ZEP SOLAR ZS Span Installation Manual Download | Manualshive

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© 2013/EN Zep Solar, Inc. reserves the right to make specifications changes without any prior notice. All rights reserved.

www.zepsolar.com

Document #800-0329-001 Rev F

File Generated July 3, 2013

Page 1

1 Introduction

ZS Span™, from Zep Solar, Inc., is an integrated roof mounting solution for installing PV arrays on tile roofs. ZS
Span offers the following benefits: rapid installation, reduced roof penetrations, reduced parts count, low sys-
tem weight, precision alignment, enhanced aesthetics, resistance to theft, redundant auto-grounding hardware,
portrait and landscape options, and an easy-to-use design tool with array-level BOM calculations.

1.1 ZS Span Overview

Figure 1.1 ZS Span for Tile Roofs

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Summary of Contents for ZS Span

Page 1: ...ZS Span Installation Manual for Rail Based Applications U S Document 800 0329 001 Rev F File Generated July 3 2013 ...

Page 2: ...Inc recommends that you save this manual in a readily accessible location should any questions arise regarding ZS Span Copyright and Trademark Information Copyright 2012 2013 by Zep Solar Inc All rights reserved ZEP ZS Comp ZS Aero ZS Seam ZS Trap ZS Wave ZS Span ZS Tile and the Zep logo are trademarks of Zep Solar Inc Zep Solar is a registered trademark of Zep Solar Inc All other trademarks are t...

Page 3: ...__________ 11 Step 1 Gather Project Data 11 Step 2 Obtain Spacing and Cantilever Allowances 12 Step 3 Create Array Layout and Bill of Material 13 3 1 Using the Zepulator Online Design Tool 14 3 2 Using the Span Tables 16 3 3 Alternative Layout Possibilities 17 4 Layout Concepts _____________________________________________________ 19 4 1 Drop In Direction 19 4 2 Engineering Rules 20 4 3 Grounding ...

Page 4: ...ecial Inset Universal Box Brackets and Other Accessories 62 6 Installation Supplement ______________________________________________ 63 6 1 Servicing an Array 63 6 2 Array Skirt Options 65 6 3 Removing the First Row Array Skirt 68 6 4 Hybrid Interlocks 71 6 5 Backwards Compatibility 73 Special Inset Component Versioning 74 Special Inset Interlock Versions and Alignment Marks 76 Special Inset Array...

Page 5: ... an integrated roof mounting solution for installing PV arrays on tile roofs ZS Span offers the following benefits rapid installation reduced roof penetrations reduced parts count low sys tem weight precision alignment enhanced aesthetics resistance to theft redundant auto grounding hardware portrait and landscape options and an easy to use design tool with array level BOM calculations 1 1 ZS Span...

Page 6: ... challenging for 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 other inappropriate roof structure Ensure that Zep Solar components are properly engaged with the PV modules Do not subject the PV modules to excessive loads or deformation such as twisti...

Page 7: ...p 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 On the other side the Zep Groove allows PV modules to drop in easily onto the Tongue of the Rockit Figure 1 3 Module Drop In Example Zep Compatible PV module Zep Groove cross section Key side For example the Rockit is a har...

Page 8: ...bonding connection between both modules and other Zep Solar components such as the Array Skirt The rotation of the Key side into the Zep Groove and the rotation of the next row of PV mod ules onto the Tongue side acts to establish an equipotential bond for all UL listed components by cutting through the surface coating tested for both anodized and painted coatings on the Zep Groove Note All compon...

Page 9: ... any prior notice All rights reserved www zepsolar com Document 800 0329 001 Rev F File Generated July 3 2013 Page 5 2 ZS Span Components 2 1 ZS Span Cutaway View Cam Foot Array Skirt Adjustable Mighty Hook Zep Groove Ground Zep Corner Cap T Lock Spanner Bar Spanner Clamp Interlock ...

Page 10: ... 2703 Secures PV Modules to the Spanner Bar and enables fine tuned leveling Create an electrical bond between modules on both Key and Tongue sides Also creates bond with Spanner Bar Listed by UL to UL 2703 Part No 850 1388 Part No 850 1413 Hybrid Interlock Ground Zep Used on Cam Foot base where the Cam Foot location conflicts with the installation of an Interlock Creates electrical bond between mo...

