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

Abbreviations .................................................................................................................................. 4

Symbol List ..................................................................................................................................... 4

Definitions ....................................................................................................................................... 5

General Safety Precautions ............................................................................................................. 6

Electrical Safety Precautions ........................................................................................................... 7

SECTION 2 - GAF SOLAR ENERGY SYSTEM OVERVIEW .............................................................................. 9

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 ...................................................................................................................................... 17

Recommended Tools ..................................................................................................................... 21

Prior to Installation ........................................................................................................................ 22

SECTION 4 — GAF SOLAR ENERGY SYSTEM INSTALLATION .................................................................... 23

Step 1: Prep the Roof ..................................................................................................................... 24

Step 2: Build the Starter Bars and the Solar Module Assemblies ................................................. 28

Step 3: Install the Starter Bar ........................................................................................................ 34

Step 4: Install the First Row of Solar Module Assemblies ........................................................... 36

Step 5: Install the Remaining Rows of Solar Module Assemblies ................................................ 41

Step 6: Install Side Flashing .......................................................................................................... 42

Step 7: Install Top Flashing ........................................................................................................... 44

Step 8: Install Top Flashing Underlayment and Complete Shingles ............................................. 49

Completed GAF Solar Energy System .......................................................................................... 51

SECTION 5 — WIRE MANAGEMENT ...................................................................................................... 52

DC Optimizer ................................................................................................................................ 52

AC Microinverter .......................................................................................................................... 52

SECTION 6 — GAF SOLAR ENERGY SYSTEM MANINENANCE ................................................................... 54

SECTION 7 — APPENDIX ....................................................................................................................... 55

GAF Solar Module Technical Data ............................................................................................... 55

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GAF Solar Energy System Codes and Standards .......................................................................... 58

Alternate Solar System Configurations ......................................................................................... 59

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

Bare Solid
Copper Wire

76" DynoBond™

Jumper

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MLPE Foot

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. For full instructions including how to use a DynoBond™ clip to ground the system, refer to the full
Dynobond™ install manual (DynoRaxx document number 070919).

Notes

 The grounding hardware for the Adjustable Foot Assembly (Figure 10) can be reused up to 3 times.
 The grounding screws for the Adjustable Feet and MLPE bracket (Figure 9) are single-time use

only.

 The DynoBond™ clips (Figure 11) are single-time use only.
 No more than two 10-14 AWG wires can be used in the Weeb® Grounding Lug (Figure 12). See

manufacturer’s instructions.

 Systems that do not use an MLPE (i.e. use a string inverter instead) must still install the MLPE

bracket and WEEB® Grounding Lug for proper system grounding.

 Use only UL-approved methods for splicing the solid copper ground wire

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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
 5/16" (8 mm) Hex driver bit (for the deck screws, solar foot and GND screw)
 #2 Phillips driver bit (for TE grounding clip and starter bar cover)
 1/2" (13 mm) socket (for MLPE screw and S-8 split-bolt)
 7/16" (11 mm) wrench
 Chalk line
 Torque wrench

Figure 14 Typical Tools Required

Figure 14: Recommended Tools

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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.

 Display permits… Ensure all building/electrical permits are posted in a visible location onsite.

 Discuss with the building owner… Confirm access roads, material staging area, and ladder access area

(as shown in the Permit Design Drawings). Also discuss work hours, installation noise, and electrical
panel shutdown timing with the building owner.

 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 planned design
o Roof obstructions
o Excessive deck-height variations

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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:

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

•Prep the Roof

•Build the Starter Bar and the Solar Module Assembly

•Install the Starter Bar

•Install the First Row of Solar Module Assemblies

•Install the Remaining Rows of Solar Module Assembles

•Install Side Flashing

•Install Top Flashing

Step 8

•Install Top Flashing Underlayment and Shingles

Step 1: Prep the Roof

Follow the sequence below to complete this step.

