On 5 August 2024 Jon West of Big Ass
Fans sent this note:
"We sent a 10'
down rod so this should help clear the slope...
The 10' down rod will have the blades spinning 150" (12.5') from the
mounting point."
On 17 February 2024 Alan Ball of Calhoun Super Structures sent this note regarding
installing the Big Ass fans:
"We have reviewed the data sheets provided.
Based on the weight of the fans, we do not see any concern mounting 2
or 3 of these units in the structure. We suggest that you use the fan
supplier's mounting kit. Please note that the fan must be connected
to the lower chord of the truss (3x3 square). It is not permissible
to connect to the purlins (z-shaped members that run the length of
the building)."
The engineering issues and discussions resulted in this fan
bracket design to adapt the standard Big Ass mounting brackets to
the Calhoon truss.
Note: The large grey triangle in the image above is the center
section
at the top of each truss.
The small red angle brackets which adapt the orange flat fan
plates to the angled bolting points of the truss are the only parts not
supplied in the fan mounting kit. They are detailed on page 5 of
the design document.
Based on this design a
Building Permit was issued (and
signed off after installation).
An emergency cutoff switch was required by the local electrical
inspector:
Big Ass Fan Installation Manuals
Recommended installation instructions were found on the Big Ass
Basic 6 Support
Page. These seemed to be incomplete so
the installation proceedure here was written by Wildstar Farm. It
is in addition to the manuals from the Big Ass page. The
manuals from that page which were used at the time of installation
are listed here.
As needed cut the hanging tube to achieve desired length
above the floor and distance to the ceiling. (At Wildstar
Farm the original 10 foot hanging
tubes were cut to 7 feet.)
Install guy wires between the fan motor assembly and the
ceiling. These steady the fan assembly preventing swaying.
The wires should be taught but not under significant
tension.
Connect power to the VFD controller, make the
electrical connections from the VFD to the motor and make
the (Modbus) Cat-5 connections to the remote controllers.
The original motor connections
were updated to support 220 V single phase wiring
using these instructions supplied with the motor.
Care must be taken since the diagram does not exactly
match the motor. The pin names are correct but the
placement of the ground wire is on the opposite side from
what is shown.
Elecrical installation tasks are step 6 in the
Overhead
Install Guide
but are not documented there. The
Electrical
Installation
manual link shown in this step documents this
task. Wire
sizes and other wiring details are in the
Electrical
Guidelines
manual also shown here.
(Some earlier documentation suggested that 30 amp circuits
were required for the Basic 6 fan. This is not the case
according to the latest manuals which only require 20 amp
circuits. At Wildstar Farm 30 amp circuits were installed
and to support that amperage 10 AWG wire was used from the
circuit breakers to the VFD. Although the latest
documentation does not require it 10 AWG wire was also used
between the VFD and the fan motor which could have used 14
AWG.)
Fire Control
As discussed in the Electrical Installation manual a
contact closure across VFD digital input terminals 12V and 13A will
result in fan shutdown. The installation kit
included a relay that uses a Normally Open
(N.O.) contact. When the relay coil is energized with 24 VDC
by the FACP the fan will shutdown. Optionally, the normally closed (N.C.)
relay contact can be used. Then the relay coil must remain energized with
24 VDC by the FACP for fan operation. This would be considered a fail
safe or fail open wiring arrangement.
Connecting 12V to 13A as a fire alarm condition will stop the fan and issue
an "F_EF" external
fault on the VFD's display. Fire alarm relays are
not used in the Wildstar Farm installation. They are
only required if sprinklers are present.
There was no useful manual provided for testing the motor
after all connections were made. At Wildstar Farm the VFD
reported an error and parameters had to be adjusted as
suggested by Big Ass support to get the fan to operate.
There is no inherently safe way to adjust parameters after
fan blades have been installed. A suggestion was made to
Big Ass Fan support on a way to use the fire turn off
connection to create a safe method of disabling the fan
and allowing parameter adjustments. It is not yet known if
this method will work.
Test the motor by putting the VFD into local mode by
setting P100 to 0 and then pressing the 'Run' Button. Stop
the fan and set P100 back to 3 to enable the remote
controller.
