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GAF DecoTech Installation Instructions Manual

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GAF Solar Energy System
©2019 GAF
All Rights Reserved.
Version 3.1
08/2019

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Summary of Contents for GAF DecoTech

  • Page 1 P a g e GAF Solar Energy System ©2019 GAF All Rights Reserved. Version 3.1 08/2019...

  • Page 2: Table Of Contents

    Main Components of the GAF Solar Energy System ..............9 GAF Solar System Components ....................10 Solar Array Configurations ......................13 SECTION 3 — GAF SOLAR ENERGY SYSTEM CONSIDERATIONS AND REQUIREMENTS ......14 Design Considerations ........................14 Installation Requirements ......................16 Grounding ............................
  • Page 3 P a g e GAF Solar Energy System Codes and Standards ................58 Alternate Solar System Configurations ..................59 Version Control ............................ 63...

  • Page 4: Section 1 - Introduction

    GAF periodically makes changes to its products and application specifications. GAF reserves the right to change or modify, at its discretion, any of the information, requirements, specifications, or policies contained herein. Please be sure to check gaf.com/solar...

  • Page 5: Definitions

    Back Figure 1 GAF Solar Module Assembly GAF Solar Energy System — The combination of GAF underlayment, Module Assemblies, Starter Bars, and Flashing make up the GAF Solar Energy System as shown in Figure 2. Figure 2 GAF Solar Energy System...

  • Page 6: General Safety Precautions

    P a g e General Safety Precautions  Must be installed by a qualified person… The GAF Solar Energy System must be installed by a PROPERLY TRAINED and QUALIFIED INSTALLER. It is the responsibility of every installer to know and follow local code requirements.

  • Page 7: Electrical Safety Precautions

    P a g e  Inspect for damage… Do not use GAF Solar Energy System components if there are visible signs of damage from transport or handling.  Handling the Module Assembly… Always have two people carry the product by its frame. Do not support the solar modules on your head as a hard hat may damage the PV back sheet.
  • Page 8 P a g e product, use care to ensure surfaces and equipment are at touch-safe temperatures and voltage potentials (by testing with a multimeter) before proceeding. Anytime the MLPE has been disconnected from the power network, use extreme caution as some components can retain a charge sufficient to create a shock hazard.

  • Page 9: Section 2 - Gaf Solar Energy System Overview

    SECTION 2 - GAF SOLAR ENERGY SYSTEM OVERVIEW Main Components of the GAF Solar Energy System The three main components of the GAF Solar Energy System are: •Attaches to the deck and is installed underneath the Solar Array GAF Underlayment System •Provides a Class A fire rating...

  • Page 10: Gaf Solar System Components

    P a g e | 10 GAF Solar System Components Figure 5 shows all of the hardware components that comprise GAF Solar Energy System. Top Corner Flashing Top Flashing Top Flashing Support MLP Bracket w/Grounding Lug Left Counterflashing Adjustable Foot...
  • Page 11 P a g e | 11 The SKU Numbers for GAF components are shown in Table 1 below. Table 1 GAF SKU Numbers COMPONENT GAF SKU # SILFAB SOLARIA Module 2947401 2947452 Starter Bar 2947405 2947441 Adjustable Foot Base 2947402...
  • Page 12 The System can be designed with either a DC power optimizer or an AC Microinverter. Follow the MLPE manufacturer’s installation instructions. Additional components may be required.  GAF recommends the use of factory-certified PV cables instead of field-crimping PV wire and connectors. ...

  • Page 13: Solar Array Configurations

    P a g e | 13 Solar Array Configurations The solar array can be laid out in various shapes. The available configurations are shown in Figure 6. The assembly instructions in Section 4 assume a rectangular Configuration “A” layout. Installation instructions for the other configurations can be found in the Appendix (Page 59).

  • Page 14: Section 3 - Gaf Solar Energy System Considerations And Requirements

    AND REQUIREMENTS Design Considerations  Slope limitations… The GAF Solar Energy System is intended for use solely on roofs having a slope between 4:12 and 12:12.  Deck mounting… The GAF Solar Energy System is installed directly to the roof deck without engaging rafters and requires underlayment as specified in these instructions.
  • Page 15 Attic ventilation… If the GAF Solar Energy System covers a large area of the roof, proper attic ventilation and moisture control must be considered.  Ice dams… Do not install the GAF Solar Energy System near areas of the roof that are prone to ice damming. ...

  • Page 16: Installation Requirements

    Safety first… Follow all of the safety precautions outlined in Section 1.  Follow roofing best practices… Follow all related GAF Shingle application instructions and industry best practices. Special attention is needed when stripping the shingles, installing underlayment, and flashing around the GAF Solar Energy System.

