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ZEP SYSTEM I INSTALLATION MANUAL

Copyright © 2012 Zep Solar, Inc.

PAGE 1 OF 50

1.0

Getting Started

Zep System I from Zep Solar, Inc. offers the fastest and least
expensive way to mount rooftop PV arrays on tile roofs using a
series of drop-in and quarter-turn connections to greatly acceler-
ate the process. Structural and grounding connections are accom-
plished using very few parts and no standard mounting rails. The
simplicity of installation delivers labor and logistics savings.

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Summary of Contents for Zep System I

Page 1: ...VERSION 1 4 ...

Page 2: ...IONS FOR ZEP SYSTEM I ZEP SOLAR INC RECOM MENDS THAT YOU SAVE THIS MANUAL IN A READILY ACCESSIBLE LOCATION SHOULD ANY QUESTIONS ARISE ABOUT THE ZEP SYSTEM Copyright 2012 by Zep Solar Inc All rights reserved Zep and Zep System are trade marks of Zep Solar Inc All other trademarks or registered trademarks are the property of their respective owners ...

Page 3: ...eneral Safety 10 2 2 Installation Safety 10 3 0 System Design 11 4 0 Installation 13 4 1 STEP 1 Formulas Layout Lines 14 4 2 STEP 2 Install the Tile Hooks 15 4 3 STEP 3 Installing Spanner Bars 16 4 4 STEP 4 Installing the Array Skirt 19 4 5 STEP 5 Installing the First Module 21 4 6 STEP 6 Installing the Remaining First Row Modules 23 4 7 STEP 7 Finishing the First Row 24 4 8 STEP 8 Installing the ...

Page 4: ...YSTEM I INSTALLATION MANUAL Copyright 2012 Zep Solar Inc PAGE ii 5 0 Options Servicing 29 5 1 Interlock vs Hybrid Interlock 30 5 2 Servicing the Array 31 6 0 Zep System I Warranty 37 6 1 Limited Warranty 38 ...

Page 5: ... fastest and least expensive way to mount rooftop PV arrays on tile roofs using a series of drop in and quarter turn connections to greatly acceler ate the process Structural and grounding connections are accom plished using very few parts and no standard mounting rails The simplicity of installation delivers labor and logistics savings ...

Page 6: ...d installation Installation is fast and easy from planning to assembly Only a few basic lines need to be laid out Spanner Bars mount to tile hooks using Spanner Clamps and other components drop in and or twist into place with quarter turns Visual cues and audible clicks tell you when parts are properly installed Supports landscape and portrait mounting options Zep System I allows you to mount modu...

Page 7: ...of each module frame This allows a module frame to act like a rail thus leveraging the existing structural characteristics of the frame and allowing the array to distribute load to fewer attachment points Modules attach to Spanner Bars using Cam Feet Spanner Bars then transfer that load to the building roof structure through tile hooks or standoffs This system level load distribution minimizes roo...

Page 8: ...ves of Zep com patible PV modules The Tongue side of these compo nents B receive adjustable drop in connections As a rule the Tongue side always faces the direction of the next module to be dropped in it receives the next module Adaptability Installers often need to mount a perfect looking array on an imperfect struc ture using imperfect PV modules Roofs are often neither square nor perfect planes...

Page 9: ...erall array square The module groove can seat at different positions on the Tongue side of Interlocks Hybrid Interlocks and Cam Feet meaning that the tongue can be fully or partially inserted into the groove and still accomplish a solid structural and ground bond connection Thus each module can be trued independently Truing a module is as sim ple as rotating it up a few degrees and adjusting the m...

Page 10: ... Solar Inc PAGE 6 OF 50 1 4 Components Zep System I consists of the following components PV modules not shown Tile Hook not included Spanner Bar Spanner Clamp Cam Foot Hybrid Interlock Interlock Spanner Sleeve Array Skirt Spacer Jam Ground Zep Wire Clip ...

Page 11: ...include Datasheet The Zep System I datasheet contains technical details and specifications Videos Watch animated installation tutorials to further familiarize yourself with the installation process Distributors Locate a Zep distribution partner who can supply you with Zep parts and accessories for all of your solar needs The Zep Solar Inc web site also includes links to manufacturers of Zep com pa...

Page 12: ...ZEP SYSTEM I INSTALLATION MANUAL Copyright 2012 Zep Solar Inc PAGE 8 OF 50 This page intentionally left blank ...

Page 13: ...is Installation Manual and all instructions in the installation manual provided by the PV module manufacturer must be read and understood before attempting to install Zep Sys tem I The installer assumes all risk of personal injury or property damage that might occur during the installation and handling of the components ...

