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Doc Number 801-00015, Version 1.1, Copyright © 2010 Zep Solar, Inc.

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ZEP SYSTEM II INSTALLATION MANUAL

1.0 > Introduction

This manual details installation procedures for the Zep System II PV Module Installation System
(Zep System II) and provides important safety information that the installer should read carefully
in its entirety prior to installation. Failure to follow these instructions may result in death, bodily
injury or property damage. Correct installation of Zep System II components will ensure reliable
structural connections and proper ground bond means throughout the array and from the array to
the equipment grounding conductor(s).

The components detailed in this manual include the Interlock, the Leveling Foot, the Ground Zep,
the Zep Wire Clip, the Zep Comp Mount and the Zep Compatible Solar Module (Module). The word
“Module” as used in this manual will refer specifically to a Zep Compatible PV Module – a PV Module
containing the patented Zep Groove frame design licensed by Zep Solar to the PV Module manufac-
turer. All components covered in this manual are protected by US patent #7,592,537 and/or multiple
pending US & International patents.

The Interlock conforms to UL Standard 1703 and is Listed by Intertek (ETL) with Control Number
4000321. The Ground Zep conforms to UL Standard 467 and is Listed by Intertek (ETL) with Control
Number 4000321.

2.0 > Safety Precautions

WARNING:

All instructions in this Installation Manual and all instructions in the installation

manual provided by the manufacturer of the Module should be read and understood before at-
tempting to install Zep System II. The installer assumes all risk of personal injury or property
damage that might occur during the installation and handling of the components.

2.1 > General Safety

1. All installations must be performed in compliance with all applicable regional and local codes,

such as the latest National Electric Code (USA), Canadian Electric Code (Canada) or other national
or international electrical standards.

2. Follow all safety precautions detailed in this Installation Manual as well as the Module instal-

lation manual.

3. Comply with all applicable OSHA or equivalent safety standards including but not limited to the

proper use of regulation fall protection equipment.

4. Do not perform any installations in wet or windy conditions.

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Summary of Contents for ZEP SYSTEM II

Page 1: ...VERSION 1 0 Zep System II PV Module Installation Manual ...

Page 2: ...n Preparation 13 5 3 Roof Layout Procedure 14 5 4 Prepare Roof for Front Row Leveling Feet 15 5 5 Interlocking the First Module Pair 16 5 6 Wiring and Wire Management 17 5 7 Leveling Foot Installation 18 5 8 Completing the First Row 19 5 9 Leveling the Row 20 5 10 Drop in and Pivot Lock Procedure 20 5 11 Installing Additional Rows 22 5 12 Final Array Wiring and Wire Management 23 5 13 Installing a...

Page 3: ...n this manual are protected by US patent 7 592 537 and or multiple pending US International patents The Interlock conforms to UL Standard 1703 and is Listed by Intertek ETL with Control Number 4000321 The Ground Zep conforms to UL Standard 467 and is Listed by Intertek ETL with Control Number 4000321 2 0 Safety Precautions WARNING All instructions in this Installation Manual and all instructions i...

Page 4: ... the installation wear suitable protection such as non slip construction gloves to protect your hands from injury from sharp edges 6 Do not expose the Modules to excessive loads or deformation such as twisting or bending 3 0 Zep System II Overview Zep System II offers an ultra rapid method for installing and electrically grounding solar arrays In addition to the application specific attachment har...

Page 5: ...ides a ground bond connection from the array to the equipment grounding conductor s Figure 3 0E Zep Comp Mount The Zep Comp Mount provides a flashed attachment solution for composition shingle roofs Refer to the Zep Comp Mount Installation Manual for installation instructions Figure 3 0D Zep Wire Clip The Zep Wire Clip snaps into the Zep Groove and provides a means for securing array wiring ...

Page 6: ...rooves running East West Figure 3 0F Landscape Orientation Figure 3 0G Portrait Orientation Zep systems can be installed in either landscape or in portrait orientation Typical residential roofs have a high aspect ratio length to width As a result typical roofs can accommodate larger arrays when installed in landscape orientation Landscape installations therefore allow for more efficient use of spa...

