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ZEP SOLAR ZS Comp Installation Manual

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

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Summary of Contents for ZEP SOLAR ZS Comp

  • Page 1 ZS Comp Installation Manual for Composition Shingle Roofs - U.S. Document #800-0351-001 Rev B...
  • Page 2 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.

  • Page 3: Table Of Contents

    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. www.zepsolar.com Document #800-0351-001 Rev B Page i...
  • Page 4 Interlock Versions and Spacers Used ................... 51 Special Inset: Hybrid Interlocks...........................52 Regulatory Information _______________________________________________ 55 UL and ETL Listings................................55 © 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 ii...

  • Page 5: Introduction

    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.

  • Page 6: General Safety Precautions

    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. www.zepsolar.com Document #800-0351-001 Rev B Page 2...

  • Page 7: Zep Compatible

    First, the Key side of the Rockit is side). inserted into the Zep Groove. © 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 3...
  • Page 8 Rotation seen from Key side Zep Groove. “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. www.zepsolar.com Document #800-0351-001 Rev B Page 4...

  • Page 9: Zs Comp Components

    Ground Zep Leveling Foot Zep Compatible PV Module Zep Groove Roof Attachment Array Skirt © 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 5...

  • Page 10: Zs Comp Core Components

    Listed by UL to UL 467 and UL 2703. ETL listing conforms to UL STD 467. © 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 11: Zs Comp Accessory Components

    * Please visit the Zep Solar web site at for additional accessories and information. © 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 7...

  • Page 12: Zs Comp Tools

    Leveling Foot height. In addition, the Flat tool performs one additional function: • Remove Interlock from between two modules © 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 13: Array Design

    Array Design Zep Solar, Inc. seeks to encourage efficient design of PV arrays by allowing users to design their own systems. The Zepulator online design tool and Span Tables are available on the Zep Solar web site to enable custom array designs.

  • Page 14: Step 2: Obtain Spacing And Cantilever Allowances

    Zepulator does not include hardware pricing, since that may depend on the distribution channel and other factors. © 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 15: Using The Zepulator Online Design Tool

    Bill of Material and spacing Engineering Calculations. © 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 11...
  • Page 16 Hybrid Interlocks in Additional Truck Stock to ensure adequate hardware supply if needed. © 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved. www.zepsolar.com...

  • Page 17: Using The Span Tables

    Wind speed Snow load Roof zone Terrain exposure category Maximum allowable span © 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 13...

  • Page 18: Alternative Layout Possibilities

    This is the same information shown in the Zepulator. © 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved. www.zepsolar.com...

  • Page 19: Layout Concepts

    Drop-in direction is down-roof Array Skirt Portrait Sideways (East-West) drop-in direction not supported for ZS Comp © 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 15...

  • Page 20: Fixed Rules

    Minimum distance: 2” or 50 mm Maximum cantilever is 1/3 of the maximum allowable spacing. © 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 16...
  • Page 21 Figure 4.4 Standalone Module Installation Portrait Landscape Leveling Foot © 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 17...

  • Page 22: Grounding/Earthing

    Ground Zep on either side of the column and a copper conductor wire between the two, in order to bond the two electrically isolated sub-array sections. © 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved. www.zepsolar.com...

  • Page 23: Thermal Expansion

    This allows the modules some added flexibility to expand in the direction that the Interlocks are running. In the other direction (North-South in the case of ZS Comp), a physical gap is required to allow for thermal expansion of the modules. Generally, a gap of at least 12” between sub-arrays is recommended, both for thermal expansion and to allow access by work crews for module ser- vicing.
  • Page 24 At a minimum, the gap should be at least 4 inches or 100 mm. However, a gap of 12 inches or 300 mm is recommended for ease of servicing. © 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved. www.zepsolar.com...
  • Page 25 Figure 4.9 North-South Drop-In, Thermal Expansion East-West Recommended physical gap 12” Thermal Array Skirt Expansion Recommended Joints physical gap 12” © 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 21...

  • Page 26: Roof Zones

    Engineering Certification Letter and Span Tables document that is appropriate for the project location. © 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved. www.zepsolar.com...

  • Page 27: Installation Process

    Installation Process ZS Comp for Composition Shingle Roofs Mounting Solution for Solar Arrays © 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 23...

  • Page 28: Step 1: Mark Out Array Layout On Roof

    Leveling Foot PV Module Module width + 1/2 inch Comp Mount 1/2” gap Leveling Foot © 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 24...

  • Page 29: Step 2: Install Roof Attachments

    Ensure proper waterproofing measures and use of properly rated sealant. CHECKPOINT: Roof Attachments (Comp Mounts not shown to scale) © 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 25...

