Energy Systems Heliostar 252 S4 and 218 S4 on-roof attachment Assembly Instructions Living full of energy
Contents System description System description and system benefits 3 System components 4 Technical data 5 Installation requirements Safety Instructions 6 Work Safety regulations, state-of-the-art technology 6 Assembly Instructions 7 Assembly Instructions for large systems 9 System versions 10 Assembly Instructions Roof positioning 12 Roof attachment 12 Safety Instructions 12 Substructure universal attachment anchor and optional rafter anchor for increased snow load 13 Assembly steps 15 Maintenance Instructions 24 Check list and commissioning log for thermal solar system 25 Guarantee 26 2
System description System description and system benefits Made of a closed polycarbonate case construction, the Roth Heliostar unites high-tech material and sophisticated technology. Polycarbonate is a perfect insulator, so the thick-walled polycarbonate case of the Roth Heliostar ensures optimal heat storage. When used in combination with the high-performance absorber, the Roth Heliostar ensures maximum effectiveness for decades. Furthermore, the material is characterised by its special impact strength, temperature and UV-resistance. The variety of usage of polycarbonates shows their outstanding material characteristics. This means they have applications in the aircraft construction and automotive industry, amongst others. Thanks to this high-tech plastic, the Roth Heliostar offers long-term stability with minimal weight. The polycarbonate case boasts additional advantages: Firstly, manufacture only needs low energy input, which is more environmentally friendly than the production of conventional designs. Secondly, the case has long-term corrosionresistance even when exposed to high levels of air pollution and an aggressive maritime climate. The collector case is deep-drawn seamlessly from one piece and therefore permanently leakproof. The unique shape of the deep-drawn polycarbonate case offers critical installation and security advantages to the installer. The criteria according to RAL-UZ 73 are fulfilled. 3
System description System components for Heliostar flat collectors 218 S4, 252 S4 vertical/horizontal on-roof attachment 7 7 4 3 1 6 5 9 4 2 3 11 16 12 17 13 14 6 10 5 8 Item Product description Basic set for two collectors vertical on-roof attachment (number) Basic set for each additional collector vertical on-roof attachment (number) Basic set for two collectors horizontal on-roof attachment (number) Basic set for each additional collector horizontal on-roof attachment (number) 1 Mounting rail made of aluminium, length 1.205 mm 4 2 2 2 2 Mounting rail made of aluminium with slot, length 1.205 mm 2 3 Profile rail connection set (2 connection profiles, 4 hex bolts, M12 x 20, with nuts and washers) 1 1 1 1 4 Attachment element D (double mounting bracket) 2 2 2 2 5 Attachment element E (4 single mounting brackets, 4 U-shaped profiles, 4 hex bolts, M 12 x 30, with nuts and washers) 1 1 6 Solar M10 screw set (stainless steel hex bolt, M 10 x 30, U-shaped profile plate with washer and nut) 6 2 2 7 Stainless steel corrugated hose with insulation 20 x 13 and sealing rings, length 1.000 mm 2 2 8 Attachment set (hex bolt, M 10 x 30, 2 x U-shaped profile plates with washers and nuts) 2 9 Universal attachment anchor extension set vertical 3 1 10 Universal attachment anchor extension set horizontal 3 1 11 Connection nipple ½ "* 1 1 12 Connection sleeve ½ "* 1 1 13 End stopper sleeve* 1 1 14 End stopper nipple* 1 1 15 Snap ring for plug-in system 6 2 6 2 16 Connection nipple ¾ "* (optional for no. 11) 1 1 17 Connection sleeve ¾ "* (optional for no. 12) 1 1 * Please note that a snap ring is needed for connecting the plug-in system. 4
System description Technical data 1 5 3 4 2 1 super-transparent safety glass 2 circumference profile 3 highly selectively coated full surface absorber 4 fixing points 5 60 mm thick heat insulation 6 grooves for easy assembly 7 collector case made of polycarbonate 6 7 Technical specifications for Roth Heliostar S4 flat collectors Heliostar 218 S4 Heliostar 252 S4 Length 1.820 mm 2.100 mm Width 1.200 mm 1.200 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 32 kg 37 kg Collector housing Heavy-duty polycarbonate case construction, sealed throughout as a result of being deep drawn seamlessly from one piece, permanently resistant to corrosion. Glass cover Low-iron solar safety glass, transmission = 91% Absorber Highly selectively vacuum-coated full surface absorber Absorption = 95% Emission = 5% Fluid capacity 0,86 l 1,16 l Heat transfer medium Heliostar solar fluid Operating pressure (max.) 10 bar Solar sensor shaft Inner Ø = 6 mm Collector connection Roth plug-in system Collector yield, annual In excess of 525 kwh/m 2 a Intended use 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 5
