ZepSolar ZS Comp User manual

ZS Comp
Installation Manual for Composition Shingle Roofs - U.S.
Document #800-0351-001 Rev B

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ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
Notices
This manual contains safety, installation, configuration and troubleshooting instructions for ZS
Comp. Zep Solar, Inc. recommends that you save this manual in a readily accessible location,
should any questions arise regarding ZS Comp.
Copyright and Trademark Information
Copyright © 2012 by Zep Solar, Inc. All rights reserved.
ZEP, Zep solar, and the Zep logo are trademarks of Zep Solar, Inc. All other trademarks are the
property of their respective owners.
Warranty Notice
Warranty void if hardware not certified by Zep Solar, Inc. is attached to the Zep Groove of a Zep
Compatible PV module frame.

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Document #800-0351-001 Rev B Page i
ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
Contents
1 Introduction ___________________________________________________________1
1.1 ZS Comp Overview .................................................................................................................................................................1
1.2 General Safety Precautions ................................................................................................................................................2
1.3 Zep Compatible ...................................................................................................................................................................... 3
2 ZS Comp Components _________________________________________________ 5
2.1 ZS Comp Cutaway View ...................................................................................................................................................... 5
2.2 ZS Comp Core Components .............................................................................................................................................. 6
2.3 ZS Comp Accessory Components....................................................................................................................................7
2.4 ZS Comp Tools ....................................................................................................................................................................... 8
3 Array Design__________________________________________________________ 9
Step 1: Gather Project Data ................................................................................................................................................. 9
Step 2: Obtain Spacing and Cantilever Allowances..................................................................................................10
Step 3: Create Array Layout and Bill of Material.......................................................................................................10
3.1 Using the Zepulator Online Design Tool ..................................................................................................................... 11
3.2 Using the Span Tables....................................................................................................................................................... 13
3.3 Alternative Layout Possibilities......................................................................................................................................14
4 Layout Concepts _____________________________________________________ 15
4.1 Drop-In Direction.................................................................................................................................................................15
4.2 Fixed Rules ............................................................................................................................................................................. 16
4.3 Grounding/Earthing............................................................................................................................................................. 18
4.4 Thermal Expansion .............................................................................................................................................................19
4.5 Roof Zones.............................................................................................................................................................................. 22
5 Installation Process __________________________________________________ 23
Step 1: Mark Out Array Layout on Roof.........................................................................................................................24
Step 2: Install Roof Attachments ...................................................................................................................................25
Step 3: Secure and Align Front-Row Leveling Feet..................................................................................................26
Step 4: Install Array Skirt ..................................................................................................................................................28
Step 5: Install First Row of Modules..............................................................................................................................32
Special Inset: Interlocks.................................................................................................................................................38
Special Inset: Flexible Positioning ...............................................................................................................................40
Special Inset: Wire Management .................................................................................................................................41
Step 6: Complete the Array................................................................................................................................................43
Step 7: Ground the Array.....................................................................................................................................................44
Special Inset: Universal Box Brackets and Other Accessories.........................................................................45

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ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
6 Installation Supplement ______________________________________________ 47
6.1 Servicing an Array................................................................................................................................................................47
6.2 Removing the Array Skirt..................................................................................................................................................49
6.3 Product Notes .......................................................................................................................................................................50
Special Inset: Interlock Versions and Functionality.............................................................................................50
Special Inset: Interlock Versions and Spacers Used ........................................................................................... 51
Special Inset: Hybrid Interlocks...................................................................................................................................52
7 Regulatory Information _______________________________________________ 55
7.1 UL and ETL Listings............................................................................................................................................................55

