Zepsolar Zep system ii User manual

VERSION 1.0

Zep System II

PV Module Installation Manual

ZEP SYSTEM  INSTALLATION MANUAL

Table of Contents

1.0 > Introduction �� 4

2.0 > Safety Precautions �� 4

2.1 > General Safety �� 4

2.2 > Installation Safety �� 5

3.0 > Zep System II Overview �� 5

4.0 > System Design and Layout �� 8

4.1 > Code Compliance Certiﬁcation and Tables �� 8

4.2 > Array Layout & Bill of Materials �� 10

5.0 > Mechanical Installation �� 13

5.1 > Mechanical Installation Requirements �� 13

5.2 > Mechanical Installation Preparation �� 13

5.3 > Roof Layout Procedure �� 14

5.4 > Prepare Roof for Front Row Leveling Feet �� 15

5.5 > Interlocking the First Module Pair �� 16

5.6 > Wiring and Wire Management �� 17

5.7 > Leveling Foot Installation �� 18

5.8 > Completing the First Row �� 19

5.9 > Leveling the Row �� 20

5.10 > Drop in and Pivot Lock Procedure �� 20

5.11 > Installing Additional Rows �� 22

5.12 > Final Array Wiring and Wire Management �� 23

5.13 > Installing an Interlock at a Thermal Break �� 23

6.0 > Electrical Installation �� 24

6.1 > Electrical Installation Requirements �� 24

6.2 > Grounding System Installation �� 24

7.0 > Maintenance and Troubleshooting �� 26

7.1 > Module Removal Procedure �� 26

8.0 > Technical Support �� 27

9.0 > Limited Warranty �� 28

ZEP SYSTEM  INSTALLATION MANUAL

1.0 > Introduction

This manual details installation procedures for the Zep System II PV Module Installation System

(Zep System II) and provides important safety information that the installer should read carefully

in its entirety prior to installation. Failure to follow these instructions may result in death, bodily

injury or property damage. Correct installation of Zep System II components will ensure reliable

structural connections and proper ground bond means throughout the array and from the array to

the equipment grounding conductor(s).

The components detailed in this manual include the Interlock, the Leveling Foot, the Ground Zep,

the Zep Wire Clip, the Zep Comp Mount and the Zep Compatible Solar Module (Module). The word

“Module” as used in this manual will refer speciﬁcally to a Zep Compatible PV Module – a PV Module

containing the patented Zep Groove frame design licensed by Zep Solar to the PV Module manufac-

turer. All components covered in this manual are protected by US patent #7,592,537 and/or multiple

pending US & International patents.

The Interlock conforms to UL Standard 1703 and is Listed by Intertek (ETL) with Control Number

4000321. The Ground Zep conforms to UL Standard 467 and is Listed by Intertek (ETL) with Control

Number 4000321.

2.0 > Safety Precautions

WARNING: All instructions in this Installation Manual and all instructions in the installation

manual provided by the manufacturer of the Module should be read and understood before at-

tempting to install Zep System II. The installer assumes all risk of personal injury or property

damage that might occur during the installation and handling of the components.

2.1 > General Safety

1. 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.

2. Follow all safety precautions detailed in this Installation Manual as well as the Module instal-

lation manual.

3. Comply with all applicable OSHA or equivalent safety standards including but not limited to the

proper use of regulation fall protection equipment.

4. Do not perform any installations in wet or windy conditions.

ZEP SYSTEM  INSTALLATION MANUAL

2.2 > Installation Safety

1.

Check applicable building codes or refer to 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.

2. Ensure that all lag screws or alternative methods of attachment have adequate pullout strength

and shear capacity for the application.

3. The Zep System must be installed over a ﬁre resistant roof covering rated for its application.

4. The Interlock, Leveling Foot, and Ground Zep should be installed only with the use of the Zep

Tool or Flat Tool provided by Zep Solar.

5. During the installation, wear suitable protection such as non-slip construction gloves to protect

your hands from injury from sharp edges.

6. Do not expose the Modules to excessive loads or deformation such as twisting or bending.

3.0 > Zep System II Overview

Zep System II offers an ultra rapid method for installing and electrically grounding solar arrays. In

addition to the application-speciﬁc attachment hardware, an entire array can be installed with only

three parts — the Interlock, the Leveling Foot, and the Ground Zep. Zep Solar also offers accessory

items such as the Zep Comp Mount and Zep Wire Clip.

