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ClearSpan Pro Solar Star R030 Instruction Manual

Double-layer greenhouse film
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Photo may show a building of a different length. Frame is shown with a roll-up side option and customer-supplied
baseboards. End wall is not included and requires an additional purchase. Actual cover may differ.
©2010 ClearSpan™
All Rights Reserved. Reproduction
is prohibited without permission.
Revision date: 05.13.10
ClearSpan
Pro Solar Star
™
Double-Layer Greenhouse Film
™
Greenhouses
STK#
R030
R035
DIMENSIONS
30' W x L (length varies)
35' W x L (length varies)
1

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  • Page 1 End wall is not included and requires an additional purchase. Actual cover may differ. STK# DIMENSIONS R030 30' W x L (length varies) ©2010 ClearSpan™ R035 35' W x L (length varies) All Rights Reserved. Reproduction is prohibited without permission.

  • Page 2: Table Of Contents

    Table of Contents Important Information ..........3 In all instances and regardless of the type and Parts Identification ............. 7 number of accessories, the main building frame is Overview..............8 always constructed first. Prepare and Square the Building Site ...... 9 Set the Ground Posts (option) ........

  • Page 3: Important Information

    YOU MUST READ THIS DOCUMENT BEFORE YOU BEGIN TO ASSEMBLE THE SHELTER. • Never erect the structure under power lines. Thank you for purchasing this ClearSpan™ greenhouse. • Identify whether underground cables and pipes are When properly assembled and maintained, this product present before preparing the site, setting ground will provide years of reliable service.
  • Page 4 These words and phrases are common to most pipe joints and to fasten brackets to rafters. ClearSpan™ shelters and identify the different parts of the shelter. (Some are used in this document. Others may not apply to this particular shelter.) These terms describe the shipped parts and can also be found on the materials list/spec sheets included with the shipment.
  • Page 5 Important Information REQUIRED TOOLS The following list identifies the main tools needed to Space below is reserved for customer notes. assemble the shelter. Additional tools and supports may be needed depending on the structure, location, and application. • Tape measure or measuring device and marker to mark locations on the pipes and rafters •...
  • Page 6 Important Information BASEBOARD NOTE RIBBON BOARD REQUIRED: DROP-DOWN SIDES A customer-supplied baseboard and retaining board A customer-supplied two-piece ribbon board is required are required to attach the drop-down side panels. The for the installation of the drop-down curtain. Consult the baseboard is optional but recommended for a building Film Cover with Drop-Down Sides procedure for details with a roll-up side.

  • Page 7: Parts Identification

    Parts Identification FA2155 and The following graphics and photos will help you identify FA1960 the different parts. (Some parts are not shown.) Eye Screw AS5020 Pulley 102197 Aluminum 104211 Aluminum FA4482B FAG304B FALB01B U-Channel 108503 U-Channel 1/4" x 1" Hex Bolt 1/4"...

  • Page 8: Overview

    Overview ClearSpan ™ Pro Solar Star Greenhouses ™ Optional end panel shown. Additional purchase required. OVERVIEW This section describes assembling your greenhouse frame. See illustration below to identify main parts. Drawing may show a model of a different length. Refer to Quick Start section located in the back of these instructions Set the ground posts or mounting feet (as equipped).

  • Page 9: Prepare And Square The Building Site

    Prepare and Square the Building Site SQUARE THE SITE: GENERAL STEPS PREPARE THE BUILDING SITE A level site is required to accurately and safely construct 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 10: Set The Ground Posts (Option)

    Set the Ground Posts (option) MARK THE SITE AND DIG POST HOLES 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.
  • Page 11 Set Ground Posts (option) SET GROUND POSTS DIAGRAM SHOWS A TYPICAL POST HOLE This procedure describes setting the ground posts in holes, bracing in place, and adding concrete. If your building includes mounting feet, skip this procedure and Ground Level continue with the installation of the mounting feet.

  • Page 12: Mounting Feet (Option)

    Mounting Feet (option) SETTING THE MOUNTING FEET In those instances where optional mounting feet have been ordered, secure the feet to a customer-supplied baseboard prior to attaching the rafter legs and assembling the frame. Customer is responsible for the necessary baseboards and fasteners used to secure the feet to the site.

  • Page 13: Rafter Assembly

    Rafter Assembly RAFTER ASSEMBLY After setting the ground posts or anchoring the mounting feet, continue with the rafter assembly. NOTE: All rafter assemblies consist of two rafter sections joined by a single splice at the peak. Consult the rafter diagram in the Quick Start section of these instructions CFG030PINSS01 Spice before and during the rafter assembly process for details.