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Document #800-0351-001 Rev B Page 1
1 Introduction
ZS Comp, from Zep Solar, Inc., is an integrated solution for installing PV arrays on composition shingle roofs. ZS
Comp offers the following benefits: rapid installation, reduced roof penetrations, reduced parts count, low sys-
tem weight, elimination of lengthy and cumbersome mounting rails and clip hardware, precision alignment,
enhanced aesthetics, resistance to theft, redundant auto-grounding matrix, portrait and landscape options, and
an easy-to-use design tool with array-level BOM calculations.
1.1 ZS Comp Overview
Figure 1.1 ZS Comp for Composition Shingle Roofs

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ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
1.2 General Safety Precautions
Follow all instructions in this manual and the PV module installation manual. The installer is ulti-
mately responsible for ensuring that all installations are performed in compliance with applicable
codes and standards, as well as industry best practices.
1.2.1 Installation Safety
• The installation process requires working on sloped and elevated building surfaces, in out-
door weather conditions, using tools and heavy components designed for the generation of
electricity.
- Use properly anchored fall protection equipment.
- Use caution to prevent objects from falling or dropping off the roof area.
- Cordon off ground areas directly beneath the roof work area when possible.
• Always use personal protection equipment such as safety glasses, gloves, etc. as neces-
sary.
• Do not perform installations in excessively wet, windy, or inclement weather conditions.
• When working in hot weather, work crews should take care to prevent symptoms of over-
heating or deyhdration.
• Use proper lifting and carrying techniques when handling heavy components at the job
site. If conditions are challenging for moving PV modules to the roof area, use a mechani-
cal lift.
• Follow best practices when working around high-voltage electrical equipment.
• Do not anchor fall protection equipment to roof mounts, or any other inappropriate roof
structure.
• The installer is responsible for:
- Following all applicable regional and local codes, standards, and regulations
- Ensuring that all personnel are properly trained, equipped, and licensed
- Obtaining all required permits and inspections
- Verifying that the roof structure can support the array under live load conditions.
- Verifying that the system is installed over a properly rated fire-resistant roof covering
• Ensure that Zep Solar components are properly engaged with the PV modules.
• Do not subject the PV modules to excessive loads or deformation such as twisting or
bending.
1.2.2 Electrical Specifications
• These instructions describe the correct installation of the Interlock, the Ground Zep, and
other listed components into a PV module that has a Zep Compatible frame.
• Product listing information is shown for each component in the Components chapter and
in the Requirements chapter. For the most up-to-date listing information, please refer to
the product datasheets on the Zep Solar web site.
• Zep Solar components are only suitable for PV modules with a series fuse rating of 15
Amps or less.
• Each array of PV modules must be grounded with a solid copper wire that is connected
between the Ground Zep and a suitable earth ground. The ground wire and torque specs
are identified in “Ground the Array” on page 44.

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ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
1.3 Zep Compatible
Zep Solar mounting solutions are based on the Zep Groove, a patented module frame profile
designed to mate easily and precisely with Zep components. Module frames with the Zep Groove
are considered "Zep Compatible", and are offered by PV module manufacturers who have estab-
lished a licensing agreement with Zep Solar, Inc.
Figure 1.2 Zep Groove and Rockit
Key and Tongue. The Key and Tongue concept informs all Zep Compatible designs. The Key side
inserts into the Zep Groove, similar to inserting a key into a lock. On the other side, the Zep Groove
allows PV modules to “drop in” easily onto the Tongue of the Rockit.
Figure 1.3 Module Drop-In Example
Zep Compatible PV module
Zep Groove cross
section
Tongue side
For example, the “Rockit” is a hardware feature used to secure PV modules
to the roof attachments. The Rockit fits into the Zep Groove on both sides:
The Key side inserts, while the Tongue side receives.
Zep Groove
Key side
In the next row, modules are “dropped in” on the Tongue side (the receiving
side).
1
First, the Key side of the Rockit is
inserted into the Zep Groove.
2

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ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
Another example of the use of Key and Tongue in a Zep Compatible design is seen with the Inter-
lock, a component that couples and bonds two modules together. Here, the Key and Tongue are
differently shaped, but they still fit into the Zep Groove in the same manner as the Rockit.
Figure 1.4 Zep Groove and Interlock
Interlock back is Key side
Other Zep Solar components such as the Interlock also use the Key and Tongue concept.
Interlock front is Tongue
side
Key side is inserted into
Zep Groove
The fasteners on the Interlock (the
“Interlock Zeps”) are tightened one-
quarter turn to lock securely into the
Zep Groove.
Open
Closed
Rotation seen from Key side
See “Interlocks” on page 38 for more information on the Interlock.

