and scalding!
Please check whether there are any load sources in the area of the
collector field that may produce chemically aggressive medium.
In condensate dissolved acids and bases can cause permanent
damage to the collector components.
Throughout the installation of a solar collector you directly
intervene into an existing roof cladding. Different roof coverings
such as tile, shingles or slate require as security against the
ingress of moisture due to rain or snow additional measures (eg
sarkings) - especially in case of extended and occupied top floors
or in case of too less roof pitch (concerning the covering).
4
Safety regulations, instructions
and guidelines
The substructure as well as its connections to the
building have to be checked on site according to the local
regulations.
The collectors have to be mounted in an angle of at least
20° to max. 70°.
Recommended heat transfer medium is a mixture of glycol
and water, e.g. Tyfocor L or similar The collectors may
never be operated or tested under pressure with water.
To protect the system of overheating during standstill and
accelerated glycole-aging a self-draining system (e.g. STI
Drain Master or Drain Box) is recommended.
It is absolutely necessary to pay attention, that the back flow
temperature is never lower than the ambient temperature. If
necessary, take appropriate action (e.g. increase back flow
temperature to at least 30°C).
Lightning protection
Note country-specific legislation!
Throughout the installation of metal fastening, a check is
needed by an authorized qualified electrician.
The metallic pipes of the solar circle are connected via
a copper pipe of at least 16 mm² with the earth circuit
connector.
Please ensure sufficient ventilation for each assembly
method. Do not close the ventilation openings. Especially
in case of roof-integrated assembly, the ventilation of the
collector is definitely necessary. Appropriate ventilation
hoods are available from the supplier. Pay attention to the
regulations of the ZVDH (Germany), SVDW (Switzerland)
as well as different local regulations concerning the ventilation. If necessary, consult an expert.
Responsibilites
The constructor of the installation is responsible for the integration of the installation according to regulations and for
compliance with the safety regualtions.
The operator of the installation is responsible for an operation of the installation according to regulations and for
consultation of experts in case of problems.
This instruction is not subjected to the control of a service of modifications. It does not absolve the manufacturer and operator of the
installation of his responsibilities to install and operate all parts of
the installation according to utmost professional knowledge. The
manufacturer of the installation is responsible to observe and keep
all appropriate regulations and instructions.
Statics
Before beginning the assembly it is vital to test the roof or
substructure on site to sufficient load-carrying capacity.
Pay increased attention to the possible durability of the screw
fittings to fasten the collectors as well as to the quality of the substructure.
According to DIN 1055 part 4 and 5 or rather according to the local
engineer standards it is necessary to check on site the whole system construction, especially in snowy regions (note: 1 m² powder
snow ~ 60 kg / 1 m² wet snow ~ 200 kg) as well as in regions with
high wind speed. Before starting the assembly all aspects that
may lead to incorrect load of the whole construction have to be
considered!
Install the collectors the way that backlog of snow (e.g. due to
snow guards or other obstacles) is not possible.
In case of correct assembly snow loads (pressure loads) up to 2
kN/m² and wind loads (suction loads) up to 1 kN/m² acting on the
collector are permitted.
For transport and stocking
Never abandon the delivered collectors unprotected at the building
site. Never lay down the collectors onto a rough surface with overhanging pieces like stones, timbers, etc.
Stock the collectors always upright leaning against a solid surface.
The rigidity of the collectors is limited. During transport to the building site always ensure a torsion-free transport type. In case of an
elevated intermediate storage make sure that the collectors are
protected against sliding down.
5
Product description
Solar collector FKA
The solar thermal collector FKA uses the radiant
energy of the sun to heat the heat transfer medium.
This glycol-water mixture gives off the stored heat via
a heat exchanger to a storage. The obtained energy
can be used for water heating and heating support.
Sectional model
1 Aluminium frame
2 Insulation
3 Insulation
4 Stucco back panel
5 Highly selective mono-material copper absorber
6 Glass
7 EPDM sealing
8 EPDM sealing
6
Product description
FKA 240 V FKA 270 V
FKA 200 H
FKA 270 H
FKA 200 V
FKA 240 H
Specifications
The FKA collector has a pure copper absorber with meander shaped tubes as well as
integrated manifolds. The hydraulic system enables to connect 15 collectors in one series
and up to six collectors on one side. In one collector field up to 45 collectors can be
connected in three rows.
