purple - static blackout components · 2019-04-26 · 6 evision date 04.18.19 the monofilament...
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1Revision date: 04.18.19
©2019 Growers SupplyAll Rights Reserved. Reproduction is prohibited without permission.
Series 500 Greenhouse Kit w/Blackout System, Ventilation & Evaporative Cooling
GB30PVPURPLE30' Wide Series 500 Static Blackout Components:
Monofilament, Fixation & Sealing
PURPLE - Static Blackout Components
2 Revision date: 04.18.19
Color Coding
READ THIS BEFORE YOU BEGINPurchased greenhouse and all accessories & systems require a specific installation sequence. All components have been separated into different categories based on common grouping and/or the chronology of installation. Each category has been color coded. All parts within any given color category will be labeled accordingly, and each color category will have its own respective instruction manual.
The following illustrates a highly recommended order in which all components should be installed.
IMPORTANT: There are some procedures that can occur simultaneously, depending on available assistants and equipment, but there are some procedures that MUST be done in chronological order. Before you begin, review below step recommendation and all technical documents to better understand overall building kit design.
Near the beginning of each color-coded instruction guide, you will find information to lead you through the installation and assembly steps. This information identifies at what point during the assembly the respective components are installed or attached to the main building frame.
Since we cannot anticipate changes made by the customer/contractor, all instructions assume the use of accessories purchased from us to be used on the building the accessory was designed for. Each instruction guide presents the basic steps to install the color-coded components.
When in doubt, consult the services of a qualified contractor experienced with the assembly of similar structures.
1 RED - MAIN FRAME (Rafters, Purlins, Chord Support and Cabling)
ORANGE - END WALL FRAMING (Columns, Cross Beams and Door Framing)
BLUE - END WALL CLADDING (Polycarbonate, Termination and Flashing)
YELLOW - EVAPORATIVE COOLING (Framing, Cooling Pads and Plumbing)
BROWN - END WALL VENT (Framing, Motor and Drive Shaft)
WHITE - VENTILATION (Exhaust Fans, Ceiling Fans and Light Traps)
PURPLE - STATIC BLACKOUT (Monofilament, Fixation and Sealing)
BLACK - MOVABLE BLACKOUT (Fabric, Leading Edge, Motor and Drive Shaft)
GRAY - BLACKOUT SIDE POCKET (Framing and Polycarbonate)
2
3
6
7
8
9
10
11
4 GREEN - ROOF CLADDING (Film, Inflation Kits and Termination)
PINK - AIR DISTRIBUTION (Fan, Vent Tube and Shutter)5
3Revision date: 04.18.19
All components that are color coded PURPLE represent the static blackout components, which are components of the system that are fixed in place.
***Color coded components that MUST be installed before installing PURPLE:
If above color coded components have not yet been installed, put this manual down and consult those manuals to install those components before returning.
If above color coded components have been installed, gather all components that have been color coded with a PURPLE label or paint splotch, and continue on the next page with the blackout installation.
ATTENTION: Recommended installation order is not critically definitive. Installation of film cladding will protect the interior of the greenhouse from weather elements, but it will also increase the temperature. Depending on personal preference and/or availability of assistants and equipment, there are some procedures that can occur before or simultaneously with this procedure.
Color coded components that can be installed before or at the same time as PURPLE:
BLUE YELLOW GREEN
Color Coding
RED ORANGE
PINK WHITEGRAY
PURPLEStatic BlackoutComponents
Installation Chronology MUST READ:
4 Revision date: 04.18.19
Important Information
READ THIS DOCUMENT BEFORE YOU BEGIN
Thank you for purchasing a Series 500 greenhouse kit with a black-out system, ventilation & evaporative cooling. When properly assembled and maintained, this product will provide years of reliable service. These instructions include helpful hints and important information needed to safely assemble and properly maintain the system. Please read these instructions before you begin.
If you have any questions during the assembly, please contact customer service for assistance.
SAFETY PRECAUTIONS
• Wear eye protection.
• Wear head protection.
• Wear gloves when handling metal parts.
• Use a portable GFCI (Ground Fault Circuit Interrupter) when working with power tools and cords.
• Do not climb on the frame during or after construction. NEVER hang items from the system components!
UNPACK AND IDENTIFY PARTS
The following steps will ensure that you have all the necessary parts before you begin to assemble the blackout system
Unpack the contents of the shipment and place where you can easily inventory the parts. Refer to the Bill of Materials/Spec Sheets.
