113532 GT80 Series Fodder & Microgreen System "...grow your own nutrient-rich fodder..." STK# DIMENSIONS 113532 36" W x 40" H x 63" L* 2018 FarmTek All Rights Reserved. Reproduction is prohibited without permission. Revision date: 9.21.18 *Dimensions have been rounded and are approximate. Dimensions are of frame only; they do not include adjustable feet or pvc plumbing and fixtures. Actual system may differ. 1
Important Information READ THIS DOCUMENT BEFORE YOU BEGIN Thank you for purchasing the GT80 Series Fodder and Microgreen system. When properly assembled and maintained, this system will provide years of reliable service. This guide includes information needed to safely assemble and maintain the system. Read these instructions before you begin. SAFETY PRECAUTIONS Wear eye protection. Wear gloves when handling metal tubes. Use a portable GFCI (Ground Fault Circuit Interrupter) when working with electric power tools and cords. REQUIRED TOOLS The following list identifies the main tools needed to assemble the system. Additional tools and supports may be needed. Tape measure and marker Variable speed drill to drive Tek screws and drill holes in drain pvc 9/32" and 5/16" drill bits 2' to 3' level Wrench set or ratchet with 1/2" socket to assemble frame 3/16" hex (Allen) wrench Adjustable pliers and small hammer Tool to cut pvc tubing 1", 1-3/8", and 5" hole saw bits ASSEMBLY PROCEDURE This manual describes how to assemble the 113532 GT80 Series system. The steps outlining the assembly process are as follows: 1. Unpack the contents of the shipment and place where you can easily inventory the parts. Refer to the Bill of Materials/Spec Sheets. 2. 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. 3. Read and understand these instructions and all additional documentation included with the shipment before you begin. 4. Gather the required tools. 5. For best results, assemble the components in the order they are presented in these instructions. ELECTRICAL WARNING! Frame is metal and will conduct electricity! Exercise caution if working around or on the frame with electric power tools. Use cordless, battery-power tools. CONSULT THE SERVICES OF A QUALIFIED ELECTRICAL TECHNICIAN WHEN INSTALLING TIMERS, ARTIFICIAL LIGHTING, OR OTHER ELECTRICALLY POWERED ACCESSORIES IF EQUIPPED. CAUTION! DO NOT CLIMB ON FRAME! TO PREVENT INJURY AND POSSIBLE DAMAGE TO THE SYSTEM AND RELATED COMPONENTS, NEVER CLIMB ON THE ASSEMBLED OR PARTIALLY ASSEMBLED FRAME. ATTENTION: CONSULT ALL DIAGRAMS AND THOSE NEAR THE BACK OF THIS GUIDE TO IDENTIFY CRITICAL DIMENSIONS, PART NUMBERS, AND PART LOCATIONS FOR YOUR GT80 SERIES SYSTEM. 2 113532 Revision date: 9.21.18
Important Information PICTORIAL GUIDE The following graphics and photos will help identify the different parts of the system. (Some parts may not be shown.) 106808 3/4" Hanger 112538 1" Hanger AC2804 112838 Tek Screw 111047 112770 111074 109242 111698 Ratchet Clamp WF1970 WF6692 WF3411 111045 111030 111029 111066R Channel FALB34B FAG338B FA4555B FAME51B 112772 Tek Screw 110729 110730 110829 Drill & Tap Combo Pak WF4790 (1) Key Punch 100442 Nut Setter WF1023 Y-Filter 112066 Shut-Off Valve 109170 112509 CA4000 Instant Adhesive WR1095 (1) 112477 110091 Clear Vinyl Tubing Revision date: 9.21.18 113532 3
Important Information PICTORIAL GUIDE (continued) PICTORIAL GUIDE continued When installing the plumbing, fully insert fittings into the 3/4" poly tubing. Secure each connection using the 111698 ratchet clamps. 110725 Air Pump 110721 Aqua Pump 109260 6" Air Stone 111623 PVC PRIMER & PVC CEMENT 111562 WF6990 PVC Cement and 113372 Purple Primer Follow all directions printed on pvc primer and cement containers. Purple color of primer does not fade! Use caution during application to reduce spills and over application at joints. Prime all joints before assembly. Install to here. Incorrect installation. Fully install tubing on each fitting. Correct. ATTENTION: During the installation of the 3/4" tubing, wet the ends of the tubing and the fitting for easier assembly. CC2652 111046 20 Gallon Reservoir Reservoir Cover Porthole Cover ATTENTION: Use pliers to gently squeeze ratchet clamps around tubing. 4 113532 Revision date: 9.21.18
