STI FKF 200 Series Assembly Instructions Manual
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STI FKF 200 Series Assembly Instructions Manual

Roof mounted
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ASSEMBLY INSTRUCTIONS
FKF 200 / 240 / 270 ROOF MOUNTED
SOLARE KOMPETENZ
AUS SACHSEN
sti-solar.de

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  • Page 1 ASSEMBLY INSTRUCTIONS FKF 200 / 240 / 270 ROOF MOUNTED SOLARE KOMPETENZ AUS SACHSEN sti-solar.de...

  • Page 2: Table Of Contents

    The collectors of the FKF series series are marked with the environmental label RAL-UZ-73 for solar collectors („Blauer Engel“). The STI GmbH is obliged to take back the products which are marked with the environmental label RAL-UZ-73 for solar collectors and to...

  • Page 3: Safety Regulations, Instruction And Guidelines

    Safety regulations, instruction and guidelines The standards and guidelines applied at the installation location of the collectors have to be considered in the latest release. Engineer standards and guidelines Notes prior to the installation start • VBG 4 Unfallverhütungsvorschriften Elektrische The installation and initial operation must be carried out by Anlagen und Betriebsmittel an expert who is responsible for the correct installation and...
  • Page 4 (e. g. substructure on site for sufficient load-carrying capacity. STI Drain Master or SolBox) is recommended. Please pay increased attention to the possible durability of It is necessary to pay attention that the back flow the screw fittings to fasten the collectors as well as to the temperature is never lower than the ambient temperature.

  • Page 5: Tools

    ‘Allen screw SW 4 * Bit TX 20, AW 20 * diamond/stone Drill 8,5 mm, 14 mm Ratchet, lenghtening and 13 mm socket wrench, combination wrench 13 mm Securing devices, Roof ladder protective equipment * included in the STI tool kit 2014 1910101...

  • Page 6: Product Description

    Product description Solar collector FKF The solar thermal collector FKF uses the radiant energy of the sun to heat a heat transfer medium. This glycol-water mixture gives off the heat to a storage via a heat exchanger. The obtained energy can be used for water heating and heating support.
  • Page 7 Product description Specifications The FKF 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.

  • Page 8: Collector Field Dimensions

    Collector field dimensions Vertical section across a collector field In case of multi-row installations, the collectors will always be mounted Lip (Collector covering) on joint on top of each other. The lip (collector covering) of the upper collector has to be put onto the lower collector.
  • Page 9 Collector field dimensions Collector type each additional collector 200 V Number of collectors Field width in mm 1.167 2.387 3.607 4.827 6.047 7.267 8.487 9.707 + 1.220 Number of rows Field height in mm 1.713 3.426 5.139 6.852 8.565 10.278 11.991 13.704 + 1.713 each additional collector 200 H...

  • Page 10: Hydraulic Connections

    Pipe routing by Tichelmann In case of multi-row installations as well as installations which include the STI Drain Back System, the connection pipe must always be connected with the diagonal line to the external manifold (Tichelmann), e. g. bottom left and top right.

  • Page 11: Spacing Multi-Row Collector Fields

    Spacing multi-row collector fields Distance measures fastening hooks Fastening hooks in roof covering For each collector row two fastening hooks Example: Arrangement for 3 rows with 3 collectors each are needed. The vertical measures H1 to Hn are each taken on the top edge of the fastening hooks.

  • Page 12: Roof-Mounted Installation On Roof-Tiles

    Roof-mounted installation on roof-tiles 1400026 Profile set Alu 200/240/270 V 1400035 Profile set Alu 200 H or 1400027 Profile set Alu 240 H or 1400028 Profile set Alu 270 H 1400025 Collector stop set for fastening profile 1400022 connection set For roof-mounted installations, a profile set aluminium 1400034, 1400026, 1400027 or 1400028 (depending on the collector type) as well as one stop set 1400025 is delivered for each collector.