Page 11: ...er roof attachment Listed by UL to UL 2703 Splice Kit Splices lengths of Spanner Bar together for use in large arrays Creates electrical bond between Spanner Bars when fully spliced together Two Splices per join 1x 3x 4x Spanner Bar Attaches to Adjustable Mighty Hook or other roof attachment to pro vide a mounting channel for the Cam Feet Pre cut lengths dimen sioned by module width for 1 3 or 4 m...

Page 12: ... row of Cam Feet Listed by UL to UL 2703 When properly installed these Accessory Hardware Components are capable of creating an electrical bond with adjacent Zep Solar hardware components See Installation Process on page 33 for details Outside Corner Cap Used to bridge the corners when Array Skirt is applied all around the perime ter of the array for a more aesthetic appearance Listed by UL to UL ...

Page 13: ...CATIONS U S ZS Span Accessory Components Continued Universal Box Bracket Allows attachment of electrical boxes to Zep Compatible PV module frame thereby eliminating additional roof penetra tions Jam Secures the Universal Box Bracket to the module frame Part No 850 1258 Jam Groove Adapter Bracket Mounts to selected microinverters and provides an electrical bond and a mechanical connection to a Zep ...

Page 14: ...emove Interlock Install and remove Ground Zep Adjust height of Cam Feet using 30 Torx Bit attachment The Flat Tool does everything that the Zep Tool can do except for adjusting the Cam Foot height In addition the Flat tool performs these additional functions Secure Cam Foot base in Spanner Bar groove Remove Interlock from between two modules 850 1412 30 Torx Bit Attachment Inserts into top of Rock...

Page 15: ...ble on the Zep Solar web site Step 1 Gather Project Data Array design begins by identifying specific information that applies to the project including Site information such as wind speed and terrain characteristics Building characteristics such as purlin battenspacing roof pitch and roof type PV array details such as PV module manufacturer mounting area and desired orientation Within each specifie...

Page 16: ...er to the the dimension that is a multiple of the spacing between rafters and the Spanner Bar spacing will be a multiple of the Tile Reveal See Engineering Rules on page 20 for more details Maximum achievable vs maximum allowable spacing The maximum allowable spacing is an absolute maximum based on Zep Solar s engineering values The maximum spacing achievable in practice is a mulitple of either ra...

Page 17: ...nd its last support point Please refer to Engineering Rules on page 20 for more information on cantilever rules for ZS Span Step 3 Create Array Layout and Bill of Material Array Layouts and a Bill of Material can be created using the Zepulator online design tool or using a CAD program The designer may also choose to generate an initial layout in the Zepulator and then further refine the design usi...

Page 18: ...m 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 Click Continue to save changes on any input screen Layout tab is for selecting module details orientation and mounting area Project tab includes the site address country and contact person Site tab includes topography weather and other site sp...

Page 19: ...le Zepulator Array Layout ZS Span US The array layout accounts for each ZS Span component listed on the Bill of Material NOTE In cases where a Cam Foot coincides with an Interlock location you may need to substitute a Hybrid Interlock However shifting the array slightly left or right in the direction perperpendicular to the Spanner Bar direction can sometimes eliminate the need for Hybrid Interloc...

Page 20: ...les represent tested structural values for every combination of hardware that is approved for use with Zep Com patible roof mounted PV arrays The Engineering Certification Letter may also be provided to build ing officials when submitting for a permit or for use by independent engineering consultants Figure 3 5 Span Table Example ZS Span US Wind speed Roof pitch Specific option for roof attachment...

Page 21: ...s are rarely as straightforward maximizing the number of modules on the available roof space while avoiding roof obstacles may require an adaptive approach The following exam ples show a few of the array designs that are possible with ZS Span Figure 3 6 Alternative Layouts Possible in ZS Span 3 3 1 Special Design Assistance The above advanced layout examples are governed by additional layout rules...

Page 22: ...ves the right to make specifications changes without any prior notice All rights reserved www zepsolar com Document 800 0329 001 Rev F File Generated July 3 2013 Page 18 ZS SPAN INSTALLATION MANUAL FOR RAIL BASED APPLICATIONS U S ...

