Roth HELIOSTAR User manual

ENERGY AND SANITARY SYSTEMS
ON-ROOF ATTACHMENT
FLAT COLLECTOR HELIOSTAR®
INSTALLATION INSTRUCTIONS

The on-roof attachment set is capable for
installation of Roth flat collectors Heliostar®
on roofs with a slope greater than 22°. One
attachment anchor universal can be used for
roofs with covering made of pantiles/ roofing
tiles and similar roofing stones as well as plain
tiles and fibre-cement corrugated plates.
Installations on roofs made of natural slates
should be carried out by companies employ-
ing professional tilers only.
Please read the installation instructions
before starting the installation carefully
and follow the indicated safety informa-
tion. The valid industrial safety instructions
and regulations of technology especially with
regard to working on the roof have to be
observed (see page 12). In case of higher
loads of snow starting from zone 4 and in
places above 600 m NN, please contact our
technical department to discuss statics of the
installation.
Please note: You may need additional mater-
ial such as ventilation roofing tiles for the roof
lead-through of the collector field connections
(available in special tiler stores and construc-
tion material wholesalers), possibly adjustment
lumbers for padding the rafter anchor, sheet
metal for sealing the rafter anchor when
using plain tiles. To carry the collector on the
roof additional equipment could be required.
Important: When storing the collectors
before installation, make sure the collectors
do not stand outside, lay on the glass and/or
are stocked uncovered, to avoid humidity
entering into the collector through the wholes
in the collector frame. Before installing the
collector connections, they must be annealed.
Therefore, always push strongly against the
1/2” thread connection when tightening.
Non-compliance can result in damage of the
collector.
The metal pipelines of the solar circuit must
be connected through a green/yellow conduc-
tor of min. 16 mm2Cu (H07 V respectively R)
with the main potential adjustment rail. If a
lightning protection installation is available,
the collectors can be linked to it. Earthing can
also be done by a depth earth electrode. The
grounding cable must be placed outside on
the house. In addition the earth electrode
must be connected with the main potential
adjustment rail with a cable of the same
diameter.
Installation requirements
Safety information
Generel requirements
Potential adjustment
and lightning
protection
2
• Spanner 13/17/19/20/22
• Boring machine,
• Cross slot PZ 3
• Angle grinder with stone shim
• Hammer
• String (approx. 10 m), measuring tape, rope
• Pencil
Overview of tools
The sensor must be installed in the last flood-
ed collector on the supply side (hot outlet).
For this purpose, the rubber sleeve must be
removed, the sensor must be threaded and
the rock wool inside of the collector should be
pushed aside. Afterwards place some heat
conducting paste on top of the sensor and
insert it as far as possible into the immersion
sleeve. In the end push the rubber sleeve back
into its position until the countering lip inter-
locks with the collector frame. To extend the
cable of the sensor up to 50 m it is sufficient
to choose a cable diameter of 2 x 0,75 mm,
for more than 50 m a diameter of 2 x 1,5 mm
must be used. To protect the connected regu-
lation units against overvoltage the collector
sensor is to be extended appropriately, directly
behind the collector, through an overvoltage
protection case (optional).
Installation of sensor

3
Vertical installation
Horizontal installation
System varieties
Collector surface area: 2,18 m2(small version)
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
1,16 m
1,0–1,2 m
0,8–1,0 m
2,40 m
1,0–1,2 m 1,0–1,2 m
6 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
0,8–1,0 m

4
Vertical installation
Horizontal installation
System varieties
Collector surface area: 2,52 m2(large version)
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
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 m 1,0–1,2 m
0,8–1,0 m

5
Overview of material
Vertical installation
Installation rail made of aluminium, length 1205 mm 4 2
Profile rail connection set (2 connection profiles, 4 hexagonal screws M 12 x 20
with nut and spring washer) 11
Attachment element D (attachment clamp double) 2 2
Attachment element E (attachment clamp single, 4 U profiles, 4 hexagonal screws M 12 x 20
with nut and spring washer) 1-
Hexagonal screws made of stainless steel M 10 x 30, U profile discs with washer and nut 6 2
Stainless steel corrugated hose with union nut 1/2”, insulation 20 x 13 mm and sealing ring, L 300 mm 1 1
Stainless steel corrugated hose with insulation 20 x 13 and sealing rings, length 900 mm 2 -
Roth attachment anchor universal vertical, incl. attachment screws 6 2
Material
System components
1
2
3
4
5
6
7
1
5
4
8
Extension set for each
additional collector
(quantity)
Basic set for
2 collectors (quantity)
Accessory
7
6
Basic set on-roof installation for vertical alignment flat collector Heliostar®
8
3
2

6
Overview of material
Horizontal installation
Installation rail made of aluminium, length 1205 mm 2 2
Installation rail made of aluminium, length 1205 mm 2 -
Profile rail connection set (2 connection profiles, 4 hexagonal screws M 12 x 20
with nut and spring washer) 11
Attachment element E (attachment clamp single, 4 U profiles, 4 hexagonal screws M 12 x 20
with nut and spring washer) 1-
Attachment element D (attachment clamp double) 2 2
Hexagonal screws made of stainless steel M 10 x 30, U profile discs with washer and nut 6 2
Installation rail extension made of aluminium, length 900 mm 2 -
Stainless steel corrugated hose with union nut 1/2”, insulation 20 x 13 mm and sealing ring, L 300 mm 1 1
Stainless steel corrugated hose with insulation 20 x 13 and sealing rings, length 900 mm 2 -
Roth attachment anchor universal horizontal, incl. attachment screws 6 2
Material
System components
1
2
3
4
5
6
7
1
5
4
8
Extension set for
each additional
collector (quantity)
Basic set for
2 collectors (quantity)
Accessory
Basic set on-roof installation for vertical alignment flat collector Heliostar®
8
3
2
7
6
9
10
9
10

