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GAF DecoTech RI 2000 Installation Instructions Manual

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Summary of Contents for GAF DecoTech RI 2000

  • Page 1 P a g e...

  • Page 2: Table Of Contents

    P a g e TABLE OF CONTENTS SECTION 1 — INTRODUCTION......................... 4 Abbreviations ..........................4 Symbol List ............................. 4 Definitions ............................5 General Safety Precautions......................6 Electrical Safety Precautions ......................7 SECTION 2 — DECOTECH™ SOLAR SYSTEM OVERVIEW ................9 Main Components of the DecoTech™...
  • Page 3 P a g e SECTION 7 — APPENDIX ........................53 ..........53 DecoTech™ Module Assembly Technical Data (Model RI 2000) ................55 DecoTech™ Solar System Codes and Standards ..................57 DecoTech™ Module Assembly Drawings ....................57 DecoTech™ Solar Array Drawing...

  • 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 gafsolar.com...

  • Page 5: Definitions

    P a g e Definitions DecoTech Framed Module (also known as solar module) — A complete environmentally protected unit ™ consisting of a UL 1703-certified PV laminate and integrated framing. This solar module is assembled in the factory and is designed to generate DC power when exposed to sunlight. The solar module is shown in Figure 1.

  • Page 6: General Safety Precautions

    P a g e DecoTech Solar System (also known as solar system) — Solar array with the roofing underlayment, ™ external metallic flashing, and electrical components. The solar system is shown in Figure 4. Figure 4: DecoTech™ S olar S ystem Follow the latest version of the NEC code for standard solar definitions.

  • Page 7: Electrical Safety Precautions

    P a g e Figure 5: Personal Protective Equipment (PPE) • Work only in dry conditions… Use dry equipment & dry tools. Protect all electrical equipment against weather elements. • Eliminate trip and fall hazards… Keep work areas on the roof and ground staging areas organized and clean.
  • Page 8 DC or AC cables or connectors in the field. • Do not repair… The solar module assembly does not contain any user-serviceable parts. If the product fails, it should be replaced by contacting GAF. Tampering with the DecoTech™ Module Assembly will void the warranty of the product. •...

  • Page 9: Section 2 - Decotech™ Solar System Overview

    P a g e SECTION 2 - DECOTECH™ SOLAR SYSTEM OVERVIEW Main Components of the DecoTech™ Solar System The three main components of the DecoTech ™ Solar System are: •Attaches to the deck & is installed underneath the DecoTech™ Solar Array Underlayment System •Provides a Class A fire rating for the entire DecoTech™...

  • Page 10: Decotech™ Solar System Parts

    P a g e | 10 DecoTech™ Solar System Parts Table 1 shows the parts provided to the installer to build the DecoTech™ Solar System model RI 2000. DecoTech™ Module Assembly Components DecoTech™ Framed Module [SKU 2947100] Solar Mounting Feet Solar Mounting Feet [SKU 2947102] with MLPE [SKU...
  • Page 11 P a g e | 11 Step Flashing [SKU 2947305] Inner Top Flashing [SKU 2947309] Top Flashing Grounding Components DynoRaxx® DynoBond™ Grounding Clip S-8 Split-Bolt Connector [SKU 2947509] [SKU 2947602] Table 1: DecoTech™ S olar S ystem Parts Besides the aforementioned parts, the installer is expected to stock the following materials: •...

  • Page 12: Array Configurations

    P a g e | 12 Array Configurations At this time, the solar array can be assembled only in a rectangular filled configuration (Figure 7). Roof vents, skylights & other obstructions in the field of the solar array need to be relocated. Figure 7: DecoTech™...
  • Page 13 P a g e | 13 Figure 8: Equipment grounding of the S olar Feet Attachments MLPE MLPE Foot ® WEEB Grounding Assembly ® Figure 9: Positioning the WEEB Grounding Assembly & MLPE Torque Wrench MLPE ® Figure 10: Tightening the WEEB Grounding Lug...
  • Page 14 P a g e | 14 #12 or #10 AWG Bare Solid Copper Grounding Wire ® WEEB Terminal Screw Figure 11: Connecting the S olar Module Assembly to the grounding path Dynobond™ Clip Top Flashing Figure 12: Equipment grounding of the Top Flashing using DynoBond™ Clips S-8 Split-Bolt Connector Bare Copper Wire...

