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FarmTek Growers Supply GrowSpan 500 Series Instructions Manual

Greenhouse kit w/blackout system
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Series 500 Greenhouse Kit w/Blackout System
©2016 Growers Supply
30' Wide Series 500 Greenhouse Kit w/Blackout System
All Rights Reserved. Reproduction
is prohibited without permission.
1
Revision date: 12.02.16

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Summary of Contents for FarmTek Growers Supply GrowSpan 500 Series

  • Page 1 Series 500 Greenhouse Kit w/Blackout System ©2016 Growers Supply 30' Wide Series 500 Greenhouse Kit w/Blackout System All Rights Reserved. Reproduction is prohibited without permission. Revision date: 12.02.16...

  • Page 2: Table Of Contents

    Table of Contents READ THIS BEFORE YOU BEGIN INSTRUCTIONS Important Information ........3 - 4 The main building and any accessory (end wall, door, etc.) Baseboards and Ribbon Boards....5 requires a specific installation sequence. All buildings .........6 - 8 include an instruction guide; each accessory includes an Overview...

  • Page 3: Important Information

    Important Information LOCATION Choosing the proper location is an important step before you begin. The following suggestions and precautions will help determine whether your selected location is best. Always check local building codes before you begin and follow codes as instructed. Never erect the structure under power lines.
  • Page 4 Important Information ASSEMBLY 17. Complete and return all warranty information as instructed if present. Following the instructions as presented will help ensure proper assembly. Failing to follow these steps may result in an improperly assembled and anchored structure. REQUIRED TOOLS IMPORTANT: There are some procedures that can occur The following list identifies the main tools needed to simultaneously, depending on available assistants and...

  • Page 5: Baseboards And Ribbon Boards

    Baseboards and Ribbon Boards A customer-supplied baseboard is recommended for roll- RIBBON BOARD FOR ROLL-UP SIDES—OPTIONAL up sides that include the stabilizer bar. A baseboard runs the length of the frame and provides a seal between the In some instances, a ribbon board is installed along ground level and the stabilizer bar.
  • Page 6 Parts Identification The following graphics will help identify the basic parts of the frame. (Some parts are not shown.) 100441, 100442 and 100443 AS1002 and FA4470B, FA4482B and 102198 102197 AS1004 Clamp Magnetic Nut Setter FA4484B Tek Screw Spring Wire Spring Channel 103856 AS2167 Anchor...
  • Page 7 Parts Identification (continued) QH1330 104548 111983 115359 104774 Bracket End Cap Foam Tape Motor Support Bracket Polycarb Tape 112567 102921B 112575 106735 Neo-bonded Cloth Weight Wire Tensioner Square Band Washer Bracket Clamp 113315 112608 115177 112569 112570 Wire Snap Clip Aluminum Clamp Drive Pipe Clamp Cable Clip...
  • Page 8 Parts Identification (continued) 103496 102569 Roller CC6212 103544 Fabric Clip Gear Box Bearing Mounting Plate 111681 FA2902 & FA2906 111612Z144 111613Z144 Vent Window Connector U-Bolt & U-Bolt Plate Ridge Vent Bottom Rail Ridge Vent Slam Rail 111673 Vent Rack & 111679 Vent Rack Drive 111674 Vent Bearing Plate ELECTRICAL WARNING This Series 500 greenhouse kit with a black-out...

  • Page 9: Overview

    Overview GrowSpan ™ Series 500 Greenhouse w/Blackout System Drawing may show a model of a different length. Refer to Quick Start section located near the back of this guide for on-center measurements and post layout. OVERVIEW This section describes assembling your building frame. See illustration below to identify main parts.

  • Page 10: Prepare And Square The Building Site

    Prepare and Square the Building Site PREPARE THE BUILDING SITE SQUARE THE SITE: GENERAL STEPS A level site is required to accurately and safely construct 1. Identify a corner where a building rafter will be the building. Consult the services of a qualified contractor positioned, drive in a stake, and string a line the exact to properly grade and prepare the site.

  • Page 11: Set Ground Posts

    Set Ground Posts These steps describe marking all post hole locations and digging the holes. For some sites, it may not be possible to complete the procedure in this manner. An alternative procedure such as working from one end of the building toward the other may be necessary. Determine the best procedure based on the site and other factors and proceed as needed.
  • Page 12 Set Ground Posts SET GROUND POSTS Required parts and equipment: Rafter mounting holes point towards ends. Ground Posts (113334) and 103856 Band Clamps Set all posts at the same Equipment to level and brace posts height. Additional bracing may be needed to keep the post plumb while concrete sets.
  • Page 13 Set the Ground Posts Ground Level Ground Post 2’ Deep Concrete In areas where frost is common, dig each post hole so it falls below the frost line. Minimum hole depth for all areas regardless of frost is 24". Minimum hole diameter Optional: Before setting the is 12".