At Wildstar Farm the fans did not work as delivered.
On initial power up the fan reported an error at the VFD
and at the remote Standard Controller reported an overload. A
support call answered by to Garrett H. suggested
parameter adjustments to get the motor to work.
Parameters are set by pressing the M button on
the VFD and
then changing the parameter selected by using the
up and down arrows choose a parameter number.
Press the M button again to see the parameter
value and use the up and down arrows to change
the value. Finally press the M button again to
save the new value and return to the parameter
number. P100 must be set to 0 to get local
control prior to setting other parameter values.
Parameter
Original Value
New Value
P100
3
Change to 0 to set parameters and do local
testing then put back to 3. When the value is 0
the VFD 'Run' button will start the fan. ??? it is
not clear if the 'Run' button will start the fan
when the
12V to 1 jumper is removed. When P100 is 3 the
VFD 'Run' button will not start the fan, The VFD
displays 'Err' if run is pressed with P100 set to
3.
P108
83
91
P171
133
148
P172
3
0
These explicit numbers were given by phone a later
email reporting what was done said that the P108 and P171 were being
increased by about 10%.
Install Remote Controller
The Standard Controller is mounted remote to the fan.
(At Wildstar Farm these remote controllers are mounted at
the entrance from the barn to the arena.)
The electrical installation above discusses how to wire the Cat-5
cable From the remote Standard Controller to the VFD.
The Standard Controller reports more
useful error information than the VFD. At Wildstar Farm
when the fans were first tested they reported 'Err' at the
VFD. On the remote controller an Overload condition was
reported. As reported above in the Testing discussion
parameter adjustements were recommended by Big
Ass suppport to correct this condition.
RJ45 pin
VFD
Terminal
Discussion
1 White/Orange
NC
2 Orange
12V jumper to VFD
1
This jumper is fan run enable. Interrupting this
connection will prevent the fan from being started
by the remote controller. ???Not clear if the fan
will run when P100 is set to 0 and the VFD 'Run'
button is pressed.
Fire relays were supplied with the fans but are not appropriate
to the Wildstar Farm installation. They are required when the fans are located
in an area with a sprinkler system and are expected to shut off the
fans when the sprinklers actuate.
Fire
Relay Kit
Manual inappropriate to this installation on the Big Ass site:
Bar
Joist Manual
A discussion of how to mount to structures than those in
the list above was not on the site. More appropriate information
was in the older installation guide:
Older
pre
Sept. 1999 Big
Ass Installation
Guide(local
copy)
with diagrams.
Handicap Lift
A Jib Crane was constructed to lift handicapped individuals onto
horses.
2022
Fire Alarm Inspection At this time an updated cellular
radio was installed that eliminated the need for a backup
phone line.
Completion Reports and Affidavits
After completion of the project at the time the apartment Special
Permit came up for renewal Wildstar submitted a
letter
justifying
that the apartment did not need a Special Permit.
Chris Canney the building inspector responded on 27 May 2020 by email in this way:
Sorry for the delayed response, it has been a busy couple of weeks at
the Building Department. I think your letter does a good job of
spelling out the size and scope of the agricultural use of your
property and connects the use of the apartment directly to the care
and maintenance of the animals living in the barn. I agree with your
assessment that the apartment is incidental to the agricultural use
and therefore is not subject to the local Zoning Bylaw’s Special
Permit requirements per MGL 40A Section 3. As you state at the
beginning of the letter, if the use of the apartment changes in the
future to no longer be directly in support of, or incidental to, the
agricultural use of the property, then you will be required to obtain
a Special Permit for the new use.
Since the Sherborn General Bylaw requires that I conduct an annual
stable inspection, I will have plenty of opportunities to visit the
property and ensure that the agricultural use is maintained.
The architectural design was done in Revit. The
Revit design is kept in the A360 system that the Architectect
uses to share the design.
A360
3D Model (Revit Design) A login is required to access this
design. Extracted data in PDF format is published later on this
page.
Construction Details
Sliding Door
The last construction task was the design:
construction
and installation:
of
this barn door:
The man door in the middle is provided so the sliding door provides a
legal handicap exit.
