COVANA Evolution User manual

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

2 INSTALLATION MANUAL
TABLE OF CONTENTS
TABLE OF CONTENTS ............................................................................................................................................. 2
SAFETY ...................................................................................................................................................................... 4
READ AND FOLLOW ALL INSTRUCTIONS...................................................................................................................................... 4
Safety information ................................................................................................................................................... 4
Avoiding the risk of electrocution ............................................................................................................................ 5
LABELING ................................................................................................................................................................. 7
GLOSSARY ..............................................................................................................................................................10
HARDWARE IDENTIFICATION TABLE .................................................................................................................14
INSTALLATION PREPARATION ............................................................................................................................16
Location considerations ........................................................................................................................................16
Foundation preparation.........................................................................................................................................17
INSTALLATION .......................................................................................................................................................18
HANDLING ...............................................................................................................................................................18
Uncrating ..............................................................................................................................................................20
Assembly preparation ...........................................................................................................................................23
Lifting mechanism assembly ................................................................................................................................29
Testing the Evolution cover ..................................................................................................................................37
Wiper bracket installation......................................................................................................................................38
Non-permanent mounting plates installation (option) ...........................................................................................39
Seal application ....................................................................................................................................................40
ELECTRICAL HOOK-UP .........................................................................................................................................42
Grounding and power supply connection .............................................................................................................43
TECHNICAL SPECIFICATIONS ..............................................................................................................................44
Side elevation dimensions ....................................................................................................................................44
Frame dimensions and footprint ...........................................................................................................................45
Electrical specifications.........................................................................................................................................47
Operating limitations .............................................................................................................................................47
General specifications ..........................................................................................................................................47
LIMIT SWITCH ADJUSTMENT ...............................................................................................................................48
TROUBLESHOOTING .............................................................................................................................................49
APPENDIX ...............................................................................................................................................................51

INSTALLATION MANUAL 3
Wiring diagram (North America) – 60 Hz, 120 VAC Operator ..............................................................................52
Wiring diagram (Europe) – 50 Hz, 220 VAC Operator .........................................................................................54
INSTALLATION CHECKLIST (Customer copy) ....................................................................................................57
INSTALLATION CHECKLIST (Installer copy) .......................................................................................................59

4 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 cover’s
warranty and nullify its 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 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 30 mph (50 km/h) in
the raised position.
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 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
in the hot tube 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 it is 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 mechanical and
electrical connections are completed.
 Step on or stack anything on the COVANA
operator cover.
 Operate the Covana cover while somebody is in
the hot tub.
 Climb, walk or stand on the Covana cover at any
time.

INSTALLATION MANUAL 5
 Leave the Covana cover open for more than
12 hours. This could cause the cover to warp over
time.
 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 instructions in this manual and
use only 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 a part, always place it in a safe
place on a clean and level surface to ensure
proper functionality.
 All four posts of the COVANA cover must be
properly anchored to the foundation using the
anchoring holes located at the foot of each post.
The optional non-permanent mounting plates can
be used when anchoring is not possible, but under
strict condition. See Non-permanent mounting
plates installation section on Installation Manual
for further details.
 This product mainly contains steel, plastic, copper
(Cu), fiberglass, foam 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 re-adjusted. The up-limit switch
should be re-adjusted 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 death by electrocution or serious injury.
Disconnect or turn off and secure all power
supplies before starting any intervention on the
COVANA cover.
 A disconnect mean needs to be incorporated into
the fixed wiring at the time of installation. This
mean 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. The 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 the 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 electrical cables. A buried power
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 INSTALLATION MANUAL
 Two lugs marked “bonding lugs” are provided on
the external surface or on the inside of the supply
terminal box or 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 not smaller than No. 6 AWG (4.11 mm).
 All field-installed metal components, such as rails,
ladders, drains or other similar hardware, within
10 ft. (3 m) of the hot tub must be bonded to the
equipment grounding bus with copper conductors
not smaller than No. 6 AWG (4.11 mm). (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 might
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 ones, 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 certifications.
SAVE THESE
INSTRUCTIONS

INSTALLATION MANUAL 7
LABELING
WARNING
Removing any labels from the COVANA cover will void product certification. All labels should always remain visible.
It is the owner’s responsibility to ensure that these labels are always visible and should never be removed.
Risk of electrocution warning, located on the
operator unit.
Drowning risk warning, located on the inside of the
Covana cover.
Specification sticker located on the operator unit
(European model)
NOTE: This sticker provides the serial number.
Key operating diagram, located on the key switch.
Specification sticker located on the operator unit
(North American model)
NOTE: This sticker provides the serial number.

