Page | 1
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
P a g e | 1
P a g e | 2
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™ Solar System...................................................................... 9
DecoTech™ Solar System Parts.................................................................................................... 10
Array Configurations ..................................................................................................................... 12
Grounding ...................................................................................................................................... 12
SECTION 3 — DECOTECH™ SOLAR SYSTEM CONSIDERATIONS AND REQUIREMENTS................................15
Design Considerations ................................................................................................................... 15
Installation Requirements .............................................................................................................. 17
Recommended Tools ..................................................................................................................... 18
Prior to Installation ........................................................................................................................ 19
SECTION 4 — DECOTECH™ SOLAR SYSTEM INSTALLATION ......................................................................20
Step 1: Build the Solar Module Assembly .................................................................................... 21
Step 2: Prep the Roof..................................................................................................................... 25
Step 3: Install the Starter Bar......................................................................................................... 31
Step 4: Install the First Row of Solar Module Assemblies ........................................................... 33
Step 5: Install Remaining Solar Module Assemblies in the Solar Array ...................................... 37
Step 6: Install Side Flashings ........................................................................................................ 38
Step 7: Install Top Flashings ......................................................................................................... 41
Step 8: Top Flashing Weatherization and Shingle Integration...................................................... 46
SECTION 5 — WIRING, LABELING, AND MONITORING....................................................................... 49 Wiring ............................................................................................................................................ 49
Solar System Safety Labels ........................................................................................................... 50
Monitoring ..................................................................................................................................... 51
SECTION 6 — DECOTECH™ SOLAR SYSTEM MAINTENANCE .....................................................................52
P a g e | 3
SECTION 7 — APPENDIX ........................................................................................................................53
DecoTech™ Module Assembly Technical Data (Model RI 2000) ................................................53
DecoTech™ Solar System Codes and Standards ...........................................................................55
DecoTech™ Module Assembly Drawings.....................................................................................57
DecoTech™ Solar Array Drawing .................................................................................................57
P a g e | 4
SECTION 1 — INTRODUCTION The DecoTech™ Solar System (also referred to as DecoTech™ RI 2000) is designed by GAF, North America’s largest roofing manufacturer. This solar roofing system was developed with roofing best practices, simplicity of installation and design, performance, safety, and aesthetics in mind. The DecoTech™ Solar System features solar laminates with integrated framing and racking. Power electronics (either AC or DC) can be integrated into the DecoTech™ Framed Module in the field. The DecoTech™ Solar System offers aesthetic appeal with its low profile design and black monochromatic color scheme. Its deck-mounting technology provides for faster installation with high-performance watershedding. This Manual contains safety, installation, and troubleshooting instructions for the DecoTech™ RI 2000. READ THESE INSTRUCTIONS ENTIRELY AND THOROUGHLY TO ENSURE A PROBLEM-FREE 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 gafsolar.com 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: The reader should 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.
P a g e | 5
Front Back
Front Back
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.
Figure 1: DecoTech™ Framed Module
DecoTech™ Module Assembly (also known as solar module assembly) — A solar module with: • Roof attachments (also known as solar mounting feet) • A power electronics component (either a DC optimizer or an AC microinverter), • Wire ties, and • Grounding Lug.
Based on the type of MLPE used, the solar module assembly is designed to generate DC or AC power when exposed to light. This solar module assembly is put together in the field at ground level. The solar module assembly is shown in Figure 2.
Figure 2: DecoTech™ Module Assembly
DecoTech™ Solar Array (also known as solar array) — Solar module assemblies (DC modules or AC modules) grouped together on top of the roof. The solar array is shown in Figure 3.
Figure 3: DecoTech™ Solar Array
PV Laminate
DecoTech™ Frame DecoTech™
Framed Module
P a g e | 6
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™ Solar System
Follow the latest version of the NEC code for standard solar definitions.
General Safety Precautions
• Must be installed by a qualified person… The DecoTech™ Solar System must be installed by a PROPERLY TRAINED and QUALIFIED INSTALLER. The installer must receive specialized SOLAR TRAINING and have ROOFING EXPERIENCE in order to install the DecoTech™ Solar System.
• Follow OSHA… OSHA standards and requirements must be followed during installation. • Wear Personal Protective Equipment (PPE)… Use proper PPE (Figure 5) 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.
P a g e | 7
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. • Beware of “in-between” roof slopes… The DecoTech™ Solar System is installed without shingles
underneath the product. 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 PV… Do not stack or store solar modules 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.
• Inspect for damages… Do not use DecoTech™ Solar System components if there are visible signs of
damage from transport or handling. • Do not overload yourself… Always have two people carry the product by its frame on the roof. • Snow guards… Snow guards should be used generously in extreme climates. The number of snow guards
needed depends on the size and slope of the roof. In some regions, additional snow guards will be required to hold the additional weight of ice and snow during severe winters. Consult with the snow guard manufacturer for further details.
Electrical Safety Precautions
• Must be competent with electrical safety work practices… The DecoTech™ Solar System is an electric-powered generation system. The installer must be knowledgeable in the safety work practices for working with electrical sources.
• De-energize… All work must be performed on DC or AC circuits only after the circuits have been de-
energized.
P a g e | 8
• Wiring on the roof… The installer must be trained in, and will be responsible for, the parallel pluggable touch-safe AC or DC connections between the solar module assemblies.
• 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 DecoTech™ Module Assembly.
• 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 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.
• Thermal & voltage hazard… Certain parts of the DecoTech™ Module Assembly may be extremely hot due to the continued exposure to the sun. This unit should be installed in a location where it is protected against casual contact. Certain parts may also be extremely hot and represent an electrical hazard while servicing the system immediately following shutdown.
• Follow codes… Perform all electrical installations in accordance with any 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. If any damage is found, the DecoTech™ Module Assembly should be replaced immediately.