Page 23: ...Array Skirt and working upwards Complete each row before proceeding to the next East West Spanner Bars run horizontally Modules are dropped in one column at a time starting at one side and working towards the other Each column is completed working from bottom to top before going on to the next The Array Skirt is typically used on the first column to keep the mod ules aligned during installation Is...

Page 24: ...ch is a horizontal dimension Typically this will be the Spanner Bar spacing assumings the Spanner Bars are running North South down a rafter Tile Reveal which is a vertical dimension Typically this will be the Tile Hook spacing Inverse Relationship Between Maximum Spans The larger the spacing in one direction the smaller the spacing in the other For example the Zepulator online design tool allows ...

Page 25: ...ntilever Cam Foot center to module edge This cantilever runs East West only For a North South drop in module cantilever is always 1 3 of the maximum allowable East West Tile Hook Spanner Bar spacing Tile Hook PV module Ground Zep Interlock 1 2 inch gap Cam Foot Rafter Tile Hook North South spacing is a multiple of the Tile Reveal equal to or less than the maximum allow able North South span Spanne...

Page 26: ...oot center to module edge North South only For an East West drop in module cantilever is always 1 3 of the maximum allowable North South Tile Hook Spanner Bar spacing Tile Hook PV module Ground Zep Interlock 1 2 inch gap Cam Foot Rafter Spanner Bar Array Skirt not shown Spanner Bar cantilever Tile Hook to module edge with supporting Cam Foot For an East West drop in the maximum allowable cantileve...

Page 27: ...stance and Spanner Bar End Distance Spacing Between Modules Any two modules bonded by the same Interlock should always be spaced 1 2 inch apart with a tolerance of 1 4 inch Figure 4 5 Allowable Module Spacing 4 2 4 Law of Perpendicularity Interlocks Must be Perpendicular to Drop In Direction For ZS Span module drop in direction parallels Spanner Bar direction which can run either North South or Ea...

Page 28: ...ON MANUAL FOR RAIL BASED APPLICATIONS U S Figure 4 6 Law of Perpendicularity Array Skirt Interlock Drop in direction Correct Incorrect Cam Foot Array Skirt Interlock Drop in direction Correct Incorrect In this diagram which shows a North South drop in Cam Feet and Interlocks should not be attached to the sides of the array The modules in the field of this array are missing Interlocks Cam Foot Nort...

Page 29: ...ize with a single ground bond connection an Equipment Grounding Conductor In a hyper bonded array every module is structurally and electrically bonded to the surrounding mod ules on all sides The rotation of the Key side into the Zep Groove and the dropping in of the next row of PV modules onto the Tongue side acts to establish an electrical bond for all UL listed com ponents by cutting through th...

Page 30: ... Interlocks Figure 4 8 Bonding Path Simple Array Figure 4 9 Bonding Path Hybrid Interlocks or Thermal Expansion Joints Interlock Ground Zep Equipment Grounding Conductor EGC Bond path Array Skirt Interlock Hybrid Interlock or Thermal Expansion Joint Ground Zep Equipment Grounding Conductor EGC Bond path An array with a continuous column of Hybrid Interlocks or a Thermal Expansion Joint must be ins...

Page 31: ...between two sections of Spanner Bar when they are fully spliced together Ground Zep Module Limit A single Ground Zep can be used as a connection point to ground an array up to 33 x 33 feet 4 4 Thermal Expansion There are two methods to address thermal expansion and contraction within Zep Compatible arrays Thermal Expansion Joints and physical gaps or breaks between sub arrays Thermal Expansion Joi...

Page 32: ...tion but does not establish an electrical bond This allows the module on the side of just past Position 2 to slide back and forth as the modules expand and contract in changing temperatures NOTE Thermal Expansion Joints require that a Ground Zep be installed on both sides of the break 4 4 3 Thermal Expansion Joints and Module Rows or Columns When there is a continuous row or column of Interlocks a...

Page 33: ...al Expansion Joints only work along the axis of the Interlock Thermal expansions running along the other axis parallel to the module drop in direction require a physical break between the sub arrays At a minimum the gap should be at least 4 inches However a gap of 12 inches is recommended for ease of servicing Figure 4 12 North South Drop In Thermal Expansion Gap Figure 4 13 East West Drop In Ther...

