COVANA HORIZON User manual

2019
Revision 1
2019-06-25
C.A. 232876

2 TABLE OF CONTENTS INSTALLATION MANUAL
TABLE OF CONTENTS
TABLE OF CONTENTS.............................................................................................................................................2
SAFETY......................................................................................................................................................................4
Safety information...................................................................................................................................................4
Avoiding the risk of electrocution............................................................................................................................5
LABELLING ...............................................................................................................................................................7
GLOSSARY..............................................................................................................................................................10
HARDWARE IDENTIFICATION TABLE .................................................................................................................15
INSTALLATION PREPARATION............................................................................................................................18
Location considerations ........................................................................................................................................18
Foundation preparation.........................................................................................................................................19
Installation reference information .........................................................................................................................20
INSTALLATION .......................................................................................................................................................21
Uncrating...............................................................................................................................................................21
Cover assembly ....................................................................................................................................................24
Tub mount assembly ............................................................................................................................................29
Ground anchoring assembly (optional).................................................................................................................30
Post assembly ......................................................................................................................................................32
Lifting mechanism assembly.................................................................................................................................33
Tub mounting........................................................................................................................................................38
Ground anchoring mounting (optional) .................................................................................................................40
Testing the Horizon cover.....................................................................................................................................41
Wiper bracket installation......................................................................................................................................42
Grounding and power supply connection .............................................................................................................46
TECHNICAL SPECIFICATIONS..............................................................................................................................47
Side elevation .......................................................................................................................................................47
Frame and footprint ..............................................................................................................................................48
Electrical specifications.........................................................................................................................................48
Operating limitations .............................................................................................................................................49
General specifications ..........................................................................................................................................49
LIMIT SWITCH ADJUSTMENT ...............................................................................................................................50
TROUBLESHOOTING.............................................................................................................................................51

INSTALLATION MANUAL TABLE OF CONTENTS 3
APPENDIX ...............................................................................................................................................................53
INSTALLATION CHECKLIST (Customer copy)....................................................................................................59
INSTALLATION CHECKLIST (Installer copy).......................................................................................................61

4 SAFETY INSTALLATION MANUAL
SAFETY
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE SAFETY INSTRUCTIONS AND
REVIEW THEM REGULARLY.
READ AND FOLLOW ALL INSTRUCTIONS
Safety information
The COVANA cover was designed, tested and
certified to be installed over a residential hot tub (spa)
and under important installation instructions issued by
COVANA. Any other type of usage will void the
warranty and product certification.
The extra load maximum weight provided in the
specification section of this manual is a provision for
environmental outcomes, such as some snow or
damp leaves that could accumulate on the cover, that
are evenly distributed on the surface of the cover.
The COVANA cover was not designed to support any
additional load or people walking or standing on its lid.
Failure to observe this instruction will void the
warranty and product certification.
The power safety cover meets ASTM F1346-91
requirements.
DANGER
To reduce the risk of injury, do not allow
children to use this product unless they are
supervised at all times.
Failure to follow all instructions may result in
injury or even death.
Do not allow people to climb or walk on the
cover at any time.
Do not allow children to have access to the
COVANA cover without supervision.
Never operate the COVANA cover until all
people and objects are out of the spa.
Lower the COVANA cover in extreme wind
conditions. Such as gusts of 20 mph (30 km/h)
in the raised position and upwards of 45 mph
(70 km/h) when completely lowered on the hot
tub.
WARNING
Be sure to keep the key switch and the key out
of the reach of children.
Do not put any type of fabric or plastic sheet,
such as a tarpaulin, on the COVANA cover.
This could overheat the cover and result in the
deformation or delamination of the cover.
Inspect the cover periodically. It should raise
smoothly and evenly. Contact your COVANA
dealer if any unusual sound is heard during
use.
Never use any type of pressure washer or
buffer to clean any surface of the COVANA
cover. This could result in premature wear or
damage.
DO
Remove the control key after operating the
COVANA cover. Store the key in a secure
location when not in use. Users must bring the
control key into the hot tub with them to prevent
unauthorized operation of the cover.
Never leave the key in the key switch.
Check the cover frequently for signs of
deterioration.
Have any repairs, adjustments or mechanical
work performed by your authorized COVANA
dealer as soon as possible should you notice a
malfunction.
Close the cover when not in use or if the hot tub
is not being monitored.
A COVANA cover should only be operated by
an adult.
This appliance can be used by children aged 8
years and above and persons with reduced
physical, sensory or mental capabilities or lack
of experience and knowledge ONLY if they are
supervised or have received instructions
regarding safe use of the cover. Children must
not play with the appliance. Cleaning and user
maintenance must not be performed by
children without supervision.
DO NOT
Operate the unit before all the mechanical and
electrical connections are completed.
Step on or stack anything on the COVANA
operator cover.
Operate the COVANA cover while someone is
in the hot tub.
Climb, walk or stand on the COVANA cover at
any time.
Leave the COVANA cover open for more than
12 hours. This could cause the cover to warp
over time.