  • Page 17: Grounding

    (See Permit Design Drawings for details on this terminating connection.) Each GAF Solar Module Assembly is bonded to the solid copper ground wire through the MLPE bracket using a UL Listed WEEB® Grounding Lug and Washer (WEEB®-LUG-...
  • Page 18 Figure 8 Bonding GAF Solar Module Assembly to Copper Wire The adjustable feet and MLPE bracket are bonded to the GAF frame with the provided hex grounding screw (10-32x3/8”, serrated washer, thread cutting type F) as shown in Figure 9 below.
  • Page 19 P a g e | 19 Top Flashing DynoBond™ Clip Figure 11 DynoBond™ clip connection to flashing MLPE WEEB ® Grounding Assembly Figure 12 Connection between DynoBond™ Jumper and copper ground wire...
  • Page 20 P a g e | 20 Bare Solid Copper Wire MLPE Foot " ™ DynoBond Jumper Figure 13 Alternate system configuration using DynoBond™ clips in place of ground wire Alternatively, the system can be gounded using only DynoBond™ clips and omitting a traditional ground wire.

  • Page 21: Recommended Tools

    P a g e | 21 Recommended Tools The following tools (Figure 14) are recommended to properly install a GAF Solar Energy System (this list is representative only; additional tools may be required depending on the installation):  Cordless drill ...

  • Page 22: Prior To Installation

    P a g e | 22 Prior to Installation The following should be completed prior to the installation of the GAF Solar Energy System:  Review documentation… Review the installation instructions and Permit Design Drawings thoroughly.  Ensure materials are onsite… Ensure that all the correct materials in the appropriate quantities are present onsite.

  • Page 23: Section 4 - Gaf Solar Energy System Installation

    P a g e | 23 SECTION 4 — GAF SOLAR ENERGY SYSTEM INSTALLATION The following steps outline the procedure to install the GAF Solar Energy System and are described in this Section: • Prep the Roof Step 1 • Build the Starter Bar and the Solar Module Assembly Step 2 •...

  • Page 24: Step 1: Prep The Roof

    Install Roofing Components on Eaves and Rakes… Install a drip edge, leak barrier, and starter roll along the eaves and rakes using industry best practices. Refer to the latest version of the GAF Steep Slope PRO Field Guide for guidance. Step 1c: Install Initial Rows of Shingles up to Planned Location of the Starter Bars...
  • Page 25 Figure 16 Install initial rows of shingles Note  The GAF Solar Energy System requires a minimum two rows of shingles to be installed at the eave. Step 1d: Install the Leak Barrier Underlayment in the Field of the Solar Array... Begin by snapping the following chalk lines on the deck: ...
  • Page 26 P a g e | 26 1.5" Leak Barrier Solar Array Figure 18 Install the leak barrier underlayment Step 1e: Install QuickStart® Peel and Stick Starter Roll... Install the QuickStart® Peel and Stick Starter Roll over the shingle headlap, covering the 1.5 inch (38 mm) gap between the leak barrier and the top of the shingle exposure (Figure 19).
  • Page 27 P a g e | 27 For slopes between 4:12 and 6:12, side and end laps should be fastened 12 inches (305 mm) on center (o.c.) and 24 inches (610 mm) o.c. elsewhere. Stagger each row of 12 inches spaced fasteners.

  • Page 28: Step 2: Build The Starter Bars And The Solar Module Assemblies

    P a g e | 28 Step 2: Build the Starter Bars and the Solar Module Assemblies Follow the sequence below to complete this step. Step 2a: Assemble the Starter Bars Step 2b: Install the Adjustable Feet Step 2c: Install the MLPE Brackets Step 2d: Install the WEEB®...
  • Page 29 | 29 Figure 22 Splice between adjacent Starter Bars The GAF Solar Module Assembly is composed of the parts shown in Figure 23 below. Steps 2b-2f describe the steps necessary to complete this assembly. The completed assembly is shown in Figure 31 on Page 33.
  • Page 30 Hook onto the Channel Channel and Rotate Solar Module Frame Adjustable Feet Wiper Seal Grounding Align the Pre- Screw drilled Holes Figure 24 Mounting the Adjustable Foot Adjustable Feet MLPE bracket location Module Junction Box Figure 25 Completed GAF Solar Module Assembly...
  • Page 31 P a g e | 31 Step 2c: Install the MLPE Bracket..Position the MLPE Bracket in between the Adjustable Feet on the junction box end of the module as shown in Figure 25. The MLPE bracket is installed in the same manner as the adjustable feet.
  • Page 32 P a g e | 32 MLPE Bracket WEEB ® Grounding Assembly Figure 28 Attach WEEB Ground Assembly to MLPE Connect the module cables to the mating connectors on the Step 2e: Connect the PV Wires... MLPE. Wiring Connectors Figure 29 Attach connectors Step 2f: Ensure Proper Wire Management...
  • Page 33 P a g e | 33 Wire Ties MLPE Bracket Figure 30 Proper wire management. Figure 31 shows the front and back of the completed GAF Solar Module Assembly. Front Back Figure 31 Completed Module Assembly...

