Summary of Contents for SolarCity ZepSolar ZS Peak
- Page 1 Installation Instructions Document #800-1600-001 Rev B Date last exported: April 14, 2015 12:27 PM...
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Page 2: Notices
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Notices This manual contains safety, installation, configuration and troubleshooting instructions for Zep Solar products. Zep Solar recommends that you save this manual in a readily accessible location, should any questions arise. Copyright and Trademark Information Copyright ©... -
Page 3: Table Of Contents
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Contents Notices ........... . Introduction . -
Page 4: Introduction
Introduction This document describes basic installation procedures for ZS Peak, Zep Solar’s PV mounting system for commercial flat and low-slope roofs. System Features: The ZS Peak auto-bonding mounting solution uses a self-templating East-West assembly with options for ballasting and positive roof attachment where needed. A low system profile allows for greater power density. -
Page 5: Core Components
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Core Components The following pictured components have been listed by UL in accordance to UL 2703 for bonding and mechanical loading for a design load up to 50 psf when used in combination with the following PV modules: REC Energy Z Link Series, Yingli Solar, Kyocera Solar, Trina Solar and QCells. -
Page 6: Additional Components
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Additional Components Positive Attachment Part No. 850-1506 Optional, per project requirements. Fasteners: Carriage Bolts + 3 Hex Nuts Third-Party Base Typically, a third-party roof anchor base consists of a cover sheeting, flashing, and a fastener system. -
Page 7: Additional Components Not Provided
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Additional Components Not Provided Full Size Ballast Block Half Size Ballast Block Slip Sheet 4” 4" 2" 16" 16" 8" 8" Slip Sheets appropriate for the roof Ballast Blocks are optional, per project requirements. Standard material may be required. -
Page 8: The Zep Compatible™ Platform
ZS Peak: PV Mounting Solution for Commercial Flat Roofs The Zep Compatible™ Platform Zep Solar mounting solutions are based on the Zep Groove, a patented module frame profile designed to mate easily and precisely with Zep Solar components. Rockit Assembly Zep Groove In ZS Peak, both the Rockit Assembly and the Lock Block insert into the Zep Groove, securing... -
Page 9: Installation Steps
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Installation Steps Step 1. Layout Following the project’s plan set, chalk out the North-South ( N|S ) and East-West ( E|W ) perimeter lines for the starting corner of the array. Installed PV Module Valley Base... -
Page 10: Step 2. Assemble Bridge Assemblies
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Step 2. Assemble Bridge Assemblies Insert both Tube Connectors into the Peak Base from above. Spread the Peak Base walls apart as shown, inserting the Tube Connectors from the inside. The side hole on the Tube Connector should be just outside of the Peak... - Page 11 ZS Peak: PV Mounting Solution for Commercial Flat Roofs Assemble Bridge Assemblies, Continued Insert Tube Assemblies into Valley Bases. Spring Buttons The Spring Button on the Tube Assemblies should be engaged into the side hole of the Valley Base. Note that on the interior side, the Spring Button is designed to extend partially out of the hole even when fully engaged.
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Page 12: Step 3. Position And Connect Bridge Assemblies
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Step 3. Position and Connect Bridge Assemblies Position the first row of Bridge Assemblies along the East-West ( E|W ) chalk line. Position mid-array Slip Sheets to fit underneath two adjacent Valley Bases. -
Page 13: Spacer Jigs
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Position and Connect Bridge Assemblies , Continued Spacer Jigs A Spacer Jig made from a piece of wood, composite, or other material can be used as a job aid to space the Bridge Assemblies according to each module’s long dimension. A minimum of 3 jigs are required to space one Brige Assembly pair. - Page 14 ZS Peak: PV Mounting Solution for Commercial Flat Roofs Position and Connect Bridge Assemblies , Continued Position the next row of Bridge Assemblies using a Spacer Jig or similar job aid. Spacer Jig Slip Sheet Install Slip Sheets prior to establishing final position.
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Page 15: Step 4. Drop In First Module
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Step 4. Drop In First Module Place the first module on edge across the first two Bridge Assemblies in the array column. It is recommended that the modules be prepped for wire management prior to installation. - Page 16 ZS Peak: PV Mounting Solution for Commercial Flat Roofs Drop In First Module, Continued Rotate module downwards until the Zep Groove is fully engaged with the Rockit Assembly. Apply slight downwards pressure when rotating, to help engage the module frame with the Rockit Assembly. Rotate module downwards...