Figure 3.0A — Interlock

The Interlock installs in the nominal east-west dimension and

provides both structural and ground bond connections in both

east-west and north-south dimensions.

Figure 3.0B — Leveling Foot

The Leveling Foot installs into the Zep Grooves and resides at

locations along the array’s horizontal seams.

ZEP SYSTEM  INSTALLATION MANUAL

Figure 3.0C — Ground Zep

The Ground Zep rotates into the Zep Groove with a quarter turn

and provides a ground bond connection from the array to the

equipment grounding conductor(s).

Figure 3.0E — Zep Comp Mount

The Zep Comp Mount provides a ﬂashed attachment solution

for composition shingle roofs. Refer to the Zep Comp Mount

Installation Manual for installation instructions.

Figure 3.0D — Zep Wire Clip

The Zep Wire Clip snaps into the Zep Groove and provides a

means for securing array wiring.

ZEP SYSTEM  INSTALLATION MANUAL

Figure 3.0H — Zep System Components in an Array

The array in the ﬁgure above consists of nine (9) Modules, eight (8) Interlocks, twelve (12) Leveling Feet and one (1) Ground Zep.

NOTE: Interlocks and Leveling Feet are always installed on the Module grooves running East-West.

Figure 3.0F — Landscape Orientation Figure 3.0G — Portrait Orientation

Zep systems can be installed in either landscape or in portrait orientation. Typical residential roofs

have a high aspect ratio (length to width). As a result, typical roofs can accommodate larger arrays

when installed in landscape orientation. Landscape installations therefore allow for more efﬁcient

use of space and can be installed faster and with greater spans between Interlocks.

INTERLOCK – 8 XMODULE – 9 X LEVELING FEET – 12 XEAST / WEST

NORTH / SOUTH

ZEP SYSTEM  INSTALLATION MANUAL

Figure 3.0I — Zep Tool Figure 3.0J — Zep Flat Tool

4.0 > System Design and Layout

4.1 > Code Compliance Certiﬁcation and Tables

Zep System II is in compliance with the structural requirements of the 2006 International Building

Code and ASCE 7-05 based on the conﬁgurations and criteria provided in the Certiﬁcation Letter and ac-

companying tables (go to: www.zepsolar.com/resources.html). These tables deﬁne the maximum lev-

eling foot spacing requirements for a range of site-speciﬁc variables including Roof Pitch (Figure 4.1A),

Wind Exposure Category (Figure 4.1B), Basic Wind Speed (www.windspeedbyzip.com or refer to your

local jurisdiction), Roof Zone (Figure 4.1C), and Ground Snow Load (www.groundsnowloadbyzip.com

or refer to your local jurisdiction). The tables assume that the Average Building Height is less than

30 feet (Figure 4.1D), Importance Factor is 1.0 (building is not a special occupancy structure such

as a public school or public safety building), and the Topographic Factor is 1.0 (building is not on a

bluff or near the top of a hill). Once you collect the site conditions for your project location, refer to

the tables in the certiﬁcation letter to determine the maximum allowable spacing between Leveling

Feet. If your site conditions are outside the assumptions above, refer to ASCE 7-05 or contact a

structural engineer for assistance.

An entire Zep array can be interconnected with the use of a single tool. Both the Zep Tool and the Flat

Tool provide means for installing the Interlock, the Leveling Foot, and the Ground Zep. The Flat Tool

provides a low-cost alternative to the Zep Tool and also functions to enable inter-Module removal.

The Zep Tool can receive a T30 Torx bit for adjusting the height of the Leveling Feet.

