Heliostar 252 S4 and 218 S4 FREE-STANDING INSTALLATION vertical ASSEMBLY INSTRUCTIONS Construction type approved Reg. no. 011-7S819 F ENERGY AND SANITARY SYSTEMS
Safety instructions Safety instructions Please read these assembly instructions carefully prior to installation and ensure adherence to all safety instructions. Always ensure adherence to all relevant Work Safety regulations and that all technology is state-of-the-art, in particular where relevant to roof work Important: With this type of assembly, it may not be possible to completely empty the collectors. For this reason, the solar system should only be filled with a mixture of water and antifreeze. This means that it is also essential to top up the collectors with antifreeze after pressure or functional tests! Important: If collectors are stored prior to assembly, always ensure that they are never stored in the open air, lying on their glass surface and/or uncovered, as this may allow moisture to penetrate the vent holes in the frame. When installing the collector connectors, please bear in mind that they are soft-annealed, so counter-pressure should always be applied when tightening the ½ threaded joint! Failure to do so may result in damage to the collector! Work Safety regulations and state-of-the-art technology Roof installations: DIN 18338 Roof covering and roof sealing works, DIN 18339 Sheet-metal works, DIN 18451 Scaffolding works. Connecting thermal solar systems: DIN 4757 Parts 1 and 3. Electrical connection: VDE 0100 Setting up electrical equipment, VDE 0185 general information for erecting lightning protection systems, VDE 0190 main equipotential bonding of electrical systems, DIN 18382 electrical cable and wiring system in buildings. The professional builders associations provide detailed information on accident prevention regulations! Proper use of ladders Ladders should only be used for a working height below 5 m. Position the ladder at an angle of 65 to 75 and secure. The top end of the ladder must extend at least 1 m above exit point. Fall protection If working at a height above 3 m, always use fall protection equipment when working on sloping roofs (20 to 60 ) (VBG 37, 8). The vertical distance for a workplace safety device (roof safety platform or other kind of protective roof barrier) is max. 5 m. A safety harness may also be used as fall protection. Secure universal fastening safety anchors to load-bearing parts above the worker. Do not use ladder hooks! Protection against falling objects Access routes and workplaces located below the work site must be protected against falling objects. These areas must be clearly signed and cordoned off. Information is also available on the Roth Hotline: 0 64 66/9 22-2 66 2
Installation requirements The free-standing mounting set is suitable for the installation of Roth Heliostar flat collectors on open ground, or on flat or low-pitched roofs. General requirements The metal pipes of the solar circuit must be connected to the main equipotential busbar by a green and yellow conductor of at least 16 mm 2 Cu (H07 V- or R). The collectors can either be included in an existing lightning protection system or can alternatively be earthed via an earth rod. The earth wire must be run down the outside of the house. The earth must also be connected to the main equipotential busbar by a wire of the same cross-section. Equipotential bonding and lightning protection The sensor must be fitted in the last collector with water flowing through it on the forward side (hot outlet). To do this, remove the rubber coupler and thread the sensor through, pushing the mineral wool inside the collector slightly to one side. Then apply a little heat conductive paste to the sensor and insert it in the immersion sleeve as far as it will go. Finally push the rubber coupler back on again until the ridge catches on the collector frame. If you need to extend the sensor wire, you can use a wire cross-section of 2 x 0.75 mm 2 up to a length of 50 m. For a longer length, you require a cross-section of 2 x 1.5 mm 2. To protect the connected controller and the sensor against power surges, we recommend extending the collector sensor over a surge plug (optional extra) directly behind the collector. Fitting the sensor Drilling machine with 8.5 mm twist drill bit or 12 mm masonry drill bit Spanner 16, 17, 19, 24 2 pipe wrenches Folding rule Metal saw for cutting sections to length (optional) List of tools 3
