Sterling Leisure Products COVANA Installation guide

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COVANAIII‐Revision5

Installation Manual

Sterling Leisure Products

www.sterlingcovana.com

Read this manual before proceeding with installation

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Laversionfrançaisedumanueldébuteàlapage21.

FRANÇAIS

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RISK OF ELECTROCUTION

THE COVANA OPERATOR MUST BE CONNECTED TO A DEDICATED GFCI

(GROUND FAULT CIRCUIT INTERRUPTERS) PROTECTED CIRCUIT.

REFERENCE: COMPLY TO ANY LOCAL CODES AND REGULATIONS.

RISK OF ELECTROCUTION

THE OPERATOR MUST BE PROPERLY BOUNDED BEFORE CONNECTING THE MAIN POWER SUPPLY.

THE OPERATOR MUST BE PROPERLY GROUNDED BEFORE CONNECTING THE MAIN POWER SUPPLY.

RISK OF INJURY

DO NOT OPERATE THE COVANA WHILE IN WATER

RISK OF INJURY

DISCONNECT OR TURN OFF ALL POWER SUPPLY BEFORE STARTING

INTERVENTION ON THE COVANA

WARNING

RISK OF ELECTROCUTION

ALL ELECTRICAL WIRING MUST BE DONE BY A QUALIFIED PROFESSIONAL

THE WIRING MUST MEET THE REQUIREMENTS OF ANY LOCAL CODES AND REGULATIONS

WARNING

AVOID DROWNING RISK

ENTRAPMENT POSSIBLE

FAILURE TO FOLLOW ALL INSTRUCTIONS MAY RESULT IN INJURY OR DROWNING

INSPECT PERIODICALLY — POWER SAFETY MEETING ASTM F1346-91 REQUIREMENTS

WARNING

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THIS OPERATOR IS SPECIALLY DESIGNED TO OPERATE ONLY WITH THE COVANA LIFTING SYSTEM.

UNDER NO CIRCUMSTANCES SHOULD THIS OPERATOR BE USED FOR ANY OTHER APPLICATIONS.

DO NOT STEP ON THE OPERATOR.

DISPOSAL: THIS PRODUCT CONTAINS MAINLY: STEEL, COPPER (CU), ALUMINUM DIE-CAST (AL).

PLEASE RECYCLE WISELY. THE GEARBOX CONTAINS OIL AND OTHER MATERIALS

REMOVE THE CONTROL KEY AFTER OPERATING THE COVANA.

STORE THE KEY IN A SECURE LOCATION WHEN NOT IN USE.

BRING KEY WITH YOU IN THE SPA TO PREVENT UNAUTHORIZED OPERATION OF THE COVANA.

NOTICE

5 feet

1.5 meters

Roof

Spa

5 feet

1.5 meters

The key switch must be permanently mounted and located

5 feet (1.5m) away from the spa and 5 feet (1.5m) above the

deck and user must have full view of the Covana.

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IMPORTANT

OBSERVE THE FOLLOWING STEPS FOR THE PROPER ASSEMBLY & SETUP OF

THE COVANA.

IMPORTANT

DO NOT OPERATE THE UNIT UNTIL ALL MECHANICAL AND ELECTRICAL

CONNECTIONS HAVE BEEN MADE.

IMPORTANT

ALL 4 POST OF THE COVANA MUST BE PROPERLY ANCHORED TO ITS FOUNDATION USING

THE ANCHORING HOLES LOCATED ON THE FOOT OF EACH POST.

IMPORTANT

LIMIT SWITCH ADJUSTMENT

BOTH THE UP & DOWN LIMITS SWITCH ARE PRE-ADJUSTED AT THE FACTORY. THE DOWN

LIMIT SWICH SHOULD NEVER NEED TO BE ADJUSTED. THE UP LIMIT SWITCH SHOULD

ONLY BE ADJUSTED TO REDUCE THE HEIGHT OF THE ROOF TO AVOID POSSIBLE CONTACT

WITH ITS SURROUNDINGS. REFER TO THE LIMIT SWITCH ADJUSTMENT GUIDE FOUND IN

THIS MANUAL BEFORE MAKING ANY ADJUSTEMTS. IMPROPER ADJUSTMENT CAN RESULT

IN DAMAGE TO THE DRIVE SYSTEM.

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Just like the spa foundation, the COVANA also requires a solid foundation. The area that the

COVANA sits on must be able to support at least 600lbs (300kg) and must be level.

Note: Damage caused by inadequate or improper foundation support is not covered by

the COVANA warranty. It is the responsibility of the owner to provide proper foundation.

