ClearSpan Hydroponic Table Kit Hydroponic Table Kit (The 109314 (4' x 16') model is shown.) Designed to grow healthy plants without soil using mineral-nutrient solutions. 2009 ClearSpan All Rights Reserved. Reproduction is prohibited without permission. STK# 109314 (4' x 16') 109316 (4' x 32') 109315 (4' x 24') 1
Important Information READ THIS DOCUMENT BEFORE YOU BEGIN TO ASSEMBLE THE HYDROPONIC TABLE. Thank you for purchasing our hydroponic table. 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 product. Please read these instructions before you begin. If you have any questions during the assembly, contact Customer Service at 1-800-245-9881 for assistance. SAFETY PRECAUTIONS Wear eye protection. Wear gloves when handling metal pipes. Use a portable GFCI (Ground Fault Circuit Interrupter) when working with power tools and cords. ASSEMBLY PROCEDURE Following the instructions as presented will help ensure the proper assembly of your hydroponic table. The steps outlining the assembly process are as follows: 1. 2. 3. 4. 5. 6. Verify that all parts are included in the shipment. Notify customer service for questions or concerns. Read these instructions and all additional documentation included with the shipment before you begin. Gather the tools and assistants needed to assemble the product. Assemble the components in the order they are presented in these instructions. Read the care and maintenance information. Complete and return all warranty information as instructed. REQUIRED TOOLS The following list identifies the main tools needed to assemble the hydroponic table. Additional tools and supports may be needed depending on the structure, location, and application. Tape measure and string line Marker to mark locations on the pipes Variable speed drill and impact driver (cordless with extra batteries works best) Metal-cutting saw Hammers and gloves Hex key (Allen) wrench set Level (6' or longer) UNPACK AND IDENTIFY PARTS The following steps will ensure that you have all the necessary parts before you begin assembly. 1. 2. Unpack the contents of the shipment and place where you can easily inventory the parts. Refer to the Bill of Materials/Spec Sheets. 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: At this time, you do not need to open the plastic bags containing smaller parts such as fasteners or washers (if equipped). CARE AND MAINTENANCE Proper care and maintenance of your hydroponic table is important. Check the following items periodically to properly maintain your hydroponic table. Check connections and all fasteners to verify that they remain tight. Do not climb or stand on the table at anytime. Verify that the bed liners are not rubbing against any sharp edge or objects. Tape the edges if needed to protect the liners. Replace all worn or damaged parts promptly. If the table is moved, inspect all parts and connections before reassembling and use. For replacement or missing parts, call 1.800.245.9881 for assistance. QUICK START GUIDE For a quick overview of this shelter, its components, and connection details consult the Quick Start Guide at the back of these instructions. Frames are constructed in 8' increments. The 16' model is used throughout this guide as an example. Consult the 24' and 32' Frame diagrams later in this guide to view those frames. Assembly steps are the same regardless of length. 2
Important Information PICTORIAL GUIDE The following graphics and photos will help you identify the different parts of the hydroponic table. Consult the Quick Start Guide for additional details and diagrams. (Some parts are not shown.) FA4482B Tek Screw 100441 Nut Setter 10015508 3-way Blind Corner Fitting 10015708 Long Tee Fitting 106487 Post Cap Aluminum Strap Hat Channel 105941 Side Outlet Tee SKU# 105932096D 105932045D 109314 8 4 109315 12 4 109316 16 4 SKU# 1085290995D 10852904725D 109314 26 8 109315 39 8 109316 52 8 3
Assembly Instructions 1 Before assembling the hydroponic table, layout and measure the round pipe lengths to verify that you have all the correct pipes. NOTE: Hydroponic table must be assembled on a flat, level surface. For tables 16' and longer, assemble these in the location where they will be used. Do not move the frame during or after assembly. 105941 Gather four (4) 96" pipes and three (3) 48" pipes for a 16' table. Assemble as shown below using 10015508 corner fittings and the 105941 side outlet tee fittings. Tighten the set screws to keep the fittings in position. Consult the frame diagrams near the back of this manual for the 24' and 32' models. 96" Pipe 10015508 IMPORTANT: The 96" pipes will span the entire length of the hydroponic table. When attaching the corner fittings to pipe, do not slide the pipe too far into the fitting. Allow room to insert the corner and mid pipes. Insert a pipe into the fitting to set the proper clearance if needed. 10015508 105941 96" Pipe 4
