COVANA EVOLUTION Installation Manual
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COVANA EVOLUTION Installation Manual

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Revision 1
2017/05/29
Revision 3
2020-04-17
1
INSTALLATION MANUAL
232864

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Summary of Contents for COVANA EVOLUTION

  • Page 1 Revision 1 2017/05/29 Revision 3 2020-04-17 INSTALLATION MANUAL 232864...

  • Page 2: Table Of Contents

    Foundation preparation............................17 INSTALLATION ...............................18 HANDLING ................................18 Uncrating ................................20 Assembly preparation ............................23 Lifting mechanism assembly ..........................29 Testing the Evolution cover ..........................37 Wiper bracket installation............................38 Non-permanent mounting plates installation (option) ...................39 Seal application ..............................40 ELECTRICAL HOOK-UP ............................42 Grounding and power supply connection ......................43 TECHNICAL SPECIFICATIONS ..........................44...
  • Page 3 Wiring diagram (North America) – 60 Hz, 120 VAC Operator ................52 Wiring diagram (Europe) – 50 Hz, 220 VAC Operator ..................54 INSTALLATION CHECKLIST (Customer copy) ....................57 INSTALLATION CHECKLIST (Installer copy) .......................59 INSTALLATION MANUAL...

  • Page 4: Safety

     Operate the Covana cover while somebody is in  Lower the COVANA cover in extreme wind the hot tub. conditions such as gusts of 30 mph (50 km/h) in  Climb, walk or stand on the Covana cover at any the raised position. time. INSTALLATION MANUAL...

  • Page 5: Avoiding The Risk Of Electrocution

    (GFCI) that complies with all tools. applicable local electrical codes and regulations.  Do not roll the Covana cover onto its side or slide  Install the COVANA cover in such a way that 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 not smaller than No. 6 AWG (4.11 mm).

  • Page 7: Labeling

    LABELING 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 that these labels are always visible and should never be removed. Risk of electrocution warning, located on the operator unit.
  • Page 8 Key switch warning, located on the key switch. Do not step symbol, located on top of the operator unit. Maintenance information located on the cover. Electrical information, located on the key switch cable. INSTALLATION MANUAL...
  • Page 9 Do not step on cover sticker located on the end C-channels of the COVANA cover. Center label located on 94 9/16 in (240 cm) C-Channel (remove after installation) Top sticker located on I-Beams and Escape hatch opening (Hidden when assembled)

  • Page 10: Glossary

    GLOSSARY Part Figure Function All-weather seal The all-weather seal will help protect sleeves from damage due to weather. Figure 1 C channel The C-channel is the outer frame of the cover. Figure 2 Contour seal The contour seal ensures uniform contact between the inner shell and the hot tub.
  • Page 11 The hammer block is a piece of plastic or wood used during the installation to hit on the panels without causing damage. Figure 10 Foot bracket The foot bracket provides a solid footing for the COVANA cover and is assembled with a jack. Figure 11 Front frame cut- The front frame cut-out gets installed under the front step of your hot tub.
  • Page 12 The motor frame is composed of the two motor-side jacks and the operator. Figure 18 Non-motor-side The non-motor-side jacks are a main part of the COVANA cover. or motor-side They and the motor-side jacks enable the cover to move. jack...
  • Page 13 Figure 22 Wiper bracket The wiper bracket is adhered under the I-beams. This part is required to ensure the waterproofing of the COVANA cover. Figure 23 I-to-C The short I-to-C connection plate makes the link between I-beams connection plate and C-Channels.

  • Page 14: Hardware Identification Table

    M6 x 20 mm screw used to hold the cover and sleeve. #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.
  • Page 15 #2 x 6” Robertson bit. 5/16″ nylon washer used to connect the U-frames 1/4″ 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 and installed on a properly prepared surface. It is located 5 ft.

  • Page 17: Foundation Preparation

    Foundation preparation  The Evolution cover requires a clean, flat and level surface such as an engineered wood deck or a concrete slab.  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

    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. HANDLING Minimum requirements ...
  • Page 19 (Figure 32)  Do not attempt anything that could compromise the safety of your crew.  Refer to the COVANA Damaged claim form attached to the crate, take pictures and simply refuse the delivery from the carrier. (Figure 33) Secure the crate ...