1. Verify that all parts listed on the Bill of Materials/Spec Sheets are present. If anything is missing or you have questions, consult the Pictorial Parts Guide and all diagrams for clarification, or contact Customer Service. NOTE: You do not need to open the plastic bags containing smaller parts such as fasteners or washers.
REQUIRED TOOLS
The following list identifies the main tools needed to assemble the shelter and black-out system. Additional tools and supports may be needed depending on the structure, system, location, conditions and application.
• Tape measure or measuring device and marker to mark locations on the pipes and rafters.
• Variable speed drills, impact drivers & drill bit set. (Cordless with extra batteries works best.)
• Metal-cutting saws or tools to cut pipe and aluminum.
• Wrenches & impact socket set, hammer, and gloves.
• Adjustable pliers and self-locking pliers.
• Level 6' (or longer) preferred
• String line (or chalk line)
• Scissors or utility knife
• Ladders, work platforms, and other machinery for lifting designed to work safely at system height.
• Safety equipment to protect head, eyes, hands & feet.
RECOMMENDED INSTALLATION CHRONOLOGY
The blackout system requires a specific installation sequence. The follow pages illustrate a highly recommended order in which the blackout system components should be installed. This information identifies at what point during the assembly a particular component is to be installed or attached to the main building frame.
1. Monofilament & Corner Cable Tensioners.
2. Monofilament Clips (MUST be installed before Panel Fixation components--102197 channel).
3. Panel Sealing components (MUST be installed before Blackout purlins).
4. Panel Fixation components.
5. Blackout Purlins (MUST be installed before corner cables and monofilament wires).
6. Corner Cables.
7. Monofilament Wires.
5Revision date: 04.18.19
Parts Identification
FA4482B Tek Screw
100441Magnetic Nut Setter
102197Spring Channel
The following graphics will help identify the basic parts of the frame. (Some parts are not shown.)
112569Cable Clip
112570Monofilament Wire
115177Drive Pipe Clamp
111984Keder Channel
115018Z046Keder Sealing Strip
115198Black-Out Tape
111983Foam Tape
AS1002 Cable Clamp
113323Monofilament Clip
113650Wire Tensioner
AR3030 Corner Cable
6 Revision date: 04.18.19
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.
MEASURE & MARK MOUNT LOCATIONSEach monofilament line consists of one (1) 113650 wire tensioner, attached at one end, and one (1) FA4482B Tek screw with a neo-bonded washer attached at the other end (shown below). At one end wall, attach the 113650 tensioners. Starting in the center, install one 113650 tensioner below the header, and one above. From there, attach a lower tensioner every 24". Attach an upper tensioner every 48". Repeat for Tek screws at the opposite end header. See below for orientation details. Adjust as needed, but it is important to MIRROR locations exactly at each end.
Arrows indicate wire tensioner locations.
NOTE: Additional end framing removed for clarity.
48"
24"
IMPORTANT: If necessary, adjust wire mounts left or right as needed to avoid obstructions such as end wall columns, mid-rafter webbing etc. Spacing is approximate recommendation and not critical, however, remember to mirror accordingly on the opposite end.
ATTENTION: Dashed boxes above indicate the locations along the header profile where drive components will be installed. Avoid installing wire tensioners or brackets in these locations. Consult BLACK manual for drive component dimensions, and install accordingly.
Monofilament Wire Mounts
ATTACH WIRE MOUNTSAttach all upper and lower 113650 tensioners at one end header using FA4482 Tek screws. At the other end header, install one Tek screw & neo-bonded washer every 24". Consult diagrams for orientation of hardware.
OUTSIDE OF GREENHOUSE
HORIZONTALBLACKOUT HEADER
SLIP-ON WIREBRACKET (113694)
HORIZONTALBLACKOUT HEADER
WIRE TENSIONER (113650)
INSIDE GREENHOUSE
**NOTE: WIRE TENSIONER BRACKETS SPACED EVERY 18" ON THE BOTTOM OFFRONT ENDWALL HEADER (36” ON THE TOP) AND ARE TO BE PATTERNED AS SHOWN.
OUTSIDE OF GREENHOUSE
INSIDE GREENHOUSE
**NOTE: SLIP-ON WIRE TENSIONERS ARE TO MIRROR THE WIRE TENSIONER BRACKETS ON THE FRONT HEADER OF THE GREENHOUSE (SPACED EVERY 18").
2424
TEK SCREWS AND WASHERS48
7Revision date: 04.18.19
Corner Cable Wire Mounts
Arrows indicate wire tensioner locations.
NOTE: Additional end framing removed for clarity.
