Cornelius CAPRI, ZEPHYR, BORA, BRISA Assembly Instructions Manual

When selecting the site for your pool, take into account city by-laws regarding fences and utilities laws pertaining to electrical cables, as well as the landscaping which you are planning once the pool is installed.
1) Drive a stake into the ground at points A and B respecting the
distance of the straight section between those two points (A-B).
2) Draw two half circles respecting the radius (R).
width between these two lines (D).
4) Verify that the total length is consistent. (E)
5) Add 15cm (6”) wide trenches on each side, respecting the
lenght (F), to leave room for the stays.
6) Remove all grass from the area which you have just outlined.
Dear Customer
Congratulations! You have purchased a pool of superior quality and durability. To achieve the best possible results, follow the instructions carefully. Failure to follow the installation procedures may result in damage to your pool or proper ty and void your warranty. We recommend that you make a preliminar y study of the instructions booklet to familiarize yourself with the different parts of your pool. Make sure that you understand each step thoroughly before you begin assembling.
We wish you a most pleasant and refreshing summer.
WARNING: Be sure you have read and understood the “Safety Information”
sheets before you begin your pool installation.
WARNING: For your safety, your pool is not designed for diving and/or jumping head first.
Please do not dive. Diving may result in permanent injury or death.
SITE PREPARATION
1
SITE LEVELLING AND EXCAVATION
2
Dig a hole 30 cm (12") wide by approximately 25 cm (10") deep in the center of the circumference.
From the center hole to the projected location of the pool motor, dig a 15 cm (6") wide trench. Place the removed soil aside to be used later to cover the hose.
Bottom Drain Assembly
Place teflon around the threaded plug. Screw in drain holes using large pliers. Glue the connector in the appropriate opening.Glue connector in the appropriate opening.
Take one of the two rubber rings and adjust it to the top of the drain, aligning the holes carefully. Secure with strips of adhesive tape to prevent sand from penetrating inside the holes once the drain has been installed.
Secure one end of the long black or white hose inside the drain spout. First apply glue on the drain spout and inside the drain end, then secure with one or two collars.
Cut the hose so that it ends with the stone dust (or sand). Measure the pool radius from the center of the drain, then add 15 cm (6").
Place the assembled bottom drain in the hole so that it is approximately 1.3cm (1/2") higher than the surface soil. Bury the hose, levelling the
drain as much as possible. Compact the
soil, using your feet and a tampering tool as well.
Mix three (3) shovels of stone or sand dust with one half shovel of pure cement, adding a small quantity of water, then pour the cement around the drain until it reaches 1.3 cm (1/2") from the top.
BOTTOM DRAIN ASSEMBLY (if applicable)
3
Chart 1.1 - Grass removal area (Figure 1.1)
1,68m (5'6") 1,68m (5'6") 2,13m (7') 2,13m (7') 2,44m (8') 2,44m (8') 2,44m (8') 2,90m (9'-6") 2,90m (9'-6") 2,90m (9'-6")
3,35m (11') 3,35m (11') 4,27m (14') 4,27m (14') 4,88m (16') 4,88m (16') 4,88m (16') 5,79m (19') 5,79m (19') 5,79m (19')
5,03m (16'-5 3/4") 6,69m (21'-11") 5,48m (17'-11 3/4") 7,14m (23'-5") 6,30m (20'-8") 7,96m (26'-1 1/2") 9,64m (31'-7 1/4") 10,29m (33'-9") 11,95m (39'-2 1/2") 13,63m (44
'-8 1/2")
1,66m (5'-5 1/2") 3,33m (10'-11") 1,66m (5'-5 1/2") 3,33m (10'-11") 1,66m (5'-5 1/2") 3,33m (10'-11") 4,99m (16'-4 1/2") 4,99m (16'-4 1/2") 6,66m (21'-10") 8,32m (27'-3 1/2")
MODELTRUE POOL SIZE
DISTANCE (A-B)
RADIUS (R) WIDTH (D) TOTAL LENGHT (E) CORRIDOR (F)
10'x16' 1,67m (5'-5 3/4") 10'x21' 3,33m (10'-11") 13'x18' 1,18m (3'-10 1/2") 13'x23' 2,84m (9'-3 3/4") 15'x20' 1,42m (4'-7 3/4") 15'x26' 3,07m (10'-1") 15'x31' 4,75m (15'-7") 18'x33' 4,53m (14'-10 1/4") 18'x38' 6,19m (20'-3 1/2") 18'x44' 7,87m (25'-9
3/4")
3,05 x 4,72 m (10' x 15' 5-3/4") 3,05 x 6,38 m (10' x 20' 11-1/8") 3,96 x 5,17 m (13' x 16' 11-3/4") 3,96 x 6,83 m (13' x 22' 5") 4,57 x 5,99 m (15' x 19' 8") 4,57 x 7,65 m (15' x 25' 1-3/8") 4,57 x 9,33 m (15' x 30' 7-1/4") 5,44 x 9,98 m (17' 10" x 32' 9") 5,44 x 11,64 m (17' 10" x 38' 2-3/8") 5,44 x 13,32 m (17' 10" x 43' 8-1/2")
A
B
A-B
R
R
D
15cm (6”)
E
F
POOL WALL
AREA TO OUTLINE
Figure 1.1
SITE LEVELLING
For an oval pool, the bottom must absolutely be levelled, using a carpenter's level and a straight plank. Eliminate any protrusions. Ensure that the surface is free of debris such as rocks, wood, etc.