  • Page 15: Section 3 - Decotech™ Solar System Considerations And Requirements

    P a g e | 15 SECTION 3 — DECOTECH™ SOLAR SYSTEM CONSIDERATIONS AND REQUIREMENTS Design Considerations • Slope limitations… DecoTech™ Module Assembles are intended for use solely on roofs having a slope between 4:12 and 12:12. • Deck mounting… DecoTech™ Module Assembles must be deck-mounted. They can not be installed over shingles.
  • Page 16 Mounting hardware… The DecoTech™ Module Assembly is intended to be mounted to a roof using only the hardware provided. If other mounting means are employed, this may affect the UL listing, the fire classification rating, and the GAF warranty. •...

  • Page 17: Installation Requirements

    Shingle mismatch… When installing a DecoTech™ Solar Array on an existing roof, all the shingles in the plane of the roof with the solar array must be removed and replaced with GAF Shingles. New shingles used in the plane of the installed solar array may not initially match existing shingles in the other roof planes due to weathering and available colors for new shingles.

  • Page 18: Recommended Tools

    P a g e | 18 • Contact local utility… Contact your local power utility grid company and all authorities having jurisdiction (AHJ) to get necessary approvals before interconnection. • Set-up monitoring… The monitoring system of the power electronics must be configured in order to commission the solar system.

  • Page 19: Prior To Installation

    Review site… Review pre-existing site conditions prior to installation. If the installer notices any abnormalities in pre-existing site conditions, do NOT proceed with the installation until the matter is resolved with the building owner and with GAF. Typical abnormalities include: o Situations where site conditions do not match proposed design...

  • Page 20: Section 4 - Decotech™ Solar System Installation

    P a g e | 20 SECTION 4 — DECOTECH™ SOLAR SYSTEM INSTALLATION The following 8 steps outline the procedure to install the DecoTech™ Solar System: • Build the Solar Module Assembly Step 1 • Prep the Roof Step 2 •...

  • Page 21: Step 1: Build The Solar Module Assembly

    P a g e | 21 Step 1: Build the Solar Module Assembly There are 5 substeps involved in building the solar module assembly. Step 1 is completed at the ground level: Step 1a: Install the Solar Step 1b: Install the WEEB® Step 1c: Ensure Proper Step 1d: Connect the PV Mounting Feet...
  • Page 22 P a g e | 22 Wiper Seal Channel Hook onto Channel Solar Module & rotate Frame Pre-drilled holes Solar Mounting Foot Grounding Screw Align the Pre- drilled Holes Figure 16: DecoTech™ Framed Module with S olar Feet Attachments Solar Mounting Feet Solar Mounting...
  • Page 23 P a g e | 23 o WEEB® Grounding Lug o WEEB® 1/4 -20 Hex Cap Screw, SS (WEEB® Terminal Screw) " o 5/16 -18 Flange Nut, Zinc. " Initially, place the flange nut loosely over the hex cap screw. •...
  • Page 24 P a g e | 24 Wire Ties Figure 20: Attaching Wire Ties Step 1d: Connect the PV Wires... Make the necessary positive (male) and negative (female) wiring connections between the solar module and the MLPE (Figure 21). See Figure 71 & Figure 72 (page 49) for the DC &...

  • Page 25: Step 2: Prep The Roof

    P a g e | 25 Step 2: Prep the Roof There are 9 substeps to be completed in sequence for prepping the roof to receive the solar array: Step 2e: Install Step 2b: Install the Step 2c: Install the Step 2d: Install the QuickStart®...
  • Page 26 Figure 25: Install the Leak Barrier across the Eave Next, install the leak barrier along the rakes, overlapping the leak barrier along the eave (Figure 26). Follow the StormGuard® Film-Surfaced Leak Barrier application instructions, available at gaf.com. Overlap the Leak Barrier...
  • Page 27 P a g e | 27 Drip Edge along the Rake Figure 27: Install the Drip Edge along the Rake Step 2e: Install QuickStart® Peel & Stick Starter Roll along the Eave and over the Rakes... Install the QuickStart® Peel & Stick Starter Roll, initially along the eave, and then proceed to install it over the rakes, covering the drip edges of the roof (Figure 28).
  • Page 28 P a g e | 28 Note: The DecoTech™ Solar System requires a minimum 1 row of shingles to be installed at the eave. Step 2g: Install the Leak Barrier in the Field of the Proposed Solar Array... Snap the following chalk lines on the deck: •...
  • Page 29 P a g e | 29 Step 2h: Install QuickStart® Peel & Stick Starter Roll over the Shingle Headlap... Install the QuickStart® Peel & Stick Starter Roll over the shingle headlap, covering the 1.5" (38 mm) gap between the leak barrier and the top of the shingle exposure (Figure 32). The QuickStart® Peel &...
  • Page 30 P a g e | 30 ® VersaShield SOLO™ Fire- Resistant Slip 1.5" Sheet Chalk line ® QuickStart Peel & Stick Starter Roll Leak Barrier ® VersaShield SOLO™ Fire-Resistant Slip Sheet ® Figure 33: Install VersaS hield S OLO™ Fire-Resistant S lip S heet...