  • Page 14: Mounting Foot Installation

    Mounting Foot Installation SETTING THE MOUNTING FEET For those buildings equipped with mounting feet, secure the feet to either a concrete foundation or concrete piers prior to attaching Customer is responsible for laying the necessary concrete foundation or the rafter legs and assembling the frame. concrete piers.

  • Page 15: Rafter Assembly

    Rafter Assembly RAFTER ASSEMBLY After setting the ground posts/base plates, continue with the rafter assembly. Do not set assembled rafters into position on the ground posts until concrete has set (if applicable). Check with contractor for set times. NOTE: All rafter assemblies consist of three main rafter sections. Consult the rafter diagrams in the technical documents at the end of these instructions before and during the rafter assembly process for details.

  • Page 16: Rafter Assembly-Support Chords

    Rafter Assembly–Support Chords RAFTER ASSEMBLY— Support Chords Support chord assemblies act as the horizontal surface to which black-out panels are attached, and against which the black-out panels seal. Additionally, support chord assemblies provide the structural support to support the weight of the black-out system components.
  • Page 17 Rafter Assembly–Support Chords BAND CLAMP (103856) BAND CLAMP (103856) DETAIL BAND CLAMP (103856) BAND CLAMP (103856) DETAIL DETAIL ST08475D13G17S1 ST08475D13G17S1 ST05050D13G17S1 ST05050D13G17S1 BAND CLAMP (106735) BAND CLAMP (106735) BAND CLAMP (106735) DETAIL CHORD TUBE (S20P126G14SGA) CHORD TUBE (S20P126G14SGA) CHORD TUBE (S20P07237G14SS1) DETAIL DETAIL (4x) 3/8"...

  • Page 18: Frame Assembly

    Frame Assembly FRAME ASSEMBLY Use the diagrams and information that follows to assemble the main frame. ATTENTION: Rafters are heavy. Always lift rafter from two separate points to prevent damage and injury. Examine the site to determine the best way to move the rafters into position and to set them onto the ends of each set of ground posts.
  • Page 19 Frame Assembly Use this diagram to properly position the purlins during the frame assembly. Side purlins will run just above the chord tubes of the rafter chord support components. Center the ridge purlin on top of the rafters. Secure using the QH1070 and FA4482 Tek screws. Install one Tek screw through the side of the strap and into the purlin pipe.
  • Page 20 Frame Assembly After setting the first end rafter and bracing it in place, set the second rafter and add the purlins and purlin clamps. Consult the techincal diagrams for connection details. Purlin Pipe After the first few rafters are set and connected by purlins, remove the end rafter bracing and continue with the frame assembly.
  • Page 21 Frame Assembly End Rafter FA4482B Tek Screw QH1070 Pipe Strap Purlin FA4482B Tek Screw FA4482B Tek Screw Photo shows the installation of the side purlin and pipe Secure each QH1070 pipe strap to the purlin pipe strap at the end rafter. See Connection Details in Quick using one Tek screw.
  • Page 22 Frame Assembly Customer-supplied rafter-spacing jig. Revision date: 12.02.16...
  • Page 23 Frame Assembly Full Frame with Rafter Chord Support components removed for clarity CABLE ASSEMBLY AND INSTALLATION IS SHOWN IN A LATER PROCEDURE. Full Frame ATTENTION: Example shows a 48' frame length. Actual frame may differ. Revision date: 12.02.16...
  • Page 24 Baseboard Installation—Recommended BASEBOARD INSTALLATION—RECOMMENDED Gather the parts: 2" x 8" treated lumber (supplied by customer). Baseboard 5/16" carriage bolts and nuts supplied by customer. Length depends on the thickness of the baseboard. When properly installed, baseboard runs the length of the frame at ground level.

  • Page 25: Diagonal Cable Installation

    Diagonal Cable Installation CABLE ASSEMBLY AND INSTALLATION CORNER Cables SEE BELOW FOR CABLE ASSEMBLY CALL-OUT CORNER Cables Cables CORNER Cables Cables Dashed lines indicate cable assembly locations. NOTE: Purchased shelter will have an even number of PGBRKAAS01 bays. Upper mid cables can bracket and and be installed in either of the AS2167 shackle...
  • Page 26 Diagonal Cable Installation Using the diagrams and photos on this and the previous page, install all cable assemblies. 104189 turnbuckle and thimble of cable assembly PGBRKAAS01 bracket and 104189 turnbuckle Secure band clamp to pipe. PGBRKAAS01 bracket and AS2167 shackle Tighten all clamps, band clamps, turnbuckles, and shackles.