TRENCHES FOR BUTTRESS ASSEMBLIES
1) Dig trenches to a depth equal to the sum of the thickness of the patio blocks (2” thick slabs recommen ded) and the thickness of the butress assembly beam 8cm (3 1/4”). (Refer to illustrations for trenches layout details).
2) Make sure trenches are smooth and leveled without compacting them.
3) Place and level patio blocks into trenches. Make sure that the top of the slabs is at a depth of 8cm (3 1/4”). Top of framework must be level with pool area.
141" - 358cm
22-3/4"
22-3/4"
10"
10"
10"
25cm
25cm
25cm
25cm
25cm
141" - 358cm
22-3/4"
22-3/4"
10"
10"
10"
25cm
25cm
25cm
25cm
25cm
FOR 10x21: 38" (97cm) 13x23: 62" (157cm) 15x26: 110" (279cm)
22-3/4"
22-3/4" 58cm
58cm
58cm
10"
10"
3-1/4" - 8cm DEEP
15cm
31"
79cm
22-3/4"
22-3/4" 58cm
58cm
58cm
10"
10"
3-1/4" - 8cm DEEP
15cm
122cm
6"
31"
79cm
122cm
6" 15cm
6"
58cm
141" - 358cm
48"
6" 15cm
43cm
58cm
141" - 358cm
48"
43cm
17"
R
10"
10"
10"
22-3/4"
22-3/4"
75-1/2" - 192cm
3-1/4" - 8cm DEEP
15cm
25cm
25cm
25cm
6" 15cm
31"
79cm
FOR: 10x16: 38" (97cm) 13x18: 62" (157cm) 15x20: 87" (221cm)
10"
10"
10"
22-3/4"
22-3/4"
75-1/2" - 192cm
75-1/2" - 192cm
3-1/4" - 8cm DEEP
15cm
25cm
25cm
25cm
R
6" 15cm
6"
43cm
31"
79cm
58cm
58cm
17"
48"
122cm
15cm
3-1/4" - 8cm DEEP
122cm
6"
79cm
15cm
FOR: 15x31: 110" (279cm) 18x33: 132" (335cm)
3-1/4" - 8cm DEEP
122cm
6"
79cm
17"
31"
206-1/2" - 525cm
17"
31"
48"
R
6" 15cm
R
43cm
206-1/2" - 525cm
22-3/4"
22-3/4"
22-3/4" 58cm
22-3/4" 58cm
10"
10"
10"
10"
10"
25cm
25cm
25cm
25cm
25cm
25cm
206-1/2" - 525cm
22-3/4"
58cm
22-3/4"
22-3/4"
22-3/4" 58cm
22-3/4" 58cm
10"
10"
10"
10"
10"
25cm
25cm
25cm
25cm
25cm
25cm
10"
10"
22-3/4" 22-3/4" 58cm
58cm
58cm
25cm
10"
10"
58cm
22-3/4"
58cm
58cm
25cm
58cm
15cm
3-1/4" - 8cm DEEP
122cm
6"
79cm
15cm
FOR: 18x38: 132" (335cm)
3-1/4" - 8cm DEEP
122cm
6"
79cm
17"
31"
206-1/2" - 525cm
17"
31"
48"
R
6" 15cm
R
43cm
272" - 691cm
22-3/4"
22-3/4"
22-3/4" 58cm
22-3/4" 58cm
10"
10"
10"
10"
10"
25cm
25cm
25cm
25cm
25cm
25cm
22-3/4"
58cm
22-3/4"
22-3/4"
10"
10"
10"
25cm
25cm
25cm
22-3/4" 58cm
10"
25cm
22-3/4" 58cm
10"
25cm
25cm
10"
10"
22-3/4" 22-3/4" 58cm
58cm
58cm
25cm
10"
10"
58cm
22-3/4"
58cm
58cm
25cm
58cm
15cm
3-1/4" - 8cm DEEP
122cm
6"
79cm
15cm
FOR: 18x44: 132" (335cm)
3-1/4" - 8cm DEEP
122cm
6"
79cm
17"
31"
206-1/2" - 525cm
17"
31"
48"
R
6" 15cm
R
43cm
337-1/2" - 857cm
22-3/4"
22-3/4"
22-3/4" 58cm
22-3/4" 58cm
10"
10"
10"
10"
10"
25cm
25cm