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Step 1a: Prep and Clean the Deck

Step 1e: Install QuickStart® Peel and Stick Starter Roll Step 1f: Install VersaShield® SOLO™ Underlayment

Step 1a: Prep and Clean the Deck…

Step 1b: Install Roofing

Componets on Eves

and Rakes

For new roofs, start with a clean plywood/OSB deck. For existing

Step 1c: Install Initial

Rows of Shingles

Barrier Underlayment

roofs, proceed with a roof tear-off and clear the existing deck of all shingles and underlayment
in the plane of the planned solar array. Remove or hammer in all protruding nails on the deck
and prepare a smooth and level deck surface. Sweep away dirt and debris from the roof deck
(Figure 15).

Step 1d: Install

StormGuard Leak

Figure 15 Prep and clean the deck

Step 1b: 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... Using the Permit

Design Drawings, determine the number of rows of shingles required between the eave and
the Starter Bars. Locate and mark the lower-left corner of the solar array. The starting point
must always land within the shingle headlap area. For example, in Figure 16 below, four rows
of shingles are required to reach the starting point.

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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:

 Snap a line 1.5" (38 mm) up from the top of the exposure of the last row of shingles

installed (Figure 17).

 Snap a line marking the left, right, and top edge of the solar array.

1.5"

Figure 17 Snap a chalk line along the array starting point

Note

 Confirm that all measurements and setbacks comply with the Permit Design Drawings.

Roll out the StormGuard® Leak Barrier, aligning its edge with the chalk line over the shingle
headlap. Extend the leak barrier 3 feet (914 mm) beyond the left and right sides of the solar
array (Figure 18).

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1.5"

Leak Barrier

3'

Solar Array

3'

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). The QuickStart® Peel and Stick Starter Roll should
be the same width as the solar array.

Leak Barrier

QuickStart®

1.5

"

Peel and Stick
Starter Roll

Figure 19 Install QuickStart

®

Peel & Stick Starter Roll

Step 1f: Install the VersaShield® SOLO™ Fire-Resistant Slip Sheet in the Field of the Solar Array... The

VersaShield® SOLO™ Fire-Resistant Slip Sheet should be installed over the StormGuard® Leak
Barrier and the QuickStart® Peel and Stick Starter Roll, leaving the same 1.5 inch (38 mm) gap
between the shingle headlap and the edge of the slip sheet (Figure 20). To fasten, use
corrosion-resistant plastic cap nails or staples with plastic caps. The Slip Sheet should be the
same width as the solar array.

1 2 3

Leak Barrier

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. The side lap should be overlapped 3 inches (76 mm) and end lap 6 inches (152
mm).

For slopes greater than 6:12, side and end laps should be fastened 9 inches (228 mm) o.c. and
18 inches (457 mm) o.c. elsewhere. Stagger each row of 9 inches spaced fasteners.

VersaShield®

SOLO™ Fire-

Resistant Slip

Sheet

QuickStart®

Peel and Stick

Starter Roll

1.5"

Leak Barrier

VersaShield®
SOLO™
Fire-Resistant
Slip Sheet

Figure 20 Install VersaShield SOLO Fire-Resistant Slip Sheet

Note

 To avoid interference with the Starter Bar, do not install the first row of cap nails along the lower

edge of the VersaShield® SOLO™ Fire-Resistant Slip Sheet.

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

P a g e | 28

Step 2a: Assemble the Starter Bars... Each Starter Bar receives 3-5 Adjustable Feet Bases (check the

Starter Bar

Adjustable

foot base

Step 2d: Install the WEEB® Lug and

MLPE

approved system drawings for your installation) which are attached using the provided
carriage bolts (5/16"-18 x 1" Steel, Zinc Plated) and nuts (Flanged, 0.313''-18, Steel, Zinc
Plated). The tooth grooves of the Adjustable Foot Base should align with the tooth groves of
the Starter Bar. Use the factory-assembled position of the Adjustable Foot (above the second
tooth) by default. Torque the nut to 75 inch-pounds (8.5 Nm) See Figure 21 below. Note
that adjacent Starter Bars share a common foot as shown in Figure 22 below. Please refer to
the Permit Design Drawings for the Starter Bar arrangement.