Hydraulic system of the absorber
Model FKA 200 V 240 V 270 V 200 H 240 H 270 H
Gross surface 2.13 m² 2.52 m
²
2.88 m² 2.13 m² 2.52 m² 2.88 m²
Net surface 1.80 m² 2.15 m
²
2.52 m² 1.80 m² 2.15 m² 2.52 m²
Length 1,777 mm 2,100 mm 2,400 mm 1,200 mm 1,200 mm 1,200 mm
Width 1,200 mm 1,200 mm 1,200 mm 1,777 mm 2,100 mm 2,400 mm
Height 115 mm 115 mm 115 mm 115 mm 115 mm 115 mm
Test pressure 10 bar 10 bar 10 bar 10 bar 10 bar 10 bar
Operating pressure 6 bar 6 bar 6 bar 6 bar 6 bar 6 bar
Fluid volume Co-Co / Al-Co 2.1 l 2.2 l 2.4 l 2.7 l 2.7 l 3.1 l
Fluid volume Al-Al 1.8 l 1.9 l 2.1 l 2.4 l 2.4 l 2.7 l
Flow per m
2
15 - 40 l/h 15 - 40 l/h 15 - 40 l/h 15 - 40 l/h 15 - 40 l/h 15 - 40 l/h
Weight Co-Co 38 kg 41 kg 44 kg 38 kg 41 kg 44 kg
Weight Al-Co 37 kg 40 kg 43 kg 37 kg 40 kg 43 kg
Weight Al-Al 36 kg 38 kg 41 kg 36 kg 38 kg 41 kg
Loss of pressure (T=20°C / 30l/h) 6,141 Pa 8,522 Pa 11,217 Pa 4,082 Pa 6,297 Pa 7,988 Pa
7
Hydraulic connections
A B
C
E
G
D
F
H
Temperature sensor
Each collector has a sleeve for inserting a temperature sensor. The sleeve is directly connected with the absorber.
If the collectors are installed correctly, the sleeve is always located on the top of the collector on the left. The
temperature sensor can be inserted in any collector. Please pay attention to the maximum inserting depth of 4 cm
and secure it against slipping out. Due to the measuring point on the absorber the temperature measured by the
sensor may differ from the fluid temperature.
Installations with one up to six collectors in one row
Connection F red
Connection BF blue,
A or B
C or D
Close unused connections with
caps.
Installations with seven up to 15 collectors in one row
Connection bottom left / at the top of
the right
BF = C / F = B
Connection at the top of the left /
bottom right
BF = D / F = A
Multi-row installations
F=Flow (collector to storage) red grommet
BF=Backflow (storage to collector) blue grommet
In case of installation of an air eliminator, install it at the opposite
end of the top flow connection!
Pipe rounting by Tichelmann
Connection F A + E / BF H + D
Connection F B + F / BF G + C
Close unused connections with caps.
In case of multi-row installations the connection pipe must always be connected to the diagonal line to the external
manifold (Tichelmann), e.g. from botton left to the top right.
8
Collector field dimensions
Horizontal section across a collector field
Collectors that are mounted side by
side in one row are always connected
by means of stainless steel
expansion joints on the manifolds.
(view photo)
1300001 Collector connection set hydraulical
1910001 Tool set
Tighten the screw on the clamp only manually. The usage of
cordless screwdrivers or the like may lead to damages of the thread
of the clamp. Tighten the clamp until the two lugs are superimposed
in the whole length.
Field width
It is possible to assemble metal sheets between the collectors to achieve a homogeneous appearance of the installation.
The distance metal sheets are assembled exclusively for optical aspects and do not have any influence on the installation.
Therefore the distance metal sheets can be ordered optionally and are not necessarily included in delivery.
Collector type
When mounting solar collectors on supports it is important to ensure that the panels are anchored either on a solid surface or
on the concrete blocks shown in this instruction. The available concrete elements are recommended as a weight for locations
up to 700 meters above sea level with leeward situation. With expected higher loads, the weights must be increased. For higher
loads a calculation must be provided, and optionally a reinforcing of the system with additional components. When attaching
the consoles on buildings please ensure that the water tightness is maintained in each case. The mounting of the consoles and
collectors is described on the following pages.
240 H Number of collectors 1 2 3 4 5 6 7 8
Field width in mm 2.067 4.187 6.307 8.427 10.547 12.667 14.787 16.907
per each additional
collector
+ 2.120
270 H Anzahl Kollektoren 1 2 3 4 5 6 7 8
Field width in mm 2.340 4.733 7.126 9.519 11.912 14.305 16.698 19.091
per each additional
collector
+ 2.393
200 V
240 V
270 V
Number of collectors 1 2 3 4 5 6 7 8
Field width in mm 1.167 2.387 3.607 4.827 6.047 7.267 8.487 9.707
+ 1.220
per each additional
collector
200 H Number of collectors 1 2 3 4 5 6 7 8
Field width in mm 1.713 3.479 5.245 7.011 8.777 10.543 12.309 14.075
per each additional
collector
+ 1.766
9
bottom support dimensions
α
δ
ε
bottom support
additional block
concrete block
base
row spacing of collectors
collector
type
distance A
20 ° 30 ° 45 ° 60 °
FKA 200 H 220 cm 265 cm 315 cm 340 cm
FKA 240 H 220 cm 265 cm 315 cm 340 cm
FKA 270 H 220 cm 265 cm 315 cm 340 cm
FKA 200 V 328 cm 391 cm 462 cm 503 cm
FKA 240 V 439 cm 513 cm 598 cm 646 cm
FKA 270 V 460 cm 550 cm 640 cm 700 cm
building height of collectors
collector
type
height H
20 ° 30 ° 45 ° 60 °
FKA 200 H 53 cm 71 cm 93 cm 110 cm
FKA 240 H 53 cm 71 cm 93 cm 110 cm
FKA 270 H 53 cm 71 cm 93 cm 110 cm
FKA 200 V 73 cm 91 cm 132 cm 156 cm
FKA 240 V 71 cm 104 cm 147 cm 180 cm
FKA 270 V 95 cm 130 cm 176 cm 211 cm
The specified levels are reported without concrete blocks. To
determine the total height the height of the concrete block
(15 cm) must be added.