Foundation recommendation:

1. Engineered wood deck

2. Concrete Pad - 4” (100mm) thickness

3. Each of the 4 posts on the Covana must be properly anchored to the foundation using

at least one of the pre-drilled holes located on the foot of each post.

 Use a 1/4” (6mm) concrete anchor for concrete pads or a 1/4” (6mm) lag bolt for

wood foundations a minimum of 1-1/4” (30mm) long

1. The COVANA requires a dedicated 115V (230V*) permanently connected (hard wired)

power supply.

2. The COVANA motor has a dedicated connection for 115V (230V*), please see enclosed

connection diagram.

3. The COVANA must be installed in accordance to and comply to any local codes and

regulations. All wiring should be installed by a qualified electrician

4. Wire and conduit should be sized as per local codes and regulations.

The electrical circuit for the COVANA must include a suitable ground fault interrupter

(GFCI) as required to comply to codes and regulations.

Required Voltage: 115V (230V*) (1 hot, 1 neutral, 1 ground)

Required GFCI Breaker: 15A (10A*) single-pole GFCI breaker, not included

Max COVANA current draw: 12 (6*) Amps

* For European customers only.

PREPARING A PROPER FOUNDATION

COVANA ELECTRICAL REQUIREMENTS

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SIDE ELEVATION DIMENSIONS

Spa Height will vary and must be

within these measurements

Minimum is 34” (860mm)

Maximum is 48” (1220mm)

Covana maximum travel is

50” (1270mm)

The maximum elevation height is

dependent of the height of the tub.

Add spa height to the Covana travel

to determine maximum elevation.

Example:

Spa height + COVANA travel which is

50” (1270mm) = Total elevation

21” (530mm)

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FRAME DIMENSIONS AND FOOTPRINT

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BONDING, GROUNDING AND CONNECTION OF POWER SUPPLY

Use the terminals provided to

bond the COVANA operator

Pre-wired key switch 20’ (7,5m)

of cable included, cable must be

passed through a conduit

Unscrew and remove the four

screws on the bottom side of

the COVANA operator and

remove the cover

Connect the main power 115V

(230V*) to their respective

terminals

Connect the ground cable of

the main power supply to the

terminal provided.

Replace the operator cover

RISK OF INJURY

DISCONNECT OR TURN OFF ALL POWER SUPPLY BEFORE STARTING

INTERVENTION ON THE COVANA

WARNING

* For European customers only.

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LIMIT SWITCH ADJUSTMENT

Note: The UP & DOWN limits are factory adjusted and there is no need for re-adjustment.

If adjustments are required to ensure the Covana roof does not come into contact with its

surroundings, while elevating, the UP direction may be decreased. Never change the

factory settings of the DOWN limits or increase the UP limit, failing to do so may result in

possible equipment damage and/or injury:

1. Remove the retaining screw and slide the camplate from operator frame.

2. To reduce the travel to UP direction, turn the UP cam counterclockwise as per arrow

3. Once the cam is set to the desired position, reinstall the camplate and make sure that

it is properly inserted in the slot of each cam. NEVER OPERATE THE SYSTEM WITH

THE CAMPLATE REMOVED.

4. Replace the retaining screw to prevent the camplate from coming out.

5. Reinstall the operator, turn the power ON and test the system.

RISK OF INJURY

DISCONNECT OR TURN OFF ALL POWER SUPPLY BEFORE STARTING

ANY INTERVENTION ON THE SPA GAZEBO

WARNING

KEY OPERATING INSTRUCTIONS

 Turn the key to the right — clockwise to raise the roof

 Turn the key to the left — counterclockwise to lower the roof

 Key will automatically return to center, off position, when released

Camplate and retaining screw

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MANUAL OPERATION IN CASE OF POWER FAILURE

RISK OF INJURY

DISCONNECT OR TURN OFF ALL POWER SUPPLY BEFORE STARTING

INTERVENTION ON THE COVANA OPERATOR

WARNING

1. Disconnect or turn off the power

2. Unscrew and remove the four screws on the cover of the operator.

3. Remove the operator

4. Use a ½" or 13mm hexagon socket wrench to operate the operator by turning the input

shaft

SLOWLY TURN THE SHAFT - STOP IF EXCESS TENSION IS FELT

NEVER USE A POWER TOOL AS THIS WILL DAMAGE UNIT

5. Turn the input shaft clockwise to lower the roof and counterclockwise to raise the roof

6. Put the cover back on the operator

7. Reconnect or turn on power

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Wiring & Schematic Diagram - 120VAC, 60Hz Operator (North America)

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Wiring & Schematic Diagram - 220VAC, 50Hz Operator (Europe Only)

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UNCRATING THE COVANA

1. Stand the Covana in the vertical position, ensure wind conditions allow for this to be done safely

2. Remove the hardware box and sort the hardware

3. Using the screwdriver bit included in the hardware kit, remove the lower corner braces of the crate

4. Remove the four screws on the metal cover of the operator

5. Remove the six screws that fix the bottom feet of the four posts to the crate

6. Using a 7/32” Allen wrench loosen the bolts in the

center of the post top plates, no more than five

turns.

