ClearSpan Premium Solar Star 104918 User manual

Premium Solar Star™
Home-Attached Greenhouse
Assembly Instructions
SKU# 104918
©2006 ClearSpan™
All rights reserved. Reproduction without permission is prohibited.
Revision date: April 2006g

YOU MUST READ THIS DOCUMENT BEFORE YOU
BEGIN TO ASSEMBLE THE GREENHOUSE.
Thank you for purchasing this ClearSpan™ Greenhouse.
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 greenhouse.
Please read these instructions before you begin.
SAFETY PRECAUTIONS
• Wear eye protection.
• Wear head protection.
• Wear gloves when handling panels.
• Use a portable GFCI when working with power tools
and cords.
• Do not climb on the greenhouse or framing during or
after construction.
• Do not occupy the greenhouse during high winds,
tornadoes, or hurricanes.
• Provide adequate ventilation if the structure is
enclosed.
• Do not store hazardous materials in the greenhouse
without proper ventilation.
• Provide proper ingress and egress to prevent
entrapment.
ANCHORING INSTRUCTIONS
Prior to assembling this greenhouse, please read the
MUST READ document included with the shipment.
WARNING: The anchor assembly is an integral part of
the greenhouse construction. Improper anchoring can
cause greenhouse instability and failure of the structure
to perform as designed. Failing to anchor the
greenhouse properly will void the manufacturer's
warranty and can cause serious injury and damage.
ATTENTION: Strong winds will cause the greenhouse to
shift if it is not adequately secured to the site.
The site on which the greenhouse was constructed will
determine the anchoring method that is required.
Consult a professional contractor to determine the best
and safest way to anchor the greenhouse.
Contact your sales representative at 1-800-245-9881 for
anchoring suggestions.
WARNING: To prevent property damage and serious
personal injury, the assembled greenhouse must be
anchored to the site.
LOCATION
Choosing the proper location is an important step before
you begin to assemble the greenhouse. The following
suggestions and precautions will help you determine
whether your selected location is the best location.
• This greenhouse has a metal frame. NEVER ERECT
THE GREENHOUSE UNDER POWER LINES.
• Identify whether underground cables and pipes are
present before preparing the site or anchoring the
greenhouse.
• Location should be away from structures that could
cause snow to drift on or around the greenhouse.
• Do not position the greenhouse in a place where
large loads such as snow and ice, large branches, or
other overhead obstacles could fall.
SITE
After choosing a location, proper preparation of the site
is essential. The following site characteristics will help
ensure the integrity of the greenhouse.
• The site must be level to properly and safely erect
and anchor the structure.
• If the site is not level, use footings to provide a
secure, level base to assemble the structure. Pre-
cast concrete blocks, pressure-treated wood posts,
or poured footings are all acceptable when properly
used.
• Drainage: Water draining off the structure and from
areas surrounding the site should drain away from
the site to prevent damage to the site, the structure,
and contents of the structure.
WARNING: The individuals assembling this structure
are responsible for furnishing all temporary bracing,
shoring and support needed during the assembly
process. For safety reasons, those who are not familiar
with recognized construction methods and techniques
must seek the help of a qualified contractor.
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ASSEMBLY PROCEDURE
Following the instructions as presented will help ensure
the proper assembly of your greenhouse. Failing to
follow these steps can result in an improperly assembled
and anchored greenhouse. The steps outlining the
assembly process are as follows:
1. Verify that all parts are included in the shipment.
Notify Customer Service for questions or concerns.
2. Read these instructions, the MUST READ
document, and all additional documentation included
with the shipment before you begin assembling the
greenhouse.
3. Gather the tools, bracing, ladders (and lifts if
applicable), and assistance needed to assemble the
greenhouse.
4. Re-evaluate the location and site based on the
information and precautions presented in the
documentation included with the shipment.
5. Prepare the site (if this has not been completed).
6. Assemble the base frame and greenhouse
components in the order they are presented in these
instructions.
7. Anchor the greenhouse.
8. Read the Greenhouse Care and Maintenance
information at the end of these instructions.
REQUIRED TOOLS
The following list identifies the main tools needed to
assemble the greenhouse.
• Tape measures or measuring devices
• Variable speed drill (cordless with extra batteries
works best)
• Hammers and gloves
• Metal Snips or similar tool to cut flashing
• Adjustable pliers and self-locking pliers
• Ladders and/or work platforms
• Adjustable Clamps to clamp panels together during
installation.
Additional tools and supports may be needed depending
on the structure, location, and application.