7
Roof connection
Installation instructions
1. Definition of position of the collector field
and corresponding attachment anchor
universal
For vertical installation:
Measure a: 1,36 m* (small version)
1,64 m* (large version)
Measure b: depends on the size of the
rafter distance and the quantity of attach-
ment anchor universal
For horizontal installation:
Measure d: depends on the quantity of
attachment anchor universal and the col-
lector field height
Measure c: 0,74 m*, (both versions).
* Measure valid for 1 collector field only
2. Removal of roofing tiles to install the
attachment anchor universal (per attach-
ment anchor universal 2-3 roofing tiles).
3. Attachment anchor universal
4. For your safety: When working in
danger of falling off the roof be sure to
wear protective equipment (see page 12).
3
4
1
2
Roof positioning
vertical horizontal
profile rail
collector
a
b
c
d
vertical horizontal
without roofing tiles
Safety information

8
Steps of installation
Installation instructions
3
1
2
1. Fix attachment anchor universal with
3 screws 6 x 80 to roof lath. Attachment
anchor universal must be positioned in
the deep part of the tile.
Important: The attachment anchor
universal may not impose pressure upon
the roof tiles.
2. Pre-assembly profile rails on ground. The
screws for the connection of profile rails
and attachment anchor universal must be
inserted before joining the individual pro-
file segments. For this purpose measure
the position of the attachment anchor uni-
versal and mark on the profile rails. At this
spot insert 1 screw with U profile disc each.
3./4. Afterwards insert connection of both
profile rails on the side.
5. When connecting both profile rails push
the attachment clamps in the designated
grooves on the front side of the profile
rails (for horizontal installation consider
that the profile rails with closed long hole
are used as rails below – see detail A,
page 6).
5
4

9
Steps of installation
Installation instructions
10
6. Secure profile rails and connector with
screw M 12 x 20.
7./8./9. Only applies for horizontal installa-
tion: For better resistance install a
securing (detail B, page 6) above the
2 lowest attachment anchors universal.
10./11. Profile rails with hexagonal screws
M 10 x 30 and U profile washers are
tightened through the long holes of the
attachment anchor universal.
6
11
7
9
8

10
Steps of installation
Installation instructions
12. Define parallelism with a consistent
measure A. Check the diagonal profile
rails with a string and adjust differences
in length if necessary. If measure C = B,
the profile rails are correctly adjusted
and can be tightened. Make sure that
measure a does not change when adju-
sting. It could be useful to mark the
position of the rail onto the attachment
anchor universal.
13. There are slots on the back side of the
collector (for vertical and horizontal
installation) to apply collector to profile
rails.
14. Place collector on profile rails and slide it
into attachment clamps from the side.
15./16. Fix both outer attachment clamps
with U profile and hexagonal screw
M 10 x 25 mm. Before installing the
second and any additional collector
remove the protection film on the sides
where the collectors touch.
17. For installing the sensor remove the
rubber sleeve, thread the sensor, place
heat conducting paste on the sensor and
insert as far as possible into the immersi-
on sleeve. Afterwards push rubber sleeve
behind the countering lip.
16
17
15
14
13
12
A
B
C
A
Profile rail 2
Profile rail 1

Installation instructions
11
Steps of installation
18
20
19
18. Secure correct position of the flat sealing
when installing the corrugated hose
plaids.
19. When tightening the screw connections
make sure to push against the collector.
Non-compliance can damage the
collector.
20. Prepare ventilation block (cut fence) and
if necessary separate available sarking
membrane and fix in raised position,
respectively use sealing member (special
wholesaler). Observe rising corrugated
hose positioning!
21

Machine no.:XXXXXXXXXX XXXXX B Subject to Technical Changes.
Installation instructions
• Installation on roofs: DIN 18338 tilers and
roof sealing work, DIN 18339 plumbing,
DIN 18451 scaffold work.
• Connection of thermal solar installations:
DIN 4757 part 1 and 3.
• Electrical connections: VDE 0100 installation
of electronic equipment, VDE 0185 general
information with regard to lightning pro-
tection installation, VDE 0190 main poten-
tial adjustment of electronic installations,
DIN 18382 electronic cables in houses.
Detailed information referring to prevention of
accidents can be found at Accident Prevention
and Insurance Association.
Use ladder appropriate
Use ladder only for a height difference up to
5 m. Lean and secure in an angle of 65-75°.
Exit must be topped by a minimum of 1 m.
Security of not falling of the roof
In case of falling height > 3m on roofs with
a slope between 20° and 60°, it is required
to provide corresponding security for falling
protection (VBG 37, § 8). The vertical distance
from the working place to the roof scaffold
or alternatively the roof protection wall should
not exceed 5 m. For protection it is also possi-
ble to use a safety line. Security hooks must
be installed above the user on a sustainable
component. Do not use ladder hooks
Security of falling parts
Protect roads and working places below
against falling or upsetting components.
These areas must be marked and blocked.
Industrial safety
instructions and
regulations of technology
ROTH WERKE GMBH
Am Seerain 2 ·35232 Dautphetal
Telefon [phone] ·Telefax 06466/9 22-1 00
Hotline [phone]
E-Mail: [email protected] ·www.roth-werke.de