  • Page 27: Install Ribbon Board-Optional

    Install Ribbon Board—Optional RIBBON BOARD INSTALLATION—Optional for Roll- Up Sides Gather the parts: 2" x 6" treated lumber (supplied by customer). Fasteners supplied by customer to attach boards to metal rafter pipes. Length depends on material thickness. The size and type of material you choose may require the use of alternative steps.
  • Page 28 Install Ribbon Board Ribbon Board Photos above show ribbon board attached to the side Ground level to of an assembled frame. Example shows using 2" Tek bottom of ribbon screws (additional purchase) to secure board to rafters. board is 72". Screw heads are countersunk below board surface to allow for the installation of the 111613Z144.
  • Page 29 Attach 111613Z144 to Ribbon Board 111613Z144 Buildings with roll-up side panels require 111613Z144 for installation. The photos for Roll-Up below show where to install the 111613Z144. Sides. Secure 111613Z144 to ribbon board (if present) using FAH005B (1/4" x 2") carriage bolts, FAMF01B (1/4") fender washers, and FALB01B (1/4") nut.
  • Page 30 Install Mid-Rafter Vertical Headers Mid-Rafter Vertical Headers are fixed sections runs of 2"x2" tubing installed just inside the rafter legs at every mid-rafter with a support chord assembly, or every 12'. Intermediate monofilament clips, panel fixation & sealing components, and drive components are all attached to the mid-rafter headers--horizontal and vertical. ASSEMBLE AND INSTALL MID-RAFTER VERTICAL HEADERS Install provided vertical header tubing as shown as every rafter with a support chord assembly.

  • Page 31: Install Ridge Vent

    Install Ridge Vent Install the ridge vent framing before the roof film is installed. Consult the technical documents at the back of these instructions to get a general understanding of how the vent is assembled. Photos below show a few ridge vent details. Photo shows a sample building with an installed ridge vent in the open position.
  • Page 32 Install Ridge Vent Ridge Vent Arm Ridge Purlin Ridge Vent Bottom Rail 111612Z144 Rafter Ridge Vent Bottom Rail Splice (S125P006) Vent Rack ATTENTION: Vent racks are either curved or straight depending on the application. A curved vent rack is shown in this example.
  • Page 33 Install Ridge Vent Graphics below show attaching the 102197 u-channel and 112390 flashing to the top of the curved ridge vent arm using FA4482B Tek screws. Attach components to the curved ridge vent arm at each end of the assembled vent frame.
  • Page 34 Install Ridge Vent 102197 U-Channel 112390 Flashing Diagram shows flashing and u-channel attached to the top of one end bow of vent frame. Revision date: 12.02.16...
  • Page 35 Install Ridge Vent 102197 U-Channel and 112390 Flashing installed at each end of the vent. Circled area shows the greenhouse vent window connector (111681) as attached to the roof vent bottom rail. Consult the technical diagrams supplied with the vent for fastener details. See also the photos near the end of this guide.
  • Page 36 Install Ridge Vent ATTENTION: Consult both the technical documents at the back of these instruction and the "Motor Care and Maintenance" page for motor installation details. Mounting plate is attached using FAG363B bolts, FALB04B nuts, and FAME08B washers. 115079 Mounting Plate ATTENTION: Position the motor at or near the center of the drive shaft.
  • Page 37 Install Ridge Vent Slam Rail 111613Z144 Bottom Rail 111612Z144 Photo above shows completed ridge vent as seen from inside the building. Review these steps to install the slam rail. 1. During the assembly, complete the hinged section of the ridge vent frame first. This is the portion of the vent that opens and closes.
  • Page 38 Install U-Bolts and Tighten Vent Rack Drive Vent rack u-bolts prevent the vent from opening too far and tracking out of the vent rack drives. After the ridge vent is assembled and attached and before the cover film is installed, install the u-bolts. There are two u-bolts for a typical ridge vent system.

  • Page 39: End Frame Assembly

    End Frame Assembly ASSEMBLE & INSTALL FRONT END WALL COLUMNS Consult the end frame diagrams near the back of these instructions before you begin. Verify the drawing is for the FRONT end wall, or the wall with the door and two fan openings. Assistance is required to assemble the end frames. The following steps describe one way to assemble and set the vertical supports.
  • Page 40 End Frame Assembly FRONT END (DOOR END) DETAIL GROUND BASE POSTS PLATES Ground Level DETAIL DETAIL DETAIL NOTE: Diagram shows both base plate and ground post options for illustration purposes only. Purchased greenhouse will either have all base plates or all [QH1330] ground posts.
  • Page 41 End Frame Assembly INSTALL FRONT END WALL HEADER & CROSS BRACES Continue to consult the end frame diagrams near the back of these instructions. Verify the drawing is for the FRONT end wall, or the wall with the door and two fan openings. FRONT END (DOOR END) DETAIL...
  • Page 42 End Frame Assembly INSTALL FRONT END WALL DOOR OPENINGS Consult the end frame diagrams near the back of these instructions. Verify the drawing is for the FRONT end wall, or the wall with the door. Cross reference with the instructions provided for the door. Verify proper dimensions and frame for doors accordingly.
  • Page 43 End Frame Assembly END WALL COLUMNS Consult the end frame diagrams near the back of these instructions before you begin. Verify the drawing is for the BACK end wall, or the plain wall with no openings. Assistance is required to assemble the end frames. The following steps describe one way to assemble and set the vertical supports.
  • Page 44 End Frame Assembly BACK END DETAIL (PLAIN END) GROUND BASE POSTS PLATES Ground Level DETAIL DETAIL DETAIL NOTE: Diagram shows both base plate and ground post options for illustration purposes only. Purchased greenhouse will either have all base plates or all ground [QH1330] posts.
  • Page 45 End Frame Assembly END WALL HEADER & CROSS BRACES Continue to consult the end frame diagrams near the back of these instructions. Verify the drawing is for the BACK end wall, or the plain end wall with no openings. BACK END (PLAIN END) DETAIL S15P069...
  • Page 46 Monofilament Wire Mounts The monofilament tensioners are used to string lines of monofilament wire from one end header to the other. These wire lines will serve as support, guiding tracks, and anti-billow agents for the shade/black-out material. Each monofilament line consists of one (1) 113650 wire tensioner, attached at one end, and one (1) 113694 slip-on bracket attached at the other end (shown below).