Page 34: ...ly every 18 module lengths depending on the module Figure 4 14 Large Array North Drop In Thermal Expansion Gap 4 5 Roof Zones Roof zones identify the interior edge and corner regions of each designated roof plane This is to take into account varying wind pressures as the wind passes over different areas of the roof The maximum allowable Cam Foot spacing may be smaller in edge and corner roof zones...

Page 35: ...rea is within an Interior roof zone For detailed examples showing applications of array layouts within edge and corner roof zones and how to determine the dimensions of these zones please refer to the Engi neering Certification Letter and Span Tables document that is appropriate for the project location This document is available on the Zep Solar web site Interior zone Edge zone Corner zone The de...

Page 36: ...ves the right to make specifications changes without any prior notice All rights reserved www zepsolar com Document 800 0329 001 Rev F File Generated July 3 2013 Page 32 ZS SPAN INSTALLATION MANUAL FOR RAIL BASED APPLICATIONS U S ...

Page 37: ...ght to make specifications changes without any prior notice All rights reserved www zepsolar com Document 800 0329 001 Rev F File Generated July 3 2013 Page 33 5 Installation Process ZS Span for Tile Roofs Mounting Solution for Solar Arrays ...

Page 38: ...h Spanner Bar PV Module Array Layout Example North South Landscape Maximum E W span Maximum N S span Cam Foot Locate the outside edges of the array Mark array perimeter according to module dimension 1 2 inch Mark intervals for Array Skirt sections custom matched for each module type and orientation to identify Cam Foot Inter lock conflicts and lay out module gaps Array can shift over attachment po...

Page 39: ...eathing not shown Rafter Install Attachment 2b Follow manufacturer s instructions for Zep Solar approved Tile Hooks or standoffs The Adjustable Mighty Hook from Zep Solar Inc can be shifted off center The hook portion of the Adjustable Mighty Hook can be shifted as well For extreme off center placement roof sheathing and additional deck screws are required Minimum rafter penetration for Adjustable...

Page 40: ... Spanner Bar 1x 3x 4x Lengths on page 39 for guidance on splicing pre cut lengths for larger arrays Splice Kit Part No 850 1401 Example 3x3 array using 3 Spanner Bars will not require splicing or cutting Shown 3x Spanner Bars Use a Splice Kit to splice two Spanner Bars together if needed Slide the Splice Kit into the first Spanner Bar until the ridge in the Splice Kit meets the Spanner Bar edge as...

Page 41: ... Cam Feet 1 25 inches from Spanner Bar ends measuring to the center of the Cam Foot threaded stud Minimum distance is 1 2 The Key side of the Cam Foot Rockit should face outwards towards the perim eter of the array Tongue side of Rockit should face inwards towards the field of the array Insert Cam Foot base into Spanner Bar channel Recommended 1 25 distance 3b Spanner Bar Cam Foot Spanner Clamp Se...

Page 42: ...nto Spanner Bars All Spanner Clamps should face the same way Spanner Bar Staging 3d Stage the Cam Feet between Spanner Clamps just past where module edge will fall Top Mount Tile Hook Side Mount Tile Hook East West drop in North South drop in Top Mount or Side Mount Tile Hook Spanner Clamp Position Matches Tile Hook Type Use Correct Tile Hook Type for Spanner Bar Direction 3e 3f Top Mount Tile Hoo...

Page 43: ...NS U S Special Inset Spanner Bar 1x 3x 4x Lengths The Spanner Bar is offered in pre cut lengths based on module width dimension 1x 3x 4x Module corner 1 5 overage each side 1 module 2 modules 3 modules 4 modules 5 modules 6 modules Splicing Guidelines Minimize Splices Do Not Cut Spanner Bars in Half Excess length Too short 1x 1x 1x 3x 4x 4x 1x 3x 3x 4x Cutting a 4x Spanner Bar in half will result ...