• Be aware of ground faults… 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 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 AC microinverter or DC optimizer has been disconnected from the power network, use extreme caution as some components can retain a charge sufficient enough to create a shock hazard.
• Licensed electrician… Installing AC or DC combined 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.
P a g e | 9
SECTION 2 - DECOTECH™ SOLAR SYSTEM OVERVIEW Main Components of the DecoTech™ Solar System The three main components of the DecoTech™ Solar System are:
The electrical inverter, disconnects, metering & monitoring solutions are dependent on the type of MLPE used and the utility. Refer to the MLPE manufacturer’s website for more information. Figure 6 is a graphical representation of the DecoTech™ Solar System components.
Figure 6: Main components of the DecoTech™ Solar System
•Attaches to the deck & is installed underneath the DecoTech™ Solar Array
•Provides a Class A fire rating for the entire DecoTech™ Solar System•Provides secondary leak protection
Underlayment System
•These units are deck-mounted UL 1703-certified solar laminates with integrated framing and racking, integrated power electronics, and flashing components
DecoTech™ Module Assembly
•Connects to all solar module assemblies in a solar array•Brings the power from the solar array to the load centerAC or DC Wiring
Underlayment System
DecoTech™ Module Assembly
AC or DC Wiring
Monitoring
Inverter, Disconnects and Metering
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 [SKU 2947102]
Solar Mounting Feet with MLPE [SKU
2947101]
MLPE
WEEB® Grounding Lug & Washer
Starter Bar Components
Starter Bar Cover (left & right) [SKU 2947306 & 2947307]
Starter Bar [SKU 2947202]
Flashing Components Counterflashing (left & right)
[SKU 2947300 & 2947301]
Top Flashing [SKU 247302]
Top Corner Flashing (left & right) [SKU 2947303 & 2947304]
Top Flashing Support [SKU 2947308]
P a g e | 11
Step Flashing [SKU 2947305]
Inner Top Flashing [SKU 2947309]
Top Flashing Grounding Components
DynoRaxx® DynoBond™ Grounding Clip [SKU 2947602]
S-8 Split-Bolt Connector [SKU 2947509]
Besides the aforementioned parts, the installer is expected to stock the following materials:
• Standard PV & roofing tools (see page 18 for the list of tools) • Roll of bare solid copper grounding wire, #10 or #12 AWG • Roll of PV wire for the home run wire • PV connectors for the home run wire • Roofing materials
o VersaShield® SOLO™ Fire-Resistant Slip Sheet o QuickStart® Peel & Stick Starter Roll (If it is unavailable locally, the installer could use Pro-
Start® Starter Strip Shingles and asphaltic plastic cement. The asphaltic plastic cement should conform to ASTM D4586 Type I or II.)
o StormGuard® Film-Surfaced Leak Barrier o Shingles o Drip edge o Shims o Drill-Tec™ #14 – 2" (51 mm) Heavy Duty Roofing Fasteners o Cap nails/staples
The electrician is expected to stock the following
• Standard electrical tools • Conduits & conduit supports • Safety labels • Combiner box and AC/DC disconnects
Note: The DecoTech™ RI 2000 can be integrated with a DC power optimizer or an AC microinverter. Depending on the type of MLPE, additional electrical components (inverters, monitoring systems, cables, connectors) & tools would also be required in the field. The DC power optimizer or the AC microinverter must be installed according to the MLPE manufacturer’s installation instruction.
Table 1: DecoTech™ Solar System Parts
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™ Solar Array configuration
Grounding The parts of DecoTech™ Solar Array that are likely to be energized during a ground fault are grounded with the use of a #12 or #10 AWG bare solid copper conductor strung throughout the solar array (Figure 11, page 14). The DecoTech™ Solar Module Assembly must be electrically grounded through the use of a UL 2703 listed WEEB® Grounding Lug (WEEB®-LUG-8.0) and WEEB® Washer. For each solar module assembly, the WEEB® Grounding Assembly (shown in Figure 18, page 23) and the MLPE are mounted onto the MLPE foot using the MLPE mounting hardware. The WEEB® Washer is placed in between the MLPE foot & the WEEB® grounding lug. The top flashings are electrically grounded through the use of a UL-approved DynoRaxx® DynoBond™ Grounding Clip (Figure 12, page 14). An S-8 split-bolt connector is a UL-approved connector used to attach the DynoBond™ clip to the copper grounding wire. Tighten all the components to the recommended minimum torque values shown in Table 2 below. All grounding screws are for single use only. The photovoltaic system grounding shall comply with the NEC, and is the responsibility of the installer.
Parts Tightening torque
Solar Feet & MLPE Feet (Figure 8, next page) 40 inch pounds
MLPE Mounting Hardware (Figure 10, next page)
10 feet pounds (120 inch pounds)
S-8 Split-Bolt Connector (Figure 13, page 14) 80 inch pounds
WEEB® Terminal Screw (Figure 11, page 14) 7 feet pounds (84 inch pounds)
Table 2: Torque table for grounding
P a g e | 13
MLPE Foot
Figure 8: Equipment grounding of the Solar Feet Attachments
MLPE
Figure 10: Tightening the WEEB® Grounding Lug
Figure 9: Positioning the WEEB® Grounding Assembly & MLPE
Torque Wrench MLPE
WEEB® Grounding Assembly
P a g e | 14
Figure 12: Equipment grounding of the Top Flashing using DynoBond™ Clips
Figure 13: Connecting the DynoBond™ Clip to the Grounding Wire using S-8 Split-Bolt Connector
#12 or #10 AWG Bare Solid Copper Grounding Wire
Dynobond™ Clip
S-8 Split-Bolt Connector
Figure 11: Connecting the Solar Module Assembly to the grounding path
Bare Copper Wire
Top Flashing
WEEB® Terminal Screw
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. • Deck thickness and fastening... The roof deck must be a minimum of 15/32" (11.9 mm) thick
plywood or 7/16" (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" (3 mm) spacing at the ends and sides using, minimum nominal thickness 1” (25 mm) X maximum 6" (152 mm) lumber. The decking must have adequate nail-holding capacity and a smooth surface. Boards with a nominal thickness of 1" (25 mm) and a maximum width of 6" (152 mm) are acceptable too. Installers should also ensure that deck is properly fastened per local building code requirements.
