ZepSolar Zep System I User manual

VERSION 1.4

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc.
THIS MANUAL CONTAINS SAFETY, INSTALLATION, CONFIGURATION AND TROU-
BLESHOOTING INSTRUCTIONS FOR ZEP SYSTEM I. ZEP SOLAR, INC. RECOM-
MENDS THAT YOU SAVE THIS MANUAL IN A READILY ACCESSIBLE LOCATION
SHOULD ANY QUESTIONS ARISE ABOUT THE ZEP SYSTEM.
Copyright ©
2012 by Zep Solar, Inc. All rights reserved. Zep and Zep System are trade-
marks of Zep Solar, Inc. All other trademarks or registered trademarks are the property
of their respective owners.

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE i
1.0 Getting Started - - - - - - - - - - - - - - - - - - - - - - 1
1.1 - Zep System I Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
1.2 - Features & Benefits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
1.3 - How It Works - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
1.4 - Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.5 - Additional Items - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
1.6 - For Further Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
2.0 Safety Precautions - - - - - - - - - - - - - - - - - - - - 9
2.1 - General Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
2.2 - Installation Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
3.0 System Design - - - - - - - - - - - - - - - - - - - - - -
11
4.0 Installation - - - - - - - - - - - - - - - - - - - - - - - 13
4.1 - STEP 1: Formulas & Layout Lines - - - - - - - - - - - - - - - - - - - - - - - - 14
4.2- STEP 2: Install the Tile Hooks - - - - - - - - - - - - - - - - - - - - - - - - - - 15
4.3 - STEP 3: Installing Spanner Bars - - - - - - - - - - - - - - - - - - - - - - - - - 16
4.4 - STEP 4: Installing the Array Skirt - - - - - - - - - - - - - - - - - - - - - - - - 19
4.5 - STEP 5: Installing the First Module - - - - - - - - - - - - - - - - - - - - - - - 21
4.6 - STEP 6: Installing the Remaining First-Row Modules - - - - - - - - - - - - - - 23
4.7 - STEP 7: Finishing the First Row - - - - - - - - - - - - - - - - - - - - - - - - - - 24
4.8 - STEP 8: Installing the Next Rows - - - - - - - - - - - - - - - - - - - - - - - - 25
4.9 - STEP 9: Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
4.10 - STEP 10: Wire Clips - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE ii
5.0 Options & Servicing - - - - - - - - - - - - - - - - - - - 29
5.1 - Interlock vs. Hybrid Interlock - - - - - - - - - - - - - - - - - - - - - - - - - - 30
5.2 - Servicing the Array - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
6.0 Zep System I Warranty - - - - - - - - - - - - - - - - - 37
6.1 - Limited Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE 1 OF 50
1.0
Getting Started
Zep System I from Zep Solar, Inc. offers the fastest and least
expensive way to mount rooftop PV arrays on tile roofs using a
series of drop-in and quarter-turn connections to greatly acceler-
ate the process. Structural and grounding connections are accom-
plished using very few parts and no standard mounting rails. The
simplicity of installation delivers labor and logistics savings.

