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ZEP SOLAR ZS Comp, Installation Manual

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ZEP SOLAR ZS Comp Installation Manual Download Page 42

© 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

ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS - U.S.

Special Inset: Interlocks

Connect Array Skirt

Connect PV modules

Built-in tolerance for module size 
variations

The Interlock creates a simultaneous structural and electrical bond on both Key and Tongue sides. 

Interlock

Array Skirt

How Interlocks Are Used

Interlock Timing Marks

Gap OK

Down-roof

Part No. 850-1388

Leveling Foot

Alignment mark for Zep 
Tool

Key side

Tongue side

Used to align module edges 
around center point

Center point

Interlock 
Zep

Farthest allowable position 
of an off-center module

Placement Between Modules

Centered

Shifted right

Shifted left

Summary of Contents for ZS Comp

Page 1: ...ZS Comp Installation Manual for Composition Shingle Roofs U S Document 800 0351 001 Rev B...

Page 2: ...ng instructions for ZS Comp Zep Solar Inc recommends that you save this manual in a readily accessible location should any questions arise regarding ZS Comp Copyright and Trademark Information Copyrig...

Page 3: ...2 Obtain Spacing and Cantilever Allowances 10 Step 3 Create Array Layout and Bill of Material 10 3 1 Using the Zepulator Online Design Tool 11 3 2 Using the Span Tables 13 3 3 Alternative Layout Possi...

Page 4: ...HINGLE ROOFS U S 6 Installation Supplement ______________________________________________ 47 6 1 Servicing an Array 47 6 2 Removing the Array Skirt 49 6 3 Product Notes 50 Special Inset Interlock Vers...

Page 5: ...sition 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...

Page 6: ...or moving PV modules to the roof area use a mechani cal lift Follow best practices when working around high voltage electrical equipment Do not anchor fall protection equipment to roof mounts or any o...

Page 7: ...Solar Inc Figure 1 2 Zep Groove and Rockit Key and Tongue The Key and Tongue concept informs all Zep Compatible designs The Key side inserts into the Zep Groove similar to inserting a key into a lock...

Page 8: ...odules together Here the Key and Tongue are differently shaped but they still fit into the Zep Groove in the same manner as the Rockit Figure 1 4 Zep Groove and Interlock Interlock back is Key side Ot...

Page 9: ...changes without any prior notice All rights reserved www zepsolar com Document 800 0351 001 Rev B Page 5 2 ZS Comp Components 2 1 ZS Comp Cutaway View Interlock Leveling Foot Key side shown Zep Compat...

Page 10: ...ructural and electrical bond between modules 850 1178 Listed by UL to UL 2703 ETL listing conforms to ULC ORD STD C1703 850 1388 Listed by UL to UL2703 Used on Leveling Foot base where the Rockit conf...

Page 11: ...t Spacer and two Jams End caps sold separately Used with the Interlock when connecting sections of Array Skirt together Spacer 850 1402 is compatible with Interlock 850 1388 Used to secure Array Skirt...

Page 12: ...Hybrid Interlock Universal Box Bracket and Groove Adapter Kit from Zep Compatible PV module frame Install and remove Ground Zep Adjust height of Leveling Feet using 30 Torx Bit attachment Secure Level...

Page 13: ...gins by identifying specific information that applies to the project including Site information such as wind speed zones snow load and terrain characteristics Building characteristics such as rafter t...

Page 14: ...tud Allow a gap between modules of 1 2 inch or 13 mm in both North South and East West directions actual tolerance is 1 4 3 4 Step 3 Create Array Layout and Bill of Material Array Layouts and a Bill o...

Page 15: ...y an explanation Access the Zepulator from the Home page of the Zep Solar web site Each tab contains a set of inputs for your project Home tab is for opening saved projects or creating new projects Cl...

Page 16: ...S Comp component listed on the Bill of Material NOTE In cases where a Leveling Foot coincides with an Interlock location you may need to substitute a Hybrid Interlock However shifting the array to the...

Page 17: ...included with the Engineering Certification Letters for each country These tables represent tested structural values for every combination of hardware that is approved for use with Zep Com patible ro...