  • Page 14: Frame Assembly

    Frame Assembly FRAME ASSEMBLY Gather the parts: • Assembled rafters and 1/2" x 2 1/2" mounting bolts, nuts, and flat washers • Ridge purlins (see Side Profile diagram for your building and for purlin identification and correct position) and 1/4" nuts •...
  • Page 15 Frame Assembly FRAME ASSEMBLY (continued) Move to the next set of ground posts (or mounting feet), attach that rafter (and rafter legs if needed), and brace in place. As previously described, use the 1/2" bolts to secure the rafter to the tops of the ground posts or rafter legs. Take the first section of ridge purlin (consult Side Profile diagram for your building length and correct purlin identification), align the pre-drilled holes with the studs of the rafter splice, and secure to the end rafter (A) and first interior rafter (B) using 1/4"...
  • Page 16 Frame Assembly FRAME ASSEMBLY (continued) Set the next rafter in place, secure it to the ground posts or rafter legs, and brace in place as needed. Take the next purlin and place the mounting holes over the splice studs and secure with the 1/4" nuts. Take one 108504 eyebolt, FAMA38B lock washer, and a 3/8"...
  • Page 17 Frame Assembly FRAME ASSEMBLY (continued) (2) 1/4" x 1" bolts and 1/4" nuts With the first two bays (3 rafters) assembled, take the first under purlin and secure it to the rafters using the Purlin 1/4" x 1" bolts and 1/4" hex nuts. See diagrams D and E at the right.

  • Page 18: Baseboard Installation

    Baseboard Installation BASEBOARD INSTALLATION Gather the parts: • 2" x 6" or treated or recycled plastic lumber (supplied by customer) • 5/16" x 5" carriage bolts (FAH325B) Baseboard • 5/16" nuts (FALB32B) The following procedure describes one way to install the Ground Level required baseboards (drop-down curtain).

  • Page 19: Cable Installation

    Cable Installation CABLE ASSEMBLY Anchor Shackle Cable assemblies provide diagonal bracing for the building. Each cable assembly includes the following items: • One (1) length of cable: Measure from point-to-point on the frame and cut cable length as needed. Remember to allow extra to secure the connections and install the clamps.
  • Page 20 Cable Installation INSTALL AND TIGHTEN ALL CABLES The diagram and inserts below identify the placement and proper way to attach the cable assemblies to the frame. After attaching all cables to the frame, tighten the turnbuckles. Turnbuckles should be snug and not overtightened.

  • Page 21: Diagonal Strut Installation

    Diagonal Strut Installation STRUT INSTALLATION For additional support, attach diagonal struts to the frame between the end rafter and the first interior rafter at each end. Collect the needed parts and install the diagonal struts as instructed below. Required parts and tools: •...

  • Page 22: Mounting Foot-To-Rafter Strut Installation

    Mounting Foot-to-Rafter Strut Installation MOUNTING FOOT-TO-RAFTER STRUT INSTALLATION Frames that include the mounting feet also include an additional strut running from the foot to the rafter. Complete the steps below to install the struts. NOTE: If your building includes ground posts, skip this section and read ANCHOR THE ASSEMBLED FRAME information on the next Foot-to-Rafter page.

  • Page 23: Optional Support Package Installation (Rafter)

    Optional Support Package Installation (Rafter) INSTALL RAFTER SUPPORT PACKAGES: R030A0015 (30' WIDE) OR R035A0015 (35' WIDE) If you purchased the rafter support package (recommended) for each rafter, excluding the two (2) end rafters for buildings with end walls, install these now. If these optional packages were not purchased, skip this section and continue with the frame assembly.
  • Page 24 Optional Support Package Installation (Rafter) SUPPORT PACKAGE INSTALLATION (continued) Using the rafter as a guide, locate and mark the centerline of the chord. Use this line to install the vertical struts. Consult the diagram, mark the mounting hole locations for each strut and drill a 3/8" hole through the installed chord.

  • Page 25: Anchor The Assembled Frame

    Anchor the Assembled Frame ANCHOR THE ASSEMBLED FRAME At this point, anchor the assembled frame. Consult the MUST READ document for anchoring information and suggestions. Please call customer service at 1-800-245-9881 for additional anchoring information if needed. CAUTION: The anchor assembly is an integral part of the greenhouse construction. Improper anchoring may cause instability and failure of the structure to perform as designed.

  • Page 26: Frame Check

    Frame Check FRAME CHECK Before you attach the main cover, inspect the frame for sharp edges or fasteners that could damage the cover. Verify that all frame members are properly secured. Verify that all bolts and screws are tight. Recheck the frame assembly for sharp edges or screws and bolts that may interfere with the installation of the cover.