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE 2 OF 50
1.1 - Zep System I Overview
The Zep System I from Zep Solar, Inc. is designed for use on sloped tile roofs. The mounting
system preserves waterproofing by using tile hooks installed beneath the tiles and a reduced
number of roof penetrations. The low number of parts and elimination of fixed mounting rails
makes installation much faster and easier than comparable systems; just lay out a few lines,
and install the tile hooks at selected locations. Spanner Bars mount to the tile hooks to provide
anchor points for the Cam Feet to twist into place. Each Cam Foot can be leveled to provide a
perfectly level array surface. PV modules drop and rotate into place on the cam feet. Interlocks
provide structural and grounding connections across rows and columns of modules, and hybrid
cam feet can be used when PV modules meet above a Spanner Bar. Zep System I supports both
landscape (horizontal) and portrait (vertical) module installation. Most components provide
visual and/or audible feedback to indicate proper installation.
1.2 - Features & Benefits
Zep System I offers the following features and benefits:
•Rapid installation: Installation is fast and easy from planning to assembly. Only a few basic
lines need to be laid out. Spanner Bars mount to tile hooks using Spanner Clamps and other
components drop in and/or twist into place with quarter turns. Visual cues and audible clicks
tell you when parts are properly installed.
•Supports landscape and portrait mounting options: Zep System I allows you to mount
modules in either landscape (horizontal) or portrait (vertical) orientation, which provides
additional flexibility for both aesthetics and maximizing the number of modules in the array.
•Ultra-low parts count: Fewer than 10 core components are required to mount an array.
•Drop-in and quarter-turn connections: PV modules drop into the front Cam Feet and
rotate into place. Rear Cam Feet rotate and lock into place. Interlocks between modules are
pressed into place and then locked using quarter turns.
•High-wind and snow load resistance: Zep System I is rated to wind speeds in excess of
120 miles per hour and snow loads in excess of 40 pounds per square foot.
•Automatic Grounding: Zep System I is auto-grounding. Every module is redundantly
bonded via the Interlocks, which have been tested to UL 1703. A single Ground Zep, tested to
UL 467, carries the array grounding to Earth for up to 72 modules. This grounding system
exceeds UL standards by 10x and is the most robust in the industry.

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE 3 OF 50
1.3 - How It Works
Zep System I contains several innovative features not found in typical mounting systems that
make design and installation simple, fast, and flexible. It is important to understand the unique
characteristics of Zep System I before installation in order to get the most from its unique capa-
bilities. The key features that separate Zep System I and typical mounting systems are:
• Reduced Roof Penetrations.
• Precise Component Mating.
• Automatic grounding.
• Adaptability
Reduced Roof Penetrations
Zep System I creates structural bonds between PV modules using mating Interlocks at the cor-
ners of each module frame. This allows a module frame to act like a rail, thus leveraging the
existing structural characteristics of the frame and allowing the array to distribute load to fewer
attachment points. Modules attach to Spanner Bars using Cam Feet. Spanner Bars then transfer
that load to the building roof structure through tile hooks or standoffs. This system-level load
distribution minimizes roof penetrations through optimization.
Automatic Grounding
The structural connections created by Interlocks simultaneously establish a ground bond path
between modules. Both the Key and Tongue sides of Interlocks cut through the anodized coating
of the module frame to create a solid conductive bond. Bonds can be reversed and reset up to 50
times with no significant degradation of the ground bond connection. Every Interlock creates a
redundant ultra-low resistance ground path.

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE 4 OF 50
The Ground Zep rotates into the module groove with a quarter turn and provides a ground bond
connection from the array to the equipment grounding conductor(s). Only one Ground Zep is
required per sub-array and can be installed anywhere on the perimeter of the array.
Precise Component Mating
Zep System I uses the
grooves in Zep-compatible
PV modules to easily and pre-
cisely mate with Zep compo-
nents. The Key side of
Interlocks, Hybrid Inter-
locks, and Cam Feet (A) lock
into the grooves of Zep-com-
patible PV modules. The
Tongue side of these compo-
nents (B) receive adjustable
drop-in connections. As a
rule, the Tongue side always
faces the direction of the next
module to be dropped in; it
“receives” the next module.
Adaptability
Installers often need to
mount a perfect-looking
array on an imperfect struc-
ture using imperfect PV modules. Roofs are often neither square nor perfect planes, making it
difficult to establish reference points for orienting each module. Also, each PV module may have
slightly different dimensions because of manufacturing tolerances. Conventional systems com-
pound slight module misalignments or dimensional deviations throughout the array. The larger
the array, the more difficult it is to counter this problem.
A B A B