  • Page 34: Step 3: Install The Starter Bar

    P a g e | 34 Step 3: Install the Starter Bar Follow the sequence below to complete this step. Step 3b: Position and Attach the Starter Bars to Step 3a: Snap Chalk Line the Deck Step 3a: Snap Chalk Line… Snap a chalk line 5.25 inches (133 mm) from the edge of the shingle exposure line (Figure 32).
  • Page 35 P a g e | 35 Note  Because adjacent Starter Bars are spliced together using a common Foot Base, it is typically easier to assemble all of the Starter Bars together before attaching them to the deck. This allows the entire row to be aligned at once (Figure 34 ).

  • Page 36: Step 4: Install The First Row Of Solar Module Assemblies

    P a g e | 36 Step 4: Install the First Row of Solar Module Assemblies Follow the sequence below to complete this step. Step 4c: Attach the Step 4b: Make Step 4a: Mount the Solar Module Solar Module Step 4d: Install Step 4e: Create the Electrical Connections Assemblies onto the Starter Bar...
  • Page 37 P a g e | 37 Stretch a mason line along the top edge of the row of Solar Module Assemblies to verify that all of the Assemblies are at the same height (Figure 37). Adjust the feet as necessary. Mason Line along the Top Edge of Solar...
  • Page 38 P a g e | 38 Figure 39 Typical MLPE Connections Note  Refer to the MLPE manufacturer’s installation instructions for any electrical testing and verification steps that may be required before proceeding. Step 4c: Align and Attach the Solar Module Assemblies to the Deck... Starting from the rightmost Solar Module Assembly in the row, align the inner edge of the module with the outer edge of the Starter Bar, per Figure 40.
  • Page 39 P a g e | 39 The number of #14 – 1-1/2” (37.5mm) Panel-Tite Roofing Fasteners required per foot depends on the number of feet and mounting surface. Follow the table below: Decking Type Plywood 3 Screws per Mounting Foot 6 Screws per Mounting Foot Do not overtighten the roofing fasteners.
  • Page 40 P a g e | 40 Affix the Bar Code to the MLPE Map Peel the MLPE Bar Code Figure 43 Create MLPE Map...

  • Page 41: Step 5: Install The Remaining Rows Of Solar Module Assemblies

    P a g e | 41 Step 5: Install the Remaining Rows of Solar Module Assemblies Follow the sequence below to complete this step. Step 5a: Install Row of Solar Step 5b: Electrically Connect Row to Module Assemblies Step 5a: Install Row of Solar Module Assemblies…...

  • Page 42: Step 6: Install Side Flashing

    Install Step Flashing… The Step Flashing installs as you would with a typical skylight. Slip the first Step Flashing behind the Starter Bar Cover. Continue installing the Step Flashing and shingles up to the top of the array. Repeat for each side. See the GAF Steep Slope PRO Field Guide for installation assistance.
  • Page 43 P a g e | 43 Last Step Flashing and Shingle Top Corner Flashing Figure 48 Step Flashing Overlap Step 6c: Install Counterflashing… The Counterflashing is installed from the bottom to the top. The Counterflashing is first mounted on a channel within the module frame and then pressed until a snap fit is created.

  • Page 44: Step 7: Install Top Flashing

    P a g e | 44 Step 7: Install Top Flashing Follow the sequence below to complete this step. Step 7b: Install the Top Step 7c: Position the Top Step 7a: Install the Top Flashing Frame Insert Flashing Supports and Flashing DynoBond™...
  • Page 45 P a g e | 45 Route Wires Through Position the Corner Top Nail Only Within 1" (25 mm) from the Edge. This Opening Flashing Support as Shown 1" ¼"-½" Top Flashing Supports within the Array Center the Top Flashing Support on the Overlap Figure 51 Locations of Top Flashing Supports Notes...
  • Page 46 P a g e | 46 Step 7c: Position the Top Flashing… Position the Top Flashing so that it is aligned with the Solar Module Assembly. The Top Flashing hooks into the Top Flashing Frame Insert (Figure 54). Figure 54 Positioning the Top Flashing Step 7d: Install the Grounding Clips on the Top Flashing...
  • Page 47 P a g e | 47 Step 7e: Nail the Top Flashing in Place... Attach the Top Flashing to the deck using a minimum of four evenly spaced standard roofing nails. Trim excess VersaShield® SOLO™ within ~1 inch of the Top Flashing.
  • Page 48 P a g e | 48 Top Flashing Top Corner Flashing Figure 57 Install Top Corner Flashing Figure 58 Top Corner Flashing with Conduit...