7. Remove the two single posts out of the shipping

bracket and carefully lay posts on the ground.

Bend the brackets up and out of the way.

8. With the help of one other person remove the

motor end post assembly out of the crate. We

recommend one hand under the main frame and

one holding the post vertical. Handle and carry the

assembly so that the posts are straight and

parallel. DO NOT TWIST.

9. Remove all of the frame pieces at the

bottom of the crate.

10.Lower the crate down in the horizontal

position, remove the wrapping from the

sides and disassemble the crate. Six

screws per side, three top and three

bottom. See arrows below

11.BE AWARE that the square drive shafts

are hidden in the bottom of the crate

directly under the roof, remove before

discarding the crate

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ASSEMBLING THE COVANA

1. Cut four 5” pieces of the Covana seal and

apply these to the tub corners to ensure tub

and roof have the required spacing and both

are protected.

2. Place and center the roof of the Covana on the

tub, pay attention to the short side and long

side. The light switch, if a LED light kit option is

installed in the roof, should be placed on the

entry side of the tub

3. Perform the LED light kit installation/

procedure, instructions included in solar panel

box.

4. On all four posts remove the top plate Allen

head bolt and bushing

5. Loosen the lower sleeve retaining bolt, no

more than five turns.

6. Slide the three part sleeve assembly off the

jack.

1. Lay the sleeves in a safe location, preferably

horizontal on a soft surface.

2. Position the motor and two post assembly in

place, usually to the rear of the spa, slide the

jacks against the roof corners

3. Slide the driveshafts over the square shaft of

both motor side jacks

4. Hold the post vertical and inline with the post.

Using a 3/4” wrench, on the shaft of the post,

make fine adjustments to the square shaft so it

is in line with the driveshaft. and carefully slide

the square shaft of the post into the driveshaft.

5. Install the aluminum U frame over the drive

shaft and post bracket. Fasten in place using

hardware provided, 4 bolts + 4 nuts + 8

washers

6. Perform steps 6 to 7 on the second non motor

side jack

7. Assemble and install the front frame with the

cut-out for steps

8. Jack lock bracket can

now be safely removed.

Flip the jack lock upside

down and screw it in

place for possible future

use.

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ASSEMBLING THE COVANA PART II

AT THIS POINT THE ELECTRICAL POWER

SUPPLY MUST BE CONNECTED TO

CONTINUE THE INSTALLATION, THIS WILL

ENSURE THE PROPER SETTINGS ARE MADE

1. Mount key box as per instructions on page 3

2. Test system by turning key clockwise to elevate

posts, continue holding key until motor stops

automatically and posts are fully elevated.

3. Turn the key counter-clockwise to lower the

posts, continue holding key until motor stops

automatically and posts are fully lowered.

Measure from the foot to the top of the jack,

should measure 51.5” (1280 mm)

4. Reinstall the post sleeves. Ensure the all

weather kit is fully slid down to make contact

with the outer sleeve.

5. Install corner brackets at each corner. Fasten

the bracket to the roof, then using the self

drilling screws insert four screws per post.

6. Test the system to ensure the roof

elevates ensuring that the roof does not

make contact with any objects while

elevating, refer to limit switch adjustment

instructions on page 9 if adjustments need

to be made.

7. Lower the roof and ensure it stops at the

point of contact with the four pieces of

seal on the tub, readjust the corner

brackets if contact is not made

8. Ensure the Covana is centered over the

tub and that proper seal can be made

between the roof and the tub

9. Each of the 4 posts on the Covana must

be properly anchored to the foundation

using at least one of the pre-drilled holes

located on the foot of each post.

 Use a 1/4” (6mm) concrete anchor for

concrete pads or a 1/4” (6mm) lag bolt

for wood foundations. Minimum of

1-1/4” (30mm) long

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**NOTE: If your install requires the non-permanent mounting plates to be installed do this

BEFORE installing the seal to ensure proper alignment. **

1. Cut four 5” pieces of seal and place them on the corner of the hot tub before lifting the

roof in place as per the installation instructions.