Assembly Instructions 2 Gather the 48" pipes as needed and insert into the corner and side outlet fittings as shown until they are seated tightly in place. Tighten the set screws to keep the pipes in position. Number of pipes varies with frame length. A 16' table is shown for an example. NOTE: If the pipes are not seated into the fitting properly, loosen all set screws and realign pipes so the corner pipes seat in the bottom of the fitting. Retighten all set screws. Seat all corner pipes tightly into the fitting. Set the vertical mid pipes flush to the bottom of the 105941 side outlet tee fittings. CORRECT INCORRECT 5
Assembly Instructions 3 When assembling the lower hydroponic bed, verify that the side hat channel sections are level. Take the first section of 99-1/2" hat channel (1085290995D), position it tight against the top of the corner fitting. Have an assistant hold the free end. Use a level to position the sections accurately. Secure to the corner pipe using FA4482B Tek screws (A). Install screws in the center of the corner pipe. Verify that the channel is level. See A in diagrams. do not allow the 99-1/2" hat channel to extend beyond the outer edges of the corner pipes. B Take another piece of hat channel (B) and move to next frame section along the same side of the frame. With assistance, overlap the end of the first hat channel section with the end of the next section. Align the pre-drilled holes with the center of the vertical mid pipe, check for level, and secure to the frame pipes. A 16' frame is shown. A ATTENTION: Differences in how the frames are assembled may cause the pre-drilled holes in the hat channel to become misaligned. Use the self-tapping screws to drill new holes if needed. Repeat as needed to install the first run of side hat channel along both sides of the frame. Take 99-1/2" hat channels (A), position at the top of the corner fittings, and secure in place using FA4482B Tek screws. A Take another section of 99-1/2" hat channel, overlap with the first section and center on the frame. Once the channel is level (B), secure to the mid pipe using Tek screws. NOTE: Channel will not rest on the 105941 side outlet. B 6
3 After installing the 99-1/2" hat channel sections along both sides of the frame, cut 8"-10" pieces of repair tape (109023) and tape over each hat channel overlap seam to protect the liner (C). Take two (2) 47-1/4" hat channel (10852904725D) sections and bend the pre-drilled anchor tab up at a 90 angle using a pliers or similar tool. See diagram D below. C Continue by attaching the 47-1/4" hat channel sections (E) to the frame using Tek screws as shown below. The lip of the channel faces toward the inside of the bed as shown in the diagrams below. E Using the 109023 repair tape, tape hat channel connection as shown. C Bend anchor tab up at a 90 angle. D Take 47-1/4" hat channels (C), align with 99-1/2" hat channel, and secure in place using FA4482B Tek screws. E 7
Assembly Instructions 4 Repeat Step 3 to attach the next set of hat channel sections. NOTE: Position the bottom edge of the hat channel against the top edge of the installed hat channel as shown in the diagrams. Install so little or no gap exists between the parallel runs of hat channel. Take 99-1/2" hat channel, rest the edge on the lower channel, and secure in place using FA4482B Tek screws. Overlap sections of 99-1/2" hat channel and center on the frame. Secure to the mid pipes using Tek screws. Drill new holes if holes do not align. Cut 8" -10" pieces of repair tape (109023) and tape the overlap seams to protect the liner. Take 47-1/4" hat channel, align with 99-1/2" hat channel, and secure at each end using FA4482B Tek screws. 8
Assembly Instructions 5 With the lower frame assembled, install the liner as shown in the photos. Each liner is shipped larger than what is required to complete a bed. After the installation, the excess material can be trimmed as needed. Before you begin, clean the surface that will support the underside of the lower bed. Check the frame and tape any areas that could rub on or damage the liner. ASSISTANCE IS REQUIRED TO PROPERLY INSTALL THE LINER. Fold the liner into the lower frame as shown below. The liner rests on the ground when properly set in place. Fold corners upward to prevent leaks. Keep the liner square with the frame. Place the first section of 105932096 strap against the liner and flush against the edge of the hat channel. Be sure to position the fold edges under the strap to anchor in place. Secure the strap to the hat channel frame using FA4482B Tek screws. Repeat the steps to attach the remaining sides of the lower bed using the Tek screws and aluminum strap. Evenly shape the liner in the bed frame as you secure the liner in place. Bottom of the liner must remain on the ground. Trim liner material as needed if desired. Fold the corners so that the loose edges are secured to the frame using the aluminium straps and Tek screws. 9
