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Use and Care Instructions

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INFORMATION BEFORE OPERATION
OPERATING INSTRUCTIONS
INSTALLATION CHECKPOINTS
MAINTENANCE
ASTM F1346-91 SAFETY STANDARD
WARRANTY INFORMATION
TROUBLESHOOTING

COVERSTAR POOL COVER SYSTEMS

Welcome to the rapidly growing group of pool owners who own Coverstar cover systems. We are proud of the advanced engineering and quality construction of each system we build.

Please read this owner's manual and follow its instructions carefully. It is designed to acquaint you with the features of your new cover system and to help you operate and maintain your system properly.

Coverstar is a "wholesale only" manufacturer of cover systems. We have selected professional distribution companies to represent our products throughout the world. They will provide you with the local service and maintenance that you may require.

The information here is the accumulated knowledge of thousands of installations. If you receive conflicting information elsewhere, please call coverstar for clarification.

For service or maintenance please contact your distributor.

IMPORTANT SAFETY INSTRUCTIONS

  1. READ AND FOLLOW ALL INSTRUCTIONS.
  2. WARNING: To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at all times.
  3. All field-installed metal components such as rails, ladders, drains, or other similar hardware within 3m of the unit shall be bonded to the equipment grounding bus with copper conductors not smaller than
    No. 8 AWG (No. 6 AWG for CANADA.)
  4. Keep the pump on the cover and set up for proper use whenever the cover is over the pool.
  5. Check cover frequently for signs of premature deterioration or weakness.

INFORMATION BEFORE OPERATION  (Top of page)

This manual is intended to instruct cover system owners in the proper operation and maintenance of their cover system. If a salesman or installer gives information that contradicts this manual, you should disregard their instruction on that topic.

1. PUMP OPERATION 

A. A cover with water on it poses the same safety hazard as an open pool.
Any accumulation of water on the surface of the cover must be removed immediately. Every cover system comes with a pump that auto- matically senses water and removes it, provided the pump is operable, properly placed, and maintained according to the pump manufacturer's instructions.

B. The pump should be upright on its base in the middle of the cover and plugged into a GFI protected outlet whenever the cover is over the pool.
You must follow all pump manufacturer's instructions regarding its use and maintenance.

C. After the pump has removed all water from one location on the cover, it may be necessary to move the pump to other locations to remove all accumulated water.
Do not operate the cover with water on it. One inch of water on a cover can weigh thousands of pounds.

D. The pump is covered under the pump manufacturer's warranty.
For service, return it to the manufacturers service center.

2. PARTIALLY COVERED POOLS  Always completely cover or uncover the pool. A partially covered pool can pose a safety hazard. Never allow anyone to swim under the cover.

3. KEY SWITCH LOCATION  All controls for the cover system must be located where the pool is completely visible during cover operation.

4. ALUMINUM LID  The aluminum lid on below-deck systems is a long-lasting cosmetic cover for the housing. It is not intended for anyone to walk or step on. It can be slippery when wet and walking on it can loosen the support brackets under it. You should instruct children not to step on the lid.

5. POOL WATER LEVEL  Maintain the water level at the middle elevation of the skimmer opening. If the water drops below this level, the cover may operate under stress. Never cover the pool without the proper water level under the cover. The water supports all surface weight. If the water level is low and rain or surface water builds up on the cover, severe damage may be done to the coping and/or the cover system.

During the winter, the water level must be high enough to support the snow melt build-up. The pump should be on the cover and plugged in.

OPERATING INSTRUCTIONS  (Top of page)

The CS 1800 and CS 200 powered safety covers are easy to use and very reliable when used and maintained properly. There are a few things to remember about the overall operation of a motorized cover.

1. COVER OPERATORS Only instructed, responsible individuals should operate the cover. For this reason, all systems are key operated. This is an expensive piece of equipment and, like your automobile, should be operated only by someone who can exercise judgment and care. Children should not be permitted to use this product unless they are closely supervised at all times.

2. COVERING THE POOL

A. Turn the key to the "Close" position. It takes a second for the gear to engage the rope take-up reels. Safety covers are required to have a momentary type of switch that requires constant pressure to operate the motor. This keeps the operator in complete control of the mechanism.
B. When closing the cover on systems where the guides are mounted on the deck, the cover should extend over the pool, but stop several inches short of reaching the end pulley housings at the end of the guides.
C. On underguide systems, lightly "bump" the leading edge against the end of the pool. Do not continue to force the cover closed after it touches the coping.
D. Release the switch when you have reached the proper closed position discussed above.
E. Place the pump on the cover.

Note: If the cover hesitates or stops before it reaches the end, you should immediately release the switch and investigate the problem. Sometimes dirt, debris, or obstacles like towels or hoses can stop the cover. Remove the obstruction and continue covering the pool. If, after investigation, you cannot find a reason for the hesitation, you should reverse the direction of the cover a foot or two and then retry to cover the pool. 