Block distance center - center Dimensional chain, bottom bracket UK mounting
collector type
distance
Bottom support Bottom support attachment points (+ / - 30 cm)
X
α δ ε
FKA 200 H 176,6 cm 1000 mm 100 mm 860 mm -
FKA 240 H 212,0 cm 1000 mm 100 mm 860 mm -
FKA 270 H 239,3 cm 1000 mm 100 mm 860 mm -
FKA 200 V 122,0 cm 1600 mm 100 mm 700 mm 1.460 mm
FKA 240 V 122,0 cm 1600 mm 100 mm 700 mm 1.460 mm
FKA 270 V 122,0 cm 1800 mm 100 mm 900 mm 1.660 mm
All values given are recommendations for an effective angle of incidence of 20 °.
Please note the wind loads according to DIN 1055-4 in the edge region of the roof. The resulting base load is
necessary in each case to the requirement of wind loads on the spot!
10
bottom support dimensions
distance of superstructures
parapet height B 30 cm 40 cm 50 cm 60 cm 70 cm 80 cm 90 cm 100 cm 110 cm
distance C 20 cm 40 cm 70 cm 100 cm 125 cm 150 cm 180 cm 205 cm 230 cm
1420100 concrete block 65 kg 1420101 additional block 45 kg
concrete block 65 kg
additional block 45 kg
console 8 kg
collector filled (240) 46 kg
travers position
angle 20° 30° 45° 60°
position P1 - P2 P3 - P2 P1 - P2 P3 - P2
200/240/270 H 487 mm 487 mm 861 mm 861 mm
200 V 675 mm 675 mm 1.224 mm 1.224 mm
240 V 832 mm 832 mm 1.490 mm 1.490 mm
position P1 - P2 P1 - P2 P1 - P2 P1 - P2
270 V 659 mm 962 mm 1.405 mm 1.820 mm
additional block
concrete block
base
11
Assembly bottom support on
concrete block
First install the base console in accordance with the requirements to
the dimensions of bottom support.
1420014 bottom support 20°/30° 200 V
1420024 bottom support 45°/60° 200 V
1420018 bottom support 20°/30° 240 V
1420022 bottom support 45°/60° 240 V
1420060 bottom support 20° 270 V
1420061 bottom support 30° 270 V
1420062 bottom support 45° 270 V
1420063 bottom support 60° 270 V
1420011 bottom support 20°/30° 200/240/270 H
1420020 bottom support 45°/60° 200/240/270 H
Next place the concrete block. Pay attention to the exact
observance of the specified clearances between the concrete
blocks. The short distance between the threaded sleeve and block
edge (10 cm) shows the front of the block. Make sure that every
concrete block is on the same mounting position and aligned in a
row (e.g. by a line mark).
1420100 concrete block 65 kg
Now remove from all concrete blocks, the protective caps for the
integrated threaded sleeves.
Then place the base consoles on the concrete blocks and secure
them with the screws M10. All other consoles have to be oriented
exactly in a row (e.g. by a line mark).
1420003 Fastening set for bottom support
Now weight down the concrete block with the additional block.
Prepare for installing the collectors all consoles as above described.
1420101 additional block 45 kg
12
Assembly bottom support with
fixed dowel pin
First install the base console in accordance with the requirements
(see page 11).
1420014 bottom support 20°/30° 200 V
1420024 bottom support 45°/60° 200 V
1420018 bottom support 20°/30° 240 V
1420022 bottom support 45°/60° 240 V
1420060 bottom support 20° 270 V
1420061 bottom support 30° 270 V
1420062 bottom support 45° 270 V
1420063 bottom support 60° 270 V
1420011 bottom support 20°/30° 200/240/270 H
1420020 bottom support 45°/60° 200/240/270 H
Drill two holes per base console in the existing surface to fix the
fixed dowel pin M10. Pay attention to precise alignment of the two
holes. In addition, all other holes hare to be oriented in exactly one
row (e.g. by a line mark)
1420004 Fastening set for concrete blocks
(with fixed dowel pin)
Then place the base consoles on the ground and secure it with the
added fixed dowel pins M10. All other consoles have to be oriented
exactly in a row (e.g. by a line mark)
Fully assembled fixed dowel pin and console (see figure 1 and 2)
Fig. 1
Fig. 2
Reliable anchoring of the bottom support with the fixed dowelpin is possible in concrete <c25/25 as well as in natural stone that
is resistant to pressure.
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