ZepSolar ZS Span User manual

ZS Span™
Installation Manual for Rail-Based Applications - U.S.
Document #800-0329-001 Rev F
File Generated July 3, 2013

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ZS SPAN INSTALLATION MANUAL FOR RAIL-BASED APPLICATIONS - U.S.
Notices
This manual contains safety, installation, configuration and troubleshooting instructions for ZS
Span. Zep Solar, Inc. recommends that you save this manual in a readily accessible location,
should any questions arise regarding ZS Span.
Copyright and Trademark Information
Copyright © 2012, 2013 by Zep Solar, Inc. All rights reserved.
ZEP™, ZS Comp™, ZS Aero™, ZS Seam™, ZS Trap™, ZS Wave™, ZS Span™, ZS Tile™, and the Zep
logo are trademarks of Zep Solar, Inc. Zep Solar® is a registered trademark 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.

© 2013/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved.
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ZS SPAN INSTALLATION MANUAL FOR RAIL-BASED APPLICATIONS - U.S.
Contents
1 Introduction ___________________________________________________________1
1.1 ZS Span Overview...................................................................................................................................................................1
1.2 General Safety Precautions ................................................................................................................................................2
1.3 Zep Compatible™ ................................................................................................................................................................... 3
2 ZS Span Components __________________________________________________ 5
2.1 ZS Span Cutaway View........................................................................................................................................................ 5
2.2 ZS Span Core Components ................................................................................................................................................ 6
2.3 ZS Span Accessory Components..................................................................................................................................... 8
2.4 ZS Span Tools .......................................................................................................................................................................10
3 Array Design_________________________________________________________ 11
Step 1: Gather Project Data ............................................................................................................................................... 11
Step 2: Obtain Spacing and Cantilever Allowances.................................................................................................. 12
Step 3: Create Array Layout and Bill of Material....................................................................................................... 13
3.1 Using the Zepulator Online Design Tool .....................................................................................................................14
3.2 Using the Span Tables....................................................................................................................................................... 16
3.3 Alternative Layout Possibilities...................................................................................................................................... 17
4 Layout Concepts _____________________________________________________ 19
4.1 Drop-In Direction.................................................................................................................................................................19
4.2 Engineering Rules................................................................................................................................................................20
4.3 Grounding/Earthing.............................................................................................................................................................25
4.4 Thermal Expansion ............................................................................................................................................................. 27
4.5 Roof Zones..............................................................................................................................................................................30
5 Installation Process __________________________________________________ 33
Step 1: Mark Out Array Layout on Roof.........................................................................................................................34
Step 2: Install Roof Attachments ...................................................................................................................................35
Step 3: Ground Prep ..............................................................................................................................................................36
Special Inset: Spanner Bar 1x 3x 4x Lengths..........................................................................................................39
Step 4: Attach Spanner Bars .............................................................................................................................................40
Step 5: Install Array Skirt ..................................................................................................................................................42
Special Inset: Grip Installation.....................................................................................................................................46
Step 6: Install First Row of Modules..............................................................................................................................47
Special Inset: Interlocks.................................................................................................................................................53
Special Inset: Wire Management .................................................................................................................................55

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ZS SPAN INSTALLATION MANUAL FOR RAIL-BASED APPLICATIONS - U.S.
Step 7: Complete the Array................................................................................................................................................57
Step 8: Ground the Array.....................................................................................................................................................58
Special Inset: Installing Side Skirt and Corner Caps...........................................................................................59
Special Inset: Universal Box Brackets and Other Accessories.........................................................................62
6 Installation Supplement ______________________________________________ 63
6.1 Servicing an Array................................................................................................................................................................63
6.2 Array Skirt Options..............................................................................................................................................................65
6.3 Removing the First-Row Array Skirt ............................................................................................................................68
6.4 Hybrid Interlocks................................................................................................................................................................. 71
6.5 Backwards Compatibility ..................................................................................................................................................73
Special Inset: Component Versioning ........................................................................................................................74
Special Inset: Interlock Versions and Alignment Marks ....................................................................................76
Special Inset: Array Skirt Version Compatibility.................................................................................................... 77
Special Inset: Array Skirts and Caps ..........................................................................................................................78
7 Regulatory Information _______________________________________________ 79
7.1 UL and ETL Listings............................................................................................................................................................79

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Document #800-0329-001 Rev F File Generated July 3, 2013 Page 1
1 Introduction
ZS Span™, from Zep Solar, Inc., is an integrated roof mounting solution for installing PV arrays on tile roofs. ZS
Span offers the following benefits: rapid installation, reduced roof penetrations, reduced parts count, low sys-
tem weight, precision alignment, enhanced aesthetics, resistance to theft, redundant auto-grounding hardware,
portrait and landscape options, and an easy-to-use design tool with array-level BOM calculations.
1.1 ZS Span Overview
Figure 1.1 ZS Span for Tile Roofs

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ZS SPAN INSTALLATION MANUAL FOR RAIL-BASED APPLICATIONS - 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.
• 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.
• 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
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 earthed 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 58.

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ZS SPAN INSTALLATION MANUAL FOR RAIL-BASED APPLICATIONS - 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. Please visit www.zepsolar.com for an updated
list of Zep Compatible partners.
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
Key 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
Tongue side
Zep Compatible PV module
Rockit
In the next row, modules are “dropped in” on the Tongue side (the receiving
side). Each Tongue provides an in/out adjustability with the Zep Groove, allow-
ing for optimized placement of each module.
1
First, the Key side of the Rockit
is inserted into the Zep Groove.
2 3 4

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ZS SPAN INSTALLATION MANUAL FOR RAIL-BASED APPLICATIONS - 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
Auto Grounding. The Key and Tongue sides of Rockits and Interlocks establish an electrical
bonding connection between both modules and other Zep Solar components such as the Array
Skirt. The rotation of the Key side into the Zep Groove, and the rotation of the next row of PV mod-
ules onto the Tongue side, acts to establish an equipotential bond for all UL listed components by
cutting through the surface coating (tested for both anodized and painted coatings) on the Zep
Groove.
Note: All components shown as UL Listed to UL 2703 are listed for bonding.
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 53 for more information on the Interlock.

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2 ZS Span Components
2.1 ZS Span Cutaway View
Cam Foot
Array Skirt
Adjustable Mighty Hook
Zep Groove
Ground Zep
Corner Cap
T-Lock
Spanner Bar
Spanner Clamp
Interlock

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ZS SPAN INSTALLATION MANUAL FOR RAIL-BASED APPLICATIONS - U.S.
2.2 ZS Span Core Components
Cam Foot
Interlock
Provides a structural and electrical bond between
modules. See “Backwards Compatibility” on page 73
for additional information regarding Interlock
versions.
Listed by UL to UL 2703.
Secures PV Modules to the Spanner Bar, and
enables fine-tuned leveling. Create an electrical
bond between modules on both Key and Tongue
sides. Also creates bond with Spanner Bar.
Listed by UL to UL 2703.
Part No. 850-1388
Part No. 850-1413
Hybrid Interlock
Ground Zep
Used on Cam Foot base where the Cam Foot location
conflicts with the installation of an Interlock. Creates
electrical bond between modules on both Key and Tongue
sides.
Listed by UL to UL 2703.
Provides a single point for grounding/earthing
the PV Array. One Ground Zep can ground an
array up to 33 x 33 feet.
Listed by UL to UL 467 and UL 2703. ETL
listing conforms to UL STD 467.
Part No. 850-1281
Part No. 850-1172