Latham CS3000 Bedienungsanleitung

INSTALLATION GUIDE

CS3000 Automatic Safety Pool Cover

Under Track System

with Aluminum Lid

SECTIONS

Standard Under Track .................................4

Mechanism ................................................ 6

Cover Fabric ............................................. 10

Classic Aluminum Lid ................................ 16

Home Owner Checklist............................. 18

Tools Required

1. Hammer drill or rotary hammer

2. Masonry drill bit 1/4” x 6” (1/4” x 12” bit)

3. Extension cords

4. #2 and #3 Phillips & standard screw drivers

5. Ratchet with 5/16” - 3/4” sockets

6. Hacksaw

7. String line

8. Utility knife

9. Broom

10. Hammer & rubber mallet

11. Pliers - standard, needle nose & channel lock

12. Files - round, triangular & flat

13. Lighter

14. Carpenter’s square

15. 5/16”hex head driver bit with 12” extension

16. Drill (cordless or corded)

17. Set of drill bits (1/4” down to 1/16”)

18. Crescent wrench

19. 100 & 25 foot tape measure

20. Chalk line (use white chalk)

21. Nut drivers - 5/16”, 3/8”, 7/16”, 1/2”

22. Chisel (wood & concrete)

23. Scissors

24. Wire strippers

25. Set of box/open end wrenches 5/16” - 3/4”

26. 6” level

27. Set of allen wrenches

28. Wire

29. Electrical tape

30. Small sledge hammer

31. Vice grips

32. #2 #3 Phillips drill bits

33. Pencil or marker

34. 6 - 8 clamps

Optional Power tools

Skill saw with carbide tipped blade

Sawzall, Grinder, Angle drill

Installation Check List ............................... 19

Parts Reference

Mechanism Components

Misc. Hardware

Cover Fabric

Cover Lid Lid Support Bracket Cover Pump

Cover Track

18 17 19

Top view

Side view

1. A0610 Motor & housing, standard 3 wire Bison motor

2. A0012 Mechanism RT or UT (Right)

A0024 Mechanism RT or UT (Left)

3. M0305 Mechanism Mounting Foot

4. A0020 Non-motor end cone assembly

5. A0797 Tube insert for 6” tube

6. X0001 6” aluminum roll-up tube

7. A2359 Non-motor end assembly RT/UT(Right)

A2358 Non-motor end assembly RT/UT(Left)

8. A0605 Key switch - Leviton assembly complete w/ light

9. A1100 Slider Assembly UT 403 & 801 for detachable ropes

10. A1688 Leading edge insert assembly UT 3”

11. X0021 Aluminum leading edge

12. Cover Cover fabric

13. PowerFlex Rope - Lengths will vary with cover length)

14. A0614 403 Under Track, 21’

15. A0958 Pulley end cap assembly 403 & 801 UT

16. A1884 Guide feed 2 piece SS UT

17. X0004 Main Lid

18. X0121 Motor End lid

19. X0659 Non-motor end lid

20. X0943 8” Lid hinge

21. A1692 Standard cover lid bracket (set of 2)

22. E1130 Little Giant cover pump & instructions

23. A0407

Under Track

retainer bracket set

24. M0104

Track

splice UT 403

25. E1086 Bonding lug ka-6u (for 1 wire)

26. H0332 Screw PPSM 12 x 1-3/4 for UT STD

(screw on

track

)

27. H0150 Parts kit cross brace joining screw

28. H0152 Screw PPMS 10-32 x 1/2

29. H0176 Nut nylock 10-32

30. H0075 Rope loop (black plastic)

31. H0310 Screw PPSM 10 x 1/2

32. H0313 Screw HHWSM tek 10 x 1/2 SS

33. H0324 Plastic anchor STD #12

34. H0331 Screw HHWSM 12 x 1-1/2 w/slot

35. H0294 Carriage bolt 1/4-20 x 3/4

36. H0096 Bolt HH 3/8-16 - 1-1/4

37. H0006 Split lock washer 3/8

38. E1098 Bonding wire

39. H9630 Spring pin for

track

alignment

40. H0276 Nut Nylock 1/4-20

41. H0130 Screw PFMS 10-32 x 1

42. H1099 Screw PPMS 10-32 1 3/4

The above parts list is typical for most pools up to 20’ x 40’ and includes all parts

necessary to install the Coverstar system, however, parts will vary for longer or

wider pools and according to your specific order.

30 31

38 39

24 25

41 42

Parts List

STANDARD UNDER TRACK

Step By Step Instructions Page/Step

Track assembly ..................................................5/1

Mounting the track

Standard under track mounting ................5/6

Encapsulated under track mounting..........5/7

Numbers in parenthesis refer to hardware shown on page 3.

Step By Step Instructions

Cut the track so it will extend from the

front edge of the coping at the far end of

the pool to 1” past the inside of the

housing if no encapsulation is being used.

When encapsulation is used, it will extend

one inch past the inside of the housing,

with the track extending one inch past the

end of the encapsulation.