1 ASSEMBLE FRAME Follow the basic steps noted below to assemble the frame. FT15G16L03600S3 FIGURE 1 Required parts: (4) FT15VMGL03600S1 (36" long) (4) FT15VMGL03600S2 (36" long) (4) FD15G16L03600S3 (36" long) 112772 Flat Head Bolt Bolt Holes (4) FD15CMGL02400S1 (24" long) (8) 112772 (5/16" x 3") Flathead Bolt (8) FAG338B (5/16" x 3") Hex Cap Bolt A FT15VMGL03600S1 (8) FAME51B (5/16") Flat Washers FT15VMGL03600S2 Complete these steps: B 1. Use Fig. 1 to construct Leg Assembly A. Secure using 112772 flathead bolts. These leg pipes do not include any bolt holes. FD15CMGL02400S1 2. Use Fig. 1 to construct Leg Assembly B. Secure using 112772 flathead bolts. Verify that the bolt holes in the leg pipes are positioned as shown. See double arrows. 3. Use Fig. 2 to connect the leg assemblies. Secure using the FAG338B (5/16" x 3") hex cap bolts and FAME51B (5/16") flat washers one per bolt. 4. Repeat the steps to assemble an identical frame section. FAG338B Hex Bolt and FAME51B Flat Washer FD15CMGL02400S1 FIGURE 2 Revision date: 9.21.18 113532 5
1 ASSEMBLE FRAME (continued) Install the adjustable frame leveling feet using these parts: (8) 112477 Leveler Insert (8) 113030S01 Adjustable Footer (8) FALB34B (3/8") Nuts (16) 112838 Tek Screws 112477 FALB34B Nut 113030S01 1. Twist one nut onto each 113030S01 footer until it meets the weld of the threaded shaft. 113030S01 2. Twist one adjustable footer into each of the 112477 inserts. 3. Slide one assembly into each leg of the frame. Secure each insert using two (2) 112838 Tek screws. Install the screws slightly off the center line of the leg tube to prevent contact with the threaded rod of the adjustable foot. Install screws into the insert and not the open side of the insert. 6 113532 Revision date: 9.21.18
1 ASSEMBLE FRAME (continued) Required parts: (2) 113532CP (Connection Plate) (4) FAG336B (5/16" x 2-1/2") Hex Head Bolts (8) FAME51B (5/16") Flat Washers Assembly Instructions (4) FALB02B (5/16") Nuts (6) 112770 Finishing Caps Complete these steps to connect the individual frame sections: 1. Position frame sections as shown and connect using two 113532CP connection plates and FAG336B (5/16" x 2-1/2") bolts, FAME51B flat washers, and FALB02B nuts. Turn leg tubes 90 if needed to align bolt holes with holes in connection plate. 2. Install one 112770 finishing cap in each horizontal frame tube. Gently tap into tube if needed. 113532CP 112770 FAME51B FAME51B FALB02B FAG336B 113532CP Do not tighten bolts at this time. Brackets must remain loose until the frame slope is set. 3. Continue with the next procedure. Revision date: 9.21.18 113532 7
2 LEVEL FRAME AND SET FRAME SLOPE When properly set, each frame section slopes 1/4" to 1/2" toward the connection plate where the 4" drain tube will be installed. This ensures proper water flow, distribution, and drainage. Use the adjustable levelers to first level the frame, then to set the 1/4" to 1/2" slope. Review the diagrams on this page and complete these steps: Assembly Instructions 1. Position frame where the system will be in operation. Verify that the mounting bolts for the connection plates are loose. 2. Level the frame along all sides and the top using the adjustable levelers. Use a string line and level to check all areas. 3. With the frame level, secure a string line across the top as shown below. 4. Lower the inner legs (or raise the outer legs) as needed to achieve the 1/4" to 1/2" pitch toward the center. 5. Once the pitch is set, remove string line and check to ensure that the frame is level across the top. See End View below. 6. Tighten set nut on all adjustable levelers. Tighten all 5/16" bolts to secure the connection plate to the frame sections. Level 1/4" to 1/2" String Line Level STEP 6 Frame leveler and nut Front & Back View STEP 6 End View 8 113532 Revision date: 9.21.18