Step 2e: Connect the PV Wires

Step 2f: Ensure Proper Wire

Management

Carriage
Bolt

Default height

of the

adjustable foot

base is to

expose 2 tooth

grooves

Nut

Figure 21 Assembling the Starter Bar

P a g e | 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.

Adjustable Feet

(x5)

MLPE

(Typical)

WEEB®

Grounding Lug

Wire Ties

MLPE bracket

Figure 23 GAF Solar Module Assembly

Step 2b: Install the Adjustable Feet...

local regulations and environmental conditions. Check the approved system drawings for your
installation to determine the proper number. After hooking the Foot onto the channel along
the solar module frame, rotate it into position and align the pre-drilled hole. Attach the Foot
using the hex grounding screw into the pre-drilled hole (Figure 24, next page). Torque the
screw to 40 inch-pounds (4.5 Nm). Repeat this step until all the Adjustable Feet are installed
as shown in Figure 25.

Module

Each solar module receives 3-5 Adjustable Feet, depending on

P a g e | 30

Pre-drilled Holes

1

2

3

4

Channel

Solar Module

Frame

Adjustable Feet

Align the Pre-

drilled Holes

Hook onto the Channel
and Rotate

Wiper Seal

Grounding
Screw

Adjustable

Feet

Figure 24 Mounting the Adjustable Foot

MLPE bracket location

Module Junction Box

Figure 25 Completed GAF Solar Module Assembly

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. Align the predrilled holes and attach the Bracket onto
the frame using the grounding screw. (Figure 26 below).

Align the

Pre-

Drilled

Holes

MLPE

Bracket

Figure 26 MLPE bracket installation

Step 2d: Install the WEEB® Lug and Power Electronics...

Grounding Lug and the MLPE onto the MLPE bracket.

 Build the WEEB® grounding assembly as shown in Figure 27. Leave the flange nut

loose for now. The WEEB® assembly consists of the following:

o 5/16"-18 x 3/4" Hex Cap Screw, zinc
o 5/16" External Tooth Washer
o WEEB® Washer
o WEEB® Grounding Lug
o WEEB® 1/4"-20 Hex Cap Screw, SS (WEEB® Terminal Screw)
o 5/16"-18 Flange Nut, Zinc.

 Slide the WEEB® assembly into the slot of the MLPE foot and center it (Figure 28).
 Slide the MLPE under the WEEB® Washer and tighten the flange nut to 120 inch-

pounds (13.5 Nm) (Figure 28).

Flange Nut

Grounding
Screw

. Follow these steps to mount the WEEB®

WEEB®

Grounding Lug

WEEB® Terminal

Screw

WEEB® Washer

Figure 27 WEEB grounding assembly

External Tooth
Washer

Hex Cap Screw

MLPE
Bracket

WEEB®

Grounding

Assembly

Step

2e: Connect the PV Wires...

MLPE.

P a g e | 32

Figure 28 Attach WEEB Ground Assembly to MLPE

Connect the module cables to the mating connectors on the

Figure 29 Attach connectors

Step 2f: Ensure Proper Wire Management...

. It is critical to ensure that no wires come in contact with

any of the Side Flashing of the array. Secure the wires to the MLPE bracket and module frame
as needed. See Figure 30.

Note

 Do not exceed the cables’ minimum bend radius. See NEC for details.

Wiring
Connectors

P a g e | 33

MLPE Bracket

Wire Ties

Figure 30 Proper wire management.

Figure 31 shows the front and back of the completed GAF Solar Module Assembly.

Front

Figure 31 Completed Module Assembly

Back

Step 3: Install the Starter Bar

Follow the sequence below to complete this step.

P a g e | 34

Step 3a: Snap Chalk Line

Step 3b: Position and Attach the Starter Bars to

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).