Page 44: ...ttach Spanner Bars Mount Outer Spanner Bar Sections on Roof Attachments 4a Torque the carriage bolt on Spanner Clamps going up the column Spanner Bar ends should be level Use String Line to Align Middle Spanner Bars and Cam Feet 4b Place string line on front side just below the Rockit on the two outermost Cam Feet Slide middle Spanner Bars into position until Cam Feet threaded studs meet string li...

Page 45: ...LLATION MANUAL FOR RAIL BASED APPLICATIONS U S Attach Spanner Bars Continued Secure Middle Spanner Bars and Align Cam Feet 4c Secure Spanner Clamps going up each middle Spanner Bar Visually check that Spanner Bars are level and not tilted Spin the Rockit to adjust Cam Foot height up or down within the allowable range 0 75 range Lowest Allowable range is as shown Highest Level Cam Feet Rockits to S...

Page 46: ... Array Skirt with the center mark on the Interlock Use the Zep Tool to secure the Interlock on one side Interlock Array Skirt i ii Rotate the Zep Tool from Position 1 to Position 3 Do not over turn Attach the second Array Skirt section and tighten the Interlock on the second side Skirt will not be flush at the bottom until Zep Tool is fully turned to Position 3 Note Pre assemble the first two Arra...

Page 47: ...h against Cam Foot Rockit i ii Array Skirt can be shifted to avoid conflicts between Interlocks and Cam Feet Be sure to stay within module cantilever allowances as described in Spacing Rules on page 20 If a conflict between an Interlock and a Cam Foot cannot be avoided by repositioning the Array Skirt see Interlocks on page 53 and Hybrid Interlocks on page 71 for additional solutions Install Remai...

Page 48: ...ed around the Rockit of every first row Cam Foot 5d Grip The Grip fits underneath the Array Skirt Press upwards and pull towards you i to engage the Grip with the Array Skirt ii Slide the Grip snugly around the right side of the threaded stud iii Make sure the Grip notch also fits into the corresponding notch in the Rockit iv For previous Cam Foot version Part No 850 1284 use the left side of the ...

Page 49: ...rt serves multiple functions As a templating tool the Array Skirt is used to mark the outside edges of the array verify or establish cantilevers identify potential Interlock and Cam Foot conflicts and ensure that the first row or column of modules is straight and level As an aesthetic feature the Array Skirt conceals module hardware for a more finished appearance If desired the Array Skirt can be ...

Page 50: ...s beneath the Array Skirt securing the Array Skirt to the first col umn of Cam Feet i Notch clips onto Array Skirt Indented notch fits over Cam Foot threaded stud Slide the Grip into position around the Rockit and threaded stud of the Cam Foot Be sure to hook the top notch into the corresponding notch on the Rockit as shown Top notch slides onto Rockit ii Part No 850 1421 Slide in from the right S...

Page 51: ...outh drop in Drop In First Module Place first module on Tongue side of Cam Feet and Interlocks at a steep angle If needed lift module up slightly and apply force towards Cam Feet to seat the module completely Adjust module edge alignment using Interlock timing marks If Interlock is offset to avoid Cam Foot conflict align module using Array Skirt Rotate module downward almost flat while pushing mod...

Page 52: ...e Row Continued Adjust First Module on Tongues Visually check that first module is aligned and straight Ideally Rockit block of Cam Foot should be flush with module edge Remove module and re seat if needed When module is fully seated tongue side of Interlock Zep is concealed within the Zep Groove of the module frame Fully Seated Optimal Acceptable Top view Top view Side view Rockit Module Interloc...

Page 53: ...ules In First Row Place the second module on Tongue side of first column Cam Feet and Interlocks Align module with Interlock tim ing marks Allow 1 2 gap between modules 1 2 i ii 6c Tolerance 1 4 Insert Cam Feet at rear of remaining first row modules iii Ensure Gaps Between Modules Are Consistent on Both Sides 6d Gap between modules should be consistent at the upper and lower edge of each module If...

Page 54: ...rners using timing marks The Interlock can slide to one side if needed to avoid conflicting with a nearby Cam Foot See Interlocks on page 53 Rotate the Zep Tool from Position 1 to Posi tion 3 Do not over turn Over turning may prevent next row of modules from seating properly 1 2 ii i Attach Interlocks to Rear Edge of Modules 6e Manage Wires Cable Clips See Wire Management on page 55 6f Connect DC ...