3. UNCOVERING THE POOL 

A. Turn the key to the "Open" position and hold it until the cover is retracted in front of the mechanism with the pool fully exposed. 

B. When uncovering the pool, the cover should retract to a point several inches in front of the emergency stops on the cover guides. The stops are there to prevent pulling the cover out of the guides in the event of over retraction, but are not meant as a stop to run the cover up against. Driving the cover into the end pulley housings or retracting against the emergency stops on a regular basis will damage several components, including the cover, rope, webbing, and possibly mechanical components.

INSTALLATION CHECKPOINTS  (Top of page)

Coverstar, Inc. is often asked how one can tell if an installation is done correctly. A few standard things that are easily checked which indicate if the system has been properly installed are listed below.

  1. GUIDE (TRACK) INSTALLATION
    1. An automatic system must be installed at the guidespace which was ordered from the factory. Measure the distance between the cover guides. If there is a discrepancy between installation and order dimensions, it may cause the system to operate improperly.
    2. The cover guides must be perpendicular to the cover roll-up tube. Measure the length of each guide, the width at each end and the diagonals from corner to corner. There should be a pure rectangle with maximum 1" variances.
  2. SLACK With the guides properly installed you will have the correct amount of slack in your cover to ensure reliable operation for many years. All covers shrink slowly over a period of years when exposed to the elements and pool chemicals. This shrinkage will amount to several inches over the life of the fabric. When a cover gets tight between cover guides, it operates under significant stress, may be unsafe, and should be replaced. Coverstar, Inc. has implemented strict quality control measures before shipment to ensure that each cover shipped matches the dimensions we received on the order.
  3. ROPES The ropes coming out of each corner guide should appear to go in a straight line from the guide to the pulley, not at an angle. On underguide systems, the rope coming out of the guides should be level as it goes to the pulley.
  4. SYSTEM MOUNTING Systems should be mounted firmly to their housing or to the deck with a sufficient number of screws.
  5. DRAINAGE Systems recessed below ground level must have sufficient drainage to prevent buildup of standing water in the housing.
  6. WHEEL ASSEMBLIES On deck mounted systems, the front corners of the cover should be attached to the wheel assemblies.
  7. COVER ROLL-UP Covers should retract and extend within 2-3 inches of being square to the mechanism at both ends of the pool. Some variance is allowed because of the diverse applications in which covers are used. Your cover is a very large piece of fabric that rolls around a 6" tube, and controlling exactly how it rolls up is a matter of pool configuration, deck surface adhesion, and environmental conditions.
  8. DECK SURFACE Any rough or sharp edges on the deck that the cover travels over should be rasped or ground smooth.
  9. LEADING EDGE The leading edge which pulls the cover out over the pool should not drag on any portion of the deck or coping as it travels back and forth across the pool.

MAINTENANCE AND CARE  (Top of page)

  1. CLEANING THE COVER When you uncover the pool, the water in the pool is transferred from the pool to the top surface of the cover. The sun then dries it, causing high concentrations of chlorine on top of the cover that may damage the fabric. Wash cover with a mild hand dishwashing liquid every 3-6 months to remove this accumulation. Do not use laundry detergent. (See Homeowner video.)

  2. HOUSING DRAINS On recessed systems, frequently check the drain(s) to be certain they drain the housing completely and do not allow water to stay in the housing area. If water is allowed to stand in the mechanism area over periods of time, the system may become damaged by the constant moisture. Damage to either electrical or mechanical components resulting from standing water or extended submersion is not covered under the warranty.

  3. WATER LEVEL Keep the water level in the pool at the mid-skimmer level. If the pool is overfilled, the water can flow over the lowered bond beam into the housing and flood the mechanism.

  4. MECHANISM Clean all rotating surfaces by spraying with a hose nozzle every 3 months or more often in sandy or windy areas.

  5. HOUSING Clean leaves and debris from deck housing every 3-6 months, depending on foreign matter accumulation. Run the cover over the pool, prop the housing lid open or remove it, and remove the debris in the housing. Accumulated debris can hinder the proper operation of the cover.

  6. GUIDES
    1. As shown in the homeowner video, retract the cover completely off the pool and clean the cover guide rope channel. Use a high pressure nozzle on a garden hose to spray directly into the slots of the aluminum deck guides to remove built-up dirt and debris in the guides. Repeat as often as necessary to keep the guides clean.
    2. Spray into the pulley housing at the end of the guides at close range to remove debris from within the housing. In windy and dusty areas with blowing dirt, covers may become inoperable until the debris has been hosed from the guides. In these areas, guides will have to be flushed clean more frequently. A build-up of sand and/or dirt will grind the webbings causing them to fail prematurely. The webbings used on our covers have been proven over many years and thousands of covers to last beyond the life of the fabric if the cover guides are kept clean. Premature webbing failure due to abrasion from debris in the guides is easily preventable and is not covered under the warranty.