3 ASSEMBLE THE GT80 CHANNELS ATTENTION: Required parts: 111030 End Cap (plain) 9/32" Drill Bit and Drill Complete these steps to prepare the 111030 end caps: 111030 Complete this procedure for the 111030 plain end caps only. Do not drill holes in the 111029 end caps, which have an outlet. ATTENTION: Cover the vice jaws or use material to protect the end cap. 1. Gently clamp the 111030 end cap in a vice or similar device with the top, curved edge up. 2. Locate the middle of the end cap lip and mark the position using a pencil. 3. Evenly mark the remaining two hole positions. TOP BOTTOM 111030 End Cap 4. Using a drill and a 9/32" bit, carefully drill 5. Remove the loose end cap material from holes in the top lip of the 111030 end cap. the drilled holes. 6. Repeat the steps to drill all remaining 111030 end caps. Do not drill the 111029 end caps. Revision date: 9.21.18 113532 9
3 ASSEMBLE THE GT80 CHANNELS (continued) ATTENTION: Attach one 111029 end cap (with outlet) and one 111030 plain end cap to each GT80 channel. A B 1. Using the assembled frame as a bench, place one 30" channel (111066R) on the cross supports. 2. Take the 112509 adhesive and attach the plain end cap (no outlet 111030) to the channel. Coat the end of the channel with adhesive before you install the end cap. See photos A & B. Also, apply adhesive to the connection on the inside of the channel. See photo E. Repeat for all 30" channels. Apply adhesive in a well-ventilated area. Read the container information for additional precautions. 3. Next, attach the 111029 end caps (with outlet). Coat the channel end with adhesive before you install the end cap. See photos C & D. Also, apply adhesive to the connection on the inside of the channel. See photo E. Repeat for all 30" channels. 4. Carefully flip all 30" channels over so the bottom is facing up. Apply adhesive along the edges to secure and seal end caps to each 30" channel. Photo F shows an end cap with an outlet as an example. NOTE: Coat all edges and seams of the end caps to prevent leaks. C E D F 5. Allow the adhesive to dry before moving the channels or testing the system. 6. Continue by installing the 4" pvc drain tube. open top-inside channel bottom 10 113532 Revision date: 9.21.18
4 ASSEMBLE AND INSTALL 4" PVC DRAIN TUBE A 4" drain tube directs the nutrient solution from each NFT channel back to the reservoir. To prepare and install this drain tube, complete these steps: 1. Take the one 3' section of the 4" pvc drain tube and cut the following pieces from it: one piece at 10-1/2" and one at 20-1/2". 2. Dry fit the pieces into 4" drain pipe tee (111562) and center assembly between channels on frame. Each end of drain tube will sit on flat bar of frame; open end of tee fitting should point straight down. 3. Snap a chalk line down the center of the 4" tube (Fig. B) at the top. 4. Place cover on tank and center under frame (below). Align outlet of 4" tee with flat area on cover. Slide tube either direction as needed (Fig. A). ATTENTION: Position tee outlet so downspout (when installed) does not interfere with raised ribs on the cover. If needed, cover can be centered under frame on the floor to allow use of the remaining 4" pvc tube to gauge downspout position. Place gasket on cover if needed to gauge position of hole. 5. Mark the tube ends where they meet the frame to ensure realignment when tubes are moved (Fig. B). 6. Align first row of channels with frame tube. See dashed line in Fig. B. 7. Mark the tube and tee so these can be aligned before final assembly. 8. Mark the center of each GT80 channel on the 4" drain tube. Revision date: 9.21.18 113532 Step 4 ATTENTION: Diagram shows a cut-away view of frame as seen from the end. Half of the frame and channels are not shown. Fig. A Fig. B TOP VIEW SHOWING FRAME AND 4" TUBE Align channel edge with frame tube. GT80 Channel Evenly Spaced Center GT80 Channel Evenly Spaced GT80 Channel Align channel edge with frame tube. Step 6: Dashed line shows end of channel aligned with edge of frame tube. Step 8: Mark Step 8: Mark Step 8: Mark Tube Chalk Line (Step 3) Step 6 Step 5: Mark frame location on tube. Step 7: Mark tube so fitting can be aligned before it is sealed. Step 5: Mark frame location on tube. 11