  • Page 49: Step 8: Install Top Flashing Underlayment And Complete Shingles

    P a g e | 49 Step 8: Install Top Flashing Underlayment and Complete Shingles Follow the sequence below to complete this step. Step 8a: Install the Step 8b: Install Step 8d: Install Step 8c: Install Step 8e: Install QuickStart® Starter Roll Shingles Over the QuickStart®...
  • Page 50 P a g e | 50 Leak Barrier Leak Barrier Top Corner Flashing Shingle Leak Barrier Figure 61 Install leak Barrier over Top Flashing and Shingles Step 8d: Install QuickStart® Peel and Stick Starter Roll over the Leak Barrier... The QuickStart® Peel and Stick Starter Roll is the starter course for the row of shingles that will be installed above the array.

  • Page 51: Completed Gaf Solar Energy System

    Install Remaining Rows of Shingles… Continue installing shingles up to the roof peak following roofing best practices (Figure 63). Figure 63 Complete Installing Shingles Completed GAF Solar Energy System The following figure shows the completed GAF Solar Energy System. Figure 64 Completed GAF Solar Energy System...

  • Page 52: Section 5 - Wire Management

    | 52 SECTION 5 — WIRE MANAGEMENT An MLPE (AC Microinverter or DC Power Optimizer) is integrated into the GAF Module Assembly. Following are typical examples of how the MLPES are wired in the field. Refer to the Permit Design Drawings for exact details for your installation.
  • Page 53 P a g e | 53 The installing contractor must ensure that none of the wiring comes in contact with any of the Side Flashing. Use wire ties wherever necessary and route the wires through the gaps between the Adjustable Feet for proper wire management (Figure 67). The minimum clearance between the wires and Side Flashing is 2 inches (51 mm).

  • Page 54: Section 6 - Gaf Solar Energy System Maninenance

     Do NOT attempt to clean soiled solar module assemblies. GAF Solar Module Assemblies are naturally cleaned by seasonal rains. In the unlikely event that cleaning is required, contact your installer.

  • Page 55: Section 7 - Appendix

    P a g e | 55 SECTION 7 — APPENDIX GAF Solar Module Technical Data Table 4 Solaria Laminate Specifications...
  • Page 56 P a g e | 56 Table 5 Silfab Laminate Specifications...
  • Page 57 P a g e | 57 Table 6 Mechanical Properties of the GAF Solar Energy System With Solaria Laminates With Silfab Laminates Weight (Framed Module + 5 Mounting Feet + MLPE Bracket) 55 lb. (53 kg) 51 lb. (23 kg) Width 45.0 inches (1,143 mm)
  • Page 58 TAS 100 ̶ Test Procedure for Wind and Wind-Driven Rain Resistance of Discontinuous Roof Systems Fire Rating The GAF Solar Module Assembly, in combination with the underlayment system, is classified as a Class A fire rated system per UL 2703.
  • Page 59 P a g e | 59 Alternate Solar System Configurations The GAF Solar Array can be assembled in non-rectangular configurations. This section describes the unique steps required for these configurations. Type B – Left Bottom Inside Corner OR Right Bottom Inside Corner Configuration With this configuration, the Counterflashing must be field-modified to accommodate the adjoining Starter Bar.
  • Page 60 P a g e | 60 Figure 70 Trimming Left Counterflashing Step 2: Install the shingles, underlayment, Starter Bar, Solar Module Assembly, Step Flashing, and the field-trimmed Counterflashing as shown in Figure 71. Underlayment Trimmed Left Trimmed Right Counterflashing Counterflashing Figure 71 Configuration B - Step 2 Step 3: Snap a chalk line to align the Adjustable Feet to the adjacent Starter Bar as shown in Figure...
  • Page 61 P a g e | 61 Figure 73 Configuration B - Step 4 Type C – Left Bottom inside Corner AND Right Bottom inside Corner Configuration With this configuration, the Left and Right Counterflashing as well as the Starter Bar must be field-modified to ensure a proper fit.
  • Page 62 P a g e | 62 Trimmed Right Counterflashing Figure 76 Configuration C - Step 2 Step 3: Install the underlayment. Field modify Starter Bar 3 by removing 1 inch from both sides. Snap a chalk line to align and attach the shortened Starter Bar 3 as shown in Figure 77. Trim the Left Counterflashing as shown in Figure 70.
  • Page 63 P a g e | 63 Version Control Version Number Date Notes 1.0.0 5/2017 Added info on Alignment Pins, Version Control Table, Custom Step Flashing, and lab tested design load values. 1.0.1 7/2017 Added alternate array configurations and 2 wire WEEB lug.

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