8 INSTALLATION MANUAL
Key switch warning, located on the key switch.
Do not step symbol, located on top of the operator unit.
Maintenance information located on the cover.
Electrical information, located on the key switch cable.

INSTALLATION MANUAL 9
Do not step on cover sticker located on the end C-channels of the COVANA cover.
Center label located on 94 9/16 in (240 cm) C-Channel (remove after installation)
Top sticker located on I-Beams and Escape hatch opening (Hidden when assembled)

10 INSTALLATION MANUAL
GLOSSARY
Part Figure Function
All-weather seal
Figure 1
The all-weather seal will help protect sleeves from damage due to
weather.
C channel
Figure 2
The C-channel is the outer frame of the cover.
Contour seal
Figure 3
The contour seal ensures uniform contact between the inner shell
and the hot tub.
Contour seal
installation clip
Figure 4
Contour seal installation clips are used during the installation
process to ensure the seal is installed properly.
Contour seal
connector
Figure 5
The seal connector is used to link both ends of the seal.
Corner bracket
Figure 6
The corner bracket is the piece that links the cover to the sleeves.

INSTALLATION MANUAL 11
Corner bracket
Figure
7
The corner bracket links the C-Channels on the side to the ones in
front and back.
Drive shaft
Figure 8
The drive shaft transmits the power between the motor-side and
non-motor-side jack assemblies.
Escape hatch
Figure 9
The escape hatch is a removable panel part of the cover.
Hammer block
Figure 10
The hammer block is a piece of plastic or wood used during the
installation to hit on the panels without causing damage.
Foot bracket
Figure 11
The foot bracket provides a solid footing for the COVANA cover and
is assembled with a jack.
Front frame cut-
out
Figure 12
The front frame cut-out gets installed under the front step of your
hot tub. It links the two non-motor-side posts.
I beam
Figure 13
The I-beams are the aluminum extrusions installed between the
panels.

12 INSTALLATION MANUAL
I to C spacer
Figure
14
The I to C spacer is used to prevent over tightening of the I to C
connection plates.
Key switch
Figure 15
The key switch is used to operate the COVANA cover.
Foam spacer
Figure 16
The foam spacer is used during the installation process to protect
the swim spa from direct contact with the cover.
Limit switch
Figure
17
The limit switches are located in the operator. Refer to the Limit
Switch Adjustment section for further details.
Motor frame
Figure 18
The motor frame is composed of the two motor-side jacks and the
operator.
Non-motor-side
or motor-side
jack
Figure 19
The non-motor-side jacks are a main part of the COVANA cover.
They and the motor-side jacks enable the cover to move.

INSTALLATION MANUAL 13
Operator
Figure
20
The operator powers and controls the lifting mechanism of the
Covana cover.
Sleeve
Figure 21
The sleeve is an aluminum case for the lifting mechanism.
U-frame
Figure 22
The U-frames protect the mechanical parts resting on the
foundation and connect all four posts.
Wiper bracket
Figure 23
The wiper bracket is adhered under the I-beams. This part is
required to ensure the waterproofing of the COVANA cover.
I-to-C
connection plate
(short)
Figure
24
The short I-to-C connection plate makes the link between I-beams
and C-Channels.
Jack lock bolts
Figure 25
The jack lock bolts prevent the non-motor jacks from extending. Do
not remove this bolt until the drive shaft is connecting the motor-
side jack to the non-motor-side jack. Follow installation steps
carefully.

