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COVANA Horizon Installation Manual

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2019
Revision 1
2019-06-25
C.A. 232876

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Summary of Contents for COVANA Horizon

  • Page 1 2019 Revision 1 2019-06-25 C.A. 232876...

  • Page 2: Table Of Contents

      Lifting mechanism assembly..........................33   Tub mounting ................................ 38   Ground anchoring mounting (optional) ......................... 40   Testing the Horizon cover ............................. 41   Wiper bracket installation ............................42   Grounding and power supply connection ......................46    ...
  • Page 3   APPENDIX ................................53   INSTALLATION CHECKLIST (Customer copy) ....................59   INSTALLATION CHECKLIST (Installer copy) ....................... 61 TABLE OF CONTENTS INSTALLATION MANUAL...

  • Page 4: Safety

    Remove the control key after operating the and under important installation instructions issued by COVANA cover. Store the key in a secure COVANA. Any other type of usage will void the location when not in use. Users must bring the warranty and product certification.

  • Page 5: Avoiding The Risk Of Electrocution

    (GFCI) that complies  Do not roll the COVANA cover onto its side or with all applicable local electrical codes and slide it on its side. This will damage the siding. regulations.
  • Page 6 WARNING REGARDING MODIFICATIONS TO THE COVANA COVER Any modifications to the COVANA cover, such  mechanical, electrical aesthetic modifications, may cause the cover to operate...

  • Page 7: Labelling

    LABELLING WARNING  Removing any labels from the COVANA cover will void product certification. All labels should always remain visible. It is the owner’s responsibility to ensure these labels are always visible and should never be removed Risk of electrocution warning, Key operating diagram, located on the operator unit.
  • Page 8 Label located on the key switch cable. Maintenance informations, located Do not step or stand on symbol, on the C-channels. located on top of the operator unit. Electrical information, located on the key switch cable. LABELLING INSTALLATION MANUAL...
  • Page 9 Do not step on cover label, located at the end C-channels of the COVANA cover. Center label, located on the center of the right and left C-channels. (remove after installation) Top label, located on the interior of the I-beams and escape hatch opening (hidden when assembled).

  • Page 10: Glossary

    Figure 3 The top plate is a cover installed on the sleeve assembly. Top plate Figure 4 The operator powers and controls the lifting mechanism of the Operator unit COVANA cover. Figure 5 GLOSSARY INSTALLATION MANUAL...
  • Page 11 Drive shaft The drive shaft transmits the power between the jack assemblies and the chains connected to the operator unit. Figure 6 The short U frames protect the mechanical parts that rest on the U frame (short) foundation and connect both posts. Figure 7 The motor-side protects the chains.
  • Page 12 The I-to-C connection plate makes the link between the I-beam and l to C connection C-channels. plate (small) Figure 14 The key switch is used to operate the COVANA cover. Key switch Figure 15 The corner brackets link the C-channels on the side to the ones in Corner bracket front and back.
  • Page 13 Figure 20 The wiper bracket is attached under the I-beam. This part is Wiper bracket required to ensure waterproofing of the COVANA cover. Figure 21 The installation foam is used during the installation process to Installation foam protect the hot tub from direct contact with the cover.
  • Page 14 The tub mount arms are used for the tub mount option only. They Tub mount arm link the sleeve brackets to the tub mount supports. (short or long) (for tub mount model only) Figure 25 These are assembled with the L brackets, the side supports and Post brackets the linkage bars.

  • Page 15: Hardware Identification Table

    HARDWARE IDENTIFICATION TABLE Quantity Visual representation Description 5/16″-18 x 2″ hexagonal bolt used to fasten the short and long U-frames. 1/4” -20 x 1” Button hex drive bolt. Used to fix the pivot joint bracket to the the cover. 10-24 x 1/2” Self-Tapping Screw.
  • Page 16 1/4” Lock washer used for cover assembly and the tub Ground mount option. anchoring Tub mount 1/4” Flat stainless steel washer. Only used for the tub mount option. Tub mount 5/16” Lock washer used to fasten the operator unit to the long U-frame.
  • Page 17 1/4”-20 Nylon insert locknut. Used with shoulder screw Ground and with ground anchoring anchoring option. Tub mount 1/4-20-5/16” Set screw used on the operator’s sprocket. 3/16-3/16-5/8” Square ends key used for the operator’s sprocket. 5/32” Hex key. Used for fastening the 1/4”-20 x 1” Button hex drive bolts.