  7. PULLEYS In windy, dusty climates, you should clean bearings as often as necessary to ensure that they turn freely. Use a hose nozzle to completely wash all surfaces of the mechanism to prevent fine dust or sand from accumulating on the moving surfaces of the mechanism.

  8. RODENTSIn certain areas rodents may nest in the cover housing and chew on the cover and ropes. A common cause of rope breakage is rodent damage, which is not covered under the warranty. Moth balls in a perforated, tamperproof container may help keep rodents under control. Keep poisons out of reach of small children.

  9. WATER CHEMISTRY
    1. We suggest, as all cover manufacturers do, that you only cover pool water that you would swim in. If the water is temporarily out of balance due to chemical additives and you wouldn’t swim in it, covering the pool may damage the cover prematurely. Water that has improper chemical balance may, over the long term, severely shorten the expected life of the fabric. Note: If the pool is left open after shocking the pool, adult supervision of an open pool should be provided.
    2. Use a good test kit frequently to maintain proper chemical balance Premature cover deterioration that is a result of improper chemical balance is not covered under the warranty.

ASTM F1346-91 SAFETY STANDARD  (Top of page)

The American Society for Testing Material created a final recommendation for powered and manual safety covers in 1991 called the ASTM F1346-91 standard. Coverstar systems have been tested, and when used and installed according to instructions, they meet or exceed this standard.

The main provisions of ASTM F1346-91 are:

  • The cover system must be labeled with warning labels. (Labels are always available either from your distributor or Coverstar if yours is illegible.)
  • The cover must support 485 lbs. in a five foot radius.
  • The cover must be operated from a position where the complete pool surface is visible to the operator.
  • The switch must be momentary and be located at least 5' above the surface where the operator stands, or be key operated.
  • An object approximately 4.5" in diameter should not be able to slide under the cover.
  • An automatic water evacuation system (self-actuating cover pump) must be used at all times. It must be placed on the cover so that rain will automatically be removed within 1/2 hour after the cessation of rain.

You should check your installation and verify that the points above are present in your installation. If any point is not present, by definition, you do not have a safety cover.

Pool safety is a major concern of Coverstar, Inc. We agree with the National Spa and Pool Institute that the first and most important component of pool safety is constant adult supervision of the pool area. There is no substitute for adult supervision.

In addition to your safety cover, additional layers of protection are available for your pool. We have included in the homeowners packet a brochure published by the National Spa and Pool Institute entitled Layers of Protection. We recommend that you evaluate your situation and decide which layers of protection you should use to protect your pool.

LIMITED WARRANTY INFORMATION  (Top of page)

Coverstar, Inc. wants to make sure you are satisfied with your installation and have received the information you need for system operation. Please fill out your warranty card complete with name and address and return it with your signed certificate of installation. Your limited warranty covering components that we manufacture will be sent directly to you from Coverstar, Inc. after you:

  1. Fill in the registration card
  2. Sign the completion certificate
  3. Send the completed registration card and completion certificate to Coverstar, Inc.

To expedite the issuing of the warranty and make it easier for you to register your cover, you can register over the internet at www.coverstar.com. After opening the web site, click on warranty registration.

No limited warranties will be issued valid without a signed completion certificate.

Note:In order for your warranty to be valid, Coverstar must receive payment in full for your system.

TROUBLESHOOTING  (Top of page)

SYMPTOM  PROBLEM  SOLUTION
1. Cover will not move forward or will not reverse.
  1. Circuit breaker or GFI is tripped.
  2. Water on cover.
  3. Water accumulated between roll-up tube and pool.
  4. Cover adhering to deck.


  5. Torque limiter loose.
  6. Motor needs service.
  1. Reset circuit breaker.
  2. Pump water from cover.
  3. Sweep water off cover.
  4. Lift cover and billow air under cover. Use replaceable welcome mat etc. under cover to break deck adhesion.
  5. Tighten both torque limiter bolts 1/2 revolution until it engages.
  6. Call reseller for service.
2. Water leaking onto cover.
  1. Cover caught on some thing sharp.
  2. Abrasion pinhole.
  1. Remove sharp object and use patch kit to repair.
  2. Use patch kit to repair.
3. Cover retracts out of square.  (Some unevenness may be unavoidable due to pool configuration.)
  1. Rope lengths unequal.


  2. Uneven drag on cover as it retracts off pool.
  1. Re-pin the rope on rope reel so the extra rope around the reels is exactly the same on both sides.
  2. Tighten rope reel brakes slightly. Do not overtighten.
4. Cover not even at end of pool. Ropes are not the same length. Re-pin the rope on rope reel so the extra rope around the reels is exactly the same on both sides.
5. Cover seems to be running under stress.
  1. Excess friction during operation.
  2. Cover adhering to deck.
  3. Debris in housing.
  4. Cover too tight.
  5. Brake too tight.
  1. Clean guides with hose. Clean all turning parts.
  2. Billow cover by lifting fabric to break adhesion.
  3. Clean housing of debris.
  4. Raise water level to mid-tile or replace cover.
  5. Loosen brake.