1,36 m 1,82 m 1,82 m 1,36 m 1,82 m 1,36 m 1,82 m 1,36 m 1,82 m 1,64 m 2,10 m 2,10 m 1,64 m 2,10 m 1,64 m 2,10 m 1,64 m 2,10 m System variants Heliostar 252 S4 and 218 S4 Collector area: 2.52 m 2 and 2.18 m 2 respectively Vertical collector installation, Heliostar 252 S4 0,8 m 0,8 m 1-1,2 m 0,8 m 1-1,2 m 1-1,2 m 1,20 m 2,40 m 3,60 m 1,64 m 0,8 m 1-1,2 m 1-1,2 m 1-1,2 m 4,80 m 0,8 m 1-1,2 m 1-1,2 m 1-1,2 m 1-1,2 m 6,00 m Vertical collector installation, Heliostar 218 S4 0,8 m 1-1,2 m 0,8 m 1-1,2 m 1-1,2 m 1,20 m 2,40 m 3,60 m 1,36 m 0,8 m 1-1,2 m 1-1,2 m 1-1,2 m 4,80 m 0,8 m 1-1,2 m 1-1,2 m 1-1,2 m 1-1,2 m 6,00 m 4
Material overview Item Material No. Description Quantity 1 1125005701 C-section, 36 x 30 x 1900 mm F3 2 2 1150002871 Hex bolt M10 x 30 DIN 933, galvanized 8 3 1150002874 Hex bolt M10 x 60 DIN 933, galvanized 6 4 1150002840 Hex nut M10 DIN 985 (EN ISO 10511), galvanized 10 5 1150002840 Hex nut M10 DIN 934, galvanized 4 6 1150006885 Washer 10.5 mm DIN 125, galvanized 14 7 1150006896 U-section 25 x 10 x 25 mm, Al 14 8 1150002928 Hex wood bolt 8 x 60 DIN 571, galvanized 8 9 1150007862 Plug S12 x 60 8 10 1125005411 Mounting rail, vertical, length: 1205 mm 4 11 1150007739 Fixing bracket, single 4 12 1150007946 Assembly instructions for Heliostar free standing installation 1 13 1150006895 T connector 60 x 60 x 6 mm, length: 40 mm 4 14 1135005561 Connection nipple 1/2" 1 15 1135005562 Connection sleeve 1/2" 1 16 1135005563 End stopper sleeve 1 17 1135005564 End stopper nipple 1 18 1115009211 Including snap ring 4 19 1155000551 Packaging 1 Vertical free-standing installation fixing Basic set H Item Material No. Description Quantity 1 1125005701 C-section, 36 x 30 x 1900 mm F3 1 2 1150002871 Hex bolt M10 x 30 DIN 933, galvanized 2 3 1150002874 Hex bolt M10 x 60 DIN 933, galvanized 3 4 1150002840 Hex nut M10 DIN 985 (EN ISO 10511), galvanized 5 5 1150006885 Washer 10.5 mm DIN 125, galvanized 5 6 1150006896 U-section 25 x 10 x 25 mm, Al 5 7 1150006884 Hex bolt M12 x 20 DIN 933, galvanized 4 8 1150002841 Hex nut M12 DIN 934, galvanized 4 9 1150006886 Washer 13 mm DIN 125, galvanized 4 10 1150002928 Hex wood bolt 8 x 60 DIN 571, galvanized 4 11 1150007862 Plug S12 x 60 4 12 1125005411 Mounting rail, vertical, length: 1205 mm 3 13 1125005192 U-shaped connecting element 25 x 25 x 3mm, length: 130 mm Al 14 1150007740 Fixing bracket, double 2 15 1150006892 Stainless steel corrugated hose, length: 300 mm 1/2" 1 16 1150007946 Assembly instructions for Heliostar free standing installation 1 17 1150006895 T connector 60 x 60 x 6 mm, length: 40 mm 2 18 1115009211 Snap ring for plug-in system 2 19 1155000551 Packaging 1 2 Vertical free-standing installation fixing Extension set H 5
Assembly steps 1. Fix the M10 x 60 screw in the mounting rail using the U-section. 1 2. Using a washer and nut, affix this to the vertical mounting rail (fully insert in end long slot). 2 3. It is essential to ensure that the vertical mounting rail is pushed down until the two rails are aligned (see white line in photo). 3 6
4. The lateral triangle you have now created is floor-mounted using the supplied T connectors as follows. Assembly steps 4 5. Insert the M10 x 30 screw in the U-section, pass it through the upper bore hole in the T connector and affix gently with a washer and nut. 5 6. The thus prepared connecting piece is inserted in the mounting rail and fixed. This process must be repeated and the connecting piece inserted in the bottom of the vertical rail and the inclined rail. 6 7. The procedure followed thus far should be repeated to assemble the second triangle. 7 7
