ClearSpan Pro Solar Star R030, Instruction Manual

Page 1: ...0 30 W x L length varies R035 35 W x L length varies ClearSpan Pro Solar Star Greenhouses 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 Double Layer Greenhouse Film ...

Page 2: ... 67 Inflation Fan Kit Photos 68 Notes 69 Mounting Feet 108500 Layout Diagram Buildings equipped with the 108500 mounting feet require additional steps for the site preparation Consult the Mounting Feet Layout diagram in the Quick Start section near the back of this guide for the required dimensions Do not prepare the site without first consulting the diagram for the proper dimensions Buildings tha...

Page 3: ... equipped or anchoring the structure Location should be away from structures that could cause snow to drift on or around the building Do not position the structure where large loads such as snow and ice large tree branches or other overhead obstacles could fall Always check local building codes before you begin and follow codes as instructed SITE After choosing a location proper preparation of the...

Page 4: ... aid in the assembly read through the following definitions before you begin to assemble your shelter Conduit An assembly of pipes used to secure the main cover and end panels if equipped Purlins and some strut assemblies also consist of connected pipes to form a conduit Each pipe joint of a conduit assembly is secured with a self tapping Tek screw Coupler or Fitting A part of the frame assembly w...

Page 5: ...r machinery for lifting designed to work safely at the height of the building Safety equipment to protect head eyes hands and feet UNPACK AND IDENTIFY PARTS The following steps will ensure that you have all the necessary parts before you begin to assemble the shelter frame Unpack the contents of the shipment and place where 1 you can easily inventory the parts Refer to the Bill of Materials Spec S...

Page 6: ...ed for buildings with a roll up side panel but installing a baseboard is strongly recommended Fasteners are included to attach the boards to the frame Secure baseboard and ribbon board joints between rafters as shown for best results Rafter Leg or Ground Post 2 x 6 Ribbon Board 1 x 4 Board Drop Down Curtain only U Channel End View 5 16 Nuts FALB32B 5 16 x 5 Carriage Bolts FA4652 Wood Grip Screw RI...

Page 7: ...E08B 3 8 Flat washer FALB04B 3 8 Nut FAG402B 1 2 x 2 1 2 Hex Bolt FAME09B 1 2 Flat washer FALB08B 1 2 Locknut 108534 or 108535 Aluminum End Cap The following graphics and photos will help you identify the different parts Some parts are not shown FAG330B 5 16 x 1 Hex Bolt FAME07B 5 16 Flat washer FALF37B 5 16 Locknut 108503 Cable Bracket FAG340B 5 16 x 3 1 2 Hex Bolt CFG030PINSS01 Splice AS1003 Cab...

Page 8: ...ions for on center measurements and post layout Optional end panel shown Additional purchase required OVERVIEW This section describes assembling your greenhouse frame See illustration below to identify main parts Set the ground posts or mounting feet as equipped 1 Locate the required parts for each assembly 2 procedure Assemble the rafters and frame 3 Anchor the frame Consult instructions for deta...

Page 9: ...k the location continue with the Mounting Feet section Do not dig holes if your building is equipped with rafter mounting feet Ground Posts If the frame includes ground posts set all ground posts as described within this manual Width of the shelter is measured from the center of one ground post to the center of the remaining ground post Length is also measured center to center If your building inc...

Page 10: ...d proceed as needed NOTE Refer to the Quick Start Section located near the back of these instructions for the Side Profile and related diagrams If your building includes mounting feet complete Step 1 only of this procedure and continue with the Mounting Feet section Stake the outline of the building using string line and batter boards Set batter boards 3 back from the building 1 corners Check to e...

Page 11: ...set the first corner 2 ground post into the hole and brace in position Fill hole so concrete remains below the finished grade Ground Post Toward the ends of the frame Toward the ends of the frame Ground Post Concrete Ground Level 2 Deep ATTENTION Position the pre drilled holes facing toward the ends of the shelter so they align with the bolt holes in the rafter sections Verify that the ground post...

Page 12: ...t of 2 x 8 baseboards on the site at the required 1 on center width of the building frame Baseboards run parallel to each other Use the layout instructions to accurately and properly set the baseboards on the site Drive a short length of rebar or similar stake through a hole 2 drilled in the boards into the ground to keep the boards in place See diagram above If mounting on concrete use wedge anch...