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Page 17: Step 5. Using The Zep Tool
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Step 5. Using the Zep Tool To secure the Lock Block to the module frame, use the Zep Tool. The head of the Zep Tool fits over the Lock Block. Zep Tool Rotate the Zep Tool from Position 1 to Position 3. - Page 18 ZS Peak: PV Mounting Solution for Commercial Flat Roofs Using the Zep Tool, Continued Make sure that both Lock Blocks for each module are closed, so that the module is fully secured. Open Closed (Not Secured) (Secured) Page 18 of 30 ©...
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Page 19: Step 6. Drop In Remaining Modules
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Step 6. Drop In Remaining Modules Module Alignment Holes Modules going up the same column should be set just outside the 1/2” wide Alignment Holes on the Valley Base. 1/2” gap 1 Bridge Assembly Starting corner Module drop-in on other... -
Page 20: Step 7. Work Across, Then Up
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Step 7. Work Across, Then Up To ensure proper access to modules and Bridge Assemblies during installation, the recommended order of operations is to build up the array row by row. Building the array in this manner allows installers to avoid walking over Bridge Assemblies and modules, or jostling the Bridge Assemblies out of position. -
Page 21: Step 8. Wire Management
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Step 8. Wire Management For information on pre-wiring, A Snap Bushing (Part No. 850-1514) is required see Wire Management at every point where wires run through the Wire Recommendations on page Management Holes in the Peak Base and the Valley Base. -
Page 22: Step 9. Ground The Array
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Step 9. Ground the Array Ground Wire Set Screw Retention Slot Ground Zep Installation: Insert into Zep Groove with ground wire retention slot facing towards you, and set screw pointing left towards 9 o’clock. Use the Zep Tool (or Flat Tool) to turn the Ground Zep 90 degrees clockwise so that the set screw is pointing straight up. -
Page 23: Grounding And Inter-Array Bonding
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Grounding and Inter-Array Bonding Auto Bonding. The Key side of the Rockit Assembly, as well as the rotating Zep on the Module Locks, establish a structural and electrical bonding connection between modules and other Zep Solar components. Turning the Key side of a Lock Block into the Zep Groove, as well as rotating a module down onto the Rockit Assembly, establishes an equipotential bond by cutting through the surface coating on the Zep Groove. -
Page 24: Wire Management Recommendations
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Wire Management Recommendations The example on the left shows pre-wiring or staging of modules prior to installation using the DC Wire Clip. The DC Wire Clip allows wires to be attached in two directions. -
Page 25: Important Safety Precautions
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Important Safety Precautions Follow all instructions in this manual and the PV module installation manual. The installer is ultimately responsible for ensuring that all installations are performed in compliance with applicable codes and standards, as well as industry best practices. -
Page 26: Additional Information
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Additional Information Ballast Blocks All requirements for ballasting and ballast block placement should be clearly called out on the engineered drawings. Ballast Blocks, if required for the project, are placed lengthwise in the Peak Base or in various combinations as illustrated on the following pages. -
Page 27: Ballast Block Maximum Configurations
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Ballast Block Maximum Configurations An optional component, the Ballast Pan, can be used if the project calls for additional ballasting. The Ballast Pan hooks into the Peak Base and the Valley Base, and does not touch the roof. The suggested maximum configurations allow for module clearance above when using the recommended Ballast Block sizes. - Page 28 ZS Peak: PV Mounting Solution for Commercial Flat Roofs Installing the Ballast Pan If used, Ballast Pans should be installed in the Bridge Assemblies prior to module drop-in. Not all Bridge Assemblies in an array may require Ballast Pans. Check the plan set for exact locations and distribution of ballast. Single flange attaches to the The three “teeth”...
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Page 29: Roof Anchors
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Roof Anchors ZS Peak uses a Zep Solar-approved third-party base with a custom-designed Positive Attachment from Zep Solar that connects directly with the Zep Groove of the module frame, on the Valley Base side. Ideally, the Positive Attachment should be centered along the module’s edge. -
Page 30: Module Servicing
ZS Peak: PV Mounting Solution for Commercial Flat Roofs Module Servicing To service individual modules within a ZS Peak array, reverse the process of installation: Disconnect module wires. Use the Zep Tool to open the Lock Blocks holding the module in place on the Peak Base of the Bridge Assemblies.
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