Power drill with 5/16 & 7/16 nut driver, 3/16 drill bit, framing square, tape measure and Sharpie.

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Jonas Banks
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2012HL Complete System Congratulations! You have just purchased a 2012HL Complete System from Hydrofarm, manufactured by American Hydroponics.

1 2012HL Complete System Congratulations! You have just purchased a 2012HL Complete System from Hydrofarm, manufactured by American Hydroponics. This system is a small example of what big commercial growers use for lettuce, herb and basil production. This system comes with everything from the standard system but also includes the NutriDose 1 which monitors your reservoir for nutrient and ph 24 hours per day, 7 days per week. This controller also comes with the PC Interface package allowing you to data-log and manage settings remotely. Tools and supplies required for assembly: Power drill with 5/16 & 7/16 nut driver, 3/16 drill bit, framing square, tape measure and Sharpie. 2012HL System components: (1) 20 x 12 steel table frame (2) 10 covered collectors with Drip Cap (2) 10 Feeder Manifolds with grommets, micro-tubes and 1 control valves (32) 12 Finishing Channels - Channels have 18 sites per channel (576 sites total) (8) 12 Nursery Channels - Channels have 72 sites per channel (576 sites total) (1) 150 gallon reservoir (1) Rio 32HF submersible pump (2) channel scrub brushes (1) 12 handle for scrub brush (1) Float Valve (1) Float Valve Plumbing Kit All necessary feed and return plumbing 2012HL Growing Supplies: 2) 5 gallon stock tanks with covers (for nutrients) (1) 1 gallon acid tank (for ph adjuster) (1) NutriTest Pro (350) Lettuce or Basil Bags (1) Cases of LC1-1 Oasis cubes (2) Gallons of 10% ph down (3) 8kg batches of Lettuce or Basil, 2-part nutrients (1) Packet of lettuce or basil seeds (roughly 3 months worth) 1

2 3Tray Propagation System with Bottom Heat Package: (1) Table Frame (3) AmHydro propagation trays with fill/drain fittings (1) 30 gallon reservoir with cover (1) Float Valve (1) Float Valve Plumb Kit (1) Timer TN311C (1) Collector with drain plumbing (1) Feeder Manifold with feed plumbing and pump (1) Quad Stat Thermostat (2) 44in by 22in heat mats (1) 44in x 46.5in piece of 3/4in plywood (1) 44in piece of 2x6 Required plastic and wire mesh for heat mats NutriDose 1 with Peristaltic Pump and PC Interface Package: (Complete System Package ONLY) (1) NutriDose 1 Controller (1) Triple Peristaltic Pump with necessary fittings and hoses (1) CF Probe (1) ph Probe (1) Power supply (1) 16oz of all buffers; ph4, ph7 and 27.7 calibration solution (1) Sample Pot with fittings (1) Rio 200 submersible pump (1) PC Interface (1) Power Supply (1) Serial cable (1) CompuGrow software (to be downloaded at manufacturers website) 2

3 10' 20' top rail 10' 138'' Table Assembly: Coupling 1' 6' 6' 6' 1' Figure 1 Look over the 20 bench frame diagrams and lay out materials to assemble frame as close to the final location as possible. Leave 12 between the collector end of table and the greenhouse side-wall (the lowest end of bench is closest the side wall). After all couplings are connected, confirm that all top rails are level. Use shims under bottom support rails for micro adjustments if need be " 35" Lay out bottom rails as per (Fig 1) about 6 apart. 37" Holes parallel with bottom rail Mark and install leg brackets to bottom rails with screws as per measurements provided. 46" 39" Lay out all leg sets as per (Fig 2) - tall to short. Orient them so bolt holes for top rails are parallel with bottom rail, then insert over leg brackets. Screw legs to bracket as per bracket detail. Note, pre-drilled top rail attaches to shortest legs. 46" Bracket 46" Figure 2 Slope toward outside of greenhouse Top Rail 32.5" 35" 37" 39" Bottom Rail 46" 46" 138" 46" 3

4 Once all legs are secured to bottom rail, hold both rail/leg assemblies upright (you ll need some help here) and bolt (hand tight) the first top rail between tallest legs. See (Fig 5). Notice on which side top rail is positioned. Use a framing square to square up top rail to legs and secure diagonal braces with screws (Fig 3). Secure pre-drilled top rail between shortest legs as per (Fig 5) to which collector will mount. Secure diagonal braces to collector legs and bottom rail. Notice on which side top rail is positioned (must be on outside of table frame). Use the Flat Phillips machine screws and tighten until screw head is flush (Fig 4). Proceed to attach remaining top rails as per diagram (Fig 5). Tighten all bolts. Diagonal Brace Top Rail Leg Figure 3 Adjust position of frame, short side, 1 from inside of greenhouse wall. (For ease of installing collector) Lock Washer Washers 1/4-20x2.5 Flat Phillips (make flush with top rail) Lock Washer Washer Figure 5 10' 20' top rail 10' Figure 4 138'' Coupling 1' 6' 6' 6' 1' Attach Manifolds and Covered Collectors: Collectors: Attach (1) 4 x4 brace 2.75 from top of each 32.5 leg. Set each pre assembled 10 collector on the 4 x4 braces and attach using clamps (not provided) or another human. Wear gloves when doing this as collector material can be sharp. 4