Page 7: ...r refer to your local jurisdiction The tables assume that the Average Building Height is less than 30 feet Figure 4 1D Importance Factor is 1 0 building is not a special occupancy structure such as a public school or public safety building and the Topographic Factor is 1 0 building is not on a bluff or near the top of a hill Once you collect the site conditions for your project location refer to t...

Page 8: ...gure 4 1C Roof Zones Interior Edge Corner Figure 4 1D Average Roof Height Ratio to Pitch Conversions 1 12 5 deg 2 12 9 deg 3 12 14 deg 4 12 18 deg 5 12 23 deg 6 12 27 deg 7 12 30 deg 8 12 34 deg 9 12 37 deg 10 12 40 deg 11 12 43 deg 12 12 45 deg B Urban Suburban C OpenTerrain ScatteredObstructions D Flat Unobstructed Area 7 DEGREES 15 12 27 DEGREES 6 12 45 DEGREES 12 12 ...

Page 9: ...Module seam Consider whether to mount the Modules in landscape or portrait orientation As discussed above landscape orientation usually offers an opportunity to fit more kilowatts of PV Modules on a typical roof It will also allow for a more economical use of mounting hardware Figure 4 2A illustrates the Leveling Feet with circles at the intersections of the Module frame and the rafters and Interl...

Page 10: ... the allowable value so Leveling Foot solid circles were placed on the rafters closest to the edge of the array to meet the cantilever requirements If the maximum cantilever allowance cannot be met by adding another Leveling Foot it may be necessary to shift the array to the East or West in order to support the array properly In Figure 4 2B distance A represents the Cantilever Allowance whereas di...

Page 11: ...ion of the array to either side of the break requires its own Ground Zep as shown in Figure 4 2C If the array exceeds 12 Modules high per column an additional thermal and ground break is required One Ground Zep is required for each array portion segmented by thermal ground breaks and a ground bond jumper must be installed between ground Zeps as described in Section 5 13 below Figure 4 2B Cantileve...

Page 12: ...nd suitable roof attachment devices to maintain the waterproof integrity of the roof The system designer and or installer are responsible for load calculations and proper quantity and locations of the Zep Leveling Feet Local wind loading and snow loading should be accounted for in the system design 2 The mounting system design shall comply with all local building codes 3 A minimum gap of 0 25 betw...

Page 13: ...hat the array will not be unnecessarily shaded Figure 5 3A 3 Locate the rafters and snap chalk lines to identify their locations Figure 5 3B 4 Snap a chalk line across the lower edge of the array to establish the relative location of the lower edge of the array Figure 5 3C NOTE Depending on the attachment solution being utilized the chalk line may represent various possible alignment points For in...

Page 14: ...methods see product instructions for proper installation procedures NOTE DO NOT secure the Leveling Foot to the roof or attachment hardware at this time The Leveling Foot must be installed in the Module grove prior to securing to the roof or attachment hardware NOTE If using accessory roof attachment hardware such as Zep Comp Mount the Zep Tile Mount and various third party products such as S 5 Cl...

Page 15: ...rait orientation near the SW or SE area of the array Figure 5 5A These instructions assume that you are starting at the SW corner of the array area Module junction boxes should be oriented per system design to allow for ease of Module interconnections 2 Insert the Interlock Assembly in the bottom groove between the Module pair spacing the Modules inch apart using the two outside alignment marks on...

Page 16: ...nue to turn clockwise until Alignment Mark 3 is lined up with the alignment mark on the Interlock Figure 5 5E NOTE It is important to NOT over or under rotate the Interlock Zep since the drop in action on the tongues when installing the next row above may be difficult unless both Interlock Zeps are properly aligned 3 Repeat the Interlock installation Steps 1 3 on the upper edge of the Module pair ...

Page 17: ... the Module and Leveling Foot according to the system design Both installers should then simultaneously insert their Leveling Foot into the bottom and top of the Module groove key first See Figure 3 0B at the 3 o clock position Figure 5 7B NOTE There is no need to measure exactly where to insert the Foot Zep just eyeball the location approximately above the rafter or attachment device If you are o...

