GAF DecoTech RI 2000, Installation Instructions Manual

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Page 2: ...ation 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 Fl...

Page 3: ...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 ...

Page 4: ...ance of its products GAF periodically makes changes to its products and applicationspecifications GAFreservesthe righttochange or modify atitsdiscretion anyof 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 AlternatingCurrent AHJ ...

Page 5: ...h 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 Basedonthe type of MLPEused the solarmodule assemblyisdesignedtogenerateDCorACpowerwhen exposedtolight Thissolarmodule assemblyisputtogetherinthe fieldatgroundlevel The solarmodule assembly is shown in Figure 2 Figure 2 DecoTech Module Assembly...

Page 6: ...ring 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 fallingobjects aswell as risk of contact withenergizedconductors AnANSIZ89 Class A helmet will satisfy this OSHA requirement o Workgloves Forslip abrasion andthermal...

Page 7: ...vent 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 guardsshouldbe usedgenerouslyinextreme climates The numberof snow guards neededdependsonthesizeandslopeof theroof Insomere...

Page 8: ...dthe NEC National Electrical Code ANSI NFPA 70for U S installations Re inspection Regularly re inspect the solar systemto 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 Thisisimportantespeciallyafterstormsandinareaspronetohail andhighwinds If anydamage is found the DecoTech Module Assemb...

Page 9: ... 6 Main components of the DecoTech Solar System Attachesto the deck is installedunderneaththe DecoTech SolarArray ProvidesaClassA fire ratingforthe entire DecoTech SolarSystem Providessecondaryleakprotection Underlayment System These unitsare deck mountedUL1703 certifiedsolarlaminates withintegratedframingandracking integratedpowerelectronics and flashingcomponents DecoTech Module Assembly Connect...

Page 10: ... 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 ...

Page 11: ...t Starter Strip Shingles and asphaltic plastic cement The asphaltic plastic cement should conform to ASTMD4586 Type I or II o StormGuard Film SurfacedLeakBarrier o Shingles o Drip edge o Shims o Drill Tec 14 2 51 mm HeavyDutyRoofingFasteners o Cap nails staples The electricianisexpectedtostockthe following Standardelectrical tools Conduits conduitsupports Safetylabels Combinerbox andAC DCdisconnec...

Page 12: ...e MLPE are mountedonto 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 approvedDynoRaxx DynoBond GroundingClip Figure12 page 14 AnS 8 split boltconnectorisaUL approved connector used to attach the DynoBond clip to the copper grounding wire Tighten all the com...

Page 13: ...LPE 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 ...

Page 14: ... 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 ...

Page 15: ...o an AC truck cable is dependentonthe solar laminate electrical output MLPE limitations andPVdesignlayout Refertothe permitpackage todeterminethemaximumnumber 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 e...

Page 16: ...Barrierand 2 SlipSheet One plyof VersaShield SOLO Fire ResistantSlipSheet mechanically fastenedwithstaples For roof mounting the acceptability of the completedassembly including the fire resistance of the underlying components of the roof shall be considered per local fire codes Solar trackers The DecoTech Module Assemblyhas not been evaluated for use on a solar tracker Nonstructural component The...

Page 17: ...twhichfirmlybondsthe shinglestogetherafterapplicationwhenexposed to sunandwarm temperatures Shinglesinstalledinfallorwintermaynotseal untilthe following spring If shingles are damaged by winds before sealing or are not exposedto 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 seali...

Page 18: ...tem 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 arra...

Page 19: ...lso 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 abnormalitiesinpre existingsite conditions doNOTproceedwiththe installationuntilthe matteris resolved with the building owner and with GAF Typical abnormalities include o Situations where site condi...

Page 20: ...ll be describedindetail inthe followingpages Build the Solar Module Assembly Step1 Prep the Roof Step2 Installthe Starter Bar Step3 Installthe FirstRow of Solar Module Assemblies Step4 InstallRemaining Solar Module Assembles in the Solar Array Step5 InstallSide Flashings Step6 InstallTop Flashings Step7 Top Flashing Weatherization Shingle Integration Step8 ...

