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DecoTech

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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1 Contents
SECTION 1 — INTRODUCTION ................................................................................................................. 4
SECTION 2 - GAF SOLAR ENERGY SYSTEM OVERVIEW .............................................................................. 9
SECTION 3 — GAF SOLAR ENERGY SYSTEM CONSIDERATIONS AND REQUIREMENTS .............................. 14
SECTION 4 — GAF SOLAR ENERGY SYSTEM INSTALLATION .................................................................... 23
SECTION 5 — WIRE MANAGEMENT ...................................................................................................... 52
SECTION 6 — GAF SOLAR ENERGY SYSTEM MANINENANCE ................................................................... 54
SECTION 7 — APPENDIX ....................................................................................................................... 55
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Version Control .................................................................................................................................... 63
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SECTION 1 — INTRODUCTION
The GAF Solar Energy System is designed by GAF, North America’s largest roofing manufacturer. The sleek, black, low-profile design delivers performance and curb appeal at an affordable price. The GAF Solar Energy System was developed with roofing best practices, simplicity of installation, performance, safety, and aesthetics in mind. Its deck-mounting technology coupled with GAF underlayment offers fast installation with high­performance water shedding and a Class A fire rating. Module Level Power Electronics (either AC or DC) is easily integrated in the field.
This Manual contains safety, installation, and troubleshooting instructions for the GAF Solar Energy System.
READ THESE INSTRUCTIONS ENTIRELY AND THOROUGHLY TO HELP ENSURE A PROBLEM­FREE INSTALLATION.
Save this Manual and keep it in a readily accessible location for future reference. As part of its continuing efforts to improve the performance of its products, 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 for the most up-to-date version of this Manual or any technical bulletins for this product.
Abbreviations
AC Alternating Current AHJ Authority Having Jurisdiction ANSI American National Standards Institute ASTM American Society for Testing and Materials AWG American Wire Gage DC Direct Current OCPD Overcurrent Protection Device OSB Oriented Strand Board
OSHA Occupational Safety and Health Administration MLPE Module Level Power Electronics NEC National Electrical Code NFPA National Fire Protection Association MC Multi-Contact PPE Personal Protective Equipment PV Photovoltaic UL Underwriters Laboratories
Symbol List
CAUTION: Use caution and fully understand the instructions before proceeding.
DANGER: Indicates a hazardous situation. Failure to follow these instructions could lead to serious injury
or death.
NOTE: Follow these instructions closely for optimal system operations and best installation practices.
MOVE: Denotes direction of movement.
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Back
Adjustable feet
Bracket
Definitions
GAF Solar Module Assembly – the GAF solar module combined with:
Roof attachments (adjustable feet) MLPE bracket MLPE (either a DC optimizer or an AC Microinverter) Wire ties Grounding lug
The Module Assembly is built in the field with the provided hardware. Detailed instructions are in Section
4.
MLPE mounted on the MLPE
Front
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
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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.
Follow OSHA… GAF recommends compliance with OSHA guidelines for Residential Fall Protection.
Wear Personal Protective Equipment (PPE)… Use proper PPE (Figure 3) and follow safety policies and
procedures. Proper PPE when dealing with rooftop solar systems includes, but is not limited to, the following:
o Hard hats… For falling objects, as well as risk of contact with energized conductors. An ANSI Z89
Class A helmet will satisfy this OSHA requirement.
o Work gloves… For slip, abrasion, and thermal resistance. Solar modules tend to get very hot when
exposed directly to the sun.
o Electrically insulated gloves… When working on energized circuits. o Appropriate footwear… Footwear with extra traction and/or heat-resistant soles. o Personal fall arrest system (PFAS)… Consists of an OSHA-approved anchor point, a full-body
harness approved for electrical workers, rope or cable, and specific connecting hardware.
o Eye protection… For site-specific hazards.
Figure 3 personal Protective Equipment
Work only in dry conditions… Use dry equipment and 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.
Beware of “in-between” roof slopes… A “walkable” roof may not be walkable once the shingles are
stripped off. A slope of 6:12 and higher generally becomes unsafe to walk on after being stripped.
No stacking of Module Assemblies… Do not stack or store Module Assemblies on the roof. For general
safety of roofing materials, use roof jacks, toe boards, or storage platforms secured to the underlying roof deck to prevent slippage of stored roofing materials.
