1) Refer to the chart below to ensure that you have the proper kit for your pool.
*** Maximum pool size: 22 ft. wide by 46 ft. long
- Vice Grips
- String (150 feet)
- Tape Measure
- Carpenter's Square
- Self Tapping Sheet Metal Screws 12 pcs x 1-1/2” long
- Hacksaw, Wood Saw / Sawzall, Jigsaw
- Utility Knife
- Common Screw Driver
- 7/16” Wrench
2) Remove outer packaging from drive end kit and extension kit. Remove parts package and instructions from the drive end kit. For Master Kit # CD1061-09, CD1061-10 and CD1061-11, it will be necessary to remove the plastic end cap from the drive end kit in order to retrieve the parts kit (CD1057). Use a Phillips screw driver to remove the screws, remove the parts kit, and replace the end cap in its original location reusing the sam e screws. Save these instructions until the entire installation is complete.
Do not remove inner foam inserts, or protective polymask tape from top of units, at this time.
3) Determine the most appropriate location for your Cleardeck Solar Blanket System. Make certain to orient the Solar Blanket System so that the lid opens away from the pool, view this from the exposed end. In addition, it should be located as close as possible to the pool coping. The exact location will be determined by using string to simulate the solar blanket location in its extended position, and ensuring that the entire water surface is covered (Diagram #1). It is very important that corners A & B are 90 degrees. This should be checked with a carpenter's square. Adjust the sideways position of the Solar Blanket System to have the same amount of protrusion past A & B as shown (approximately 9”).
4) Once the final location has been established, added digging may be required for the Cleardeck unit. Be sure to clear enough space to support and secure the Solar Blanket System. Normally the pool wall braces will need to be modified to accommodate the solar blanket system. The elevation of the top of the system should be flush or slightly higher (¼”) than the top of the pool coping, or finished concrete elevation. A total depth of 15” is required for the Cleardeck unit. Where further support is required, (normally at each end), extended braces or sono tubes may be used.
NOTE: Pool kit designs and pool shapes vary. It is imperative that the solar blanket system be installed straight and level, and be properly secured to prevent shifting. Refer to Diagram #2 for some suggested installation methods. Extra time spent to insure that the unit is well secured, straight and level, will insure a quality installation and trouble free operation.
Facing the pool, with the Cleardeck unit between the pool and yourself, the drive end must be on the left. Make sure that the lid opens away from the pool. See the diagram to the left for proper orientation. .
5) Master Kit Assembly Instructions:
NOTE: Master kits CD1061-09, CD1061-10, and CD1061-11 are single piece construction, and do not require splicing. Please ignore steps 5a, 5b, 5c, 5f, and 5g.
Now to assemble the housings. With the units resting on the supports and in the final location:
- Insert the tee fasteners into the housing holes of the drive kit end
- Align the drive end kit housing with extension kit housing, and butt the ends together tightly as shown above.
- Assemble splice brackets over tee fasteners (both sides), and secure using ¼” nut (see FIG 1). Do not over tighten.
- Clamp the unit to the leveled supports to insure correct location. Make sure that the unit extends approximately 9” beyond the widest point of the pool on each side.
- Secure the unit to the leveled supports using screws (not supplied).
- Install the retaining clips onto the top flange and bottom support legs (see FIG 2), insuring not to damage the top finish. The clip should be equally spaced on either side of the splice joint.
- Secure using 2 self tapping screws per retaining clip.
- Install the concrete clips on the top flanges (see FIG 3) at approximately 18” spacing along the length of the housing on both sides. Secure each clip using one self tapping screw in the center of the clip.
Once the assembly is properly secured, check again that it is straight and level, adjust if necessary.
6) CAUTION: It may be necessary to ground the reel and lid assemblies depending on local electrical code requirements. Check with your local electrical authorities. Should continuous grounding be required, a hole may be drilled through the housing or end cap in order to feed the ground wire. A grounding strip may also be required (not included) must also be installed between the two hinges, (See Diagram #4A). Refer to Diagram #4B for suggested grounding lug locations or termination points. It may be necessary to separately ground each end of the Cleardeck Solar Reel System.
7) You are now ready to backfill. It is extremely important that backfilling be done gently and carefully to prevent the solar blanket system housing from shifting or distorting. The perimeter of the housing should be backfilled with clear stone, making sure to fill between the housing and the pool.
Do not use tampers or heavy equipment around the unit. Also use caution when using heavy equipment, such as bobcats and wheelbarrows. Use of this equipment too close to the solar blanket system housing may cause it to shift or distort. Do a final check to ensure the unit is straight and level before pouring concrete .