INSTALLATION MANUAL SAFETY 5
Converge or directly reflect sunlight on the
cover. This could cause permanent damage.
Wash the cover with harsh chemicals or
cleaners.
Use a pressure washer to clean any component
of the COVANA cover. This could result in
premature wear or damage.
Use an extension cord to connect the COVANA
cover to its power source. The cord may not be
properly grounded, and the connection is a
shock hazard. An extension cord may cause a
voltage drop, which would cause the motor to
overheat.
CAUTION
Be sure to follow all the instructions in this
manual and only use COVANA-approved
accessories and tools.
Do not roll the COVANA cover onto its side or
slide it on its side. This will damage the siding.
After removing any part, always place it in a
safe place on a clean and level surface to
ensure proper functionality.
For anchoring models: Both posts of the
COVANA cover must be properly anchored to
the foundation using the anchoring holes
located at the foot of each post.
For tub-mount models: Both posts of the
COVANA cover must be properly anchored to
the hot tub frame using the tub-mount brackets
and arms.
This product mainly contains steel, fiberglass,
foam, copper (Cu) and die-cast aluminum (Al).
The gearbox contains oil and other materials.
Please recycle them properly.
Both the up and down limit switches are pre-
adjusted at the factory. The down-limit switch
should never be readjusted. The up-limit switch
should be readjusted only to reduce the
maximum height of the cover to avoid possible
contact with its surroundings. Please refer to
the Limit Switch Adjustment section in this
manual before making any adjustments. An
improper adjustment can result in damage to
the drive system and/or cover.
Avoiding the risk of electrocution
ELECTRICAL DANGER
Failure to comply with these instructions may
result in serious injury or death by electrocution.
Disconnect or turn off and secure all power
supplies before starting any maintenance on
the COVANA cover.
A disconnecting mean needs to be
incorporated into the fixed wiring at the time of
installation. This device must be accessible to
the user or service technician to turn the power
off for future maintenance or repair
Always have a licensed electrical contractor
perform any electrical maintenance or repairs
on the COVANA cover. Wiring must comply
with all applicable local electrical codes and
regulations.
The COVANA operator must be connected to a
circuit that is protected by a dedicated ground
fault circuit interrupter (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 all electrical
and base mechanical components.
Do not connect any auxiliary components to the
electrical system of the COVANA cover unless
they have been approved by COVANA.
Replace electrical components with original
components provided or approved by
COVANA. Ask your dealer for replacement
parts.
To reduce the risk of electrical shock, replace
all damaged electrical cables immediately.
Failure to do so may result in death or serious
personal injury due to electrocution.
Do not bury any electricalcables. A buried cable
may result in death or serious personal injury
due to electrocution if direct burial-type cable is
not used, or if improper digging occurs.
ELECTRICAL WARNING
To reduce the risk of electric shock, the green-
colored terminal or the terminal marked “g,”
“gr,” “ground,” “grounding” or with a ⏚symbol
that is located inside the supply terminal box or
compartment must be connected to the
grounding means provided in the electric
supply service panel with a continuous copper
wire equivalent in size to the circuit conductors
supplying the equipment.

