BWT COVERDECK AX-IN User manual

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Code : 34561
INSTALLATION AND MAINTENANCE INSTRUCTIONS
To be read carefully and kept for future reference
You have just acquired an automatic pool cover, thank-you for placing your trust in us. Before
commencing installation and operation of the cover, please read the following document carefully, it
contains important recommendations concerning the various manipulations and advice for use. Keep
this manual and show it to any other users.
COVERDECK AX-IN
Submerged automatic
covers

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FOREWORD
Congratulations! You have just purchased an automatic cover made by PROCOPI and we would like to thank
you for placing your trust in us.
By choosing this cover, you have selected a cutting-edge product perfectly adapted to its function as a pool
safety cover.
You also benefit from the competence and know-how of the PROCOPI Group, (registered office - Zone
d'Activités, les Landes d'Apigné in LE RHEU (35650), France.
Your installation is the last link in a chain of pool professionals.
How-ever, despite the excellent quality of every component of this cover, we cannot guarantee the user’s total
satisfaction unless the user scrupulously observes and applies the recommendations and instructions provided
in this manual.

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TABLE OF CONTENTS
INSTALLATION INSTRUCTIONS ................................................................................7
1. Important safety notice ......................................................................................7
2. Installation recommendations ...........................................................................7
2.1.Tools required........................................................................................................................ 8
2.2.People required ..................................................................................................................... 8
3. Civil engineering.................................................................................................9
3.1.With masonry pit wall............................................................................................................. 9
3.1.With a separating pit wall....................................................................................................... 9
4. Preparation before installing the mechanical assembly ...............................10
4.1.Deck box ............................................................................................................................. 10
4.2.Verify dimensions and squaring .......................................................................................... 11
4.3.Check the electrical point of supply ..................................................................................... 11
4.4.Preparation of the coping .................................................................................................... 11
COVERDECK AX-IN AXLE........................................................................................12
1. Axle, diameter 190 or 192 mm .........................................................................12
2. Assembly prior to submersion ........................................................................13
3. Installation of the axle......................................................................................14
4. Disengaging the AX-IN motor ..........................................................................16
MOTOR DRIVE SYSTEM...........................................................................................17
1. Wiring in the electrical panel ...........................................................................17
1.1.Installation of the electrical panel......................................................................................... 17
1.2.Reversing the electrical panel door swing ........................................................................... 17
2. Key switch.........................................................................................................18
3. Electrical wiring................................................................................................18
3.1.Slaving................................................................................................................................. 19
3.2.Coverdeck AX-IN deck box ................................................................................................. 19
4. Setting and programming ends of travel ........................................................20
4.1.The printed circuit board...................................................................................................... 20
5. The electrical panel ..........................................................................................21

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5.1.Initialisation of the printed circuit board ............................................................................... 21
5.2.Validation of the direction of rotation of the axle.................................................................. 21
5.3.Programming the ends of travel .......................................................................................... 21
6. Wiring diagram .................................................................................................22
SEPARATING PIT WALL...........................................................................................23
1. Product description..........................................................................................23
2. Mounting the flanges - Coverdeck ..................................................................23
3. Assembling the separating pit wall.................................................................25
3.1.Straight wall......................................................................................................................... 25
3.2.Trapezoïdal ......................................................................................................................... 25
4. Putting the separating pit wall in position......................................................26
ASSEMBLY OF THE COVER APRON ......................................................................27
1. Preparation prior to assembly.........................................................................27
2. Assembly of the slat apron..............................................................................27
2.1.Assembly of cover apron, slats finished with plugs.............................................................. 27
2.2.Assembly of the cover apron, slats finished with silicon ...................................................... 28
2.3.Assembly of the complete cover.......................................................................................... 28
2.4.Attach the slat apron to the axle .......................................................................................... 28
2.5.Retainers for pools with step pieces (option)....................................................................... 29
2.6.PVC slats: Guide weights for overflow pools (option).......................................................... 29
2.7.Cover apron safety fasteners .............................................................................................. 30
2.7.1. Wall mounted safety fastener ................................................................................................. 30
2.7.2. Sub-coping mounted safety fastener ..................................................................................... 31
2.8.Adjustable strap at the end of the pool ................................................................................ 32
2.8.1. Strap configurations ........................................................................................................... 32
2.8.2. Stainless steel, fixed hasp fastener........................................................................................ 33
2.8.3. Stainless steel, collapsible hasp fastener............................................................................... 33
2.8.4. Attaching the strap to the hasp ............................................................................................... 33
2.8.5. Hasp fastener for overflow and buffer tank ............................................................................ 34
2.8.6. Installation of the lateral fasteners .......................................................................................... 34
2.8.7. Recommendations concerning the installation of hasps....................................................... 35
BEAM .........................................................................................................................36
1. Beam and counterweight .................................................................................36
1.1.Coverdeck beam mounting unit with sub-coping sealing plate ............................................ 36
2. High water level bracket...................................................................................38

