GAF DecoTech User manual

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GAF Solar Energy System ©2019 GAF All Rights Reserved. Version 3.1 08/2019

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1 Contents
SECTION 1 — INTRODUCTION ................................................................................................................. 4
Abbreviations .................................................................................................................................. 4
Symbol List ..................................................................................................................................... 4
Definitions ....................................................................................................................................... 5
General Safety Precautions ............................................................................................................. 6
Electrical Safety Precautions ........................................................................................................... 7
SECTION 2 - GAF SOLAR ENERGY SYSTEM OVERVIEW .............................................................................. 9
Main Components of the GAF Solar Energy System ..................................................................... 9
GAF Solar System Components .................................................................................................... 10
Solar Array Configurations ........................................................................................................... 13
SECTION 3 — GAF SOLAR ENERGY SYSTEM CONSIDERATIONS AND REQUIREMENTS .............................. 14
Design Considerations ................................................................................................................... 14
Installation Requirements .............................................................................................................. 16
Grounding ...................................................................................................................................... 17
Recommended Tools ..................................................................................................................... 21
Prior to Installation ........................................................................................................................ 22
SECTION 4 — GAF SOLAR ENERGY SYSTEM INSTALLATION .................................................................... 23
Step 1: Prep the Roof ..................................................................................................................... 24
Step 2: Build the Starter Bars and the Solar Module Assemblies ................................................. 28
Step 3: Install the Starter Bar ........................................................................................................ 34
Step 4: Install the First Row of Solar Module Assemblies ........................................................... 36
Step 5: Install the Remaining Rows of Solar Module Assemblies ................................................ 41
Step 6: Install Side Flashing .......................................................................................................... 42
Step 7: Install Top Flashing ........................................................................................................... 44
Step 8: Install Top Flashing Underlayment and Complete Shingles ............................................. 49
Completed GAF Solar Energy System .......................................................................................... 51
SECTION 5 — WIRE MANAGEMENT ...................................................................................................... 52
DC Optimizer ................................................................................................................................ 52
AC Microinverter .......................................................................................................................... 52
SECTION 6 — GAF SOLAR ENERGY SYSTEM MANINENANCE ................................................................... 54
SECTION 7 — APPENDIX ....................................................................................................................... 55
GAF Solar Module Technical Data ............................................................................................... 55

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GAF Solar Energy System Codes and Standards .......................................................................... 58
Alternate Solar System Configurations ......................................................................................... 59
Version Control .................................................................................................................................... 63

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SECTION 1 — INTRODUCTION
The GAF Solar Energy System is designed by GAF, North America’s largest roofing manufacturer. The sleek,
black, low-profile design delivers performance and curb appeal at an affordable price. The GAF Solar Energy
System was developed with roofing best practices, simplicity of installation, performance, safety, and aesthetics
in mind. Its deck-mounting technology coupled with GAF underlayment offers fast installation with high-
performance water shedding and a Class A fire rating. Module Level Power Electronics (either AC or DC) is easily
integrated in the field.
This Manual contains safety, installation, and troubleshooting instructions for the GAF Solar Energy System.
READ THESE INSTRUCTIONS ENTIRELY AND THOROUGHLY TO HELP ENSURE A 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 gaf.com/solar for the most
up-to-date version of this Manual or any technical bulletins for this product.
Abbreviations
AC Alternating Current
AHJ Authority Having Jurisdiction
ANSI American National Standards Institute
ASTM American Society for Testing and Materials
AWG American Wire Gage
DC Direct Current
OCPD Overcurrent Protection Device
OSB Oriented Strand Board
OSHA Occupational Safety and Health Administration
MLPE Module Level Power Electronics
NEC National Electrical Code
NFPA National Fire Protection Association
MC Multi-Contact
PPE Personal Protective Equipment
PV Photovoltaic
UL Underwriters Laboratories
Symbol List
CAUTION: Use caution and fully understand the instructions before proceeding.
DANGER: Indicates a hazardous situation. Failure to follow these instructions could lead to serious injury
or death.
NOTE: Follow these instructions closely for optimal system operations and best installation practices.
MOVE: Denotes direction of movement.

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Definitions
GAF Solar Module Assembly – the GAF solar module combined with:
 Roof attachments (adjustable feet)
 MLPE bracket
 MLPE (either a DC optimizer or an AC Microinverter)
 Wire ties
 Grounding lug
The Module Assembly is built in the field with the provided hardware. Detailed instructions are in Section
4.
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

