Installation Instructions

Transcription

1 Tile Integrated Mounting System Installation Instructions This document describes basic installation procedures for Zep Solar s tile-integrated mounting system for use with Zep Compatible PV modules installed on tile roofs. The ZS Tile mounting solution for tile roofs completely eliminates the need for mounting rails and modification of eisting roof tiles. ZS Tile utilizes a replacement tile system that attaches directly to the rafter or framing member. Designed for ease and speed of installation, ZS Tile works with all Zep Compatible PV modules. ZS Tile is compatible with most common roof tile types where each tile interlocks with the surrounding tile. Flashings are offered for S tile, W tile, and flat tile. Notes Suitable for Landscape and Portrait orientations. (Drop-in direction is North-South only.) Roof sheathing required, 15/32 minimum thickness. Assumes a tile reveal between 13 and 14 inches. This is not a full installation manual. The installation of the replacement tile system is covered in detail. The remainder of the system installation is similar to that for ZS Comp or ZS Span. Please refer to the installation manuals and videos for those solutions for complete instructions. 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 1 of 20 Document # Rev C Date last eported: December 4, :29 AM

2 Components and Fasteners Tile Roof Attachment Kit Part No Mounting Platform Alignment Ridge EPDM backing Anti-Rotation Plate Lag Screw Plates Mounting Base Top Arm stud, used for attaching the Leveling Foot 5/16 threaded stud Mounting Holes Shipped Separately Part No Top Arm 5/16 4 Stainless steel 5/16 he nut Stainless steel 5/16 washer Stainless steel M10 25mm M10 70mm Lag Screws (2) Attaches Mounting Base to rafter. Note: additional deck screws (not included) may be required in some conditions. See Additional Items Required on page 8. Custom Flange Bolt (1) Attaches Anti-Rotation Plate and Tile Flashing to Mounting Base Custom Flange Bolt (1) Attaches Top Arm to Anti-Rotation Plate, Tile Flashing, and Mounting Base All fasteners use a 1/2 socket. Nut (1) Washer (1) Attaches Leveling Foot to Arm 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 2 of 20 Document # Rev C Date last eported: December 4, :29 AM

3 ZS TILE: TILE INTEGRATED MOUNTING SYSTEM INSTALL ATION Components and Fasteners, Continued Tile Flashings - S-Tile Landing Pad S-Tile Flashing, Type A Part No overall X dimension Suitable as a replacement for compatible concrete S-tiles /EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. Document # Rev C PAGE: 3 of 20 Date last eported: December 4, :29 AM

4 ZS TILE: TILE INTEGRATED MOUNTING SYSTEM INSTALL ATION Components and Fasteners, Continued Tile Flashings - W-Tile eposed X dimension W-Tile Flashing, Type A Part No Suitable as a replacement for compatible concrete W-tiles /EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. Document # Rev C PAGE: 4 of 20 Date last eported: December 4, :29 AM

5 Components and Fasteners, Continued Tile Flashings - Flat Tile Flat Tile Flashing, Type A Part No eposed X dimension 12.2 Suitable as a replacement for compatible concrete flat tiles 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 5 of 20 Document # Rev C Date last eported: December 4, :29 AM

6 Eploded Installation Diagram Leveling Foot attaches to Top Arm stud Top Arm attaches to Anti-Rotation Plate, Tile Flashing, and Mounting Base Top Arm stud Anti-Rotation Plate attaches to Tile Flashing and Mounting Base Roof sheathing Mounting Base attaches through roof sheathing to rafter Rafter 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 6 of 20 Document # Rev C Date last eported: December 4, :29 AM

7 Determining Tile Compatibility ZS Tile flashings are designed to be compatible with a range of roof tiles, with options for the most typical S, W, and Flat tiles found in the U.S. market. Zep Solar, Inc. has developed a series of tools and documents to aid in visual and measurable roof assessment. ZS Tile Process - A high-level presentation for project managers that outlines the tools and aids available to support each step of the sales and installation process, from visual assessment through final site inspection. ZS Tile Compatibility Guide for Sales - A presentation for front-line salespeople who may be responsible for identifying potentially compatible buildings from the street, without having access to the roof. ZS Tile Compatibility Guide for Auditors - A guide for site surveyors or designers who are responsible for making the final determination of tile compatibility. This guide contains detailed tile measurements, tile brands, and visual comparisons. Additional items are available to assist installers, system designers, and other project team members at various stages during the project. Please contact Zep Solar Support for a complete list of available resources. Note Zep Solar also offers an alternate solution, ZS Span, which works on tile roofs that may not be compatible with ZS Tile. 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 7 of 20 Document # Rev C Date last eported: December 4, :29 AM