  • Page 18: Installation Preparation

    To ensure the safe use of the COVANA cover, it must contaminants, such as rocks, dust or sand. be installed on a properly prepared surface. It is  The key switch must be permanently mounted important to adequately prepare the foundation and and located 5’.

  • Page 19: Foundation Preparation

    The ground anchoring option should not be used in an excessively windy area.  Just like the hot tub, the Horizon cover requires a solid foundation. The foundation for the Figure 31 Horizon cover must be able to support at least 550 lb.

  • Page 20: Installation Reference Information

    Installation reference information Throughout the following installation instructions, we will refer to the front, rear, left and right sides of the cover. Please refer to Figures 32 and 33. The front of the cover is the side with the higher point of the tilt and the back of the cover is the operator’s side.

  • Page 21: Installation

    24” (61 cm) level  1/8″ (3 mm) Allen key CAUTION The COVANA cover should be installed by an authorized COVANA installer. Having the COVANA cover installed by someone who is not authorized will void the warranty. Ask your local COVANA dealer for information on authorized installers.
  • Page 22 Remove the seal, the foam spacers and the optional parts boxes, either the tub mounting or the ground anchoring hardware, from the bottom of the crate and place them in a safe place. (Figure 35) Tie-wrap Carefully cut the tie-wrap holding the long U- Motor-side frame motor-side to the stud, remove the motor- side from the crate and place it in a safe place.
  • Page 23 11) Unscrew the top #8-10 x 1½” Robertson screws holding the posts to the crate as shown in Figure CAUTION  Be careful not to drop screws or metal pieces into the sleeves as this may cause damage to #8-10 x 1½” Robertson screws the mechanism during operations.

  • Page 24: Cover Assembly

    Cover assembly WARNING  While assembling the cover, make sure not to over tighten bolts. Power tools must not be used to prevent any bolt failures. Attach the foam spacers to the top of the hot tub near each corner using the masking tape provided in the seal pack.
  • Page 25 CAUTION Carriage I to C 1/4” lock 1/4-20  Be careful while taking the I-beams out as the bolt spacer washer hex nut wiper brackets might fall out the plastic bag. 6) Install the I to C small connection plate and the I to C spacer to the I-beam by using ¼”...
  • Page 26 Approximately center into the C-channels using TOP VIEW the center label, make sure the I to C bracket is pointing towards the front. (Figure 51 & Figure Slide the remaining panel into the C channels and press it slightly against the I-beam. (Figure C-channel CAUTION ...
  • Page 27 11) Slide on one of the long C-channel previously assembled with the corner brackets at the end of the front panel. (Figure 55) 12) Screw in the phillips #10-24 x ½” screws in the pre-drilled holes of the C-channel through the corner bracket holes.
  • Page 28  Failure to improperly install or simply not installing the escape hatch may present a security risk such as drowning, injury or undesired entry into the spa. That installation will be disapproved by COVANA and will consequently void its warranty. Figure 60 INSTALLATION...

  • Page 29: Tub Mount Assembly

    Tub mount assembly Note: If the cover was supplied with the ground 1/4-20 x 1/2” anchoring option, skip to the ground anchoring Phillips screws assembly section. Loosen the four top 1/4-20 x 1/2” Phillips screws so you have an approximately 1/4” (6.35 mm) gap between the heads of the screws and the outer sleeve.