• Horizontal mode… Install the DecoTech™ Module Assembly with its longer edge parallel to the
eave of the roof (landscape orientation). • Maximum number of connected solar modules… The number of modules that can be connected
in a DC string or to an AC truck cable is dependent on the solar laminate electrical output, MLPE limitations, and PV design layout. Refer to the permit package to determine the maximum number of modules that can be connected together in a single string.
• Operating temperature… The DecoTech™ Module Assembly with SolarWorld laminates has an operating temperature range of -40 to +185°F (-40 to +85°C).
• DC electrical output... Under certain ideal environmental conditions, the DecoTech™ Framed Module 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.
• Installation environment exclusions… Do not install the DecoTech™ Solar Array in areas with atmospheric contaminants such as, but not limited to, industrial locations with chemical emissions and the in vicinity of volcanoes (sulfur). Do not immerse the DecoTech™ Solar Module Assemblies in water nor expose them to continuous spraying (e.g., by fountains). Exposure to chemical loads, sulfur, or salt implies a risk of corrosion. The DecoTech™ Solar System must not be used on stables. The DecoTech™ Solar System must not be installed in the vicinity of highly flammable gases, vapors, or dust.
• Paint... Do not apply paint to any part of the DecoTech™ Solar System.
P a g e | 16
• Fuses... For DC & AC systems, refer to the manufacturer’s specification for the overcurrent protection device (OCPD) rating & quantity.
• Array setbacks... Comply with the fire code for setbacks required for the solar array from the edges of the roof. The DecoTech™ Solar System requires a minimum of one row of shingles to be installed at the eave and the ridge. It is recommended to keep 3' (914 mm) from the rake edge (to roll out the underlayment beyond the footprint of the array on the sides).
• Concentrated sunlight… Artificially concentrated sunlight must not be directed onto the solar module assembly.
• 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.
• Design loading… The DecoTech™ Module Assembly with SolarWorld laminates has been
evaluated by UL for a maximum positive design loading of 50 lb/ft2 (244 kg/m2).
• Fire classification… The DecoTech™ Solar System has been rated as Class A for resistance to external fire exposure per UL 2703 when used with both the following materials on a roof:
1. Leak Barrier: One ply of self-adhered StormGuard® Film-Surfaced Leak Barrier and 2. Slip Sheet: One ply of VersaShield® SOLO™ Fire-Resistant Slip Sheet, mechanically
fastened with staples For roof mounting, the acceptability of the completed assembly, including the fire resistance of the underlying components of the roof, shall be considered per local fire codes.
• Solar trackers… The DecoTech™ Module Assembly 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 DecoTech™ 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.
• 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 array over any roof obstructions, plumbing, or attic vents. Do not attempt to cut or modify the solar module assembly to accommodate any roof projections. Explore whether a roof obstruction can be removed or relocated to another area of the roof.
P a g e | 17
• Underlayment footprint... The boundaries of the underlayment (i.e., both Leak Barrier and Roof Deck Protection) are recommended to extend approximately 3' (914 mm) beyond the boundary edge of the sides and the top of the solar array. Extension of the underlayment footprint from the solar array is not required from the bottom edge of the solar array.
• Roof penetration… Conductors entering the building roof shall comply with NEC and be installed with appropriate conduit penetration flashing.
• Attic ventilation… Address the requirements for proper attic ventilation if the underlayment used underneath the DecoTech™ Solar System covers large areas of the roof.
• Ice dams… Do not install the DecoTech™ Solar Array near areas of the roof that are prone to ice
damming. • 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. However, color variation may diminish over time.
• Wind resistance/hand sealing... Generally, shingles that are installed around the solar array have a special thermal sealant which firmly bonds the shingles together after application when exposed to sun and warm temperatures. Shingles installed in fall or winter may not seal until the following spring. If shingles are damaged by winds before sealing or are not exposed to adequate surface temperatures, or if the self-sealant gets dirty, the shingles may never seal. Failure to seal under these circumstances results from the nature of self-sealing shingles, and is not a manufacturing defect. If shingles are to be applied during PROLONGED COLD periods or in areas where airborne dust or sand can be expected before sealing occurs, the shingles MUST be hand-sealed. See GAF Shingle application instructions for more information.
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 standard trade practices. Special attention is needed when stripping the shingles, installing underlayment, and flashing around the DecoTech™ Solar Array.
• Install direction… The rows of solar module assemblies are initially positioned from left to right,
and then attached to the deck from right to left. Rows of solar module assemblies 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 DecoTech™ Solar System.
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.
Recommended Tools The following tools (Figure 14) are needed to properly install a DecoTech™ Solar System (this list is representative only; additional tools may be required depending on the installation):
• Standard selection of roofer’s tools • Cordless drill • 5/16" (8 mm) Hex driver bit (for the solar foot GND screw) • #2 Phillips driver bit (for TE grounding clip & starter bar cover) • #3 Phillips driver bit (for deck screws) • 1/2" (13 mm) socket (for MLPE screw & S-8 split-bolt) • 7/16" (11 mm) wrench • Chalk line • Drill bit for array exit wires • Torque wrench • Wiring, conduit, enclosures, and disconnects from roof penetration down through the house • Wire cutters • Wire strippers • Solar crimping tool
Figure 14: Recommended tools
P a g e | 19
Prior to Installation When the installation crew is onsite, complete all items below prior to the installation of the DecoTech™ Solar System:
• Review documentation… Review the installation instructions and system design 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 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 proposed design o Roof obstructions o Excessive deck-height variations
Note: Repair roof if deck-height variation (either a peak or valley) is greater than 0.75" (19 mm) over a 4' (1,219 mm) span between trusses.