Page 14: ...ions Check applicable building codes or consult with a structural engineer to ensure that the structure upon which the Zep System is being installed can properly support the array under live load conditions The Zep System I must be installed over an appropriately rated fire resistant roof covering The Cam Feet and Interlocks must be fully engaged with both the PV modules and Spanner Bars You will ...

Page 15: ...gned for use on sloped tile roofs This chapter provides a high level overview of the process of assessing and planning a prospective Zep System I installation Each installation is unique and has unique requirements that go beyond the high level overview included in this manual Please contact Zep Solar Inc for more details ...

Page 16: ...nner Bar N S columns The maximum allowable cantilever for a Spanner Clamp relative to a Spanner Bar edge is either 1 3 of the Spanner Bar length or 1 3 of the Spanner Bar E W spacing whichever value is lower l r 9 3 3 Getting Started Please contact Zep Solar Inc to begin planning yourZep System I installation if you have not done so a ready You may contact Zep Solar Inc via Email to sales zepsola ...

Page 17: ...tem I installation pro cess Please read this chapter in its entirety to familiarize yourself with the process before beginning the installation You may also visit the Resources section at www zepsolar com to view videos and other training materials Also be sure that the site has been completely prepped before beginning the installation ...

Page 18: ... distance between tile hooks To lay out a PORTRAIT installation E W line spacing per span tables N S line spacing per span tables Max cantilever is 1 3 of the distance between tile hooks Select tile hooks for use with the installation Horizontal tile hooks right may be used with both portrait and landscape installations Vertical tile hooks left may only be used for landscape installations Tile hoo...

Page 19: ...ner Bars run parallel to rafters for landscape installations Spanner Bars run perpendicular to raf ters for portrait installations 2 B Remove the necessary tiles Preserve for later reinstallation 2 C Install tile hooks Secure tile hooks to rafters at selected attachment points Follow manufacturer instructions for installation Adhere to all local and national codes for structural loading and weathe...

Page 20: ...ll the tiles Tiles may require grinding in order to fit flush 3 A Assemble the Spanner Bars Slide Spanner Bar A onto the splice protruding from Spanner Bar B Ensure that the Spanner Bars are tightly butted together 3 B Slide Spanner Clamps over Spanner Bars Orient for horizontal H or vertical V tile hooks as shown A B H V ...

Page 21: ...all the remaining Spanner Bars Repeat Steps 3 A through 3 C for each remaining column landscape or row portrait of Spanner Bars Use a string line to align the front ends of the Spanner Bars 3 E Install the first Cam Foot Insert Cam Foot into Spanner Bar approximately 1 from the end The Key side of a Cam Foot A always snaps into a module or Array Skirt while the Tongue side B always accepts a modul...

Page 22: ...age 2 3 G Install remaining Cam Feet Repeat Steps 3 E and 3 F for the remaining Cam Feet Use a string to ensure that Cam Feet are aligned Adjust the Cam Feet on the Spanner Bars as needed 3 H Adjust Cam Foot height The tops of all Cam Feet should be coplanar Spin the top portion of the Cam Foot on the threaded stud to level the Cam Feet Verify that the Tongue sides of all Cam Feet are facing the r...

Page 23: ... for Interlocks that connect to the Array Skirt 4 B Connect two Array Skirt segments together Place two Array Skirt segments together end to end Rotate and press the Interlock firmly into place 4 C Secure the Interlock using a Zep Tool Place the Zep Tool over the fastener with the 1 aligned with the reference mark on the Interlock Rotate the Zep Tool CW to Position 3 CAUTION Do not over or under t...

Page 24: ...the Array Skirt into place You will feel a snap when the Array Skirt is properly installed 4 F Insert Jams into the Cam Feet Place one Jam in each front row Cam Foot Note When using the Array Skirt as a temporary installation jig proceed to install the first row of modules To remove the Array Skirt remove the Jams then use the Flat Tool to uninstall the Interlocks between the modules and the Array...

Page 25: ... Module 5 A Lower module onto Cam Feet The module groove rests on the Tongue side of Cam Feet and Inter locks 5 B Verify module alignment The Array Skirt should extend approxi mately 1 4 beyond the edge of the module 5 C Rotate module to 15 degrees Rotate module until it is 15 degrees above the roof plane 15 ...

Page 26: ...oes not fully seat raise it slightly 4 5 degrees and press for ward again while lowering 5 E Add rear Cam Feet Engage the Key side of the Cam Foot with groove in module then rotate into position See Step 3 E The Cam Foot will snap into place when properly installed Secure Cam Feet to Spanner Bar using the Flat Tool as described in Step 3 F 5 F Ground the Array Add a Ground Zep to the outside mod u...