  • Page 47: Corner Cable Wire Mounts

    Corner Cable Wire Mounts INSTALL CORNER CABLE WIRE MOUNTS Each corner cable line consists of end header. At one end, attach the 112575 brackets in locations shown below using FAG312B bolts & FALB01B nuts. Repeat for the other end. Verify wire tensioners are positioned on the inside edge of the tubes, as shown. Install Corner Cable Wire Mounts an inch in from the corner to allow for access to crank wire tensioner.

  • Page 48: End Panel Installation

    End Panel Installation END PANEL INSTALLATION Consult the polycarbonate panel layouts in the technical documents towards the end of these The steps that follow describe one way to complete the instructions for the location and lengths of each polycarbonate panel installation. The materials and parts panel.
  • Page 49 End Panel Installation Consult the technical documents at the back of these instructions for further detail. Repeat steps for both end walls. 1. Using #14x1-1/2" Tek screws (FA4484B) & neo-bonded washers (102981B), attach sections of 113236Z127 H-channel to the outside face of the 2"x2" end wall header, rafter-to-rafter, as shown below. Cut to fit as needed. IMPORTANT: Verify that H-Channel is positioned so that the center channel is facing the attachment surface.
  • Page 50 End Panel Installation POLYCARBONATE PANEL INSTALLATION Consult the technical documents at the back of these instructions for additional detail. Repeat steps for both end walls. Panel layout is applicable for BOTH ends. ATTENTION: Remove the protective film from each panel before installation. Mark the panel if needed to ensure the uv-protected side is installed toward the sun.
  • Page 51 End Panel Installation DETAIL DETAIL DETAIL DETAIL NOTE: DETAIL DETAIL Cut upper panel to proper length. ATTENTION: Horizontal run of H-Channel that splices clear 8MM polycarbonate panels and blackout polycarbonate panels is uninterrupted as Photo shows an example of end shown to the right.
  • Page 52 Attach 104546 to End Rafters INSTALL 104546 Secure 104546 to top of both end rafters so that it extends over the top of the end wall panels to create a finished edge using FA4482 Tek screws spaced at 16" on-center. See below for details about position of 104546 on end rafter. IMPORTANT: For the 104546 for cover rounded edge of the rafter,...
  • Page 53 Frame Check and Light Deprivation Inspect the entire greenhouse frame for sharp edges or fasteners that could damage the cover during installation. 1. Verify that all frame members are properly secured and that all bolts and clamps are tight. 2. Recheck the frame assembly for sharp edges or clamps and bolts that may interfere with the installation of the curtain.