Before splicing the sections of track

together, file all track ends thoroughly,

rounding all edges and removing all burrs.

This step is extremely important!

Tap the splice pins (39) into one end of the

track and slide the center splice (24) into

the center channel.

Lay the sections of track on the deck and tap

them together using a rubber mallet so the

center splice and splice pins interlock with

each section of track. It’s important that, the

splice is tight together so there is not a gap

from one track to the next. Slide pulley end

cap (15) into the end of the track at that is at

the opposite end of the pool from the

mechanism.

Using a 5/32” allen wrench, loosen the

screw on the top of the guide feed (16).

Insert the guide feed on the end of the

track that will extend into the housing.

12 3

Standard Under Track

Clamp the track with pulley to underside of

the coping flush with the coping face. (If water

is in the pool, place the hammer drill with a

1/4” masonry (carbide-tipped) bit into a large

bucket) Drill holes approx. 3” deep on a slight

angle toward the pool wall. Remove clamps

and track, then drive plastic anchors (33) into

each hole. Finally, fasten the track to the

underside of the coping with #12 screws (26).

Encapsulated Under Track (optional)

If encapsulation is being used, the track is

normally installed during the cover

installation. (See cover installation section page

11, step 9).

Holding the guide feed firmly, use a 6 inch

3/16” bit to drill through the hole in the track

feed and through the track. Remove the

guide feed. Do this for the track on both

sides of the pool.

To determine if the cover system was ordered

correctly for the pool, the length of the roll-up

tube should be 3 inches shorter than the track

space.

For example, for a 20 ft track space, the

correct length of roll-up tube is 19 ft 9 in.

MECHANISM

Step By Step Instructions Page/Step

Housing preparation ................................................7/1

Connecting the roll-up tube .....................................7/2

Adjusting the mechanism height .............................7/4

Positioning the roll-up tube/mechanism .................7/7

Anchoring the mechanism .....................................8/12

Extending the pulley brackets ................................8/13

Anchoring the pulley brackets ................................8/17

Wiring the electrical switch ....................................9/19

Electrical wiring & bonding diagram .......................9/24

Step By Step Instructions Numbers in parenthesis refer to hardware shown on page 3.

Adjusting Mechanism Height

Measure from the bottom of the housing to

the top of the track or encapsulation. This is

the installed height of the mechanism. Use

this measurement to determine which holes

to use when adding the mechanism feet.

Install the roll-up tube as high as possible

without rubbing on the lid brackets.

Position the mechanism with the pulley

brackets on the bottom. Install the feet on

the mechanism using the carriage bolts (35)

and nylock nuts (40) provided. Install the

feet so the top of the mechanism will be

flush with the top of the encapsulation.

Install the feet on the non-motor end. The

top of the pulley bracket should be flush

with the top of the encapsulation.

Note: The height of the non-motor end might

need to be adjusted after the mechanism has

been placed in the housing.

Connecting the Roll-up Tube

With the non-motor end turned upside down,

attach the cone for the non-motor end to

the roll-up tube using the 3/8” x 1-1/4” bolts

(36) and lock washers (37) provided. Use a

torque wrench to tighten the bolts to 180 inch

pounds. Over tightening may cause damage to

the threads and failure of the cover system.

With the motor end turned upside down,

attach the cone on the motor end using the

same bolts (36) and washers (37). Tighten the

bolts using a 9/16” wrench.

Positioning the Mechanism

Lower the assembled mechanism and tube

into the housing and place it roughly in the

position that it will anchored.

2 3

45 6

Position the mechanism in the housing so that

the roll-up tube is centered in the housing

front to back.

Note: If the cover housing isn’t square to the

pool, position the mechanism in the

housing so it will be square to the cover track.

With the mechanism and tube assembled and

set in place in the housing, check the roll-up

tube for level. This is crucial to proper

operation of the cover. Position a level across

the housing. Measure from the roll-up tube

to the bottom of the level on both the motor

end and non-motor end of the mechanism.

Adjust height of the non-motor end feet if

needed to level the roll-up tube.

Housing Preparation

Use a garden hose to clean out the housing.

During this process, make sure the water is

draining from the housing. It is critical that all

cover housings have adequate drainage. If

there is no drain or inadequate drainage in

the cover housing, contact your Coverstar

Representative.

Align the mechanism on the motor side first

by using a straight edge or a piece of rope

and extending it from the back side of the

cover track to the pulley to make sure the

rope is running straight into pulley #1.

Tip: The pulley bracket on the front side of

the cover housing should be 1 inch from

outside of track.

Extending the Pulley Brackets

Loosen the nuts in the four positions on the

adjustable brackets of the mechanism. Spread

the brackets outward against the walls of the

housing.

Raise the pulley brackets up so that the top of

the bracket is even with the top of the

encapsulation or guide. This insures the ropes

will be level.

With the brackets in position, level the

pulley brackets. Tighten the four nuts on

the adjustable brackets.