INSTALL CORNER CABLE WIRE MOUNTSEach corner cable line consists of two (2) 113650 wire tensioners; one attached ON THE TOPSIDE at each end header. At one end, attach the 113650 tensioners in locations shown below using FAG312B bolts & FALB01B nuts. Field drill 5/16" attachment holes. Repeat for the other end. Verify wire tensioners are oriented towards the inside of the greenhouse as shown.
Corner Cable Wire Mount
Corner Cable Wire Mount
ATTENTION: If completing this step before finishing end wall cladding, return to the BLUE manual at this point, and return to this manual when ready.
Towards INSIDE of structure.
HEADER
FAG312B bolt & FALF35B lock nut.
113650 wire tensioner
Pre-drill 5/16" through-holes.
8 Revision date: 04.18.19
INSTALL MONOFILAMENT WIRE CLIPS
Black-out System Installation
1. Consult diagram below and pages 6 & 7 and install a 113323 monofilament tube clip at EVERY monofilament wire & corner cable location at EVERY mid-rafter header. It is important that clip locations mirror the monofilament wire mount locations. Note that the motor and rack drive locations on the power rafter may interfere with tube clip installation. It is acceptable to not install tube clips at those locations on the power rafter only, if necessary. HELPFUL HINT: At every top and bottom monofilament wire location, snap chalk lines from one 113650 wire tensioner at one end wall to the corresponding Tek screws & washers at the opposite end wall, and install the monofilament wire clips at the marks on every mid-rafter.
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. Verify that the faces of the 113323 monofilament wire clips are facing towards the end wall header with the FA4482B Tek screws & neo-washers attached.
Tube clips are pushed into place over the 2"x2" rafter chord and will stay in place, once installed. Orient each clip so that the monofilament support tab is on the side the monofilament will run in that location. See above.
Tube clips ARE attached to End Black-Out Header #1, but NOT in the the monofilament wire mount locations. These tube clips serve as panel fixation components only. Attach in between the monofilament wire mounts on End Black-Out Header #1.
Arrows indicate 113323 tube clip locations, based on monofilament wire mount locations on page 6, and corner cable locations on page 7.
EndBlack-Out Header #1
EndBlack-Out Header #2
113323tube clip
113323tube clip
Mid-RafterHeaders
113323 tube clip
Monofilament Wire
(installed later)
2"x2"Header
9Revision date: 04.18.19
Black-out System Installation
ATTACH PANEL SEALING COMPONENTS
ATTENTION: Dashed lines around the "x"s indicate sections of keder channel to notch and discard. Notch around obstruction areas, and where horizontal and vertical sections meet for a uniform attachment surface.
NOTE: Leave approximately 1" to 2" of space between the vertical and horizontal sections to allow for the keder sealing strip to pass through (installed later).
X
XX
1. Using FA4482B Tek screws, attach the 111984 sealing keder channel to the topside of all headers except end black-out header #1. Keder channel will follow the contour of the header tubes and continue down the outside edge of the vertical header as shown below. ATTENTION: There will be obstructions preventing the flat uniform surface to attach the keder channels--webbing brackets, bolt heads & threads etc. A certain high level of craftsmanship will need to be exercised to attach over top these obstructions. Notch around obstructions as best as possible. See below.
2. Where the horizontal header meets the vertical header, cut keder channel to fit, leaving 1" to 2" of space between. Bottom of the vertical keder channels to be level with the bottom of the vertical header profile tube.
3. File sharp edges of keder channel where cut.
Consult diagrams below and technical documents at 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. Verify that the open channel of the 111984 keder channel is facing towards the end wall header with the 113650 wire tensioners attached.
EndBlack-Out Header #1
EndBlack-Out Header #2
113323tube clip
111984keder channel
CUT-AWAYSIDE VIEW
Mid-RafterHeaders
1"-2"
10 Revision date: 04.18.19
1. Once an entire run of keder channel has been installed on a rafter, slide a continuous length of 115018Z047 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. Then slide those dangling sections into the vertical sections of keder channel from the top.
2. Once installed, use provided 115198 blackout-out tape, sealing caulk, etc. to seal these locations for light leakage prevention. See below.
Black-out System Installation
INSERT KEDER SEALING STRIP
115018Z046Keder Sealing Strip
115198Black-Out Tape
11Revision date: 04.18.19
1. Once an entire run of keder channel has been installed on a rafter, line the 2"x2" rafter underneath the keder sealing strip with a continuous length of 111983 expanding foam tape along the entire contour of the profile. Cut to fit where necessary.