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2 ZS Comp Components
2.1 ZS Comp Cutaway View
Interlock
Leveling Foot (Key side shown)
Zep Compatible PV Module
Array Skirt
Roof Attachment
Zep Groove
Ground Zep

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ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
2.2 ZS Comp Core Components
Comp Mount, Type C
Leveling Foot
Interlock
Hybrid Interlock
Ground Zep
Provides a roof mounting attachment point for the array.
Flashing and waterproofing measures included.
Provides a structural and electrical bond between
modules.
850-1178:
Listed by UL to UL 2703.
ETL listing conforms to ULC ORD STD C1703.
850-1388:
Listed by UL to UL2703.
Used on Leveling Foot base where the Rockit conflicts
with the installation of an Interlock.
Grounding version is listed by UL to UL 2703.
Provides a single point for grounding/earthing
the PV Array. A single Ground Zep can ground
up to 72 modules.
Listed by UL to UL 467 and UL 2703.
ETL listing conforms to UL STD 467.
Secured PV Modules to the Comp Mount flashing and
enables fine-tuned leveling.
Grounding version is listed by UL to UL 2703.
Part No. 850-1178
Part No. 850-1388
Part No. 850-1408
- or -

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ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
2.3 ZS Comp Accessory Components
Array Skirt and End Caps
Array Skirt Spacer Jams
AC/DC Cable Clip
Universal Box Bracket Groove Adapter Kit
++
Conceals hardware for an aesthetic appearance, and also
serves as a jig during installation to keep the first row of
modules straight. The Array Skirt comes with one Array
Skirt Spacer and two Jams.
End caps sold separately.
Used with the Interlock when
connecting sections of Array
Skirt together.
Spacer 850-1402 is compatible
with Interlock 850-1388.
Used to secure Array Skirt
after attaching the Array
Skirt to the first row of
Leveling Feet.
Snaps into the Zep Groove to secure array
wiring, and to adjust wire tension.
Allows attachment of electrical boxes to Zep Compatible PV
module frame, thereby eliminating additional roof penetra-
tions.
Attaches to the bracket of a microinverter, DC
optimizer, or other module-level electronic
device in order to secure the device to a Zep
Compatible PV module frame.
850-1402
850-1286
- or -
* Please visit the Zep Solar web site at www.zepsolar.com for additional accessories and information.

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ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
2.4 ZS Comp Tools
Zep Tool
#30 Torx Bit Attachment
Flat Tool
The Zep Tool performs the following functions:
• Install and remove Interlock
• Attach and remove Leveling Foot, Hybrid Interlock,
Universal Box Bracket, and Groove Adapter Kit from Zep
Compatible PV module frame
• Install and remove Ground Zep
• Adjust height of Leveling Feet using #30 Torx Bit
attachment
• Secure Leveling Foot base using 1/2” socket wrench
attachment
The Flat Tool does everything that the Zep Tool can do,
except for attaching the Leveling Foot and adjusting the
Leveling Foot height. In addition, the Flat tool performs
one additional function:
• Remove Interlock from between two modules
850-1199 850-1412
Attaches to the end of the Zep Tool for raising and
lowering of the array at the attachment points.