Now loosen the bolts and spread the pulley

brackets at the non-motor end making sure

they are also level. Raise the pulley bracket so

it is flush with the top of the encapsulation.

Anchoring the Pulley Brackets

Anchor the motor and non-motor end

brackets into the housing in as many

places as possible.

10 11 12

13 14 15

17 18

Anchoring the Mechanism

Center the motor end and non-motor end in

the housing front to back. Anchor the non-

motor and motor end feet into the housing

using as many anchor points as possible.

On the motor and non-motor side, use a

3/16” bit and drill through the cross braces.

To secure, use the half inch screws (28) and

nylock nuts (29) provided and bolt the cross

braces together in two places on each cross

bracket.

On the non-motor end, make sure the

rope will travel straight from the track to

the pulley. It is important that the roll-

up tube be centered between the cover

tracks.

Tip: The end of the roll-up tube should be

1-1/2 inches from the inside edge of the

cover track.

Step By Step Instructions Numbers in parenthesis refer to hardware shown on page 3.

Wiring the Electrical Switch

Connect the electric switch by wiring the

neutral wire from the power supply, the white

wire from the motor and one of the wires

from the indicator light together using a wire

nut.

Note: Switch must be mounted in a position

with a full view of the pool.

Connect the ground wires from the power

supply and the motor together using a wire

nut. Run a pig tail from this wire nut to the

grounding lug on the switch.

Insert the hot wire from the power supply

into terminal L1 on the back of the switch

and tighten the screw. Do not loosen the

screws too much or the internal switch

connections will be permanently lost.

Attach the other leg from the indicator

light and the BLUE DIRECTIONAL WIRE

into terminal A1, and tighten the screw.

Insert the RED DIRECTIONAL WIRE into

terminal B1, and tighten the screw.

Note: Reverse directional wires if cover runs

opposite to the direction indicated on the

switch.

20 21

22 23

24 Electrical Wiring & Bonding

The system must be bonded to meet the

National Electrical Code. Bond both tracks

to the mechanism by attaching a bonding

lug to the guide feed screw and running a

#8 solid copper bond wire to the

mechanism. Bond the lid to the mechanism

by drilling a hole in the lid at either end of

the lid and attaching a bonding lug in each

position and bonding it to the mechanism.

All brackets and any other metal over 4”

long should likewise be bonded to the

mechanism. There should be a bond wire

from the equipment pad inside the

housing. Attach this bond wire to the

mechanism to complete the bonding

requirement. Note: Builder is responsible to

bring proper electrical lines, conduit and

bonding to the mechanism. Electrical wiring

diagram and details are shown above with

instructions on the right.

#8 bond wire

Conduit with 4 wires

(2 directional wires, neutral &

unbroken ground)

Single gang all-weather box mounted on

corner of end wall of cover vault approx. 3”

from top of deck.

Key switch is mounted in a standard all-weather UL

listed, single gang box. The box must be mounted

60 inches off the ground and in a location where

100% of the pool is visible.

It is recommended that this switch be mounted

halfway along the side of the pool, and within 12 ft

of the waters edge.

Conduit with 3 wires

(hot, neutral & unbroken ground)

Note: wires must be sized to meet all

applicable codes. Motor draws 8.8 amps.

Sub-panel with

dedicated

110 Volt,

15 amp breaker

and GFCI

Ground Fault Circuit Interrupter

A GFCI must be used in the electrical supply line for the motor.

This should be on a separate dedicated circuit only for the pool cover.

Running Wires

Bring 110 V to the key switch. From the panel to the key switch, run 3

wires (hot,

neutral & unbroken ground). From the key switch to the motor end of the

housing, run 4 wires (2 directional, a neutral and an unbroken ground). Terminate the

wires in a weather tight “J” box. The motor is 110 V, 3/4 HP with full load amperage

of 8.8 amps. Follow all applicable codes regarding wire size, grounding,

connections, etc.

Key Switches

Mount a standard, single gang, all-weather junction box for the key switch

at a point where 100% of the pool is visible. This is a mandatory requirement to meet

ASTM safety standards. The key switch should not be placed in the mechanism box. This

does not meet UL code.

Options

Coverstar has several different wiring options that include limit switches wireless

remote control, water feature shutoffs, etc. See your Coverstar distributor for details.

COVER FABRIC

Step by Step Instructions Page/Step

Opening the cover package .....................................11/1

Running ropes through the cover track. .................11/4

Alternate rope feed method ...................................11/8

Installing the cover track ........................................11/9

Routing the ropes .................................................12/11

Attaching the cover leading edge ........................12/15

Track retainer method ..........................................13/21

Attaching the ropes to the reels ...........................13/26

Running out the cover ...........................................14/30

Attaching the cover and bonding wire ..................14/31

Mechanism adjustments (if needed only)

Rope adjustment ...................................................14/34

Torque limiter adjustment ....................................15/37

Rope reel and non-motor end brake ....................15/39

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