2. Repeat for every bay.
Black-out System Installation
INSTALL EXPANDING FOAM SEALING TAPE
EndBlack-Out Header #1
EndBlack-Out Header #2
CUT-AWAYSIDE VIEW
Mid-RafterHeaders
111983Foam Tape
12 Revision date: 04.18.19
Black-out System Installation
ATTACH PANEL FIXATION COMPONENTS
1. Using FA4482B Tek screws, attach the 102197 spring channel as shown to all headers except end black-out header #2. Spring channel will follow the contour of the header tubes and continue down the outside edge of the vertical header as shown below. IMPORTANT: 102197 spring channel is to be attached over the top of the installed 113323 monofilament wire clips. If clips have not been installed at this point, reference page 8 and install BEFORE attaching the spring channel.
2. Where the horizontal header meets the vertical header, cut spring channel to fit, leaving 1" to 2" of space between. Bottom of the vertical spring channel sections to be level with the bottom of the vertical header profile tube.
3. File sharp edges of spring channel where cut.
Consult diagrams below and technical documents at 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. Verify that the open channel of the 102197 spring channel is facing towards the end wall header with the Tek screws & neo-bonded washers attached.
EndBlack-Out Header #1
EndBlack-Out Header #2
CUT-AWAYSIDE VIEW
Mid-RafterHeaders
102197Spring Channel
13Revision date: 04.18.19
Black-out System Installation
BLACKOUT PURLIN 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. If those components have not been installed, return to those instructions and do so before continuing with blackout purlin installation.
DIAGONAL PURLIN
MID RAFTERHEADER
RAFTER
KEDER
(1x) 3/8" X 3" HEX BOLT [FAG363B](1x) 3/8" LOCK WASHER [FAMA38B]
[115362]
(2x) #14 X 1" TEK SCREW [FA4482B]
KEDER*
CROSS BEAM
1.5" X 1.5" SQUARE TUBE [115361]
KEDER*
CROSS BEAM
CROSS BEAM
COLUMN
PIPE CLAMP [115177]
KEDER*
CROSS BEAM
PURLIN
PIPE CLAMP [115177]
[105S156]
[105S156]
- (1X) 1/4" THREADED ROD - (2X) 1/4" WASHER- (2X) 1/4" LOCK NUT
[FAK14Z006][FAME16B][FALF15B]
- (1X) 1/4" THREADED ROD - (2X) 1/4" WASHER- (2X) 1/4" LOCK NUT
[FAK14Z006][FAME16B][FALF15B]
DIAGONAL PURLIN
MID RAFTERHEADER
RAFTER
KEDER
(1x) 3/8" X 3" HEX BOLT [FAG363B](1x) 3/8" LOCK WASHER [FAMA38B]
[115362]
(2x) #14 X 1" TEK SCREW [FA4482B]
KEDER*
CROSS BEAM
1.5" X 1.5" SQUARE TUBE [115361]
KEDER*
CROSS BEAM
CROSS BEAM
COLUMN
PIPE CLAMP [115177]
KEDER*
CROSS BEAM
PURLIN
PIPE CLAMP [115177]
[105S156]
[105S156]
- (1X) 1/4" THREADED ROD - (2X) 1/4" WASHER- (2X) 1/4" LOCK NUT
[FAK14Z006][FAME16B][FALF15B]
- (1X) 1/4" THREADED ROD - (2X) 1/4" WASHER- (2X) 1/4" LOCK NUT
[FAK14Z006][FAME16B][FALF15B]
DIAGONAL PURLIN
MID RAFTERHEADER
RAFTER
KEDER
(1x) 3/8" X 3" HEX BOLT [FAG363B](1x) 3/8" LOCK WASHER [FAMA38B]
[115362]PURLIN
(2x) #14 X 1" TEK SCREW [FA4482B]
KEDER*
CROSS BEAM
1.5" X 1.5" SQUARE TUBE [115361]
PIPE CLAMP [115177]
KEDER*
CROSS BEAM
CROSS BEAM
COLUMN
PIPE CLAMP [115177]
KEDER*
CROSS BEAM
PURLIN
PIPE CLAMP [115177]
[105S156]
[105S156]
[105S156]
- (1X) 1/4" THREADED ROD - (2X) 1/4" WASHER- (2X) 1/4" LOCK NUT
[FAK14Z006][FAME16B][FALF15B]
- (1X) 1/4" THREADED ROD - (2X) 1/4" WASHER- (2X) 1/4" LOCK NUT
[FAK14Z006][FAME16B][FALF15B]
- (1X) 1/4" THREADED ROD - (2X) 1/4" WASHER- (2X) 1/4" LOCK NUT
[FAK14Z006][FAME16B][FALF15B]
DETAILA
DETAILA
DETAILA
DETAILC
DETAILB
DETAILB
DETAILC
115362Diagonal Purlin
(attached to mid header)
NOTE: Unfasten existing bolt, and reattach accordingly.
