Sterling Leisure Products COVANA User manual

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Installation Manual
Sterling Leisure Products
www.sterlingcovana.com
Read this manual before proceeding with installation

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Laversionfrançaisedumanueldébuteàlapage21.
FRANÇAIS

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RISK OF ELECTROCUTION
THE COVANA OPERATOR MUST BE CONNECTED TO A DEDICATED GFCI
(GROUND FAULT CIRCUIT INTERRUPTERS) PROTECTED CIRCUIT.
REFERENCE: COMPLY TO ANY LOCAL CODES AND REGULATIONS.
RISK OF ELECTROCUTION
THE OPERATOR MUST BE PROPERLY BOUNDED BEFORE CONNECTING THE MAIN POWER SUPPLY.
THE OPERATOR MUST BE PROPERLY GROUNDED BEFORE CONNECTING THE MAIN POWER SUPPLY.
RISK OF INJURY
DO NOT OPERATE THE COVANA WHILE IN WATER
RISK OF INJURY
DISCONNECT OR TURN OFF ALL POWER SUPPLY BEFORE STARTING
INTERVENTION ON THE COVANA
WARNING
WARNING
WARNING
RISK OF ELECTROCUTION
ALL ELECTRICAL WIRING MUST BE DONE BY A QUALIFIED PROFESSIONAL
THE WIRING MUST MEET THE REQUIREMENTS OF ANY LOCAL CODES AND REGULATIONS
WARNING
AVOID DROWNING RISK
ENTRAPMENT POSSIBLE
FAILURE TO FOLLOW ALL INSTRUCTIONS MAY RESULT IN INJURY OR DROWNING
INSPECT PERIODICALLY — POWER SAFETY MEETING ASTM F1346-91 REQUIREMENTS
WARNING
WARNING

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THIS OPERATOR IS SPECIALLY DESIGNED TO OPERATE ONLY WITH THE COVANA LIFTING SYSTEM.
UNDER NO CIRCUMSTANCES SHOULD THIS OPERATOR BE USED FOR ANY OTHER APPLICATIONS.
DO NOT STEP ON THE OPERATOR.
DISPOSAL: THIS PRODUCT CONTAINS MAINLY: STEEL, COPPER (CU), ALUMINUM DIE-CAST (AL).
PLEASE RECYCLE WISELY. THE GEARBOX CONTAINS OIL AND OTHER MATERIALS
REMOVE THE CONTROL KEY AFTER OPERATING THE COVANA.
STORE THE KEY IN A SECURE LOCATION WHEN NOT IN USE.
BRING KEY WITH YOU IN THE SPA TO PREVENT UNAUTHORIZED OPERATION OF THE COVANA.
NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
5 feet
1.5 meters
Roof
Spa
5 feet
1.5 meters
The key switch must be permanently mounted and located
5 feet (1.5m) away from the spa and 5 feet (1.5m) above the
deck and user must have full view of the Covana.

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IMPORTANT
OBSERVE THE FOLLOWING STEPS FOR THE PROPER ASSEMBLY & SETUP OF
THE COVANA.
IMPORTANT
DO NOT OPERATE THE UNIT UNTIL ALL MECHANICAL AND ELECTRICAL
CONNECTIONS HAVE BEEN MADE.
IMPORTANT
ALL 4 POST OF THE COVANA MUST BE PROPERLY ANCHORED TO ITS FOUNDATION USING
THE ANCHORING HOLES LOCATED ON THE FOOT OF EACH POST.
IMPORTANT
LIMIT SWITCH ADJUSTMENT
BOTH THE UP & DOWN LIMITS SWITCH ARE PRE-ADJUSTED AT THE FACTORY. THE DOWN
LIMIT SWICH SHOULD NEVER NEED TO BE ADJUSTED. THE UP LIMIT SWITCH SHOULD
ONLY BE ADJUSTED TO REDUCE THE HEIGHT OF THE ROOF TO AVOID POSSIBLE CONTACT
WITH ITS SURROUNDINGS. REFER TO THE LIMIT SWITCH ADJUSTMENT GUIDE FOUND IN
THIS MANUAL BEFORE MAKING ANY ADJUSTEMTS. IMPROPER ADJUSTMENT CAN RESULT
IN DAMAGE TO THE DRIVE SYSTEM.