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General Safety Precautions
 Must be installed by a qualified person… The GAF Solar Energy System must be installed by a PROPERLY
TRAINED and QUALIFIED INSTALLER. It is the responsibility of every installer to know and follow local
code requirements.
 Follow OSHA… GAF recommends compliance with OSHA guidelines for Residential Fall Protection.
 Wear Personal Protective Equipment (PPE)… Use proper PPE (Figure 3) and follow safety policies and
procedures. Proper PPE when dealing with rooftop solar systems includes, but is not limited to, the
following:
o Hard hats… For falling objects, as well as risk of contact with energized conductors. An ANSI Z89
Class A helmet will satisfy this OSHA requirement.
o Work gloves… For slip, abrasion, and thermal resistance. Solar modules tend to get very hot when
exposed directly to the sun.
o Electrically insulated gloves… When working on energized circuits.
o Appropriate footwear… Footwear with extra traction and/or heat-resistant soles.
o Personal fall arrest system (PFAS)… Consists of an OSHA-approved anchor point, a full-body
harness approved for electrical workers, rope or cable, and specific connecting hardware.
o Eye protection… For site-specific hazards.
Figure 3 personal Protective Equipment
 Work only in dry conditions… Use dry equipment and dry tools. Protect all electrical equipment against
weather elements.
 Eliminate trip and fall hazards… Keep work areas on the roof and ground staging areas organized and
clean.
 Beware of “in-between” roof slopes… A “walkable” roof may not be walkable once the shingles are
stripped off. A slope of 6:12 and higher generally becomes unsafe to walk on after being stripped.
 No stacking of Module Assemblies… Do not stack or store Module Assemblies on the roof. For general
safety of roofing materials, use roof jacks, toe boards, or storage platforms secured to the underlying roof
deck to prevent slippage of stored roofing materials.

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 Inspect for damage… Do not use GAF Solar Energy System components if there are visible signs of damage
from transport or handling.
 Handling the Module Assembly… Always have two people carry the product by its frame. Do not support
the solar modules on your head as a hard hat may damage the PV back sheet.
 Working Safely with PV systems… Be aware of the hazards at the jobsite as well as the hazards of working
on PV systems. Be alert at all times. Never work alone on PV systems. Always have at least two people
installing solar systems on the roof.
Electrical Safety Precautions
 Must be competent with electrical safety work practices… The GAF Solar Energy System is an electric-
powered generation system. The installer must be qualified according to state and local requirements.
 De-energize… All work must be performed on DC or AC circuits only after the circuits have been de-
energized.
 Use proper wire management techniques... Ensure that none of the AC or DC wires are pinched or
damaged during installation. Secure all loose cables with wire ties to the GAF Solar Module Assembly. Do
not exceed the minimum bend radius of the cables.
 Do not modify factory-applied connectors, terminals, or jumper cables… Do not customize or modify the
provided DC or AC cables or connectors in the field.
 Do not repair… The GAF Solar Energy System does not contain any user-serviceable parts. Replacement
products should be obtained through GAF. Tampering with the GAF Solar Energy System will void the
warranty.
 Thermal and voltage hazard… Certain parts of the GAF Solar Energy System may become extremely hot
due to continued exposure to the sun. It should be installed in a location where it is protected against
casual contact. It may also represent an electrical hazard while servicing the system immediately following
shutdown.
 Follow codes… Perform all electrical installations in accordance with all local codes and the NEC (National
Electrical Code) ANSI/NFPA 70 for U.S. installations.
 Re-inspection… Regularly re-inspect the solar system to ensure that all fasteners are securely tightened
and corrosion free; that wiring is securely connected and free of corrosion; and that cables are free of
damage. This is important especially after storms and in areas prone to hail and high winds. Any damaged
parts should be replaced immediately.
 Be aware of ground faults… Functionally grounded conductors may become ungrounded and energized
when a ground fault is indicated, resulting in risk of electric shock. Prior to touching any part of the

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product, use care to ensure surfaces and equipment are at touch-safe temperatures and voltage
potentials (by testing with a multimeter) before proceeding. Anytime the MLPE has been disconnected
from the power network, use extreme caution as some components can retain a charge sufficient to
create a shock hazard.
 Licensed Electrician… Installing AC or DC circuits, switches, tie-in to the PV point of connection, OCPDs,
and initial startup of the PV system must be performed by a licensed electrician. Make all electrical
connections (e.g., conductor termination, fuses, potential earth connection, etc.) in accordance with the
electrical standards prescribed by the applicable NEC wiring methods and/or by other local regulations
and codes.

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Figure 4 Main Components of Solar Installation
SECTION 2 - GAF SOLAR ENERGY SYSTEM OVERVIEW
Main Components of the GAF Solar Energy System
The three main components of the GAF Solar Energy System are:
The Balance Of System components that make up the remainder of the solar installation are outside the
scope of this manual. Typical components are: roof-top junction box, conduit and cables, disconnect
switch, meter, monitoring system, and inverter. See the Project Installation Drawings for more
information.
•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 leak protection and module
ventilation
•Presents an aesthetically-pleasing finished look
Flashing
Monitoring
Inverter,
Disconnects, and
Metering
Junction Box and
Wiring
GAF Array with
Flashing
GAF
Underlayment

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GAF Solar System Components
Figure 5 shows all of the hardware components that comprise GAF Solar 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