4 ASSEMBLE AND ATTACH 4" PVC DRAIN TUBE continued 9. Take the "Hole Template for Drain Tube" page from the back of this guide, fold it, and cut out the 1-3/8" holes with a scissors. 10. Move the 4" tube assembly to a bench and place the template over the 4" tube. Align the center lines as noted on template and mark the center of each hole. Remove template and drill holes using a 1-3/8" hole saw bit and drill. Clamp or hold the 4" pipe in place while drilling holes. Use light pressure on the drill. Do not force bit. Keep hands away from bit during drilling. 11. Clean the 4" tube to remove pvc debris and set it on frame. Use the alignment marks made earlier to align the assembly on the frame. 12. Slide one 111045 drain elbow onto each channel outlet and slide each elbow into the 4" drain tube hole to check fit. Adjust as needed. 13. Remove drain elbow (111045) from each channel, apply pvc primer and cement, and slide elbows back onto channel end caps. 14. Disassemble the tee and 4" tubes, apply pvc primer and pvc cement, and reassemble. Use alignment marks and chalk line to reassemble. Set back on frame. 15. Add the CC2652 end caps (4") to the drain tube assembly. Do not cement. Caps are to remain loose to allow cleaning of the drain tube. Cement caps later if leaks occur. 16. Allow connections to dry and continue with next procedure. Bottom of Channel Step 13 111045 Elbow Step 13 CC2652 12 113532 Revision date: 9.21.18
5 ATTACH 1" HANGERS FOR NUTRIENT SUPPLY MANIFOLD Move to the supply ends of the frame and attach one (1) 112538 pipe hanger to each frame leg in the locations shown. Secure each hanger to the frame using one FA4555B Tek screw and the 100442 magnetic driver. Circles identify hanger position at one end of the frame. Do not overtighten the Tek screws. Verify that you have selected the correct hangers. Use the 112538 hangers for 1" pvc pipe. Supply End Top View of Assembled Frame Supply End FA4555B (4) Tek Screw 112538 Hanger 5" 5" Complete these steps: 1. At one end of the frame, measure 5" down from the cross tube and mark the center of leg tube. 2. Slide the 112538 hanger over the FA4555B Tek screw and attach hanger to the frame. NOTE: Before the screw is tight, align the hanger on the frame to prepare for the manifold installation. Tighten the screw. Do not strip the threads. 112538 Pipe Hanger 3. Repeat the steps to install the remaining pipe hanger. 4. Move to the other end and install the remaining two 112538 1" pipe hangers. 5. Continue with the next procedure. Supply End Revision date: 9.21.18 113532 13
6 ASSEMBLE NUTRIENT SUPPLY MANIFOLDS AND ATTACH TO FRAME Complete these steps: 1. Take one WF4135Z3 (1" x 36") pvc tube and cut it to 33". 2. Slide a WF6692 elbow onto each end of the pvc pipe. Do not cement at this time. 3. Wrap the threads of the 111074 fittings a few times with WR1095 thread tape. Wrap in a direction that will not unwrap when you thread it into the WF6692 elbow. 4. Thread one 111074 fitting into each WF6692 elbow and tighten slightly until snug. 111074 WF6692 The WF6692 elbow includes a threaded end to accept the 111074 fitting. 5. Move to the frame and snap the supply manifold into the 1" hangers. Center the manifold as shown below. 6. Mark the hanger positions on the pvc tube so it can be reinstalled in the same position. Drain End of Manifold 7. Repeat procedure for the remaining supply manifold. 8. Continue with the next procedure. Mark position on pvc. Supply End of Manifold Supply Manifold 14 113532 Revision date: 9.21.18
7 DRILL HOLES TO INSTALL THE 109242 ADAPTERS Complete these steps: 1. Verify that all channels are in the correct positions on the frame. 2. Snap a chalk line along the pvc tubes to identify the center. Use non-permanent chalk so it can be removed later. 3. Verify that channels are in the desired position and mark three (3) hole locations on the supply manifold for each NFT channel. Align holes with the holes in the end caps. 4. Carefully remove a manifold using a small screwdriver to release the jaws of each hanger. 