  • Page 54: Film Cover Installation

    Film Cover Installation INSTALL IR/AC FILM COVER IMPORTANT: Before installing the cover, verify that the following have been installed: ridge vent, end wall frame, and end wall cladding. Only after these items have been installed should you continue with the cover installation. Greenhouse includes two film types.
  • Page 55 Film Cover Installation 2. Take cover material and position it along the base of one side of the building. 3. Unfold cover and locate edge. Verify that the width and length are properly oriented with the width and length of the building.
  • Page 56 Film Cover Installation 5. After tying ropes/straps to main cover, throw them over the building and pull cover onto frame and up to the top edge of the closed ridge vent frame. See photos throughout this section. Photo above shows straps clamped to the edge of the cover material which is being pulled up to the installed ridge vent.
  • Page 57 Film Cover Installation 6. Have assistants pull the cover end-to-end and square the cover on the frame. Working from inside the frame on a lift, secure cover to the vent frame using the 102198 spring wire. See dashed line below. Allow a few inches of material to extend past the 111613Z144.
  • Page 58 Film Cover Installation 7. After securing cover edge, continue installing spring wire and work down the vent frame to the 104546 attached to rafter. Continue to secure cover and work down to side 104546. Cover Panel B is installed in a later step. Step 7 End Rafter End Panel...
  • Page 59 Film Cover Installation 8. Move to the other end rafter and attach the cover to that 104546 using the 102198 spring wire. Step 8 Panel A Step 9 Cut and use for Panel B. 9. Cut cover along the side and finish installation of first panel (Panel A) by stretching and attaching cover to the upper channel of the side run of 111613Z144.
  • Page 60 Film Cover Installation 10. Take the remaining material and use it to cover the other side of the frame. Repeat steps to pull cover onto frame. Step 10 Step 11 11. Secure cover to 111613Z144 attached to frame. Open vent to gain access to the 111613Z144 as needed. Using the proper lifts, work from inside to secure cover to the 111613Z144 attached to the frame.
  • Page 61 Inflation Fan Kit Installation The 110094 Air Inflation System assembly is quick and easy. Follow the procedure as shown. You will need a socket wrench set, utility knife, marker, and repair tape or heavy-duty duct tape to complete the steps. Deflector Blower Bracket GREENHOUSE WITH RIDGE VENT...
  • Page 62 Inflation Fan Kit Installation : After determining the regulator position, use the regulator as a template and mark the location on the end panel. Hose must reach from the blower motor to the regulator once it is installed. Carefully cut a mounting hole in the panel using a utility knife or other cutting tool.
  • Page 63 Inflation Fan Kit Installation Once the air inflation kit or kits are installed, install the remaining layer of film for the greenhouse (#108661). Simply repeat the steps for the cover installation for your greenhouse. Follow these guidelines to install the remaining film: Ensure that the deflector bushing for the air inflation kit remains in place when the final film is pulled.

  • Page 64: Curtain Stabilizer Bar Installation

    Curtain Stabilizer Bar Installation The curtain stabilizer bar secures the lower end of the roll-up side panel when it is closed (or down). It is installed just above the baseboard attached to the frame and ground level. Secure the stabilizer bar to each ground post using an FA4482 Tek screw.