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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.
Working Safely with PV systems… Be aware of the hazards at the jobsite as well as the hazards of working
on PV systems. Be alert at all times. Never work alone on PV systems. Always have at least two people installing solar systems on the roof.
Electrical Safety Precautions
Must be competent with electrical safety work practices… The GAF Solar Energy System is an electric-
powered generation system. The installer must be qualified according to state and local requirements.
De-energize… All work must be performed on DC or AC circuits only after the circuits have been de-
energized.
Use proper wire management techniques... Ensure that none of the AC or DC wires are pinched or
damaged during installation. Secure all loose cables with wire ties to the GAF Solar Module Assembly. Do not exceed the minimum bend radius of the cables.
Do not modify factory-applied connectors, terminals, or jumper cables… Do not customize or modify the
provided DC or AC cables or connectors in the field.
Do not repair… The GAF Solar Energy System does not contain any user-serviceable parts. Replacement
products should be obtained through GAF. Tampering with the GAF Solar Energy System will void the warranty.
Thermal and voltage hazard… Certain parts of the GAF Solar Energy System may become extremely hot
due to continued exposure to the sun. It should be installed in a location where it is protected against casual contact. It may also represent an electrical hazard while servicing the system immediately following shutdown.
Follow codes… Perform all electrical installations in accordance with all local codes and the NEC (National
Electrical Code) ANSI/NFPA 70 for U.S. installations.
Re-inspection… Regularly re-inspect the solar system to ensure that all fasteners are securely tightened
and corrosion free; that wiring is securely connected and free of corrosion; and that cables are free of damage. This is important especially after storms and in areas prone to hail and high winds. Any damaged parts should be replaced immediately.
Be aware of ground faults… Functionally grounded conductors may become ungrounded and energized
when a ground fault is indicated, resulting in risk of electric shock. Prior to touching any part of the
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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.
Licensed Electrician… Installing AC or DC circuits, switches, tie-in to the PV point of connection, OCPDs,
and initial startup of the PV system must be performed by a licensed electrician. Make all electrical connections (e.g., conductor termination, fuses, potential earth connection, etc.) in accordance with the electrical standards prescribed by the applicable NEC wiring methods and/or by other local regulations and codes.
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
•Provides secondary leak protection
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Module Assembly
Flashing
•Deck-mounted Solar Module integrated with power electronics and grounding lug
• Starter Bar and Flashing provides primary leak protection and module ventilation
•Presents an aesthetically-pleasing finished look
The Balance Of System components that make up the remainder of the solar installation are outside the scope of this manual. Typical components are: roof-top junction box, conduit and cables, disconnect switch, meter, monitoring system, and inverter. See the Project Installation Drawings for more information.
GAF Array with Flashing
Junction Box and Wiring
GAF Underlayment
Figure 4 Main Components of Solar Installation
Inverter, Disconnects, and Metering
Monitoring
Assembly
GAF Solar System Components
Figure 5 shows all of the hardware components that comprise GAF Solar Energy System.
Top Corner Flashing
Top Flashing Support
MLP Bracket w/Grounding Lug
Left Counterflashing
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Top Flashing
Adjustable Foot
Module
Starter Bar
Adjustable Foot Base
Figure 5 GAF Solar Energy System Components
Starter Bar Cover
Top Flashing Frame Insert
Right Counterflashing
Step Flashing
COMPONENT
GAF SKU #
SILFAB
SOLARIA
Module
2947401
2947452
Starter Bar
2947405
2947441
Adjustable Foot Base
2947402
2947434
Starter Bar Cover
-
Left 2947412
2947446
Starter Bar Cover
-
Right
2947413
2947446
* Step Flashing
2947411
2947447
Counterflashing
-
Left 2947406
2947448
Counterflashing
-
Right
2947407
2947449
MLPE Bracket
2947404
2947436
Adjustable Foot
2947403
2947435
Top Flashing Frame Insert
2947415
2947445
Top Flashing Support
2947414
2947444
Top Flashing
2947408
2947450
Top Corner Flashing
-
Left 2947409
2947442
Top Corner
Flashing
-
Right
2947410
2947443
COMPONENT
MANUF
PART NUMBER
WEEB Grounding Lug
Wiley
WEEB
-
LUG-8.0 DynoBond™ Grounding
Jumper
-
38" DynoRaxx
DynoBond
-38
DynoBond™ Grounding
Jumper
-
76" DynoRaxx
DynoBond
-76
MLPE
TBD TBD
ITEM
GAF SKU #
VersaShield® SOLO™ Fire
-
Resistant Slip Sheet
905500
QuickStart® Peel & Stick Starter Roll
1122000ST
StormGuard® Film
-
Surfaced Leak Barrier
092500MV
The SKU Numbers for GAF components are shown in Table 1 below.