Page 18: ...that Leveling Foot may be difficult unless the stud is oriented perpendicular to the Module frame 5 8 Completing the First Row 1 Lay out the next Module on the roof spaced from the previously attached Module pair 2 Attach the Leveling Foot Zep to the Module groove on top and bottom of the frame immediately above the attachment point to the roof or attachment hardware and loosely secure the Levelin...

Page 19: ... adjustment is necessary Figure 5 9A Use the Zep Tool or a drill with a T30 Torx bit to raise counter clockwise or lower clockwise the height at the Leveling Foot Figure 5 9B Figure 5 9A Figure 5 10A Figure 5 9B Figure 5 10B 5 10 Drop in and Pivot Lock Procedure 1 Movinguptothenextrow resttheedgeofthenextModuleonthetopoftheFootZeps Figure5 10A In order for the Zep tongue to fully seat into the Mod...

Page 20: ...e 5 10D Figure 5 10F 3 Proceed to lower all the way to the surface of the roof while continuing to apply pressure toward the tongues Figure 5 10E and Figure 5 10F If the newly installed Module does not fully seat into the Zeps bring it back up to 15 degrees and apply pressure once again to fully seat it NOTE Zep System II has been designed to take up tolerance from Module to Module so the Zep Groo...

Page 21: ...ances Figure 5 10G lift the Module to 15 and re seat while applying pressure towards the Zeps Figure 5 10G 5 11 Installing Additional Rows 1 Continue to install the remaining Modules in the new row using the Drop in and Pivot Lock Procedure Section 5 10 and attach all Leveling Feet Section 5 7 according to design drawings 2 Once all Modules and Leveling Feet have been installed in the row attach t...

Page 22: ...mal break is within 2 of a Leveling Foot tighten the Interlock Zep that is closest to the Leveling Foot in order to avoid conflict with the Leveling Foot in a fully expanded condition Keep the selection of which Interlock Zep is tightened consistent throughout the thermal break For instance if the Zep on the east side of the Interlock is tightened on the thermal break s first Interlock secure all ...

Page 23: ... code standards 3 All Ground Wire shall have a temperature rating of at least 40C to 90C 4 Zep System II components are only suitable for Modules with a series fuse rating of 15 Amps or less 5 Tools required for the Zep System electrical installation are as follows a Zep Tool for installing and removing Interlocks Leveling Feet and Ground Zeps b Flat bladed screwdriver for fastening the ground wir...

Page 24: ...lat bladed screw driver until the wire is captured by the set screw Figure 6 2D Continue turning the set screw until the installation torque requirements of Table 6 2E are met Figure 6 2A Figure 6 2C Figure 6 2E Set Screw Installation Torque Requirements Figure 6 2B Figure 6 2D Ground Wire AWG Torque in In Lbs 14 AWG 40 LBS 12 AWG 40 LBS 10 AWG 40 LBS Ground Wire AWG Torque in In Lbs 8 AWG 45 LBS ...

Page 25: ...instructions remove the Module by pivoting it up and out or reverse drop in procedure Figure 7 1B Then using the Flat Tool rotate both Interlock Zeps from each of the Interlocks connected to the top edge of the second Module going down the column to positions 1 Figure 7 1C Once the Interlock Zeps have been rotated place the Flat Tool in the gap between the two Modules attach it between the Interlo...

Page 26: ... 26 of 28 ZEP SYSTEM II INSTALLATION MANUAL Figure 7 1C Figure 7 1E Figure 7 1D Figure 7 1F 8 0 Technical Support For questions regarding the design and installation of the Zep System II PV Module Installation System please contact support zepsolar com or 415 479 6900 ...

Page 27: ...ompleted or 2 thirty 30 days after the purchase of the Products by the original Purchaser What We Will Do ZEP SOLAR will at its sole option either repair or replace 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 component within a...

Page 28: ...ive components How to Make a Warranty Claim If Purchaser believes that it has a claim for repair or replacement under this warranty Purchaser must contact Zep 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 10...

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