6 SAFETY INSTALLATION MANUAL
Two lugs marked “bonding lugs” are provided
on the external surface or on the inside of the
supply terminal box or its compartment. 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 no smaller
than No. 6 AWG (13.3 mm2).
All field-installed metal components, such as
rails, ladders, drains or other similar hardware,
within 10’. (3 m) of the hot tub must be bonded
to the equipment grounding bus with copper
conductors not smaller than No. 6 AWG (13.3
mm2). (NEC art. 680.)
WARNING REGARDING DRUG OR
ALCOHOL USE
The use of drugs or alcohol while operating the
COVANA cover is strictly prohibited. The
impairment of judgement, vision or hearing may
affect the safety of other people or result in
death.
WARNING REGARDING
MODIFICATIONS TO THE COVANA
COVER
Any modifications to the COVANA cover, such
as mechanical, electrical or aesthetic
modifications, may cause the cover to operate
in an unwanted or dangerous way.
Furthermore, these modifications might void
the warranty and certification.
The COVANA cover was designed, tested and
certified for the sole purpose of covering and
securing a spa. Any installation that differs in
whole or in part from this purpose will void the
‘warranty and certification.
SAVE THESE INSTRUCTIONS

INSTALLATION MANUAL LABELLING 7
LABELLING
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 these labels are always visible and
should never be removed
Key operating diagram,
located on the ke
y
switch.
Risk of electrocution warning,
located on the operator unit.
Drowning risk warning, located on the outside of the COVANA cover.
Specification label, located on the operator unit.
(North American model)
Note: This label provides the serial number
C-HOR
Specification label, located on the operator unit.
(European model)
Note: This label provides the serial number

8 LABELLING INSTALLATION MANUAL
Label located on the key switch cable.
Do not step or stand on symbol,
located on top of the operator unit.
Electrical information, located on the key switch cable.
Maintenance informations, located
on the C-channels.

INSTALLATION MANUAL LABELLING 9
Do not step on cover label, located at the end C-channels of the COVANA cover.
Center label, located on the center of the right and left C-channels.
(remove after installation)
Top label, located on the interior of the I-beams and escape hatch opening
(hidden when assembled).

10 GLOSSARY INSTALLATION MANUAL
GLOSSARY
Part Figure Function
Post assembly The posts are fastened to the cover and will allow it to raise or lower.
All-weather seal The all-weather seal will help protect sleeves from damage due to
weather.
Blue sticker The blue sticker is for aesthetic purposes only. It sticks to the front
lip of the top plate cover.
Top plate
The top plate is a cover installed on the sleeve assembly.
Operator unit The operator powers and controls the lifting mechanism of the
COVANA cover.
Figure 2
Figure 1
Figure 5
Figure 4
Figure 3

INSTALLATION MANUAL GLOSSARY 11
Drive shaft The drive shaft transmits the power between the jack assemblies
and the chains connected to the operator unit.
U frame (short)
The short U frames protect the mechanical parts that rest on the
foundation and connect both posts.
Motor-side
The motor-side protects the chains.
Pivot arm
Figure 9
Links the cover to the posts.
C channel The C-channel is the outer frame of the cover.
I beam The I-beam is the aluminum extrusion installed between the panels.
Figure 10
Figure 11
Figure 6
Figure 7
Figure 8

12 GLOSSARY INSTALLATION MANUAL
Spacer The I to C spacer creates the perfect gap to slide the I-beams in the
c channels.
I to C connection
plate (long) The I to C long connection plate is used to screw the pivot arm to the c channels.
l to C connection
plate (small)
The I-to-C connection plate makes the link between the I-beam and
C-channels.
Key switch The key switch is used to operate the COVANA cover.
Corner bracket The corner brackets link the C-channels on the side to the ones in
front and back.
Escape hatch
The escape hatch is a removable panel and part of the cover. Refer
to Using the escape hatch section.
Contour seal
The contour seal ensures uniform contact between the cover and
the hot tub. It prevents excessive water and other contaminants
from entering the spa. It also reduces heat loss.
Figure 12
Figure 14
Figure 13
Figure 15
Figure 17
Figure 18
Figure 16