Page 13: ...ground end to end The end of each section includes the two mounting holes 1 to secure the splice Support the rafter sections with blocks as needed Consult the diagrams for details Connect the two rafter sections using a splice 3 8 x 2 1 2 machine bolts 3 8 flat washers and 3 8 nuts 2 Position the installed studs of the splice so they point up to accept the top purlins when these are installed See ...

Page 14: ...er onto a 1 2 x 2 1 2 bolt and insert a bolt into each mounting hole Position bolt head to the outside of the frame Ground Level Rope or Cable 1 2 x 2 1 2 Bolt ATTENTION If mounting feet are used attach the first set of rafter legs to the mounted feet and secure with the 3 8 x 3 1 2 bolts and nuts Consult the connection diagrams located in the Quick Start section of these instructions for addition...

Page 15: ... a short purlin spans the first bay do not secure the purlin to the second rafter until next purlin is added Consult the Side Profile diagram for your frame for details FRAME ASSEMBLY continued A 1 4 Nuts Ridge Purlin B Ridge Purlin Splice Studs Frame Assembly A B Ground Level Rope or Cable NOTE The 20 30 and 36 long frames use a combination of different purlin lengths during frame assembly Consul...

Page 16: ...ut FALB04B and attach the eyebolt to the splice of 8 the third 3rd rafter as shown C Position the eye of the bolt toward the end rafter for the cable installation Frame Assembly C DO NOT secure this end of the ridge purlin to the rafter at this time Ridge purlin is secured to the rafter in the following steps Ridge Purlin Overlap ridge purlins and secure in place using 1 4 nuts Diagram above shows...

Page 17: ... and 1 4 hex nuts See diagrams D and E at the right NOTE The purlin pattern is the same as the ridge purlin Consult the Side Profile diagrams for details Install and secure the remaining under purlins for the 10 first bay as previously described and as shown in the Quick Start section of these instructions Repeat the previous steps to assemble the remainder 11 of the frame ATTENTION Attach the fin...

Page 18: ...ountersink bolt heads if needed Continue adding baseboards to complete the first run Splices are made between posts as shown in the drawing below Use a short section of baseboard to secure separate baseboards at a splice See diagram below Repeat steps to install the second run of baseboards on the remaining side of the frame NOTE The boards should be at ground level or slightly into grade to preve...

Page 19: ...cut the cable to length All cable sections will be the same length Finish one cable end of each cable Step 1 using 2 a thimble and two 2 cable clamps Use the diagrams as guides Remove the bolt from the anchor shackle and 3 slide the finished end of each rough cable onto the shackle See the diagram at the upper right corner of this page Secure the anchor shackle to the eyebolt attached 4 to the pea...

Page 20: ... if you are unable to tighten the turnbuckle to remove cable slack Cable Ground Level Frame length and design of your building may differ from what is shown Secure the turnbuckle directly to the cable bracket attached to each end rafter mounting bolt If necessary use a bar or clamp to slightly bend the bracket to allow the needed clearance to install the jaw bolt of the turnbuckle Actual turnbuckl...

Page 21: ...nstalled ends are tight to the frame ATTENTION Verify you have selected the correct strut Some frames include struts of different lengths Consult the diagrams in the Quick Start section for your building for additional details Position strut as shown lower right photo 2 between the end rafter and first interior rafter Adjust position so strut does not interfere with any other building component A ...

Page 22: ...h it to the rafter foot using the 5 16 fasteners listed above 1 Swing the diagonal strut up into position until it reaches the underside of the rafter 2 Mark the hole location and drill a mounting hole using the 3 8 drill bit 3 Insert the bolt through the rafter hole and through the mounting hole in the diagonal strut 4 Add a flat washer and locknut and tighten to secure the strut to the rafter 5 ...

Page 23: ... the 1 66 pipe 30 wide or the 1 90 pipe 35 wide and assemble the rafter 1 chord as shown Consult the Rafter Profile diagram for your support package in the Quick Start section back Measure approximately 1 2 in from each end of the assembled chord and drill a 3 8 mounting hole 2 With assistance lift the chord up into position verify that it is level and mark and drill the mounting holes through 3 t...