5. Take the drill bit from the 110829 tap and drill combo pak and drill a hole in the manifold at each mark. Clamp tube in a small vice if possible. Drill nine (9) holes for each manifold. After drilling, remove bit from the drill. 6. Take the tap from the combo pak and lock it squarely in the chuck of a reversible, variable speed drill. Carefully and slowly tap threads in each hole drilled in previous step. ATTENTION: Use a reversible, variable speed drill for this step! If one is not available, use a socket to hold the tap and turn it with a ratchet. Center the tap in the hole and turn it slowly to tap the threads. Do not allow the tap to bottom out and contact the inside wall of the pvc tube. Once the threads are tapped, slowly back the tap out of the hole being careful to keep the tap straight. 7. Remove the elbow assemblies for the pvc tube ends and clean the tube. 8. Repeat procedure for the remaining supply manifold. 9. Continue with the installation of the 109242 adapters. Chalk line To maintain hole alignment, snap a chalk line from one end of the manifold tube to the other. Use non-permanent chalk. Tighten tap in drill chuck. After drilling all holes, remove drill bit and use the tap tool to tap threads in the holes. Slowly turn tap into hole, stop before tap bottoms out on inside of tube, and reverse drill to back tap out of hole. Keep drill steady and straight during the process. Clamp pvc tube in place to prevent mistakes when drilling. 110829 Drill & Tap Combo Pak Revision date: 9.21.18 113532 15
8 INSTALL THE 109242 ADAPTERS 1. While holding the barbed end of an adapter, wrap the threads 3-4 times with WR1095 thread tape. Wrap in a direction that will not unwind when installed. 109242 2. Carefully twist the adapter into the manifold. 3. Use the WF4790 key punch tool to gently turn the adapter until slight resistance is felt. ATTENTION: To prevent stripping of the treads or breaking the adapter, do not overtighten! Using your fingers, gently turn the adapters into the manifold. Next, use the installation tool to turn the adapter until slight resistance is felt and stop! Adapters will break if too much force is applied. 4. Repeat these steps to tape and install all remaining 109242 adapters. 5. Next, snap tube into hangers. Align marks on tube with each hanger. 6. Apply pvc primer and pvc cement to each end of the pvc supply manifold and reinstall elbows. Position elbows as shown below and on page 14 with the drain elbow pointing down and the supply elbow pointing toward the center of the frame. Allow cement to set. WF4790 Key Punch WR1095 Teflon Tape WF6990 PVC Cement and 113372 Purple Primer Apply tape to adapters. Install adapters using WF4790 key punch. Drain End Primer and Cement Supply Manifold Installed Primer and Cement Supply End 7. Repeat procedure for the remaining supply manifold. 8. Continue with the next procedure. Apply pvc primer and cement to both ends of supply manifolds and install elbows. 16 113532 Revision date: 9.21.18
9 INSTALL THE SUPPLY MANIFOLD DRAIN LINES Using the photos, diagrams, and notes on this page, install the AC2804 drain valve: 1. Using the 109170 tube cutter, cut a 3" to 4" section of 111627 (3/4" poly tube) and slide it onto one end of the AC2804 in-line valve. Wet the end of valve for easier installation. See page 4 if needed to fully install tubing onto fittings. 109170 111698 Ratchet Clamp AC2804 2. Slide two (2) 111698 ratchet clamps over the tube and slide the valve and tube assembly onto the fitting at the end of the supply manifold. See diagram at the right. 3. Reposition the clamps as needed and use a pliers to gently squeeze ratchet clamps around tubing. 4. Repeat steps to attach the AC2804 valve to the remaining supply manifold at the other end of the frame. Supply Manifold Installed Drain End 3"- 4" Verify that all fittings are fully inserted into the 3/4" tubing. Use a hair dryer to heat the tubing, or wet the end of the valve for easier installation. Do not overheat the tubing! Revision date: 9.21.18 113532 17