Assembly Instructions 6 With the lower liner installed, install the end braces, mid braces, and hat channel for the upper bed. To protect the liner from debris and tools, use customersupplied panels to cover the lower bed. At each end brace, measure 31" up from top of each corner fitting and mark the location on the side of each corner pipe. Gather two (2) 48" pipes (A) and slide a 10015708 long tee onto each end. do not slide the pipe too far into the fitting. Position set screws as desired. A C With assistance, slide one (1) end brace onto each set of 48" corner pipes and align the lower edge of the long tee fittings with the marks on the pipe. Verify that each end brace is level and tighten all set screws to secure the braces in position (A). B A 31" With the end braces level, repeat the steps to install the mid brace supports (B). Stretch a string line from end brace to end brace to set the height of each mid brace. Secure each fitting to the mid post by drilling a Tek screw through each set screw as shown below. CORRECT Verify that the corner posts are plumb and attach the first run of 99-1/2" side hat channel (C) for the upper bed. Rest these against the tops of the long tee fittings and secure using FA4482B Tek screws. Overlap and tape the seam as needed. A END BRACE Actual frame may differ. A 16' frame is shown. Typically, frames are divided into 8' sections. Longer frames will include additional mid supports (B). drill Tek screws into set screws to secure end and mid braces. Secure hat channel in place using Tek screws. Check that the side hat channel runs are level. TEK SCREw TEK SCREw INCORRECT 31" MARK B 10
Assembly Instructions 7 To install the bed support hat channel, find the center of each end and mid brace pipe and center the first section of hat channel over the center mark. Secure using Tek screws. See diagram A. Verify that the pre-drilled holes in the hat channel at each end brace (A) are aligned with the center of the end brace and secure with Tek screws. B Overlap the individual sections of hat channel at each mid support, secure with Tek screws, and tape the overlap seam using the supplied 109023 tape to protect the liner. (See Section 3 if needed.) Align holes of the hat channel at each mid support if possible. Minor differences in the assembly process may cause holes to become misaligned. Drill new holes if needed at the mid braces where the hat channel sections overlap and tape seam. See diagram B. Continue to attach the remaining sections of bed support hat channel until all sections are secure and all overlap seams are taped. Space these sections evenly between the corner post and the center run of hat channel as shown. Hat channel sections will run parallel to each other. Find center of pipe. A A Centerline B Bed Support Hat Channel CENTER MARK 11
Assembly Instructions 8 Prepare the 47-1/4" hat channel sections by bending the pre-drilled anchor tab upward at 90. Attach each section to the installed side hat channel using Tek screws as shown below. The lip of the hat channel faces toward the inside of the bed. Bend anchor tab up at a 90 angle. Take 47-1/4" hat channels (A), position onto the frame, and secure in place using FA4482B Tek screws. 12
Assembly Instructions 9 Repeat previous steps as needed to install the remaining hat channel for the upper bed. ATTENTION: For the upper bed, install the hat channel sections so a space remains between the upper and lower runs of hat channel. Bed depth is 8" and is measured from the tops of the bed support hat channel to the mounting lip of the upper run of hat channel. See diagrams below. Place a post cap (A) on each corner pipe and secure in using a Tek screw for each cap. A Take the 99-1/2" hat channel, position as shown below, and secure in place using FA4482B Tek screws. Verify that bed depth is 8". Install the 47-1/4" hat channel sections (B) and secure in place using FA4482B Tek screws to complete the upper frame. Place a post cap (A) on each corner and mid pipe and secure in place using FA4482B Tek screws. A BED DEPTH: UPPER FRAME Measure bed depth from top of bed support hat channel to the mounting lip of the side frame hat channel. Space hat channel runs as needed to achieve the 8" bed depth. 8" 13
Assembly Instructions 10 With the upper frame installed, repeat the steps to install the upper bed liner. Check the frame and tape sharp edges that could damage the liner. ASSISTANCE IS REQUIRED TO PROPERLY INSTALL THE LINER. Fold the liner into the upper frame as shown below. The liner rests on the bed support hat channel when properly set in place. Fold corners upward to hold water in the bed. Keep the liner square with the frame. Place the first section of 105932096 strap against the liner and flush against the edge of the hat channel. Be sure to position the folded liner edges under the strap to anchor in place. Secure the strap to the hat channel frame using FA4482B Tek screws. Repeat the steps to attach the remaining sides of the bed liner using the Tek screws and aluminum strap. Evenly shape the liner in the bed frame as you secure the liner in place. Bottom of the liner must rest on the bed support hat channel. Trim liner material as needed if desired. After the assembly is complete, remove all debris and metal shavings from the bed liners before use. Do not move the assembled bed frame. Check all connections to verify they are tight. 14