5.25"

Figure 32 Position the first Starter Bar

Step 3b: Position and Attach the Starter Bars... Align the top edge of the feet of the Starter Bars with

the chalk line as shown in Figure 32. Each Foot has two rows of three pre-drilled screw holes.
Use either row of screw holes to avoid seams and knots in the roof deck. Fasten the starter
bar to the deck using #14 – 1-1/2" (37.5 mm) Panel-Tite™ Roofing Fasteners (Figure 33). Do
not overtighten the roofing fasteners.

Align the
Mounting
Foot with the
Chalk Line.

Panel-Tite™

Roofing Fasteners

(x3)

Figure 33 Attach the Starter Bar to the deck

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 ).

Adjacent Starter
Bars share Foot
Base

Gap

Figure 34 Row of Starter Bars

Starter Bars

Stretch a mason line along the top edge of the Start Bars to verify that everything is at the
same height (Figure 37). Adjust the feet as necessary (Figure 38).

Step 4: Install the First Row of Solar Module Assemblies

Follow the sequence below to complete this step.

P a g e | 36

Step 4a: Mount the Solar Module

Assemblies onto the Starter Bar

Step 4b: Make

Electrical Connections

Between MLPEs

Step 4c: Attach the

Solar Module

Assemblies to the

Deck

Step 4d: Install

Grounding

Step 4e: Create the

MLPE Map

Step 4a: Mount the Solar Module Assemblies onto the Starter Bar... Place the Solar Module

Assemblies into the Starter Bars from left to right. Holding the Solar Module Assembly at ~15°
angle, slide it downward until it hooks into the starter bar (Figure 35).

Solar Module
Assembly

Starter Bar

Figure 35 Mount Solar Module Assembly onto the Starter Bar

Align the first Solar Module Assembly with left edge of the Starter bar. Place the next Solar
Module Assembly into the Starter Bar a few inches to the right of the first Solar Module
Assembly. Slide it to the left until it interlocks with the first Solar Module Assembly (Figure

36). Repeat these steps from left to right until the row is complete.

Figure 36 Placing and Aligning Solar Module Assemblies

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
Module
Assemblies

Figure 37 Checking Height of Solar Module Assemblies

The height of the foot can be adjusted from a minimum 1.72 inches to a maximum 3.15 inches.
(Figure 38). If height adjustments are needed:

1. Loosen the carriage bolt and nut.

2. Align the interface to the correct tooth groove height

3. Retighten the carriage bolt and nut to 125 inch-pounds (14.12 Nm). The nut may be
re-torqued up to 3 times when adjusting the height.

3.15"

1.72"

Figure 38 Foot Adjustment Range

Step 4b: Make Electrical Connections between MLPEs… Complete the wiring according to the Permit

Design Drawings. Typical connections are shown in Figure 39. Follow proper wire
management techniques to secure the wires.

P a g e | 38

Starter Bar

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. This step is critical to ensure proper flashing installation.

Align the Right Inner Edge of
the Solar Module Assembly
with the Starter Bar

Figure 40 Aligning Solar Module Assembly with Starter Bar

Note

 Ensure that the right edge of the array is properly aligned.

WARNING: Before attaching the Adjustable Feet to the deck, ensure that no electrical cables are stuck

underneath the mounting feet.

P a g e | 39

Decking Type

Plywood

3 Screws per Mounting Foot

OSB 6 Screws per Mounting Foot

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:

Do not overtighten the roofing fasteners.

Figure 41 Attach the Solar Module Assembly to the Deck

Step 4d: Install Grounding... Attach the continuous bare copper ground wire to each WEEB®

Grounding Lug. Include the DynoBond® Ground Jumper where applicable (Figure 42).
Tighten the WEEB® Terminal Screw to 84 inch-pounds (9.5 Nm). Leave some slack in the
copper wire between Solar Module Assemblies for wire management.

WEEB®

Grounding Lug

Bare Copper

Wire

Figure 42 Attaching Ground Wire(s) to WEEB® Grounding Lug

Step 4e: Create the MLPE Map... Create the MLPE map per manufacturer’s instructions (Figure 43).

This map is required for system monitoring and maintenance.