Page 55: ...w Continued Tighten Cam Foot base 100 degrees using Flat Tool Open position Closed position Note positioning of correctly tightened Cam Foot base Secure Cam Foot Base 6h Attach Cam Foot to Rear Edge of First Module North South drop in Flat face of Rockit should be flush with module frame 6g Manually insert the Key side of the Cam Foot into Zep Groove while aligning Cam Foot base with Spanner Bar c...

Page 56: ...nued Use the Zep Tool with 30 torx bit to raise or lower the Cam Feet as needed Adjust Cam Foot Height 6i 0 75 Ensure that all modules in first column are level This will aid in keeping the rest of the array true Not level Level i ii CHECKPOINT First Module Row East West drop in If an Array Skirt is not desired on the finished array the installer may choose to remove it at this point See Array Ski...

Page 57: ...ates a simultaneous structural and electrical bond on both Key and Tongue sides Interlock Array Skirt How Interlocks Are Used Interlock Timing and Alignment Marks Gap OK Down roof Part No 850 1388 Timing mark for Zep Tool Key side Tongue side Used to align module edges around center point Center point Interlock Zep Farthest allowable position to align with module edge when shifting Interlock Note ...

Page 58: ...AN INSTALLATION MANUAL FOR RAIL BASED APPLICATIONS U S Interlocks Continued Position 1 Open Position 3 Closed Incorrect Position Over Turned Position 2 Thermal Expansion Joint Closed and Open Positions Position 3 Position 2 Tongue Side Front Zep Tool Position NOTE An over turned Interlock Zep will interfere with the drop in of the next row of modules Flats should be facing up not the points Flat P...

Page 59: ... U S Special Inset Wire Management The AC DC Cable Clip fits both DC and AC cable sizes Basket Friction clip Loop Attach to Zep Groove Upper bend Release Adjust Wire Tension Zep Groove clip The DC Wire Clip fits wire diameters 5 2mm 7 6mm and attaches wires in two directions Parallel Perpendicular Flange clip Zep Groove clip AC DC Cable Clip AC DC Cable Clip Part No 850 1222 Part No 850 1448 DC Wi...

Page 60: ...ray 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 far edge of the module as shown on lower right rather than clipping along the top side as shown in Method B Down roof Wires are shown stylized to make the diagram more readable In practice wires should not have slack between clipping points A B North South drop in NOTE Pl...

Page 61: ...o Attach Interlocks and Cam Feet as before Clip and secure wires for each row before moving on to the next row Note For large arrays the installer must address thermal expansion Thermal Expansion on page 27 describes when Thermal Expansion Joints are needed and Interlocks on page 53 contains installation details Note Additional aesthetic options are available for a more finished appearance of the ...

Page 62: ...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 to Building Ground Insert solid copper ground wire into the ground wire retention slot and turn the set screw wtih a flat bladed screwdriver until the ground wire is captured by the set screw Torque the set scre...

Page 63: ... Skirt Options on page 65 for information on various configura tions achievable with ZS Span Engage one side of the T Lock head with the Zep Groove i Then snap the Array Skirt onto the T Lock from the other side ii Notes Use two T Locks per Array Skirt section If using a Universal Box Bracket or other PV electronic device that attaches directly to a module s Zep Groove omit one section of perimete...

Page 64: ... of the Array Skirt Drill through the pre drilled hole into the Array Skirt To ensure proper electrical bonding secure using thread cutting screw and tooth washer provided Note The same fastener specifications apply to the Inside Corner Cap Outside Corner Cap and End Cap Drill hole must be perpendicular to Array Skirt Torque screw to 12 inch lbs No gap at bottom Tabs should bend tightly around the...

Page 65: ... 61 ZS SPAN INSTALLATION MANUAL FOR RAIL BASED APPLICATIONS U S Installing Side Skirt and Corner Caps continued Installing Array Skirt End Caps End Caps are used with bottom only Array Skirt for a more finished appearance See Bottom Skirt Option on page 67 for more information i ii Installing the Inside Corner Cap The Inside Corner Cap installation is similar to that for the Outside Corner Cap ...