Page 27: ...a guide for module spac ing 6 B Insert an Interlock between the modules to bond the modules Rotate and press the Interlock firmly into place as described in Step 4 B Modules should be spaced approxi mately 1 2 apart The acceptable range is 1 4 3 4 6 C Secure the Interlock to the modules Place the Zep Tool over the fastener with the 1 aligned with the reference mark on the Interlock Rotate the Zep ...

Page 28: ...Cam Foot Attach and secure as described in Step 5 E 7 A Add the remaining modules to the first row Repeat Steps 6 A through 6 D for each remaining module in the row Ensure that the modules are level by using a 30 Torx bit to adjust each Cam Foot as needed Z axis 7 B Wire the PV modules Use Wire Clips as described in Step 10 ...

Page 29: ...in Step 8 B for a square level array Proceed to Step 8 C when you reach the final row of modules 8 B Adjust module truing and leveling as you go Please refer to Section 1 3 8 C Install Spanner Sleeves and Cam Feet on top row Spanner Bars Install the Cam Foot on the Module 1 Slide a Spanner Sleeve onto the Span ner Bar splice until flush 2 Push the Spanner Sleeve and Splice forward until Spanner Sl...

Page 30: ...rounded during installation for tech nician safety Insert the Ground Zep into the module groove with the set screw at the 9 o clock position 9 B Lock the Ground Zep into place Rotate the Ground Zep 1 4 turn clock wise using the Zep Tool 9 C Connect the Ground Zep to the building ground Connect the Ground Zep to the build ing ground Torque set screw as fol lows 14 10AWG 40 inch lbs 8AWG 45 inch lbs...

Page 31: ... that the Wire Clip is sitting flush with the bottom of the module groove 10 B Press the Wire Clip into place Push the thumb tab inward until it clips into the module groove 10 C Connect wires and adjust tension Lay wires in the wire basket portion of the Wire Clip or press into wire reten tion feature To adjust wire tension squeeze the Wire Clip and slide it along the module groove 1 2 1 2 ...

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Page 33: ...ibes the standard and Hybrid Interlocks used for the Zep System I Most modules will connect to Spanner Bars using standard Cam Feet however Hybrid Interlocks may be used in certain cases This chapter also describes the process of remov ing a module for servicing or replacement Zep System I makes repairs fast and easy ...

Page 34: ...rlock standard and hybrid Option A Standard Cam Foot and Interlock The standard Cam Foot A secures a module to the Spanner Bar anywhere along the module frame Interlocks B secure modules to each other Option B Cam Foot and Hybrid Interlock The Hybrid Interlock allows for the installation of a Cam Foot in the same location as an Interlock A B 1 2 ...

Page 35: ...ne module at a time SVC B Remove the top row Interlock s Place the Zep Tool over the fastener with the 3 aligned with the reference mark on the Interlock Rotate the Zep Tool CCW to Position 1 Repeat for the second fastener CAUTION Turn to Position 1 exactly SVC C Remove Cam Feet Use Flat Tool to loosen Cam Foot 1 4 turn as shown Use Flat Tool to rotate Cam Foot as shown and disengage from groove i...

Page 36: ...of the array SVC E Remove Interlock s from the next row of modules Rotate both fasteners to Position 1 using Flat Tool as shown SVC F Disengage the Interlocks using the Flat Tool Use the Flat Tool to lever the Interlock lug out of the module groove Slide the Interlock clear of the mod ules You may need to tap the Interlock with a rubber mallet to free it from the module 15 1 2 ...

Page 37: ... the Cam Foot Rotate the module up and out of the array SVC H Remove the remaining modules Repeat Steps SVC E through SVC G to remove the remaining modules until you reach the module you are going to replace SVC I Install the new module Follow Steps 5 A through 5 E in Chap ter 4 to install the new module 1 2 1 2 ...

Page 38: ...terlock s Slide the Interlock into position Twist the Interlock with the Flat Tool to press the lugs back into the groove in the module SVC K Secure the Interlock s Twist the fasteners to Position 3 using the Flat Tool SVC L Wire the module Use Zep wire clips to rewire the mod ule See Section 4 10 ...

Page 39: ...ZEP SYSTEM I INSTALLATION MANUAL Copyright 2012 Zep Solar Inc PAGE 35 OF 50 SVC M Install the remaining modules Follow Steps SVC H through SVC L to install the remaining modules in the column ...

