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COVANA C-HOR Instruction Manual

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Revision 13
2018-04-23

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  • Page 1 Revision 13 2018-04-23...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS ............................. 2 SAFETY ..................................4 Safety information ..............................4 Avoiding the risk of electrocution ..........................5 LABELLING ................................7 GLOSSARY ................................10 HARDWARE IDENTIFICATION TABLE .........................15 INSTALLATION PREPARATION ..........................18 Location considerations ............................18 Foundation preparation............................19 Installation reference information .........................20 INSTALLATION ...............................21 Uncrating ................................21 Cover assembly ..............................24...
  • Page 3 APPENDIX ................................53 Wiring diagram (North America) – 60 Hz, 120 VAC Operator ................54 INSTALLATION CHECKLIST (Customer copy) ....................57 INSTALLATION CHECKLIST (Installer copy) .......................59 INSTALLATION MANUAL TABLE OF CONTENTS...

  • Page 4: Safety

     Do not put any type of fabric or plastic sheet, SAVE THESE SAFETY INSTRUCTIONS AND such as a tarpaulin, on the Covana cover. This REVIEW THEM REGULARLY. could overheat the cover and result in the READ AND FOLLOW ALL INSTRUCTIONS deformation or delamination of the cover.

  • Page 5: Avoiding The Risk Of Electrocution

    Covana. and regulations.  Do not roll the Covana cover onto its side or  Install the Covana cover in such a way that slide it on its side. This will damage the siding.
  • Page 6 To reduce the risk of electric shock, connect the local common bonding grid in the area of the Covana cover. Use terminals with an insulated or bare copper conductor no smaller than No. 6 AWG (13.3 mm ...

  • 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 owners’ 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

    The top plate is a cover that is installed on the sleeve assembly. It will protect the lifting mechanism from any debris. Top plate Figure 3 The operator powers and controls the lifting mechanism of the Operator unit Covana cover. Figure 4 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 5 The short U frames protect the mechanical parts that rest on the U frame (short) foundation and connect both posts. Figure 6 The motor-side protect the chains.
  • Page 12 The I-to-C bracket makes the link between I-beam and C-channels. plate (small) Figure 12 Key switch The key switch is used to operate the Covana cover. Figure 13 Corner bracket The corner brackets link the C-channels on the side to the ones in front and back.
  • Page 13 Figure 18 Wiper bracket The wiper bracket is attached under the I-beam. This part is required to ensure waterproofing of the Covana cover. Figure 19 Installation foam The installation foam is used during the installation process to protect the hot tub from direct contact with the cover.
  • Page 14 Tub mount arm The tub mount arms are used for the tub mount option only. They (short or long) link the sleeve brackets to the tub mount supports. (for tub mount model only) Figure 23 Post brackets These are assembled with the L brackets, the side supports and 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. 1/4in. -20 x 1 in. Button hex drive bolt. Used to fix the pivot joint bracket the the cover. 10-24 x 1/2 in. Thread cutting screw.
  • Page 16 1/4 in. Lock washer used for cover assembly and the tub Ground mount option. anchoring Tub mount 1/4 in. Flat stainless steel washer. Only used for the tub mount option. Tub mount 5/16 in. Lock washer used to fasten the operator unit to the long U-frame.
  • Page 17 in.-20 Nylon insert locknut. Used with shoulder Ground screw with ground anchoring anchoring option. Tub mount 1/4-20-5/16 in. Set screw used operator’s sprocket. 3/16-3/16-5/8 Square ends key used for the operator’s sprocket. 5/32 in. Hex key. Used for fastening the 1/4in.-20 x 1 in. 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 ft.

  • Page 19: Foundation Preparation

     Each of the two jacks of the Covana cover must be properly fastened to the tub frame. It is the installer’s responsibility to ensure the Horizon cover is properly fastened in a safe manner.