  • Page 65: Roll-Up Side Panel Installation

    Roll-Up Side Panel Installation Revision date: 12.02.16...
  • Page 66 Roll-Up Side Panel Installation INSTALL ROLL-UP PANELS ASSEMBLE ROLL-UP SIDE PANEL CONDUIT Gather the parts: Film: Single roll of 108655: Field cut length in half. Pipe 1.315'' x 147'' swaged (#131S147) Complete these steps: Tek screws (#FA4482B) 1. For film, locate the roll of 108655 film, roll it out and The roll-up conduit assembly attaches to the bottom edge fold it in half (lengthwise).
  • Page 67 Roll-Up Side Panel Installation ATTACH CONDUIT TO ROLL-UP PANEL Gather the parts: Assembled conduit from previous procedure Fabric clips #CC6212 (Divide quantity in half.) Tek screws (#FA4482B) CC6212 Fabric Clip To this point, the roll-up side panel along one side is secured to and hanging down from the 111613Z144.
  • Page 68 Roll-Up Side Panel Installation TWIST-OF-THE-WRIST ASSEMBLY 3. Select the aluminum channel, drill a 3/8" hole through the channel approximately 2" from the end, and attach Gather the parts: a threaded rod using a 3/8" nut on each side of the Aluminum channel (102570) and drive handle 102570 channel.
  • Page 69 Roll-Up Side Panel Installation 1. Select the bearing bracket and attach the bearings as 5. Attach the Twist-of-the-Wrist gearbox to the mounting needed. (In some instances, the bearings may come plate using hex head bolts. already attached.) Assemble as follows if needed: NOTE: Single bearings are attached to the sides of the bracket and double bearings to the middle portion of the bracket.
  • Page 70 Roll-Up Side Panel Installation INSTALL THE ANTI-BILLOW ROPES The anti-billow rope is installed along the outside of the 8. Slide the Twist-of-the-Wrist assembly onto the frame and stretches between the ribbon board and the aluminum channel from the ground end. (This is the baseboard.
  • Page 71 Black-out System Installation The following pages include important information needed to safely assemble and maintain the system. Please read these instructions before you begin. REQUIRED TOOLS RECOMMENDED INSTALLATION CHRONOLOGY The following list identifies the main tools needed to The blackout system requires a specific installation assemble the vent system and attach it to your building.
  • Page 72 Black-out System Installation ASSEMBLE MOTOR SUPPORT 1. Locate the 115359 motor support bracket and the 113299 motor mounting plate. 2. Using 1/2"x3" bolts (112722), 1/2" flat-washers (106953) and 1/2" nuts (106977), attach the motor support bracket to the motor mounting plate as shown below. 115359 Motor Support Bracket 1/2"...
  • Page 73 Black-out System Installation INSTALL MOTOR SUPPORT ASSEMBLY 1. Establish the "power rafter", which will be the rafter under which all drive shaft components will be attached. ATTENTION: If greenhouse is 48', 72', 96' or 120' in length, there will be a center chord rafter, which will also serve as the "power rafter".
  • Page 74 Black-out System Installation ATTACH CHAIN COUPLINGS TO MOTOR 111676 Motor 111675 Chain Coupling 1. Set one 111676 motor on a flat surface and 2. Wrap chain around the two separate align 111675 coupling and motor sprockets sprockets. with chain. 3. Take connecting chain link and slide it 4.
  • Page 75 Black-out System Installation 7. Take outer spacer and place it over the 8. Check connecting link to ensure it is tight ends of connecting link. against chain. 10. Using a pair of needle-nosed pliers, snap 9. Place locking clip over the ends of locking clip onto connecting link.
  • Page 76 Black-out System Installation ATTENTION: Assistance required! Motor is heavy. Using a lift as a means of hoisting motor into position is highly recommended. MOUNT MOTOR Remove attachment bolts from motor, if necessary. Hoist and stablize motor into motor mounting plate as shown.
  • Page 77 Black-out System Installation NOTE: There may be instances where the couplers tightly fit onto the rack drives, and it may be very difficult to install once rack drives have been attached to the rafter chord. Test couplers on all rack drives. If the couplers are a snug fit, and/or need to be attached with added force, continue with steps below.
  • Page 78 Black-out System Installation 1. Measure and mark the locations for the rack drives as shown below. Measurements shown indicate the CENTERS of the rack drive gears. ATTENTION: It is important that the "left" and "right" rack drives be installed as far to the outer corners as possible without running interference with the vertical header.
  • Page 79 Black-out System Installation ASSEMBLE DRIVE SHAFT 1. For each span between the rack drives, measure the distance from the insides of the drive couplers. See diagram. X'-X" X'-X" X'-X" X'-X" Measure from the insides of the couplers, located approximately 2-1/2" inches in from the second splice hole, as shown.
  • Page 80 Black-out System Installation 113323 INSTALL MONOFILAMENT WIRE CLIPS 113323 tube clip tube clip Consult diagrams below and technical documents at the back of these instructions for location details. IMPORTANT: Orientation of the monofilament clips is critical. Use side view diagram to the right to determine orientation of the monofilament wire clips.
  • Page 81 Black-out System Installation ASSEMBLE DRIVE PIPE SUPPORT COMPONENTS 1. Using FA4482B Tek screws, attach the 112581 drive pipe rollers to the mid-rafter headers in the locations indicated by the arrows below. See diagrams for details. It is important that drive pipe roller locations mirror the rack-drive locations shown on page 78.
  • Page 82 Black-out System Installation ATTACH PANEL SEALING COMPONENTS 111984 CUT-AWAY Consult diagrams below and technical documents at keder channel SIDE VIEW the back of these instructions for location details. IMPORTANT: Orientation of the 111984 sealing keder channel is critical. Use side view diagram to the right to determine orientation.
  • Page 83 Black-out System Installation 1. Once an entire run of keder channel has been installed on a rafter, slide a continuous length of 115018Z046 keder sealing strip into the 111984 keder channel along the entire contour of the profile. Cut to fit, if necessary. HELPFUL HINT: For ease of installtion, slide the sealing strip through the horizontal section of the keder channel first, leaving approximately 8' of sealing strip dangling on either side.
  • Page 84 Black-out System Installation ATTACH PANEL FIXATION COMPONENTS CUT-AWAY 102197 Consult diagrams below and technical documents at SIDE VIEW Spring Channel the back of these instructions for location details. IMPORTANT: Orientation of the 102197 spring channel is critical. Use side view diagram to the right to determine orientation.
  • Page 85 Black-out System Installation Tensioning of the corner cables and monofilament wires (installed later) puts lateral pressure on the greenhouse end walls. Blackout purlins reinforce the structure lengthwise, and help to prevent end walls from bowing inward. Install blackout purlin components as shown in diagrams below. KEDER SEALING CHANNEL AND MONOFILAMENT WIRE CLIPS MUST BE INSTALLED BEFORE INSTALLING BLACKOUT PURLINS.
  • Page 86 Black-out System Installation INSTALL CORNER CABLES 1. Using the corner cable wire tensioners installed on the end black-out headers (page 46), string AR3030 cable lengthwise from one tensioner, THROUGH the flange of the corresponding 113323 monofilament wire clips on mid-rafter AS1002 headers (page 80), and attach to tensioner at the opposite Cable Clamp...
  • Page 87 Black-out System Installation 113318 Leading edge extrusions are installed at the "leading edges" of the black-out Leading Edge panels (installed later). Orient the leading edges so that the rubber sealing gasket will be FACING the keder sealing strip in each bay, as shown in diagram below. IMPORTANT: Due to the 20' lengths of the 113318 leading edges, it is recommended that the horizontal sections of the leading edges be temporarily installed BEFORE installing the monofilament wires to avoid the obstruction.
  • Page 88 Black-out System Installation Dashed line indicates horizontal leading edge Temporarily secure in location at each bay. place against the header with 115199 tape. See splice diagram below. Measure this distance. Cut to fit sections of 113318 leading edge and splice together. LEADING Slide continuous length 107777...