• Replace water-damaged sheathing (if any).
• Relocate obstructions… Relocate rooftop obstructions that are directly under the proposed solar
array location.
P a g e | 20
SECTION 4 — DECOTECH™ SOLAR SYSTEM INSTALLATION The following 8 steps outline the procedure to install the DecoTech™ Solar System:
These installation steps will be described in detail in the following pages.
• Build the Solar Module AssemblyStep 1
• Prep the RoofStep 2
• Install the Starter BarStep 3
• Install the First Row of Solar Module AssembliesStep 4
• Install Remaining Solar Module Assembles in the Solar ArrayStep 5
• Install Side FlashingsStep 6
• Install Top FlashingsStep 7
• Top Flashing Weatherization & Shingle IntegrationStep 8
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:
Figure 15 shows all of the attachments of the solar framed module:
Step 1a: Install the Solar Mounting Feet... There are 5 solar mounting feet that must be attached to the underside of the solar module along the longer edge. This particular edge is identified by a channel on the underside of the edge with the exposed wiper seal. Identify the MLPE foot. The MLPE foot is shaped differently from the other solar feet and has a UL label attached on the underside The MLPE foot is used to attach the power electronics.
To install the solar mounting feet, first hook each solar foot onto the channel along the solar module frame. Position the five solar mounting feet so that the pre-drilled holes in the feet and the module frame align. As shown in Figure 2, note the location of the MLPE foot relative to the solar module. The MLPE solar foot should be located one from the middle on the side closer to the solar junction box. This ensures that the cables being routed from the solar module’s junction box to the MLPE is sufficient in length. Next, rotate it into position and drill a hex grounding screw into the pre-drilled hole to lock it in place (Figure 17). Torque the screw to 40 psf (195 kg/m2). This achieves an electrical bond and mechanically secures the foot to the frame. Continue this step until all the solar mounting feet are installed (Figure 18, next page).
Step 1a: Install the Solar Mounting Feet
Step 1b: Install the WEEB® Lug & Power Electronics
Step 1c: Ensure Proper Wire Management
Step 1d: Connect the PV Wires
Solar Mounting Foot (x5)
Wire Ties
MLPE
WEEB® Grounding Lug
Figure 15: DecoTech™ Framed Module with attachments
MLPE Foot
DecoTech™ Framed Module
P a g e | 22
Step 1b: Install the WEEB® Lug and Power Electronics.... Follow these 3 steps to mount the WEEB® Grounding Lug & the MLPE on the MLPE feet.
• Create the WEEB® grounding assembly as shown in Figure 18. The WEEB® assembly consists of the following
o 5/16"-18 x 0.759 Hex Cap Screw, Zinc o 5/16" External Tooth Washer o WEEB® Washer
Solar Mounting
Feet
Solar Mounting Foot with MLPE
Figure 16: DecoTech™ Framed Module with Solar Feet Attachments
Solar Mounting Foot
Solar Module Frame
Wiper Seal
Grounding Screw
Figure 17: DecoTech™ Framed Module with Solar Mounting Feet
Channel
Hook onto the Channel & rotate
Pre-drilled holes
Align the Pre-drilled Holes
1 2
3 4
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.
• Slide the WEEB® assembly into the slot of the MLPE foot & center it (Figure 19). • Slide the MLPE under the WEEB® washer & tighten the flange nut to 10 ft-lbs. to
ensure proper grounding.
Step 1c: Ensure Proper Wire Management... Route the negative wire (female) through the hollow of the end solar mounting foot and then secure both the positive (male) and negative wire to the frame using UV-resistant solar wire ties (Figure 20, next page).
Figure 18: Parts of the WEEB® Grounding Assembly
5/16"-18 Flange Nut, Zinc
WEEB® Grounding Lug
WEEB® Terminal Screw
WEEB® Washer
5/16" External Tooth Washer
5/16"-18 x 0.750 Hex Cap Screw, Zinc
MLPE Feet
Figure 19: Attaching the WEEB® Grounding Assembly
WEEB® Grounding Assembly
P a g e | 24
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 & AC wiring schematic.
Figure 22 shows the front & back of the DecoTech™ Module Assembly after Step 1 is completed.
Figure 20: Attaching Wire Ties
Wiring Connectors
Figure 21: Make wiring connections
Figure 22: Front & back view of the Solar Module Assembly
Wire Ties
Front Back
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 2a: Prep and Clean the Deck… Refer to the PV system design and identify the plane of the roof that will receive the solar array. For new roofs, start with a clean plywood/OSB deck. For existing roofs, proceed with a roof tear-off & clear the existing deck of all shingles and underlayment in the plane of the proposed 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 23).
Step 2b: Install the Drip Edge along the Eave… Install the drip edge directly to the deck along the eave as shown in Figure 24 (next page).
Step 2a: Prep and Clean the Deck
Step 2b: Install the Drip Edge along the
Eave
Step 2c: Install the Leak Barrier along the Eave and Rakes
Step 2d: Install the Drip Edge along the
Rakes
Step 2e: Install QuickStart® Peel &
Stick Starter Roll along the Eave and
over the Rakes
Step 2f: Install Initial Rows of Shingles up to the Proposed Location of the Starter Bars
Step 2g: Install the Leak Barrier in the Field of the
Proposed Solar Array
Step 2h: Install QuickStart® Peel & Stick Starter Roll
over the Shingle Headlap
Step 2i: Install the VersaShield® SOLO™ Fire-
Resistant Slip Sheet
Figure 23: Clean the Deck
P a g e | 26
Step 2c: Install the Leak Barrier along the Eave and Rakes... First, install the StormGuard® Film-
Surfaced Leak Barrier across the eave, overlapping the drip edge (Figure 25).