Page 66: ...cket is for PV electronic devices such as rooftop isolators or com biner boxes that are typically bottom mounted and attached on the perimeter of the array Each of the above components includes installation details on the Component Level Instruction sheets that are shipped with the component For some third party Zep Compatible items addi tional manual supplements are available Contact Zep Solar Su...

Page 67: ...rocedure below 1 Start at the opposide end of the row with the module to be removed 2 Disconnect wires from first module to be removed 3 Remove the first Interlocks Remove the two Interlocks on either side of the module column to be removed using the Zep Tool turning the Interlock Zeps from Position 3 to Position 1 4 Detach Cam Foot base and remove Cam Foot from module frame 5 Remove the first mod...

Page 68: ...at Tool i ii iii 1 2 3 Rotate Flat Tool from Position 3 to Position 1 to open both Interlock Zeps Note that Flat Tool is reversed Use the Flat Tool to rotate the Interlock out of the Zep Groove Slide the Interlock out from between modules Tap gently with the Flat Tool if needed For easier Interlock removal hold modules up to keep them from sagging For a Hybrid Interlock remove the exposed Rockit u...

Page 69: ...irt is an optional accessory Its purpose is to aesthetically finish the array conceal wires and hardware and also to serve as an installation jig for the first column of modules 6 2 1 Array Skirt Attachment Methods If the Array Skirt is used as a jig during initial installation it is attached to the Key side of the first column of Cam Feet and is further secured to the Cam Feet using Grips The res...

Page 70: ...ent 800 0329 001 Rev F File Generated July 3 2013 Page 66 ZS SPAN INSTALLATION MANUAL FOR RAIL BASED APPLICATIONS U S 6 2 2 Using Array Skirt as Jig During Installation After the first column of modules is fully secured leveled and aligned the installer may choose to remove the Array Skirt subsequent to completing the installation 1 2 3 4 5 ...

Page 71: ...d of the Array Skirt to conceal the extrusion profile 6 2 4 Side Skirt and Corner Cap Options If the Array Skirt is attached all around the array perimeter on front sides and back Corner Caps can provide additional finishing touch Outside Corner Caps connect the Array Skirt at the outside corners of a array Inside Corner Caps connect Array Skirt sections at the inside corners in arrays containing ...

Page 72: ...ditional mesh can be attached either to the Array Skirt or directly to the Zep Groove of the module frames Mesh can also be used as a screen to prevent rooftop debris from collecting underneath the array Contact Zep Solar Support for more information 6 3 Removing the First Row Array Skirt Follow these steps to remove the Array Skirt subsequent to module installation 1 Slide Grips off the first row...

Page 73: ... File Generated July 3 2013 Page 69 ZS SPAN INSTALLATION MANUAL FOR RAIL BASED APPLICATIONS U S 2 Use the Flat Tool to open Interlock Zeps on Array Skirt from Position 3 to Position 1 3 Remove Array Skirt sections by rotating them up and off the first column Cam Feet 4 The Interlocks are revealed with the Key side showing Array Skirt Interlock Flat Tool Key side ...

Page 74: ...0329 001 Rev F File Generated July 3 2013 Page 70 ZS SPAN INSTALLATION MANUAL FOR RAIL BASED APPLICATIONS U S 5 After all sections of Array Skirt are removed the Interlocks will be loose for removal Hybrid Interlocks can remain and do not need to be removed 6 Re install and secure the Interlock with the Key side facing inwards Key side Tongue side ...

Page 75: ...ound Zep on both sides of the break A bonding version of the Hybrid Interlock is available in selected regions and the bonding Hybrid Interlock does create a bonding path across modules 3 holes can receive Cam Foot threaded stud In the event that a module must be removed for servicing the Rockit can be removed from Hybrid Interlock using 30 Torx Bit in set screw Level using 30 Torx Bit in hole rec...

Page 76: ...ol to provide leverage as needed attach the Hybrid Interlock to the PV module frame or Array Skirt Connecting the Hybrid Interlock to the Cam Foot Base Spin the Rockit to remove it from the threaded stud and the Cam Foot base Insert the Cam Foot stud into one of the holes on the Hybrid Interlock and spin the Hybrid Interlock to attach it Installing the Hybrid Interlock Secure Cam Foot base to Big ...