2. When the complete Covana assembly has been performed,

lift the roof using the key switch and remove the temporary

seal sections. Lower the roof, walk around the entire hot tub

observing where the white inside shell makes contact with

the hot tub. This will determine the best location to apply the

seal.

3. Ensure the tub edge is completely dry.

4. With the roof elevated apply the seal clips provided, to the

tub in the predetermined area for the seal. The ideal location

for the seal is closer to the inside/water edge.

5. Install the seal starting at motor end with the adhesive layer

pointing up towards the roof.

6. NOTE – At this stage if the ambient air temperature is below

32⁰F (0⁰C) then a temporarily heater should be placed inside

the tub for 10-15mins. When the heater is in the tub bring

down the roof until it touches the seal to increase the air temperature. After 10-15mins

remove the heater and continue with the seal installation.

7. TEST - By lowering the roof again to ensure that the seal makes contact with the entire

perimeter. If satisfied elevate the roof, remove the red plastic backing of the seal and

lower the roof to the seal.

8. Let the roof rest in this position for two minutes to ensure proper seal to roof adhesion.

Important- Now elevate the roof no more than an inch and let the roof rest again for a

short period as this will allow the seal time to slowly and fully release from the seal

clips, if not a dull tool can be used to help the seal release.

Once satisfied that the seal is released, elevate the roof and remove the seal clips from

the tub edge.

Lower the roof and verify again for proper seal.

ASSEMBLING THE COVANA PART III - APPLYING THE SEAL

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COVANA LIGHTING

Operating procedures

Press the light switch, located in the inner shell in one of the

four corners, to turn the lights on. The Covana lights operate

in four modes. The modes are changed by turn the lights off

and then immediately back on.

Four Modes:

1. Fading: Cycles through the seven colors fading out

one color and fading back in with a new color.

2. Color Locked: Color of choice is locked

3. Rotating: Each color is cycled on and off for a few

seconds

4. Flashing: White light flashes quickly, on and off.

In the off position the lights will reset after 10 seconds and

will restart in the fading cycle.

Installation

IMPORTANT

- Determine the corner of the Covana that is likely to receive

the most sun, generally south is best; ensure there are no

interfering objects.

- Take note that the battery is located on the same short

side as the on and off switch.

- Take note the switch should be positioned to the entry side

of the spa.

- Ensure that all hardware is removed securing the outer

shell to the inner shell and no corner brackets are installed.

1. Lift the outer shell on the side where the battery is

located to access the connections of the Solar Panel.

Do not lift more than 16”(400mm)

2. Connect the solar panel to the Lighting wire harness

and route the wires and panel to the corner of the

Covana where the panel will be mounted.

3. Lower the outer shell back over the inner shell taking

care to ensure the wires are not pinched and are

placed in the slit of the outer shell corner.

4. Insert the suction cups in the panel, remove the

protective layer from the foam tape on the back

suction cups. Carefully place the panel

3” (75mm) up from the corner and center the

panel on the ridge of the roof. Rock the panel

back and forth to ensure proper adhesion.

5. Check to ensure the panel is charging – blue

flashing light

6. Continue with Covana installation.

Maintenance

1. Ensure solar panel is clean and free of snow.

2. Always turn lights off - if left on battery will need

2 to 3 sunny days to fully recharge.

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COVANA LIGHTING — OPTIONAL CHARGER INSTALLATION

IMPORTANT

- Take note that the battery is located on the same short

side as the on and off switch

- Ensure that all hardware is removed securing the outer

shell to the inner shell and no corner brackets are installed

- Lights can be operated while charging

- Lights will operate for 4 hours on a full charge.

1. Lift the outer shell on the side where the battery is

located to access the connections of the Solar Panel

and battery charger. Do not lift more than

16”(400mm) .

2. Connect the wires of the charger extension kit to the

connector of the Covana LED lighting kit.

3. Determine the best corner to locate the charger

connection; generally the back side would be less

visible.

4. Lower the outer shell back over the inner shell taking

care to ensure the wires are not pinched and are

placed in the slit of the outer shell corner.

5. Install the corner post bracket; ensuring the wire

comes over the top. Using the bottom bolt of the

bracket fasten the connector in place.

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Made in Canada

Sterling Leisure Products

www.sterlingcovana.com

PATENTED

CANADA 2,532,429

US 11/162,557

UK 0515168.3

AUSTRALIA 2006200251

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