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.
Step 2d: Install the Drip Edge along the Rakes... Install the drip edge along the rakes, overlapping the leak barrier (Figure 27, next page).
Figure 25: Install the Leak Barrier across the Eave
Figure 24: Install the Drip Edge along the Eave
Drip Edge along the Eave
Figure 26: Overlap the Leak Barrier as shown
Overlap the Leak Barrier
Drip Edge Corner Detail
P a g e | 27
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). Staple or nail it as necessary. If the installer is using Pro-Start® Starter Strip Shingle and roofing cement, apply ONLY a thin uniform layer of asphalt plastic cement less than 1/8" (3 mm) thick. Excess amounts can cause blistering of the shingles and may soften the asphalt in underlayments and leak barriers, resulting in asphalt dripping and staining.
Step 2f: Install Initial Rows of Shingles up to Proposed Location of the Starter Bars... From the solar
design drawings, locate and mark the lower-left corner of the proposed solar array (also called the starting point). The starting point must always land on the headlap area of the shingle. Determine the number of rows of shingles required to be installed from the eave, up to the starting point. In this example shown below, 4 rows of shingles were required to be installed (Figure 29).
Figure 27: Install the Drip Edge along the Rake
Figure 28: Install the QuickStart® Peel & Stick Starter Roll
Figure 29: Install initial few rows of Shingles
Drip Edge along the
Rake
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: • Chalk a line 1.5" (38 mm) up from the top of the exposure of the last row of shingles
installed (Figure 30).
• Chalk a line marking the left, right, and top edge of the proposed solar array.
Note: Ensure that there is enough room around the array to comply with the local fire code, as well as to accommodate the top flashing. Roll out the leak barrier, aligning its edge along the chalk line over the shingle headlap. Extend it approximately 3' (914 mm) beyond the width of the solar array on the left and right side (Figure 31).
Figure 30: Snap a chalk line along the Array starting point.
Figure 31: Install the Leak Barrier
Proposed Solar Array 3' 3'
1.5"
Leak Barrier extends 3' (914 mm) beyond the proposed Solar Array
1.5"
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 & Stick Starter Roll extends the same length as the lower edge of the proposed solar array.
Step 2i: Install the VersaShield® SOLO™ Fire-Resistant Slip Sheet... Snap a chalk line 1.5" (38 mm)
above the edge of the QuickStart® Peel & Stick Starter Roll to line up the VersaShield® SOLO™ Fire-Resistant Slip Sheet (Figure 33, next page). It should be installed over the leak barrier, leaving the same 1.5" (38 mm) gap between the headlap and the start of the roll (Figure 31, previous page). VersaShield® Solo™ Fire-Resistant Slip Sheet is a fire-retardant layer and is required for a Class A fire rating. It should be installed only in the field of the proposed solar array. VersaShield® SOLO™ Fire-Resistant Slip Sheet that extends beyond the field of the proposed solar array must be trimmed. To fasten, use corrosion-resistant plastic cap nails or staples with plastic caps. Side and end laps should be fastened 12" (305 mm) o.c. and within the field of the roll 24" (610 mm) o.c., staggering each row of fasteners that are spaced approximately 12" (305 mm) apart. Overlap of the side lap should be 3" (76 mm) and end lap 6" (152 mm).
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. However, do nail the top edge of the VersaShield® SOLO™ Fire-Resistant Slip Sheet.
Figure 32: Install the QuickStart® Peel & Stick Starter Roll
QuickStart® Peel & Stick Starter Roll
Leak Barrier
1.5”
P a g e | 30
VersaShield® SOLO™ Fire-Resistant Slip Sheet
Leak Barrier
Figure 33: Install VersaShield® SOLO™ Fire-Resistant S lip Sheet
1 2
3
1.5"
Chalk line
VersaShield® SOLO™ Fire-Resistant Slip
Sheet
QuickStart® Peel & Stick Starter Roll
P a g e | 31
Step 3: Install the Starter Bar
Step 3a: Position the Left Starter Bar… Snap a chalk line 5" (127 mm) from the edge of the VersaShield® SOLO™ Fire-Resistant Slip Sheet. Starting with the leftmost starter bar in the proposed solar array, align the top edge of the feet of the starter bar with the chalk line (Figure 34).
Step 3b: Fasten the Starter Bar to the Deck... Each starter bar foot has 2 rows of three pre-drilled
screw holes. Use either row of screw holes to avoid seams and knot holes in the roof deck. Fasten the starter bar to the deck by drilling into 3 of the 6 available screw holes of the feet with #14 – 2" (51 mm) Drill-Tec® Roofing Fasteners (Figure 35). Do not overtighten the roofing fasteners.
Figure 35: Attach the Starter Bar to the Deck
Step 3c: Complete the Row of Starter Bars… Next, attach the remaining starter bars from left to right (Figure 36, next page). A gap of 1/8" (3 mm) should be allowed between each starter bar to accommodate for thermal expansion at higher ambient temperatures. Shim the starter bars, if needed, to adjust their height.
Step 3a: Position the Left Starter Bar
Step 3b: Fasten the Starter Bar to the Deck
Step 3c: Complete the Row of Starter Bars
Drill-Tec® Roofing Fasteners (x3)
5"
Align the Solar Foot with the Chalk Line.