If the sliding door is open far enough that the
man door becomes obstructed than there is a sufficient opening to
satisfy the handicap exit rules.
Structural anlysis was done on this door because the top section is
fairly narrow 2 by 3 steel channel and a top panel with steel
plates was required to satisfy wind loads:
and the possible load of
sliding the door into an obstruction:
Barn Permit Plans Egress Update (revision 4)
These plans were submitted to amend the exit route allowing egress
through the sliding door of the old barn. The egress is enabled by
putting a man door in the sliding door and positioning the man door
so that if the sliding door is opened an acceptable egress exists
when the man door passes beyond the side of the aisle opening.
Egress
Paths through the 6 bay old barn. Top View of
sliding door assembly showing critical dimensions. This view also
shows that the sliding door track is at a slight angle to
facilitate window frame clearance. Elevation View
showing end view of the barn with the sliding door positioned at the
critical point where the man door starts to be obstructed. Section View
showing proposed mounting methods for the tracks.
Barn Permit Plans Apartment Update (revision 3)
These plans were submitted to amend the building permit a second
time. They add the apartment and raise the roof in the hayloft
perimeter to make better use of the hayloft space. Unfortunately
the north windows of the apartment have to be eliminated to
accomplish this.
These plans were a draft of what to submit to amend the building
permit to add the apartment. They add the apartment and raise the roof in the hayloft
perimeter to make better use of the hayloft space. Unfortunately
the north windows of the apartment have to be eliminated to
accomplish this.
These plans update the overall design to remove all mention of the
apartment, bathroom and fixtures that require plumbing (listed as
future items in the 12/28 permit plans). They were
required by the town to issue a building permit for the barn while
pool septic system repair was incomplete. Everyone agreed that the
plans could be amended to add the septic related systems once the
pool septic repair was complete.
Final survey data showed the barn to be 6 inches off in the GLM
survey. The arena and new barn positions were adjusted to maintain
setback clearances. These new positions are reflected in the
architectural plans dated 17 September 2017 and any later updates. Adjustment
showing old and new positions Updated
barn positions in CAD (ftp 382 Kb)
Code compliance was performed by
Harold Cutler. The code that
applies is the Eighth edition of the Mass. building code which
consists of the 2009 IBC with Mass amendments. The result of that
compliance
analysis was included verbatum as text in the overall
architectural plans. These plans were
submitted as part of the initial arena design and have been
included with each
sucessive set of architectural plans. On 1 February 2018 Mr.
Cutler when asked if we could use his name and credentials said by email:
"That’s fine. I have been an integral part of the development of
the plans for the project and concur with the accessory use
designation given the restriction to occupancy of the apartment by
a barn manager." In actual fact the characterization of the
apartment as an accessory use was first used in a draft of the code
analysis by Mr. Cutler.
Fire Alarm
Wildstar installed a commercial grade fire alarm. Although the
Wildstar code consultant did not believe that this was true the
building inspector claimed that Massachusetts code amendments
required sprinklers throughout the facility. He then encouraged
Wildstar to obtain a variance to allow what the code consultant
expected to be required.
Wildstar obtained this variance to allow sprinklers only in the
apartment section. Part of the variance said that the Fire Offical
had to approve the Fire Alarm systems. That official did not accept
the original design (presented at the variance hearing)
which expanded the existing house and barn alarms to the entire new
facility. The Fire Official wanted a commercial grade alarm system.
Rather than delay the project Wildstar installed the much more
expensive commercial system.
Sirens and strobes in a horse riding area are considered by PATH to
be a hazard to riders. Any triggering of these is likely to spook a
horse and injure the rider. Other jurisdictions prohibit these
items in a riding arena. Rather than fight this issue Wildstar has
installed them as demanded by the Fire Official. Wildstar has
requested of the Sherborn Fire Department
that this requirement be eliminated, this has has not yet occured.
(The elimination is a simple programming update to the existing
system.)