  • Page 20: Uncrating

    In case of any Front suspicious damage, take pictures first and side please call COVANA customer service immediately. Always stand the crate in the vertical position. Ensure that the uncrating can be done safely given the wind conditions.
  • Page 21 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. (Erreur ! Source du renvoi introuvable.) WARNING  Do not remove the alignment bracket on the top of the jack (red part).
  • Page 22 I-beams  Dropping the crate could damage the cover. 13) 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 23: Assembly Preparation

    Note: The cover is rectangular. The standard model will need the motor frame to be on the short side of the 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 long side version.
  • Page 24 2) Assemble two I to C short connection plate as Carriage Spacer shown in Figure 46. Use 1/4".-20 x 5/8 in. bolt carriage bolts, 1/4".-20 nuts and 7/16” (11 mm) socket wrench and spanner. Insert the I to C spacer between the I to C connection plate and the bent part.
  • Page 25 7) Slide one I-beam with short I to C connection I-beams plates in the C-channels on both side of the middle panel. Place the I-beams in such manner where the bent portion of I to C connection is pointing inwards. (Figure 48, Figure 49 and Figure 52) Ensure they fit snug with foam panel.
  • Page 26 9) Insert the corner brackets in both ends of the C- channels remaining. Use the provided Robertson sheet metal #8 x 3/4 in. screws on the inside holes. The two remaining holes will be used later. (Figure 53) WARNING  Do not overtighten the screws as they might break. #8 x ¾...
  • Page 27 12) 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 56) CAUTION ...
  • Page 28 Closed Opened unwanted access to hot tub.  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.

  • Page 29: Lifting Mechanism Assembly

    Figure 59. The standard model will need the motor frame to be on the short side of Motor jack the COVANA cover, whereas the long-side model will need the motor frame on the long Right side side of the COVANA cover.
  • Page 30 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.
  • Page 31 11) Install the long aluminum U-frame over the left Plastic Motor-side driveshaft and ensure it lines up with motor-side washer direction Non-motor-side jack assembly 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 32 16) Verify whether the drive shafts fell off during Jack lock installation. If so, review the previous steps. If bolt not, tighten all U-frame bolts. Alignment DANGER bracket  Failure to verify the proper installation of the drive shafts could result in the non-motor-side jacks extending on their own.
  • Page 33 20) Slide the sleeves over all four jacks. (Figure 70) Be sure to align the opening at the bottom of the sleeves with the U-frames attached. (Figure 71) 21) Screw in the Phillips M6 x 20 mm screws at the bottom of all four sleeves.
  • Page 34  Ensure the hole in each top plate is aligned with the jack assembly’s threads before installing the screw. (Figure 75) 24) Ensure the COVANA cover is centered. Use a measuring tape on all 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 35 27) Repeat step 26 for each remaining corner bracket, follow the order of installation as shown in Figure 76, 1 to 4. 28) Then, use four #8 x 1/2″ self-tapping Robertson screws to fasten one bracket to its post. (Figure 77) Tighten with care;...
  • Page 36 30) Verify the installation of the brackets by trying to lift each inner sleeve. Review steps 26 to 27 for any broken screws or to retighten screws if an inner sleeve continues to move. (Figure 79) 31) Install the rubber caps on all four posts. These caps are in the parts box and help protect the post assembly tops from weathering.

  • Page 37: Testing The Evolution Cover

    If not, adjust the corner brackets (Follow  Ensure that the base of the COVANA cover is not steps 26 and 27 in the Lifting mechanism in a flood zone. Any damage caused by flooding assembly section.

  • Page 38: Wiper Bracket Installation

    Wiper bracket installation Lift cover halfway up to proceed to the next steps. The next steps are important for minimizing water intrusion. CAUTION  The number of wiper brackets is four.  Ensure the I-beams are dry and clean.  Ensure ambient temperature is between 70°F to 100°F (21°C to 38°C) for ideal application temperature.