Figure 34: Position the Starter Bar
P a g e | 32
Figure 36: Row of Starter Bars
Starter Bars Gap
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 4a: Hook the Solar Module Assemblies onto the Starter Bar... Begin with the leftmost solar module assembly in the row. Align the left side of the solar module assembly with the edge of the starter bar, and slide it downward until it hooks into the starter bar (Figure 37).
Figure 37: Hook the Solar Module Assembly onto the Starter Bar
Place this adjacent solar module assembly a few inches apart on the right side of the previously installed solar module assembly. Hook this adjacent solar module assembly downward into the starter bar. Slide the adjacent solar module assembly sideways into the previously installed solar module assembly until it interlocks (Figure 38, next page). Repeat these steps from left to right until a row of solar module assemblies is positioned.
Step 4a: Hook the Solar Module Assemblies onto the Starter Bar
Step 4b: Make Electrical
Connections between Solar Module
Assemblies
Step 4c: Align and Attach the Solar
Module Assemblies to the Deck
Step 4d: Install Grounding
Step 4e: Create the MLPE Map
Starter Bar
Solar Module Assembly
1 2
3
P a g e | 34
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.
.
Step 4b: Make Electrical Connections between Solar Module Assemblies… Wiring connections
between solar module assemblies are dependent on whether the solar module assembly has an integrated AC microinverter or a DC optimizer. Figure 40 (next page) shows the module-to-module connection with a DC optimizer.
Typically, DC optimizers are simply daisy-chained together into DC strings. Route the home run wire (see Figure 71, page 49) up and around the planned array area, so as not to get in the way of subsequent runs.
Figure 38: Interlocking between the Solar Module Assemblies
1 2
3
Figure 39: Ensuring that the Solar Module Assemblies are aligned
Mason Line along the Top Edge of Solar Module Assemblies
P a g e | 35
+ve (Male
-ve (Female
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.
Step 4c: Align & Attach the Solar Module Assemblies to the Deck... Starting from the rightmost
module assembly in the row, align the inner edge of the module with the edge of the starter bar, per Figure 41. This step is critical to ensure that the system flashes properly.
WARNING: Before attaching the solar mounting feet to the deck, ensure that no electrical
cables are inadvertently routed directly under the solar mounting feet.
Use three Drill-Tec™ Roofing Fasteners per foot to attach the rightmost solar module assembly to the deck (Figure 42, next page). Follow proper wire management techniques before attaching the solar module assembly to the deck. Continue attaching the row of solar module assemblies to the deck from right to left.
Note: The install sequence is to always ‘place’ the solar module assemblies from left to right in each row. Next, ‘align & attach’ the solar module assemblies from right to left in each row.
Figure 40: Electrical connection between the MLPEs
Figure 41: Aligning the Solar Module Assembly with the Starter Bar
Align the right inner edge of the Solar Module Assembly with the Starter Bar
Starter Bar
P a g e | 36
Figure 42: Attach the Solar 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). Tighten the WEEB® terminal screw with to 7 ft.-lbs. leave some slack in the copper wire between solar module assemblies for wire management.
Step 4e: Create the MLPE Map... Create the MLPE map per manufacturer’s instructions (Figure 44). This map is necessary to set up the monitoring system.
Figure 43: Solar Module Assemblies are grounded using #12 or #10 AWG Copper Wire
Bare Copper Wire
MLPE
Peel the MLPE Bar Code Affix the Bar Code to the MLPE Map
Figure 44: Create the MLPE Map
WEEB® Grounding Lug
WEEB® Terminal Screw
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 Rows of Solar Module Assemblies… Follow Steps 4a and 4b to place each solar module assembly in its row from left to right & from bottom up. Each solar module assembly must align with the one below within its respective column. Start with the right-most solar module assembly & ensure that its right edge aligns with the right edge of the row below (Figure 45).
Next, check for alignment at the overlapping edges (Figure 46).
Step 5a: Install Subsequent Rows of Solar Module Assemblies
Step 5b: Electrically Connect Row to Row
Figure 46: Install subsequent rows of Solar Module Assemblies
Ensure that the overlapping edges align
Figure 45: Install subsequent rows of Solar Module Assemblies
Ensure that the Right Edges of each Row align
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. The existing cables are long enough to extend from one row to the other. Continue with Steps 4c to 4e for each row.
Step 6: Install Side Flashings Remove the plastic film covering from all side flashings before installing them. Follow these 3 substeps to install the side flashings:
Step 6a: Install Starter Bar Covers… Attach the starter bar cover on the left & right side of the starter bar row using 2 starter bar cover screws with the #2 Phillips bit. (Figure 48).
Step 6b: Install Step Flashing… Start at the corner of the bottom row of the solar module assemblies
and position the first step flashing. The first step flashing should extend down to the top of the exposure of the shingle. Slip the first step flashing behind the starter bar cover. Nail the
Step 6a: Install Starter Bar Covers
Step 6b: Install Step Flashing Step 6c: Install Counterflashing
Wiring from bottom row
Figure 47: Row to row electrical connections
Figure 48: Installing the Starter Bar Cover
Wiring from upper row Electrical connection
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.
When installing the step flashing at the top corner of the solar array, ensure that the top corner step flashing extends a few inches beyond the solar module assembly (Figure 50). See Step 7f for further details for installing the corner step flashing.
Step 6c: Install Counterflashing… Counterflashings are designed to overlap the step flashing. The left
counterflashing is first mounted on a channel within the module frame, and then pressed until a snap fit is created (Figure 51, next page). Continue installing the left counterflashings bottom up on the left edge of each row.
Extend
Top corner Step Flashing extends beyond the Solar Module Assembly
Figure 49: Installing the Step Flashing
Step Flashing
Figure 50: Positioning the Top Corner Step Flashing
P a g e | 40
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.