  • Page 89 Black-out System Installation STRING AND TENSION MONOFILAMENT WIRES 112570 DETAIL Monofilament 1. Starting in the middle of the header, and working Wire outward, string 112570 monofilament wire from the bottom wire tensioner brackets installed every 18" along one end wall header, to the 113694 wire brackets in the exact locations along the opposite end wall header.
  • Page 90 Black-out System Installation VERTICAL LEADING EDGES 1. Remove the 115199 tape that is temporarily holding up the assembled horizontal sections of leading edge (page 88). The installed monofilament wires will now support the weight of the section. 2. Measure and cut to fit vertical sections of 113318 leading edge. Bottom edge of the vertical sections will be flush with the bottom edge of the vertical header.
  • Page 91 Black-out System Installation SECURE LEADNG EDGES TO MONOFILAMENT WIRES IMPORTANT: Before attaching leading edges to vertical sections. 1. On the underside of the leading edges, snap 113314 wire location, which is approximately every Wire Guide the leading edge channel. See photos. 2.
  • Page 92 Black-out System Installation TELESCOPING PURLINS ATTENTION: Telescoping purlins will NOT be installed in greenhouses that are 60' or shorter. If purchased greenhouse is 60' or shorter, skip this step and continue on the following page. 1. Locate eight (8) swaged sections of 1/2" pipe (113300). At the swaged end, CUT the 113300 sections to 12'-5" lengths.
  • Page 93 Black-out System Installation ASSEMBLE AND INSTALL DRIVE PIPE COMPONENTS 1. Attach a 112582 rack drive coupler to each end of the four (4) 112586 rack arms using 113307 bolts & 113310 nuts. NOTE: Square ends of the couplers will sit inside the rack arms as shown below. 2.
  • Page 94 Black-out System Installation 4. Each loosely suspended rack arm/drive pipe assembly will have the rounded ends of the 112582 couplers open at the rack arm end. With assistance, or a lift machine, guide the plain end of another 105S156 drive pipe through the drive roller of the next rafter, and splice onto the coupler using 1/4"x1-1/2"...
  • Page 95 Black-out System Installation Below diagrams show the layout of the drive pipe assemblies for greenhouses that are 72' or Telescoping purlin (inside longer, as swaged end locations and cut-to-fit pipe locations are important, due to the telescoping drive pipe) purlins. If purchased greenhouse is 60' or shorter, and telescoping purlins are not included, continue by assembling the drive pipes to fit as needed.
  • Page 96 Black-out System Installation SPLICE DRIVE SHAFT 1. Position all four drive pipe runs in the CLOSED position. In this position, the open bay--or the bay without the drive pipes--will be the bay at the end wall to which the 113650 wire tensioners are attached. Verify that 2" of drive pipe extends into the open bay.
  • Page 97 Black-out System Installation ATTACH LEADING EDGES TO DRIVE PIPES 1. Leading edges are secured to the drive pipes with 115177 drive pipe clamps. Slip one 115177 clamp onto each of the four drive pipes per bay. NOTE: open slightly to slip over the drive pipes, or drive pipes can be unspliced in the necessary locations to guide the 115177 clamps into place.
  • Page 98 Black-out System Installation SIDE STRUT INSTALLATION Leading edges are only attached to the drive pipes along the horizontal sections. Because of this, when opening and closing, the vertical leading edge sections will trail behind, preventing a full light-seal along the header profile. Side struts are installed to reinforce the vertical edges, keeping them uniform with the horizontal leading edge sections during operation, so that the entire leading edge profile seals against the header profile flat and consistent.
  • Page 99 Black-out System Installation 5. Using 1/2" x 156" swaged tubing (113300), install side support strut assembies along the chalked lines marked in nuts (113310). Splice 113300 tube where necessary using FAG104B bolts and FALF35B lock-nuts. IT IS VERY IMPORTANT THAT THE VERTICAL LEADING EDGES BE SEALED TIGHT AGAINST THE VERTICAL HEADERS WHEN SIDE SUPPORT STRUTS ARE ATTACHED.
  • Page 100 Black-out System Installation diagonal strut supports as shown below. Verify that all vertical leading edges are still tightly sealed against the header pro les. NOTE: DIAGONAL STRUT CAN BE ADJUSTED TO FIX SMALL LIGHT-LEAKS. INSTALL AT A 45-DEGREE ANGLE AND ADJUST IF NECESSARY. NOTE: GRIND EXCESS OF BOLT FROM LEADING EDGE CLAMP PAST THE NUT.
  • Page 101 Black-out System Installation Black-out material hangs loosely along the bottom of the side walls. For light deprivation, the bottom edges of the black-out material will hang between a side pocket of black-out polycarbonate and the outer film covering, preventing light from leaking into the greenhouse along the bottom of the side walls when the system is in the "closed" position. 1.
  • Page 102 Black-out System Installation 4. Using FA4484B Tek screws, attach a 113236Z036 H-channel section to the end rafter section of previously installed pipe pocket. Trim if needed. Verify that the channel of the 113236Z036 is inverted towards the 131P034 pipe. 5. Trim 12" off of one 113296Z144 black-out polycarbonate panel LENGTHWISE.
  • Page 103 Black-out System Installation 1. Verify that the leading edges are still in the "closed" position, with the rubber gasket against the keder sealing edges of the header 2. Prepare a blackout panel roll (QSH115338Z47) to be pulled into place. See diagram below. Note that the material consists of three individual layers--two black and one silver--that are independent from one another.
  • Page 104 Black-out System Installation 113316 5. With the leading edges still in the "closed" position, Cloth Fastener overlap the edge of the panel 2"-3" past the cloth-clip Clip 2" to 3" flange of the leading edges. overlap 6. Starting in the CENTER of the leading edge and moving outward, use 113316 cloth fastener clips to secure the panel to the leading edges.
  • Page 105 Black-out System Installation OPERATION TESTING 1. With all blackout system components fully installed, it will be imperitive to test the operation to verify funcionality. If not already done so, CONTACT A LICENSED ELECTRICIAN FOR ALL MOTOR WIRING DETAILS. If electrical wiring is not completed, motor can be manually operated with a drill and a 6mm Allen key adaptor inserted in the center of the motor fan, though this will make operational test very slow-going.
  • Page 106 Shelter Care and Maintenance SHELTER CARE AND MAINTENANCE Proper care and maintenance of the shelter is important. Check the following items periodically to properly maintain the shelter: Regularly check the cover to ensure that it remains tight and in proper repair. 105435 film repair tape is included for minor damages.
  • Page 107 Motor Care and Maintenance MOTOR-DRIVEN POWER VENT SYSTEMS Regular inspections of your vent systems helps to ensure dependable, safe, and efficient operation. Complete If you are assembling a motor-driven power vent system that the following inspections at least once every 30 days. If includes an electric motor and related drive components, weather and environmental conditions are extreme in continue with the information on the following pages.
  • Page 108 Blackout System Care and Maintenance 1. Complete and return all warranty documentation. 2. Perform all initial and periodic inspections as described in this 3-page care and maintenance guide. 3. Follow the instructions under the Blackout System Care heading. 4. Contact your sales representative for answers to your blackout system questions. 5.
  • Page 109 Blackout System Care and Maintenance Semi-Annual Inspections In addition to items in previous inspections, check these items at least two (2) times throughout the year. (Allow a few months to pass between each inspection unless weather conditions, weather-related events, or Inspect all material for worn or damaged areas.
  • Page 110 Blackout System Care and Maintenance Additional Care and Maintenance Instructions for Harsh or Humid Environments mendations can further protect the material and its components. Use caution if corrosive materials are stored inside the greenhouse. (Storing these and other harmful chemicals inside greenhouse is not recommended.) Do not allow greenhouse contents to contact metal frame parts, cover panels, end panels, or blackout system components.