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2.1.Bracket installation instructions ........................................................................................... 38
2.2. High water level finishing profile ......................................................................................... 40
2.3.Commissioning and operating instructions .......................................................................... 41
3. Installation of the duckboarding .....................................................................41
3.1.Duckboarding angle iron...................................................................................................... 42
OPERATING INSTRUCTIONS...................................................................................43
1. Precautions.......................................................................................................43
2. Cover closing procedure .................................................................................43
3. Cover opening procedure ................................................................................43
4. Safety fasteners................................................................................................44
4.1.Engaging the cover in the safety fasteners.......................................................................... 44
4.2.Releasing the cover from the safety fasteners .................................................................... 44
5. Water level ........................................................................................................44
6. Water quality.....................................................................................................45
7. Maintenance......................................................................................................45
8. Winterizing ........................................................................................................46
9. Specific precautions ........................................................................................47
9.1.Beam and duckboarding...................................................................................................... 47
9.2.Cover apron......................................................................................................................... 47
9.3.Pit wall ................................................................................................................................. 47
10. Scope of use .....................................................................................................47
GENERAL GUARANTEE CONDITIONS................................Erreur ! Signet non défini.
1. Guarantee on the slat apron (PVC, PC).......................Erreur ! Signet non défini.
1.1.Guarantee covering slat leak tightness and structural integrity ... Erreur ! Signet non défini.
1.2.Guarantee covering stains and discoloration............................... Erreur ! Signet non défini.
2. Guarantee on mechanical parts ..................................Erreur ! Signet non défini.
2.1.Guarantee covering the motor..................................................... Erreur ! Signet non défini.
2.2.Guarantee on the electrical panel................................................ Erreur ! Signet non défini.
2.3.Guarantee covering rechargeable batteries and the solar panel . Erreur ! Signet non défini.
2.4.Guarantee covering the axle ....................................................... Erreur ! Signet non défini.
2.5.Guarantee covering the beam flange and brackets (for models equipped with said) . Erreur !
Signet non défini.
3. Guarantees covering accessories...............................Erreur ! Signet non défini.

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3.1.Guarantee on the beam and the finishing trim............................. Erreur ! Signet non défini.
3.2.Guarantee on the high pressure cleaning system, Cleandeck – Stardeck covers...... Erreur !
Signet non défini.
3.3.Guarantee on duckboarding ........................................................ Erreur ! Signet non défini.
3.4.Guarantee on the storage bench housing of above-ground covers (models that are
equipped with above-ground storage benches)........................... Erreur ! Signet non défini.
3.5.Guarantee on the prefabricated separating pit wall ..................... Erreur ! Signet non défini.
4. Guarantee on pool fittings ...........................................Erreur ! Signet non défini.
5. Other elements not previously mentioned .................Erreur ! Signet non défini.
6. Application of guarantees............................................Erreur ! Signet non défini.