INSTALLATION MANUAL GLOSSARY 13
Contour seal
connector The seal connector is used to link both ends of the seal. It ensures a strong and effective joint.
Contour seal
installation clip Contour seal installation clips are used during the installation process to ensure the seal is installed properly.
Wiper bracket The wiper bracket is attached under the I-beam. This part is
required to ensure waterproofing of the COVANA cover.
Installation foam The installation foam is used during the installation process to
protect the hot tub from direct contact with the cover.
Sleeve bracket
(for tub mount
model only)
Used for the standard tub mount option to mount the sleeves to the
hot tub. It is the part resting against the sleeves.
Tub mount
support
(for tub mount
model only)
The tub mount supports are used to mount the sleeves to the hot
tub. It is the part resting against the hot tub.
Figure 19
Figure 22
Figure 23
Figure 24
Figure 20
Figure 21

14 INSTALLATION MANUAL
Tub mount arm
(short or long)
(for tub mount
model only)
The tub mount arms are used for the tub mount option only. They
link the sleeve brackets to the tub mount supports.
Post brackets
(for ground
anchoring option
only)
These are assembled with the L brackets, the side supports and
the linkage bars. The post brackets give the posts stability without
the need to mount any hardware to the hot tub.
L bracket
(for ground
anchoring option
only)
It is assembled with the post brackets, the side supports and the
linkage bars. The L brackets give the posts stability without the
need to mount any hardware to the hot tub.
Side support
(for ground
anchoring option
only)
It is assembled with the L brackets, the post brackets and the
linkage bars. The side supports give the posts stability without the
need to mount any hardware to the hot tub.
Linkage bar
(for ground
anchoring option
only)
It is assembled with the L brackets, the side supports and the post
brackets. The linkage bars give the posts stability without the need
to mount any hardware to the hot tub.
Figure 26
Figure 2714
Figure 28
Figure 29
Figure 25

INSTALLATION MANUAL HARDWARE IDENTIFICATION TABLE 15
HARDWARE IDENTIFICATION TABLE
Quantity Visual representation Description
6x
5/16″-18 x 2″hexagonal bolt
used to fasten the short and
long U-frames.
8x
1/4” -20 x 1” Button hex
drive bolt. Used to fix the
pivot joint bracket to the the
cover.
16x
10-24 x 1/2” Self-Tapping
Screw. Used on the cover’s
corner brackets.
4x
Ground
anchoring
28x
Tub mount
1/4”-20 x 5/8” Carriage bolt.
Used for fastening the I-
beam assemblies.These
bolts are also used for the
tub mount option.
16x
Ground
anchoring
1/4”-20 x 3/4” Carriage bolt.
Only used for the
stabilization option.
4x
#8 x1/2” Self-drilling screw.
Used to fasten the sleeves
top plates.
32x
Tub mount
#10-12 x 3/4” self-tapping
screws. Only used for the
tub mount option.

16 HARDWARE IDENTIFICATION TABLE INSTALLATION MANUAL
4x
Ground
anchoring
28x
Tub mount
1/4” Lock washer used for
cover assembly and the tub
mount option.
8x
Tub mount
1/4” Flat stainless steel
washer. Only used for the
tub mount option.
2x
5/16” Lock washer used to
fasten the operator unit to
the long U-frame.
2x
5/16” Flat stainless steel
washer used to fasten the
operator to the long U-frame.
8x
5/16” Flat nylon washer used
on the bindings of the short
U-frames.
4x
Ground
anchoring
28x
Tub mount
1/4”-20 Hex nut. Used for
cover assembly and the tub
mount option.
2x
5/16”-18 Hex nut. Used to
fasten the operator to the
long U-frame.
6x
5/16”-18 Nylon insert
locknut. Used to fasten the
short and U-frame to the
long u-frame and to the post.

INSTALLATION MANUAL HARDWARE IDENTIFICATION TABLE 17
18x
Ground
anchoring
2x
Tub mount
1/4”-20 Nylon insert locknut.
Used with shoulder screw
and with ground anchoring
option.
2x
1/4-20-5/16” Set screw used
on the operator’s sprocket.
1x
3/16-3/16-5/8” Square ends
key used for the operator’s
sprocket.
1x
5/32” Hex key. Used for
fastening the 1/4”-20 x 1”
Button hex drive bolts.
2x
5/16x1 ¼” shoulder screw
used to lock pivot arm and
post togheter
2x
1” diameter black cap. Used
to close the end of the pivot
arm.