Page 24: ...r dimension Centerline QH1304 Strut B Step 6 Using the rafter as a guide locate and mark the centerline of the chord Use this line to install the vertical struts 5 Consult the diagram mark the mounting hole locations for each strut and drill a 3 8 hole through the installed 6 chord ATTENTION Verify that the chord is level and not sagging Before drilling the mounting hole check that the QH1304 stru...

Page 25: ... may cause serious injury and damage If the optional anchor kit was purchased use the diagrams below to properly install the auger style earth anchor and to attach the brackets to the ground posts or rafter legs ATTENTION Concrete must be used in loose or sandy soil types For best results install the auger style earth anchor as close to the ground post or rafter leg as possible After anchoring the...

Page 26: ... are tight 2 Recheck the frame assembly for sharp edges 3 or screws and bolts that may interfere with the installation of the cover Reposition if needed Cut 10 12 pieces of repair tape 109023 and tape 4 the tops of all interior rafters to protect the cover See insert below Verify that the main building frame is properly and 5 adequately anchored Do not attach the cover to an unanchored frame Groun...

Page 27: ... meet to form a finished joint Continue with Step 2 To finish as shown in Fig 2 align the end of the end cap with the upper end of the end rafter Continue with Step 2 Move to the lower end and mark the rafter position on the end cap 3 and cut the end cap to length End cap must align with the end of the rafter Align end cap on the end rafter as shown and secure in place using 4 two or three wafer h...

Page 28: ...vel 3 Attach the poly latch U channel 102197 to the ribbon board Drill a 5 16 hole through the U channel and board 4 Secure using 1 4 x 2 carriage bolts fender washers and nuts Attach U channel flush with the outside edge of the ribbon board Use one 1 4 x 2 carriage bolt per rafter along each side to secure U channel to ribbon board Install fender washer against the ribbon board on the inside of t...

Page 29: ...ie rope or straps to the cover If you do not want to cut holes in the material clamp self locking duck billed pliers to the cover and tie ropes or straps to the pliers Photos show tying ropes to the cover Pliers are not shown NOTE The ropes or straps should be long enough to reach over the top of the building to the other side Long buildings require additional ropes to prevent tearing the main cov...

Page 30: ... secure Continue down both edges of the first end rafter until 5 the entire length of the end of the main cover film is secured in place Verify that the ends of the end cap are taped to protect the cover material See the end cap installation steps if needed for details Move to the other end of the building pull the cover 6 tight and repeat the steps to secure the cover in the end cap channel After...

Page 31: ... the 10 inflation fan kit in the desired location and according to the instructions sent with the kit ATTENTION Install the inflation fan kit before installing the second main cover Consult the instructions included with the fan kit to install the fan FOR ADDITIONAL DETAILS CONSULT THE INFLATION FAN INSTALLATION PHOTOS FOR A SIMILAR BUILDING IN THE QUICK START GUIDE AT THE BACK OF THESE INSTRUCTIO...

Page 32: ...he frame x 2 Axle Hole U Channel INSTALL THE DROP DOWN CURTAIN Locate these parts to attach the pulleys and drop down curtain axle 131S075 1 315 swaged pipe for axle and curtain conduit 106734 band clamps for curtain axle 103496 gearbox and 103544 mounting plate 102717 double drive FA4482B Tek screws to secure band clamps and pipe joints FAH325B 5 16 x 5 carriage bolts and FALB32B 5 16 nuts FAH005...

Page 33: ...ose end of the axle to prevent damage 1 4 x 2 bolt FAH005B and 1 4 nuts FALB01B 131S075 Pipe plain end 102717 Drive 3 pieces Mounting bolts included with the mounting plate 5 16 x 5 carriage bolts and 5 16 nuts to mount plate to end rafter Diagram shows the assembled components 1 2 INSTALL THE DROP DOWN CURTAIN continued If an optional end panel has been installed carefully insert the alxe through...