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Document #800-0351-001 Rev B Page 9
3 Array Design
Zep Solar, Inc. seeks to encourage efficient design of PV arrays by allowing users to design their own systems.
The Zepulator online design tool and Span Tables are available on the Zep Solar web site to enable custom
array designs. Additional information on fine-tuning array designs can be found in training videos, also available
on the Zep Solar web site.
Step 1: Gather Project Data
Array design begins by identifying specific information that applies to the project, including:
• Site information such as wind speed/zones, snow load, and terrain characteristics
• Building characteristics such as rafter/truss spacing, roof pitch, and roof type
• PV array details such as PV module manufacturer, mounting area size, and desired orien-
tation
Within each specified roof type, users can select a preferred Zep Solar approved roof attachment
when using the Zepulator. The Span Tables and Certification Letters are only valid for hardware
specifically tested and approved by Zep Solar, Inc. for use within each country.
NOTE: Input variables may vary from one country to the next. To see variables for
other countries supported in the Zepulator, select another country for the proj-
ect on the Project page.

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ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
Step 2: Obtain Spacing and Cantilever Allowances
After gathering the project data, the designer can either look up the allowances in the Span Tables,
or s/he can enter the project information into the Zepulator in order to obtain the spacing and can-
tilever allowances. (The terms “spacing” and “span” are interchangeable.)
Figure 3.1 Spacing and Cantilever: Composition Shingle Roof With Vertical Rafters
Note the following points:
• Interlocks are always aligned perpendicular to the module drop-in direction.
• Leveling Foot minimum distance from module corner is 2 inches or 50 mm to center of
threaded Leveling Foot stud.
• Allow a gap between modules of 1/2 inch or 13 mm, in both North-South and East-West
directions; actual tolerance is 1/4”-3/4”.
Step 3: Create Array Layout and Bill of Material
Array Layouts and a Bill of Material can be created using the Zepulator online design tool or using
a CAD program. The designer may also choose to generate an initial layout in the Zepulator and
then further refine the design using another program. Zep Solar, Inc. provides downloadable CAD
blocks on the Zep Solar web site for Zep Solar components. Note that the Bill of Material created
by the Zepulator does not include hardware pricing, since that may depend on the distribution
channel and other factors.
North-South spacing
is determined by
module dimension
plus 1/2” or 13mm
East-West spacing is a multiple of
the distance between rafters
Down-roof
Module Cantilever: Leveling Foot center to
module edge.
Maximum cantilever is always 1/3 of
the maximum allowable spacing.
Roof attachment and Leveling Foot
PV module Ground Zep
Array Skirt
Interlock
1/2 inch gap
(13mm)

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Document #800-0351-001 Rev B Page 11
ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
3.1 Using the Zepulator Online Design Tool
The Zepulator online design tool is available from the Zep Solar web site, or directly at 
www.zepulator.com.
Figure 3.2 Zepulator Online Design Tool
Place your cursor in a field to display
an explanation.
Access the Zepulator from the Home
page of the Zep Solar web site
Each tab contains a set of inputs for
your project
Home tab is for opening saved
projects or creating new projects Click Continue to save changes on
any input screen.
Layout tab is for selecting module
details, orientation, and mounting
area.
Project tab includes the site address,
country, and contact person
Site tab includes topography,
weather, and other site-specific data
that may vary by country
Building tab includes inputs for roof
type, attachment method, and rafter
spacing
Use the Summary page to view, edit,
or print the Bill of Material and
Engineering Calculations.
1
2
3
4
5

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ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
3.1.1 Zepulator Layout Example
After all information is entered or selected, click the Update button on the Layout tab to see a
suggested layout similar to the one shown below. Note that the Zepulator optimizes the layout to
minimize the number of roof penetrations.
Figure 3.3 Example Zepulator Array Layout (ZS Comp, U.S.)
The array layout accounts for each ZS Comp component listed on the Bill of Material.
NOTE: In cases where a Leveling Foot coincides with an Interlock location, you may
need to substitute a Hybrid Interlock. However, shifting the array to the east or
west may eliminate the need for Hybrid Interlocks altogether, especially when
using the Comp Mount C flashing. The Zepulator does not show Hybrid Inter-
locks on the layout, although it will include Hybrid Interlocks in Additional
Truck Stock to ensure adequate hardware supply if needed.
Ground Zep
Roof Attachment
and Leveling Foot
Array Skirt
PV module
Rafters
For ZS Comp, modules are
always installed (dropped-
in) starting at the gutter and
working towards the ridge,
parallel with the rafters
Interlock
Down-roof
The Zepulator centers the array in the specified roof
mounting area.