Bare Copper
Wire

DynoBond®
Jumper

P a g e | 40

Peel the MLPE Bar Code

Affix the Bar Code to the MLPE Map

Figure 43 Create MLPE Map

Home Run Wire

Step 5: Install the Remaining Rows of Solar Module Assemblies

Follow the sequence below to complete this step.

P a g e | 41

Step 5a: Install Row of Solar

Module Assemblies

Step 5a: Install Row of Solar Module Assemblies… Repeat the sequence in Step 4 to build each row

from left to right and from bottom to top. Each Solar Module Assembly must align with the
one below it. Align the Solar Module Assemblies from right to left.

Figure 44 Align Solar Module Assemblies

Step 5b: Electrically Connect Row-to-Row... Make the necessary electrical connections from row-to-

row (Figure 45) following the Permit Design Drawings. Ensure proper wire management
including the home run and the ground wire. Ensure that the wires will not come in contact
with the side flashing. Route the home run wire in the spacing between the mounting feet.
The existing cables are long enough to extend from one row to the other.

MLPE

+

Figure 45 Complete Row-To-Row Wiring

Step 5b: Electrically Connect Row to

Row

Ensure that
the Right
Edges of Each
Row Align

Row-to-Row Wiring

Step 6: Install Side Flashing

Follow the sequence below to complete this step.

P a g e | 42

Step 6a: Install Starter

Bar Covers

Step 6a: Install Starter Bar Covers… Attach the Left and Right Starter Bar Covers using the provided

screws with a #2 Phillips bit (Figure 46).

Step 6b: 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.

Step 6b: Install Step Flashing Step 6c: Install Counterflashing

Figure 46 Installing Starter Bar Cover

Figure 47 Completed Step Flashing

The final Step Flashing should extend past the top of the array. In addition, make sure the
shingle exposure will extend underneath the Top Corner Flashing (installed in next step). See
Figure 48 .

P a g e | 43

Top Corner Flashing

Last Step Flashing and Shingle

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. Install the Left and Right Counterflashing as shown in Figure 49.

Figure 49 Left and Right Counterflashing

Notes

 Remove the plastic film covering from the flashing before installation. Leaving the flashing

exposed to high outdoor temperatures for prolonged periods may make it difficult to remove.

 The Left and Right Counterflashing are tapered from bottom (wide) to top (narrow).

Top Flashing Frame Insert

Step 7: Install Top Flashing

Follow the sequence below to complete this step.

P a g e | 44

Step 7a: Install the Top Flashing Frame Insert

Step 7d: Install the Grounding Clips

on the Top Flashing

Step 7b: Install the Top

Flashing Supports and

DynoBond™ Jumpers

Step7e: Nail the Top Flashing in

Place

Step 7c: Position the Top

Flashing

Step 7f: Install the Top Corner

Flashing

Step 7a: Install the Top Flashing Frame Inserts… The Top Flashing Frame Insert snaps onto the top

edge of the Solar Module Assembly as shown in Figure 50. Verify that every tab is engaged by
pulling back on the Frame Insert. Install one Frame Insert for each Solar Module Assembly
along the top row.

Step 7b: Install the Top Flashing Supports and Position the DynoBond™ Jumpers… Place Top Flashing

Figure 50 Install Top Flashing Frame Insert

Supports at the corners of the array and at every module-to-module joint. It is important to
place the corner Top Flashing Supports 1/4"-1/2" (6-12 mm) from the edge of the
Counterflashing as shown in Figure 51. The remaining Top Flashing Supports must be
centered on the joint between the Solar Module Assemblies. Each support should be fastened
to the deck with two standard roofing nails within 1 inch (25 mm) of the edge. See Figure 51.

¼"-½"

1"

38” DynoBond™

Center the Top Flashing

Support on the Overlap

Route Wires Through

This Opening

Nail Only Within 1" (25 mm) from the Edge.

Figure 51 Locations of Top Flashing Supports

P a g e | 45

Position the Corner Top
Flashing Support as Shown

Top Flashing
Supports
within the
Array

Notes

 In high snow load areas, additional Top Flashing Supports may be required.