  • Page 30: Step 3: Secure And Align Front-Row Leveling Feet

    Secure outer Leveling Feet first. Ensure proper orientation of the Rockit. The Tongue side should face up-roof. © 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 26...
  • Page 31 Spin the Rockit to adjust Leveling Foot height up or down within Allowable range is as shown. the allowable range. © 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 32: Step 4: Install Array Skirt

    Marks farthest allowable range of module edge when sliding Interlock to accommodate Tongue side a nearby Leveling Foot © 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 28...
  • Page 33 Spacer. (closed) while rotating next section of Array Skirt into place on the front-row Leveling Feet. © 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 34 Array Skirt End Caps attach on either end of the completed Array Skirt. (The End Caps are optional accessory components.) © 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved. www.zepsolar.com...
  • Page 35 Spacer for the mid-section Interlock. If there are an uneven number of modules in the first row, one Array Skirt section must be cut to match the front edge of the array. © 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved. www.zepsolar.com...

  • Page 36: Step 5: Install First Row Of Modules

    Leveling Feet towards Leveling Feet to seat the module completely. and Interlocks. Frame engages at 15 degrees. © 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 37 When removing a module from a Leveling Foot, first pull the module out of CAUTION: seat and then lift module upwards. See “Installation Supplement” on page 47. © 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 33...
  • Page 38 Comp Mount by eye.  frame. Do not attach the Leveling Foot base until the next step. © 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 34...
  • Page 39 Note: If the Interlock Zeps are showing, the Interlock is positioned too far to one side. © 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 40 Leveling Feet the rest of the array true. as needed. © 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 36...
  • Page 41 Manage Wires Using Cable Clips “Wire Management” Cable Clips page 41. CHECKPOINT: First Module Row North-South drop-in © 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 37...

  • Page 42: Special Inset: Interlocks

    Part No. 850-1388 Center point Tongue side Placement Between Modules Centered Shifted right Shifted left © 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 38...
  • Page 43 An over-turned Interlock Zep will interfere with the drop-in of the next NOTE: row of modules. © 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 44: Special Inset: Flexible Positioning

    Please refer to the Zep Solar Engineering Certification full slot range Letter for full details. © 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 40...

  • Page 45: Special Inset: Wire Management

    DC Cable Clip back and forth. To release, press the top of the loop. © 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 41...
  • Page 46 Method B. © 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved. www.zepsolar.com...

  • Page 47: Step 6: Complete The Array

    38 for details. Portrait orientation is also supported for ZS Comp. NOTE: © 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 43...

  • Page 48: Step 7: Ground The Array

    Thermal Expansion Joints, a Ground Zep is required on both sides of the break. See “Thermal Expansion” on page 19. © 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 44...

  • Page 49: Special Inset: Universal Box Brackets And Other Accessories

    Ground Wire Universal Box Bracket * See the Zep Solar web site for additional information and accessories. © 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 50 Z S C O M P I N S T A L L A T I O N M A N U A L F O R CO M P O S I T I O N S H I N G L E R O O F S - U . S . © 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved.

  • Page 51: Installation Supplement

    3. Detach Leveling Foot base. 4. Remove Leveling Foot from module frame. 5. Disconnect wires from module to be removed. © 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 52 Hybrid Interlock in place. Slide the Interlock out from between modules. Tap gently with the Flat Tool if needed. © 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 53: Removing The Array Skirt

    6. Re-install and secure the Interlock with the Key side facing inwards. Do not use the Array Skirt Spacer. © 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 54: Product Notes

    1/2” gap between modules. 1/2” gap between modules Part No. 850-1388 range © 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 50...

  • Page 55: Special Inset: Interlock Versions And Spacers Used

    Part No. 850-1402 Part No. 850-1178 Profile No. 500-0104 only Part No. 850-1402 Part No. 850-1388 © 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 51...

  • Page 56: Special Inset: Hybrid Interlocks

    Hybrid Interlock is available in selected regions, and the Grounding Hybrid Interlock does create a bonding path across modules.) © 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 57 Hybrid Interlock to the PV module frame Rockit minimum 2 inches from module corner. or Array Skirt. © 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 58 When attaching to an Array Skirt, insert 2 Jams into the holes so that each Jam touches one of the Array Skirt sections. Do not use Jams when attaching to modules. © 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved. www.zepsolar.com...

  • Page 59: Regulatory Information

    Canadian Standards Association (CSA) - These items appear as “Certified to ULC ORD STD…” or “Certified to CSA STD…” © 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 60 SKU. **UL 2703 certification testing was performed for Grounding Leveling Foot with a torque value of 25.5 ft-lbs. © 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved. www.zepsolar.com...
  • Page 61 Z S C O M P I N S T A L L A T I O N M A N U A L F O R CO M P O S I T I O N S H I N G L E R O O F S - U . S . © 2012/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved.
  • Page 62 Zep Solar, Inc. www.zepsolar.com 161 Mitchell Blvd., Suite 104 P (415) 479-6900 San Rafael, CA 94903 F (415) 479-6901 YOUR ZEP SOLAR DISTRIBUTOR SOLIGENT 800-967-6917 www.soligent.net...

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