UNPACK AND IDENTIFY PARTS
The following steps will ensure that you have all the
necessary parts before you begin to assemble the
greenhouse.
1. Unpack the contents of the box and place them
where you can easily inventory the shipment. 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 for clarification, or contact customer
service.
NOTE: At this time, you do not need to open the plastic
bags containing the fasteners.
WARNING: FLASHING IS SHARP! USE GLOVES
WHEN HANDLING AND DURING ITS INSTALLATION.
PANELS ARE HEAVY. USE CAUTION AND
ASSISTANCE WHEN LIFTING AND DURING
INSTALLTION.
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The following graphics help to identify the different parts and show how they are used. (Not all parts are shown.)
Steel frame with corner bracket. View shows the inside of the greenhouse.
A-Angle (104642) to secure steel Neo-Bonded washers Roof Support Plates
frame to recycled plastic base and Tek Screws
(if recycled plastic base is used).
Pictorial Parts Guide
Not all parts are shown.
104645 3" x 3" Flat
Bracket
104639 Pass-
Through
Connector
104636
Corner Bracket
Panel Frame
Metal Frame
Recycled Plastic Base
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After all parts are identified, the site is prepared, and the
Must Read document is read, assemble the base for the
greenhouse. The following steps describe one way to
assemble the greenhouse.
RECYCLED PLASTIC BASE BOARDS
ATTENTION: The longer boards may exceed 96".
Measure and cut these to 96" if needed.
The front and back/open side base assemblies are
identical. Each includes two (2) lengths of plastic lumber:
• 1 section @ 44"
• 1 section @ 96"
The two end base assemblies are identical. Each
includes two (2) lengths of plastic lumber:
• 1 section @ 32"
• 1 section @ 96"
The boards for the recycled plastic base are positioned
end-to-end. The joints are not secured with any
brackets. See the following diagrams.
Back/Open Side
Front
NOTE: The front and back base boards are positioned
between (or to the inside) of the door and non-door end
base as shown to achieve the required length and width.
This base can be placed on the site before or after
assembling the metal base.
The metal base is attached to the plastic lumber base
using A-Angle brackets after the panels are secured to
the metal frame. This prevents placing the A-Angled
brackets in a position that interferes with the installation
of panel brackets.
ASSEMBLE THE METAL FRAME BASE
Locate the following brackets and tubes needed to
assemble the frame base:
Required tubes for each side/end:
Front and Back/Open: 1 length @ 48" (plain)
1 length @ 99" (swaged)
Door End: 1 length @ 25" (plain)
1 length @ 61" (plain)
Non-Door End: 1 length @ 27" (plain)
1 length @ 99" (swaged)
1. Assemble the metal frame as shown below:
NOTE: Do not seat the plain pipe tightly to the swaged
pipe. The separate pipes must be allowed to adjust
outward during assembly to allow proper panel fit.
Back (or Open) Side
Door End
104636 Corner Bracket
44"
32"
Door (or
Non-Door)
End Front Board
Non-Door
End
Front
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2. Secure the frame tubes at each corner using a
corner bracket and 3/4" Tek screws.
NOTE: To maintain the proper dimensions, the frame
tubes for the door and non-door ends must be seated
into the each corner bracket. See above and below
illustrations.
Top View of Frame Tubes and Corner Bracket
NOTE: If the metal frame was not assembled on the
recycled plastic lumber frame, set the metal frame on the
plastic frame base.
3. After assembling the metal base and securing it with
the corner brackets, choose the first two panels (as
shown in the following diagram) and set them on the
metal frame.
NOTE: Install the panels with the UV-protected
polycarbonate to the outside and the frame to the inside.
NOTE: The angled panel is installed first and is seated
into the corner bracket. The short, front panel is installed
next and is flush with the front of the angled panel.
View is from the inside of the greenhouse looking at the
corner where the panels meet.
4. With the panels set in the corner and the edges tight
together, secure the panels to the corner bracket
using 3/4" Tek screws.
5. Secure the corner with a 3" x 3" square plate.
NOTE: All 3" x 3" square plates are attached to the
greenhouse on the inside using self-tapping screws. See
the photo that follows.
Front (or Back) Frame
Door End
Base Frame
Door (or Non-Door)
Frame Tube
Front
Panel
Non-Door End Panel
Front
Panel
Door (or Non–
Door) End
Angled Panel Front Panel
Frame Base
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HINT: When installing panels, use a clamp at the top
and bottom corners (when possible) to clamp the panels
together before installing the flat brackets.