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Just like the spa foundation, the COVANA also requires a solid foundation. The area that the
COVANA sits on must be able to support at least 600lbs (300kg) and must be level.
Note: Damage caused by inadequate or improper foundation support is not covered by
the COVANA warranty. It is the responsibility of the owner to provide proper foundation.
Foundation recommendation:
1. Engineered wood deck
2. Concrete Pad - 4” (100mm) thickness
3. Each of the 4 posts on the Covana must be properly anchored to the foundation using
at least one of the pre-drilled holes located on the foot of each post.
 Use a 1/4” (6mm) concrete anchor for concrete pads or a 1/4” (6mm) lag bolt for
wood foundations a minimum of 1-1/4” (30mm) long
1. The COVANA requires a dedicated 115V (230V*) permanently connected (hard wired)
power supply.
2. The COVANA motor has a dedicated connection for 115V (230V*), please see enclosed
connection diagram.
3. The COVANA must be installed in accordance to and comply to any local codes and
regulations. All wiring should be installed by a qualified electrician
4. Wire and conduit should be sized as per local codes and regulations.
The electrical circuit for the COVANA must include a suitable ground fault interrupter
(GFCI) as required to comply to codes and regulations.
Required Voltage: 115V (230V*) (1 hot, 1 neutral, 1 ground)
Required GFCI Breaker: 15A (10A*) single-pole GFCI breaker, not included
Max COVANA current draw: 12 (6*) Amps
* For European customers only.
PREPARING A PROPER FOUNDATION
COVANA ELECTRICAL REQUIREMENTS

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SIDE ELEVATION DIMENSIONS
Spa Height will vary and must be
within these measurements
Minimum is 34” (860mm)
Maximum is 48” (1220mm)
Covana maximum travel is
50” (1270mm)
The maximum elevation height is
dependent of the height of the tub.
Add spa height to the Covana travel
to determine maximum elevation.
Example:
Spa height + COVANA travel which is
50” (1270mm) = Total elevation
21” (530mm)

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FRAME DIMENSIONS AND FOOTPRINT

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BONDING, GROUNDING AND CONNECTION OF POWER SUPPLY
Use the terminals provided to
bond the COVANA operator
Pre-wired key switch 20’ (7,5m)
of cable included, cable must be
passed through a conduit
Unscrew and remove the four
screws on the bottom side of
the COVANA operator and
remove the cover
Connect the main power 115V
(230V*) to their respective
terminals
Connect the ground cable of
the main power supply to the
terminal provided.
Replace the operator cover
RISK OF INJURY
DISCONNECT OR TURN OFF ALL POWER SUPPLY BEFORE STARTING
INTERVENTION ON THE COVANA
WARNING
* For European customers only.
COVER
OPERATOR

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LIMIT SWITCH ADJUSTMENT
Note: The UP & DOWN limits are factory adjusted and there is no need for re-adjustment.
If adjustments are required to ensure the Covana roof does not come into contact with its
surroundings, while elevating, the UP direction may be decreased. Never change the
factory settings of the DOWN limits or increase the UP limit, failing to do so may result in
possible equipment damage and/or injury:
1. Remove the retaining screw and slide the camplate from operator frame.
2. To reduce the travel to UP direction, turn the UP cam counterclockwise as per arrow
3. Once the cam is set to the desired position, reinstall the camplate and make sure that
it is properly inserted in the slot of each cam. NEVER OPERATE THE SYSTEM WITH
THE CAMPLATE REMOVED.
4. Replace the retaining screw to prevent the camplate from coming out.
5. Reinstall the operator, turn the power ON and test the system.
RISK OF INJURY
DISCONNECT OR TURN OFF ALL POWER SUPPLY BEFORE STARTING
ANY INTERVENTION ON THE SPA GAZEBO
WARNING
KEY OPERATING INSTRUCTIONS
 Turn the key to the right — clockwise to raise the roof
 Turn the key to the left — counterclockwise to lower the roof
 Key will automatically return to center, off position, when released
Camplate and retaining screw

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MANUAL OPERATION IN CASE OF POWER FAILURE
RISK OF INJURY
DISCONNECT OR TURN OFF ALL POWER SUPPLY BEFORE STARTING
INTERVENTION ON THE COVANA OPERATOR
WARNING
1.Disconnect or turn off the power
2.Unscrew and remove the four screws on the cover of the operator.
3.Remove the operator
4.Use a ½" or 13mm hexagon socket wrench to operate the operator by turning the input
shaft SLOWLY TURN THE SHAFT - STOP IF EXCESS TENSION IS FELT
NEVER USE A POWER TOOL AS THIS WILL DAMAGE UNIT
5.Turn the input shaft clockwise to lower the roof and counterclockwise to raise the roof
6.Put the cover back on the operator
7.Reconnect or turn on power
COVER
OPERATOR