  • 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 Figure 30 and Figure 31. 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 in. (61 cm) level CAUTION • The Covana cover should be installed by a certified Covana installer. Having the Covana cover installed by someone who is not certified will void the warranty. Ask your local Covana dealer for information on certified installers.
  • Page 22 Remove the seal, the foam spacers and the optional parts box, either the tub mounting or the ground anchoring hardware, from the bottom of the crate and place them in a safe place. (Figure Tie-wrap Motor-side Carefully cut the tie wrap holding the long U- frame 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 in. Robertson screws holding the posts to the crate as shown in Figure 36. 12) Remove both post assemblies from the crate and place them in a safe place. #8-10 x 1½ in. Robertson screws WARNING Figure 36...

  • Page 24: Cover Assembly

    Cover assembly WARNING  Before assembling the cover, keep in mind not to overtighten bolts. Power tools must not be used. The bolts will break or strip under too much torque. 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 CARRIAGE 1/4 in. lock 1/4-20 BOLT washer hex nut 5) Install the I to C small connection plate to the I- beam by using 1/4 in.-20 x 5/8 in. carriage bolts, 1/4in. lock washers, 1/4 in.-20 nuts and 7/16 (11 mm) socket wrench and spanner.
  • Page 26 TOP VIEW Once the I-beam is properly centered into the C- channels using the center label (Figure 49), lock it in place by tightening the four nuts and carriage bolts on both ends of the I-beam (two on each end). (Figure 50) WARNING ...
  • Page 27 10) Slide on one of the 93 7/16in. (237 cm) C- channel previously assembled with the corner brackets on the end of the front panel. (Figure 11) Screw in the phillips #10-24 x 1/2in. screws in the pre-drilled holes of the C-channel through the corner brackets holes.
  • Page 28 Closed Opened  All security risks such as drowning, injury or undesired entry due to an open Covana cover without an escape hatch installed are not approved by Covana and product certification will be void. Figure 58...

  • Page 29: Tub Mount Assembly

    Tub mount assembly Note: If the cover was supplied with the ground 1/4-20 x 1/2 in. anchoring option, skip to the ground anchoring Phillips screws assembly section. Loosen the four top 1/4-20 x 1/2 in. Phillips screws so you have an approx. 1/4 in. (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 view Figure 61 Attach the L bracket on the post bracket with Post bracket included 1/4-20 x 3/4 in. carriage bolts and 1/4- 20 nylon hex lock nuts. (Figure 62) Repeat for all four post brackets.
  • Page 31 Insert the side support bracket hook in the notch of the outer sleeve. (Figure 64) Slide on the post bracket on the side support bracket using the slots as guide. (Figure 64) post bracket Place the 1/4-20 x 3/4 in. carriage bolts hanging slots in their square holes as it will be harder to do later.

  • 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 in. (91.4 cm) high or less, place the pivot arm flat side facing down. For hot tubs above 36 in. (91.4 cm) high, place the pivot arm flat side facind up.

  • Page 33: Lifting Mechanism Assembly

    Lifting mechanism assembly Insert the square drive-shaft over the square shaft on the bottom of the jack through the Rear opening in the bottom of the post and push it as side far as possible. (Figure 72) 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 76) Motor-side’s CAUTION input shaft • Ensure the input shaft in the middle of the U frame is pointing outwards from the cover.
  • Page 35 10) Repeat steps 8 an 9 on the opposite side. Remove the 11) Remove the four slotted screws at the bottom of tape on the the operator and remove the cover. Do not sprocket. discard these screws. (Figure 78) 12) Install the 3/16-3/16 x 5/8 in. square key into the motorside’s input shaft’s 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 warning red tag) in the extra holes on top of the posts (Figure 81). Extra holes (Hex cap screw WITH a washer)
  • Page 37 ¼-20 x 1 in. back screws. (DO NOT REMOVE) 23) Use the threaded rod screws (Figure 81) on both posts to align the pivot arms’ screw slots with the screw on the cover. Raise the post by turning the threaded rod screw counter clockwise and lower the post by turning the threaded rod screw Can go from clockwise.

