STI FKA 240 Series User manual

1
Assembly Instructions
Solar collectors FKA 240/270
Roof-mounted installation

2
Table of contents
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 to lapse of the warranty.
The collectors FKA 240 and FKA 270 are monitored according to the CEN-Keymark program rules Solarthermal
Products and are certied with the registration numbers 011-7S154F and 011-7S832F.
The copyright of this instruction incl. graphical material remains in any case at 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
Collector eld dimensions 7
Hydraulic connections 9
Spacing multi-row collector elds 10
Roof-mounted installation on roof-tiles 11
Assembly roof-tile clamp 12
Assembly roof-tile clamps with lead 14
Assembly plain tile clamps without lead 16
Assembly plain tile clamps with lead 17
Assembly roof-tile clamps corrugated 19
Assembly mounting proles 20
Assembly collectors 22
Arrangement hydraulic connections 29
Hydraulic connection with manifold 30
Overview hydraulic connections / accessories 31
Assembly distance metal sheets 32
Pipe dimension of the connecting pipe 33
Initial operation 35
Appendix 38
Contents Page

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 abgesichterte
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
• EN 12976: Thermische Solaranlagen und ihre Bauteile
(vorgefertigte Anlagen)
• ENV 12977: Thermische Solaranlagen und ihre Bauteile
(kundenspezisch gefertigte Anlagen)
• DIN 1988: Technische Regeln für Trinkwasser-Installation
(TRWI)
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 50 °C,
there is a danger of burning and scalding!
Please check whether there are any load sources in the area of the
collector eld 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 oors
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
circumstances.
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. 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 ow
temperature is never lower than the ambient temperature. If
necessary, take appropriate action (e.g. increase back ow
temperature to at least 30°C).
Lightning protection
Note country-specic legislation!
Throughout the installation of metal fastening, a check is
needed by an authorized qualied 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 sufcient ventilation for each assembly
method. Do not close the ventilation openings. Especially
in case of roof-integrated assembly, the ventilation of the
collector is denitely 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 ventila-
tion. If necessary, consult an expert.
Responsibilites
The constructor of the installation is responsible for the in-
tegration of the installation according to regulations and for
compliance with the safety regualtions.
The operator of the installation is responsible for an ope-
ration 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 modi-
cations. 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 sufcient load-carrying capacity.
Pay increased attention to the possible durability of the screw
ttings to fasten the collectors as well as to the quality of the sub-
structure.
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 col-
lector installation, 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 up to 2 kN/m²
and wind loads up to 80 km/h (inland up to 10 meters
height of buildings) on the collectors are permissible.
For transport and stocking
Never abandon the delivered collectors unprotected at the building
site. Never lay down the collectors onto a rough surface with over-
hanging pieces like stones, timbers, etc.
Stock the collectors always upright leaning against a solid sur-
face.
The rigidity of the collectors is limited. During transport to the buil-
ding 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
Specications
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 eld up to 45 collectors can be
connected in three rows.
Model FKA 240 V 270 V 240 H 270 H
Gross surface 2.52 m22.85 m22.52 m22.85 m2
Net surface 2.20 m22.50 m22.20 m22.50 m2
Length 2,100 mm 2,380 mm 1,200 mm 1,200 mm
Width 1,200 mm 1,200 mm 2,100 mm 2,380 mm
Height 110 mm 110 mm 110 mm 110 mm
Test pressure 10 bar 10 bar 10 bar 10 bar
Operating pressure 6 bar 6 bar 6 bar 6 bar
Fluid volume 2,2 l 2.4 l 2.7 l 3.1 l
Flow per m215 - 40 l/h 15 - 40 l/h 15 - 40 l/h 15 - 40 l/h
Weight 42 kg 54 kg 42 kg 54 kg
Loss of pressure (T=20°C / 30l/h) 3,272 Pa 3,272 Pa
Hydraulic system of the absorber
FKA 240 V
FKA 270 V
FKA 270 H
FKA 240 H

7
Collector eld dimensions
Vertical section across a collector eld
In case of multi-row installations the
collectors will always be mounted
on joint on top of each other . The
lip (collector cover) of the upper
collector has to be put onto the
lower collector. The lip (collector
cover) of the lower collector has to
be clamped in the joint area so that
an optimum water ow is ensured.
Field height
Horizontal section across a collector eld 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
Field width
Lip (Collector cover)
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 inuence on the installation.
Therefore the distance metal sheets can be ordered optionally and are not necessarily included in delivery.
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.