Assembly steps 8. To mount the two horizontal rails (top and bottom), proceed as follows: Important: The horizontal rails are supplied with ready-made bore holes by the factory. There are two bore holes in the top part of the rail, as shown on the rail in the photo. The top bore hole serves to position the horizontal rail when assembling the Heliostar 252 S4. the lower one is for assembling the Heliostar 218 S4. for Heliostar 218 S4 8 for Heliostar 252 S4> > 9. The horizontal rail is to be inserted into the U-shaped profile using M10 x 60 screws and pushed into the mounting rail completely. 9 10. The distance from the outer edge of the inclined rail should be 75 mm from the horizontal rail. 10 75 11. After the upper horizontal rail has been fixed, the lower rail is assembled with the same procedure. 11 8
12. Finished assembly of the lower horizontal rail. Assembly steps 12 13. The two diagonal distances are to be determined to check that the two horizontal rails are the same distance apart. 13 14. After completing the retaining frame, this must be fixed to the ground; 2 holes are to be marked in each T-connector for this. The frame is to be moved to the side and the holes are to be made using a 12 mm masonry drill bit. Then the 12 mm plugs are knocked into the holes, the frame is to be put back on the holes and fixed to the ground with the 8 x 60 mm wood screws. 14 15. After the frame has been fixed to the ground, the Heliostar collector is to be placed on the frame. 15 9
Assembly steps 16. Affix the collector to the frame using the fixing brackets (4 lateral brackets on the first collector). 16 17. Secure the lateral fixing brackets in the side slot of the horizontal mounting rail using an M10 x 30 screw, washer and nut. 17 18. Completed side mount. 18 19. - 22. A diagonal flow should be ensured when operating an individual collector and any further collectors. To do this, the end and connection plugs are to be fastened as shown, with an appropriate locking ring. Important: Ensure that the plug-in system is always sufficiently lubricated. 19 20 10
21 22 Assembly steps 23. Insert the two M12 x 20 screws in the mounting rail connectors for the top and bottom mounting rail as shown in the photo. 23 24. Place the washer and nut on the other side of the connector and tighten gently by hand. 24 25. Push the connecting elements halfway into the mounting rail and turn. 25 26 11
Assembly steps 27. Push the double fixing bracket onto the top and bottom mounting rail. 27 28. Depending on the number of Heliostar collectors you are installing, create the next triangle as described at the beginning of these instructions. 28 29. Insert the top and bottom horizontal mounting rail and secure in place. 29 30. Repeat this process until you have mounted all the Heliostar collectors. 30 12
31. When assembling the second and each further collector, push the collectors together using the plug-in system (sleeve + nipple). Important: Ensure that the plug-in system is always sufficiently lubricated! Assembly steps 31 32./33. Use the locking ring to connect the plug-in system that has been pushed together. 32 33 34. Secure the first and last Heliostar collector with the side mounting brackets. 34 13
Assembly steps 35. To fit the sensor, remove the rubber coupler, thread the sensor through, apply heat conductive paste and push it into the immersion sleeve as far as it will go. Then push in the rubber coupler as far as the back ridge. 35 36. When assembling the corrugated hose couplings, ensure that they fit correctly. When tightening the threaded connections, always hold the collector up in position. Failure to do so may cause irreparable damage to the collector. A diagonal flow should be ensured with this method of operation. To do this, end plugs are to be attached as shown in pictures 21 to 24 and installed with a locking ring. Important It should be ensured during assembly that the attachment parts are always sufficiently lubricated! 37 14