  • 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 Tighten all the bolts and ensure the tub mount supports are lying flat on the surface of the tub. WARNING  Do not overtighten any hardware. Failure to follow this instruction could damage the paint or the hardware itself.  Ensure the arms’...

  • Page 40: Ground Anchoring Mounting (Optional)

    Ground anchoring mounting (optional) Ensure the system is well positioned around the 24in. (61 cm) level hot tub and the cover is lying flat and centered. Check whether the posts are still level before anchoring. Use a 24in. (61 cm) level. CAUTION Figure 95 •...

  • Page 41: Testing The Horizon Cover

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

  • Page 42: Wiper Brackets Installation

    (Figure 99) Remove the siding on the double-sided tape of one wiper bracket. (Figure 99) Under the Covana cover locate the I-beam and orient the wide flap of the wiper bracket outwards of cover. (Figure 100)
  • Page 43 Seal application Masking tape 1) Once the Covana cover has been fully assembled, raise the cover and remove the foam spacers and tape. Lower the cover and walk around the entire perimeter of the hot tub, observing where the inside surface of the cover will make contact with the hot tub.
  • Page 44 If you are satisfied, raise the cover and remove the red plastic backing off the seal. 14) Raise the Covana cover again to approx. 6 in. (15 cm) and stop. CAUTION 15) Make sure the cover is flat and there are no ...
  • Page 45 10 ft. (3 m) of the hot tub, must be bonded  Install the Covana cover in such a way that water to the equipment grounding bus with copper drainage is directed away from the electrical 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 108) 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 dimensions 25° The maximum raised height is 104 in. (264 cm) The minimum raised height is 46 in. (117 cm) The hot tub must fit within these height specifications: Min.: 32 in. (81 cm) Max.: 48 in. (122 cm) Figure 106 INSTALLATION MANUAL TECHNICAL SPECIFICATIONS...

  • Page 48: Frame Dimensions And Footprint

    Frame dimensions and footprint Figure 107 TECHNICAL SPECIFICATIONS INSTALLATION MANUAL...

  • Page 49: Electrical Specifications

    3) The Covana cover requires a dedicated single-phase 115 VAC (North America) or 220 VAC (European) hard- wired power supply. 4) The Covana cover must be installed in accordance with and comply with all the applicable local codes and regulations. All wiring and connections should be performed by a qualified electrician.

  • Page 50: Limit Switch Adjustment

    Figure 108 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. Never change the factory settings of the down limit nor increase the up limit beyond the factory setting.

  • Page 51: Troubleshooting

    TROUBLESHOOTING Problem Probable Causes Solutions   The Covana cover will Reset the GFCI. The GFCI is tripped.  not raise or lower.  Verify that the power source is enabled. The power source is  (Silent motor and no Check the breaker panel.
  • Page 52  The cover lowers, but  Only a certified electrician can open the plate does not rise. operator and check for faulty up and down missing.  limit switches. The key switch is  Verify whether there is any corrosion on the faulty.

  • Page 53: Appendix

    APPENDIX INSTALLATION MANUAL APPENDIX...

  • Page 54: Wiring Diagram (North America) - 60 Hz, 120 Vac Operator

    Wiring diagram (North America) – 60 Hz, 120 VAC Operator APPENDIX INSTALLATION MANUAL...
  • Page 55 Wiring diagram (Europe) – 50 Hz, 220 VAC Operator INSTALLATION MANUAL APPENDIX...
  • Page 56 APPENDIX INSTALLATION MANUAL...

  • Page 57: Installation Checklist Customer Copy

    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 have been installed. □ The start-up procedure was completed. (The key sequence responds correctly) □...
  • Page 58 Contact your dealer for all related service 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 59: Installation Checklist Installer Copy

    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 have been installed. □ The start-up procedure was completed. (The key sequence responds correctly) The all-weather seal functions properly.
  • Page 60 Contact your dealer for all related service 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.

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