Bend each 38” DynoBond™ Jumper into a U-shape and pass it through the slot in one of the Top Flashing
Supports. The 76” DynoBond™ Jumper is further routed through one of the MLPE Weeb® Grounding Lugs.
See Figure 52. Further details on the system grounding can be found in the grounding Section on Page 17.

Figure 52 Position DynoBond Jumpers

Bare Copper
Grounding Wire

DynoBond™
Grounding Jumper

76” DynoBond™

Top
Flashing
Support

Figure 53 WEEB® Grounding Lug Connection

Attach the 76” DynoBond™ Jumper to the copper grounding wire at a WEEB™ Grounding Lug
(Figure 53). Torque the terminal screw to 85 inch-pounds (9.6 Nm).

P a g e | 46

Top Flashing

1

2

3

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... The DynoBond™ Jumper clips are designed

to penetrate the finishing coat on the edge of the Top Flashing. Use a hammer to lightly tap
the clip into place (Figure 55).

Figure 55 Attaching the DynoBond™ Grounding Jumper Clip

Note

 The DynoBond™ Grounding Jumper Clips are designed for 1-time use only.

DynoBond™
Grounding Clips

P a g e | 47

Top Flashing

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. (Figure 56)

WARNING: Before fastening the Top Flashing to the deck, make sure that no electrical cables are
trapped underneath the flat portion.

Top Flashing

Support

Trim the
VersaShield® Solo™
as needed

Figure 60: Position and Nail the Top Flashing in Place

Check for Cables Trapped
Under Top Flashing

Figure 56 Installing the Top Flashing

Step 7f: Install the Top Corner Flashing… See the Permit Design Drawings to identify the Top Corner

Flashing (Left or Right) that contains the wire conduit. Attach the prescribed conduit to the
Top Corner Flashing before proceeding. See Figure 58 for a typical example. Install the Top
Corner Flashing over the Top Flashing (Figure 57). Remember to attach the previously
installed DynoBond™ Jumper Clip to each flashing. The Top Corner Flashing should be
fastened with standard roofing nails along the top edge.

NOTE

 The nails should be covered by the leak barrier that will be installed in Step 8c.

Top Corner Flashing

P a g e | 48

Top Flashing

Figure 57 Install Top Corner Flashing

Figure 58 Top Corner Flashing with Conduit

Step 8: Install Top Flashing Underlayment and Complete Shingles

Follow the sequence below to complete this step.

P a g e | 49

Step 8a: Install the

QuickStart® Starter Roll

Over the Top Corner

Flashing

Step 8b: Install

Shingles Over the

Top Corner

Flashing

Step 8c: Install

Leak Barrier Over

the Top Flashing

Step 8d: Install

QuickStart®

Starter Roll Over

the Leak Barrier

Step 8e: Install

Remaining Rows

of Shingles

Step 8a: Install the QuickStart® Starter Roll over the Top Corner Flashing... Install a strip of

QuickStart® Peel and Stick Starter Roll over each the Top Corner Flashing as shown in Figure

59. Notch as needed.

Top Corner
Flashing

QuickStart® Peel and
Stick Starter Roll.

Figure 59 Apply QuickStart® Peel and Stick Over the Top Corner Flashing

Step 8b: Install Shingles over the Top Corner Flashing… Install the shingles over the Top Corner

Flashing. Notch as needed as shown in Figure 60.

Notch the Shingle
as needed

Figure 60 Install Shingles over Top Corner Flashing

NOTE

 Protect the wires from abrasion on the shingles and other physical damage until the installation is

complete.

Step 8c: Install the Leak Barrier over the Top Flashing… Install StormGuard® Leak Barrier over the

nailing area of the Top Flashing. The Leak Barrier should cover the headlap of the adjacent
row of shingles and extend past the array approximately 3 feet (914 mm) (Figure 61).

P a g e | 50

Leak Barrier

Shingle

Leak Barrier

Leak Barrier

Leak Barrier

Top Corner
Flashing

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. The QuickStart® Peel and Stick Starter Roll is should extend to the edges of the
Leak Barrier (Figure 62).