  • Page 13: Assembly Of The Roof-Tile Clamps

    Assembly of the roof-tile clamps Completely tiled roof When mounting the roof in regions with high snow load zone of more than 2 kN/m², it is necessary to place the roof hooks in the rafter. Removal of the tiles after previous determination of the placement of the roof-tile clamps (see page 11 „Spacing multi- row collector fields“).
  • Page 14 Assembly of the roof-tile clamps In addition to the grinding of the roof-tiles we recommend using a screw which will be mounted on the roof-tile clamp support as a distance saver. Mounted screw as a distance saver. If necessary, caulk the coarsely ground brick with a foam tape as a protection against water.

  • Page 15: Assembly Of The Roof-Tile Clamps With Lead Cloth

    Assembly of the roof-tile clamps with lead cloth Completely tiled roof. Removal of the tiles after previous determination of the placement of the roof-tile clamps (see page 11 „Spacing multi- row collector fields“). When mounting the field in regions with high snow load zone of 2 kN/m², it is necessary to place the roof hooks in the rafter area.
  • Page 16 Assembly of the roof-tile clamps with lead cloth Place the first mounting tab in such a way that the lower tile is covered. Additionally make sure that the mounting tab is put sideways under the adjacent tiles (bend up mounting tabs sidewisely).

  • Page 17: Assembly Of The Roof-Tile Clamps For Plain Tile

    Assembly of the roof-tile clamps for plain tile The roof-tile clamp for a roof-mounted assembly with a plain tile covering is also usable for roofs with slate, shingle and Prefa sheet metal roof systems. Fixture of the lower lath 24 x 80 x 600 mm with two screws 4 x 50 mm.

  • Page 18: Assembly Of The Plain Tile Clamps With Lead

    Assembly of the plain tile clamps with lead Fixation of the lower lath 24 x 80 x 600 mm with two screws 5 x 60 mm. When mountig the field in regions with high snow load zone of more than 2 kN/m², it is necessary to place the roof hooks in the rafter area.
  • Page 19 Assembly of the plain tile clamps Assembly of the plain tile clamps with lead with lead Make sure that the corners of the lead sheet are bent under the tile to avoid a slipping off. 1410005 Roof-tile clamp V2 plain tile with lead Fixation of the roof-tile clamp with two screws 5 x 60 mm.

  • Page 20: Assembly Roof-Tile Clamps For Corrugated Sheet

    If the roof clamps cannot be mounted within the limits indicated (see „spacing roof hooks“), you have to mount horizontal or vertical STI system profiles onto the roof clamp first of all. Afterwards the supplied fastening profiles can be mounted.

  • Page 21: Assembly Of The Fastening Profiles

    Assembly of the fastening profiles Pre-assembled roof-tile brackets for a collector field of two collectors. Above: Roof-tile brackets left out and hook set assembled with an assembly edge. Below: Grinded bricks and hooks assembled without an assembly edge. Roof hooks Assembling sequence profile set: Profile set Vario Fix 200 V, 240 V, 270 V Profile set Alu 200 V, 240 V, 270 V...
  • Page 22 Assembly of the fastening profiles 1400022 Connection set for profile set In the edging area of the fastening profiles which have to be mounted, the connecting profiles will be inserted and centred. The connecting profile will be mounted in every collector row. 1400025 Arrester set for profile set For every collector, two stop profiles with a length of 5 cm are available.
  • Page 23 Assembly of the fastening profiles Afterwards, insert the square-head bolt 90° offset to the connecting profile into the notch for an assembly with the rooftile bracket. 1400023 Fastening profile on roof hooks (2 fastening points) 1400024 Fastening profile on roof hooks (4 fastening profiles) Place the premounted rail clips for the fastening of the profiles in the upper and lower profile rail.
  • Page 24 Assembly of the fastening profiles 90° Ends of profile set aluminium lie flush against each other. Completely mounted fastening profiles which are prepared for the assembly of the collectors. Pay attention to the conclusive alignment of the profile rails.