Page 34: ...ition clamps and screws if these prevent smooth operation of the axle conduit After verifying that the axle turns smoothly repeat the 14 procedure to assemble and attach the gearbox and axle conduit to the other side of the shelter Continue by attaching the drop down curtains 15 As seen from the inside the shelter Axle Conduit Ribbon Board Band Clamp Move inside the frame and slide a 106734 band c...

Page 35: ... one pulley for each rafter along each side of the frame Continue installing eye screws and pulleys into the ribbon board 4 next to each rafter until all pulleys are installed along both sides of the shelter Install the curtain conduit and attach cords as described in the next procedure 5 Attach Drop Down Curtain Pulleys Continue with the steps that follow Gather the pulleys and the same quantity ...

Page 36: ...end secure the joint using an FA4482B Tek screw and tape the conduit joint using duct tape Continue adding conduit sections and securing each 4 joint until the conduit is as long as the curtain panel Complete the curtain conduit installation by cutting 5 the conduit so that it extends from the panel pocket approximately 1 at each end ATTENTION Allowing the curtain to extend beyond the end rafters ...

Page 37: ...xle conduit in the same direction and manner as the first cord Film Cover Installation with Drop Down Sides Repeat the above steps until all cords are attached to 12 the first curtain panel along one side of the shelter Diagram shows cords attached to the curtain conduit and to the axle Dashed line shows the position of the curtain conduit Continue by attaching the lower curtain edge to the 13 bas...

Page 38: ...taining Board Curtain Panel Optional End Panel Lower Edge of Curtain Panel Space FA4652 screws at 24 Outside View Film Cover Installation with Drop Down Sides INSTALL THE ANTI BILLOW ROPES The anti billow rope is installed along the outside of the frame and stretches between the ribbon board and the baseboard When installed correctly the anti billow rope helps keep the drop down curtain in place w...

Page 39: ...your building includes a drop down side curtain return to and complete the Film Cover Installation with Drop Down Sides procedure Do not continue with these roll up side steps Gather the parts Double poly latch U Channel 104211 and ribbon board 2 x 6 board minimum dimension 5 16 x 5 carriage bolts FAH325B and nuts FALB32B 1 4 x 2 carriage bolts FAH005B 1 4 nuts FALB01B and fender washers FAMF01B C...

Page 40: ...Along the edge make small holes in the cover at 2 evenly spaced intervals and tie rope or straps to the cover If you do not want to cut holes in the material clamp self locking duck billed pliers to the cover and tie ropes or straps to the pliers Photos show tying ropes to the cover Pliers are not shown NOTE The ropes or straps must be long enough to reach over the top of the building to the other...

Page 41: ...ver side to side and end to end Some 4 film covers include additional material for the width due to standard material dimensions This film can be removed and recycled or it can be used by the customer IMPORTANT To prevent damage to the main cover during installation additional personnel and lifts may be needed Once the main cover is in place and centered begin 5 at the peak of one end and install ...

Page 42: ... fan kit before installing the second main cover Consult the instructions included with the fan kit to install the fan FOR ADDITIONAL DETAILS CONSULT THE INFLATION FAN INSTALLATION PHOTOS FOR A SIMILAR BUILDING IN THE QUICK START GUIDE AT THE BACK OF THESE INSTRUCTIONS After installing the inflation fan kit repeat the steps to 11 install the film for the second main cover NOTE When installing the ...

Page 43: ...ist of the Wrist components for the roll up sides ASSEMBLE THE ROLL UP SIDE CONDUIT Gather the parts Pipe 1 315 x 75 swaged 131S075 Tek screws FA4482B The roll up side conduit assembly attaches to the bottom edge of the roll up film material This assembly runs the length of the frame and serves as the center pipe that the roll up film wraps around when it is opened to ventilate the shelter Complet...

Page 44: ...he conduit 2 Position the channel along the end rafter where the 4 Twist of the Wrist assembly will be located Secure the upper end of the channel by drilling a 3 8 5 hole through the end rafter and attach as shown The lower end of the channel will float and is not attached Photo shows a different model and is used for illustration purposes only Select the aluminum channel drill a 3 8 hole through...

Page 45: ...e of the 7 bracket that has the two holes Install these before installing the double bearing assembles See the figures below For the spacers on the long bolts insert a 5 16 nut 8 over each bolt These nuts are used as spacers only 5 16 Nut 5 16 Nut Slide the Twist of the Wrist mounting plate over the 9 long bolts and secure the plate with two lock nuts Lock Nuts Attach the Twist of the Wrist gearbo...