Page 18: ...show a few of the array designs that are possible with ZS Comp for composition shingle roofs Please contact Zep Solar Support if you need assistance in creating a complex array layout design for a sp...

Page 19: ...n row by row going upwards beginning at the Array Skirt which is nearest to the eave NOTE East West drop ins with the Array Skirt to one side are not supported for ZS Comp except in the rare case wher...

Page 20: ...cing and Distance Maximum Allowable Spacing The maximum allowable spacing between roof attachment points is determined by various site specific and building inputs which are captured in the Zepulator...

Page 21: ...g the upper edge of each module row Feet Attach on Opposing Sides of Module Leveling Feet must always attach on opposite sides of the module with the Tongue and Groove facing along the drop in directi...

Page 22: ...he array may require additional ground bond connections The illustrations on the following pages show when additional Equipment Grounding Conductors or jumpers are required 4 3 1 Grounding Path Exampl...

Page 23: ...daily temperature swings on the roof 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...

Page 24: ...nsions that run East West could be installed as follows Figure 4 7 Thermal Expansion Joint Interlock Tightening Positions North South Drop In Note that the Interlock Position 3 also locks in the Tongu...

Page 25: ...e axis of the Interlock large arrays also need a physical gap after two Thermal Expansion Joints For example a North South drop in Landscape orientation might require a physical gap approximately ever...

Page 26: ...g may be smaller in edge and corner roof zones Figure 4 10 Roof Zone Example U S NOTE When generating array layouts the Zepulator assumes that the entire mounting area is within an Interior roof zone...

Page 27: ...he right to make specifications changes without any prior notice All rights reserved www zepsolar com Document 800 0351 001 Rev B Page 23 5 Installation Process ZS Comp for Composition Shingle Roofs M...

Page 28: ...m span multiple of distance between rafters Module dimension 1 2 inch Comp Mount Leveling Foot Identify Attachment Locations Using Chalk Line Module width 1 2 inch PV Module Array Layout Example Lands...

Page 29: ...h Layout mark Drill pilot hole at layout mark centered on rafter Slide flashing into position referring to the Comp Mount Installation Manual for details on placement of the flashing and correct up ro...

Page 30: ...eveling Feet 3b Secure the Leveling Foot to the Comp Mount using machine screw provided Leveling Foot position can be adjusted in several ways Alternate mounting hole on Comp Mount Slotted bolt hole o...

Page 31: ...t Continued Place string line directly beneath the Rockit and on the front side of the Leveling Foot stud of the two outermost Leveling Feet String line Adjust Leveling Feet to String Line 3c Align th...

Page 32: ...secure the Interlock on one side Spacer Interlock Array Skirt i ii Used to verify alignment when tightening the Interlock Zeps Key side Tongue side Used to align module edges around center point Cent...

Page 33: ...Simultaneously tighten Interlock to Position 3 closed while rotating next section of Array Skirt into place on the front row Leveling Feet 4c i ii Rotate First Array Skirt Sections onto Key Side of Le...

Page 34: ...end of the completed Array Skirt The End Caps are optional accessory components To completely secure the Array Skirt a Jam is required in the Rockit of every front row Leveling Foot 4d 4e i ii If the...

Page 35: ...tify any potential Interlock and Leveling Foot conflicts ensure that the first row of modules is straight and level and as an aesthetic feature to blend the array into the roof while concealing all th...

Page 36: ...t Row of Modules North South drop in Drop In First Module Place first module on Tongue side of Leveling Feet and Interlocks at a steep angle If needed lift module up slightly and apply force towards L...

Page 37: ...ally check the first row of modules Ideally Rockit of Leveling Foot should be flush with module edge Remove and re seat if needed When module is fully seated tongue side of Interlock is fully conceale...

Page 38: ...th South drop in Position the Leveling Foot above the Comp Mount by eye Key side Flat face of Rockit should be flush with module frame 5d Manually insert the Key side of the Leveling Foot into Zep Gro...

Page 39: ...on 1 to Posi tion 3 Do not over turn Over turning may prevent next row of modules from seating properly 1 2 ii i Note If the Interlock Zeps are showing the Interlock is positioned too far to one side...