Quick Start Guide (Sample 16' Frame) 105941 96" Pipe Insert pipes into the side outlet fitting as shown until seated. Vertical pipe is flush to the bottom of the fitting. Tighten the set screws. Repeat steps for remaining center pipes. ATTENTION: Frames are constructed in 8' increments. The 16' model is used throughout this guide as an example. 105941 96" Pipe Consult the 24' and 32' Frame diagrams later in this guide to view those frames. Assembly steps are similar regardless of frame length. 10015508 96" Pipe Gather a 96" pipe and a 48" pipe. Assemble as shown below using 10015508 corner fitting. Tighten the set screws to keep the fittings in position. When attaching the corner fittings to pipe, do not slide the pipe too far into the fitting. Allow room to insert the vertical pipe. Use a pipe to set clearance if desired. Insert a 48" pipe into the corner fitting as shown until seated tightly in place. Tighten the set screw. Repeat steps for remaining corner pipes. If the pipes are not seated properly into the fitting properly, loosen set screws and realign pipes so the corner pipes seat to the bottom of the fitting. Retighten set screws. 10015508 CORRECT INCORRECT 96" Pipe 15
Quick Start Guide The lower liner will touch the ground when properly installed. (Upper liner rests on the bed support hat channel.) Fold corners upward and secure under the aluminum strap to prevent leaks. Keep the liner square with the frame during the installation. Liner not shown. Assistants are needed to attach the hat channel to the frame pipes. Take 99-1/2" hat channel, position flush with the top edge of corner fitting, and secure in place using FA4482B Tek screws. Take 47-1/4" hat channel, align with 99-1/2" hat channel, and secure in place using FA4482B Tek screws. Repeat steps to attach the second run of hat channel. Fold liner in the lower bed and fold corners upward to prevent leaks. Keep liner square with the frame. Secure liner flush against the edge of the hat channel using the pre-drilled aluminium strap and Tek screws. B TEK SCREw TEK SCREwS STRAP 16
NOTE: Using customer-supplied materials, cover the lower bed to protect the liner from falling debris and metal shavings. On each corner pipe, measure 31" up from top of the corner fitting and mark the location on the side of the corner pipes. Assemble and install the end braces. Mark the center of each end brace pipe and install the bed support hat channel. Evenly space the bed support hat channel. Quick Start Guide Assemble a end brace by sliding a 10015708 long tee onto each end of a 48" pipe. Repeat step for remaining side brace. do not slide the pipes too far into the fitting. Allow room for the corner pipes to be inserted. 31" Evenly spaced Slide end brace onto the corner pipes and align the lower edge of the long tee fittings with the 31" marks. Tighten the set screws to keep the braces in position. With the end braces level, secure each fitting in place by drilling a Tek screw through each set screw to secure the fitting to the corner posts. Attach two (2) sections of 99-1/2" hat channel to the corner posts above the lip of the tee fittings and secure in place using FA4482B Tek screws. Using 99-1/2" hat channel for the bed supports, evenly space the sections on the end and mid braces and secure in place using FA4482B Tek screws. 48" PIPE 10015708 HAT CHANNEL TEK SCREw TEK SCREw Inside of bed 31" MARK Evenly spaced 17
Quick Start Guide NOTE: For the upper bed, space the side runs of hat channel as needed to create a bed depth of 8". Bed depth measures from the top of the bed support hat channel to the lip of the top run of side hat channel where aluminum strap is secured. Fold the corners of the liner upward and secure using aluminum strap to prevent leaks. Evenly shape the liner with the bed frame as you secure the liner in place. Trim the liner edge as needed if desired. Secure upper bed frame hat channel in place using FA4482B Tek screws. Upper bed depth is 8". Place a post cap on each vertical pipe and secure in place using a Tek screw. Carefully place the liner onto the upper bed frame and evenly pull into place. Upper bed frame shown below. Secure liner flush against the edge of the hat channel using aluminum straps and FA4482B Tek screws. FA4482B 106487 FA4482B FA4482B STRAP 8" 18
Frame Diagram 109314 (4' x 16') ATTENTION: To prevent damage, do not move the assembled frame. Remove all debris and metal shavings from both beds before use. 19
Frame Diagram 109315 (4' x 24') ATTENTION: To prevent damage, do not move the assembled frame. Remove all debris and metal shavings from both beds before use. 20
Frame Diagram 109316 (4' x 32') ATTENTION: To prevent damage, do not move the assembled frame. Remove all debris and metal shavings from both beds before use. 21