  • Page 30: Ground Anchoring Assembly (Optional)

    Ground anchoring assembly (optional) Top view Bottom Figure 63 Attach the L bracket on the post bracket with Post bracket included 1/4-20 x 3/4” carriage bolts and 1/4-20 nylon hex lock nuts. (Figure 64) Repeat for all four post brackets. Note: Depending on the space between the hot tub and the posts, the location chosen for the L bracket...
  • Page 31 Insert the hook of the side support bracket into the notch of the outer sleeve. (Figure 66) Screw back the two 1/4-20x1/2” Phillips screws for only one and a half rotation. Post bracket Slide on the post bracket on the side support bracket using the slots as guide.

  • Page 32: Post Assembly

    Post assembly Pivot tube Insert the pivot arm on the tube on top of the first post assembly. For hot tubs 36” (91.4 cm) high or less, place the pivot arm flat side of the arm facing down. For hot tubs above 36” (91.4 cm) high, place the pivot arm flat side facing up.

  • Page 33: Lifting Mechanism Assembly

    Lifting mechanism assembly Insert the square drive shaft over the square axle at the bottom of the jack through the post Rear opening and push it as far as possible (Figure side 74). Slide a short U-frame over the first square drive shaft and push it in as deep as possible into the Drive opening at the bottom of the post.
  • Page 34 Place the motor-side along the rear of the cover with each end close to the two square drive shafts that were installed previously. (Figure 78) CAUTION Motor-side’s  Ensure the input shaft in the middle of the U- input shaft frame is pointing outwards from the cover.
  • Page 35 10) Repeat steps 8 and 9 on the opposite side. Remove the 11) Remove the four screws at the bottom of the tape on the operator and remove the cover. Do not discard sprocket. these screws. (Figure 80) 12) Install the 3/16-3/16 x 5/8” square key into the motorside’s input shaft’s keyway and ensure it’s completely seated in the keyway.
  • Page 36 19) Once the operator is properly installed, remove Jack lock screw Threaded the jack lock screws from the posts and put them (Hex cap screw with a rod’s screw in the extra holes on top of the posts (Figure 83). warning red tag) Extra holes (Hex cap screw...
  • Page 37 ¼-20 x 1” back screws. (DO NOT REMOVE) 23) Use the threaded rod screws (Figure 83) on both posts to align the pivot arms’ screw slots with the screws on the cover. Raise the post by turning the threaded rod screw counter clockwise and Can go from lower the post by turning the threaded rod screw approx.

  • Page 38: Tub Mounting

    Tub mounting 1/4 lock 1/4-20 washer Note: If the cover was supplied with the ground hex nut anchoring option, skip to the ground anchoring mounting section. Ensure the system is well positioned around the hot tub and the cover is lying flat and centered on the hot tub.
  • Page 39 (two on each side) to prevent dirt or water from getting into the sleeves. (Figure 95) Repeat for other post assembly. Once the Horizon cover is properly mounted to the hot tub, anchor both U-frames’ corner brackets to the ground using at least ¼ x 2”...

  • Page 40: Ground Anchoring Mounting (Optional)

    Ground anchoring mounting (optional) Ensure the system is well positioned around the 24” (61 cm) level hot tub and the cover is lying flat and centered. Check whether the posts are still level before anchoring. Use a 24” (61 cm) level. CAUTION Figure 97 ...

  • Page 41: Testing The Horizon Cover

    Testing the Horizon cover Both jacks on the COVANA cover must be properly anchored to the foundation using at Plug in the COVANA cover. (Have a certified least one of the pre-drilled holes located on the electrician complete the electrical hook-up roof of each post.

  • Page 42: Wiper Bracket Installation

    I-beam Remove the siding on the double-sided tape of one wiper bracket. (Figure 101) Under the COVANA cover locate the I-beam and orient the wide flap of the wiper bracket outwards of cover. (Figure 102) Stick the wiper bracket on the middle of the I-...
  • Page 43 Seal application 1) Once the COVANA cover has been fully assembled, raise the cover and remove the Masking tape foam spacers and tape. Lower the cover and walk around the entire perimeter of the spa, observing where the inside surface of the cover will make contact with the spa.
  • Page 44 10 to 15 minutes, remove the heater and continue underside of the cover. To apply pressure to the with the seal installation. The rubber seal should seal, simply push it against the COVANA cover not be overheated. Do not directly heat the acrylic with your hands.
  • Page 45 10’. (3 m) of the hot tub, must be bonded to  Install the COVANA cover in such a way that the equipment grounding bus with copper water drainage is directed away from the conductors no smaller than No.