  • Page 39: Non-Permanent Mounting Plates Installation (Option)

    If you don’t have non-permanent mounting plates, skip to next section. Note: This setup is only available for hot tub base sizes larger than 82” wide for standard COVANA units and 87” wide for long side COVANA units. 1) After the unit has been installed, but BEFORE installing the seal, proceed with the non-permanent mounting plate installation.

  • Page 40: Seal Application

    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 Clip of the spa, observing where the inside surface of the cover will make contact with the hot tube.
  • Page 41 WARNING underside of the cover. To apply pressure to the seal, simply push it against the COVANA cover  At this point, if there is no water in the spa and the with your hands.

  • Page 42: Electrical Hook-Up

    GFCI that complies with all applicable local electrical codes and regulations.  Install the COVANA cover in such a way that drainage directs water away from the electrical components.  Do not connect any auxiliary components to the electrical system of the COVANA cover unless they have been approved by COVANA.

  • Page 43: Grounding And Power Supply Connection

    Grounding and power supply connection Remove the four screws on the bottom side of the COVANA operator and remove the cover (Figure 90). 2) Refer to the complete wiring diagrams for the European model and North American model in the appendix.

  • Page 44: Technical Specifications

    TECHNICAL SPECIFICATIONS Side elevation dimensions The maximum distance the Covana cover travels is B – See below table The hot tub must fit within these height specifications: Min: A – See below table Max: 48 in. (122 cm) Figure 90...

  • Page 45: Frame Dimensions And Footprint

    Frame dimensions and footprint Standard model **NOT TO SCALE** Figure 92 Table 1: Dimension in accordance to cover length Cover length 8’ 118’’ (2997 mm) 105¾’’ (2685 mm) 95¼'' (2422 mm) 101½'' (2576 mm) 98'' (2490 mm) 131¼'' (3334 mm) 9’...
  • Page 46 **NOT TO SCALE** Long side (LS) model (8 feet only) Figure 93 Figure 85 INSTALLATION MANUAL...

  • Page 47: Electrical Specifications

    Electrical specifications  The COVANA cover requires a dedicated single-phase 115 V AC (North America) or 220 V AC (Europe) hard- wired power supply.   The COVANA cover must be installed in accordance with and comply with all applicable local codes and regulations.

  • Page 48: 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 Figure 94 surrounding obstacles while being raised, the maximum height may be reduced.

  • Page 49: Troubleshooting

     Check if any electrical cables are damaged or pinched. The Covana cover will  Posts are frozen. Remove all debris from top of the COVANA cover. not raise or lower.  Cover is obstructed. Check if posts are obstructed.
  • Page 50  If all previous attempts failed, contact your local authorized COVANA dealer. Cover raises unevenly  A chain is broken.  Contact your local authorized COVANA dealer for  A spring pin is broken. technical support immediately.  A drive shaft has fallen off.

  • Page 51: Appendix

    APPENDIX INSTALLATION MANUAL...

  • Page 52: Wiring Diagram (North America) - 60 Hz, 120 Vac Operator

    Wiring diagram (North America) – 60 Hz, 120 VAC Operator Figure 97 INSTALLATION MANUAL...
  • Page 53 Figure 98 INSTALLATION MANUAL APPENDIX...

  • Page 54: Wiring Diagram (Europe) - 50 Hz, 220 Vac Operator

    Wiring diagram (Europe) – 50 Hz, 220 VAC Operator Figure 99 INSTALLATION MANUAL...
  • Page 55 Figure 100 INSTALLATION MANUAL APPENDIX...
  • Page 56 (This page is intentionally left blank, See next page) INSTALLATION MANUAL...

  • Page 57: Installation Checklist Customer Copy

    □ All the parts that came with the COVANA cover are installed. □ The start-up procedure is completed. (The key sequence responds correctly and Testing the COVANA cover section is completed.) □ The all-weather seal functions properly. (The cover raises and lowers properly) □...
  • Page 58 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 59: Installation Checklist Installer Copy

    □ All the parts that came with the COVANA cover are installed. □ The start-up procedure is completed. (The key sequence responds correctly and Testing the COVANA cover section is completed.) □ The all-weather seal functions properly. (The cover raises and lowers properly) □...
  • Page 60 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.

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