6. Position a pass-through connector in the locations
shown below, move to the remaining front corner
and install another angled panel and small, front
panel as shown below and secure these as before.
NOTE: The raised portion of the pass-through connector
is positioned to the inside of the greenhouse.
DO NOT SECURE ANY PASS-THROUGH CONNECTORS
TO THE METAL BASE FRAME AT THIS TIME.
7. Choose the remaining front panel, set it in place,
and install a 3" x 3" square plate on the inside to
secure the panel seams.
NOTE: Adjust the frame tubes as needed to allow the
panels to fit properly.
8. Position another pass-through connector on the
frame rail (see arrow below) and set the rectangular
end panel in place as shown.
9. Secure the panel to the corner bracket only.
10. Set the final panel for the non-door end in position
and secure it to the adjacent panels using pass-
through connectors and 3" x 3" flat plates.
Pass-Through
Connector
Front Panel
View shows the inside of frame.
Brace panel
if needed.
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11. Move to the door end and place the final end panel
in position (as shown in the following diagram) and
fasten it to the corner bracket.
12. Brace the end panel in place and install a flat
bracket a few inches in from the door opening on the
inside to secure each end panel to the base frame.
13. With the final end panel in place and secured to the
corner bracket, assemble the tubes for the upper
frame support for the back/open wall. This support
consists of the same frame tubes and is the same
length as the front and back metal base frame tubes.
14. Attach the frame support to the end panels using the
104640 tie connector (corner bracket) as shown
below.
View shows the inside of the greenhouse.
NOTE: This upper frame support secures the upper
portion of the end panels. Its position can be adjusted
and depends on the structure that the greenhouse is
attached to.
15. To prevent interfering with the door installation,
remove the screws from the angled end panels
along the door edges. See vertical dashed lines
above.
16. Set the door in place and slide the end panels
together to sandwich the door in the opening.
ATTENTION: Lock the deadbolt of the door before you
slide the base rails together.
17. Place one upper, angled end panel in position on the
non-door end wall panels, align the edges and ends
of the panel with the lower panels, and secure the
upper panel using 3/4" Tek screws and 3" x 3"
square plates. (See the diagrams and photos that
follow.)
18. Take the remaining upper, angled end panel, loosen
the screws, used to secure the polycarbonate along
the bottom of the panel, and set the panel in
position.
104640
Door (or
Non-Door)
End Panel
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ATTENTION: The lip of the metal trim at the bottom of
the upper angled end panel will overlap the top of the
doorframe.
Photo shows a different greenhouse. Procedure is the
same however.
Diagram above may show a model of a different length.
It is used to show the panel location only. Installation is
the same for your greenhouse if it differs in design.
Dashed line below shows where the trim of the upper
panel overlaps the top of the doorframe.
19. Secure the end of each angled panel to the lower
panels using 3/4" Tek screws and neo-bonded
washers. See Figure 1 (previous column).
20. Retighten the screws to secure the polycarbonate to
the frame of the angled panel above the door.
DO NOT SECURE THE DOOR TO THE ASSEMBLED
FRAME AT THIS TIME.
21. After the greenhouse is assembled to this point,
return to each tube splice on the metal base frame
and install a Tek screw through the tubes at each
splice to secure the joint.
22. Next, secure all pass-through connectors to the
metal base tubes and square the metal base frame
by measuring diagonally from corner-to-corner.
View is from the top looking down on the frame.
Retighten (Step 20)
Loosen these screws before installing the
upper, angled end panels.
Figure 1
The open
tube ends
are covered
with flashing
later in these
instructions. Base Frame Tubes
3/4" Tek
Screw
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NOTE: The distances measured in the previous diagram
are the same when the frame is square. When installing
the roof panels, periodically check the frame for square.
The frame must remain square for the roof panels to
install correctly.
23. With the frame squared, locate a short section of
roof support plate #SG10150 (26") and attach the
support to the inside top of the first small front panel.
NOTE: The first roof support plate is installed with one
end positioned past the edge of the short front panel and
flush with the polycarbonate of the angled end panel.
24. Choose two (2) forty-eight inch (48") roof support
plates, attach these to the tops of the short front
panels, and work toward the other end of the
greenhouse.
25. Complete the installation of the lower roof support
plates by installing another 26" section.
NOTE: In the above diagram, the front panel has been
moved to better show the roof support plates.
26. After installing the lower roof support plates, attach
three 3" x 3" flat brackets to the end panels in the
locations shown below for both ends.