ZEP SYSTEM  INSTALLATION MANUAL

Figure 4.1A — Roof Pitch

Figure 4.1B — Wind Exposure Categories

Figure 4.1C — Roof Zones – Interior, Edge, Corner Figure 4.1D — Average Roof Height

Ratio-to-Pitch Conversions:

1:12 = 5 deg�

2:12 = 9 deg�

3:12 = 14 deg�

4:12 = 18 deg�

5:12 = 23 deg�

6:12 = 27 deg�

7:12 = 30 deg�

8:12 = 34 deg�

9:12 = 37 deg�

10:12 = 40 deg�

11:12 = 43 deg�

12:12 = 45 deg�

B — Urban/Suburban

C — Open Terrain/Scattered Obstructions

D — Flat, Unobstructed Area

7 DEGREES – 15:12

27 DEGREES – 6:12

45 DEGREES – 12:12

ZEP SYSTEM  INSTALLATION MANUAL

4.2 > Array Layout & Bill of Materials

During the site visit, record information pertaining to the speciﬁc roof area where the Modules will be

mounted. This includes roof azimuth angle, roof pitch, dimensions of the mounting area including all

obstructions such as chimneys or vents, the rafter schedule, rafter lumber type if available, rooﬁng

material, and shading factor. Once you have this information, you can begin to create a layout diagram

on paper or with a drawing program that identiﬁes the placement of the array.

NOTE:

Alternately, you can create your layout directly on the roof at the time of installation.

However, since this method will not allow you to conﬁrm the exact quantity of components

ahead of time, it is recommended that you have extra hardware available to account for

unforeseen layout conﬁgurations.

When determining the overall array dimensions, calculate ½" gaps per every vertical and horizontal

Module seam.

Consider whether to mount the Modules in landscape or portrait orientation. As discussed above,

landscape orientation usually offers an opportunity to ﬁt more kilowatts of PV Modules on a typical

roof. It will also allow for a more economical use of mounting hardware.

Figure 4.2A illustrates the Leveling Feet with circles at the intersections of the Module frame and

the rafters and Interlocks have been indicated with rectangles where the corners of the Modules

intersect.

On your diagram, draw your rafter layout and then superimpose a drawing of your array in its desired

location. Locate an Interlock at every vertical seam in an east-west orientation as in Figure 4.2A.

Then, mark the Leveling Feet locations according to the maximum allowable spacing determined by

your span tables.

NOTE: It is not necessary to install Interlocks along the east and west edges of the array.

If the location of an Interlock prevents locating the Leveling Foot on a desired rafter, shift the

Leveling Foot to the nearest adjacent rafter while maintaining span and cantilever requirements.

This is indicated in Figure 4.2A with dashed circles where Leveling Feet have been relocated to the

left due to an Interlock location conﬂict.

ZEP SYSTEM  INSTALLATION MANUAL

The maximum cantilever at the edge of the array is determined by multiplying the maximum span

by 0.33. In the example below, the span between Leveling Feet is 48” which allows for a maximum

cantilever of 16”. It is recommended that Leveling Feet not be installed within 2” of the corner of the

Module. Therefore, the allowable mounting zone for the last foot in a row (End-Foot Zone) is in an

area within the cantilever allowance not including the last two inches of the Module. On the right side

of Figure 4.2A, the cantilever originally exceeded the allowable value so Leveling Foot (solid circles)

were placed on the rafters closest to the edge of the array to meet the cantilever requirements.

If the maximum cantilever allowance cannot be met by adding another Leveling Foot, it may be

necessary to shift the array to the East or West in order to support the array properly. In Figure 4.2B,

distance A represents the Cantilever Allowance whereas distance B represents the area where a

Leveling Foot can be attached (End-Foot Zone). In Figure 4.2B, example #1 illustrates proper place-

ment, allowing the rafters to meet the cantilever requirements. In example #2, the right side of the

row does not meet the cantilever requirements so the entire array would need to shift a few inches

to the left in order to allow for proper support of the cantilevers.

Figure 4.2A — Identifying Leveling Feet and Interlocks

ZEP SYSTEM  INSTALLATION MANUAL

After the array layout is determined, verify that

thermal and ground bond allowances are not

exceeded. The Zep array requires a thermal

break at every sixth vertical Module seam as

shown in Figure 4.2C. In order to accomplish a

thermal break, the Interlocks installed at the

thermal break must be only partially secured

as per Section 5.13 below. Interlocks installed

in this fashion do not carry the ground bond so

each portion of the array to either side of the

break requires its own Ground Zep as shown in

Figure 4.2C. If the array exceeds 12 Modules

high (per column) an additional thermal and

ground break is required. One Ground Zep is

required for each array portion segmented

by thermal/ground breaks and a ground bond

jumper must be installed between ground

Zeps as described in Section 5.13 below.