Continue installing the right counterflashings from the bottom up, on the right edge of each row (Figure 53).
Left Counterflashing
Figure 51: Installing the left Counterflashing
Figure 52: Installing the right Counterflashing
Figure 53: Counterflashings along the right edge of the Solar Array
Right Counterflashing
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 7a: Install the inner Top Flashings… The inner top flashing snaps onto the top edge of the solar
module assembly as shown in Figure 54. Verify that every tab is engaged by pulling back on the inner top flashing. Install one for each solar module assembly in the top row.
Step 7b: Install the Top Flashing Supports and position the DynoBond™ Clips… Place top flashing
supports at the corners of the array and at every module-to-module joint. It is important to place the corner top flashing support as shown in Figure 56 (next page). This step would allow proper placement of the top corner flashing later on. In high snow load areas, additional supports may be required. The supports also serve as a water trough between top flashing butt-joints. Therefore, it is important that the supports be centered to the module overlap. The support should be fastened with two standard roofing nails. These roofing nails should be attached only through the flat portion of the top flashing support within 1" of the edge as shown in Figure 55 (next page). Position the corner top flashing support at the corner of the solar array as shown in Figure 55 (next page). Ensure proper wire management underneath these supports.
Step 7a: Install the inner Top Flashings
Step 7b: Install the Top Flashing Support and
position the DynoBond™ Clips
Step 7c: Position the Top Flashings
Step 7d: Install the Grounding Clips on the Top Flashings
Step7e: Nail the Row of Top Flashings in Place Step 7f: Install the Corner Step Flashing
Step 7g: Install the Top Corner Flashings
Figure 54: Counterflashings along the right edge of the Solar Array Inner Top Flashing
P a g e | 42
The Dynoraxx® DynoBond™ is a stainless steel clip and tin-plated copper wire. Bend the Dynobond™ wire into a U-shape and pass it through each one of the top flashing supports (Figure 56).
Use a split-bolt connector to attach the DynoBond™ wire to the copper grounding wire (Figure 57). Only one split-bolt connector is required per array.
Figure 55: Location of the Top Flashing Supports
Top Flashing Supports within the Array
Dynobond™ Grounding Clips
Figure 56: Positioning the Dynobond™ Grounding Clips
Figure 57: Installing the S-8 Split-Bolt Connector
Route Wires through this opening
Nail only at this Flat End (shown hatched), within 1" from the Edge.
Top Flashing Support
¼"-½"
Center the Top Flashing Support over the overlap
Position the Corner Top Flashing Support as shown
1"
Dynobond™ Grounding Clips
S-8 Split-Bolt Grounding Connector
Bare Copper Grounding Wire
1"
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).
Step 7d: Install the Grounding Clips on the Top Flashings... Each top flashing and top corner flashing must be grounded with the DynoBond™ clips. The DynoBond™ clips are designed to penetrate the finishing coat on the edge of the top flashing. Using a hammer to lightly tap the clip into place makes installation easier (Figure 59). The clips are attached to each other by a coated copper wire that electrically bonds the top flashing parts together. Adjacent top flashings share the same DynoBond™ clip.
Figure 58: Positioning the Top Flashing
Figure 59: Install the Grounding Clip on the Top Flashing
Dynobond™ Grounding Clips
Top Flashing
1
2 3
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). Fasten the top flashings with standard roofing nails. A minimum of 4 nails per top flashing is required and should be evenly spaced
Step 7f: Install the Corner Step Flashing… Proceed with this step only if the step flashing does not interfere with the exit wires. At the top corners of the solar array, trim the step flashing by following the contour of the top flashing support and install it as shown in Figure 61.
Figure 60: Position & nail the Top Flashing in place
Top Flashing Support
Top Flashing
Ensure there are no Electrical Cables under this Flat Part of the Top Flashing
Figure 61: Install the Step Flashing
Trim the Step Flashing
P a g e | 45
Step 7g: Install the Top Corner Flashings… At the point where the electrical wires exit the solar array, drill a hole through the top corner flashing (Figure 62).
Attach an electrical conduit through this hole and pull all the wires through this conduit (Figure 63). These wires are routed into an appropriately sized electrical combiner box within 5' (1,524 mm) of the array.
Install the top corner flashing by overlapping the top flashing (Figure 64). Ground the top corner flashing using the DynoBond™ clip. The top corner flashing should be fastened with roofing nails in a location away from water flow.
Figure 62: Hole for conduit exit in the Top Corner Flashing
Figure 63: Attach an electrical conduit through the hole in the Top Corner Flashing
Figure 64: Overlap and nail the Top Corner Flashing in place
Top Corner Flashing
Top Corner Flashing
Top Flashing
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 8a: Install the QuickStart® Peel & Stick Starter Roll over the Top Corner Flashing... Install a strip of QuickStart® Peel & Stick Starter Roll or leak barrier over the top corner flashing as shown in Figure 65.
Step 8b: Apply Shingles over the Top Corner Flashing… It may be required to notch the corner shingle
transitioning from the side of the array to the top flashing (Figure 66).
Step 8c: Install the Leak Barrier over the Row of Top Flashings… Install the leak barrier over the nailing
area of the top flashing. This ensures that nail penetrations are sealed from any possible water
Step 8a: Install the QuickStart® Peel & Stick Starter Roll over the Top
Corner Flashing
Step 8b: Apply Shingles over the
Top Corner Flashing
Step 8c: Install the Leak Barrier over the row of Top Flashings
Step 8d: Roll out the QuickStart®
Peel & Stick Starter Roll over the Leak Barrier
Step 8e: Shingle around the Top
Flashing
Figure 65: Apply a strip of QuickStart® Peel & Stick Starter Roll at the Top Corner Flashing
Top Corner Flashing
QuickStart® Peel & Stick Starter Roll or leak barrier. Notch as needed.