Diagram above shows a wider model.
27. Place the first two roof panels in place and secure
them to the lower roof support plates from the inside.
Roof Support Plate
Roof Support Plate
Angled End
Panel
Angled End
Panel
(Inside view)
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REMEMBER: The lower roof support plates are
attached to the top edge of the front panels.
Install all roof panels with the extended polycarbonate
drip edge at the lower end of the panel.
The following diagram shows the union of the long roof
panel and the small front panel as seen from the outside
of the greenhouse. The lower roof support plates and the
3" x 3" square brackets secure roof panels.
ATTENTION: Roof panels are flush with the end panels.
They do not rest on top of the end panels.
28. Secure the roof panels to the end panels using Tek
screws and 3" x 3" flat plates installed earlier.
View shows the inside of the greenhouse from the back.
The arrows show the locations of the 3" x 3" flat plates
for the panel. These were installed in a previous step.
The roof panel (x) is secured to the end panel in the
same way. Dashed line represents the frame support
member that was installed earlier.
Diagram may show a greenhouse of a different length.
29. With the two outside panels in place and secured to
the lower roof support plates and to the end panels,
attach three (3) additional 3" x 3" square flat
brackets to each of the installed roof panels in the
locations shown in the next diagram.
REMEMBER: All 3" x 3" square flat brackets are
installed from the inside to the underside of the panels.
Diagram shows a longer greenhouse. Locations of the
flat brackets are the same for all greenhouse lengths.
30. Install the remaining long roof panel and secure it as
previously described.
Long Roof Panel
A
ngled End
Panel
Panels are flush.
Hinged
Front Panel
A
ngled End
Panel
Roof Panel Drip
Edge
Dashed line indicates the
drip edge of the roof panel.
x
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31. Attach two 3" x 3" square flat brackets to the
underside of each upper side panel frame tube (on
the inside of the greenhouse) as shown above.
32. Locate the remaining roof support plates and attach
these to the underside edge of the installed roof
panels at the top.
NOTE: The upper roof support plates are attached in the
same manner as the lower roof plates and in the same
pattern, beginning with a short section and ending with a
short section.
33. With all roof support plates installed, set the two
smaller, upper roof panels in position as shown in
the next diagram.
NOTE: The front edge of the panel will rest on top of the
upper roof support plates. The top of the panel is flush
with the top of the angled end panel. See the following
diagrams.
View is from the back of the greenhouse.
Upper Roof Support
Plates
Angled Side Panel
Back Edge of the Top Roof Panel (arrow)
Roof
Support
Plates
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34. From inside the greenhouse, attach each roof panel
to the roof plates using 3/4" Tek screws, and to the
end panel (using the previously installed 3" x 3" flat
brackets) and Tek screws as previously described.
NOTE: The arrows show where the 3" x 3" square flat
brackets were installed. View is from the back of the
greenhouse looking to the inside.
35. Attach two additional 3" x 3" square flat brackets to
the underside of the smaller roof panels in the
locations shown below.
36. Install the vented roof panel and secure as
previously described.
37. With the greenhouse assembled as shown below,
return to the door and center and adjust it as needed
to ensure proper operation.
38. Using the long Tek screws and neo-bonded
washers, secure the door to the angled end panels.
Tek screws are installed through the doorframe and into
the square tubes of the angled end panels.
ATTENTION: The screws of the angled end panels that
were removed can be reinstalled. The doorframe of the
door however will serve to secure these panels.
39. After the door is secured, attach the solar-powered
vent openers to each of the vented panels.
NOTE: Consult the directions included with the solar-
powered openers to install these items. Install two (2)
openers for the vented roof panel.
40. After installing the vent openers, read the Foil Tape
and Silicone Sealant information and attach the
greenhouse flashing as described.
Door
Angled
End
Panel
Tek Screw and
Neo-Bonded
Washer
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FOIL TAPE AND SILICONE SEALANT
Foil tape and silicone sealant are included with the
greenhouse to seal the spaces between the panels if
desired.
Tape and sealant can be applied from the outside or the
inside depending on the desired results.
For some panels, tape can be applied at the seam
between panels and under the polycarbonate by
removing the screws and washers, installing the tape
under the polycarbonate panels, and reinstalling the
screws.
Tape or sealant can also be applied to the seam that will
be under the flashing when that is installed.
View above shows foil tape applied over the seam of two
panels on the inside of the greenhouse.
ATTACH THE FLASHING
The metal flashing is used to finish the outside panel
edges. The flashing is shipped in 6' lengths and must be
cut to fit.
