Doc Number 801-00016, Version 2.0, Copyright © 2010 Zep Solar, Inc. PAGE: 7 of 23
ZEP SYSTEM INSTALLATION MANUAL
solid conductive bond. When an adjacent module’s groove is dropped onto the Tongue side of the
Interlock Zep, the Tongue too cuts through the frame’s anodized coating to create a solid conductive
bond. This bond may be reversed and reset up to 50 times with no significant degradation of the
ground bond connection.
How Does Zep System II Adapt to Variable Conditions?
Roofs and other mounting surfaces are not perfect planes. And because they are often not perfectly
square, it is difficult to establish reference points from which to perfectly orient each module. Also,
PV module outside-dimensions do not always perfectly match their mechanical specifications and
are often not identical to each other. In essence, the installer’s job is to mount a perfect-looking
array on an imperfect structure using imperfect PV modules. In conventional systems, slight module
misalignments or dimensional deviations force the misalignment of adjacent modules so that these
slight misalignments are compounded throughout the array. The larger the array, the more difficult
it is to counter this problem. Unlike rail-based systems, Zep System II PV arrays can be precisely
installed square and in a level plane with very little effort required to achieve that goal. This is ac-
complished through built-in flexibility in the X, Y, and Z axes.
> Module Positioning is Flexible (X, Y-axis Adjustability)
With Zep System II, X and Y-axis flexibility is possible because each module can be set slightly off-
axis to account for the above mentioned variables. By making minor adjustments at the module level,
the installer can keep the array in alignment with system-level reference points such as a lower-edge
chalk line and by sighting along seams and edges to keep the array “looking good.” This freedom
allowed in the positioning of PV modules is a result of a unique system feature as described below.
Interlocks, Hybrid Interlocks, and Leveling Feet all contain tongues that mate with the Zep Grooves
of Zep Compatible PV modules. A defining characteristic of the tongue-to-groove connection is that
the tongue can seat at variable positions with respect to the groove – i.e. the tongue can be fully or
partially pushed into the groove and still accomplish a solid structural and ground bond connection.
Because of this freedom, a module can be rotated slightly out of axis – thus allowing for independent
module-level adjustments.
> PV Array Can be Easily Leveled (Z-axis Adjustability)
Zep System II PV arrays can be easily leveled by rotating the studs of the Leveling Feet. The Leveling
Feet can be adjusted up or down over a range of 1 ¼” in order to achieve a perfect-looking array.
How Do Zep System II Components Mate?
Whereas Zep System II is flexible in order to adapt to variable conditions, it also employs specific