8) Concrete should be poured carefully around the unit.
Make sure that concrete is thoroughly packed under the outer flange of the housing and around concrete clips per
Diagram #5. This is very important.
9) After the concrete has set, carefully peel back the protective tape covering the lid. Do not allow the tape to remain for longer than a few days as it will become difficult to remove and it will leave an adhesive residue. Any remaining adhesive may be cleaned using acetone or mineral spirits
10) Once the concrete has cured, carefully cut out the knockout panels using a skill saw, jigsaw or sawzall. Two saw cuts are provided at one end to allow the initial saw blade access. Continue cutting along the path of the existing cuts. Be careful not to damage any exposed surfaces. The panels may also be scored with a utility knife and knocked out using a hammer. Discard the panels which have been cut out. Make certain any rough edges are filed or sanded to prevent damage to your solar blanket during operation.
11) Remove the handle, the parts bag, and the top half of the foam insert from the unit. The bottom foam insert will provide location and support for the roller tubes until assembled in step 14. Completion of any necessary grounding, per step 6, should also be completed at this time.
Splicing the Roller Tubes:
NOTE: Master kits CD1061-09, CD1061-10, and CD1061-11 are single piece construction, and do not require splicing. Please ignore steps 13, and 14.
12) Remove each of the 2 solar blanket retaining strips from the roller tubes. Save the screws, since they will be reused to attach the solar blanket.
13) Slide the splice tube which is in the drive end roller tube into the extension kit roller tube. Check to ensure that the mounting plates are pushed all the way to the ends of the housing until they contact the end cap at each end, as shown above. The splice tube is marked at the middle of its length as a guide for installation. Move the splice tube until the mark is approximately centered. The tubes are locked in position with a ratcheting action. Grip the splice tube and a roller tube in each hand (a tool such as a strap wrench may be used) and rotate the splice and roller tubes in the appropriate opposite directions. Enough force must be applied to engage the ratcheting action. Repeat for the other roller and splice tube connection. You may use the die lines on the tubes to confirm engagement. Once locked, the splice tube can not be moved.
14) To permanently attach the splice tube to each of the roller tubes, use 8 tek screws (4 per side) supplied in the parts bag. Equi-space the screws around the roller tubes approximately 3” from the spliced end. See Diagram #7. Once the splice tube is secured, remove the remaining foam inserts and any debris that may damage the unit or solar blanket during operation.
Solar Blanket Installation (blanket not included)
Once the pool has been filled you are ready to install the solar blanket. Many styles of solar blankets are available. Contact your dealer to determine the appropriate selection for your pool. To allow for fitting and trimming, the new solar blanket should be a minimum of 4 feet longer than the overall length of the pool. The minimum width of the solar blanket should be equal to the maximum pool width.
15) Carefully unroll the entire solar blanket over the pool surface making sure that the blanket lays flat with no wrinkles. Adjust the lengthwise position of the blanket to ensure that the roller end of the blanket will meet with the top of the roller tube. Attach the roller end of the solar blanket to the roller tube by laying the end of the blanket over the existing pre-drilled retaining strip holes, and then laying the retaining strip over the blanket. Re-insert the tek screws into the existing holes from step 12. The solar blanket bubbles can be used as a guide to ensure that the end of the blanket is parallel to the roller tube. Once secured, wrap the blanket one full wrap around the roller tube. Adjust the blanket to follow the contour of the pool prior to trimming. (Refer to Diagram #8)
16) After final positioning of the blanket, it must be trimmed to fit the pool contour. A “tongue” should be left where the blanket rises to the surface of the deck to enter the housing. Finally, a draw strap and three button fasteners are included with your solar blanket system.
17) Locate the draw strap at the approximate center of the end of the pool cover. The end of the draw strap is split into 2 strips with 3 snap closures and 2 plastic bolts in the webbing. Remove the nylon fasteners and separate the snaps. Place one strip under and one strip over the pool cover and snap together with the cover sandwiched between. Start at the outside edge and work toward the inside of the pool. Now cut holes for the nylon bolts using the holes in the strap for location. Install the bolts, being careful not to over tighten the nylon nuts.
The installation of your new Cleardeck Solar Blanket System is now complete. For best performance and longer blanket life, the solar blanket should be extended and retracted slowly . (Approximately one minute in either direction). When retracting the solar blanket make sure the blanket remains flat and wrinkle free, manually adjust if necessary. Wrinkles will increase the force required to retract the blanket and result in possible damage to the blanket and/or the drive mechanism. Keep the surface of the solar blanket clean and free of debris for optimum performance.