Certikin COVERSTAR User manual

Coverstar automatic safety pool cover
Installation Guide
Read this manual before using the equipment
Retain this manual for future use

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Published on: 15 Aug 2023
Document ID: cover.eclipse.mech - 1
Copyright
Copyright © 2023 Certikin International Limited All Rights Reserved.
Contains information owned by Certikin International Limited and/or its affiliates. Do not copy, store, transmit or disclose to any
third party without prior written permission from Certikin International Limited
Certikin International Limited is part of the Fluidra S.A. group.
Other product and company names may be trademarks or registered trademarks of other companies, and are the property of their
owners. They are used only for explanation, without intent to infringe.
Contact address
Certikin International Limited
Unit 4, Tungsten Park
Colletts Way
Witney
Oxfordshire
OX29 0AX
[email protected]
01993 777200
Intended purpose
The purpose of this guide is to provide instructions and information for the safe installation of automatic pool covers.

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Contents
Coverstar automatic safety pool cover 1
1 Safety 5
2 Hardware description 7
2.1 Overview 7
2.1.1 Overview of encapsulated track installation 8
2.1.2 Overview of flush track installation 9
2.1.3 Overview of deck-mounted mechanism installation 10
2.2 Track overview 11
2.2.1 Encapsulated track 11
2.2.2 Top track 12
2.2.3 Flush track 12
2.3 Mechanism overview 13
2.4 Cover overview 13
2.5 Lid overview 13
2.6 Power pack and key switch 14
3 Getting Started 15
3.1 What's in the box 15
4 Encapsulated track type installation 17
4.1 Encapsulated track installation 17
4.2 Mechanism installation 17
4.3 Cover installation 19
4.3.1 Attaching the cover to the roller 20
4.3.2 Testing the cover and ropes 21
5 Top track and flush track type installation 23
5.1 Top track installation 23
5.2 Flush track installation 25
5.3 Deck-mounted mechanism installation 25
5.4 Pit-mounted mechanism installation 28
5.5 Cover for top and flush installation 28

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6 Pit lid installation 31
6.1 Pit bracket installation for trays or decking 31
6.2 Aluminium lid installation 33
7 Customer handover 35
7.1 Final adjustments 35
7.2 Submersible pump operation 35
7.3 Handover instructions for installer 36
8 Troubleshooting 37
8.1 Track issues 37
8.2 Mechanism issues 37
8.3 Cover issues 38
8.4 Cover lid and miscellaneous issues 40
9 Regulatory 41
A Appendix - Drawings and information 43
A.1 UK Declaration of incorporation 44
A.2 UK Declaration of conformity 45
A.3 Electrical wiring for hydraulic power pack and key switch 46
A.4 Encapsulated track pit dimensions 47
A.5 Pit or deck-mount mechanism with top or flush track 48
A.6 Slider types 49
A.7 Rope path diagram 50
A.8 Power pack 51

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1 Safety
This section provides an overview of all safety aspects for the protection of people as well as
safe installation. Other task-related safety instructions are included in the specific sections.
In addition to these safety instructions, you must also comply with all local and site-specific
health and safety regulations, and environmental protection requirements.
WARNING
Risk of injury!
The hydraulic system of the power operates at a high pressure.
Do not operate the system if any leaks are detected, or any of the hydraulic lines
are damaged.
WARNING
Risk of electrical shock!
The power pack is powered using high voltages.
Do not operate the equipment if there are any exposed or damaged electrical wires.
WARNING
Risk of injury from lifting heavy objects!
The cover, and related parts, are heavy.
Use at least two people when lifting heavy parts.
Caution
Risk of injury!
Use personal protective equipment (PPE), such as safety shoes and safety glasses,
as required.
Do not wear loose clothing when installing equipment or operating power tools.

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2 Hardware description
Before installing the Coverstar automatic safety pool cover, you should be familiar with the
location and names of all parts of the product.
2.1 Overview
This section provides an overview of the hardware components of the Coverstar automatic
safety pool cover for all product variants and installation types.
Notice
As part of the pre-installation, a recess channel for the flush track must be in place.