Figure 4.2B — Cantilever Allowance

Figure 4.2C — Ground and Thermal Break

NOTE: Having conﬁgured the array, count

the number of Interlocks, Leveling Feet, and

Ground Zeps to create a core components bill

of material.

A = CANTILEVER ALLOWANCE

B = A – 2" (END-FOOT ZONE)

CORRECT

INCORRECT

FOOT LOCATION

END-FOOT ZONE

EDGE OF ARRAY

RAFTERS

END-FOOT ZONE

GROUND & THERMAL BREAK

ZEP SYSTEM  INSTALLATION MANUAL

5.0 > Mechanical Installation

The following instructions and accompanying ﬁgures describe and illustrate the mechanical instal-

lation of Zep System II. For the purpose of illustration, the drawings in this manual assume the use

of Zep Comp Mount attachment hardware. However, Zep System II can be installed with the use

of various application-speciﬁc attachment solutions including the Zep Comp Mount, the Zep Tile

Mount, and various third party products such as S-5! Clips for standing seam metal roofs, hanger

bolts, spanning rails, etc. Refer to the installation manuals of each attachment solution for detailed

installation instructions prior to installing Zep System II. Zep System II can also be installed directly

to a roof surface or a pre-engineered substructure such as a ground-mount support or parking lot

shade structure. When mounting directly to a surface, ensure that proper waterprooﬁng and/or

attachment methods are used.

5.1 > Mechanical Installation Requirements

1.

The array of Modules must be mounted to the roof with Zep Leveling Feet and suitable roof

attachment devices to maintain the waterproof integrity of the roof. The system designer and/

or installer are responsible for load calculations and proper quantity and locations of the Zep

Leveling Feet. Local wind loading and snow loading should be accounted for in the system design.

2. The mounting system design shall comply with all local building codes.

3. A minimum gap of 0.25” between Modules is required to allow for thermal expansion.

4. The Zep System must not be immersed in water or constantly exposed to water spray.

5.2 > Mechanical Installation Preparation

1. Gather all necessary tools for the Zep System installation including the following:

a.

Zep Tool and/or Zep Flat Tool for installing and removing Interlocks, Leveling Feet, and

Ground Zeps on the Zep Groove.

b. T30 Torx bit (comes with Zep Tool) for Leveling Foot height adjustment.

c. Flat bladed screwdriver for fastening the equipment grounding wire to the Ground Zep.

d. Chalk Line and tape measure to mark the Module layout and roof rafter positions.

e.

Power drill with pilot drill bit and impact driver to properly fasten lag screws to the structural

support members.

2.

Supply all installation personnel with appropriate safety gear including personal protection

equipment (eye protection, footwear, hard hat, etc.) and fall protection gear (harness, anchor,

rope or retractable lanyard, etc.)

ZEP SYSTEM  INSTALLATION MANUAL

3.

Ensure you have received all the necessary system components based on the system design

drawings.

4. Collect the design drawings and structural design calculation results to determine the location

of the array and the attachment points based on the site conditions

5.3 > Roof Layout Procedure

1. Determine the exact roof location and layout for the Modules and Zep Leveling Feet as speciﬁed

in the design drawings. It is the responsibility of the installer to verify that the roof structure is

adequate for the system design.

2.

Mark the perimeter of the array to verify that the location of the array is consistent with the design

drawings and conﬁrm that the array will not be unnecessarily shaded (Figure 5.3A).

3. Locate the rafters and snap chalk lines to identify their locations (Figure 5.3B).

4. Snap a chalk line across the lower edge of the array to establish the relative location of the lower

edge of the array. (Figure 5.3C).

NOTE: Depending on the attachment solution being utilized, the chalk line may represent

various possible alignment points. For instance, with the Zep Comp Mount, this line will

represent the lower edge of the ﬂashing whereas with a direct mount installation the lower

chalk line will determine the location of the “toe” of the front row Leveling Feet.

5. Mark the intersection of the lower edge chalk line and the rafter marks where Zep Leveling Feet

will be installed per the approved system design.

6.

Conﬁrm that Leveling Foot locations will not interfere with the placement of the Interlocks.

Modify Leveling Foot locations as needed (refer to design drawing).