8
Collector eld dimensions
240 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
Number of rows 1 2 3 4 5 6 7 8
Field height in mm 2,067 4,134 6,201 8,268 10,335 12,402 14,469 16,536
Collector type
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
Number of rows 1 2 3 4 5 6 7 8
Field height in mm 1,167 2,334 3,501 4,668 5,835 7,002 8,169 9,336
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
Number of rows 1 2 3 4 5 6 7 8
Field height in mm 2,340 4,680 7,020 9,360 11,700 14,040 16,380 18,720
270 H Number of collectors 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
Number of rows 1 2 3 4 5 6 7 8
Field height in mm 1,167 2,334 3,501 4,668 5,835 7,002 8,169 9,336
per each additional collector
+ 1,220
+ 2,067
+ 2,120
+ 1,167
+ 1,220
+ 2,340
+ 2,393
+ 1,167
Example
Six collectors FKA 240H in two rows
Field width: 6,307 mm
Field height: 2,334 mm
Example
Three collectors FKA 240V in one row
Field width: 3,607 mm
Field height: 2,067 mm
per each additional collector
per each additional collector
per each additional collector

9
Hydraulic connections
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 secure it against slipping out. Due to the measuring
point on the absorber the temperature measured by the sensor may differ from the uid 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
Connection F A + E / B +F
Connection BF G + C / H + D
Close unused connections with caps.
In case of installations in two rows that are smaller than 15 m² the connection pipe can be connected to the extern
manifold in any direction from the bottom or the top. In case of installations with more than two rows or larger than
15 m² the connection pipe must always be connected to the diagonal line to the extern manifold (Tichelmann), e.g.
from botton left to the top of the right.
F=Flow (collector to storage) red grommet
BF=Backow (storage to collector) blue grommet
In case of installation of an air eliminator, install it at the opposite
end of the top ow connection!
Pipe routing by Tichelmann

10
Spacing multi-row collector elds
1410002 Roof-tile bracket V2
..
..
..
1410009 Roof-tile bracket at roof-tile
with lead 30 mm battens
Distance measures roof-tiles
Roof-tiles
roof covering
Initial position:
top edge
roof-tiles
Horizontal size FKA 240 H FKA 240 V FKA 270 H FKA 270 V
Measure A 212 cm 122 cm 239.3 cm 122 cm
Vertical size
Tolerance
FKA 240 H
+ / - 10 cm
FKA 240 V
+ / - 10 cm
FKA 270 H
+ / - 10 cm
FKA 270 V
+ / - 10cm
Measure H1 97 cm 187 cm 97 cm 214 cm
Measure H2 137 cm 227 cm 137 cm 254 cm
Measure H3 214 cm 394 cm 214 cm 448 cm
Measure H4 254 cm 434 cm 254 cm 488 cm
Measure H5 331 cm 601 cm 331 cm 682 cm
x 117 cm 207 cm 117 cm 234 cm
The next series is given by:
Hn = Hn - 2 + x
n is the number of the row of roof-tiles to be
calculated
example FKA 240 H
H6 = H6 - 2 + x
H6 = H4 + x (Height H4 see table)
H6 = 254 cm + 117 cm
H6 = 374 cm
For each collector row two rows roof-tiles are
necessary.
The vertical sizes H1 to Hn are each taken on
the top edge of the roof-tiles.
The measures for installation of the roof-tiles
are obligatory. Otherwise, the hydraulic collector
connection may be lying at the height of the
mounting prole, making it difcult to fasten the
collectors on the prole.
Initial position
If high snow loads are to be expected, the roof-
tiles have to be mounted above the rafters (in
other words the support must lie on the rafter /
alternatively, a higher number of roof-tiles may be
considered, depending on load).