Page 77: ...al are versions scheduled for 2013 release In most cases previous and current generations are fully compatible with one another However the installer should be aware of specific part versions in order to ensure compatibility in the field This section contains important information regarding inter operability among components Centering the Hybrid Interlock When threading the Cam Foot base for a Hyb...

Page 78: ...OR RAIL BASED APPLICATIONS U S Special Inset Component Versioning Cam Foot Interlock Part No 850 1413 Part No 850 1242 Part No 850 1388 Part No 850 1178 This section shows which part designs have been recently updated Spanner Bar Assembly Part No 850 1192 Splice is included Part No 850 1143 Bar Sleeve Three Spanner Bar lengths 1x Part No 850 1398 3x Part No 850 1399 4x Part No 850 1400 Part No 850...

Page 79: ...F File Generated July 3 2013 Page 75 ZS SPAN INSTALLATION MANUAL FOR RAIL BASED APPLICATIONS U S Component Versioning Continued Array Skirt End Caps Grip Profile No 500 0113 Frofile No 500 0104 Please contact Zep Solar Support for a complete list of associated SKUS for each Array Skirt profile Part No 850 1405 Part No 850 1215 Part No 850 1421 Part No 850 1258 ...

Page 80: ...Special Inset Interlock Versions and Alignment 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 center marks The Interlock with 7 timing marks can be 1 5 off center between the PV modules up to marks as shown Maintain the same 1 2 gap between modules Part No 850 1178 1 5 Total range 1 5 1 2 gap between modules range Part ...

Page 81: ...284 Jam Part No 850 1258 Grip Part No 850 1421 Cam Foot Part No 850 1284 Cam Foot Part No 850 1413 or with with only Interlock Part No 850 1388 Interlock Part No 850 1178 or Interlock Part No 850 1388 Interlock Part No 850 1178 or with with either or Spacer Part No 850 1402 Spacer Part No 850 1296 Spacer Part No 850 1402 uses either uses uses either uses either The Spacer is only needed with the p...

Page 82: ...STALLATION MANUAL FOR RAIL BASED APPLICATIONS U S Special Inset Array Skirts and Caps Array Skirt Profile No 500 0113 Array Skirt Frofile No 500 0104 Current Version Previous Version End Caps Part No 850 1405 End Caps Part No 850 1215 only fits fits Outside Corner Cap Part No 850 1386 Inside Corner Cap Part No 850 1425 Please contact Zep Solar Support for a complete list of SKUS for each Array Ski...

Page 83: ...both regulatory agencies 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 Selected Zep Solar products have been tested for electrical bonding functionality and have been approved by the following testing agencies Underwriters Laboratories Inc UL These listing...

Page 84: ...m Foot 850 1413 UL Listings 2703 Listed by UL to UL 2703 Insertion of Cam Foot Rockit into Zep Groove is self grounding Installing the Cam Foot base into the Big Foot uses the Flat Tool with a defined 100 degree turn See the Installation chapter for details Creates an electrical bond between mod ules and with Spanner Bar Cam Foot 850 1284 UL Listings 2703 Listed by UL to UL 2703 Insertion of Cam F...

Page 85: ...n nections according to alignment marks provided 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 nections according to alignment marks provided using the Zep Tool or Flat Tool See the Installa tion chapter for further details Outside Corner Cap 850 1386 UL Li...

Page 86: ... Kit 850 1401 Used to splice multiple lengths of Spanner Bar together Built in tab indicates when splice is fully completed T Lock 850 1409 UL Listings 2703 Listed by UL to UL 2703 T Lock flanges are inserted into Zep Groove in the module frame and the Array Skirt to secure the Array Skirt to the perimeter of the array Table 7 1 Zep Solar Product Listing and Torque Specifications Product Name and ...

Page 87: ...ves the right to make specifications changes without any prior notice All rights reserved www zepsolar com Document 800 0329 001 Rev F File Generated July 3 2013 Page 83 ZS SPAN INSTALLATION MANUAL FOR RAIL BASED APPLICATIONS U S ...

Page 88: ...Zep Solar Inc www zepsolar com 161 Mitchell Blvd Suite 104 P 415 479 6900 San Rafael CA 94903 F 415 479 6901 ...

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