Use Tek screws (1 1/2") and neo-bonded washers to
install the flashing.
NOTE: Flashing is installed along the edges of the door
and non-door end panels as identified by dashed lines in
the diagram below.
ATTENTION: Before installing the flashing, remove the
screws holding the polycarbonate panels to the roof and
end panel frames. See the dashed lines above.
White dashed line shows the edge of the flashing under
the polycarbonate of the roof panel.
Remove and
Reinstall Tek Screws
Flashing
Foil Tape
WARNING: FLASHING IS SHARP! WEAR
GLOVES WHEN HANDLING AND INSTALLING
ALL FLASHING.
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Tek screws and washers are reinstalled through the
flashing to secure it to the greenhouse.
Complete these steps to install the flashing.
1. To install the flashing, begin at one of the lower front
corners and work to the other lower corner of the
same end.
Photo shows installing the first section of flashing.
Greenhouse may be a similar model.
2. Cut the flashing edge to allow it to bend at the
correct angle as it is attached.
ATTENTION: To prevent interference with the hinged
small side panels and solar openers, additional
"trimming" of the flashing is necessary along the edges
of the hinged panels.
3. After attaching the first section, install the next
section and overlap the first section by a few inches.
REMEMBER: Flashing is installed under the
polycarbonate of the roof panels and it overlaps the
polycarbonate of the end panels.
4. Continue to install the flashing until one end is
complete.
5. Repeat the steps until all flashing is installed.
6. Continue with the final check of the greenhouse.
NOTE: The flashing that remains can be used when the
greenhouse is attached to the permanent structure.
FINAL CHECK OF ASSEMBLED GREENHOUSE
1. After all flashing is installed, inspect the assembled
greenhouse and verify that all brackets are in place
and secure.
2. Inspect all corner brackets to verify that all panel are
secured to these brackets.
3. Verify that all pass-through connectors are secured
to the metal base frame and to the panels.
4. Remove any sharp corners or edges that are
present to prevent injury.
Flashing will over-
lap the angled end
panels as shown. Door (and
Non-Door)
End Panel
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5. Align the plastic lumber base (if needed) with the
metal frame base and secure the plastic lumber to
the frame base using the A-Angle brackets as
shown,
6. Read the MUST READ document and the anchoring
information for the greenhouse.
ANCHOR THE GREENHOUSE
Strong winds will cause the greenhouse to shift. It must
be anchored to the site.
The site on which the greenhouse was constructed will
determine the required anchoring method. Consult a
professional contractor to determine the best and safest
way to anchor the greenhouse.
WARNING: To prevent property damage and serious
personal injury, the assembled greenhouse must be
anchored to the site. READ THE MUST READ
DOCUMENT.
ANCHORING EXAMPLES
The diagrams below illustrate two possible ways to
properly anchor the shelter to the site.
The parts shown in the diagrams below are not included
with the shelter and must be purchased separately.
Contact Customer Service at 1-800-245-9881 to
purchase additional parts to anchor the shelter.
ANCHORING SUGGESTIONS
ATTENTION: After anchoring the greenhouse, read the
Care and Maintenance information that follows.
CONSULT THE MUST READ DOCUMENT FOR
ADDITIONAL ANCHORING INFORMATION.
A
nchoring System
when on concrete
Ground Anchoring
System
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Greenhouse Care and Maintenance
Proper care and maintenance of your greenhouse will help to ensure years of service. The following
items identify areas that must be periodically checked to ensure that your greenhouse is maintained
properly:
• Check the anchoring system to see that all components are tight and in good repair.
• Check connections and all fasteners to verify that they remain tight.
• Verify that all flashing is in place and secure. To prevent injury, bend sharp corners over so
nothing catches on them.
• Check the polycarbonate panels (if equipped) to verify that these are in good repair.
• Do not climb or stand on the greenhouse at anytime.
• Remove debris and objects that can accumulate on the greenhouse. 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 panels that could cause
damage.
• If the shelter is moved, inspect all parts and connections before reassembling.
• Depending on the contents, construction of the shelter, shelter materials, and shelter location,
the potential for condensation exists. ClearSpan™ offers several items that can be used to
help resolve a condensation condition. Please contact a ClearSpan™ representative for
additional information.
• For replacement or missing parts, call 1-800-245-9881 for assistance.
NOTE: With the exception of Truss Arch buildings, ClearSpan™ shelters and greenhouses do not
have any tested loading criteria.
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