Installation requirements Safety Instructions Please read these assembly instructions carefully prior to installation and ensure adherence to all the safety instructions given here. 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: 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 otherwise this may allow moisture to penetrate the vent holes in the frame. The collectors must only be stored on a level surface and the housing protected against external forces! To avoid the risk of scalding, the system should not be filled in bright sunlight! If there is a risk of frost, always make sure there is sufficient antifreeze available when filling and rinsing the system. Work Safety regulations, 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 devices 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 fall-protection device (roof fall-prevention device or alternative protective roof barrier) is max. 5 m. A safety harness may also be used as fall protection. Secure universal attachment 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 or toppling objects. These areas must be clearly signed and cordoned off. Information is also available via the Roth hotline: +49 (0)6466/922-266 6
Installation requirements Assembly Instructions General requirements The on-roof attachment set is suitable for installing Roth Heliostar flat collectors on roofs with a slope angle of 22 or more. Universal fastening anchor versions are available for roofs covered with roof pantiles and similar roof tiles, as well as plain tiles and fibre cement corrugated sheets. On natural slate roofs, you should only have work carried out by a professional roofing firm. Equipotential bonding and lightning protection 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 be included in an existing lightning protection system if one is available. Alternatively, they can 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. Fitting the sensor The sensor must be fitted in the last collector with fluid flowing through it on the side of the forward flow to the storage tank (hot outlet). To do this, remove the rubber sleeve 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 sleeve 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 up to a length of 50 m. For a longer length, you need to select a crosssection of 2 x 1,5 mm. To protect the connected controller from power surges, the collector sensor must be appropriately extended via a surge plug (optional extra) directly behind the collector. List of tools > Spanner 13/17/19/20/22 > Drilling machine, star drill bit PZ 3 > Angle grinder with stone cutting disc > Hammer > String (approx. 10 m), tape measure and rope > Pencil Statics Check that the roof construction is appropriate for the solar system before installing it. In addition, sheet metal roof tiles or metal plates must be used as the substructure for the universal attachment anchors! Taking account of the relevant local conditions, such as snow load, wind load, building height and roof substructure, it is the responsibility of the planner and/or the building owner to secure the solar system by increasing the number of attachment anchors if necessary (see also instructions for increased snow loads). The manufacturer can accept no liability in this regard! We would be pleased to advise you! 7
Installation requirements Assembly Instructions Instructions for increased snow loads Maximum snow load for an installation with a collector slope of 30 to 40 for Heliostar 252 S4 and 218 S4 Universal attachment anchor Snow heights m AMSL Special rafter anchor Snow heights m AMSL. SLZ 1 1.056/1.048 1.539/1.660 SLZ 1a 909/1.003 1.363/1.465 SLZ 2 682/731 1.011/1.096 SLZ 2 a 571/639 882/958 SLZ 3 521/557 786/859 Max. surface load 1,9/2,2 kn/m 2 3,65/4,21 kn/m 2 SLZ = snow load zone When calculating the applicable snow load zones, you must take into account the map in accordance with DIN 1055-5. A shape coefficient of 0,8 in accordance with DIN 1055-5 is used for the calculation, which corresponds to a roof slope of 30. 8
Installation requirements Assembly Instructions for large systems Please note that for large systems of five collectors or more, a compensator must be installed! Compensators for Heliostar 252 S4 and 218 S4 Max. 5 collectors in series without compensators Collector fields larger than 5 and up to a maximum of 10 in series require 2 x compensators (mat. no. 1135006765)! CAUTION: Remember that a compensator changes the length of a collector field! Make sure that, after each compensator set, the extension of the field starts with a basic set. A 0,085 m compensator A Basic set Expansion Expansion Basic set Expansion Expansion 0,085 m compensator 2 x Roth compensators, mat. no. 1135006765 Basic set Expansion Expansion Expansion Basic set Expansion Expansion Expansion 0,085 m compensator Basic set Expansion Expansion Expansion Expansion Basic set Expansion Expansion Expansion Expansion 9
0.8 1,0 m 0.8 1,0 m 2,40 m 3,60 m 4,80 m 6,00 m 1,0 1,2 m 0,8 1,0 m 1,20 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 Installation requirements Heliostar 252 S4 system versions Collector area: 2,52 m 2 Vertical collector installation 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 For collector fields >5 collectors, please follow the assembly instruction on page 9. Horizontal collector installation 1,64 m 1,64 m 1,64 m 1,64 m 1,64 m 1.0 1,2 m 1.0 1,2 m For collector fields >5 collectors, please follow the assembly instruction on page 9. 10
0,8 1,0 m 0,8 1,0 m 2,40 m 3,60 m 4,80 m 6,00 m 1,0 1,2 m 0,8 1,0 m 1,20 m 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 Installation requirements Heliostar 218 S4 system versions Collector area: 2,18 m 2 Vertical collector installation 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 1,36 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 For collector fields >5 collectors, please follow the assembly instruction on page 9. Horizontal collector installation 1,36 m 1,36 m 1,36 m 1,36 m 1,36 m 1,0 1,2 m 1,0 1,2 m For collector fields >5 collectors, please follow the assembly instruction on page 9. 11