11
Roof-mounted installation
on roof-tiles
lateral view
sketchy depiction for roof-tiles brackets
without cover.
1400026 Prole set alu 240V / 270V
1400027 Prole set alu 240H
1400028 Prole set alu 270H
1400025 Stop set for prole set
1400022 Connection set for prole set
For roof-mounted installations one prole set alu 1400026, 1400027 or 1400028 (depending on the collector type) as well
as one stop set for prole set 1400025 are deliverd for each collector. If several collectors are mounted in one row, for each
collector crossing one connection set for prole set 1400022 is necessary.
In case of multi-row systems only in the lowermost row the stop set for prole set 1400025 is used. In the other rows the
collectors are lying on top of each other.
The stop set is to be mounted so that it is fastened dented at maximum 20 cm
from the outer edge of the collector.

12
Assembly roof-tile clamps
Completely tiled roof.
When mounting the eld in regions with snow load zone III and
higher or with expected increased snow loads, it is necessary to
place the roof hooks in the rafter area.
Removal of the tiles after previous determination of the placement
of the roof-tile clamps (see page 10 „Spacing multi-row collector
elds“).
Fixation of the lower lath 24x80x600 mm with two screws 5x60 mm.
If the lath is placed near the counter lath, the lath 24x80x600 mm
must not be applied.
1410002 Roof-tile clamp V2 without lead
The lower roof-tile must be remounted.
Before covering the lower roof-tile must be coarsly ground.
To avoid breaking of the tile the roof-tile clamp must not rest on the
tile.
The lower tile must be coarsly ground so that the roof-tile clamp
rests in the middle of the tile.
Mount the tile clamp support 80x270x30 mm and x it with two
screws 5x60 mm.

13
Assembly roof-tile clamps
Fix the roof-tile clamp with the support 50x150x5 mm using two
screws 5x60 mm.
Before roong the covering tile has to be coarsly ground accordingly.
Finished mounting of screw as distance saver.
In addition to the grinding of the roof-tile we recommend to use a
screw that is mounted on the roof-tile clamp support as distance
saver.
Complete covered roof-tile clamp after covering.
Further roof-tile clamps in one row must be adjusted exactly (e.g. by
a line mark)

14
Assembly roof-tile clamps
with lead
Completely tiled roof.
Removal of the tiles after previous determination of the placement
of the roof-tile clamps (see page 10 „Spacing multi-row collector
elds“)
When mounting the eld in regions with snow load zone III and
higher or with expected increased snow loads, it is necessary to
place the roof hooks in the rafter area.
Completely lifted area for placement of a hook.
Mount the lower lath 24x80x600 mm with two screws 4x50 mm.
If the lath is placed near the counter lath, the lath 24x80x600 mm
must not be applied.
1410002 Roof-tile clamp V2 with lead
Replace the lower roof-tile.
Afterwards the tile clamp support 24x150x270 mm is to be xed with
two screws 6x60 mm.

15
Assembly roof-tile clamps
with lead
Place the rst mounting tab so that the lower tile is covered.
Additionally make sure that the mounting tab is put sideways under
the adjacent tiles (bend up mounting tabs sidewise).
Mount the roof-tile clamps without covering the lower tile.
The roof-tile clamp must not cover the lower tile. Otherwise, a
pressure point on the lower tile may arise.
Mount the upper mounting tab. Bend it up sidewise. The screws of
the roof-tile clamp must be covered.
Protect the mounting tab against slipping.
The added foam wedge is placed under the adjacent tiles on both
sides as well as above (protection against splash water and snow).
Completely mounted roof-tile clamp.
Further roof-tile clamps in one row must be adjusted exactly (e.g. by
a line mark)