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

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

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UNCRATING THE COVANA
1. Stand the Covana in the vertical position, ensure wind conditions allow for this to be done safely
2. Remove the hardware box and sort the hardware
3. Using the screwdriver bit included in the hardware kit, remove the lower corner braces of the crate
4. Remove the four screws on the metal cover of the operator
5. Remove the six screws that fix the bottom feet of the four posts to the crate
6. Using a 7/32” Allen wrench loosen the bolts in the
center of the post top plates, no more than five
turns.
7. Remove the two single posts out of the shipping
bracket and carefully lay posts on the ground.
Bend the brackets up and out of the way.
8. With the help of one other person remove the
motor end post assembly out of the crate. We
recommend one hand under the main frame and
one holding the post vertical. Handle and carry the
assembly so that the posts are straight and
parallel. DO NOT TWIST.
9. Remove all of the frame pieces at the
bottom of the crate.
10.Lower the crate down in the horizontal
position, remove the wrapping from the
sides and disassemble the crate. Six
screws per side, three top and three
bottom. See arrows below
11.BE AWARE that the square drive shafts
are hidden in the bottom of the crate
directly under the roof, remove before
discarding the crate

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ASSEMBLING THE COVANA
1. Cut four 5” pieces of the Covana seal and
apply these to the tub corners to ensure tub
and roof have the required spacing and both
are protected.
2. Place and center the roof of the Covana on the
tub, pay attention to the short side and long
side. The light switch, if a LED light kit option is
installed in the roof, should be placed on the
entry side of the tub
3. Perform the LED light kit installation/
procedure, instructions included in solar panel
box.
4. On all four posts remove the top plate Allen
head bolt and bushing
5. Loosen the lower sleeve retaining bolt, no
more than five turns.
6. Slide the three part sleeve assembly off the
jack.
1. Lay the sleeves in a safe location, preferably
horizontal on a soft surface.
2. Position the motor and two post assembly in
place, usually to the rear of the spa, slide the
jacks against the roof corners
3. Slide the driveshafts over the square shaft of
both motor side jacks
4. Hold the post vertical and inline with the post.
Using a 3/4” wrench, on the shaft of the post,
make fine adjustments to the square shaft so it
is in line with the driveshaft. and carefully slide
the square shaft of the post into the driveshaft.
5. Install the aluminum U frame over the drive
shaft and post bracket. Fasten in place using
hardware provided, 4 bolts + 4 nuts + 8
washers
6. Perform steps 6 to 7 on the second non motor
side jack
7. Assemble and install the front frame with the
cut-out for steps
8. Jack lock bracket can
now be safely removed.
Flip the jack lock upside
down and screw it in
place for possible future
use.

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ASSEMBLING THE COVANA PART II
AT THIS POINT THE ELECTRICAL POWER
SUPPLY MUST BE CONNECTED TO
CONTINUE THE INSTALLATION, THIS WILL
ENSURE THE PROPER SETTINGS ARE MADE
1. Mount key box as per instructions on page 3
2. Test system by turning key clockwise to elevate
posts, continue holding key until motor stops
automatically and posts are fully elevated.
3. Turn the key counter-clockwise to lower the
posts, continue holding key until motor stops
automatically and posts are fully lowered.
Measure from the foot to the top of the jack,
should measure 51.5” (1280 mm)
4. Reinstall the post sleeves. Ensure the all
weather kit is fully slid down to make contact
with the outer sleeve.
5. Install corner brackets at each corner. Fasten
the bracket to the roof, then using the self
drilling screws insert four screws per post.
6. Test the system to ensure the roof
elevates ensuring that the roof does not
make contact with any objects while
elevating, refer to limit switch adjustment
instructions on page 9 if adjustments need
to be made.
7. Lower the roof and ensure it stops at the
point of contact with the four pieces of
seal on the tub, readjust the corner
brackets if contact is not made
8. Ensure the Covana is centered over the
tub and that proper seal can be made
between the roof and the tub
9. Each of the 4 posts on the Covana must
be properly anchored to the foundation
using at least one of the pre-drilled holes
located on the foot of each post.
 Use a 1/4” (6mm) concrete anchor for
concrete pads or a 1/4” (6mm) lag bolt
for wood foundations. Minimum of
1-1/4” (30mm) long