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INSTALLATION INSTRUCTIONS
1. Important safety notice
‐This cover is no substitute for common sense or individual responsibility. Nor is it intended to
substitute the vigilance of parents and/or responsible adults which remains the key factor in
ensuring the safety of young children;
‐Caution: safety is only assured when the cover is closed, locked and correctly installed in
accordance with the manufacturer’s instructions;
‐In the event of any absence, how-ever brief, from the home, the cover must be installed
systematically;
‐Check that there is no person or foreign body in the pool both prior to and during opening and
closing of the cover;
‐Keep the key used to activate the cover mechanism out of reach of children;
‐The cover should only be opened/ closed by a responsible adult ;
‐Standing, walking and jumping on the safety cover should be prohibited;
‐In general, implement all steps necessary to deny young children access to the pool while the
cover is pending repair or during any malfunction preventing the pool from being closed and
secured or in the event that the pool or equipment is temporarily unavailable.
‐A pool can represent a serious danger to your children. A person can drown very quickly. Children
near a pool require your constant vigilance and active supervision, even if they know how to swim.
‐The physical presence of a responsible adult is absolutely mandatory while the pool is open.
Learn first aid techniques
Memorise emergency numbers and display these close to the
pool:
‐Fire brigade:
‐Medical emergency services:
‐Poison treatment centre:
2. Installation recommendations
The Coverdeck AX-IN automatic cover is designed for pool slat aprons at most 6.09 m wide.
According to the standard NF C15-100, a 30 mA RCD must be installed at the head of the electrical line powering
the Coverdeck AX-IN automatic cover.
The motorisation system is delivered with an electrical panel, it may only be operated with this electrical panel.
Any other use of the motor without the electrical panel, or vice versa, is dangerous and not advised.
The Coverdeck AX-IN cover may only be operated using a mechanism described in the NF P90-308, such as
the key switch supplied.
The automatic nature of the Coverdeck AX-IN cover in no way dispenses with the need for vigilance when the
cover is in motion. On encountering the slightest issue rolling the cover up or our, stop the movement and contact
a professional.

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2.1. Tools required
Step Tools required
Assembling the axle ‐Spirit level
‐Set of wrenches
‐Mallet
‐Spanners
‐Concrete drill bit Ø10 mm
‐Disk grinder with diamond disk
‐Flat chisel and hammer
Mounting the motor and the
control panel
‐Small flat head screw driver
‐Cross-head screw driver
‐Stripping pliers
‐Cutting pliers
‐Stanley knife
‐Percussion drill and Ø 8 mm concrete drill bit
Assembling the pit wall ‐Rivet pliers
‐Mallet
‐Percussion drill
‐Measuring tape
‐Drill, 5 mm
‐Concrete drill bit, 13 mm
‐Allen key, no. 5
‐Cross-head screw driver, no. 2
Assembling the beam and
brackets
‐Wrenches
‐Allen keys
‐Wood cutting tools (wooden duckboarding)
2.2. People required
Step Number of people Length of time
Assembling the cover axle 2 1 hour
Setting up the motor
1
0.5 hour
Installing the pit wall
2
1 hour
Assembling the slat cover apron 2 1 hour
Mounting the beam or brackets 2 0.1 hour
The lengths of time quoted do not take the time required to fill the pool into consideration, this will depend on
the flow rate of the water supply and the volume of the pool.

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3. Civil engineering
3.1. With masonry pit wall
Pool width ≤6.09 m Duckboarding 830 950
Beam
133 mm
Distance to wall
880
1000
Wall height 210 Distance to beam support
plate
900 1020
Coping M30 M40 M55 Distance to the cover flange 130 180
Water 135 125 110 Distance to duct 305 355
Standard separating pit wall width: Wall width = 250 mm
Minimum cover pit depth: pit depth = min 1.06 m
3.1. With a separating pit wall
Pool width ≤6,09 m Duckboarding 680 830 830 950
Beam 133 mm Corner 90° 90° R=150 R=150
Wall height 210 Dist to beam support
plate
750 900 900 1020
Coping M30 M40 M55 Dist to cover flange 130 180 275 330
Water 135 125 110
Standard separating pit panel width = 40 mm
Minimum cover pit depth: pit depth = min 1.06 m
Standard vertical radius: R = square corner or 150 mm
Distance to beam support plate
Distance to beam support plate
Distance to cover flange
Distance to cover flange
Cover pit depth
Cover pit depth
Partition th.
Pool width
Return fitting
Return fitting
Main drain
Pool width
Distance to wall
Wall th.
Wall height
Water
Dist to duct
Dist to duct