  • Page 27: End Cap Installation

    End Cap Installation INSTALL ALUMINUM END CAP End Cap If optional fabric end panels have been ordered, install the panels before attaching the end cap. Consult the end panel instructions for details. Gather the parts: • Aluminum end caps (#108534 - 30' wide shelters or #108535 - 35' wide shelters) •...

  • Page 28: Film Cover Installation With Drop-Down Sides

    Film Cover Installation with Drop-Down Sides INSTALL POLY LATCH U-CHANNEL End View If your building includes the roll-up side feature, skip to and continue 2" x 6" Ribbon Board with the "Film Cover Installation with Roll-up Sides" steps. Gather the parts: 5/16"...
  • Page 29 Film Cover Installation with Drop-Down Sides INSTALL MAIN COVER Photo shows the cover film in position to pull over the building. Gather the parts: • Main covers, inflation fan kit, box cutter or utility knife • U-Channel spring (#102198) for side U-channel •...
  • Page 30 Film Cover Installation with Drop-Down Sides INSTALL MAIN COVER (continued) Center cover side-to-side and end-to-end. Some Move to the other end of the building, pull the cover film covers include additional material for the width tight, and repeat the steps to secure the cover in the due to standard material dimensions.
  • Page 31 Film Cover Installation with Drop-Down Sides INSTALL MAIN COVER (continued) BASEBOARD NOTE Once the first cover is stretched and secure, install the A customer-supplied baseboard and retaining board are inflation fan kit in the desired location and according required to attach the drop-down curtain's lower edge. to the instructions sent with the kit.
  • Page 32 Film Cover Installation with Drop-Down Sides INSTALL THE DROP-DOWN CURTAIN Mark plate mounting hole locations and drill the holes. Locate these parts to attach the pulleys and drop-down Use a 3/8" drill bit for the mounting holes. curtain axle: • 131S075 (1.315 swaged pipe for axle and curtain conduit) Two-Piece Ribbon...
  • Page 33 Film Cover Installation with Drop-Down Sides INSTALL THE DROP-DOWN CURTAIN (continued) If an optional end panel has been installed, carefully With the mounting plate installed, take the 103496 insert the alxe through the 2" axle conduit hole in the gearbox, place it against the mounting plate at the optional end panel.
  • Page 34 Film Cover Installation with Drop-Down Sides INSTALL THE DROP-DOWN CURTAIN (continued) Continue adding 131S075 conduit and band clamps and work toward the other end of the shelter. Verify Move inside the frame and slide a 106734 band clamp that the axle conduit remains level throughout the over the tapered end of the 131S075 pipe.
  • Page 35 Film Cover Installation with Drop-Down Sides INSTALL THE DROP-DOWN CURTAIN (continued) End View Locate these parts to prepare the drop-down curtain for 2" x 6" Ribbon installation and to attach it to the axle conduit: Board • 131S075 (75" pipe conduit) FA1960 AS5020 •...
  • Page 36 Film Cover Installation with Drop-Down Sides INSTALL THE DROP-DOWN CURTAIN (continued) Continue adding conduit sections and securing each joint until the conduit is as long as the curtain panel. Install Curtain Conduit and Attach Rope Complete the curtain conduit installation by cutting After installing all eye screws and pulleys, locate the the conduit so that it extends from the panel pocket curtain panel, 131S075 conduit, 1/8"...
  • Page 37 Film Cover Installation with Drop-Down Sides INSTALL THE DROP-DOWN CURTAIN (continued) Repeat the above steps until all cords are attached to the first curtain panel along one side of the shelter. Move to the axle and drive two (2) FA4482 Tek screws with neo-bonded washers (102921) into the axle conduit where the cord is located.
  • Page 38 Film Cover Installation with Drop-Down Sides INSTALL THE DROP-DOWN CURTAIN (continued) Repeat the steps to secure the remaining lower edge of the curtain to the baseboard along the side. Complete these steps to attach the lower edge of the curtain to the customer-supplied baseboard. Return to the gearbox and check the operation of the drop-down curtain panel using the crank handle.