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2.1.1 Overview of encapsulated track installation
1Key switch Used to control opening and closing the cover. This switch can be locked.
The key switch must be located where the operator has full view of the pool
area while operating the cover.
2Hydraulic
power pack
The power pack must be positioned in a location where it is protected from
extreme temperatures, dust, water, condensation, and moisture.
3Hydraulic hoses Carries hydraulic fluid from power pack to the hydraulic motor.
4Hydraulic motor Part of the mechanism drive-end assembly.
5Mechanism Pulley system, gears, and rope wind and unwind reels. Drive-end assembly.
6Roller Roller for the cover. Note the direction of cover winding indicated on the
roller.
7Lid support
brackets
Brackets used to support the lid covering the roller pit. The amount and
installation pitch of the brackets depends on the lid type to be fitted.
8Mechanism Pulley system for rope wind and unwind. Non drive-end assembly.
9Roller pit Pit that houses the roller and mechanism assemblies. Refer to the pre-
installation manual for details
10 Coping Pool edging. This can be stone or decking type.
11 Encapsulated
track
Encapsulated track, inner guide, and spacer are installed as part of the pool
construction. Refer to the pre-installation guide for details.
12 Track pulley Used to return the rope inside the inner guide. Fitted to the end of each inner
track.
13 Lead edge bar Attached to the front of the cover fabric.
14 Cover Vinyl composite that covers the pool area.
Figure 1 - Overview of pit installation
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2.1.2 Overview of flush track installation
1Mechanism (non drive-end assembly) Pulley system for rope wind and unwind.
2Roller and cover Roller for the cover.
3Mechanism (drive-end assembly) and
hydraulic motor
Pulley system, gears, and rope wind and unwind
reels.
4Flush track Flush track C channel is installed as part of the pool
construction.
Refer to the pre-installation guide for details.
5Lead edge bar Attached to the front of the cover fabric.
This can be fitted as wrapped or unwrapped.
Figure 2 - Overview of flush track and pit mechanism installation
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2.1.3 Overview of deck-mounted mechanism installation
1Mechanism (non drive-end assembly) Pulley system for rope wind and unwind.
Shown with mech housing fitted.
2Roller Roller for the cover. Note the direction of cover winding
indicated on the roller.
3Mechanism (drive-end assembly) and
hydraulic motor
Pulley system, gears, and rope wind and unwind reels.
Shown with mech housing fitted.
4Top or flush track Flush track C channel is installed as part of the pool
construction.
Refer to the pre-installation guide for details.
5Lead edge bar Attached to the front of the cover fabric.
This can be fitted as wrapped or unwrapped.
6Cover Vinyl composite that covers the pool area.
Cover unwinds and winds from the base of the roller.
Figure 3 - Overview of deck-mounted installation
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2.2 Track overview
Depending on the design and shape of the swimming pool, the Coverstar automatic safety
pool cover can be used with the following types of tracks:
lEncapsulated track — embedded in the pool wall
lTop track — mounted on the surface of the deck
lFlush track — recessed in the deck
Generally, the top and flush type tracks can be fitted after the pool has been constructed.
2.2.1 Encapsulated track
The encapsulated track is built directly into the pool wall. There are three variants of the
encapsulated track:
lEncapsulated track for concrete tile pools
lEncapsulated track for liner pools
lEncapsulated track for fibre-glass pools
1Encapsulated
track
Built into the pool walls and held in place on three sides.
2Inner guide Inserts into the encapsulated track and provides the channel for the ropes
and cover sliders.
3Spacer Inserts between the encapsulated track and inner guide to hold the inner
guide in place.
4Fibre-glass track Track profile of encapsulated track for fibre-glass pool types.
5Liner-lock track Track profile of encapsulated track for liner pool types.
Figure 4 - Encapsulated track parts cross-section
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2.2.2 Top track
The top track can be used on both new and existing pools. Top tracks are mounted on the pool
surround. This type of track is ideal for irregular shaped pools.
Figure 5 - Top track profile
2.2.3 Flush track
The flush track can be used on both new or existing pools. Flush tracks are recessed into the
pool surround. This type of track is ideal for irregular shaped pools.
Notice
As part of the pre-installation, a recess channel for the flush track must be in place.
1White plastic C channel
2Recessed track
Figure 6 - Flush track profile
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2.3 Mechanism overview
The mechanism is a heavy-duty pulley system with gears that wind and unwind the ropes to
move the cover on and off the pool. The cover is attached to the leading edge bar and roller.
The key elements of the mechanism are:
lMechanism (drive-end assembly) — pulley system, gear and motor for rope wind and
unwind.
lRoller — roller for the cover fabric.
lMechanism (non drive-end assembly) — pulley system for rope wind and unwind.
lHydraulic motor and hydraulic lines — carries hydraulic fluid from power pack to motor.
The mechanism can be mounted either in the pit (typical) or on the deck.
2.4 Cover overview
The cover (fabric) is a vinyl composite that covers the whole pool area.
All covers are manufactured with a quantity of slack relevant to the pool size and style of cover
system.
WARNING
Risk of serious injury or death!
The cover must lie on the water in order to be safe.
The supporting strength of the cover comes from the support of the water directly
under it.
2.5 Lid overview
If required, a pit lid can be supplied, which covers the pit neatly and allows easy access to the
cover roller and mechanism. The lid is supported by brackets.
There are different types of lids, depending on the track system:
lTop and flush tracks:
nAluminium non walk-on lid
lEncapsulated tracks:
nDecking
nHeavy-duty trays (to accept coping stones)
nAluminium non walk-on lid
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2.6 Power pack and key switch
The power pack is used to provide high-pressure hydraulic power for the mechanism motor.
The power pack is powered using an electrical motor and is controlled using the pool cover key
switch.
►For more information about installation and configuration of the power pack, refer to the
separate Hydraulic Power Pack installation manual.
Notice
The key switch must be positioned so that both ends of the pool are visible when
operating the Coverstar automatic safety pool cover.
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3 Getting Started
This section describes the initial steps required to start installing the Coverstar automatic
safety pool cover.
3.1 What's in the box
For a detailed list of parts, refer to the pick-list supplied from Certikin with the Coverstar
automatic safety pool cover.
Confirm you have all the parts you need before starting the installation procedures. If you
believe any parts are missing, contact Certikin before starting the installation.
As a guideline, you should have the following parts:
lHydraulic power pack, with hoses and installation manual
lHydraulic motor
lDrive-end mechanism with hydraulic motor attached
lRoller
lNon-drive-end mechanism
lPit lid support brackets — depending on the lid type to be installed
lPit lid items — depending on the lid type to be installed
lRopes
lCover
lTrack — depending on the type to be installed
lFeed guides
lTrack end-pulleys
lVarious fixes — screws, bolts, and so on
lFor retro-fit deck-mounted mechanism — end caps included
Make sure you have the required tools for the installation. The Coverstar automatic safety
pool cover is manufactured in the United States of America so the dimensions and parts are in
imperial sizes (inches and feet).
The following tools are required:
lPowered hammer-drill with masonry bits for drilling concrete and metal.
lLong-handled socket spanners and tools for fixing parts in the cover pit area.