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4. Preparation before installing the mechanical assembly
Coverdeck AX-IN standard water level
4.1. Deck box
Ref Description Qty
1 Deck box lid 1
2 O-ring Ø72.4x5.3 1
3 Terminal block 10 mm² 1
4
Deck box body
1
5 Cable gland seal (signal cable) 1
6 Cable gland 2
7 PARA seal Ø20x9 thickness 10mm 1
8 Hose tail 1
- Corrugated sheath, 1m 1
Glue the hose tail into the bottom of the connection deck, then push the sheath onto the hose tail.
Deck box
Duckboarding
Beam
Flange –
bearing side
Flange –
motor side
Motor
integrated into
the axle
Counterweight
Slat apron

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4.2. Verify dimensions and squaring
Before beginning installation of the automatic cover’s mechanical assembly, check that dimensions and squaring
comply with the civil engineering diagrams.
4.3. Check the electrical point of supply
Lay a duct to run the cable between the electrical supply and the electrical panel.
Distance
motor/panel
Recommended cross section for the
motor power cable
Recommended
cross section for
the sheathed
signal cable
Recommended
cross section for
the key switch
cable
C120 C300
10 m
3 x 2.5 mm²
3 x 4 mm²
3 x 1 mm²
3 x 1.5 mm²
20 m 3 x 2.5 mm² 3 x 6 mm² 3 x 1 mm² 3 x 1.5 mm²
30 m 3 x 4 mm² 3 x 10 mm² 3 x 1 mm² 3 x 1.5 mm²
40 m 3 x 6 mm² 3 x 16 mm² 3 x 1 mm² 3 x 1.5 mm²
4.4. Preparation of the coping
Lift the coping along at least 45 cm on both sides of the
pool at the points where the flanges will be installations.
Check that the installation sites are level with each other.
Resurface one of the sides if necessary.
In the case of a prefabricated thin wall pool, hollow wall
pool or polystyrene block pool, pour a concrete
reinforcement at least 50 cm long and 20 cm deep just
behind the walls, to avoid any risk of deformation.
Create a trench 50 x 50 mm to run the corrugated sheath.
In the case of a M20 coping, create two additional
trenches 100x20 mm for the flange sealing plates.
Trench to run the
corrugated sheath

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COVERDECK AX-IN AXLE
1. Axle, diameter 190 or 192 mm
Product presentation
Ref
Description
Qty
1 Flange, motor side 1
2 Safety splint Ø3, A2 SS 2
3 Clamping pin Ø12 106mm, SS 1
4 Aluminium axle 1
5 HE nut M8 A4 SS 4
6
HSHC screw M8 x 35 A4 SS
4
7
Flange, bearing side
1
8 Stainless steel clevis mount 1
CAUTION
The curved side on the top of the flange should be oriented towards the axle.

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2. Assembly prior to submersion
Assembly, motor side
Ref Description Qty
1
Sub-coping sealing plate
1
2 Round head screw M8 x 20 A2 SS 4
3 H 8 nut A4 SS 4
4 Washer Z 8 A4 SS 4
5 Flange, motor side 1
6 Stainless steel clevis mount 1
7 Washer W 8 A4 SS 4
8
HSHC screw M8 x 30 A4 SS
4
9 Safety splint Ø3, A2 SS 2
10 Clamping pin Ø12 106mm, SS 1
11 Countersunk hex socket screw M8
x 20 A2 SS
4
- Upat bushing M8 x 50 A4 SS 4
Attach the clevis mount (6) to the flange (5) using the washers (7) and the screws
(8). Fasten the aluminium axle to the flange by sliding the clamping pin (10) into
the clevis mount and the stainless steel shaft of the axle and fasten the assembly
together by placing a safety splint (9) on either side of the clevis mount.
Dismantle the casing by removing the screw and washer. Run the motor cable
up the flange.
Thread on the gasket Ø20 x 9,10mm thick, before running the cable through the
corrugated sheath up to the deck box. Position the gasket at the entrance of the
sheath to ensure waterproofing.
CAUTION
Both pins must remain in their original position (facing towards the motor
cable).
Sub-coping sealing plate M30/M40/M55: Attach the sealing plate (11) to the flange using the screws (2), washers
(4) and nuts (3).
Sub-coping sealing plate M20: Attach the flange using the HSHC M12 x 30 screw and Z12 washers supplied
with the M20 sealing plate.
Fastening the flange to the wall: The
flanges can be mounted directly on
the wall. The fastening system (not
supplied) depends on the support
on which the flanges will be
mounted. Sizing will be carried out
by the professional. Position the top
fastening portion of the flange on
the pit side to avoid hindering
movement of the slat apron.