  • Page 46: Grounding And Power Supply Connection

    Grounding and power supply connection 1) Remove the four screws on the bottom side of the COVANA operator and remove the cover. (Figure 107) 2) Refer to the complete wiring diagrams for the European model and North American model in the appendix.

  • Page 47: Technical Specifications

    TECHNICAL SPECIFICATIONS Side elevation 25° The maximum raised height is 104” (264 cm) The maximum clearance is 26” (66cm) The hot tub must fit within these height specifications: Min.: 32” (81 cm) Max.: 48” (122 cm) Figure 108 TECHNICAL SPECIFICATIONS INSTALLATION MANUAL...

  • Page 48: Frame And Footprint

    Frame and footprint Figure 109 TECHNICAL SPECIFICATIONS INSTALLATION MANUAL...

  • Page 49: Electrical Specifications

    120 lb. (54 kg) Maximum weight on the cover (evenly distributed) * The load specification for the HORIZON cover is a provision for environmental outcomes, typically some snow or damp leaves that could accumulate on the cover General specifications 2.5”/s (6.35 cm/s)

  • Page 50: Limit Switch Adjustment

    Note: The up and down limit switches have been factory-adjusted and there should be no need to re-adjust them. If adjustments are required to ensure the COVANA cover does not come in contact with surrounding obstacles while being raised, the maximum height may be reduced.

  • Page 51: Troubleshooting

    Check the breaker panel. motor and no movement) disconnected.  Check if any electrical cables are damaged or pinched.  Remove all debris from top of COVANA COVANA cover does not  Posts are frozen. cover. raise or lower. (Motor ...
  • Page 52  If all previous attempts failed, contact your local authorized COVANA dealer.  Clean the affected areas with bleach and a Cover seal turned black.  The seal has accumulated soft brush.

  • Page 53: Appendix

    APPENDIX APPENDIX INSTALLATION MANUAL...
  • Page 54 APPENDIX INSTALLATION MANUAL...
  • Page 55 APPENDIX INSTALLATION MANUAL...
  • Page 56 APPENDIX INSTALLATION MANUAL...
  • Page 57 APPENDIX INSTALLATION MANUAL...
  • Page 58 (This page intentionally left blank, see next page) INSTALLATION MANUAL...
  • Page 59 The electrical portion of the installation was done by a certified electrician. (Electrical hook-up, limit switch adjustment sections) □ All the parts that came with the COVANA cover are installed. □ The start-up procedure is completed. (The key sequence responds correctly) □...

  • Page 60: Installation Checklist (Customer Copy)

    Contact your authorized CoVANA dealer for all service-related issues. Made in Canada by COVANA, a division of the Canimex group www.COVANA.com PATENTED CANADA 2,532,429 US 11/162,557 UK 0515168.3 AUSTRALIA 2006200251 The information in this manual was accurate at the time of print. The manufacturer reserves the right to change or improve its product without prior notice.
  • Page 61 The electrical portion of the installation was done by a certified electrician. (Electrical hook-up, limit switch adjustment sections) □ All the parts that came with the COVANA cover are installed. □ The start-up procedure is completed. (The key sequence responds correctly) □...

  • Page 62: Installation Checklist (Installer Copy)

    Contact your authorized COVANA dealer for all service-related issues. Made in Canada by COVANA, a division of the Canimex group www.COVANA.com PATENTED CANADA 2,532,429 US 11/162,557 UK 0515168.3 AUSTRALIA 2006200251 The information in this manual was accurate at the time of print. The manufacturer reserves the right to change or improve its product without prior notice.
  • Page 63 NOTES : APPENDIX INSTALLATION MANUAL...
  • Page 64 INSTALLATION CHECKLIST (Installer copy) INSTALLATION MANUAL...

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