  • Page 39: Film Cover Installation With Roll-Up Sides

    Film Cover Installation with Roll-Up Sides INSTALL POLY LATCH U-CHANNEL 2" x 6" Board For the roll-up sides, the double poly latch U-Channel (#104211) is attached to each side of the frame and runs Double Poly Latch 5/16" Nuts U-Channel from the front to the back of the shelter.
  • Page 40 Film Cover Installation with Roll-Up Sides INSTALL MAIN COVER Photo shows the cover film in position to pull over the building. Gather the parts: • Main covers and inflation fan kit • U-Channel spring (#102198) for side U-channel • Coated end cap spring (#108536) for end cap •...
  • Page 41 Film Cover Installation with Roll-Up Sides INSTALL MAIN COVER (continued) Move to the other end of the building, pull the cover Center cover side-to-side and end-to-end. Some tight, and repeat the steps to secure the cover in the film covers include additional material for the width end cap channel.
  • Page 42 Film Cover Installation with Roll-Up Sides INSTALL MAIN COVER (continued) INSTALL ROLL-UP PANELS Once the first cover is stretched and secure, install the This model includes a roll-up side panel for each side of inflation fan kit in the desired location and according the shelter.
  • Page 43 Film Cover Installation with Roll-Up Sides ASSEMBLE THE ROLL-UP SIDE CONDUIT ATTACH CONDUIT TO ROLL-UP SIDE FILM Gather the parts: Gather the parts: • Pipe 1.315'' x 75'' swaged (#131S075) • Assembled conduit • Tek screws (#FA4482B) • Fabric clips #CC6212 (Divide quantity in half.) •...
  • Page 44 Film Cover Installation with Roll-Up Sides TWIST-OF-THE-WRIST ASSEMBLY 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 •...
  • Page 45 Film Cover Installation with Roll-Up Sides TWIST-OF-THE-WRIST ASSEMBLY (continued) Select the bearing bracket and attach the bearings as 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 46 Film Cover Installation with Roll-Up Sides INSTALL THE ANTI-BILLOW ROPES TWIST-OF-THE-WRIST ASSEMBLY (continued) The anti-billow rope is installed along the outside of the 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 47: Shelter Care And Maintenance

    Please contact a ClearSpan™ representative for additional information. • For replacement or missing parts, call 1-800-245-9881 for assistance. NOTE: With the exception of Truss Arch buildings, ClearSpan™ shelters and buildings do not have any tested loading criteria. Revision date: 05.13.10...

  • Page 48: Quick Start Guide

    Quick Start Guide QUICK START GUIDE 30' and 35' Wide Greenhouse with Film Cover ATTENTION: Shelter to the right shows mount- Ground Level ing feet and an installed anchor system. Actual building may differ in length or design or both. Ground Level Building is shown with customer-supplied base-...

  • Page 49: 30' Wide Front Profile Grid With Ground Posts

    Revision date: 05.13.10...

  • Page 50: 30' Wide Front Profile Grid With Mounting Feet

    Revision date: 05.13.10...

  • Page 51: 35' Wide Front Profile Grid With Ground Posts

    Revision date: 05.13.10...

  • Page 52: 35' Wide Front Profile Grid With Mounting Feet

    Revision date: 05.13.10...

  • Page 53: Front Profile With Ground Posts

    Revision date: 05.13.10...

  • Page 54: Front Profile With Rafter Feet

    Revision date: 05.13.10...

  • Page 55: Purlin Locations

    Revision date: 05.13.10...

  • Page 56: Side Profile - 36' Length

    Revision date: 05.13.10...

  • Page 57: Side Profile - 48' Length

    Revision date: 05.13.10...

  • Page 58: Side Profile - Longer Than 48

    Revision date: 05.13.10...

  • Page 59: Connections With Ground Posts

    Revision date: 05.13.10...

  • Page 60: Connection Details - Ground Posts

    Revision date: 05.13.10...

  • Page 61: Connections With Rafter Feet

    Revision date: 05.13.10...

  • Page 62: Connection Details - Rafter Feet

    Revision date: 05.13.10...

  • Page 63: Mounting Feet Layout

    Revision date: 05.13.10...

  • Page 64: 30' Wide Over-The-Top Measurements

    Revision date: 05.13.10...

  • Page 65: 35' Wide Over-The-Top Measurements

    Revision date: 05.13.10...

  • Page 66: 30' Rafter Profile With Optional Support Bracing (R030A0015)

    Revision date: 05.13.10...

  • Page 67: 35' Rafter Profile With Optional Support Bracing (R035A0015)

    Revision date: 05.13.10...

  • Page 68: Inflation Fan Kit Photos

    Inflation Fan Kit Photos These photos show an installed inflation fan kit. Consult the instructions sent with the kit and use these photos to help with the installation. (Building design may differ from actual building. Some photos may not apply to your building.) Fan motor shown attached to fan bracket (View 1).

  • Page 69: Notes

    Notes This page is reserved for customer notes. Revision date: 05.13.10...

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Pro solar star r035

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