heliostar 252, 218 vertical, elevation for roof mounting

ENERGY AND SANITARY SYSTEMS

HELIOSTAR® 252, 218 VERTICAL, ELEVATION FOR ROOF MOUNTING INSTALLATION INSTRUCTIONS

Installation requirements

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Safety instructions Please read these Installation instructions carefully prior to installation and ensure ad-herence 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. In the case of snow loads that exceed Zone 4 and installation sites higher than 600 m above sea level, please contact the Roth hotline for further information on structural forces. 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 fi 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 assem-bly, always ensure that they are never stored in the open air, lying on their glass surface and/or uncov-ered, as this may allow moisture to penetrate the vent holes located in the channel surrounding the frame. When installing the collector connectors, please bear in mind that they are soft-annealed, so that counter-pressure should always be applied when tightening the ½” threaded joints! Failure to do so may result in damage to the collector!

The installation engineer bears sole responsibility for ensuring that the collectors are adequately an-chored on open ground or on the roof, particularly if the location is subject to strong winds. Any data pertaining to weight contained in these Installation 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. Minimum weight loads for different building heights are defi ned in the pertinent standards and directives, DIN 1055-T4 in particular.

The metal pipes of the solar circuit must be con-nected 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 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 equipo-tential busbar by a wire of the same cross-section.

The sensor must be installed in the last collector of the fl ow circuit (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 in-sert it in the immersion coupler 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 mm2 up 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.

Requirements for structural forces

Equipotential bond-ing and lightning protection

Fitting the sensor

• Drill with 8.5 mm twist drill bit or 12 mm masonry drill bit

• Wrenches in sizes: 16, 17, 19, 24• 2 pipe wrenches• Folding rule• Metal saw for cutting sections to length

(optional)

List of tools

The free-standing mounting set is suitable for the installation of Roth Heliostar® fl at collectors on open ground, or on fl at or low-pitched roofs.

General requirements

Item Material No. Description Quantity

1 1125005701 C-section, 36 x 30 x 1900 mm F3 2

2 1150002871 Hex bolts M10 x 30 DIN 933, galvanized 8


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 4, aluminium 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 6

11 1150007739 Fixing bracket, single 4

12 1150007946 Installation instructions for Heliostar® roof mounting 1

13 1150006895 T connector 60 x 60 x 6 mm, length: 40 mm 4

14 1155000551 Packaging 1


16 1150002838 Hex nuts M10 DIN 934, galvanized 4


List of required materials

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Fixing for basic roof mounting set H

Fixing for extended roof mounting 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


4 1150002840 Hex nut M10 DIN 985 (EN ISO 10511), galvanized 5


6 1150006896 U-section 25 x 10 x 25mm, Al 5


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 5

13 1125005192 U-shaped connecting element 25x25x3 mm, l: 130 mm Al 2

14 1150007740 Fixing bracket, double 2

15 1150006892 Stainless steel corrugated hose, length: 300 mm 1/2" 1

16 1150007946 Installation instructions for Heliostar® roof mounting 1

17 1150006895 T-section 60 x 60 x 6 mm, length: 40 mm Al 2

18 1155000551 Packaging 1


20 1150002838 Hex nuts M10 DIN 934, galvanized 2


22 1125005192 U-shaped connecting element 25 x 25 x 3, Al 2

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Installation instructions

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1. Fix the M10 x 60 screw in the mounting rail using the U-section.

2. Using a washer and nut, affi 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).

4. The lateral triangle you have now created is fl oor-mounted using the supplied T connectors as follows.

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5. Insert the M10 x 30 screw in the U-section, pass it through the upper bore hole in the T connec-tor and affi x gently with a washer and nut.

6. The thus prepared connecting piece is inserted in the mounting rail and fi xed. This process must be repeated and the connecting piece inserted in the bottom of the vertical rail and the inclined rail.

7. Roth universal fastening anchor

8. To fi x the Roth universal fastening anchor, push the roof tile up underneath the overlying tile. Affi x the universal fastening anchor to the roof beam using 3 screws, 6x80.