When the fire alarm system detects an alarm it is supposed to call the
fire department. Apartment issues are not supposed to set off the
sirens and strobes in the arena. About 10 June 2023 the alarm system correctly
detected smoke in the apartment. This correctly did not trigger
arena alerts, but, the fire department was not called until much
later (perhaps an hour) after calls to the people! The behavior was
about what we expect if the house detects smoke, but, calling for
confirmation first is not
supposed to be allowed for the barn system.
Clearing the alarm so it turns off the audible and strobe
signalling requires a human
intervention. Press and hold the Reset button in the fire panel
until it says 'Output in Progress'. Then enter *259## on the panel.
This should reset the alarm and turn off the signalling. NOTE: if
the cause is still present the system will detect it again and
trigger a new alarm.
Sprinklers
A complete discussion of sprinkers and fire alarm requirements is
in the Sprinkler Appeal page.
Septic Discussion with the Board of Health
Civilized Solutions prepared a
31 January 2017 letter for the Board of
Health
discussing why the existing septic system could support an
additional bedroom. The letter states that the system can support
a 5 bedroom flow with a 50 percent overcapacity for the installation
of a garbage grinder. No garbage grinder is installed or planned.
Wildstar's expectation in addition to this letter is that the site should
be considered as a multi-structure campus in the same way as the
Pope campus at 26 Bullard Street was considered. The bedroom count
evaluation there was performed on a building by building basis
rather than by adding up the room count of each building.
The existing house at 16 Nason Hill Lane contains four bedrooms.
The current assessment records have this narrative:
This parcel contains 11.3 ACRES of land mainly classified as
ONE FAM with a CONTEMP Building built about 1980,
having primarily WOOD Exterior and 8445 Square Feet,
with 1 Unit, 4 Baths, 0 3/4 Bath, 1 HalfBath, 9 Rooms, and 4 Bdrms.
Spelling and capitalization from the narrative.
The health agent gets a slightly different room count by counting one
of the basement rooms. He also considered the kitchen and dining room a
single room.
The barn and associated apartment contain one bedroom. There are
two conditioned rooms in the apartment plus the tack room and
office. There is one
bathroom in the apartment and on half bath adjacent to the tack
room. There is also an entry-way containing a sink and washer/dryer
adjacent to the tack room.
The Board of Health indicated that they would approve this system
with a deed restriction when a full septic plan for the barn was proposed.
Drainage and Septic Layout
Joe Marquedant is following on from the work by Civilized
Solutions. He has completed drainage plans for the barn and
arena: Drainage Page 1 Drainage Page 2
As well as a septic design: Septic Page 1 Septic Page 2
On Monday 14 November 2017 the Board of Health approved these plans
giving the health agent authority to grant final approvals when
Fred King renews his license. The Board wants the pool septic
repair completed
before approval of the apartment. The pipe was lined from the
new pumping chamber up to the pool house. The final approval is
still pending a signoff from GLM. Unfortunately the septic engineer
that was doing the work has left GLM.
On 25 July 2019 Joe Marquedant submitted a
Finish Grades Survey
(DWG
file) to the town of Sherborn completing the septic
construction for the barn. This survey also included finish grades for
the pool repair and completes that construction too.
Septic Layout
Civilized Solutions proposed two possible choices for the septic layout and connection to the
existing septic system. The Gravity system is the selected
strategy.
Gravity
fed septic design This passes under the chicken coop and runs
entirely by gravity.
Supplement Sheet 1 Pumped
septic design This has less disturbance but requires a pump and
associated alarm.
The septic system from the barn to the D-box of the house septic
system was built, inspected by Mark Oram and approved for cover.
This is the as build septic plan.
Well Pump Info
On August 15 2024 the well pump failed. It was replaced by a
Grundfos SQ, SQE pump. This pump has a soft start feature that
ramps up the current draw. It has a 2 year warranty. The well is
160 feet deep. The old pump was a 300 foot deep type inappropriate
for this depth. Dover Pump 508 785-0463 did the installation. They were prompt
but expensive, they invoices $2232 for the pump (available online for
$1600), they also charged $395 to use a pump puller and $800 for
labor. A 1 hp 30gpm pump was used likely a:
Grundfos 30SQ10-130-230V.
Poolhouse Septic Repair
When the house was purchased a cesspool was found southeast of the
outdoor pool that supported a toilet and shower in the pool house.