  • Page 25: Assembly Preparation - Sequence

    Assembly preparation - sequence Single-row collector field When assembling single-row collector fields, the collectors will be mounted starting with the respectively outer collector. The exact assembly of the collectors will be described starting with page 29. Single-row collector field Assembly sequence Multi-row collector field When assembling mulit-row collector fields, the collectors which are located one above the other will be mounted first of all.
  • Page 26 Assembly preparation - sequence Assembly sequence Lip (collector covering) In case of multi-row installations, the collectors have to be mounted adjoining. The lip (collector covering) of the top collector is set over the lower collector. The lip (collector covering) of the lower collector is clamped into the joining area which guarantees an optimum waterflow.

  • Page 27: Assembly Of The Intermediate Plates/ Multi-Row Collector Fields

    Assembly of the intermediate plates/ multi-row collector fields Multi-row collector fields with intermediate plates To attain a homogenous appearance of the collector installation, the assembly of sheets between the collectors is possible. The intermediate plates are exclusively assembled due to optical aspects and do not have a functional impact on the installation.
  • Page 28 Assembly of the intermediate plates By a removal of the lip (collector covering) at the designated position, the intermediate plates can be mounted easily. When assembling the upper collector, you have to pay attention that the lip (collector covering) of the lower collector is covered by the upper collector.

  • Page 29: Assembly Of The Solar Collectors

    Assembly of the solar collectors Place the first collector. To do so, place it on the upper section rail and drop it on the lowest one. Be aware of not damaging the back panel by protruding devices. At the outside of the collector, the mounting plate „onefold“...
  • Page 30 Assembly of the solar collectors Before the following collector can be assembled, the hydraulic collector connection has to be mounted with the conclusively protruding collector connection. 1300002 Collector connection set hydraulically pluggable Insert the hydraulic collector connection into the manifold. In so doing, make sure that the two O-rings are assembled.
  • Page 31 Assembly of the solar collectors Fix the stretching compensator with the locking spring. Tighten the bolt nut at the mounting plate „twofold“ firmly. The torsional moment of 17 Nm must not be exceeded. Fix the mounting plates „onefold“ at the end and tighten the bolt nut.The torsional moment of 17 Nm must not be exceeded.

  • Page 32: Assembly Of The Probe

    Assembly of the probe Every collector is equipped with a sheath for the positioning of a temperature sensor. The position of the temperature sensor is located below the upper left manifold outflow or to the left of the sticker with the label „above“...

  • Page 33: Collector Connections

    Collector connections The assembly of the hydraulic system depends on the delivery contents: hydraulic system Standard or hydraulic system Smart Lock System. The cap will be mounted everywhere where a collector connection is not used. 1310209 Cap set (2 pieces complete) 1310119 Cap set aluminium (2 pieces complete) Connection 3/4“...

  • Page 34: Hydraulic Connection With Manifold

    Hydraulic connections for multi-row systems T-double Elbow collecting collecting pipe pipe connection connection T-double Elbow collecting collecting pipe pipe connection connection Elbow collecting T-double pipe connection collecting pipe connection T-double collecting pipe Elbow collecting connection pipe connection The whole equipment is available from STI.

  • Page 35: Overview Hydraulic Connections Sls / Accessories

    Overview hydraulic connections SLS / accessories Hydraulic connections Exhauster connection for the Collector connection 3/4“ Collector connection 22 mm installation at the collector for thread fittings for soldered fittings or clamping without extension Smart Lock System ring joints Smart Lock System Smart Lock System Collector connection hydraulic Clamp collector connection and...

  • Page 36: Overview Hydraulic Connections / Accessories Aluminium

    Overview hydraulic connections / accessories aluminium Collector connections aluminium for collectros with aluminium pipe Collector connection 22 mm Collector connection hydraulic Aluminium Aluminium Smart Lock System Smart Lock System Hydraulic connection set Hydraulical connection T-piece Safety line clamping ring 90 ° Pressfitting M-shape Pressfitting M-Shape Notes Al/Al absorber...

  • Page 37: Assembly Intermediate Plates

    Assembly intermediate plates It is possible to mount metal sheets between the collectors for a homogenous appearance. The distance metal sheets are only assembled for optical aspects ad do not have any functional influence on the system. Therefore, the distance metal sheets have to be ordered separately and are not necessarily included in the delivery.