Page 46: ... billow rope is installed along the outside of the frame and stretches between the ribbon board and the baseboard When installed correctly the anti billow rope helps keep the roll up panel in place when it is fully or partially closed Use the diagram as a guide and complete the steps to install the anti billow rope Beginning at 1 one end rafter take two 2 eye screws FA2155 and attach one to the ba...

Page 47: ...e curtain cords if installed and anti billow rope immediately if worn or broken Remove debris and objects that can accumulate on the building Use tools that will not damage the cover when removing debris Remove snow to prevent excess accumulation Use tools that will not damage the cover when removing snow Check the contents of the shelter to verify that nothing is touching the cover that could cau...

Page 48: ...e length and width of your building may differ from what is shown Ground Level Ground Level ATTENTION Shelter to the right shows mount ing feet and an installed anchor system Actual building may differ in length or design or both Building is shown with customer supplied base boards Frame includes ground posts ...

Page 49: ...49 Revision date 05 13 10 30 Wide Front Profile Grid with Ground Posts 16 8 14 8 30 0 ON CENTER 2 0 6 0 8 8 GROUND LEVEL FRONT VIEW 12 SQUARE GRID ...

Page 50: ...50 Revision date 05 13 10 30 Wide Front Profile Grid with Mounting Feet 30 0 ON CENTER GROUND LEVEL FRONT VIEW 12 SQUARE GRID 14 8 6 0 8 8 ...

Page 51: ...51 Revision date 05 13 10 35 Wide Front Profile Grid with Ground Posts 35 0 ON CENTER 2 0 6 0 9 11 1 4 15 11 1 4 17 11 1 4 FRONT VIEW 12 SQUARE GRID GROUND LEVEL ...

Page 52: ...52 Revision date 05 13 10 35 Wide Front Profile Grid with Mounting Feet 35 0 ON CENTER FRONT VIEW 12 SQUARE GRID GROUND LEVEL 6 0 9 11 1 4 15 11 1 4 ...

Page 53: ...nd Post CFG096ANCS001 Ground Post CFG096ANCS001 Rafter Section Rafter Section Rafter Insert CFG030PINSS01 All R030 Buildings 30 on center All R035 Buildings 35 on center CFG030PCS001 for 30 CFG035PCS001 for 35 CFG030PCS001 for 30 CFG035PCS001 for 35 Ground Level ...

Page 54: ... Mounting Foot 108500 Rafter Leg CFG072ANCS002 Strut 105119 Mounting Foot 108500 Rafter Section Rafter Section Rafter Insert CFG030PINSS01 All R030 Buildings 30 on center All R035 Buildings 35 on center CFG030PCS001 for 30 CFG035PCS001 for 35 CFG030PCS001 for 30 CFG035PCS001 for 35 Ground Level ...

Page 55: ...55 Revision date 05 13 10 T TOP PURLIN U UNDER PURLIN U U T U U T TOP PURLIN U UNDER PURLIN GROUND LEVEL T RFB144CCS001 12 U RFB1204EES002 12 TOP VIEW Purlin Locations ...

Page 56: ...ND LEVEL 36 0 on center on center 6 0 RFB144CCS001 RFB1204EES002 RFB1204EES002 RFB1204EES002 RFB144CCS001 RFB144CCS001 T Top Style Purlin Run U Under Purlin Run NOTE Side profile shown using optional ground posts Profile is the same when using optional rafter feet ...

Page 57: ...001 RFB144CCS001 6 0 RFB144CCS001 RFB144CCS001 RFB1204EES002 RFB1204EES002 RFB1204EES002 RFB1204EES002 2 0 on center T Top Style Purlin Run U Under Purlin Run 48 0 on center NOTE Side profile shown using optional ground posts Profile is the same when using optional rafter feet ...

Page 58: ... posts Profile is the same when using optional rafter feet Side Profile Longer than 48 U U T GROUND LEVEL RFB144CCS001 RFB144CCS001 6 0 RFB144CCS001 RFB144CCS001 RFB1204EES002 RFB1204EES002 RFB1204EES002 RFB1204EES002 2 0 on center T Top Style Purlin Run U Under Purlin Run ...