Page 21: ...ting feet so that the pre drilled holesin the feet and the module frame align AsshowninFigure2 note the locationof the MLPEfootrelative to the solarmodule The MLPE solarfoot shouldbe locatedone fromthe middle onthe side closer to the solar junction box This ensures that the cables being routed from the solar module sjunctionbox tothe MLPEissufficientinlength Next rotate itintopositionanddrill a he...

Page 22: ...s 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 P...

Page 23: ...re proper grounding Step 1c Ensure Proper Wire Management Route the negative wire female throughthe hollowof 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 To...

Page 24: ...dule and the MLPE Figure 21 See Figure 71 Figure 72 page 49 for the DC AC wiring schematic Figure 22 showsthe front back of the DecoTech Module AssemblyafterStep1iscompleted 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 ...

Page 25: ...debris from the roof deck Figure 23 Step 2b Install the Drip Edge along the Eave Install the dripedge directlytothe deckalongthe 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 al...

Page 26: ...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 dripedge alongthe rakes overlappingthe 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 Barrie...

Page 27: ...t in underlayments and leak barriers resulting in asphalt dripping and staining Step 2f Install Initial Rows of Shinglesupto ProposedLocation of the Starter Bars From the solar designdrawings locateandmarkthe lower leftcornerof theproposedsolararray alsocalled the starting point The starting pointmust always land on the headlap area of the shingle Determine the number of rows of shinglesrequired t...

Page 28: ...ft right and top edge of the proposed solar array Note Ensure that there isenoughroom aroundthe array to complywiththe local fire code as well as to accommodate the top flashing Roll outthe leakbarrier aligningitsedgealongthe chalklineoverthe shingleheadlap Extend it approximately 3 914 mm beyond the width of the solar array on the left and right side Figure 31 Figure 30 Snapa chalk line along the...

Page 29: ...ield Solo Fire Resistant Slip Sheet is a fire retardant layer and is requiredfora Class A fire rating It shouldbe installedonlyinthe fieldof the proposedsolar array VersaShield SOLO Fire Resistant Slip Sheet that extends beyond the field of the proposedsolararray must be trimmed Tofasten use corrosion resistantplasticcap nailsor stapleswithplasticcaps Side and endlaps shouldbe fastened12 305 mm o ...

Page 30: ...ersaShield SOLO Fire Resistant Slip Sheet Leak Barrier Figure 33 Install VersaShield SOLO Fire Resistant Slip Sheet 1 2 3 1 5 Chalk line VersaShield SOLO Fire Resistant Slip Sheet QuickStart Peel Stick Starter Roll ...

Page 31: ... bar to the deck by drillinginto3 of the 6 available screw holesof the feet with 14 2 51 mm Drill Tec RoofingFasteners Figure35 Donotovertightentheroofing fasteners Figure 35 Attach the Starter Bar to the Deck Step 3c Complete the Row of Starter Bars Next attachthe remainingstarterbarsfromlefttoright Figure 36 nextpage A gap of 1 8 3 mm shouldbe allowedbetweeneachstarter bar to accommodate forther...

Page 32: ...P a g e 32 Figure 36 Row of Starter Bars Starter Bars Gap ...

Page 33: ...nt 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 assemblysidewaysinto 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 ...

Page 34: ...tonwhetherthe solarmoduleassemblyhas an integrated AC microinverter or a DC optimizer Figure 40 next page showsthe 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 th...

Page 35: ... 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 attachingthe solarmodule assemblytothe deck Continue attachingthe row of solar module assemblies to the deck from right to left Note The inst...

Page 36: ...al screwwithto7ft lbs leavesome slackinthe copper wire between solar module assemblies for wire management Step 4e Create the MLPE Map Create the MLPE map permanufacturer sinstructions Figure 44 Thismap isnecessaryto setup the monitoringsystem 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 Ma...

Page 37: ...ebelow withinitsrespective 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 ElectricallyConnect Row to Row Figure 46 Install subsequent rows of Solar Module Assemblies Ensure that the ov...

Page 38: ...stepsto 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 extenddown to the top...

Page 39: ...rmodule assembly Figure 50 See Step 7f for further details for installing the corner step flashing Step 6c Install Counterflashing Counterflashingsare designedtooverlapthe stepflashing The left counterflashingisfirstmountedonachannel withinthemoduleframe andthenpresseduntil a snapfitiscreated Figure 51 nextpage Continueinstallingtheleftcounterflashingsbottom up on the left edge of each row Extend ...

