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Summary of Contents for ZepSolar Zep System II
- Page 1 V ERS I ON 2. 0 Zep System II use this manual for Zep Systems that use Type B leveling PV Module Installation Manual Foot (ZS-lFB)
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Page 2: Table Of Contents
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Page 3: Introduction
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. -
Page 4: Installation Safety
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. Zep Solar PV arrays are installed without the use of rails and therefore greatly simplify the process of installation. -
Page 5: Components Overview
ZEP SYSTEM II INSTAllATIoN MANuAl 3.1 > Components Overview LEVELING ADJUSTMENT POINT MODULE ALIGNMENT MARKS “KEY SIDE” ROCKIT “TONGUE SIDE” KEY SIDE ZEP TOOL ALIGNMENT MARK MOUNTING SLOT “TONGUE SIDE” FLANGE INTERLOCK ZEP FOOT BASE Figure 3.1A — Interlock Figure 3.1B — leveling Foot... -
Page 6: Zep System Ii Basics (Theory Of Operation)
(4) it employs unique and precise mating techniques for joining components. How is a Zep System II Array Supported? Chief among Zep System II’s distinctions is that it installs without the use of mounting rails by creating structural bonds between modules through the mating of Interlocks to the corner locations of each module’s frame. - Page 7 > 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.
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Page 8: System Design
4.0 > System Design 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 with accompanying span tables (www.zepsolar.com/resources.html) and also the Zep Solar web-based... -
Page 9: Determine Method For Calculating Design Loads
ZEP SYSTEM II INSTAllATIoN MANuAl the certification letter or enter your variables in the Zepulator to determine the maximum allowable spacing between Leveling Feet. If your site or building conditions are outside the assumptions on the span tables or outside the allowable ranges on the Zepulator, refer to ASCE 7-05 or contact a structural engineer for assistance. - Page 10 ZEP SYSTEM II INSTAllATIoN MANuAl specific site of your project. Exposure Category The exposure of a building is based on ground surface roughness that is determined from natural topography, vegetation and construction facilities. Select the most appropriate exposure category as defined by ASCE 7-05.
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Page 11: Gather Building Information
As a starting point for creating your array layout, determine the module manufacturer and model and the length and width of that module. Next, determine number of modules, row/column configura- tion, and module orientation. Zep System II arrays can be installed in both lasscape and portrait orientations. - Page 12 ZEP SYSTEM II INSTAllATIoN MANuAl After determining allowable span and cantilever, layout the locations of the Leveling Feet accordingly. The maximum cantilever at the edge of the array is determined by multiplying the maximum span by 0.33. In the example below, the maximum foot spacing is 48” which allows for a maximum cantilever of 16”.
- Page 13 ZEP SYSTEM II INSTAllATIoN MANuAl Calculate Bill of Material After confi guring the components, count each component to create a bill of material. Note: Often times the actual roof dimensions and rafter or purlin schedules differ from the information collected during the site visit and layout modifi cations are necessary.
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Page 14: Mechanical Installation
ZEP SYSTEM II INSTAllATIoN MANuAl 5.0 > Mechanical Installation This section details the procedure for installing a Zep System II PV array. For illustration purposes, the fi gures show the use of the Comp Mount fl ashed attachment solution. However, this section does not intend to provide instructions on how to install the Comp Mount. - Page 15 ZEP SYSTEM II INSTAllATIoN MANuAl Step 1: Array Layout 1. Visit: www.zepsolar.com, and click the “Zepulator” link in the upper, right-hand corner, to access the Zepulator online design tool. The Zepulator will assist with your layout design, specify attachment-point span and cantilever allowances, and generate a bill of materials for your project.
- Page 16 Leveling Feet installed on Comp Mount fl ashings. For complete instructions on layout and installation procedures for Comp Mounts, see the Comp Mount Instructions on the Resources page of the Zep Solar website at: www.zepsolar. Leveling Foot com/resources.html Step 3: Install Array Skirt (If you do not wish to use the Array Skirt, couple the fi rst two modules together along their upper and lower edges following the interlocking procedure on Page 19.
- Page 17 ZEP SYSTEM II INSTAllATIoN MANuAl With the Spacer between Attach these sections to the Attach additional sections the Array Skirt and the front row leveling feet by rest- by butting the joints together, Interlock, interlock the fi rst ing on the key and rotating...
- Page 18 ZEP SYSTEM II INSTAllATIoN MANuAl Step 4: Install First Row of Modules STANDARD IF TIGHT, USE TOOL Drop the fi rst module into After dropping in the fi rst module, install a Leveling Foot along place by setting the Groove the upper edge of the module over the attachment point.
- Page 19 ZEP SYSTEM II INSTAllATIoN MANuAl Step 5: Interlock Installation The Interlock provides north-south and east- west structural and grounding connections, INTERLOCK ZEPS creating a structurally contiguous, hyper-bonded array. ETL listed to UL 1703. Estimating a ½" gap between modules, engage With Interlock engaged into Module groove, Interlock into groove at an angle.
- Page 20 ZEP SYSTEM II INSTAllATIoN MANuAl Step 6: Install Remaining Modules Install each additional module along the fi rst row. Add Leveling Feet along the top edge of each module and an Interlock at each north-south seam as before. After completing the fi rst row, check that the array is level and adjust the elevations of the Leveling Feet as needed according to the instructions below.
- Page 21 ZEP SYSTEM INSTALLATION MANUAL Step 7: Grounding To connect the array to a grounding system, install a Ground Zep in the Zep Groove of a module. Install one Ground Zep for every section of array that is not conductively isolated by a thermal expansion joint (up to 72 modules per Ground Zep).
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Page 22: Limited Warranty
ZEP SYSTEM II INSTAllATIoN MANuAl 6.0 > Limited Warranty What is Covered: ZEP SOLAR, INC., a California corporation, (called “Zep Solar”) with its principal place of business located at 161 Mitchell Blvd., Suite 104, San Rafael, California 94903 war- rants to the original retail purchaser (called “Purchaser”) of Zep Solar’s solar panel rack products, manufactured by Zep Solar,... - Page 23 ZEP SYSTEM II INSTAllATIoN MANuAl This Warranty does not cover damage to the Products that occurs during shipment, storage, or installation. This Warranty shall be VOID if the Product is not installed in accordance with Zep Solar’s written installation instructions, if the Products are installed in an environment for which they were not designed, or if the Products have been modified, repaired, or reworked in a manner not previously authorized by Zep Solar in writing.
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