COVANA Evolution Series Installation Manual
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COVANA Evolution Series Installation Manual

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Revision 1
2017/05/29
Revision 2
INSTALLATION MANUAL
2017/11/10

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Summary of Contents for COVANA Evolution Series

  • Page 1 Revision 1 2017/05/29 Revision 2 INSTALLATION MANUAL 2017/11/10...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS ............................. 2 SAFETY ..................................4 Safety information ..............................4 LABELING ................................. 7 GLOSSARY ................................10 HARDWARE IDENTIFICATION TABLE .........................14 INSTALLATION PREPARATION ..........................16 Location considerations ............................16 Foundation preparation............................18 INSTALLATION ...............................18 Uncrating ................................18 Assembly ................................22 Lifting mechanism assembly ..........................27 Testing the Evolution cover ..........................35 Applying the wiper bracket............................36 Seal application ..............................37...
  • Page 3 INSTALLATION CHECKLIST (Customer copy) ....................52 INSTALLATION CHECKLIST (Installer copy) .......................55 INSTALLATION MANUAL TABLE OF CONTENTS...

  • Page 4: Safety

     Never operate the Covana cover until all people the hot tube. and objects are out of the spa.  Climb, walk or stand on the Covana cover at any time. WARNING  Leave the Covana cover open for more than 12 ...
  • Page 5  Do not roll the Covana cover onto its side or slide  The Covana operator must be connected to a it on its side. This will damage the siding. circuit that is protected by a Class A dedicated ...
  • Page 6 “g,” “gr,” COVER ⏚ “ground,” “grounding” or with a symbol that is  Any modifications to the Covana cover, such as located inside the supply terminal box or mechanical, electrical or aesthetic ones, may compartment must...

  • Page 7: Labeling

    Risk of electrocution warning, located on the operator. Key operating diagram, located on the key switch. Drowning risk warning, located on the inside of the Covana cover. Specification sticker, located on the Specification sticker, located on the operator operator. (European model) Note: This sticker (North American model) Note: This sticker provides the serial number.
  • Page 8 Sticker located on the key switch cable. Do not step symbol, located on top of the operator. Sticker located on the outer shell. Electrical information, located on the key switch cable. LABELING INSTALLATION MANUAL...
  • Page 9 Do not step on cover sticker located of the end C-channels of the Evolution cover. Center sticker located on the center of the 94 9/16 in. (240 cm) C-channel. Top sticker, located on the interior of the I-beams and escape hatch opening to indicate orientation.

  • Page 10: Glossary

    Function All-weather seal The all-weather seal prevents water from leaking between the sleeves when the Covana cover is fully closed. Failure to install this part may result in water infiltration in between the sleeves and damage to the mechanism. Figure 1...
  • Page 11 Corner bracket The corner bracket is the piece that links the cover to the sleeves. There is one in each corner of the Covana cover to ensure proper weight distribution. Figure 7 Corner bracket The corner brackets links the C-channels on the side to the ones in front and back.
  • Page 12 Figure 17 Limit switch The limit switches are located in the operator. They control the minimum and maximum travel height of the Covana cover. Refer to the Limit Switch Adjustment section for further details. Figure 18 Motor frame The motor frame is composed of the two motor-side jacks and the operator.
  • Page 13 Non-motor-side The non-motor-side jacks are a main part of the Covana cover. jack They and the motor-side jacks enable the cover to move. Figure 20 Operator The operator powers and controls the lifting mechanism of the Covana cover. It contains the motor and the limit switches.

  • Page 14: Hardware Identification Table

    #8 x 1/2″ self-drilling Robertson screw used to fasten the inner sleeve to the Covana cover. 1/4″-20 x 2 1/4″ hexagonal bolt used to assemble the feet of the posts. 1/4″″-20 Nylon- insert locknut.
  • Page 15 #2 x 2″ Robertson bit. 5/16″ nylon washer used to connect the U-frames 5/16″ painted washer. 1/4″ nylon washers used to fasten the bottom of the sleeves with M6 x 20 mm screw. M6 clip-on barrel nut used to secure the sleeve at the bottom of each post.

  • Page 16: Installation Preparation

    To ensure safe use of the Covana cover, it must be  The key switch must be permanently mounted installed on a properly prepared surface. It is and located 5 ft.

  • Page 17: Foundation Preparation

     Each of the four jacks of the Covana cover must be properly anchored to the foundation using at least one of the pre-drilled holes located at the foot of each post.