16
Assembly plain tile clamps
without lead
Use the roof-tile for roof-mounted installation for plain tile roof covering also for slate, shingle and prefa covering.
Fixation of the lower lath 24x80x600 mm with two screws 4x50 mm.
If the lath is placed near the counter lath, the lath 24x80x600 mm
must not be applied.
Adjust the roof-tile laterally so that only one tile must be coarsly
ground. Place the hook so that there is enough space for a covering
tile to avoid grinding.
The tile clamp is xed with two screws 5x60 mm.
The roof-tile clamp may not rest or rather cause pressure points on
the tile.
If the tile clamp is mounted too low, the added 5 mm timbers can be
placed under the tile clamp.
When mounting the eld in regions with snow load zone III and
higher or with expected increased snow loads, it is necessary to
place the roof hooks in the rafter area.
Covering of tile laterally.
Grinding and covering of the tile.
Covering of the remaining tiles.
Further roof-tile clamps in one row must be adjusted exactly
(e.g. by a line mark)
1410004 Roof-tile clamp V2 plain tile without lead

17
Assembly plain tile clamps
with lead
Fixation of the lower lath 24x80x600 mm with two screws 4x50 mm.
Assembly of the upper tile clamp support 100x80x25 mm with two
screws 5x60 mm.
When mounting the eld in regions with snow load zone III and
higher or with expected increased snow loads, it is necessary to
place the roof hooks in the rafter area.
Assembly of the lower tile clamp supporte 80x50x45 mm with two
screws 5x60 mm.
Timber excess length of 5 mm (timber is higher than tile).
Completely mounted timber supports.
Mount the lower lead sheet while placing the lead laterally under the
tiles.
Pay attention that the corners are bent under the tile on both sides.
1410002 Roof-tile clamp V2 plain tile with lead

18
Assembly plain tile clamps
with lead
Fixation of the roof-tile clamp with two screws 5x60 mm.
Screw the lower one into the tile lath and the upper one into the tile
clamp support.
Completely mounted roof-tile clamp with lower lead sheet.
The tile clamp must have a minimum distance to the underlying tile
of 5 mm.
Mount the upper lead sheet while placing the lead laterally under the
tiles.
Pay attention that the corners are bent under the tile on both sides.
See assembly lower lead sheet.
Covering of the upper tiles.
Completely mounted roof-tile clamp.
Further roof-tile clamps in one row must be adjusted exactly
(e.g. by a line mark)

19
Assembly roof-tile clamp
corrugated
The placement of the roof-tile clamps corrugated is determined
according to page 10.
Pay attention that the clamps are placed near an existing mounting
lath.
The holes for the xation screws have to be pre-drilled with a 8 mm
borer.
The xation of the clamps is realised by façade screws 6,5x100 mm
with sealing gasket.
Depending on the width of the substructure underneath the
corrugated roof covering the roof clamp can additionally be xed
with a second fastening screw.
Completely mounted roof clamp ready for assembly of fastening
proles (see page 20).
If the roof clamps cannot be mounted within the limits indicated on page 10, you rst have to mount horizontal or vertical STI
system proles onto the roof clamp. Afterwards the added fastening proles are mounted.
1410001 Roof-tile clamp corrugated V2

20
Assembly mounting proles
Readily mounted tile clamps for one collector eld with two collec-
tors.
Top: Tiles left out and clamp set with mounting tabs assembled
Bottom: Tiles coarsly ground and clamps assembled without
mounting tabs
Place the T-head screws laterally into the prole into any groove.
1400026 Prole set Alu 240V and 270V or
1400027 Prole set Alu 240H or
1400028 Prole set Alu 270H
1400024 Fastening set for prole set on roof hooks (4 fast. pts.)
for every additional collector in one row
1400023 Fastening set for prole set on roof hooks (2 fast. pts.)
Fix the T-head screw with the washer and the nut after putting it
through the slot.
Do not exceed the T-head screw‘s tightening torque of 27 Nm.
The slots in the hooks are for evening out bumps. The fastening of
the prole must be realised in the upper third of the slot.
At an angle of 90° to the T-head screw the stop sets are put into
the groove; protruding side up. For each collector there are two 5
cm long stop proles. The xation is effected, each time indented
maximal 20 cm from the end of the collector.
Only in the lowest row the stop proles are supplied and assembled.
1400025 Stop set for prole set
Dachhaken