Notch the Shingle as needed
Figure 66: Shingling at the corner of the Solar Array
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)
Step 8d: Roll out the QuickStart® Peel & Stick Starter Roll over the Leak Barrier... The QuickStart®
Peel & Stick Starter Roll is the starter course required for the shingles that will be installed (Figure 68). This ensures that the leak barrier is not exposed to UV degradation between the butt joints of the shingles. The QuickStart® Peel & Stick Starter Roll is adhered to the leak barrier and should extend past the solar array by a minimum of 6" (152 mm).
Leak Barrier
Shingle
Top Corner Flashing
Figure 67: Installing the Leak Barrier over the Top Flashing
Figure 68: Installing the QuickStart® Peel & Stick Starter Roll over the Leak Barrier
QuickStart® Peel & Stick Starter Roll
Leak Barrier
Leak Barrier
Leak Barrier
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 70 shows the completed DecoTech™ Solar Array.
Figure 69: Installing Shingles around the Solar Array
Figure 70: Completed DecoTech™ Solar Array
P a g e | 49
Field-installed Connection
Home Run Wire
DecoTech™ Module Assembly Junction Box
DecoTech™ Module Assembly
DC Optimizer Inverter
with DC Disconnect
DC Combiner Box
-ve -ve -ve +ve +ve
+ve
+ve (Male)
DecoTech™ Module Assembly Junction Box
DecoTech™ Module Assembly AC
Microinverter
AC Disconnect
AC Combiner Box
AC Trunk Cable
Trunk Cable End Cap
AC Connector
-ve (Female)
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. This integration occurs in the field. The wiring cable, connectors, and wiring schematics will vary depending on whether an AC microinverter or a DC power optimizer is integrated in the system. Use color-coded wire per NEC & MLPE manufacturer’s instructions.
Wiring
The basic schematic of wiring with a DC optimizer is shown in Figure 71: The basic schematic of wiring with an AC microinverter is shown in Figure 72:
Figure 71: Typical DC Optimizer wiring diagram
Figure 72: Typical AC Microinverter wiring diagram
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 • Wiring between rows of solar module assemblies • Home run cable routing within the solar array for DC optimizer systems • AC trunk cable routing for AC microinverter systems • Exit wiring from solar array to the roofing junction box
The work in this step must be completed by a licensed electrician.
The licensed electrician is responsible for the wiring from the junction box to the point of interconnection, as well as laying the conduit and junction box on the roof. If required by the AHJ, elevate the electrical conduit a few inches off the roof. The AC or DC cable must transition to a properly sized cable in a junction box after it leaves the solar array (Figure 73). Review the electrical design of the solar array.
Solar System Safety Labels
Apply labels per Table 3 (next page) and any applicable local codes. The MLPE and SolarWorld laminate will have their own code and safety labels affixed.
Figure 73: Exit wiring from the Solar Array
Electrical Conduit Routing
Junction Box
P a g e | 51
On the Conduit
On the Main Switchboard & Main Electric Meter
On the DC/AC Disconnect
On the J Box, DC/AC Disconnect, and Tap Box
On the AC Disconnect
On the AC Combiner Panel
On the DC Inverter & AC Disconnect
On the DC Disconnect
Table 3: Solar System Safety Labels
Monitoring Monitoring can be set up either by the installer or the licensed electrician after wiring is complete. Follow the power electronics manufacturer’s application instructions to set up 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.
P a g e | 52
SECTION 6 — DECOTECH™ SOLAR SYSTEM MAINTENANCE
• The DecoTech™ Solar System has no user-serviceable parts and needs no routine maintenance interventions. 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 are to 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. DecoTech™ 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.
• For more information on GAF solar products and services for solar applications, visit gafsolar.com.
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: SolarWorld laminate electrical specifications
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" (42 mm) Depth, Back 3.41" (87 mm)
Frame Black powder-coated aluminum
Mechanical Loading 50 lb/ft2 (244 kg/m2) positive design load
Fire Rating Class A per UL 2703 To achieve a Class A fire rating, the solar array must be installed with one ply of StormGuard® Film-Surfaced Leak Barrier, followed by one ply of VersaShield® SOLO™ Fire-Resistant Slip Sheet over minimum 15/32" (11.9 mm) thick plywood or 7/16" (11.1 mm) OSB roof deck. Please refer to Underwriters Laboratories Certifications Directory for actual assemblies.
Table 5: DecoTech™ RI 2000 Solar Module mechanical characteristics
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.
PV Laminate (frameless) The SolarWorld laminate within the DecoTech™ Framed Module is certified to UL 1703 Standard for Flat-Plate Photovoltaic Modules and Panels. DecoTech™ Module Assembly The DecoTech™ Module Assembly is tested and certified to comply with the following standard:
• UL 2703 ̶ Standard for Mounting Systems, Mounting Devices, Clamping/Retention Devices, and Ground Lugs for Use with Flat-Plate Photovoltaic Modules and Panels.
The top flashing and the top corner flashing are included in the UL 2703 listing. The starter bar, counter-flashings, top flashing support, inner top flashing, and the MLPE are not included as part of the DecoTech™ UL 2703 electrical certification.
DecoTech™ Solar Array
The DecoTech™ Solar Array is tested and certified 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
The DecoTech™ 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:
• 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 • State of Florida Approved • UL Classified. See complete marking on product.
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:
• ASTM D1970 • Florida Building Code approved
P a g e | 57
DecoTech™ Module Assembly Drawings
Figure 74: DecoTech™ RI 2000 Module Assembly Drawing
BACKSHEET
PV SIDE
P a g e | 58
DecoTech™ Solar Array Drawing
Figure 75: DecoTech™ RI 2000 Solar Array Drawing
Related Documents
