ZepSolar ZEP SYSTEM II Manuale utente

VERSION 1.0

Zep System II

PV Module Installation Manual

ZEP SYSTEM  INSTALLATION MANUAL

Table of Contents

1.0 > Introduction �� 4

2.0 > Safety Precautions �� 4

2.1 > General Safety �� 4

2.2 > Installation Safety �� 5

3.0 > Zep System II Overview �� 5

4.0 > System Design and Layout �� 8

4.1 > Code Compliance Certiﬁcation and Tables �� 8

4.2 > Array Layout & Bill of Materials �� 10

5.0 > Mechanical Installation �� 13

5.1 > Mechanical Installation Requirements �� 13

5.2 > Mechanical Installation 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 an Interlock at a Thermal Break �� 23

6.0 > Electrical Installation �� 24

6.1 > Electrical Installation Requirements �� 24

6.2 > Grounding System Installation �� 24

7.0 > Maintenance and Troubleshooting �� 26

7.1 > Module Removal Procedure �� 26

8.0 > Technical Support �� 27

9.0 > Limited Warranty �� 28

ZEP SYSTEM  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.

ZEP SYSTEM  INSTALLATION MANUAL

2.2 > Installation Safety

Check applicable building codes or refer to 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.

2. Ensure that all lag screws or alternative methods of attachment have adequate pullout strength

and shear capacity for the application.

3. The Zep System must be installed over a ﬁre resistant roof covering rated for its application.

4. The Interlock, Leveling Foot, and Ground Zep should be installed only with the use of the Zep

Tool or Flat Tool provided by Zep Solar.

5. During 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 hardware, an entire array can be installed with only

three parts — the Interlock, the Leveling Foot, and the Ground Zep. Zep Solar also offers accessory

items such as the Zep Comp Mount and Zep Wire Clip.

Figure 3.0A — Interlock

The Interlock installs in the nominal east-west dimension and

provides both structural and ground bond connections in both

east-west and north-south dimensions.

Figure 3.0B — Leveling Foot

The Leveling Foot installs into the Zep Grooves and resides at

locations along the array’s horizontal seams.

ZEP SYSTEM  INSTALLATION MANUAL

Figure 3.0C — Ground Zep

The Ground Zep rotates into the Zep Groove with a quarter turn

and provides 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.

ZEP SYSTEM  INSTALLATION MANUAL

Figure 3.0H — Zep System Components in an Array

The array in the ﬁgure above consists of nine (9) Modules, eight (8) Interlocks, twelve (12) Leveling Feet and one (1) Ground Zep.

NOTE: Interlocks and Leveling Feet are always installed on the Module grooves 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 space and can be installed faster and with greater spans between Interlocks.

INTERLOCK – 8 XMODULE – 9 X LEVELING FEET – 12 XEAST / WEST

NORTH / SOUTH

ZEP SYSTEM  INSTALLATION MANUAL

Figure 3.0I — Zep Tool Figure 3.0J — Zep Flat Tool

4.0 > System Design and Layout

4.1 > Code Compliance Certiﬁcation and Tables

Zep System II is in compliance with the structural requirements of the 2006 International Building

Code and ASCE 7-05 based on the conﬁgurations and criteria provided in the Certiﬁcation Letter and ac-

companying tables (go to: www.zepsolar.com/resources.html). These tables deﬁne the maximum lev-

eling foot spacing requirements for a range of site-speciﬁc variables including Roof Pitch (Figure 4.1A),

Wind Exposure Category (Figure 4.1B), Basic Wind Speed (www.windspeedbyzip.com or refer to your

local jurisdiction), Roof Zone (Figure 4.1C), and Ground Snow Load (www.groundsnowloadbyzip.com

or 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

the tables in the certiﬁcation letter to determine the maximum allowable spacing between Leveling

Feet. If your site conditions are outside the assumptions above, refer to ASCE 7-05 or contact a

structural engineer for assistance.

An entire Zep array can be interconnected with the use of a single tool. Both the Zep Tool and the Flat

Tool provide means for installing the Interlock, the Leveling Foot, and the Ground Zep. The Flat Tool

provides a low-cost alternative to the Zep Tool and also functions to enable inter-Module removal.

The Zep Tool can receive a T30 Torx bit for adjusting the height of the Leveling Feet.

ZEP SYSTEM  INSTALLATION MANUAL

Figure 4.1A — Roof Pitch

Figure 4.1B — Wind Exposure Categories

Figure 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 — Open Terrain/Scattered Obstructions

D — Flat, Unobstructed Area

7 DEGREES – 15:12

27 DEGREES – 6:12

45 DEGREES – 12:12

ZEP SYSTEM  INSTALLATION MANUAL

4.2 > Array Layout & Bill of Materials

During the site visit, record information pertaining to the speciﬁc roof area where the Modules will be

mounted. This includes roof azimuth angle, roof pitch, dimensions of the mounting area including all

obstructions such as chimneys or vents, the rafter schedule, rafter lumber type if available, rooﬁng

material, and shading factor. Once you have this information, you can begin to create a layout diagram

on paper or with a drawing program that identiﬁes the placement of the array.

NOTE:

Alternately, you can create your layout directly on the roof at the time of installation.

However, since this method will not allow you to conﬁrm the exact quantity of components

ahead of time, it is recommended that you have extra hardware available to account for

unforeseen layout conﬁgurations.

When determining the overall array dimensions, calculate ½" gaps per every vertical and horizontal

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 Interlocks have been indicated with rectangles where the corners of the Modules

intersect.

On your diagram, draw your rafter layout and then superimpose a drawing of your array in its desired

location. Locate an Interlock at every vertical seam in an east-west orientation as in Figure 4.2A.

Then, mark the Leveling Feet locations according to the maximum allowable spacing determined by

your span tables.

NOTE: It is not necessary to install Interlocks along the east and west edges of the array.

If the location of an Interlock prevents locating the Leveling Foot on a desired rafter, shift the

Leveling Foot to the nearest adjacent rafter while maintaining span and cantilever requirements.

This is indicated in Figure 4.2A with dashed circles where Leveling Feet have been relocated to the

left due to an Interlock location conﬂict.

ZEP SYSTEM  INSTALLATION MANUAL

The maximum cantilever at the edge of the array is determined by multiplying the maximum span

by 0.33. In the example below, the span between Leveling Feet is 48” which allows for a maximum

cantilever of 16”. It is recommended that Leveling Feet not be installed within 2” of the corner of the

Module. Therefore, the allowable mounting zone for the last foot in a row (End-Foot Zone) is in an

area within the cantilever allowance not including the last two inches of the Module. On the right side

of Figure 4.2A, the cantilever originally exceeded 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 distance B represents the area where a

Leveling Foot can be attached (End-Foot Zone). In Figure 4.2B, example #1 illustrates proper place-

ment, allowing the rafters to meet the cantilever requirements. In example #2, the right side of the

row does not meet the cantilever requirements so the entire array would need to shift a few inches

to the left in order to allow for proper support of the cantilevers.

Figure 4.2A — Identifying Leveling Feet and Interlocks

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