8 Additional Items Required 3/16 or 7/32 drill bit 1/2 socket and socket wrench An additional 1/8 drill bit may be required for installation of modules in Portrait orientation. (Required when installing modules in Portrait orientation) Deck screws #10 1 1/2 sharp point Philips pancake head screw 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 8 of 20 Document # Rev C Date last eported: December 4, :29 AM

9 Installation Step 1. Mark Array Perimeter 1 Mark lower array perimeter 4 inches up from lower edge of first tile course to be pulled Array dimension = Module dimension + 1/2 inch per module 2 Chalk module spacing at East and West edges of array Module dimension + 1/2 2 modules + (2 1/2 ) 3 modules + (3 1/2 ) 3 4 Snap horizontal chalk lines Mark module vertical seams along lower edge of array, to help identify potential Interlock/Leveling Foot conflicts later on. 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 9 of 20 Document # Rev C Date last eported: December 4, :29 AM

10 Step 2. Choose Rafters 1 2 Pulled tile Identify first rafters within East and West edges of array and verify that these rafters are within allowable module cantilever. Maimum allowable module cantilever is 1/3 of the maimum allowable span. For modules in Portrait orientation, the cantilever cannot be greater than 1/2 the module s width. Pull tiles all the way up the outer columns. Verify rafter location at each tile pulled and mark rafter center on roof sheathing. Note: If a rafter drifts to a different tile going up the column, verify that rafter remains within module cantilever allowance all the way up. Shift array if needed. 3 Sample layout diagram Maimum span Rafters Staggered attachment points OK Work across the array and choose rafters based on the project s maimum allowable span. 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 10 of 20 Document # Rev C Date last eported: December 4, :29 AM

11 Step 3. Remove Tiles and Mark Rafter Centers Verify rafter position after removing tiles. Mark roof sheathing to indicate rafter centers. Which Tile to Pull? East or West Tile? Chalk line falls in the middle of a tile - pull that tile Pull tile closest to center of rafter Chalk line falls at lower edge of a tile - pull upper tile Chalk line falls within 1 of tile above - pull upper tile 1 or less 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 11 of 20 Document # Rev C Date last eported: December 4, :29 AM

12 Step 4. Install Mounting Bases Orient the Mounting Base to reach the nearest rafter 1 Vertical Position Mounting Platform Headlap Tile reveal 7.0 Measure from lower edge of tiles in same row Center of Mounting Platform on the Mounting Base must be positioned 7 up from down-roof edge of adjacent tiles. (not to scale) 2 Horizontal Position Landing Pad Place the Mounting Base in the approimate position. Place the Tile Flashing on top so it fits with the surrounding tiles. Adjust Mounting Base position. Holes in the Tile Flashing should align with the holes in the Mounting Base. Note: Zep Solar, Inc. is developing placement jigs to aid in Mounting Base placement. Please contact Zep Solar Support for more information. Mounting Platform 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 12 of 20 Document # Rev C Date last eported: December 4, :29 AM

13 Install Mounting Bases, Continued 3 Drill and Seal Drill closest to the chalk mark indicating rafter center. With the Mounting Base in position, drill the desired lag screw holes into the rafter. Lift the Mounting Base, remove debris, and add appropriately rated sealant. 4 Secure Mounting Base to Rafter Use Lag Screws provided or Zep Solar-approved equivalent. Important Note: Additional fasteners and battens are required for the Mounting Base when installing modules in Portrait orientation. Lag Screw minimum penetration into rafter is 2.5 (65mm). See Additional Notes on page 20 or contact Zep Solar Support for more information. 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 13 of 20 Document # Rev C Date last eported: December 4, :29 AM