G Please note that for large systems of five collectors or more, a compensator must be installed! Note for large systems The collectors must be secured on the roof because loose installation frames can be knocked over and damaged by the wind. First check the structural suitability of the substructure and the permissible surface load for the roof cladding (consult a structural engineer if necessary). To avoid damaging (drilling through) the roof cladding, you can use weights (e.g. Roth gravel plate set, concrete ties) to weigh it down. Max. pressure on the collector cover is 1667 Pa. for Heliostar 252 S4 and 673 Pa. for Heliostar 218 S4. Fixing instructions Height of building Surface Heliostar (m 2 ) Wind force (N) Needed weight per Kollektor Heliostar (kg) 0 to 8 m 2,18 / 2,52 1924 / 2224 163,5 / 189 8 to 20 m 2,18 / 2,52 2654 / 3068 277 / 320 > 20 m 2,18 / 2,52 Individual calculation in accordance with DIN 1055-4 Minimum clearance to roof edge The installation engineer bears sole responsibility for ensuring that the collectors are adequately anchored on open ground or on the roof, particularly if the location is subject to strong winds. Any data pertaining to weight contained in these assembly instructions is provided by the manufacturer for information purposes only and is not intended as any form of warranty! Roth shall accept no liability whatsoever in the event of damage or loss. This does not affect the terms of the warranty with regard to material supplied by Roth. The relevant standards and directives apply, particularly DIN 1055-4, governing minimum weight loads for different building heights. Requirements for structural forces 15
Technical data 1 3 5 6 7 4 2 1 super-transparent safety glass 2 circumference profile 3 highly selective coated full surface absorber 4 Fixing points 5 60 mm thick heat insulation 6 Grooves for easy assembly 7 Collector tray made of polycarbonate Roth Heliostar S4 flat collector technical specifications Heliostar 218 S4 Heliostar 252 S4 Length 1820 mm 2100 mm Width 1200 mm 1200 mm Height 109 mm 109 mm Gross surface area 2.18 m 2 2.52 m 2 Aperture surface area 1.96 m 2 2.30 m 2 Weight 35 kg 36 kg Collector housing Heavy-duty polycarbonate tray construction, sealed throughout as a result of being deep drawn seamlessly from one piece, permanently resistant to corrosion. Glass cover ESG safety glass, transmission t = 91 % Absorber vacuum highly selective coated full surface absorber Absorption a = 95 % Emission e = 5 % Fluid capacity 0.86 l 1.16 l Heat transfer medium Operating pressure (max) Solar sensor shaft Collector connection Collector yield, annual Intended use Heliostar solar fluid 10 bar Interior Ø = 6 mm Roth plug-in system over 525 kwh/m 2 a To heat water and support the heating system Idle temperature 208 C Pressure loss 17.8 mbar at 233 kg/h 41.9 mbar at 485 kg/h Slope angle range 20 to 50 Maintenance instructions Intended use to heat water and support the heating system In order for the thermal solar system to work without problems it should be subjected to annual maintenance (ideally as part of the annual heating maintenance). This should include: Visual inspection of the collectors and pipe insulation Examination of electrical connections Examination of switching functions and through flow amount Examination of the anti-freeze 16
Check list and commissioning log for thermal solar systems Equipment operator Installation company Name Company First name Installed by Street Street Postcode, city/town Postcode, city/town Telephone Telephone Date of first operation: Collectors Manufactured by Quantity Serial number Gross surface area total Alignment Circuitry N W E S Storage tank Type of storage tank Size Quantity Use of the solar heating equipment Preparation of domestic water Domestic water with heating support Other Control system Roth BW control system Roth BW/H control system Roth BW/H Comfort control system Roth BW efficiency control system Roth BW/H efficiency control system Solar station RS 25/6 RS 25/7 ST 20/11 ST 15/1-7 with efficiency pump Expansion tank litres System pressure bar Flow volume litre/minute System properly flushed and aired Anti-freeze content tested (recommendation: 40 %) Sensor correctly positioned Regulator functionality check yes no Operator's signature Installer's signature 17
ROTH WERKE GMBH Am Seerain 2 D-35232 Dautphetal Phone +49 (0)64 66/9 22-0 Fax +49 (0)64 66/9 22-1 00 Hotline +49 (0)64 66/9 22-2 66 Email service@roth-werke.de www.roth-werke.de Subject to technical modifications. 18