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Document #800-0351-001 Rev B

Page i

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

Contents

Introduction ___________________________________________________________1

1.1

ZS Comp Overview .................................................................................................................................................................1

1.2

General Safety Precautions ................................................................................................................................................2

1.3

Zep Compatible ...................................................................................................................................................................... 3

ZS Comp Components _________________________________________________ 5

2.1

ZS Comp Cutaway View ...................................................................................................................................................... 5

2.2

ZS Comp Core Components .............................................................................................................................................. 6

2.3

ZS Comp Accessory Components....................................................................................................................................7

2.4

ZS Comp Tools ....................................................................................................................................................................... 8

Array Design__________________________________________________________ 9

Step 1: Gather Project Data ................................................................................................................................................. 9

Step 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 Possibilities......................................................................................................................................14

Layout Concepts _____________________________________________________ 15

4.1

Drop-In Direction................................................................................................................................................................. 15

4.2

Fixed Rules ............................................................................................................................................................................. 16

4.3

Grounding/Earthing............................................................................................................................................................. 18

4.4

Thermal Expansion ............................................................................................................................................................. 19

4.5

Roof Zones.............................................................................................................................................................................. 22

Installation Process __________________________________________________ 23

Step 1: Mark Out Array Layout on Roof.........................................................................................................................24

Step 2: Install Roof Attachments ...................................................................................................................................25

Step 3: Secure and Align Front-Row Leveling Feet ..................................................................................................26

Step 4: Install Array Skirt ..................................................................................................................................................28

Step 5: Install First Row of Modules..............................................................................................................................32

Special Inset:

Interlocks .................................................................................................................................................38

Special Inset:

Flexible Positioning ...............................................................................................................................40

Special Inset:

Wire Management .................................................................................................................................41

Step 6: Complete the Array................................................................................................................................................43

Step 7: Ground the Array.....................................................................................................................................................44

Special Inset:

Universal Box Brackets and Other Accessories.........................................................................45

Содержание ZS Comp

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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