5 Use holes in top rail as pilot holes. Drill 3/16 holes through collector. Bend hinge back on collector to get at the inside. Attach to table frame using hardware provided: (14) 1.75 Pan head screws, (28) washers and (14) nuts. When doing this step, it is easiest to drill hole in collector than immediately install hardware to secure. Repeat this procedure as you move down the length of the table. After covered collectors are attached, 10 drip caps can be installed. Clean collector top rails with rubbing alcohol (household 3% is fine) to remove any oils or dust. Apply 3 pieces of 3M double stick tape to collector top rails (Figure 7a). Pan Head Screw 1.75 SS Washer #10 SS Loosen nuts that hold the collector top rail to legs (Figure 7b). Remove tape backing and push on drip cap until secure so the back end rests between leg and top rail. Washer #10 SS Nut 8-32 Re-tighten nuts to pinch and secure drip cap. Collector Top Rail FRONT VIEW Figure 7a 120 in Collector Top Rail TOP VIEW 3M Double stick tape (3 inch pieces) 12 in 44 in 76 in 108 in Figure 7b Drip Cap Channel slides all the way in to touch collector cover Hinge Drip Cap Leg 3M double stick tape Back end of drip cap Collector Top Rail Pinch drip cap between top rail and leg 5

6 (2) of the 4 x 4 L-braces Have been modified with an extra hole (3 holes on one side verses 2). Attach (1) of these on Leg 2, 7.5 down from the top of the leg. Make sure the side with the three holes is facing up. Attach Use 2 front holes for nylon tie the other L-brace on Leg 3, 8.25 down from the top of the leg. Dry fit the return plumbing together No Glue If your system is on gravel, the reservoir may be sitting below grade, or just below bottom rails. If this is the case, return plumbing pitch will be greater. Install the first L-brace on Leg 2 and rest the other end of the drain plumbing on top of the reservoir. Secure the other L-brace on leg 3 just under the return plumbing. After L-braces are attached, glue the two pieces of return plumbing so the Tee s line up with the drains. Cut the (2) 1 pieces of 1.5 flexible tubing at the top in three places, about 1/2 down. Push tubing on drain and thread until you hit nut. Secure with hose clamp. Cut other end of tubing allowing at least 1 of tubing material to insert into open Tee. Secure return plumbing assembly with 11 nylon ties using the two front holes on the L-braces. Collector Toprail Leg 4 x4 Brace Flex Tubing Cleanout 6

7 Manifolds: Insert ball valve/union piece to manifolds. Insert grommets into manifold holes (20 per manifold) and attach manifolds with nylon ties provided (manifold goes UNDER top rail). Each manifold gets (6) nylon ties and is attached to high end of table as shown. Microtube Grommet Manifold Insert microtube to middle of manifold 39 Legs Nylon Ties 11 Nylon Tie six per 10 manifold Assemble manifold supply plumbing: Follow the illustrations below to glue (7) pieces of supply plumbing to (2) manifolds. Dry fit all connections together before gluing. Use 3/4 metal clamps provided to secure fill plumbing to legs. A 1 2 B 2 1 C 3 3 D E F G 6 To Manifolds 5 Fill Manifold End View C B D A F G Pump 7

8 Fill Manifold Top View A B C D E Once all plumbing is dry fitted together, glue all (7) sections together. Fill Manifold Side View B C A D E F 8

9 Channel Layout and Micro Tubes: Channel will come with fill hole for 1/4 microtube pre drilled. You will receive (32) finishing channel with a fill hole on each end so they can be installed in either direction, along with (8) nursery channel. Lay Channel on table frame so plant sites are staggered as shown in illustration. Microtube Manifold Insert microtube to middle of manifold Grommet Once all the channels are on the table, space them out evenly. (20) channel will fit in each 10 modular covered collector. Lift hinge of covered collector and insert channel all the way to the back of the covered collector. The pitch of the table frame, length of channel inserted into the collector and the drip cap, work together to eliminate drip-back leaking. Keep the drip cap clean between harvests. Insert all 40 microtubes into grommets. Use soapy water or plumbers grease to make insertion easy. Insert microtube to the middle of the manifold. Not to far as flow can be restricted. Insert the other end of the microtube into the fill hole on the channel. Diagonals End Caps come with the system but are rarely required. They can be installed if you are growing very large plants and roots make it to the uphill end of the channels. Most growers have not needed them. The best glue for attaching the end caps is called Contact Adhesive 600 made by Weld-on (#10077). If you cannot source, we can send you a pint. 9