14 Step 5. Attach Tile Flashings 1 Flashing Postion 2 Flashing should fit snugly. Water channels should match up with surrounding tiles on both sides, within acceptable range. Anti-Rotation Plate Use 25mm Custom Flange Bolt provided. Either hole OK - helps to avoid conflicts between Leveling Feet and Interlocks Water Channel Should Fit Both Sides Ideal fit W-Tile Flat Tile Acceptable fit is anywhere within range Flat Tile W-Tile Left Side Right Side 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 14 of 20 Document # Rev C Date last eported: December 4, :29 AM

15 Step 6. Install Top Arms Use 70mm Custom Flange Bolt provided. Horizontal Positioning Fleibility (For front row, ideal Top Arm position is lowest hole, just past Top Arm stud) 2.0 Align the Top Arm stud at or above chalk marks for module seam (0-2 range). Note: The most ideal position is eactly 2 above module seam. The Top Arm and the fastener for the Anti- Rotation Plate can go in either hole. (Shifting the Top Arm can help avoid conflicts between Interlocks and Leveling Feet.) Top Arm Stud Vertical Positioning For easier installation, Top Arm stud should be within 2 inches above the chalk line indicating the module seam. Allowable But Less Advised Top Arm stud can land below chalk line, but this makes the Leveling Foot more difficult to attach. (Typically, in the field of the array, the installer will attach the Key side of the Leveling Foot Rockit to the rear of the lower module first, before bolting the Leveling Foot to the Top Arm. If the Leveling Foot base is underneath the module, bolting it down requires reaching underneath the module.) 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 15 of 20 Document # Rev C Date last eported: December 4, :29 AM

16 Install Top Arms, Continued Avoid NO NO Do not install Top Arm horizontally (design prevents this) Top Arm should not touch tile edge above 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 16 of 20 Document # Rev C Date last eported: December 4, :29 AM

17 Step 7. Install Front-Row Leveling Feet 1 Install Outer Leveling Feet Use 5/16 Nut and Washer provided. Chalk line indicating module seam 2 String Line 3 Align Middle Leveling Feet Use Leveling Foot stud to align the middle Leveling Feet to the string line. 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 17 of 20 Document # Rev C Date last eported: December 4, :29 AM

18 Front-Row Leveling Feet, Continued 4 Level Rockits to String Line Rockit Spin the Rockit to raise or lower. Key side Tongue side Before After Leveling Foot Fleible Positioning 360 degrees Slot range Eception: If the Arm is etended all the way up or all the way down, the Leveling Foot cannot be at an angle greater than 90 degrees. NO NO 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 18 of 20 Document # Rev C Date last eported: December 4, :29 AM

19 From this point onwards, the installation sequence for ZS Tile is similar to that for ZS Comp. Proceed at will, young Jedi. Please refer to the ZS Comp Installation Manual and/or the Zep Solar installation videos for more information. 2013/EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 19 of 20 Document # Rev C Date last eported: December 4, :29 AM

20 Additional Notes Design Setback Recommendations for ZS Tile Minimum recommended buffers are as follows: 18 from eave (no closer than 2nd tile course) Ridge Obstacle from center of un-mortared ridge cap (no closer than 2nd tile course) from center of mortared ridge cap (no closer than 3rd tile course) 12 from rooftop obstructions (i.e., 1 tile width) from hips, valleys, and roof edges, more if these areas are mortared Do not lay out modules directly over non-removable tiles. 18 Observe local fire code setbacks where required. Special Requirements for Portrait Installation When installing modules in Portrait orientation, the Mounting Base requires either an additional pre-drilled batten placed up-roof from the Mounting Base attached with deck screws, or additional deck screws attached to the opposite end of the lag screws. Both of these are in addition to the usual Lag Screws. Roof sheathing minimum thickness of 15/32 required. Please contact Zep Solar Support for further information. Portrait orientation #10 1 1/2 sharp point Philips pancake head deck screw Pre-drilled batten /8 (Use 1/8 drill bit for pre-drilling the batten) Mounting Base Option 1 Option /EN Zep Solar, Inc. Zep Solar reserves the right to make specifications changes without any prior notice. All rights reserved. PAGE: 20 of 20 Document # Rev C Date last eported: December 4, :29 AM