  • Page 31: Step 3: Install The Starter Bar

    P a g e | 31 Step 3: Install the Starter Bar Step 3a: Position the Step 3b: Fasten the Step 3c: Complete the Row of Starter Bars Left Starter Bar Starter Bar to the Deck Step 3a: Position the Left Starter Bar… Snap a chalk line 5" (127 mm) from the edge of the VersaShield®...
  • Page 32 P a g e | 32 Starter Bars Figure 36: Row of S tarter Bars...

  • Page 33: Step 4: Install The First Row Of Solar Module Assemblies

    P a g e | 33 Step 4: Install the First Row of Solar Module Assemblies Installing the first row of solar module assemblies involves 5 substeps as described below: Step 4b: Make Step 4c: Align and Electrical Step 4a: Hook the Solar Module Step 4d: Install Step 4e: Create the Attach the Solar...
  • Page 34 P a g e | 34 Figure 38: Interlocking between the S olar Module Assemblies 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 39). Shim the solar module assemblies if their height needs to be adjusted.
  • Page 35 P a g e | 35 (Male (Female Figure 40: Electrical connection between the MLPEs Note: At this juncture, MLPE manufacturers may have test methods for checking the integrity of the MLPE & the electrical connections. Refer to the MLPE manufacturer’s installation instructions for the process.
  • Page 36 P a g e | 36 Figure 42: Attach the S olar Module Assembly to the Deck Step 4d: Install Grounding... The solar module assemblies must be grounded by following the techniques described on pages 12-14. Slide the copper wire into WEEB® Grounding Lug. (Figure 43).

  • Page 37: Step 5: Install Remaining Solar Module Assemblies In The Solar Array

    P a g e | 37 Step 5: Install Remaining Solar Module Assemblies in the Solar Array Repeat Step 4 for each subsequent row in the array. Step 5a: Install Subsequent Step 5b: Electrically Connect Row to Row Rows of Solar Module Assemblies Step 5a: Install Subsequent Rows of Solar Module Assemblies…...

  • Page 38: Step 6: Install Side Flashings

    P a g e | 38 Step 5b: Electrically Connect Row to Row... Make the necessary electrical connections from row to row (Figure 47, next page), following the permit design. Ensure proper wire management of all the wires, including the home run and the ground wire. Route the home run wire in the spacing between the solar mounting feet.
  • Page 39 P a g e | 39 step flashing in place. Continue step flashing and shingling up to the top left and right corners of the array per roofing best practices (Figure 49, next page). Note: Install step flashing similar to a typical skylight installation. Step Flashing Figure 49: Installing the S tep Flashing...
  • Page 40 P a g e | 40 Left Counterflashing Figure 51: Installing the left Counterflashing Slide the right side counterflashings onto the right side edges of the solar module assemblies (Figure 52). Slide this counterflashing up until it locks in place. The bottom face of the counterflashing will be flush with the module frame.

  • Page 41: Step 7: Install Top Flashings

    P a g e | 41 Step 7: Install Top Flashings Remove the plastic film covering from all top flashing components before installing them. There are 7 substeps to be followed in sequence to install the top flashings: Step 7b: Install the Top Step 7d: Install the Step 7a: Install the inner Top Step 7c: Position the...
  • Page 42 P a g e | 42 Route Wires through Nail only at this Flat End (shown hatched), this opening within 1" from the Edge. Position the Corner Top Flashing Support as 1" shown ¼"-½" Top Flashing Supports within the Array Center the Top Flashing Support over the overlap Figure 55: Location of the Top Flashing S upports...
  • Page 43 P a g e | 43 Step 7c: Position the Top Flashings… Position the top flashings so that they are centered with the solar module assembly below. The top metal flashing hooks into the inner top flashing (Figure 58). Figure 58: Positioning the Top Flashing Step 7d: Install the Grounding Clips on the Top Flashings...
  • Page 44 P a g e | 44 Step 7e: Nail the Row of Top Flashings in Place... Position the row of top flashings. The butt joint between the top flashings should be positioned over the middle of the top flashing support. WARNING: Before fastening the top flashings into the deck, inspect to ensure that no electrical cables are inadvertently routed under the flat portion of the top flashing (Figure 60).
  • Page 45 P a g e | 45 Install the Top Corner Flashings… At the point where the electrical wires exit the solar array, Step drill a hole through the top corner flashing (Figure 62). Top Corner Flashing Figure 62: Hole for conduit exit in the Top Corner Flashing Attach an electrical conduit through this hole and pull all the wires through this conduit (Figure 63).