QuickStart® Peel
and Stick Starter
Roll

Figure 62 Install QuickStart Starter Roll over the Leak Barrier

P a g e | 51

Step 8e: 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

P a g e | 52

Box

Module Assembly

AC Microinverter

Cap

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.

DC Optimizer

The typical schematic with a DC optimizer is shown below:

= MC-4 Type Connector

Home Run Wire

V+

V-

V+

Figure 65 Typical DC Optimizer Wiring

V-

Module Assembly DC Optimizer

V+

V-

DC
Combiner

Inverter
with DC
Disconnect

AC Microinverter

The typical schematic with an AC Microinverter is shown below:

Trunk
Cable End

AC Trunk
Cable

Figure 66 Typical AC Microinverter Wiring

AC
Connector

AC Combiner
Box

AC
Disconnect

P a g e | 53

Detail B

Detail A

Detail B

Detail A

Flashing)

MLPE

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). Always obey the cables’ minimum bend radius.

Side Flashing (Step
Flashing & Counter

Figure 67 Typical Wire Management

P a g e | 54

SECTION 6 — GAF SOLAR ENERGY SYSTEM MANINENANCE

 The GAF Solar Energy System has no user-serviceable parts and requires no routine maintenance.

However, periodic re-inspection of the PV installation for loose components, loose fasteners, and any
corrosion of components is required. If any issues are found, the affected components must be
immediately replaced by the installer.

 Do NOT attempt to dismantle the equipment or make any internal repairs. Any attempt to open the

equipment could compromise the integrity of the system and void the warranty on the system.

 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.

 Direct all inquiries to GAF Solar Technical Support at 1-800-ROOF-411.

 For more information on GAF solar products and services for solar applications, visit gaf.com/solar.

SECTION 7 — APPENDIX

GAF Solar Module Technical Data

Table 4 Solaria Laminate Specifications

P a g e | 55

Table 5 Silfab Laminate Specifications

P a g e | 56

Length

65.3 inches

(1,

659 mm)

66.5

inches

(1,689

mm)

To achieve a Class A fire rating, the solar array must be installed with one ply of

StormGuard® Film

-

Surfaced

Table 6 Mechanical Properties of the GAF Solar Energy System

With Solaria Laminates With Silfab Laminates

P a g e | 57

Weight (Framed Module + 5

Mounting Feet + MLPE Bracket)

55 lb. (53 kg) 51 lb. (23 kg)

Width 45.0 inches (1,143 mm) 40 inches (1,016 mm)

Depth, Front 1.67 inches (42 mm)

Depth, Back Adjustable

Frame Black anodized aluminum Black powder-coated aluminum

Mechanical Loading

50 lb./ft2 (244 kg/m2) positive
design load
40 lb./ft2 (195 kg/m2) negative
design load

50 lb./ft2 (244 kg/m2) positive
design load
50 lb./ft2 (244 kg/m2) negative
design load

Fire Rating Class A per UL 2703

Leak Barrier followed by one ply of VersaShield® SOLO™ Fire-Resistant Slip Sheet over minimum 15/32
inches (11.9 mm) thick plywood or 7/16 inches (11.1 mm) OSB roof deck. Please refer to Underwriters
Laboratories Certifications Directory for actual assemblies.

P a g e | 58

GAF Solar Energy System Codes and Standards

The GAF Solar Energy System includes the GAF Solar Module Assembly, the underlayment system, and flashing
components. Certifications are listed below.

PV Laminate (Frameless)

The PV laminates are certified to UL 1703.

GAF Solar Module Assembly and Flashing

 The GAF Solar Module Assembly and Flashing are certified to UL 2703.
 The certification includes the MLPE Mounting Bracket and Grounding Lug.

GAF Solar Array

The GAF Solar Array was tested to comply with the following roofing standards:

 UL 1897  Uplift Tests for Roof-Covering Systems
 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.