Table 1 GAF SKU Numbers
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* Left and Right Covers are the same.
Table 2 Non-GAF Components
The required GAF underlayment is listed in Table 3.
Table 3 GAF Underlayment
(Note: 3 foot wide roll)
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In addition to the above, the installer will need to provide the following typical Balance of System items:
Bare solid copper grounding wire PV wire/jumpers Wire and conduit for homeruns Junction box AC/DC Disconnect Meter Inverter Roofing materials
o Shingles o Shingle Underlayment o Drip edge o Shims o Triangle Fastener Panel-Tite™ #14 – 1-1/2" (37.5 mm) heavy-duty roofing fasteners o Cap nails/staples
Notes
Do not mix Solaria and Silfab GAF components.
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.
If the installer wishes to use his or her own non-corrosive metal step flashing, the flashing must have
a vertical height of 2 inches (51 mm) up the side of the modules, be a minimum of 2 inches (51 mm) longer up the roof than the exposure of the asphalt shingle being installed, and must extend horizontally over the shingle on the roof a minimum of 5 inches (127 mm).
Except as noted, no substitutions are allowed without prior written approval from GAF.
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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).
Left Inside Corner
Config A
Figure 6 Solar Arrray Configuations
Right Inside Corner
Config B
Left and Right Inside Corners
Config C
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SECTION 3 — GAF SOLAR ENERGY SYSTEM CONSIDERATIONS 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. It cannot be installed over shingles.
Deck thickness and fastening... The roof deck must be a minimum of 15/32 inches (11.9 mm)
thick plywood or 7/16 inches (11.1 mm) OSB decking as recommended by APA – The Engineered Wood Association. Wood plank decking must be well-seasoned and supported having a maximum 1/8 inch (3 mm) spacing at the ends and sides using minimum nominal thickness 1 inch (25 mm) x maximum 6 inches (152 mm) lumber. The decking must have adequate nail-holding capacity and a smooth surface. Boards with a nominal thickness of 1 inch (25 mm) and a maximum width of 6 inches (152 mm) are also acceptable. Installers should ensure that the deck is properly fastened per local building code requirements.
Landscape orientation… The GAF Solar Energy System is designed for landscape orientation only.
Solar Array wiring… Refer to the Permit Design Drawings for the system wiring details. The
system electrical design is outside the scope of this manual.
Operating temperature… The GAF Solar Energy System has an operating temperature range of -
40°F to +185°F (-40°C to +85°C).
DC electrical output... Under certain environmental conditions, the GAF Solar Array may produce
more current and/or voltage than reported at standard test conditions (irradiance of 1000 W/m², AM 1.5 spectrum, and a cell temperature of 25°C [77°F]). The solar designer should account for these conditions when designing the solar array.
Suitable ambient conditions… Artificially concentrated sunlight shall not be directed on the Solar
Array. The modules must neither be immersed in water nor be exposed to continuous wetting (e.g. by fountains). Exposure to salt or sulfur (sulfur sources, volcanoes) implies a risk of corrosion. The system must not be used for maritime (e.g. boats) or automotive (vehicles) purposes. The system must not be exposed to extraordinary chemical loads (e.g. emissions from manufacturing plants). The GAF Solar Energy System should not be installed on stables.
Paint... Do not apply paint to any part of the GAF Solar Energy System.
Roof Setbacks... The GAF Solar Energy System requires the installation of a minimum of two full
rows of shingles at the eave and the ridge. The minimum allowable offset to the rake is 18" (457
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mm). Please refer to the local building and fire codes for additional setback and pathway requirements.
Mounting hardware… The GAF Solar Energy System is intended to be mounted to a roof using
only the hardware provided. Using other unapproved means is a violation of the UL listing and will impact the GAF warranty.
