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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...

Each Starter Bar receives 3-5 Adjustable Feet Bases (check the

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 2a: Assemble the Starter Bars

Step 2b: Install the Adjustable Feet

Step 2c: Install the MLPE Brackets

Step 2d: Install the WEEB® Lug and

MLPE

Step 2e: Connect the PV Wires

Step 2f: Ensure Proper Wire

Management

Default height

of the

adjustable foot

base is to

expose 2 tooth

grooves

Adjustable

foot base

Starter Bar

Carriage
Bolt

Nut

Figure 21 Assembling the Starter Bar

Содержание DecoTech

Страница 2: ... 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 Insta...

Страница 3: ...P a g e 3 GAF Solar Energy System Codes and Standards 58 Alternate Solar System Configurations 59 Version Control 63 ...

Страница 4: ...s 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 Ameri...

Страница 5: ...lug The Module Assembly is built in the field with the provided hardware Detailed instructions are in Section 4 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 Back Front Adjustable feet MLPE mounted on the MLPE Bracket...

Страница 6: ...loves 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 cond...

Страница 7: ...y 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 ...

Страница 8: ... 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 applica...

Страница 9: ...ect switch meter monitoring system and inverter See the Project Installation Drawings for more information Attaches to the deck and is installed underneath the Solar Array Provides a Class A fire rating Provides secondary leak protection GAF Underlayment System Deck mounted Solar Module integrated with power electronics and grounding lug Module Assembly Starter Bar and Flashing provides primary le...

Страница 10: ...ar Energy System Module Adjustable Foot Assembly MLP Bracket w Grounding Lug Step Flashing Starter Bar Cover Starter Bar Right Counterflashing Top Flashing Support Top Corner Flashing Top Flashing Adjustable Foot Base Left Counterflashing Top Flashing Frame Insert Figure 5 GAF Solar Energy System Components ...

Страница 11: ...ng 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 Left and Right Covers are the same Table 2 Non GAF Components COMPONENT MANUF PART NUMBER WEEB Grounding Lug Wiley WEEB LUG 8 0 DynoBond Grounding Jumper 38 DynoRaxx DynoBond 38 DynoBond Grounding Jumper 76 DynoRaxx Dyn...

Страница 12: ... 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...

Страница 13: ...hown 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 Config A Config B Config C Left Inside Corner Right Inside Corner Left and Right Inside Corners Figure 6 Solar Arrray Configuations ...

Страница 14: ... 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 ...

Страница 15: ...porting 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 h...

Страница 16: ...ght 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 requireme...

Страница 17: ...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 38 DynoBond Jumper 76 DynoBond Jumper Solid ...

Страница 18: ...noRaxx 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 wir...

Страница 19: ...P a g e 19 Figure 11 DynoBond clip connection to flashing DynoBond Clip Top Flashing MLPE WEEB Grounding Assembly Figure 12 Connection between DynoBond Jumper and copper ground wire ...

Страница 20: ...ustable 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 ...

Страница 21: ...onal 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 Recommended Tools Figure 14 Typical Tools Required ...

Страница 22: ...scuss 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 w...

Страница 23: ...ed in this Section Prep the Roof Step 1 Build the Starter Bar and the Solar Module Assembly Step 2 Install the Starter Bar Step 3 Install the First Row of Solar Module Assemblies Step 4 Install the Remaining Rows of Solar Module Assembles Step 5 Install Side Flashing Step 6 Install Top Flashing Step 7 Install Top Flashing Underlayment and Shingles Step 8 ...

Страница 24: ...nd 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 ...

Страница 25: ... 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 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...

Страница 26: ...Start 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...

Страница 27: ...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 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 VersaShield SOLO Fire Resistant Slip Sheet Leak B...

Страница 28: ...rter 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 2a Assemble the Starter Bars Step 2b Install the Adjustable Feet Step 2c Instal...

Страница 29: ...nmental 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 Adju...

Страница 30: ...ly Adjustable Feet Adjustable Feet Solar Module Frame Wiper Seal Grounding Screw Channel Hook onto the Channel and Rotate Pre drilled Holes Align the Pre drilled Holes 1 2 3 4 MLPE bracket location Module Junction Box Figure 24 Mounting the Adjustable Foot ...

Страница 31: ...unding 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 WEE...

Страница 32: ...o 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 MLPE Bracket WEEB Grounding Assembly Figure 28 Attach WEEB Ground Assembly to MLPE Wiring Connectors Figure 29 Attach connectors ...