Assembly Instructions Roof positioning 1. Determining the position of the collector field and accordingly that of the universal attachment anchors > for vertical installation: Measurement a: 1,36 m* (small configuration) 1,64 m* (large configuration) Measurement b: based on the number of universal attachment anchors > for horizontal installation: Measurement c: based on the number of universal attachment anchors and the height of the collector field Measurement d: see measurement a (1,36 - small configuration/ 1,64 - large configuration). * Measurement data for one collector field only a 1 vertical b horizontal d c Profile rail Collector 2. Removing roof tiles for the purpose of fitting universal attachment anchors (2 to 3 tiles per universal attachment anchor). vertical horizontal 2 without roofing tile Roof attachment Version 1: Universal attachment anchor. Optional version 2: Rafter anchors for increased snow load 12
Assembly Instructions Safety Instruction 3. For your safety: Fall arresters must be worn for all tasks where there is a risk of falling (see page 6). 3 4. Do not step onto the mounting rail. 4 Substructure universal attachment anchor and optional rafter anchor for increased snow load Fitting rafter anchors for increased snow load Fasten rafter anchors to roof batten using 3 screws, 6 x 80, each. Roof hook must sit in the recess above the tiles. Important: The roof hook must not exert any pressure on the roof tiles! continue with assembly steps, point 1 13
Assembly Instructions Substructure universal attachment anchor and optional rafter anchor for increased snow load Assembly steps with universal attachment anchor Sheet metal tiles are strongly recommended for use as the substructure! Set screw to vary the rafter anchor spacing Not required for slate and plain tile covering Placement of sheet metal tiles Fasten universal attachment anchor to roof batten using 3 screws, 6 x 80. Universal attachment anchor must sit in the recess above the tiles. Important: The universal attachment anchor must not exert any pressure on the roof tiles! 14
Assembly Instructions Assembly steps 1. Preassemble profile rails on the ground. Important: The screws for the connection between profile rail and universal attachment anchor must be inserted before the individual profile segments are joined. To do this, measure the positions of the universal attachment anchors and mark them on the profile rails. Insert a screw with U-shaped profile plate there in each case. 1 2./3. After this, insert the connector into the side of the profile rails. 2 3 4. When connecting the two profile rails, push the mounting bracket into the notch provided on the front side of the profile rails (with horizontal assembly, ensure that the profile rail with a closed slot is used as the lower rail see detail A, page 4). 4 15
Assembly Instructions Assembly steps 5. Secure profile rails and connector with an M 12 x 20 screw. 5 6./7./8. Horizontal installation only: For better grip, a retainer (detail B, page 4) must be installed above the two lowest universal attachment anchors. 6 7 8 16
Assembly Instructions Assembly steps 9./10. Screw on the profile rails with M 10 x 30 hex bolts and screw on the U-shaped profile plates through the slots in the universal attachment anchors. 9 10 A B Profile rail 1 Profile rail 2 C A 11. Use uniform measurement A to ensure that the profiles are parallel (see page 12). Use a piece of string to check the diagonals of the profile rails and readjust differences in length if necessary. If measurement is C = B, the profile rails are flush and can be screwed in place. Ensure that measurement A does not change again during readjustment. If necessary, you should mark the position of the rail on the universal attachment anchor for this purpose. 11 12. There are slots located on the rear of the collector (for vertical and horizontal installation) to fit the collector onto the profile rails. 12 17
Assembly Instructions Assembly steps 13. Place the collector on the guide rails and push it sideways into the mounting brackets. 14./15./16. Then fasten the two outer mounting brackets with a U-shaped profile and an M 10 x 25 mm hex bolt. Remove the protective film on the abutting sides, before assembling the second and any further collector. 13 14 15 18
Assembly Instructions Assembly steps 16 17. When assembling the second and each further collector, push the collectors together using the plug-in system (sleeve + nipple). Important! The plug-in system is lubricated on the plug-in sleeve side ex works. When the collectors are pushed together, make sure this is done evenly to prevent them from tilting! 17 Lift the collector slightly and push onto the plug-in connector using the ball of your hand. Hold them in the same way on the other side. 19
Assembly Instructions Assembly steps Do not push against the glass strip. To prevent the plug-in connections being incorrectly positioned, the collectors must be pushed to the level of the connectors at the top and bottom. Pushing a collector in the middle can lead to incorrect positioning. 18./19. Use the locking ring to connect the plug-in system that has been pushed together. 18 20
