Roth Heliostar 252 S4 User manual

ENERGY AND SANITARY SYSTEMS
HELIOSTAR®252 S4 AND 218 S4
FREE-STANDING INSTALLATION VERTICAL
ASSEMBLY INSTRUCTIONS
Construction type approved
Reg. no. 011-7S819 F

2
Safety instructions
2
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 lled 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 sur-
face and/or uncovered, as this may allow mois-
ture 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!
Safety instructions
Work Safety regulations
and state-of-the-art tech-
nology
• 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: [phone]

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3
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
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.
The sensor must be tted in the last collector
with water owing 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 mm2up to a
length of 50 m. For a longer length, you require
a cross-section of 2 x 1.5 mm2. 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.
Equipotential bonding
and lightning protection
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
The free-standing mounting set is suitable for
the installation of Roth Heliostar® at collectors
on open ground, or on at or low-pitched
roofs.
General
requirements
Installation requirements

4
Vertical collector
installation,
Heliostar®252 S4
System variants Heliostar®252 S4 and 218 S4
Collector area: 2.52 m2and 2.18 m2respectively
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
Vertical collector
installation,
Heliostar®218 S4
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

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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 xing
Basic set H
Vertical free-standing
installation xing
Extension 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 2
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
Material overview

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Assembly instructions
Assembly steps
1
2
3
1. Fix the M10 x 60 screw in the mounting rail
using the U-section.
2. Using a washer and nut, afx this to the vertical
mounting rail (fully insert in end long slot).
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).

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7
4. The lateral triangle you have now created
is oor-mounted using the supplied T
connectors as follows.
5. Insert the M10 x 30 screw in the U-section,
pass it through the upper bore hole in the
T connector and afx gently with a washer
and nut.
6. The thus prepared connecting piece is
inserted in the mounting rail and xed.
This process must be repeated and the
connecting piece inserted in the bottom of
the vertical rail and the inclined rail.
7. The procedure followed thus far should be
repeated to assemble the second triangle.
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4
Assembly instructions
Assembly steps
5
6
7

8
Assembly instructions
8
Assembly steps
9
10
11
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.
9. The horizontal rail is to be inserted into the
U-shaped prole using M10 x 60 screws and
pushed into the mounting rail completely.
10. The distance from the outer edge of the
inclined rail should be 75 mm from the
horizontal rail.
11. After the upper horizontal rail has been
xed, the lower rail is assembled with the
same procedure.
8
for Heliostar®252 S4>
75
for Heliostar®218 S4
>

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99
Assembly instructions
12. Finished assembly of the lower horizontal
rail.
13. The two diagonal distances are to be
determined to check that the two
horizontal rails are the same distance
apart.
14. After completing the retaining frame, this
must be xed 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 xed to the
ground with the 8 x 60 mm wood screws.
15. After the frame has been xed to the
ground, the Heliostar®collector is to be
placed on the frame.
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Assembly steps
13
14
15

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Assembly instructions
10
Assembly steps
17
18
16. Afx the collector to the frame using the
xing brackets (4 lateral brackets on the
rst collector).
17. Secure the lateral xing brackets in the side
slot of the horizontal mounting rail using
an M10 x 30 screw, washer and nut.
18. Completed side mount.
19. - 22. A diagonal ow 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 sufciently lubricated.
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19 20

10
1111
Assembly instructions
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.
24. Place the washer and nut on the other
side of the connector and tighten gently
by hand.
25. Push the connecting elements halfway into
the mounting rail and turn.
23
Assembly steps
24
25
26
21 22

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Assembly instructions
Assembly steps
28
29
30
27. Push the double xing bracket onto the top
and bottom mounting rail.
28. Depending on the number of Heliostar®
collectors you are installing, create the next
triangle as described at the beginning of
these instructions.
29. Insert the top and bottom horizontal
mounting rail and secure in place.
30. Repeat this process until you have mounted
all the Heliostar®collectors.
27

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1313
Assembly instructions
Assembly steps31. 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 sufciently lubricated!
32./33. Use the locking ring to connect the
plug-in system that has been pushed
together.
34. Secure the rst and last Heliostar®collector
with the side mounting brackets.
31
32
33
34

14
Assembly instructions
35. To t 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.
36. When assembling the corrugated hose
couplings, ensure that they t 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 ow 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 sufciently lubricated!
Assembly steps
35
37

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15
Please note that for large systems of five
collectors or more, a compensator must be
installed!
Note for large systems
G
Assembly instructions
The collectors must be secured on the roof be-
cause 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.
Fixing instructions
Height of building Surface
Heliostar (m2)
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
Max. pressure on the collector cover is
1667 Pa. for Heliostar®252 S4 and 673 Pa.
for Heliostar®218 S4.

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Roth Heliostar® S4 at collector technical specications
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 m22.52 m2
Aperture surface area 1.96 m22.30 m2
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 Heliostar® solar uid
Operating pressure (max) 10 bar
Solar sensor shaft Interior Ø = 6 mm
Collector connection Roth plug-in system
Collector yield, annual over 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°
Technical data 11 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
2
4
3
5
6 7
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).
Maintenance
instructions
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
Assembly instructions

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Equipment operator
Name ___________________________________________
First name ___________________________________________
Street ___________________________________________
Postcode,
city/town ___________________________________________
Telephone ___________________________________________
Date of first operation: ________________________________
Check list and commissioning log for
thermal solar systems
Installation company
Company ___________________________________________
Installed by ___________________________________________
Street ___________________________________________
Postcode,
city/town ___________________________________________
Telephone ___________________________________________
Collectors
Manufactured by _______________________________________
Serial number ________________________________________
________________________________________
Alignment
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 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
yes no
System properly flushed and aired
Anti-freeze content tested
(recommendation: 40 %)
Sensor correctly positioned
Regulator functionality check
N
S
WE
Storage tank
Type of storage tank ___________________________________ Size ___________________________
Quantity ___________________________
Operator's signature Installer's signature

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Subject to technical modications.
ROTH WERKE GMBH
Am Seerain 2 •D-35232 Dautphetal
Phone [phone] • Fax [phone]
Hotline [phone]
Email [email protected] •www.roth-werke.de