This failed title 5. The
sellers provided an approved design for repair of this system that
replaced the cesspool with a pumped system. The pump basin joins
the house septic system. The initial design did not have a cleanout
anywhere in this line and was updated to add the cleanout. The pump
basin and forced main were constructed after the purchase of the
house. The septic system for the barn apartment requires that this
pool house repair is completed prior to approval.
Pool
septic repair initial design This design is what was presented
to the board of health. It required modification to add cleanouts.
Final Compliance for
this repair was recieved on 3 October 2019.
Light Fixture Interpretation
Wildstar wanted to use inexpensive
Shop light LED luninares from Costco
throughout the barn and arena. These fixtures are UL dust and damp rated. The electrical inspector pushed our
electrician to use vapor sealed fixtures in the barn aisles. His
rationale was that dust and wet rated fixtures were needed in a barn. The
fixtures used were dust and wet rated with a cord that plugged in
to an outlet. They cost three times what the Costco luninares cost.
The inspector then wanted the fixtures to be connected by runs of
conduit. The electrician modified the fixtures removing the cord,
drilling holes and attaching conduit to the holes. The inspector
liked this change. Wildstar
believes that the change violates the
wet rating and could not be used if wet rated fixtures were actually
required. Wildstar consulted a friend (the electrical inspector for
a much larger town) who held that only dust rated
fixtures should be required in barn aisles (wet rated fixtures are required
in areas of animal confinement such as stalls). Given this opinion Wildstar did not
object to the fixture modifications which due to that modification are
no longer either wet or damp rated.
The inspector wanted the same sealed fixtures in the arena. His
rationale was that for this area three prong plugs were required.
The Costco fixtures only had two prong plugs.
Wildstar already owned and had temporarily installed the Costco
lights. For the arena Wildstar contacted the state Board of Fire Prevention
Regulations. Phone conversations were held with Paul Vigneau in
early December 2018 followed by an email on December 7th 2018 with a
Request for Interpretation
attached. A follow up email was sent on January 11th to Richard
Fredette. On May 28th, 2019 a formal
response was sent that said
that the "authority having jurisdiction ... shall accept listed and
labeled equipment...". Long befor this letter arrived the
electrical inspector allowed the Costco lights in the arena.
Site Information
Overall
Site
Plan
for the barn and arena location.
The scale is 1 inch to 20 feet. This plan shows the grades prior to
construction. After construction the area beyond the end of the
arena was leveled to make a round pen.
The surveyors provided these Pin
Locations to reference where the foundation goes. This
detail is important because the retaining wall does not have
easy corners to pin. The locations were taken from the 17
September 2017 design.
Early GLM layout of the barn
site. REVISED
Setbacks SKETCH - 16 NASON HILL LANE.pdf Shows 30 foot rear
setback in the area of the planned barn and riding ring. This sketch
was used in a dialog with the building inspector. It represents what
the building inspector agreed by email should be used for the lot
line setbacks and the strategy depicted is what is used in all barn planning.
These
setback
requirements (revised version) were proposed by GLM and confirmed by
email with building inspector Henry Fontaine who said: 'As I review I agree with what you have with the exception of the front
set-back, it is 60 feet.'. The original sketch incorrectly showed 40
foot distance at the front of the lot while calling out a front
setback.
Use of Native Lumber
To be able to use the trees cut from the land Wildstar has
become a certified mill. This allows Wildstar to certify native
lumber for structural use.
This
email chain with Mass. DPS shows the trials and
tribulations of that process.
OUTDATED Architectural Supplement to Foundation plans 4 Aug 2017
These supplements show the placement of the slab in the barn area
and the placement of the footings that support the ramp in the
arena. They also contain waterproofing and under slab insulation
details.
OUTDATED Architectural Supplement to Foundation plans 4 July 2017
(via
ftp 1.0 Mb) Additional data from the architectural plans add
information to these plans (i.e. the exact locations of the ramp
footings). These plans call out where they have to be coordinated
with the architectural plans. This set should be superceeded by the 4
August version above. Check this set to make sure all details are
properly superceeded.