10 PREPARE RESERVOIR COVER Drill the 5/16" Holes for Air Pump Tubing 1. Take a 5/16" drill bit and drill two holes through the raised area of the cover. See photo below for location. Air Tube Holes x x x Supply Tube Hole ATTENTION: Actual cover may differ from the example shown. Actual cover may differ slightly from what is shown in this example. ATTENTION: X marks hole locations based on reservoir design and position. Drill the 1" Hole 2. Remove all debris from the cover and around all holes to prevent it from dropping into the reservoir when cover is set in place. A x B Drill the 1" Hole for Supply Tube from Pump 1. Locate the center of the porthole opening in the cover. See the X in the photo to the right (A). 2. Using a 1" hole saw, drill the hole for the supply tube from the pump. Drill this hole at the edge of the porthole. See photo B & C for clarification. Mark location. Drill 1" hole. NOTE: Do not drill cover over the reservoir. Move to a separate set of supports during drilling. C D 3. Using a hand saw or similar tool, carefully remove material between the porthole and 1" hole (C). 4. Clean cover to prevent contamination of nutrient solution when reservoir is filled. 5. Continue with the next procedure. Remove lip. Remove debris. 18 113532 Revision date: 9.21.18
11 COMPLETE 4" PVC DRAIN ASSEMBLY Drill Hole for the 4" Drain Tube 1. Use the 4" tee as a guide to determine gasket position on reservoir cover. Place cover on the floor centered under the frame if needed to gauge location. Center gasket on the cover in the recessed area and mark the location. 2. Drill the drain hole using a 5" hole saw. Do not drill cover over the reservoir. Debris will damage the pump and clog filters. 3. Once hole is drilled, install the 111623 gasket in the cover. 4. Place cover on the reservoir and slide reservoir under the frame as shown. 5. Determine required length of 4" vertical drain tube and cut to length. Tube should extend through gasket and into the cover 2"-3". End of tube should remain above the nutrient level when reservoir is filled. 6. Install the 4" drain tube. If needed, lift the 4" drain manifold from the system for easier assembly. Wet the lower end of the 4" tube to slide it into the gasket when setting the drain manifold assembly back on the system. ATTENTION: To better service the reservoir, do not cement the 4" tube to the tee fitting. Gasket should hold tube in place. Check frequently to ensure placement. If leaks are noticed or tube works loose, prime and cement tube to tee fitting as needed. Supply fittings are installed in the next procedures. 111623 7. Continue with the next procedure. ATTENTION: Diagram shows a cut-away view of the frame as seen from the end. Half of the frame and channels are not shown. Revision date: 9.21.18 113532 19
12 ASSEMBLE FILTER, PUMP, AND MAIN SUPPLY LINE 1. Attach two (2) 106808 3/4" hangers to the supply manifold side of the frame using FA4555B Tek screws. Measure 5" down from tube. Consult diagram at the right for location. Step 1 2. Assemble the supply tubes, filters, and related fittings. Wrap all threads with thread tape before assembly. Verify you have installed filters according to arrow on filter housing indicating direction of water flow. See diagrams. 106808 106808 5" 3. Attach assembly to the 1" pvc tubes at each end and snap into the 3/4" hangers. 111074 WF3411 111074 Steps 2 & 3 WF1023 WF1970 112066 111698 3/4" Poly Tubing 3/4" Poly Tubing WF3411 111698 WF1970 (cut to length) (cut to length) WF1970 111698 111074 3/4" Poly Tubing (cut to length) 111074 AC2804 AC2804 111074 3/4" Poly Tubing 110730 (cut to length) 20 113532 Revision date: 9.21.18
12 ASSEMBLE FILTER, PUMP, AND MAIN SUPPLY LINE (continued) 4. Using the fittings, 3/4" tubing, and 109170 tube cutter assemble and install the vertical supply line that connects the water pump to the horizontal supply line. NOTE: Consult the diagrams and photos on this page. Cut the 3/4" tubing to the required length for proper assembly. 5. Install the 3/4" fitting in the pump housing according to the manual sent with the pump. 6. Attach assembled 3/4" vertical supply tube to the pump, secure with a ratchet clamp, and set pump into the reservoir through porthole in cover. 7. Attach the remaining end of the supply tube to the tee fitting installed in the horizontal supply tube assembly. Secure with ratchet clamp. 8. Continue with the next procedure. WF3411 111698 Ratchet Clamp 110729 Consult guide included with the pump for pump fitting installation. 111074 110722 Utility Pump 110729 111074 WF3411 111698 3/4" Poly Tubing (cut to length) View of Vertical Supply Tube from End of System Revision date: 9.21.18 113532 21