14 INSTALLATION MANUAL
HARDWARE IDENTIFICATION TABLE
Quantity Visual representation Description
4
1/4″-20 x 3/4″ carriage bolt
used to assemble the front
frame cut-out.
8
1/4”-20 x 5/8” Carriage bolt.
Used for fastening the I-beam
assemblies.
16
5/16″-18 x 2″ hexagonal bolt
used to assemble the lower
frame.
18
M6 x 20 mm screw used to
hold the cover and sleeve.
16
#8 x 1/2″ self-drilling Robertson
screw used to fasten the inner
sleeve to the Covana cover.
4
1/4″-20 x 2 1/4″ hexagonal bolt
used to assemble the feet of
the posts.
24x
#8 x 3/4” Self-tapping screw.
Used to fasten the corner
brackets.
8
1/4’’-20 Nylon- insert locknut.
Used to assemble the feet of
the posts and the front cut-out.
8
1/4-20 Hex nut. Used for I-
beam assemblies.
16
5/16″-18 nylon-insert locknut
used to connect the U-frames.

INSTALLATION MANUAL 15
1
#2 x 6” Robertson bit.
32
5/16″ nylon washer used to
connect the U-frames
16
1/4″ painted washer.
2
1/4″ nylon washers used to
fasten the bottom of the
sleeves with M6 x 20 mm
screw.
2
M6 clip-on barrel nut used to
secure the sleeve at the bottom
of each post.

16 INSTALLATION MANUAL
INSTALLATION
PREPARATION
To ensure 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 COVANA cover location is not
subjected to water downpour or debris falling from
another or covering.
 Ensure that the base of the COVAN cover is not in
a flood zone. Any damage caused by flooding or
water accumulation will not be covered under the
warranty.
 Ensure there are no obstacles, such as branches
or electrical power lines, in the operating range of
the COVANA cover.
 Refer to the Technical specifications section for
cover dimensions
 Ensure there is safe access to the hot tub, free of
obstacles or debris.
 All the base components of the COVANA cover
must be supported by the foundation.
 Do not converge or directly reflect sunlight on the
cover. This could cause permanent damage. (i.e.:
reflection by a window)
 Ensure the COVANA cover is installed on a clean
surface free of any vegetation, such as grass,
branches or roots, or mineral contaminants, such
as rocks, dust or sand.
 The key switch must be permanently mounted and
located 5 ft. (1.5 m) away from the hot tub and 5 ft.
(1.5 m) above the deck or ground level. (Figure 26)
This ensures the user has a clear view of the
COVANA 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 26)
WARNING
 Failure to permanently install the key switch as
indicated could cause serious injury or even death
and void the warranty and certification. Only
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 and water runoff.
DANGER
 Failure to properly install the key switch according
to these instructions could result in injury or even
death.

Figure 26
Evolution Cover
Spa

INSTALLATION MANUAL 17
Foundation preparation
 The Evolution cover requires a clean, flat and level
surface such as an engineered wood deck or a
concrete slab.
 Each of the four jacks of the Covana cover must
be properly anchored to the foundation using at
least one of the pre-drilled holes located at the foot
of each post. Use a 1/4 in. (6 mm) concrete anchor
for concrete pads or a 1/4 in. (6 mm) lag bolt for
wood foundations and insert minimum 11/4 in.
(30 mm) deep (not included). If you cannot meet
these requirements, install a set of non-permanent
mounting plates.
WARNING
 The non-permanent mounting plates can only be
used in areas with low winds (less than 30 mph (50
km/h) open and less than 45 mph (70 km/h) in
close position).
 The non-permanent mounting plates must also be
properly installed.
 Just like the hot tub, the Covana cover requires a
solid foundation. The foundation for the Covana
cover must be able to support at least 600 lb.
(272 kg).
 The foundation must be leveled with a maximum
tolerance of 1 in. (2.54 cm) over a diagonal
section. (Figure 27). Refer to Frame dimensions
and foot print section for information on the
minimum base size.
 The annual variation in levelness for the same
diagonal section cannot exceed 1/4 in. (6 mm)
CAUTION
 Damage caused by inadequate foundation
construction is not covered by the Covana
warranty. It is the responsibility of the owner to
provide a proper foundation.
 Failure to follow these guidelines might cause
permanent damage or improper functioning of the
Covana cover. Such damage might not be
covered by the warranty.
Figure 27