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Assembly, bearing side
Ref Description Qty
1 Round head screw M8 x 20 A2 SS 4
2 Countersunk hex socket screw M8 x 20 A2
SS
4
3 H nut 8 A4 SS 4
4 Washer Z 8 A4 SS 4
5 Upat bushing M8 x 50 A4 SS 4
6
Sub-coping sealing plate
1
7 Flange, bearing side 1
8 Countersunk hex socket screw M8 35 A4 SS 4
9 HE nut M 8 A4 SS 4
10 Aluminium axle bearing 1
Side opposite the motor; fasten the bearing to the flange using 4 countersunk hex socket screws M8x35 shoulder
nuts.
Refer to the previous page for assembly of the sealing plate.
3. Installation of the axle
Submersion of the axle
Before submersion, reduce the length of the assembly as much as possible by sliding the stainless steel shaft
on the bearing side as far as possible into the axle.
Lower the axle carefully under the water (two people will be needed). Be careful not to knock against the pool’s
inner waterproofing surface while doing this.

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Force the assembly under the water, remain standing on the plates for approx. two minutes. During this time, air
will escape from the axle as it fills with water.
Before fastening the flanges in position, check that the axle is perpendicular to the axis of the pool, to make sure
that the slat apron rolls out properly. Refer to the civil engineering diagrams for the position.
On the bearing side, tighten the
nut as much as possible towards
the axle to reveal the ring
threading.
Insert the Ø 8 mm pin into the
hole in the stainless steel shaft,
passing through the apertures in
the threaded ring. Take care to
centre the pin in the shaft.
Unscrew the nut as far as possible towards the pin by hand (do not
use a tool). This will push the flanges out against the walls.
Fastening the assembly in position
Check that the top of each flange is up against the pool wall. Drill holes Ø 10 mm, depth 80 mm, through the
holes in the flanges. In the case of a Blokit pool, drill through the holes furthest from the pool.
Check that the sub-coping plate is horizontal. Insert wedges underneath if necessary.
Insert the screws in the Upat bushings, leave them protruding by 10 mm.
Insert the bushing assemblies into the holes and push them in with a mallet until the head of the screw is in
contact with the plate. Finish tightening using the hex key wrench no. 5.
COMPLIANT
NON-COMPLIANT

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4. Disengaging the AX-IN motor
The motor can be disengaged to secure the pool in the event of a problem with the motor.
Undo the screws holding the casing in position. Remove the casing.
Detach the deck box cable and remove it, leaving a needle in the corrugated sheath.
Rotate both axles by 180°.
Pull gently on the slat apron to roll it out over the water. Be careful not to let the slat apron pick up speed as it
rolls out. The cable will wind around the Aluminium axle.
Secure the pool with safety fasteners.

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MOTOR DRIVE SYSTEM
1. Wiring in the electrical panel
1.1. Installation of the electrical panel
The electrical panel should be mounted on a wall in the plant room, protected from sun and rain, and at a
distance of more than 3.5 m from the pool.
The installation steps are as follows:
1.2. Reversing the electrical panel door swing
Take the door off its hinges.
Remove the hinges and the locks.
Invert and replace the hinges and locks.
Clip the door back onto its hinges.
Unscrew the 6 plastic screws and remove the front facing of the
electrical panel.
Remove the retaining screw from the mounting bracket at the
bottom of the electrical panel.
Use the mounting bracket as a drilling template.
Mount the bracket on the wall using the screws and bushings
provided.
Hang the electrical panel on the bracket and put the
retaining screw back in position.
Insert the cable glands and carry out wiring.
Replace the front facing once wiring is complete.