Spliced with FA4482B Tek screws
115361Diagonal Purlin
(attached to end header)
131S147Reinforcement Purlin
131S147Reinforcement Purlin
Each end bay support pipe consists of a section of 1.315" pipe attached to the underside of the header profiles with 115859 support pipe brackets & 115858 U-bolts and one 116260 slipper clamp.
At each end and every first interior header rafter, attach a 115859 support pipe bracket in the indicated locations using FAG312B bolts and FALB01B nuts.
IMPORTANT: Verify bracket locations on end rafters and first interior rafters are MIRRORED and that no header brackets will obstruct the support pipes. Support pipes MUST run perpendicular to the rafters.
DETAILA
14 Revision date: 04.18.19
Dashed lines indicate locations of corner cables.
Black-out System Installation
INSTALL CORNER CABLES
INSTALL UPPER CABLES
AS1002 Cable Clamp
AR3030 Upper Cable
1. Using the upper cable wire tensioners installed on top of the end black-out headers, string AR3030 cable lengthwise from one tensioner to the tensioner at the opposite end and secure with AS1002 clamps. Tension until taut, but do not over-tighten. IMPORTANT: Tape loose ends of the cable to avoid snagging on material when installed.
2. Using FA4482B Tek screws & 102921B neo-bonded washers, secure AR3030 wire to the upper wire spacers installed at each rafter as shown below.
3. To protect the black-out material from the upper cables, install sections of 112569 PVC tube clip on the upper cables in every bay, as shown below. Cut to fit between headers.
End Header
End Header
Rafter
Rafter
Mid Header
FA4482B Tek screw &
102921B neo-bonded washer
AR3030Cable
NOTE: Diagram shows only end headers and one mid header for illustrational purposes. Install FA4482B Tek screws and 102921B washers at each mid rafter.
IMPORTANT: Diagram may not exactly reflect actual frame. Applications are the same. Adjust accordingly.
112569Cable Clip
Step 1
Step 2
Upper Cable
112569 PVC tube clipStep 3
15Revision date: 04.18.19
Black-out System Installation
STRING AND TENSION MONOFILAMENT WIRES
1. Starting in the middle of the header profile, string 112570 monofilament wire from one wire tensioner installed every 24" along one end wall header, to the Tek screw wire anchor in the exact location along the opposite end wall header.
2. Tie wire off around the wire anchor Tek screw, and then tighten anchor screw to secure in place.
3. Snap monofilament wires into the tabs of the corresponding 113323 tube clips at EACH mid rafter header.
4. Crank wire tensioner until monofilament wire is taut. DO NOT OVER-TIGHTEN.
5. Once tightened, cut excess monofilament wire from each end.
6. Repeat for each bottom and top wire tensioner.
DETAILA
DETAILA
DETAILB
DETAILC
DETAILB
DETAILC
MONOFILAMENT
BLACKOUT HEADER
WIRE TENSIONERBRACKET
BLACKOUT HEADER
FA4482B Tek screw&
102921B Neo-bonded washer
TUBE CLIP
MONOFILAMENT
MONOFILAMENT
BLACKOUTHEADER
MONOFILAMENT
BLACKOUT HEADER
SLIP-ON BRACKET
CABLE CLAMP
WIRE TENSIONERBRACKET
BLACKOUT HEADER
TUBE CLIP
MONOFILAMENT
MONOFILAMENT
BLACKOUTHEADER
NOTE: CABLE CLAMP SHOWN AWAY FROM THE HEADERFOR CLARITY. CABLE CLAMP MUST BE AS CLOSE AS POSSIBLETO THE BRACKET AND HEADER AS POSSIBLE.
MONOFILAMENT
BLACKOUT HEADER
SLIP-ON BRACKET
CABLE CLAMP
WIRE TENSIONERBRACKET
BLACKOUT HEADER
TUBE CLIP
MONOFILAMENT
MONOFILAMENT
BLACKOUTHEADER
NOTE: CABLE CLAMP SHOWN AWAY FROM THE HEADERFOR CLARITY. CABLE CLAMP MUST BE AS CLOSE AS POSSIBLETO THE BRACKET AND HEADER AS POSSIBLE.
112570Monofilament
Wire
16 Revision date: 04.18.19
Additional Notes
Space below is reserved for customer notes.