10 Float Valve Installation: 1. Remove reservoir and tubing nut. Insert valve body through the existing 7/16 valve hole. Make sure sealing washer is on the inside of the reservoir. Secure with reservoir nut. note: If there is no pre-drilled hole, fill up your reservoir and turn on pump. Once the system equalizes (same amount of water is feeding your system as returning to your reservoir) mark the water level and drill a 7/16 hole for float valve. If the pump turns off, reservoir will not overflow. 2. Loosely screw on tubing nut with compression fittings. Stick the 1/4 tubing coming from your Float Valve Plumb Kit into the tubing nut about 3/4 of an inch. Fasten tubing until tight. 3. Adjust wing nut if needed 4. Turn on needle valve attached to your Float Valve Plumb Kit and you are ready to grow. Sealing Washer Reservoir Compression fittings Wing Nut Valve Body Reservoir nut Tubing Nut Micro Tube to Float Valve Plumb Kit 10

11 Plumbing Kit Installation: 1. If not already pre assembled, screw threaded valve tee into custom hose bib until it is well seated. Teflon tape is supplied for a water tight seal. (Figure a). 2. Screw custom hose bib onto closest hose bib on your house or in your greenhouse. You will still be able to use house hose bib (Figure b). 3. If supply tube is not long enough, you will have to purchase a length that will suit your needs. You can go 100 if you like. 4. Slide brass nut over 1/4 supply tube as in (Figure a). 5. Slide plastic compression fitting over 1/4 supply tube. IMPORTANT (be sure short taper is toward the threaded valve tee.) 6. Slip brass ferrule into 1/4 supply tube until it is seated. (be sure end of 1/4 supply tube is cut square). 7. Push 1/4 supply tube into threaded valve tee and tighten brass nut finger tight. 8. Turn house hose bib on and then threaded valve. Continue tightening brass nut until there are no leaks. Too tight will crush plastic ferrule. You now have a float valve hooked up. Threaded valve Brass ferrule Brass nut Plastic compression fitting 11

12 Crop Turn Technology (CTT): A Crop Turn is a number determined by how many plants you can harvest, per finishing hole, per year. The 2012HL System is designed for (26) crop turns per year at (6) week cycles (2 weeks in propagation, 2 weeks in nursery and 2 weeks in finishing). That means, that from the day you plant a seed it will take 42 days before you harvest. Out of each finishing hole you will harvest (26) plants per year. With (576) finishing sites in your system, that s (14,976) plants per year. Not bad for a 240 square foot system. The initial stages of growing with an NFT system, requires mastering important variables in order to achieve (26) crop turns per year. Most growers start at about (13) crop turns per year and increase as experience is gained. The bottom line is, plant s do not like fluctuations. The more stable you can make your environment (temperature, RH, Conductivity, ph, etc...), the more yield you can achieve. Stage one: Propagation Propagation is the first step and is key to a successful operation. Always add 10% to your propagation number to account for loss. If your goal is (26) CT per year, you want to plant ( % = 317) per week. To make it easy, plant two whole flats (324) sites, so you don t have to break up the oasis. Week 1: Plant (324) seeds. Week 2: Plant (324) seeds. Stage two: Nursery In week 3, you need to move (288) plants to nursery channel. Take the strongest looking plants and discard the rest. Week 3: Move (288) seedling to nursery. Plant (324) seeds. Week 4: Move (288) seedling to nursery. Plant (324) seeds. Stage Three: Finishing Week 5: Move (288) nursery plants to finishing channels. Move (288) seedlings to nursery channels. Plant (324) seeds. Week 6: Move (288) nursery plants to finishing channels. Move (288) seedlings to nursery channels. Plant (324) seeds. End of week 6, beginning of week 7: Harvest (288) plants. Move (288) nursery plants to finishing channels. Move (288) seedlings to nursery channels. Plant (324) seeds. From this point on, you should be Harvesting (288) plants, moving (288) nursery plants to finishing channels, moving (288) seedlings to nursery channels and planting (324) seeds every week. 12

13 Crop Turn Technology (CTT): Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 1: Plant (324) seeds. Week 2: Plant (324) seeds. Week 3: Move (288) seedling to nursery. Plant (324) seeds. Week 1 Week 2 Week 3 13

14 Crop Turn Technology (CTT): Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 4: Move (288) seedling to nursery. Plant (324) seeds. Week 4 14

15 Crop Turn Technology (CTT): Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 5: Move (288) nursery plants to finishing channels. Move (288) seedlings to nursery channels. Plant (324) seeds. Week

16 Crop Turn Technology (CTT): Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 6: Move (288) nursery plants to finishing channels. Move (288) seedlings to nursery channels. Plant (324) seeds. Week

17 Crop Turn Technology (CTT): Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 End of week 6, begenning of week 7: Harvest (288) plants. Move (288) nursery plants to finishing channels. Move (288) seedlings to nursery channels. Plant (324) seeds. Market Week After crop is harvested, step 1, clean finishing gullys. Place channels back in system and proceed to step 2. Clean nursery channels and proceed to step 3. Reseed propagation and your ready for next week. 2 17

HydroCycle 4" Pro NFT Lettuce Systems

HydroCycle 4 Pro NFT Lettuce Systems HydroCycle 4" Pro NFT Lettuce Systems 110830 Hydroponic Table Kit* Designed to grow healthy plants without soil using mineral-nutrient solutions. 2016 Growers Supply All Rights Reserved. Reproduction is