  • Page 38: Assembly Of The Roof Implementation Set

    Assembly of the roof implementation set For the assembly of the roof implementation, the roof tiles have to be removed at the assembly site. The connection pipe will be conducted through the roof and afterwards will be connected with the collector connection. 1210900 roof feed-through set 1320303 connection pipe 2,5 m 1320304 connection pipe 15 m...
  • Page 39 (e. g. shingle roof). In the last step, the roof tiles have to be inserted again. If the assembly of a Drain Back system (STI SolBox) is going to take place, the roof implementation (return pipe) has to be...

  • Page 40: Assembly Of The Connecting Pipe

    Please be aware that only the connecting pipe DN20 l = 15 m can be adjusted individually. Any other corru- gated pipe lines from stainless steel of the STI pro- gramme will be delivered in fixed lengths. 1320304 Connecting pipe DN20 l=15 m,...

  • Page 41: Snapcover

    SnapCover The assembly of the intermediate plates is absolutely necessary when using the SnapCover. After having assembled the intermediate plates, the assembly starts at the lower left corner. An exact order of the assembly including a labelling of the sheets will be descrieb on page 44. Numbered sheets are included in the scope of delivery.
  • Page 42 SnapCover After having completed the left corner, the extension sheets of the eave will be assembled. In doing so, please start from the left side. The sheets can be moved but will be limited by the recess in the plate and thus by the collector frame.
  • Page 43 SnapCover When the eave sheets and the lower side plates will be assembled and algined properly, the extension of the side plates can take place (only in case of vertical collectors or multi-row collector fields). The side plates will be clicked into the collector frame and then be evenly pushed over the lower side plate from above.

  • Page 44: Snapcover - Assembly Sequence

    SnapCover - assembly sequence Vertical assembly 1210401 SnapCover FKF 200 V BLS 2x1 1210402 SnapCover FKF 200 V ER - 1 1210403 SnapCover FKF 200 V ZR - 1 1210411 SnapCover FKF 240 V BLS 2x1 1210412 SnapCover FKF 240 V ER - 1 1210413 SnapCover FKF 240 V ZR - 1 1210421 SnapCover FKF 270 V BLS 2x1 1210422 SnapCover FKF 270 V ER - 1...

  • Page 45: Pipe Dimension Of The Connecting Pipe

    Pipe dimension of the connecting pipe Recommended pipe dimension of the connecting pipe Length of pipe F + BF up to 10 m from 10 m from 15 m Number of collectors to 15 m to 20 m 2 coll. - 132 L/h 12 x1 15 x 1 15 x 1...
  • Page 46 Pipe dimensions of the connecting pipe Recommended pipe dimension of the connecting pipe Length of pipe F + BF from 40 m from 45 m from 50 m from 55 m Number of collectors to 45 m to 50 m to 55 m to 60 m 2 coll.

  • Page 47: Initial Operation

    Initial operation Initial operation An annual review is recommended. The following compon- After installing the other components such as flow ents must be checked for proper function (if installed): pipe, return pipe, insulation, pump group, expansion tank and controller, the installation can be put into •...
  • Page 48 Initial operation Commissioning report       Special Material Product Type Material feature Date of assembly tick accordingly (description) (Serial N° ) Net surface  Date of commissioning          ...
  • Page 49 Initial operation Schematic drawing of the system construction and piping scheme:...
  • Page 50 Initial operation Notes...

  • Page 51: Appendix

    Appendix Important to observe Any guarantee and warranty for collectors as well as for resulting damages on the system or building expires due to unauthorized changes on the collectors and the accessories. There is no guarantee or warranty due to optical or technical reduction or defects on the collector resulting from external influences, forasmuch as these influences are not part of the supplier’s sphere or influence and they are not explicitly known before execution.
  • Page 52 STI Solar-Technologie-International GmbH STI Solar-Technologie-International GmbH Seiferitzer Allee 14 Seiferitzer Allee 14 sti-solar.de D-08393 Meerane D-08393 Meerane sti-solar.de Tel 0049 3764 795610 Tel 0049 3764 795610 info@sti-solar.de info@sti-solar.de © Copyright 2019 Version 02/19...

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