Page 59: ...59 Revision date 05 13 10 Connections with Ground Posts Ridge Purlin Rafter View 1 Purlin Rafter View 2 Ground Post Rafter View 3 Strut Ground Post View 4 Ground Level ...

Page 60: ...G304B RAFTER INSERT CFG030PINSS01 1 2 LOCKNUT FALB08B 1 2 FLAT WASHER FAME09B 1 2 FLAT WASHER FAME09B FAG402B GROUND POST CFG096ANCS001 GROUND POST CFG096ANCS001 Ridge Purlin Rafter View 1 FAG361B 3 8 FLAT WASHER FAME08B END RAFTERS ONLY 108503 CABLE BRACKET Strut Ground Post View 4 5 16 x 3 1 2 HEX BOLT FAG340B STRUT 5 16 FLAT WASHER FAME07B 5 16 FLAT WASHER FAME07B 5 16 LOCKNUT FALF37B ...

Page 61: ...61 Revision date 05 13 10 Connections with Rafter Feet Ridge Purlin Rafter View 1 Purlin Rafter View 2 Rafter Leg Foot Strut View 4 Rafter Leg Rafter View 3 Strut Rafter View 5 Strut Rafter Leg View 6 ...

Page 62: ... 3 8 FLAT WASHER FAME08B 1 4 ZINC NUT FALB01B 3 8 NUT FALB04B RAFTER INSERT CFG030PINSS01 Ridge Purlin Rafter View 1 FAG361B 3 8 FLAT WASHER FAME08B 5 16 LOCKNUT FALF37B 5 16 LOCKNUT FALF37B FAG304B RAFTER LEG CFG072ANCS002 Rafter Leg Rafter View 3 1 2 LOCKNUT FALB08B 1 2 FLAT WASHER FAME09B 1 2 FLAT WASHER FAME09B FAG402B END RAFTERS ONLY 108503 CABLE BRACKET RAFTER LEG CFG072ANCS002 Strut Rafter...

Page 63: ...L 30 PROFILE 35 PROFILE 30 3 7 8 29 0 7 8 C L C L 35 3 7 8 34 0 7 8 2 5 8 34 8 3 8 12 PIER PIER 12 2 5 8 29 8 3 8 Minimum diameter of concrete pier is 12 Hole for pier should extend below the geographic frost line Consult local building codes for details ...

Page 64: ...64 Revision date 05 13 10 30 Wide Over The Top Measurements 30 0 ON CENTER 6 0 5 8 17 8 1 3 4 3 8 1 3 4 17 8 6 0 5 8 GROUND LEVEL FRONT VIEW OVER THE TOP 47 9 1 8 ...

Page 65: ...65 Revision date 05 13 10 35 Wide Over The Top Measurements 35 0 ON CENTER 6 0 5 8 20 6 11 16 1 11 16 1 11 16 20 6 11 16 3 8 6 0 5 8 FRONT VIEW GROUND LEVEL OVER THE TOP 53 6 3 8 ...

Page 66: ...30A0015 Ground Level 64 On Center Approximate height of chord is 9 NOTE Rafter shown in this example may differ in design from the actual rafter Additional purchase required for support bracing kit for each rafter 166S099 QH1304 QH1304 166S099 166S075 166P027 30 Wide On Center ...

Page 67: ...5A0015 Ground Level 105 On Center Approximate height of chord is 9 NOTE Rafter shown in this example may differ in design from the actual rafter Additional purchase required for support bracing kit for each rafter 190S099 QH1304 QH1304 190S099 190S099 190P058 35 Wide On Center ...

Page 68: ...ket secured to the rafter Apply tape not shown over bracket to protect covers Inside view showing fan mounting bracket and the mounting bolts for the fan Inside view showing fan mounting bracket and the mounting bolts for the fan Fan motor shown attached to fan bracket View 1 Fan motor shown with intake hose attached Intake hose above shown attached through end wall polycarbonate panel as seen fro...

Page 69: ...69 Revision date 05 13 10 Notes This page is reserved for customer notes ...