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Page 41: ...Tools This chapter describes the Zep Tool and the Flat Tool used for installing and maintaining Zep System arrays Each tool has sev eral uses and is designed to make working with Zep components fast and easy Some uses overlap which saves you time because you will not be stopping to change tools as often ...

Page 42: ... the Interlocks in the PV module groove as described in the installation instructions Place the Zep Tool over the fastener with the 1 aligned with the reference mark on the Interlock interlocks secure at exactly Position 3 Rotate the Zep Tool CW to Position 3 CAUTION Do not over or under tighten Turn to Position 3 exactly Repeat for the second fastener to fin ish installing the Interlock ...

Page 43: ...rming the joint secure at Position 2 CAUTION Do not over or under tighten Turn to Position 2 exactly Turn fasteners to Position 1 to remove Interlock Place the Zep Tool over the fastener at Position 3 or 2 as appropriate and then turn CCW to Position 1 Remove the Interlock using a Flat Tool as described in the installation instruc tions and in Section 6 2 Rock Cam Feet into place in module grooves...

Page 44: ...he handle end of the Zep Tool Engage the Torx bit with the adjust ment screw inside the Cam Foot Rotate the Zep Tool CW or CCW as needed to raise lower the Cam Foot Engage the Zep Tool with the Cam Foot to be removed Slide the Rockit end of the Zep Tool sideways over the Cam Foot as shown here Rock Cam Foot out of Module Groove Rotate the Zep Tool up to rock the Cam Foot free of the module groove ...

Page 45: ...on Engage the Zep tool with the Ground Zep Rotate 90 degrees CW to lock the Ground Zep into place Use the Zep Tool to press Spanner Sleeves on Splices Place the Spanner Sleeve on the Splice Press the Spanner Sleeve into place with the handle end of the Zep Tool Use the Zep Tool to tap Spanner Sleeves flush Tap the Spanner Sleeve and Splice with the head of the Zep Tool until the Spanner Sleeve is ...

Page 46: ...ling Interlocks Engage the fastener at Position 1 Hook the end of the Flat Tool on the Interlock fastener at Position 1 as shown interlocks secure at exactly Position 3 Rotate the Flat Tool CW to Position 3 CAUTION Do not over or under tighten Turn to Position 3 exactly Repeat for the second fastener to fin ish installing the Interlock ...

Page 47: ... design docu ments the Interlocks forming the joint secure at Position 2 CAUTION Do not over or under tighten Turn to Position 2 exactly Loosen the fasteners by turning them CCW to Position 1 The Flat Tool alignment mark lines up with the mark on the Interlock when the fastener is at Position 1 Rock the Interlock to free the Interlock Hook the Flat Tool on the Interlock as shown and pull it toward...

Page 48: ...f needed You may use the Flat Tool to install Cam Feet in Modules Hook the Rock In portion of the Flat Tool onto the Cam Foot as shown Rotate to lock the Cam Foot into place in the module groove You may use the Flat Tool to remove Cam Feet from Modules Insert the Rock Out side of the Flat Tool into the slot in the Cam Foot and then rotate the Flat Tool as shown to rock the Cam Foot free of the mod...

Page 49: ... the Rock In por tion of the Flat Tool as shown Lock the Cam Feet into the Spanner Bar Hook the Flat Tool onto the bottom of the Cam Foot and rotate 90 degrees CCW to lock the Cam Foot into position in the Spanner Bar The Flat Tool can be used to install Ground Zeps Place the Ground Zep in the module groove Hook the Flat Tool over the Ground Zep as shown Rotate 90 degrees CW to secure the Ground Z...

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Page 51: ...Zep System I Warranty This chapter contains the Zep System I limited warranty Please visit www zepsolar com for additional resources including product support training and service needs Zep Solar Inc is always add ing additional information to the site in response to customer needs ...

Page 52: ...lace any Products or components of the Products that fail to meet the performance standards set forth in this warranty on an exchange basis without charge If Zep SOLAR is unable to repair or replace a defective Product or compo nent within a reasonable time Zep SOLAR will at its sole and exclusive option either replace the defective Product or component with a functionally equivalent Product or co...

Page 53: ...Solar s Warranty Service Department within thirty 30 days of the end of the applicable warranty period to initiate the warranty claim process Address all warranty claims to Zep Solar Inc Warranty Service Department 161 Mitchell Blvd Suite 104 San Rafael California 94903 Any claim under the above warranty must include proof of the date the Product installation was completed or the date of original ...

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Page 56: ...Zep System I Installation Manual VERSION 1 2 Copyright 2012 Zep Solar Inc For product and purchase inquiries contact www ecodirect com 888 899 3509 ...

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