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lPowered chop-saw for making accurate square or mitred cuts of the tracking.
lRubber mallet for tapping in the spacer shim for the encapsulated track.
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4 Encapsulated track type installation
This section provides step-by-step procedures for installing the Coverstar automatic safety
pool cover for encapsulated track types. These procedures apply to the standard concrete
encapsulated track and liner-lock track types.
The installation process follows these main stages:
lSection 4.1 "Encapsulated track installation" on page 17
lSection 4.2 "Mechanism installation" on page 17
lSection 4.3 "Cover installation" on page 19
4.1 Encapsulated track installation
The installation of the main components of the encapsulated track should be done as part of
the pre-installation and site preparation.
Refer to the pre-installation guide for more information.
4.2 Mechanism installation
Notice
Before installing the mechanism, make sure the pit is clean and has no debris in it.
The pit drain should be open and working.
As part of the pre-installation, the conduit for the hydraulic hoses should already be in place.
Make sure either the hoses or a draw-cord for the hoses are ready before starting this part of
the installation process.
►For more information, refer to the Pre-installation Guide.
To install the mechanism, follow these steps:
1. Next to the cover pit, assemble the drive mechanism, roller, and end pulleys using the
3/8ʺx1¼ʺ bolts and washers.
2. Place the mechanism assembly into the cover pit.