18 INSTALLATION PREPARATION INSTALLATION MANUAL
INSTALLATION
PREPARATION
To ensure the safe use of the COVANA cover, it must
be installed on a properly prepared surface. It is
important to adequately prepare the foundation and
carefully read the following recommendations.
Location considerations
Ensure the future location of the COVANA
cover is not subject to any downpour of water
or debris falling from another rooftop.
Ensure that the base of the cover is not in a
flood zone. Any damage caused by flooding or
water accumulation will not be covered under
the warranty.
Ensure that there are no obstacles, such as
branches or electrical power lines, in the
operating range of the cover.
Refer to section Technical specifications for
dimensions of cover.
Ensure there is safe access to the tub, free of
obstacles or debris.
All the base components of the COVANA cover
must be supported by the foundation.
Do not concentrate or directly reflect sunlight
onto the cover. This could cause permanent
damage (e.g. reflection from a window).
Ensure the COVANA cover is installed on a
clean surface free of any vegetation, such as
grass, branches, roots or mineral
contaminants, such as rocks, dust or sand.
The key switch must be permanently mounted
and located 5’. (1.5 m) away from the hot tub
and 5’. (1.5 m) above the deck or ground level.
Be sure that the user has a clear view of the
Horizon cover when operating it. Furthermore,
the key switch terminal should be located in a
place where no water downpour or debris could
fall on it. (Figure 30)
WARNING
Failure to permanently install the key switch as
indicated could cause serious injury or even
death and void the warranty and certification.
Only the proper installation of the key switch
combined with the suggested procedures and
caution will reduce such risks.
Do not place the cover in an area prone to snow
accumulation or water runoff.
DANGER
Failure to properly install the key switch
according to these instructions could result in
injury or even death.
1.5 metres
1.5 metres
5 feet
5 feet
Hot tub
Figure 30

INSTALLATION MANUAL INSTALLATION PREPARATION 19
Foundation preparation
The Horizon cover requires a clean, flat and
level surface such as an engineered wood deck
or a concrete slab.
Both jacks of the COVANA cover must be
properly fastened to the tub frame. It is the
installer’s responsibility to ensure the Horizon
cover is properly fastened in a safe manner. If
you cannot meet these requirements, COVANA
offers the ground anchoring option for the
Horizon. It is the installer’s responsibility to
ensure the Horizon cover is properly anchored
to the ground with the proper anchoring
hardware.
WARNING
The ground anchoring option should not be
used in an excessively windy area.
Just like the hot tub, the Horizon cover requires
a solid foundation. The foundation for the
Horizon cover must be able to support at least
550 lb. (250 kg).
The foundation must be levelled with a
maximum tolerance of 1” (2.5 cm) over a 113
3/4” (2.89 m) by 56½” (1.44 m) rectangle
(Figure 31). Refer to Frame and footprint
section for information on minimum base size.
The annual variation in levelness for the same
area cannot exceed 1/4” (6 mm).
CAUTION
Damage caused by inadequate foundation
construction is not covered by the COVANA
warranty. It is the owner’s responsibility to
provide a proper foundation.
Failure to follow these guidelines may cause
permanent damage or the improper functioning
of the COVANA cover. Such damage may not
be covered by the warranty.
56½” (1.44 m)
Figure 31
113 3/4” (2.89 m)

20 INSTALLATION PREPARATION INSTALLATION MANUAL
REAR of
the cover
FRONT of
the cover
Figure 33
Operator unit
Installation reference information
Throughout the following installation instructions, we
will refer to the front, rear, left and right sides of the
cover. Please refer to Figures 32 and 33. The front of
the cover is the side with the higher point of the tilt
and the back of the cover is the operator’s side.
LEFT of
the cover
RIGHT of
the cover
Figure 32
Operator unit