Figure 5.3A Figure 5.3B Figure 5.3C

ZEP SYSTEM  INSTALLATION MANUAL

5.4 > Prepare Roof for Front Row Leveling Feet

For the front row, Leveling Feet are oriented with the “toe” facing down roof (for all other rows, the

“toes” face up-roof). Once the location of the front row Leveling Feet have been identiﬁed, mark and

then drill pilot holes in the locations where the lag screws will attach to the roof. For a direct mount

installation, this will be the lag that is installed through the oval slot of the Leveling Foot. Use a

stainless steel lag screw (" shaft with sufﬁcient thread depth to satisfy the uplift point load force

requirements) along with a fender washer. For other attachment methods, see product instructions

for proper installation procedures.

NOTE: DO NOT secure the Leveling Foot to the roof or attachment hardware at this time.

The Leveling Foot must be installed in the Module grove prior to securing to the roof or

attachment hardware.

NOTE: If using accessory roof attachment hardware such as Zep Comp Mount, the Zep

Tile Mount, and various third party products such as S-5! Clips for standing seam metal

roofs, hanger bolts, spanning rails, etc., it may be desirable to install all of the attachment

hardware prior to the installation of the Module array. In this case, it is important to

determine the north-south spacing of attachment points as follows (Figures 5.4A, 5.4B):

Landscape Orientation: Row 1 to Row 2 = Module width + ⅝" + 3"

Row 2 to Row X = Module width + ⅝" (same for all other rows)

Portrait Orientation: Row 1 to Row 2 = Module length + ⅝" + 3"

Row 2 to Row X = Module length + ⅝" (same for all other rows)

Figure 5.4A Figure 5.4B

ZEP SYSTEM  INSTALLATION MANUAL

All measurements are from the center of the accessory roof attachment hardware that will attach

to the center of the Leveling Foot slot. The measurement between Row 1 and Row 2 requires an

additional three (3) inches to account for the fact that the leveling feet face down roof on the ﬁrst

row and up roof on all other rows (Figure 5.4B)

5.5 > Interlocking the First Module Pair

1. Bring the ﬁrst two Modules on the roof and set them down end-to-end in landscape orientation

or side-to-side in portrait orientation near the SW or SE area of the array (Figure 5.5A). These

instructions assume that you are starting at the SW corner of the array area. Module junction

boxes should be oriented per system design to allow for ease of Module interconnections.

2.

Insert the Interlock Assembly in the bottom groove between the Module pair, spacing the Modules

½ inch apart using the two outside alignment marks on the Interlock Assembly (Figure 5.5B).

NOTE: It is generally much easier if you DO NOT pick up the Modules, but rather leave them

on the roof and insert the Interlock by holding the tongues of the Interlock Zeps.

Figure 5.5A Figure 5.5B

Figure 5.5C — Step 1 Figure 5.5D — Step 2 Figure 5.5E — Step 3

ZEP TOO L AT MARK 2 ZEP TOOL AT MARK 3

ZEP ALIGNMENT MARKS ZEP ALIGNMENT MARKS

ZEP TOOL AT MARK 3

ZEP ALIGNMENT MARKS

ZEP SYSTEM  INSTALLATION MANUAL

The Zep Tool is designed to engage and rotate to positions labeled 1, 2, or 3 based on the

alignment of the mark on the Interlock with the numbered alignment marks on the Zep

Tool. Engage the Zep Tool on one of the Interlock Zeps in position #1 then use the Zep Tool

to turn the Interlock Zep clockwise until Alignment Mark #2 on the tool is lined up with the

alignment mark on the Interlock (Figure 5.5C). Next, turn the other Interlock Zep clockwise

a full ¼ turn until Alignment Mark #3 is lined up with the alignment mark on the Interlock

(Figure 5.5D). Lastly, engage the Zep tool on the ﬁrst Interlock Zep and continue to turn

clockwise until Alignment Mark #3 is lined up with the alignment mark on the Interlock

(Figure 5.5E)

NOTE: It is important to NOT over or under-rotate the Interlock Zep since the drop-in action

on the tongues (when installing the next row above) may be difﬁcult unless both Interlock

Zeps are properly aligned.