Страница 33: ...P a g e 33 Back Front Figure 31 shows the front and back of the completed GAF Solar Module Assembly MLPE Bracket Wire Ties Figure 30 Proper wire management Figure 31 Completed Module Assembly ...

Страница 34: ...n 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 Figure 33 Attach the Starter Bar to the deck Step 3a Snap Chalk Line Step 3b Position and Attach the Starter Bars to th...

Страница 35: ... Bars together before attaching them to the deck This allows the entire row to be aligned at once Figure 34 Figure 34 Row of 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 Starter Bars Gap Adjacent Starter Bars share Foot Base ...

Страница 36: ...ace 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 Step 4a Mount the Solar Module Assemblies onto the Starter Bar Step 4b Make Electrical Connections Between MLPEs Step 4c Attach the...

Страница 37: ...ustments 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 Step 4b Make Electrical Connections between MLPEs Complete the wiring according to the Permit Design Drawings Typical connections are shown in Figure 39 Fol...

Страница 38: ...edge of the module with the outer edge of the Starter Bar per Figure 40 This step is critical to ensure proper flashing installation 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 Align the Right...

Страница 39: ...nding 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 Step 4e Create the MLPE Map Create the MLPE map per manufacturer s instructions Figure 43 This map is required for...

Страница 40: ...P a g e 40 Peel the MLPE Bar Code Affix the Bar Code to the MLPE Map Figure 43 Create MLPE Map ...

Страница 41: ...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 Step 5a Install Row ...

Страница 42: ...ylight 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 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 ...

Страница 43: ... and Right Counterflashing as shown in Figure 49 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 Corner Flashing Last Step Flashing and Shingle Figure 48 Step Flashing Overlap F...

Страница 44: ...rts 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 o...

Страница 45: ...Page 17 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 Top Flashing Supports within the Array 76 DynoBond Route Wires Through This Opening Nail Only Within 1 25 mm from the Edge Top Flashing Support Center the Top Flashing Support on the Overlap Position the Corner Top Flashing Support as Shown DynoBon...

Страница 46: ...ning 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 Top Fla...

Страница 47: ... 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...

Страница 48: ...P a g e 48 Top Corner Flashing Top Flashing Figure 57 Install Top Corner Flashing Figure 58 Top Corner Flashing with Conduit ...

Страница 49: ... 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 6...

Страница 50: ...tarter 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 Figure 62 Install QuickStart Starter Roll over the Leak Barrier Leak Barrier Shingle Top Corner Flashing QuickStart Peel and Stick Starter Roll Leak Barrier Leak Barrier Leak Barrier ...

Страница 51: ...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 ...

Страница 52: ...T 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 AC Microinverter The typical schematic with an AC Microinverter is shown below Figure 65 Ty...

Страница 53: ...essary 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 Figure 67 Typical Wire Management Detail B Detail A Detail B Detail A Side Flashing Step Flashing Counter Flashing MLPE ...

Страница 54: ...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 Dir...

Страница 55: ...P a g e 55 SECTION 7 APPENDIX GAF Solar Module Technical Data Table 4 Solaria Laminate Specifications ...

Страница 56: ...P a g e 56 Table 5 Silfab Laminate Specifications ...

Страница 57: ...ed 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 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 Resista...

Страница 58: ...ass 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 appr...

Страница 59: ...n the Counterflashing must be field modified to accommodate the adjoining Starter Bar The other flashing components are used as is 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 Starte...

Страница 60: ...71 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 Step 4 Align and attach Solar Module Assemblies 2 and 3 as shown below Complete the array following the standard installation procedures Trimmed Right Counterflas...

Страница 61: ... Bar 2 using the appropriate spacing per the Permit Design Drawings 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 Sol...

Страница 62: ...he 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 2 1 2 Figure 76 Configuration C Step 2 Figure 77 Configuration C Step 3 Trimmed Right Counterflashing Trimmed Left Counterflashing ...

Страница 63: ... wire WEEB lug 1 1 0 11 2017 Added Silfab laminate adjustable feet updated SKU numbers and right counterflashing install wire management techniques and grounding methods for the adjustable feet 2 0 03 2018 Edited for clarity 3 0 04 2019 Updated product name updated SKUs added Solaria laminate removed SolarWorld laminate 3 1 08 2019 Added three feet mounting option more Dynobond grounding options T...

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