9. The universal fastening anchor must be located above the tiles in the trough of the tile.

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Installation steps5

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Installation steps


10./11. If the collectors are subject to harsh condi-tions, a special raft anchor can be used for roof mounting as an alternative to items 8 and 9

12. To change the angle of inclination, shorten the rear profi le rail of the triangle to the required length

13./14. Inserting the screws from underneath, now affi x the pre-mounted T connectors to the universal fastening anchor using the M10x30 hex bolts and the 25x10x25 U-sections and hex nuts.

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Installation steps15. To mount the two horizontal rails (top and bottom), proceed as follows:

IMPORTANT: The horizontal rails are supplied ex works with ready-made bore holes. 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 mounting the Helio star® 252, the lower bore hole is for mounting the Heliostar® 218.

16. Insert the horizontal rail in the U-section using the M10 x 60 screws and push fully into the mounting rail.

The distance between the outer edge of the inclined rail and the outer edge of the horizon-tal rail should be 75 mm.

17./18. Push the profi le rail underneath the universal fastening anchor onto the 25x10x25 U-section and secure with an M10 hex nut.

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15 for Helio star® 252 >

for Helio star® 218 >

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19. Affi x the collector to the frame using the fi xing brackets (4 lateral brackets on the fi rst collector).

20. Secure the lateral fi xing brackets in the side slot of the horizontal mounting rail using an M10 x 30 screw and washer and nut.

21. Completed side mount.

22. Secure the fi rst and last Heliostar® collector with the side mounting brackets.

Installation steps

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Installation steps

The steps here show how to affi x a vertical Heliostar® collector using the Roth basic set. If you are mounting a series of Helio star® collectors in a row, then you need to substitute the side bracket on one side of the frame with a double brack-et. These are supplied with the Roth vertical extended roof mounting set. To install the extended set, proceed as follows:

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23. To fi t the sensor, remove the rubber cou-pler, thread the sensor through, apply heat conductive paste and push it into the immer-sion coupler as far as it will go. Then push the rubber coupler in until it is pressing against the back ridge.

24. When mounting the corrugated hose cou-plings, always ensure that the fl at packing is fi tted correctly. Always apply counter pressure when tightening the threaded connections on the collector. Failure to do so may cause irreparable damage to the collector.

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Ground anchoring

System versions:• with concrete base• with aluminium standing seam sheets and gravel layer

Minimum weight loading according to DIN 1055-4:

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25. Insert the two M12 x 20 screws in the mount-ing rail connectors for the top and bottom mounting rail as shown in the photo.

26. Place the washer and nut on the other side of the connector and tighten gently by hand.

27. Push the connecting elements halfway into the mounting rail and turn.

Extended assembly steps

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Extended assembly steps

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28. Push the double fi xing bracket onto the top and bottom mounting rail.

29. Depending on the number of Heliostar® collec-tors you are installing, create the next triangle as described at the beginning of these instruc-tions.

30. Insert the top and bottom horizontal mounting rail and secure in place.

31. Repeat this process until you have mounted all the Heliostar® collectors.

Safety instructions 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 Erection of elec-trical equipment, VDE 0185 General information for the erection of lightning protection systems, VDE 0190 Main equipotential bonding of electri-cal systems, DIN 18382 Electrical cable and line system in buildings - you can obtain detailed information on safety regulations from the Trade Association for the German Building Industry!

Proper use of laddersLadders should only be used for a working height of less than 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 the exit point.

Fall protection If working at a height above 3 m, always use fall protection equipment when working on slop-ing 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 roof safety hooks 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 +49 (0) 64 66/9 22-2 66

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ROTH WERKE GMBHAm Seerain 2 • D-35232 DautphetalPhone +49(0) 64 66/9 22-0 • Fax +49(0) 64 66/9 22-1 00Hotline +49(0) 64 66/9 22-2 66email [email protected] • www.roth-werke.de

heliostar 252, 218 vertical, elevation for roof mounting

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