13 ATTENTION: Always position the air pump above the nutrient level to prevent siphoning of the reservoir. ATTACH THE AIR PUMP AND AERATOR STONES For optimal system performance and to extend the life of the nutrient solution through increased oxygenation, an aerator pump and aerator stones are included. Position stones at the bottom of the reservoir opposite the water pump. Air pump must remain above nutrient level to prevent siphoning. 109170 110091 Clear Vinyl Tubing 1. Cut the 110091 vinyl tubing in half using the 109170 tube cutter. ATTENTION: Position the air pump at a level that is above the nutrient level at all times to prevent siphoning of the reservoir. 2. Attach one stone to each tube and slide the stones in the reservoir. See photo for stone position opposite the water pump. 3. Feed the free end of each tube up through the access holes and connect each to the air pump. Actual cover may differ from the example shown. Attach 110091 tube to air stone. 109260 Air Stone 4. Place the air pump in the position chosen in Step 1. 5. Connect air pump to power and test the operation. Verify that air is filtering through each air stone. Monitor air pump regularly to ensure proper operation of the aerator system. View from inside the reservoir. Actual reservoir may differ. NOTE: When the system is fully operational, the air pump must run continuously. Do not connect the air pump to any circuit controlled by a timer or shutoff switch. 6. After testing air flow, turn off the aerator pump until the system is fully functional. 22 113532 Revision date: 9.21.18
14 CUT AND INSTALL THE 1/4" MICRO TUBES Complete these steps: 1. Using the 109170 tube cutter, cut a section of 111046 (1/4") micro tubing (not to exceed 20") to determine how long you want each 1/4" supply tube to be. ATTENTION: Use photos and diagram to decide where you want micro valve positioned in each supply tube for a uniform look. Location of micro valve in each supply tube should allow easy access to operate valve once installed. 2. Cut tube from Step 1 into two pieces length may differ depending on valve position and add 111047 micro valve. Check the fit on the system by holding the tube next to where it will be installed. 3. Adjust tube length and valve position as needed and create the remaining tube and valve assemblies by using the first one as the template. 4. Install each tube by sliding one end onto one 109242 adapter and inserting the remaining free end into the drilled hole of the 111030 end cap directly above that adapter. Wet the adapter and tube for easier installation. 5. Test the system. See steps on the next page. Revision date: 9.21.18 113532 23
Start-Up Steps, Basic Maintenance & Growing Tips Start-Up Procedure Basic Maintenance After assembly, complete these steps to check the system before operation: 1. Ensure that the drain elbow of each channel is inserted into the 4" drain tube. 2. Check that the 4" vertical drain tube is inserted through the gasket in the reservoir cover. 3. Verify that the AC2804 in-line valve at the drain end of each 1" pvc manifold is closed. 4. Open each AC2804 valve positioned near the Y-filters. 5. Close the shut-off valves at the end of each Y-filter. 6. Check that each 1/4" micro tube and valve assembly is inserted into the end cap of the GT80 channel. 7. Open all micro valves in the 1/4" micro tubes. 8. Verify that no electrical cords are inside the reservoir. 9. Fill reservoir with water until water pump is submerged. 10. Plug in the air pump to ensure air is flowing through each stone. 11. Plug in the water pump to circulate water throughout the system. 12. Check all fittings and channel end caps for leaks. Repair as needed. 