Page 40: ...Mounts using machine screw provided Note that there is flexibility in the posi tioning of the Leveling Foot on the Comp Mount as well as in the positioning of the Interlock as described in Flexible Po...

Page 41: ...otice All rights reserved www zepsolar com Document 800 0351 001 Rev B Page 37 ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS U S First Module Row Continued CHECKPOINT First Module Row Nort...

Page 42: ...Built in tolerance for module size variations The Interlock creates a simultaneous structural and electrical bond on both Key and Tongue sides Interlock Array Skirt How Interlocks Are Used Interlock T...

Page 43: ...ge 39 ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS U S Interlocks Continued Position 1 Open Position 3 Closed Incorrect Position Over Turned Position 2 Thermal Expansion Joint Closed and...

Page 44: ...angle provides additional range and flexibility Scenario 2 Mounting Angle and Slot Range In this example the Leveling Foot is mounted in one of the alternate mounting holes on the Comp Mount flashing...

Page 45: ...Clip snaps into the Zep Groove and slides back and forth to secure array wiring The AC DC Cable Clip can accommodate many sizes of wire and cable Basket Friction clip Loop Place the AC DC Cable Clip i...

Page 46: ...LE ROOFS U S Wire Management Continued Example Array Wiring Using 2 Clips Per Module NOTE Two variants for row to row wire management are shown Method A is to clip wires to the upper edge of the modul...

Page 47: ...Complete the Array Install Remaining Modules 6a Install remaining modules row by row True and level the array as you go Attach Leveling Feet and Interlocks as before Clip and secure wires for each ro...

Page 48: ...the Ground Zep is turned 90 degrees the set screw should be pointing straight up This locks the Ground Zep into the Zep Groove and creates a solid ground bond with the module frame Connect Ground Zep...

Page 49: ...is for items such as microinverters or DC to DC optimizers that are side mounted and may be attached either on the perimeter or underneath each mod ule The Groove Adapter Bracket works with selected...

Page 50: ...ar 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 46 ZS COMP INSTALLATION MANUAL FOR COMPOSITION S...

Page 51: ...eans identifying and replacing a malfunctioning PV module 1 Start at the top of the column with the faulty module 2 Remove the top row Interlocks Remove the two Interlocks on either side of the module...

Page 52: ...e to ensure that it is completely pulled out and then rotate module up and out of the array 7 Remove mid array Interlocks from next row of modules using Flat Tool i ii iii 1 2 3 Rotate Flat Tool from...

Page 53: ...e edges of the array to identify any potential conflicts between Interlocks and Leveling Feet and to ensure that the first row of modules is straight and level However the Array Skirt is not required...

Page 54: ...Product Notes Special Inset Interlock Versions and Functionality Timing Marks Part No 850 1388 The Interlock with 5 timing marks must be centered with 1 2 gap between the PV modules using the three ce...

Page 55: ...01 Rev B Page 51 ZS COMP INSTALLATION MANUAL FOR COMPOSITION SHINGLE ROOFS U S Special Inset Interlock Versions and Spacers Used Part No 850 1388 Part No 850 1178 Profile No 500 0104 Either version of...

Page 56: ...Interlock is available in selected regions and the Grounding Hybrid Interlock does create a bonding path across modules 3 holes can receive Leveling Foot threaded stud some applications require use of...

Page 57: ...eded attach the Hybrid Interlock to the PV module frame or Array Skirt Connecting the Hybrid Interlock to the Leveling Foot Base Spin the Rockit to remove it from the threaded stud and the Leveling Fo...

Page 58: ...ray 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 Left Center Right Jams Centering the Hybrid Interlock When thr...

Page 59: ...ies and field installers NOTE Structural testing and related requirements are contained within the Engineer ing Certification Letters available on the Zep Solar web site 7 1 UL and ETL Listings Select...

Page 60: ...ovided using the Zep Tool or Flat Tool See the Installa tion chapter for further details Interlock 850 1388 UL Listings 2703 Listed by UL to UL 2703 Installation requires precise quarter turn con nect...

Page 61: ...ar 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 ZS COMP INSTALLATION MANUAL FOR COMPOSITION S...

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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