  • Page 111: Additional Notes

    Additional Notes Space below is reserved for customer notes. Revision date: 12.02.16...

  • Page 130: Motorized Ridge Vent

    DEVELOPED BY S500 MOTORIZED RIDGE VENT A DIVISION OF ENGINEERING SERVICES & PRODUCTS CO. 1440 18TH AVENUE SW DYERSVILLE, IA 52040 P: 563.875.6113 F: 563.875.2317 WWW.ESAPCO.COM ORDER #: CUSTOMER #: [ A1] ......COVER SHEET [ B1] ......DETAIL LOCATION CALL-OUTS [ C1] ......
  • Page 131 NOTE: Drive shaft and rack arm components removed for clarity.
  • Page 133 DEVELOPED BY **NOTE: RACK ARM, RACK ARM BRACKET, & HARDWARE NOT RIDGE VENT RAIL LAYOUT PRESENT ON VENT ARM WHEN CONNECTED TO SAME RAFTER AS MOTOR. A DIVISION OF ENGINEERING SERVICES & PRODUCTS CO. 1440 18TH AVENUE SW DYERSVILLE, IA 52040 P: 563.875.6113 F: 563.875.2317 ROOF VENT BOTTOM RAIL [111612Z144]...
  • Page 134 DEVELOPED BY **NOTE: SAME HARDWARE APPLIES TO SPLICES OF SWAGED PIPE THROUGHOUT THE DRIVESHAFT SYSTEM. CHAIN DRIVE COUPLING [113652] CHAIN DRIVE COUPLING ENGINEERING SERVICES & PRODUCTS CO. [113652] 1440 18TH AVENUE SW DYERSVILLE, IA 52040 P: 563.875.6113 - (2X) 5/16" X 2" HEX BOLT F: 563.875.2317 WWW.ESAPCO.COM - (2X) 5/16"...

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