Design loading… Refer to Table 6 (Page 57) for the allowed mechanical loading of the GAF Solar
Module Assembly.
Fire classification… The GAF Solar Energy System has been rated as Class A for resistance to
external fire exposure per UL 2703 when used with the following underlayment:
1. One ply of self-adhered StormGuard® Film-Surfaced Leak Barrier
2. One ply of VersaShield® SOLO™ Fire-Resistant Slip Sheet, mechanically fastened with plastic cap nails or staples.
For roof mounting, the acceptability of the completed assembly, including the fire resistance of the underlying components of the roof, shall be evaluated per local fire codes.
Solar trackers… The GAF Solar Energy System has not been evaluated for use on a solar tracker.
Nonstructural component… These products have been evaluated for serving as a nonstructural
component of a building only. They are not intended to serve as a primary component of the building’s exterior surface. The supporting structure (integrated racking) provided with these systems can only support the solar laminate.
PV laminate specific... The GAF Solar Module Assembly may be used to ground and/or mount a
PV laminate complying with UL 1703 only when the specific module has been evaluated for grounding and/or mounting in compliance with the included instructions. The Solaria PowerXT and the Silfab SLA-M laminates have been evaluated for use on the GAF PV Mounting System.
Wiring accessibility… These products and associated wiring must not be accessible from the
interior space of the building. NEC procedures for installation of wiring must be followed.
Roof obstructions… Do not install any portion of the solar system over any roof obstructions,
plumbing, or attic vents. Do not attempt to cut or modify the Solar Module Assembly to accommodate any roof projections. Roof obstructions must be removed or relocated to another area of the roof.
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.
Shingle mismatch… When installing a GAF 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
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the other roof planes due to weathering and available colors for new shingles. However, color variation may diminish over time.
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.
Installation direction… each row of Solar Module Assemblies is positioned from left to right and
then attached to the deck from right to left. Rows are installed from bottom to top.
Obtain permits… The installer must comply with local, regional, and national building codes (IBC,
IFC, NEC, etc.) and obtain necessary permits and approvals from the local jurisdiction prior to installing the GAF Solar Energy System.
Contact local utility… Contact your local power provider for grid connection requirements prior
to the system design and installation.
Deck-height variations… Repair roof if deck-height variation (either a peak or valley) is greater
than 0.75 inches (19 mm) over a 4' (1,219 mm) span between trusses.
Water damage… Replace water-damaged sheathing (if any).
Relocate obstructions… Relocate rooftop obstructions that are directly under the planned solar
array location.
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Grounding
Figure 7 below summarizes the GAF Solar Energy System grounding requirements and components. Details of the assembly steps are covered in Section 4.
38” DynoBond™ Jumper
See Figure 11
76” DynoBond™ Jumper
To System Grounding Point
Solid Copper Ground Wire
See Figure 9
Figure 7 GAF Solar Energy System grounding requirements
See Figure 12
See Figure 8
A continuous bare solid copper conductor is strung throughout the solar array connecting each MLPE bracket and provides the connection to the system’s main grounding point. (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-
8.0) as shown in Figure 8 below.
®
Bare Solid Copper Grounding Wire
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WEEB Assembly
Grounding
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.
Grounding Screw
Figure 9 Feet and bracket bonding screw
The two parts of the Adjustable Foot Assembly are bonded together via the provided hardware as shown in Figure 10 below.
Internal Tooth Washer
Figure 10 Adjustable Foot Bonding Hardware
External Tooth Washer
Serrated Nut
The Top Flashing and Top Corner Flashing are bonded together using UL-approved DynoRaxx® DynoBond™ Grounding Jumpers as shown in Figure 7 above. A single 38" DynoBond™ is used between two flashing pieces. The 76" DynoBond™ is used in one location to provide bonding between the flashing pieces and the bare copper system ground wire. Figure 11 below shows how the DynoBond® clip attaches to the flashing piece. Figure 12 shows the connection between the 76” DynoBond® jumper and bare copper wire at one of the MLPE WEEB® Ground Lugs.
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Top Flashing
DynoBond™ Clip
WEEB® Grounding
Assembly
Figure 11 DynoBond™ clip connection to flashing
Figure 12 Connection between DynoBond™ Jumper and copper ground wire
MLPE
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