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Document #800-0351-001 Rev B Page 13
ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
3.2 Using the Span Tables
In addition to the Zepulator online design tool, Zep Solar, Inc. provides complete Span Tables that
are included with the Engineering Certification Letters for each country. These tables represent
tested structural values for every combination of hardware that is approved for use with Zep Com-
patible roof mounted PV arrays. The Engineering Certification Letter may also be provided to build-
ing officials when submitting for a permit, or for use by independent engineering consultants.
Figure 3.4 Span Table Example (ZS Comp - U.S.)
Wind speed
Roof pitch
Specific option for
roof attachment
hardware
Roof zone
Snow load
Maximum allowable span
Terrain exposure
category

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ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
3.3 Alternative Layout Possibilities
The layouts shown thus far have been simple examples for the purposes of illustration. In the real
world, things are rarely as straightforward: roof obstacles, shading, and multiple roof planes may
require an adaptive approach. The following examples show a few of the array designs that are
possible with ZS Comp for composition shingle roofs. Please contact Zep Solar Support if you need
assistance in creating a complex array layout design for a specific project or field condition.
Figure 3.5 Alternative Layouts Possible in ZS Comp
3.3.1 Site Assessment Form
Please contact Zep Solar Support for design assistance with unusual array configurations or spe-
cial site conditions. Zep Solar Support will ask you to complete a Site Assessment Form, which
lists all the site information required to create a custom layout. This is the same information
shown in the Zepulator.
Staggered Modules Hybrid Orientation Pyramid Array
Stair-Step Array
Staggered Attachment Points

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4 Layout Concepts
This chapter contains important information on the rules governing Zep Compatible array layouts.
4.1 Drop-In Direction
The PV module drop-in process is specific to Zep Solar hardware designs.
North-South. Roof attachments run along the vertical rafters. Modules are “dropped in” row by
row going upwards, beginning at the Array Skirt, which is nearest to the eave.
NOTE: East-West drop-ins, with the Array Skirt to one side, are not supported for ZS
Comp, except in the rare case where the roof is supported by horizontal purlins
instead of vertical rafters.
Is There a Preferred Portait or Landscape Orientation? ZS Comp can be installed in either
Landscape or Portrait orientation. A Landscape orientation will generally maximize spans in the
East-West direction.
Figure 4.1 Drop-In and Orientation Supported for ZS Comp
Drop-in direction is
down-roof
Portrait
Sideways (East-West) drop-in
direction not supported for ZS
Comp
Landscape
Array Skirt

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ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.
4.2 Fixed Rules
The rules and guidelines described in this section, together with the Span Tables, are important
factors in array design and must be considered when adjusting or customizing array designs.
Installers must be aware of these rules when making field adjustments during installation.
4.2.1 Laws of Spacing and Distance
Maximum Allowable Spacing. The maximum allowable spacing between roof attachment points
is determined by various site-specific and building inputs, which are captured in the Zepulator and/
or the Span Tables.
Maximum Cantilever. The maximum module cantilever distance is always 1/3 of the maximum
allowable spacing.
Module Corner Minimum Distance. Zep Solar hardware such as Leveling Feet and Ground Zeps
must be installed a minimum distance of 2 inches or 50mm from module corners, measured from
the center of the Leveling Foot Rockit.
Figure 4.2 Maximum Spacing, Cantilever, and Corner Distance
Maximum allowable spacing
(site and project specific)
Minimum distance:
2” or 50 mm
Maximum cantilever is 1/3 of the
maximum allowable spacing.