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**NOTE: If your install requires the non-permanent mounting plates to be installed do this
BEFORE installing the seal to ensure proper alignment. **
1. Cut four 5” pieces of seal and place them on the corner of the hot tub before lifting the
roof in place as per the installation instructions.
2. When the complete Covana assembly has been performed,
lift the roof using the key switch and remove the temporary
seal sections. Lower the roof, walk around the entire hot tub
observing where the white inside shell makes contact with
the hot tub. This will determine the best location to apply the
seal.
3. Ensure the tub edge is completely dry.
4. With the roof elevated apply the seal clips provided, to the
tub in the predetermined area for the seal. The ideal location
for the seal is closer to the inside/water edge.
5. Install the seal starting at motor end with the adhesive layer
pointing up towards the roof.
6. NOTE – At this stage if the ambient air temperature is below
32⁰F (0⁰C) then a temporarily heater should be placed inside
the tub for 10-15mins. When the heater is in the tub bring
down the roof until it touches the seal to increase the air temperature. After 10-15mins
remove the heater and continue with the seal installation.
7. TEST - By lowering the roof again to ensure that the seal makes contact with the entire
perimeter. If satisfied elevate the roof, remove the red plastic backing of the seal and
lower the roof to the seal.
8. Let the roof rest in this position for two minutes to ensure proper seal to roof adhesion.
Important- Now elevate the roof no more than an inch and let the roof rest again for a
short period as this will allow the seal time to slowly and fully release from the seal
clips, if not a dull tool can be used to help the seal release.
Once satisfied that the seal is released, elevate the roof and remove the seal clips from
the tub edge.
Lower the roof and verify again for proper seal.
ASSEMBLING THE COVANA PART III - APPLYING THE SEAL

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COVANA LIGHTING
Operating procedures
Press the light switch, located in the inner shell in one of the
four corners, to turn the lights on. The Covana lights operate
in four modes. The modes are changed by turn the lights off
and then immediately back on.
Four Modes:
1. Fading: Cycles through the seven colors fading out
one color and fading back in with a new color.
2. Color Locked: Color of choice is locked
3. Rotating: Each color is cycled on and off for a few
seconds
4. Flashing: White light flashes quickly, on and off.
In the off position the lights will reset after 10 seconds and
will restart in the fading cycle.
Installation
IMPORTANT
- Determine the corner of the Covana that is likely to receive
the most sun, generally south is best; ensure there are no
interfering objects.
- Take note that the battery is located on the same short
side as the on and off switch.
- Take note the switch should be positioned to the entry side
of the spa.
- Ensure that all hardware is removed securing the outer
shell to the inner shell and no corner brackets are installed.
1. Lift the outer shell on the side where the battery is
located to access the connections of the Solar Panel.
Do not lift more than 16”(400mm)
2. Connect the solar panel to the Lighting wire harness
and route the wires and panel to the corner of the
Covana where the panel will be mounted.
3. Lower the outer shell back over the inner shell taking
care to ensure the wires are not pinched and are
placed in the slit of the outer shell corner.
4. Insert the suction cups in the panel, remove the
protective layer from the foam tape on the back
suction cups. Carefully place the panel
3” (75mm) up from the corner and center the
panel on the ridge of the roof. Rock the panel
back and forth to ensure proper adhesion.
5. Check to ensure the panel is charging – blue
flashing light
6. Continue with Covana installation.
Maintenance
1. Ensure solar panel is clean and free of snow.
2. Always turn lights off - if left on battery will need
2 to 3 sunny days to fully recharge.

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COVANA LIGHTING — OPTIONAL CHARGER INSTALLATION
IMPORTANT
- Take note that the battery is located on the same short
side as the on and off switch
- Ensure that all hardware is removed securing the outer
shell to the inner shell and no corner brackets are installed
- Lights can be operated while charging
- Lights will operate for 4 hours on a full charge.
1. Lift the outer shell on the side where the battery is
located to access the connections of the Solar Panel
and battery charger. Do not lift more than
16”(400mm) .
2. Connect the wires of the charger extension kit to the
connector of the Covana LED lighting kit.
3. Determine the best corner to locate the charger
connection; generally the back side would be less
visible.
4. Lower the outer shell back over the inner shell taking
care to ensure the wires are not pinched and are
placed in the slit of the outer shell corner.
5. Install the corner post bracket; ensuring the wire
comes over the top. Using the bottom bolt of the
bracket fasten the connector in place.

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

Made in Canada
Sterling Leisure Products
www.sterlingcovana.com
PATENTED
CANADA 2,532,429
US 11/162,557
UK 0515168.3
AUSTRALIA 2006200251