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE 5 OF 50
Zep System I is flexible in the X, Y, & Z axes, making square and level installations easy. The
position and orientation of each module can be adjusted during installation, allowing the
installer to keep the array aligned with system-level reference points such as a lower-edge
chalk line and by sighting along seams and edges to make the array look good with little effort.
•Module Truing (X-Y): This consists of adjusting each module in the X-Y (horizontal) axes to
keep the overall array square. The module groove can seat at different positions on the
Tongue side of Interlocks, Hybrid Interlocks, and Cam Feet, meaning that the tongue can be
fully or partially inserted into the groove and still accomplish a solid structural and ground
bond connection. Thus, each module can be trued independently. Truing a module is as sim-
ple as rotating it up a few degrees and adjusting the module on the Tongues as needed.
•Module Leveling (Z): This consists of adjusting each module in the Z (vertical) axis to main-
tain a planar array over imperfections in the roof surface. Each Cam Foot can be raised or
lowered over a range of 3/4” by rotating the threaded stud using a #30 Torx bit to achieve a
perfectly planar array.
1 2 3
4 5 6
X
;
¾”XXX

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE 6 OF 50
1.4 - Components
Zep System I consists of the following components (PV modules not shown):
Tile Hook (not included) Spanner Bar Spanner Clamp
Cam Foot Hybrid Interlock Interlock
Spanner Sleeve Array Skirt, Spacer, Jam Ground Zep & Wire Clip

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE 7 OF 50
1.5 - Additional Items
You will also need the following additional items:
•Zep Tool: The Zep Tool is used to install the Interlocks and Ground
Zep and to level the Cam Feet using a #30 Torx bit. It can also help
with installing Cam Feet and Hybrid Interlocks that are snug in the
module groove.
•Flat Tool: This tool is used to install the Cam Feet in the Spanner Bar
and may also be used for installing Interlocks. It is also customized
for module removal.
See Chapter 6 for instructions on using the Zep Tool and the Flat Tool.
1.6 - For Further Information
Additional information about Zep System I is available online at
www.zepsolar.com. The available resources include:
•Datasheet: The Zep System I datasheet contains technical details and
specifications.
•Videos: Watch animated installation tutorials to further familiarize
yourself with the installation process.
•Distributors: Locate a Zep distribution partner who can supply you
with Zep parts and accessories for all of your solar needs. The Zep
Solar, Inc. web site also includes links to manufacturers of Zep-com-
patible PV modules.
•Supplemental documentation: Additional documentation varies by
product and may include engineering certifications, supplemental
installation instructions, updates, and more. You may also download
CAD models of Zep parts to help you design your array.
•Training: Zep Solar, Inc. offers training sessions that provide hands-
on opportunities to use the products and ask questions.
•Contact: Contact Zep Solar, Inc. for any additional support that you are not able to obtain
using the available online resources.
Zep Tool
Flat Tool

ZEP SYSTEM I INSTALLATION MANUAL
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ZEP SYSTEM I INSTALLATION MANUAL
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2.0
Safety Precautions
All instructions in this Installation Manual and all instructions in
the installation manual provided by the PV module manufacturer
must be read and understood before attempting to install Zep Sys-
tem I. The installer assumes all risk of personal injury or property
damage that might occur during the installation and handling of
the components.

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE 10 OF 50
2.1 - General Safety
• All installations must be performed in compliance with all applicable regional and local
codes, such as the latest National Electric Code (USA), Canadian Electric Code (Canada) or
other national or international electrical standards.
• Follow all safety precautions contained in both this Installation Manual and the module
installation manual.
• Always comply with all applicable OSHA or equivalent safety standards including but not
limited to the proper use of regulation fall-protection equipment.
•Donotperformanyinstallations in wet or windy conditions.
2.2 - Installation Safety
• The installation must conform to the details on the Project Assessment Package and Design
Guidelines provided by Zep Solar, Inc.
• All installation and servicing must be performed by qualified personnel. The installer is
responsible for ensuring that all personnel are properly trained and licensed.
•Theinstallerisresponsiblefor knowing and following all applicable codes and regulations
and for obtaining all required permits and inspections.
• Check applicable building codes or consult with a structural engineer to ensure that the
structure upon which the Zep System is being installed can properly support the array under
live load conditions.
• The Zep System I must be installed over an appropriately rated fire resistant roof covering.
•TheCamFeetandInterlocksmustbefullyengaged with both the PV modules and Spanner
Bars. You will feel a snap when Cam Feet are properly installed.
• Always use appropriate personal protective equipment (PPE) such as safety glasses, gloves,
hard hat, etc. as needed and as required by OSHA or other equivalent safety standards.
•NeverexposethePVmodulestoexcessive loads or deformation such as twisting or bending.
•Somecomponentsmaybeheavyand/orbulky.Always use proper lifting and carrying tech-
niques when handling components and materials at the job site.
• The installation process involves working around high-voltage electrical equipment. Follow
applicable safety regulations and best practices to avoid creating an electrocution hazard.
• The installation process requires working on roofs. Follow applicable safety regulations and
best practices to avoid a fall. Use caution to prevent objects from falling or dropping off the
roof area. Cordon off ground areas directly below roof-related work when possible.