Assembly Instructions Assembly steps 19 20. The flow must pass diagonally through the collectors which are switched in rows! Connection and end plugs with a locking ring are required for this as follows (see pictures 21 to 24). 20 21 21
Assembly Instructions Assembly steps 22 23 24 25. When mounting the corrugated hose couplings, ensure that the flat packing is correctly seated. Always apply counter pressure when tightening the threaded connections on the collector. Failure to do so may cause irreparable damage to the collector. 25 22
Assembly Instructions Assembly steps 26. To fit the sensor, remove the rubber sleeve on the short upper side of the collector, 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 sleeve as far as the back of the ridge. 26 27. Prepare ventilation tile (cut open grid) and, if necessary, remove any existing sarking felt underlay and attach in the raised position or use adhesive couplers (from specialist outlet). Take care that the corrugated hose is installed in ascending position! 27 28 23
Installation requirements Maintenance Instructions Intended use to heat water and support the heating system In order for the thermal solar system to work without any technical problems, it should be maintained regularly (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 flow rate > Examination of the anti-freeze 24
Check list and commissioning log for thermal solar systems Equipment operator Installation company Surname Company First name Installed by Street Street Postcode, city Postcode, city Telephone Telephone Commissioning date: Collectors Manufactured by Quantity Serial number Gross surface area, total Direction N Circuitry W E S Storage tank Type 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 HE efficiency control system Roth BW/H-HE efficiency control system Roth BW/H Comfort HE efficiency control system Solar station RS 25/6 RS 25/7 UPS 25/12 ST 25/7 PWM Expansion tank System pressure Volume flow litres bar litres per minute System properly flushed and aired Anti-freeze content tested (recomm.: 40%) Sensor correctly positioned Controller functionality check yes no Equipment operator's signature Installer's signature 25
Guarantee Roth grants a 10-year guarantee on defects that can be shown to have been caused by the manufacturer. Damage caused by the non-observance of the operating instructions will render the guarantee void. Structural alterations and modifications not approved by Roth will also lead to loss of the guarantee! GUARANTEE DOCUMENT Roth Solar Systems Heliostar at olle tors 1. Within 10 years of the date of manufacture, at our discretion, we provide free product replacement or carry out an appropriate repair if damage occurs to the solar collectors manufactured by us, which can be attributed to material or manufacturing defects and which signi cantly limits the performance of the solar heating system and jeopardises the leaktightness of the roof and its stability in a concrete way. 2. Requirements for this guarantee are: a. exclusive use and tting of all the system components belonging to the respective Roth solar heating system, in particular the use of the prescribed heat transfer uid, b. documented compliance with the planning, installation and operating instructions valid at the time of installation, c. that neither glass breakage nor the effects of frost are responsible for the damage that has occurred, d. compliance with the standards and directives valid for these works and the applicable adjoining works in connection with the relevant Roth solar heating system, e. that the installation company is a recognised and authorised specialist company and this company has provided con rmation on this certi cate with their name and signature, f. immediate return of a copy of the completely lled out guarantee certi cate to us, g. immediate reporting of damage and simultaneous dispatch of the guarantee certi cate to us and h. assertion of the claim within the guarantee period. The statutory consumer protection regulations remain unaffected by this guarantee. The above guarantee concerns: Building Building owner Production no. of the collectors: In each case, the system components belonging to the relevant Roth solar heating system on the day of the installation were delivered and installed in full. Specialist company Signature Stamp Installation date Commissioning Signature Stamp Commissioning date ROTH WERKE GMBH Am Seerain 2 35232 Dautphetal, Germany Tel. +49 (0) 6466/922-0 Fax +49 (0)6466/922-100 Hotline +49 (0)6466/922-266 Email service@roth-werke.de www.roth-werke.de 26
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Roth Energy and Sanitary Systems Generation > Solar systems > Heat pump systems > Solar heat pump systems Storage Storage systems for > Domestic and heating water > Combustibles and biofuels > Rainwater and waste water Application > Radiant heating and cooling systems > Pipe installation systems > Shower systems ROTH WERKE GMBH Am Seerain 2 35232 Dautphetal, Germany Telefon: +49 6466/922-0 Telefax: +49 6466/922-100 Hotline: +49 6466/922-266 E-Mail: service@roth-werke.de www.roth-werke.de Material No.: 1150010580 Subject to technical modifications.