18 INSTALLATION MANUAL
INSTALLATION
Tools required
 Scissors or a utility knife
 Robertson screwdriver
 Hammer
 Slotted screwdriver
 Phillips screwdriver
 3/8” (10 mm) socket wrench and spanner
 7/16” (11 mm) socket wrench and spanner
 1/2" (13 mm) socket wrench and spanner
 7/32” (5.5 mm) Allen key
 25’ (7.62 m) measuring tape
 Rubber mallet
 SAE or metric Socket kit
 48” (122 cm) level
 2 x 50’ (15 m) Ratchet straps
 5/32″ (4 mm) Allen key (supplied)
 48 in. (122 cm) level
 Stepladder
CAUTION
 The COVANA cover should be installed by a certified COVANA installer. Having the COVANA cover installed
by someone who is not certified will void the warranty. Ask your local COVANA dealer for information on
certified installers.
HANDLING
Minimum requirements
 The forklift used must have a minimum capacity of
5,000 lb (2,268 kg) at 24” (610 mm) from the fork
arm and 96” (2.44 m) length fork. (Figure 28)
OR
 64” (1.6 m) with 96” (2.44 m) extension forks.
(Figure 29)
 Overall total grip of 16” (432 mm) in both setups.
(Figure 30)
Figure 28
Figure 29
Figure 30

INSTALLATION MANUAL 19
Upon delivery
During the delivery process with the carrier, if you
notice any sign of damage to the crate that could
compromise the stability, the transportation or
unloading of the crate, there is a high risk that the
merchandise is also damaged. (Figure 32)
 Do not attempt anything that could compromise
the safety of your crew.
 Refer to the COVANA Damaged claim form
attached to the crate, take pictures and simply
refuse the delivery from the carrier. (Figure 33)
Secure the crate
 Before unloading the merchandise, for security
and safety, the crate must be secured to the forklift
with ratchet tie down straps or similar tools. (Figure
34 and Figure 35)
 Always make a visual inspection of the condition
of the crate before attempting any action with the
forklift.
 If the crate is unstable prior to any attempt, this is
already a safe risk.
Secure perimeter
 Before or while handling the crate with the forklift
or any other lifting tool, the forks should be fully
under the crate before any elevation and should
be moved by one of the two short sides indicated
on the crate.
 No one should be in front, beside or around within
12’ (3.6 m) of the crate being handled. The crate
should not be kept higher than 6” (152 mm) from
the ground at all times to avoid injury to all
personnel. ( Figure 31)
 Make sure the forklift is stopped and the crate
down and stable on the floor before approaching
the crate for further handling or uncrating. If the
crate seems to be unbalanced, unstable, tilting or
wobbly, do not attempt any action in any
circumstances to stabilize by hand.
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
2 Ratchet Tie
D
own
-
S
trap
Ratchet Tie
Down Strap

20 INSTALLATION MANUAL
Uncrating
1) Before uncrating the unit, ensure there is no
visible damage to the crate. In case of any
suspicious damage, take pictures first and
please call COVANA customer service
immediately. Always stand the crate in the
vertical position. Ensure that the uncrating can
be done safely given the wind conditions.
(Figure 36)
2) Remove the cardboard on the front side. (Figure
36)
3) Hammer off the wood furring strip by hitting on
the inside of the side panels. (Figure 36)
CAUTION
 Be careful not to damage the cover components
and other parts in the crate.
 Flatten any protruding nails.
4) Remove the C-channels, the escape hatch box,
the parts box, the foam pieces and the seal from
the crate. Temporarily put these items in a safe
place. (Figure 37)
5) Use a slotted screwdriver to remove the two
slotted #10-24 x 3/8″ screws holding the
operator in place. (Figure 38)
6) Bend the metal strapping all the way back and
reinstall the screws on the operator. (Figure 38)
7) Use the 3/8″ (10 mm) socket wrench to unscrew
the hexagonal 1/4″-14 x 2″ lag bolts on the
bottom of both jacks. There are two lag bolts per
jack. (Figure 39)
Figure 36
Figure 37
Figure 38
Figure 39
Furring
Front
side
Seal
Foam pieces
Part box
C-channels
Escape
hatch box
Figure 40
Alignment
bra
cket