  • Page 18: Installation

      48 in. (122 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 19 5) Remove the C-channels, the escape hatch box, the part box, the foam pieces and the seal from Escape the crate. Temporarily put these items in a safe hatch box place. (Figure 29) Seal C-channels 6) Use a slotted screwdriver to remove the two slotted #10-24 x 3/8″...
  • Page 20 1″ bolt holding the jack to the bracket. There is one bolt per jack. Do not discard this bolt and bushing; they are required to assemble the Covana cover. (Figure 32) 10) With the help of another person, remove the motor frame assembly from the crate. Place one...
  • Page 21 I-beams  Dropping the crate could damage the cover. 14) If your Covana cover was delivered with roller shades, remove the cardboard cylinders from the holes in the side panels and place them in a safe place.

  • Page 22: Assembly

    Covana cover, whereas the long-side will need the motor frame on the long side of the Covana cover. Only the 8 feet model Is available in the longside version. (Figure 38) CAUTION ...
  • Page 23 3) It is recommended to use a table or crate as a base to build the top section of the cover, and later transfer it to the hot tube once it is assembled. If you use a table, use the foam to support the cover assembly and prevent damage to the cover.
  • Page 24 End panels 7) Slide the end panels on both ends of the cover. Ensure the I-beams have slid over the panel on both bottom and top side. (Figure 44) CAUTION  Ensure that the panels are pushed as far as possible by hand and are completely inserted in the I-beam.
  • Page 25 11) On the other end of the cover, slide the other corner bracket and C-channel assembly. Use the 50 ft. (15 m) ratchet straps to properly lock in the foam panels. It will also help you to assemble the final part of the cover. (Figure 48) 12) On both corner of the assembly, tighten the Robertson sheet metal #8 x ½...
  • Page 26  All security risks such as drowning, injury or undesired entry due to an open Evolution cover Closed Opened without an escape hatch installed are not approved by Covana and product certification will be void. Figure 50 INSTALLATION INSTALLATION MANUAL...

  • Page 27: Lifting Mechanism Assembly

    Figure 51. The standard model will need the motor frame to be on the short side of Right side for the Covana cover, whereas the long-side model post assembly will need the motor frame on the long side of the Figure 51 Covana cover.
  • Page 28 Motor-side jack assembly 8) Position the left non-motor-side jack in the remaining corner of the Covana cover. The square shaft at the bottom of the jack should face toward the motor frame, and the U-frame bracket should be inwards. If not, review the previous steps to assemble the left and right post feet.
  • Page 29 Motor-side Non-motor-side direction jack assembly 11) Install the long aluminum U-frame over the left driveshaft and ensure it lines up with motor-side and non-motor-side jack assemblies. Fasten it in place using two hexagonal 5/16″-18 x 2″ bolts, two 5/16″-18 nylon-insert lock nuts and four 5/16″...
  • Page 30 15) Fasten a short U-frame to each end of the front frame cut-out and then install the entire assembly between the front posts. Use four hexagonal 5/16″-18 x 2″ bolts, four 5/16″-18 nylon-insert lock nuts and eight 5/16″ washers per side. Use 1/2″ (13 mm) socket wrench and spanner.
  • Page 31 18) Install the clip-on barrel nuts at the bottom of the non-motor-side jack assemblies for the sleeves, using Phillips M6 x 20 mm screws and 1/4″ Clip-on washers. Only non-motor-side jack barrel nut assemblies need clip-on barrel nuts installed. (Figure 61). Do not fully screw in the M6 screws; ″...
  • Page 32 20) Unscrew the 3/8″-24 x 1″ Allen bolt with a 7/32″ (5.5 mm) socket on the top of all four jack assemblies. Put these parts in safe place. 21) Slide the sleeves over all four jacks. (Figure 64) Be sure to align the opening at the bottom of the sleeves with the U-frames attached.
  • Page 33 Painted 25) Ensure the Covana cover is correctly aligned washer with the hot tub. Use a measuring tape on all 5/16″ four sides and make sure it is still resting on the foam spacers. If not, center the Covana cover, using a measuring tape on all four sides.
  • Page 34 29) Then, use four #8 x 1/2″ self-tapping Robertson screws to fasten one bracket to its post. (Figure 70) Tighten with care; self-tapping screws can break when screwed in too hard. Note: Follow the pattern shown in Figure 71 (A to D).