  • Page 46: Step 8: Top Flashing Weatherization And Shingle Integration

    P a g e | 46 Step 8: Top Flashing Weatherization and Shingle Integration Follow these 5 substeps to complete the top flashing weatherization & shingle integration. These steps should follow roofing industry best practices: Step 8d: Roll out Step 8a: Install the Step 8b: Apply Step 8c: Install the QuickStart®...
  • Page 47 P a g e | 47 infiltration. The leak barrier should extend past the array approximately 3' (914 mm), covering the headlap of the shingles installed along the side of the array. (Figure 67, next page) Leak Barrier Leak Barrier Top Corner Flashing Shingle...
  • Page 48 P a g e | 48 Step 8e: Shingle around the top flashing: Continue installing shingles across the top flashing and above the PV array, following roofing best practices (Figure 69). Figure 69: Installing S hingles around the S olar Array Figure 70 shows the completed DecoTech™...

  • Page 49: Section 5 - Wiring, Labeling, And Monitoring

    P a g e | 49 SECTION 5 — WIRING, LABELING, AND MONITORING An AC microinverter and a DC power optimizer are power electronics components that can be integrated into the DecoTech™ RI 2000 Framed Module. The power electronics is integrated into the frame with appropriate hardware to ensure proper grounding.

  • Page 50: Solar System Safety Labels

    P a g e | 50 The following wiring connections and wire management are done by the installer: • Wiring from solar module to DC optimizer or AC microinverter • Wiring between solar module assemblies for DC optimizer systems • Wiring from the solar module assemblies to the AC trunk cable for AC microinverter systems •...

  • Page 51: Monitoring

    This Manual is not intended to provide exhaustive instructions on the set-up and integration of the monitoring system. GAF is not responsible for any troubleshooting associated with, or failure in, the set-up and integration of the monitoring system.

  • Page 52: Section 6 - Decotech™ Solar System Maintenance

    In the unlikely event that cleaning is required, contact your installer. • Direct all inquiries to GAF Solar Technical Support. • For more information on GAF solar products and services for solar applications, visit gafsolar.com.

  • Page 53: Section 7 - Appendix

    P a g e | 53 SECTION 7 — APPENDIX DecoTech™ Module Assembly Technical Data (Model RI 2000) DecoTech™ RI 2000 laminate specifications (with SolarWorld Sunmodule® Plus laminate): Table 4: S olarWorld laminate electrical specifications...
  • Page 54 P a g e | 54 Mechanical Properties of the DecoTech™ RI 2000 Solar Module (Standard Test Conditions) Weight (DecoTech™ Framed Module + 5 Solar Mounting Feet) 49.1 lb (22.27 kg) Width 40.49" (1,028 mm) Length 67.49" (1,714 mm) Depth, Front 1.67"...

  • Page 55: Decotech™ Solar System Codes And Standards

    P a g e | 55 DecoTech™ Solar System Codes and Standards (Model RI 2000) The DecoTech™ Solar System includes the DecoTech™ Module Assembly (with PV laminate), the underlayment system, and the DC/AC wiring components. Certifications for the DecoTech™ Module Assembly (with PV laminate) and the underlayment system are mentioned below.
  • Page 56 P a g e | 56 VersaShield® SOLO™ Fire-Resistant Slip Sheet is tested and certified to comply with the following standards: • ASTM D146/D828, D1922 • UL Classified • Miami-Dade County Product Control approved 14-1022.26 QuickStart® Peel & Stick Starter Roll is tested and certified to comply with the following standards: •...

  • Page 57: Decotech™ Module Assembly Drawings

    P a g e | 57 DecoTech™ Module Assembly Drawings BACKSHEET P V SIDE Figure 74: DecoTech™ RI 2000 Module Assembly Drawing...
  • Page 58 P a g e | 58 DecoTech™ Solar Array Drawing Figure 75: DecoTech™ RI 2000 S olar Array Drawing...

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