Underlayment System

StormGuard® Film-Surfaced Leak Barrier is tested and certified to comply with the following standards:

 Meets or exceeds ASTM D1970 – Standard Specification for Self-Adhering Polymer Modified

Bituminous Sheet Materials

 Used as Steep Roofing Underlayment for Ice Dam Protection
 ICC-ES Evaluation Report (ESR-1322)
 Miami-Dade County Product Control approved (18-0119.15)
 State of Florida approved (FL10626)
 UL Classified

VersaShield® SOLO™ Fire-Resistant Slip Sheet is tested and certified to comply with the following standards:

 UL Classified
 Miami-Dade County Product Control approved (16-1216.02)

QuickStart® Peel and Stick Starter Roll is tested and certified to comply with the following standards:

 Meets or exceeds the physical requirements of ASTM D1970
 State of Florida approved (FL10124)

Note

 Refer to UL Online Certification Directory for actual assemblies.
 Follow all instructions in this document to assure the system is installed as certified.

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. The other flashing components are used as is.

Trimmed Right
Counterflashing

Figure 68 Configuration Type B

Starter Bar

Trimmed Left
Counterflashing

Step 1: Trim the Right Counterflashing as shown in Figure 69 or the Left Counterflashing as shown in

Figure 70. The Right Counterflashing requires a compound cut while the Left Counterflashing
requires a single straight cut.

Figure 69 Trimming Right Counterflashing

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 Right
Counterflashing

`

Figure 71 Configuration B - Step 2

Trimmed Left

Counterflashing

Step 3: Snap a chalk line to align the Adjustable Feet to the adjacent Starter Bar as shown in Figure

72. Leave a small (approximately 1/8 inch) gap between the Inside Counterflashing and the
Starter Bar. Attach the Starter Bar to the deck.

Chalk Line

Figure 72 Configuration B - Step 3

1/8” Gap

Step 4: Align and attach Solar Module Assemblies 2 and 3 as shown below. Complete the array following the
standard installation procedures.

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2

1

3

Figure 73 Configuration B - Step 4

3 2

1

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. The other flashing components remain the same.

1 2

Trimmed Right

Counterflashing

Figure 74 Configuration Type C

Trimmed

Starter

Bar

Trimmed Left
Counterflashing

Step 1: Following the standard installation procedures, install the shingles up to the location of

Starter Bars 1 and 2 as well as the adjacent underlayment. Locate and attach Starter Bar 1.
Next, align and attach Starter Bar 2 using the appropriate spacing per the Permit Design
Drawings.

Underlayment

D x No. of Module Assemblies

Shingle to Here

1

Obstruction

2

Figure 75 Configuration C - Step 1

Note

 Accurate placement of Starter Bar 2 is critical to the assembly of the rest of the array.

Step 2: Attach the Solar Module Assemblies as shown in Figure 76. Continue to step flash and shingle

along the sides of the Solar Module Assemblies. Trim the Right Counterflashing as shown in
Figure 69. Attach the Right Counterflashing to Solar Module Assembly 1.

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2

1

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. Install the Left Counterflashing to Solar Module
Assembly 2. Complete the array following the standard installation procedures.

1

Figure 77 Configuration C - Step 3

Trimmed Right Counterflashing

Trimmed Left Counterflashing

Starter Bar 3

2

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Version Control

Version Number

1.0.0

1.0.1

1.1.0

2.0

3.0

3.1

Table 8: Version Control Table

Date

Notes

5/2017 Added info on Alignment Pins,

Version Control Table,

Custom Step Flashing, and lab

tested design load values.

7/2017

Added alternate array

configurations and 2 wire

WEEB lug.

11/2017

Added Silfab laminate,

adjustable feet, updated SKU

numbers and right

counterflashing install, wire

management techniques and

grounding methods for the

adjustable feet.
03/2018
04/2019

Updated product name,

Edited for clarity

updated SKUs, added Solaria

laminate, removed SolarWorld

laminate

08/2019

Added three-feet mounting

option, more Dynobond

grounding options