ZepSolar ZS Comp User manual

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

© 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved.
www.zepsolar.com
Document #800-0351-001 Rev B Page 2
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.

© 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved.
www.zepsolar.com
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

© 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved.
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Document #800-0351-001 Rev B Page ii
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

© 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved.
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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

© 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved.
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Document #800-0351-001 Rev B Page 2
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.

© 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved.
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Document #800-0351-001 Rev B Page 3
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

© 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved.
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Document #800-0351-001 Rev B Page 4
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.

© 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved.
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Document #800-0351-001 Rev B Page 5
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

© 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved.
www.zepsolar.com
Document #800-0351-001 Rev B Page 6
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
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