13. Check all 1/4" micro tube and adapter connections to ensure none are leaking. 14. Check drain tube connections and caps for leaks. Seal as needed. 15. Monitor the flow of water through the trays. Adjust frame pitch if needed or level frame if water flows to one side of the channels. Water should flow evenly and consistently throughout all channels. 16. After making the necessary adjustments, the system is ready for production. This system requires regular maintenance and cleaning. The duration between the maintenance and cleaning sessions, however, depends on how and where the system is used and what seeds are grown. The only way to determine a regular maintenance and cleaning schedule is to closely monitor your system once it is fully functioning. A clean system increases production and reduces loss due to mold and other harmful factors. Below are a few suggestions to help maintain and clean the system: Check all fittings to ensure there are no leaks. Repair or replace damaged parts immediately. Seal all leaks when found. For best results, clean and disinfect the channels after each harvest. System is designed so channels can be removed and cleaned. Use a 10:1 mixture (water/bleach) to disinfect the channels when cleaning. Rinse thoroughly to remove the cleaning solution before reseeding the channels. Store and prepare seeds in an area that is separate from the operating system if possible. General Growing Tips Despite the factors that must be addressed before you begin using your system, these general tips will help you get started: Water Quality: Clean water is a must. If you can t drink it, don t use it. If you are not sure about the water quality, have it tested. Water Temperature: Keep the water temperature constant and in the range suitable for the seed or grain you are using. Seed Quality: While it may cost slightly more, good quality, clean seed will save time. You won t have to clean the seed, or worry about foreign objects in the seed. Climate Control: A properly maintained environment is a must. Ensure you have controls in place to automatically control temperature and humidity. Additionally, do not rely solely on automatic equipment; ensure you are physically monitoring the environment daily and make adjustments if needed. Keep the System Clean: Follow the cleaning guidelines presented in this guide. 24 113532 Revision date: 9.21.18
Filter Cleaning Steps Clean the Filter Screen and Housing Regular cleaning of the filter is recommended to ensure proper flow. Filter should also be cleaned after cleaning the reservoir to remove sediment. When a reduced flow rate is noticed, follow these steps to clean the filter and filter housing. ATTENTION: SYSTEM SHOWN MAY DIFFER FROM ACTUAL SYSTEM. FILTER ASSEMBLY IS THE SAME. STEPS FOR CLEANING THE FILTER ARE THE SAME. Flow 1. Turn off the nutrient pump. 2. Grip the filter housing and the main supply line and unscrew the housing. Do not apply force to the filter or the supply line fittings. Hold these steady when disassembling the filter. 3. Remove the screen from the housing. Using clean water, rinse the housing and the screen. 4. Insert the screen back into the housing, reassemble the filter, and close the valve. 5. Turn on the pump and check the flow from the supply tubes to each bucket. 6. Check filter for leaks. Revision date: 9.21.18 113532 25
Frame Assembly Diagrams Full Frame Top View Front & Back View End View 26 113532 Revision date: 9.21.18
Additional Diagrams & Photos Drain Manifold Location 4" Drain Manifold (above) Full System Revision date: 9.21.18 113532 27
Additional Diagrams & Photos 112538 1" Hanger 111047 111074 109242 111698 Ratchet Clamp Supply Manifold with Supply Tubes to Channels AC2804 WF6692 30" Tray 111046 111047 WF6692 111074 1" PVC 111698 3/4" Tube AC2804 109242 112538 WF6692 28 113532 Revision date: 9.21.18
Additional Diagrams Supply Manifold with Supply Tubes to Channels Front View Revision date: 9.21.18 113532 29
Additional Diagrams Complete System 30 113532 Revision date: 9.21.18
Hole Template for Drain Tube Revision date: 9.21.18 113532 31