energy systems heliostar® 252 s4 and 218 s4 on-roof attachment · energy systems heliostar® 252...

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Energy Systems

Heliostar® 252 S4 and

218 S4 on-roof attachment

Assembly Instructions

2

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


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

Contents

3

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 corrosion-

resistance – 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.

4

System description

Item Product description

Basic set for two

collectors vertical

on-roof attachment

(number)

Basic set for each

additional collector

vertical on-roof at-

tachment (number)

Basic set for two col-

lectors horizontal

on-roof attachment

(number)

Basic set for each ad-

ditional 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 mm2 – 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.

System components for Heliostar® flat collectors 218 S4, 252 S4

vertical/horizontal on-roof attachment

7

7

34

2

5

10

96

1

4

3

5

8

611 12 13 1416 17

5

System description

Technical data

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

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 m2 2,52 m2

Aperture surface area 1,96 m2 2,30 m2

Weight 32 kg 37 kg

Collector housing Heavy-duty polycarbonate case construction, sealed throughout as a result of be-

ing 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/m2a

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°

12

4

3

5

6 7

Technical specifications for Roth Heliostar® S4 flat collectors

6


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 particu-

lar 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

7



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 mm2 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 cross-

section 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!

8



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

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°.

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 load1,9/2,2 kN/m2 3,65/4,21 kN/m2

9

2 x Roth compensators, mat. no. 1135006765

A

Please note that for large systems of five collectors or

more, a compensator must be installed!

Basic set Expansion Expansion Expansion Expansion Basic set

0,085 m compensator

Expansion Expansion Expansion Expansion


Assembly Instructions for large systems

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.

Basic set Expansion Expansion Basic set

0,085 m compensator

A

Expansion Expansion

Basic set Expansion Expansion Expansion Basic set

0,085 m compensator

Expansion Expansion Expansion

10


Heliostar® 252 S4 system versions

Collector area: 2,52 m2

0,8 m 0,8 m

1,20 m 2,40 m

1-1,2 m

4,80 m

0,8 m 1-1,2 m 1-1,2 m 1-1,2 m

6,00 m

0,8 m 1-1,2 m 1-1,2 m 1-1,2 m 1-1,2 m

0,8 m 1-1,2 m 1-1,2 m

2,10

m

2,10

m

2,10

m

2,10

m

2,10

m

1,64

m

1,64

m

1,64

m

1,64

m

1,64

m

3,60 m

For collector fields >5 collectors, please follow the assembly instruction on page 9.

1,20

m

2,40

m

6,00

m

4,80

m

3,60

m

1,64 m

1,64 m

1,64 m

1,64 m

1,64 m

0,8–

1,0

m

1,0–

1,2

m

0.8–

1,0

m

1.0–

1,2

m1.

0–1,

2 m

0.8–

1,0

m


Vertical collector installation

Horizontal collector installation

11


Heliostar®218 S4 system versions

Collector area: 2,18 m2

Vertical collector installation

Horizontal collector installation

0,8 m 0,8 m

1,20 m 2,40 m

1-1,2 m

4,80 m

0,8 m 1-1,2 m 1-1,2 m 1-1,2 m

6,00 m

0,8 m 1-1,2 m 1-1,2 m 1-1,2 m 1-1,2 m

0,8 m 1-1,2 m 1-1,2 m

1,82

m

1,82

m

1,82

m

1,82

m

1,82

m

1,36

m

1,36

m

1,36

m

1,36

m

1,36

m

3,60 m


1,20

m

2,40

m

6,00

m

4,80

m

3,60

m

1,36 m

1,36 m

1,36 m

1,36 m

1,36 m

0,8–

1,0

m

1,0–

1,2

m

0,8–

1,0

m

1,0–

1,2

m1,

0–1,

2 m

0,8–

1,0

m


12


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

2. Removing roof tiles for the purpose of fitting universal

attachment anchors (2 to 3 tiles per universal attachment

anchor).

vertical horizontal

Profile rail

Collector

a

b

c

d

1

vertical horizontal

without roofing tile2

Roof attachment

Version 1: Universal attachment anchor.

Optional version 2: Rafter anchors for increased

snow load

13


3

3. For your safety: Fall arresters must be worn for all tasks where

there is a risk of falling (see page 6).

4. Do not step onto the mounting rail.

4

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

Safety Instruction

Substructure universal attachment anchor and optional rafter anchor for increased snow load

14


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!

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!

Placement of sheet metal tiles

Set screw to vary the rafter anchor spacing

Not required for slate and plain tile covering

15


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.

2./3. After this, insert the connector into the side of the profile

rails.

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).

1

Assembly steps

2

3

4

16


Assembly steps

5. Secure profile rails and connector with an M 12 x 20 screw.

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.

5

6

7

8

17


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.

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.

12. There are slots located on the rear of the collector (for vertical

and horizontal installation) to fit the collector onto the profile

rails.

B

9

10

AC

A

Profile rail 2

Profile rail 1

11

12

18


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

19


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!

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.

17

20


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

21


Assembly steps

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).

19

20

21

22


Assembly steps

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.

22

23

24

25

23


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.

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!

26

27

28

24


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

25

Equipment operator

Surname ___________________________________________

First name ___________________________________________

Street ___________________________________________

Postcode, city ___________________________________________

Telephone ___________________________________________

Commissioning date: ________________________________

Check list and commissioning log

for thermal solar systems

Installation company

Company ___________________________________________

Installed by ___________________________________________

Street ___________________________________________

Postcode, city ___________________________________________

Telephone ___________________________________________

Collectors

Manufactured by ________________________________________

Serial number ________________________________________

________________________________________

Direction

Quantity ___________________________

Gross surface

area, total ___________________________

Circuitry

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 ________ litres

System pressure ________ bar

Volume flow ________ litres per minute

yes no

System properly flushed and aired

Anti-freeze content tested (recomm.: 40%)

Sensor correctly positioned

Controller functionality check

N

S

W E

Storage tank

Type ___________________________________ Size ___________________________

Quantity ___________________________

Equipment operator's signature Installer's signature

26

Guarantee

GUARANTEE DOCUMENTRoth 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.

ROTH WERKE GMBHAm Seerain 2 35232 Dautphetal, Germany Tel. +49 (0) 6466/922-0 Fax +49 (0)6466/922-100Hotline +49 (0)6466/922-266 Email [email protected] www.roth-werke.de

Specialist company Signature Stamp Installation date

Commissioning Signature Stamp Commissioning date

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 andh. assertion of the claim within the guarantee period.

The statutory consumer protection regulations remain unaffected by this guarantee.

The above guarantee concerns:BuildingBuilding ownerProduction 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.

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 guar-

antee void. Structural alterations and modifications not approved

by Roth will also lead to loss of the guarantee!

27

Notes

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 Energy and Sanitary 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: [email protected]

www.roth-werke.de

Mat

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: 115

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energy systems heliostar® 252 s4 and 218 s4 on-roof attachment · energy systems heliostar® 252...

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