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE 11 OF 50
3.0
System Design Process
Zep System I is designed for use on sloped tile roofs. This chapter
provides a high-level overview of the process of assessing and
planning a prospective Zep System I installation. Each installation
is unique and has unique requirements that go beyond the high-
level overview included in this manual. Please contact Zep Solar,
Inc. for more details.

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE 12 OF 50
3.2 - System Design
3.1 - Site Assessment Information
Spanner Clampsmust be placed at a minimum distance of 4 inches from the top and bottom
edge of Spanner Bar N-S columns. The maximum allowable cantilever for a Spanner Clamp
relativeto a Spanner Bar edge iseither 1/3of the Spanner Bar lengthor 1/3 of the Spanner
Bar E-W spacing, whichever value islower.
l
r
9
3.3 - Getting Started
Please contact Zep Solar, Inc. to begin planning your Zep System I installation if you have not
done so a ready. You may contact Zep Solar, Inc. via:
Email to sales@zepsola .com
Phone to 1-415-32 -0768

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE 13 OF 50
4.0
Installation
This chapter guides you through the Zep System I installation pro-
cess. Please read this chapter in its entirety to familiarize yourself
with the process before beginning the installation. You may also
visit the Resources section at www.zepsolar.com to view videos
and other training materials. Also, be sure that the site has been
completely prepped before beginning the installation.

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAG E 14 OF 50
4.1 - STEP 1: Formulas & Layout Lines
To lay out a LANDSCAPE installation:
E/W line spacing = per span tables.
N/S line spacing = per span tables.
Max cantilever is 1/3 of the distance
between tile hooks.
To lay out a PORTRAIT installation:
E/W line spacing = per span tables.
N/S line spacing = per span tables.
Max cantilever is 1/3 of the distance
between tile hooks.
Select tile hooks for use with the installation.
Horizontal tile hooks (right) may be
used with both portrait and landscape
installations
Vertical tile hooks (left) may only be
used for landscape installations.
Tile hooks are not included with the
Zep System I.

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE 15 OF 50
4.2- STEP 2: Install the Tile Hooks
2-A: Lay out the locations of the tile hooks.
NOTE: This manual details a landscape
installation.
Spanner Bars run parallel to rafters for
landscape installations
Spanner Bars run perpendicular to raf-
ters for portrait installations.
2-B: Remove the necessary tiles.
Preserve for later reinstallation.
2-C: Install tile hooks.
Secure tile hooks to rafters at selected
attachment points.
Follow manufacturer instructions for
installation.
Adhere to all local and national codes
for structural loading and weather-
proofing.

ZEP SYSTEM I INSTALLATION MANUAL
Copyright © 2012 Zep Solar, Inc. PAGE 16 OF 50
4.3 - STEP 3: Installing Spanner Bars
2-D: Reinstall the tiles.
Tiles may require grinding in order to
fit flush.
3-A: Assemble the Spanner Bars.
Slide Spanner Bar A onto the splice
protruding from Spanner Bar B.
Ensure that the Spanner Bars are
tightly butted together.
3-B: Slide Spanner Clamps over Spanner Bars.
Orient for horizontal (H) or vertical (V)
tile hooks, as shown.
A
B
H V
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