Page 40: ...ottom face of the counterflashing will be flush with the module frame Continue installingthe rightcounterflashingsfromthe bottomup onthe rightedge 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 ...

Page 41: ...h 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 attachedonlythroughthe flatportionof the top flashingsupportwithin1 of the edge as shownin Figure 55...

Page 42: ...er array Figure 55 Location of the Top Flashing Supports Top Flashing Supports within the Array Dynobond GroundingClips Figure 56 Positioning the Dynobond Grounding Clips Figure 57 Installing the S 8 Split Bolt Connector Route Wires through this opening Nail only atthis FlatEnd shown hatched within 1 from the Edge Top Flashing Support Center the Top Flashing Support over the overlap Position the C...

Page 43: ...hthe DynoBond clips The DynoBond clipsare designedtopenetrate the finishingcoaton the edge of the top flashing Usinga hammerto lightlytapthe 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...

Page 44: ...ithstandardroofingnails A minimumof 4 nailspertop flashingis 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 withthe exitwires At the top corners of the solar array trim the step flashingby following the contour of the top flashing support and install it as shown in Figure 61 Figure 60 Position nail t...

Page 45: ...mbinerbox 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 ...

Page 46: ... 66 Step 8c Install the LeakBarrier overthe Rowof TopFlashings Install theleakbarrieroverthenailing areaof the topflashing Thisensuresthatnailpenetrationsare sealedfromanypossiblewater 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...

Page 47: ...he shingles that will be installed Figure 68 Thisensuresthatthe leakbarrierisnot exposedtoUV degradationbetweenthe 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 t...

Page 48: ...ontinue installingshinglesacrossthe topflashingand above the PV array followingroofingbestpractices Figure 69 Figure 70 shows the completed DecoTech Solar Array Figure 69 Installing Shingles around the Solar Array Figure 70 Completed DecoTech Solar Array ...

Page 49: ...componentsthatcanbe integrated into the DecoTech RI 2000 Framed Module The power electronics is integrated into the frame with appropriate hardware to ensure propergrounding This integrationoccursin the field The wiringcable connectors and wiring schematics will vary depending on whether an AC microinverter or a DC power optimizerisintegratedinthe system Use color codedwire perNEC MLPE manufacture...

Page 50: ...box The work in this stepmust be completed by a licensed electrician The licensed electrician is responsible for the wiring from the junction box to the point of interconnection aswell aslayingthe conduitandjunctionboxonthe roof If requiredbythe 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 leave...

Page 51: ...lar System Safety Labels Monitoring Monitoringcanbe set upeitherbythe installerorthe licensedelectricianafterwiringiscomplete Followthe power electronics manufacturer s application instructions to set up monitoring ThisManual isnotintendedtoprovideexhaustive instructionsontheset upandintegrationof themonitoring system GAF is not responsible for any troubleshooting associated with or failure in the...

Page 52: ...ly 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 Assembliesare naturally cleaned by seasonal rains In the unlikely event that cleaning is required contact yo...

Page 53: ... 53 SECTION 7 APPENDIX DecoTech Module Assembly Technical Data Model RI 2000 DecoTech RI 2000 laminate specifications withSolarWorldSunmodule Pluslaminate Table 4 SolarWorld laminate electrical specifications ...

Page 54: ...al Loading 50 lb ft2 244 kg m2 positive design load Fire Rating ClassA perUL 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 Dir...

Page 55: ...g 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 SolarArray istestedandcertifiedtocomplywiththe followingroofingstandards UL 1897 UpliftTestsforRoof CoveringSystems TAS 100 Test Procedure forWindandWind DrivenRainRes...

Page 56: ...andcertifiedtocomplywiththe following standards ASTMD146 D828 D1922 UL Classified Miami Dade CountyProductControl approved14 1022 26 QuickStart Peel Stick Starter Roll istestedandcertifiedtocomplywiththe followingstandards ASTMD1970 FloridaBuildingCode approved ...

Page 57: ...P a g e 57 DecoTech Module Assembly Drawings Figure 74 DecoTech RI 2000 Module Assembly Drawing BACKSHEET PV SIDE ...

Page 58: ...P a g e 58 DecoTech Solar Array Drawing Figure 75 DecoTech RI 2000 Solar Array Drawing ...