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CAUTION
The instructions set out here only concern connections to be carried out by the installer.
The electrical panel is pre-wired in the factory and should under no circumstances be modified at the risk of
damage or injury.
It is of utmost importance to use cables with a cross section that is adequate for the current that they will
carry.
Check that connections are correctly tightened.
An inadequately sized cable or loose connection could heat up and start a fire.
According to the standard C15-100, a 30 mA residual current device must be installed at the head of the line.
2. Key switch
The key switch must be installed in a place from which the entire pool is visible. This will allow the person
operating the key switch to unroll the cover over the pool to ensure that there is no-one in the pool for the entire
duration of the operation (NF P90-308 requirement).
Lay a duct between the key switch and the electrical panel to run the cables.
3. Electrical wiring
Check that the electrical panel terminals are connected to their corresponding terminals in the connection box.
Check that the stripped sections of the wires are tightened correctly in their terminal contacts.
The electrical connections to be made are as follows:
Electrical panel terminals
For slaving
“cover open”
220 – 240 V
1ph/ 50 Hz
Cable 3 x 2.5
2
3g2.52up to 20 m
3g42up to 30 m
3g62up to 40 m
HO7RNF or
HO6RNF
Deck box terminal block
Slaving
“cover in
motion”
Slaving
“cover
closed”
3x12shielded
Key switch
box

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3.1. Slaving
Slaving is possible via a potential free dry contact (refer to the diagram on the previous page and the wiring
diagram).
Slaving can be associated with the filtration pump, booster pump, etc.
The connection at the relay in the automatic cover electrical panel is normally open (NO). This must be changed
to normally closed (NC) to carry out slaving.
Filtration panel wiring diagram:
3.2. Coverdeck AX-IN deck box
In the deck box, connect the 5 motor wires to the terminal block. The motor cable is comprised of:
‐2 wires for the sensor signal (S),
‐2 wires for the sensor power supply (A/C),
‐2 wires for the motor power supply (rotation direction +/-).
Connecting the cable in the deck box.
*The orange wire is not used
The deck box features two cable glands, one for the power supply cable and one
for the signal cable. Leaktightness of the signal wire is ensured by the cable gland
(9). The seal Ø30.5x5 (4) should be threaded onto the motor cable to retain the
two-component gel in the deck box.
Once correct operation of the cover has been verified (direction of rotation of
the axle, memorisation of ends of travel, etc.), and the deck box has been fixed, it can be filled with the removable
waterproof gel (supplied) to protect the contacts against humidity.
If the rotation of the axle is incorrect, invert it as shown in the section describing the printed circuit board.
Sensor signals
Sensor power supply
Motor power supply
White
Brown (+24V DC)
Blue (0V DC)
Red
Black
Sensors

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4. Setting and programming ends of travel
The ends of travel are managed by a printed circuit board. An electrical panel is used to program the ends of
travel.
4.1. The printed circuit board
Number 1: Jumper
There are two possible positions for the jumper, the position is selected depending on the motor drive system.
In the case of an AX-IN motor, the jumper connects the right-hand side pine and the centre pin.
Number 2: Dipswitch
Dipswitch number 1 is used to change the direction of rotation of the motor, this will
depend on the side of the pool on which the motor is located (refer to the figure
opposite):
‐Motor on the right-hand side: dipswitch 1 should be set to OFF
‐Motor on the left-hand site: dipswitch 1 should be set to ON
Dipswitch number to 2 is used for the anti-tear (“ON” deactivated).
Number 3: Fuse
The board should never be fitted with a fuse with a rating above 20 A. The use of a fuse rated for the automatic
cover motor is highly recommended.
In the case of an AX-IN-120 motor, place the 7.5 A fuse (supplied) on the PCB.
In the case of an AX-IN-300 motor, place the 10 A fuse (supplied) on the PCB.
Number 4: Reset
This is used to reset the PCB.
Motor on the
RH side
Motor on the
LH side