  • Page 35: Testing The Evolution Cover

    If not, adjust the corner brackets (Follow respected. steps 27 to 30 in the Lifting mechanism  Ensure that the base of the Covana cover is not assembly (continued) section. in a flood zone. Any damage caused by flooding...

  • Page 36: Applying The Wiper Bracket

    Applying the wiper bracket Lift cover halfway up to proceed with next steps. The next steps are important for making the cover water tight. CAUTION Back siding  Insure the I-beams are dry and clean. Figure 74  Insure ambient temperature is between 70°F to 100°F (21°C to 38°C) for ideal application temperature.

  • Page 37: Seal Application

    Masking tape Seal application 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 tube, observing where the inside surface of the cover Clip will make contact the hot tube.
  • Page 38 To apply pressure to the seal, simply The rubber seal should not be overheated; the push it against the Covana cover with your maximum temperature it can withstand is 302 hands. (150 C).

  • Page 39: Non-Permanent Mounting Plates Installation

    After the unit has been installed, but BEFORE installing the seal, proceed with the non- permanent mounting plates installation. Using the key switch, lift the Covana cover up to give room for maneuvering the tub. Have three installers present. Two of them should lift the tub at one end approx.

  • Page 40: Electrical Hook-Up

     Install the Covana cover in such a way that within 10 ft. (3 m) of the hot tub must be bonded drainage directs water away from the electrical to the equipment grounding bus with copper components.

  • Page 41: 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 86) 2) Refer to the complete wiring diagrams for the European model and North American model in the appendix Grounding lug ⏚...

  • Page 42: Technical Specifications

    TECHNICAL SPECIFICATIONS Side elevation dimensions The maximum distance the Covana cover travels is 52 in. (132 cm). The maximum raised height depends on the height of the hot tub. Add the hot tub height to distance the Covana cover travels to determine the maximum height.

  • Page 43: Frame Dimensions And Foot Print

    Frame dimensions and foot print Standard model Figure 98 **NOT TO SCALE** Figure 84 Cover length 8’ 118’’ (2997 mm) 105¾’’ (2685 mm) 95¼'' (2422 mm) 101½'' (2576 mm) 98'' (2490 mm) 131¼'' (3334 mm) 9’ 130½’’ (3315 mm) 118¼’’ (3004 mm) 107½’’...
  • Page 44 Long side (LS) model (8 feet only) **NOT TO SCALE** Figure 85 TECHNICAL SPECIFICATIONS INSTALLATION MANUAL...

  • Page 45: Electrical Specifications

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

  • Page 46: Limit Switch Adjustment

    If adjustments are required to Figure 86 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 setting of the down limit nor increase the up limit beyond the factory setting.

  • Page 47: Troubleshooting

    TROUBLESHOOTING Problem Probable Causes Solutions The Covana cover will  The GFCI is tripped.  Reset the GFCI. not raise or lower.  The power source is  Verify that the power source is enabled. (Silent motor and no disconnected.
  • Page 48 The middle sleeve has  Posts are frozen.  Verify whether the all-weather seal is on the fallen. inner post and at proper position.  The stopper  Check broken/missing. whether stopper broken/missing.  Call your local dealer for the reassembly procedure.

  • Page 49: Appendix

    APPENDIX INSTALLATION MANUAL APPENDIX...

  • Page 50: Wiring Diagram (North America) - 60 Hz, 120 Vac Operator

    Wiring diagram (North America) – 60 Hz, 120 VAC Operator APPENDIX INSTALLATION MANUAL...

  • Page 51: Wiring Diagram (Europe) - 50 Hz, 220 Vac Operator

    Wiring diagram (Europe) – 50 Hz, 220 VAC Operator INSTALLATION MANUAL APPENDIX...
  • Page 52 The key switch is permanently installed at least 5 ft. (1.5 m) away from the hot tub and 5 ft. (1.5 m) from the ground. □ All the parts that came with the Covana cover have been installed. □ The start-up procedure was completed. (The key sequence responds correctly) □...
  • Page 53 INSTALLATION MANUAL INSTALLATION CHECKLIST (Customer copy)
  • Page 54 Contact your Covana dealer for all related service issues. Made in Canada by Covana, a division of 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 55 The key switch is permanently installed 5 ft. (1.52 m) away from the hot tub and 5 ft. (1.52 m) from the ground. □ All the parts that came with the Covana cover have been installed. □ The start-up procedure was completed. (The key sequence responds correctly) □...
  • Page 56 INSTALLATION MANUAL...

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