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WARNING
Risk of injury from lifting heavy objects!
The mechanism assembly is heavy. At least two persons should lift and
position the mechanism assembly.
3. Adjust and position the drive mechanism.
The drive mechanism must align with the track and be centred in the cover pit, from
front to back.
Use a length of rope from the return side of the track to the pulley of the drive
mechanism to make sure the mechanism is positioned correctly reducing the angle at
which the rope travels.
If required, use shims to increase the height of the drive mechanism.
For covers that are 45ʹ (13.7m) or less, you need to minimise the stress on the drive
mechanism.
Figure 7 - Mechanism in the cover pit
4. Adjust and position the non-drive-end pulley bracket.
Use a length of rope from the return side of the track to the pulley of the non-drive-end
pulley bracket to make sure the pulley is positioned correctly. This reduces the angle at
which the rope travels.
5. Secure the drive mechanism and non-drive-end pulley bracket to the cover pit floor
using the supplied fixings.
Caution
Risk of damage!
The mechanism assembly must be secured to a strong base.
If there is any movement of any part of the mechanism, this must be fixed
before proceeding with the installation.
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6. Loosen the bolts of the adjustable parts of the drive mechanism and non-drive-end
pulley bracket.
7. Adjust and secure the adjustable parts to the front and back walls of the cover pit.
8. If not already in place, use the draw-cord to pull throw the hydraulic hoses from the
power pack located in the plant room.
9. Attach the hoses to the hydraulic motor.
►For more information about the motor installation, refer to the Power Pack
Installation Manual.
10. Connect and test the power pack.
WARNING
Risk of electrical shock!
Only an approved electrician can wire and test the power pack.
Caution
Risk of damage!
After the hydraulic system has been tested, check for any leaks.
If any leaks are found these must be fixed before proceeding with the
installation.
The mechanism has now been installed.
4.3 Cover installation
There are two methods for attaching the cover to the leading edge bar.
lLooped — a loop at the end of the cover wraps around the leading edge bar.
lExposed — the cover is attached to the leading edge bar leaving the bar exposed.
To install the cover, follow these steps:
1. Carefully remove the inner guide and spacer shim from the encapsulated track.
2. Insert the ropes and track-end pulleys on both sides of each inner guide.
3. Assemble the inner guide and spacer shim back into the encapsulated track.
Starting at the cover pit-end of the track, using a rubber mallet, tap in the spacer shim
between the encapsulated track and inner guide.
Make sure the spacer shim is flush with the track edge.
4. At the pit-end of the pool, unwrap the cover.
5. Attach the ropes to the track slider on each side of the pool.
6. Attach the track sliders to the lead edge using the white nylon insert.
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7. Attach the cover to the lead edge.
Figure 8 - Exposed or wrapped cover to leading edge.
8. Insert the track slider and lead edge assembly into the inner guide.
9. Move the track slider at least 6ʺ (150mm) into the inner guide.
10. Fit the feed guides to the pit-end of the tracks and screw in place.
►For more information, see "Rope path diagram" on page 50
11. Pull the ropes tight, and then cut the ropes.
Allow at least 6ʹ (1.8m) extra rope at the reels.
Heat the ends of the ropes to prevent fraying.
12. Attach the ropes to the reels.
Before inserting the rope into the reel holes, make sure to wrap the ends of the rope
with PTFE.
13. Holding the ropes, close the cover, and evenly feed the rope onto the reels.
The leading edge and rope at the non-drive-end assembly may move before the other
end of the cover. This difference in movement is expected but it must not be greater
than 1ʺ (25mm).
The cover has now to be attached to the roller.
4.3.1 Attaching the cover to the roller
The last part of the cover installation is to attach the cover to the roller. The cover is slightly
wider than the pool width to allow it to lay on the pool surface. This extra slack in the cover
needs to be allowed for when attaching the cover to the roller.
To attach the cover to the roller, follow these steps:
1. Mark the approximate location of where the self-tapping screws will be positioned on
the roller.
Coverstar automatic safety pool cover - Installation Guide 4 Encapsulated track type installation