3. Repeat the Interlock installation (Steps 1 – 3) on the upper edge of the Module pair.

5.6 > Wiring and Wire Management

1. Connect the Module leads together according to the system design drawing once the Modules

have been connected with an Interlock.

2. Use Zep Wire Clips to properly manage series and home run wires while protecting them from

damage. Insert the Zep Wire Clip into the Module groove (Figure 5.6A) then lay the conductors

Figure 5.6A Figure 5.6B

into the wire clip housings so that they are properly secured (Figure 5.6B).

3. Continue to connect and manage Module leads as new Modules are installed.

ZEP SYSTEM  INSTALLATION MANUAL

5.7 > Leveling Foot Installation

1. With two installers, one above and one below the Module pair, load a Leveling Foot into the Zep

Tool (Figure 5.7A). Use the array perimeter marking and the rafter chalk line to identify where to

place the Module and Leveling Foot according to the system design. Both installers should then

simultaneously insert their Leveling Foot into the bottom and top of the Module groove, key ﬁrst

(See Figure 3.0B), at the 3 o’clock position (Figure 5.7B).

NOTE: There is no need to measure exactly where to insert the Foot Zep: just “eyeball”

the location approximately above the rafter or attachment device. If you are off by a small

margin, you can swing the base of the Foot to align it with the rafter location.

Figure 5.7A

Figure 5.7C

Figure 5.7B

Figure 5.7D

ZEP SYSTEM  INSTALLATION MANUAL

2.

Use the Zep Tool to rotate the Leveling Foot 90° clockwise until the base of the foot is parallel with

the roof surface (Figure 5.7C). With the fastener appropriate to mounting method being utilized,

secure the Leveling Foot to the mounting surface or attachment hardware.

NOTE: It is important to NOT over or under-rotate the Leveling Foot since the drop-in

action on the tongue for that Leveling Foot may be difﬁcult unless the stud is oriented

perpendicular to the Module frame.

5.8 > Completing the First Row

1. Lay out the next Module on the roof spaced ½" from the previously attached Module pair.

2. Attach the Leveling Foot Zep to the Module groove on top and bottom of the frame immediately

above the attachment point to the roof or attachment hardware and loosely secure the Leveling

Feet to the roof (Fig. 5.8A).

3. Install the Interlocks where the Modules join in the East-West direction on the top and bottom

of the row (Figure 5.8B). Tighten the lower Leveling Foot to the roof or attachment hardware.

4. Repeat for the remaining Modules in the ﬁrst row.

Figure 5.8A Figure 5.8B

ZEP SYSTEM  INSTALLATION MANUAL

5.9 > Leveling the Row

1. Once the row has been completed, attach all the Leveling Feet on the upper row to the roof or to

their respective attachment hardware.

2. Next, use a laser level, string line or careful eye to determine if height adjustment is necessary

(Figure 5.9A). Use the Zep Tool or a drill with a T30 Torx bit to raise (counter-clockwise) or lower

(clockwise) the height at the Leveling Foot (Figure 5.9B).

Figure 5.9A

Figure 5.10A

Figure 5.9B

Figure 5.10B

5.10 > Drop in and Pivot Lock Procedure

1.

Moving up to the next row, rest the edge of the next Module on the top of the Foot Zeps (Figure 5.10A).

In order for the Zep tongue to fully seat into the Module groove, the Module should cover about

half of the top of the foot stud prior to starting the drop in and pivot lock procedure (Figure 5.10B).

ZEP SYSTEM  INSTALLATION MANUAL

2.

Lower the Module grooves onto the Zep Tongues and rotate downward, applying pressure toward

the tongues when the Modules reach an angle of approximately 15 degrees from the roof (Figure

5.10C and Figure 5.10D).

Figure 5.10C

Figure 5.10E

Figure 5.10D

Figure 5.10F

3. Proceed to lower all the way to the surface of the roof while continuing to apply pressure toward

the tongues (Figure 5.10E and Figure 5.10F). If the newly installed Module does not fully seat into

the Zeps, bring it back up to 15 degrees and apply pressure once again to fully seat it.

NOTE: Zep System II has been designed to take up tolerance from Module to Module so

the Zep Groove may engage the tongue at varying depths in order to allow for tolerance

take up and/or slight Module rotation to maintain overall squareness of array.

ZepSolar ZEP SYSTEM II User manual

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