25cm
25cm
25cm
25cm
22-3/4"
58cm
22-3/4"
22-3/4"
10"
10"
10"
25cm
25cm
25cm
22-3/4" 58cm
10"
25cm
22-3/4" 58cm
10"
25cm
22-3/4" 58cm
10"
25cm
22-3/4" 58cm
10"
25cm
25cm
10"
10"
22-3/4" 22-3/4" 58cm
58cm
58cm
25cm
10"
10"
58cm
22-3/4"
58cm
58cm
25cm
58cm
Chart: Sand quantity
ASSEMBLY INSTRUCTIONS
OVAL POOLS
MODELS: CAPRI / ZEPHYR / BORA / BRISA
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1) Dump the sand.
2) Choose the filter location beside a round section (never a straight
section). The starting point will be at that location so that the skimmer and retur n holes are as close as possible to the filtration system.
3) Before uncoiling the wall, make sure the pre-punched holes for the skimmer and pump return are at the top and facing the planned location of your filter.
SRTAIGHT SECTION BUTTRESS ASSEMBLY
4
1) Refer to Illustration 4.1. To assemble, join splice brackets (R) to the horizontal beam (Q) using the bolt 1/2 "X 3" X #13 (12.7 mm x 76.2 mm) (U), nuts (UU ) and washers (V). Remember to insert a spacer (T) inside the beams aligned to each bolt.
2) Refer to Illustration 4.2. Assemble the post using bolts 1/2" X 3" X #13 (12,7 mm X 76,2 mm) (U), nuts (UU) and washers (V). Remember to insert a spacer (T) and two washers (V) inside the beam aligned to each bolt.
3) Refer to Illustration 4.3. Cover the bolt heads with bolt caps (W) and insert the styrofoam caps (X) at both ends of foot beam.
1/2” BOLT CAP COVER
STYROFOAM CAP
SPLICE BRACKET
WASHER 1/2”
NUT 1/2”
FOOT BEAM
SPOOL SLEEVE
BOLT 1/2” X 3”
BUTTRESS POST
Illustration 4.1
Illustration 4.3
Illustration 4.2
1) Position the buttress pillars assembled in Step 4 on the patio blocks in the trenches previously dug.
2) Refer to Illustration 5.1 : Once the buttress pillars are placed in the trenches, assemble the straight sections bottom tracks (J) between the pillars on the foot beams.
3) Refer to Illustration 5.2 : Fix the pressure plates between foot beams using 4 standard screws #14.
BOTTOM TRACK STRAIGHT SECTION
BOTTOM TRACKS (STRAIGHT) AND PRESSURE PLATES
5
STANDARD SCREW # 14
PRESSURE PLATE
Illustration 5.2
Illustration 5.1
1) Study illustrations and chart carefully. You are now ready to assemble the metallic tension straps. Refer to indications on the chart for the exact number of tension straps and sections per straps according to their respective pool size.
2) Refer to Illustration 6.1: If there is more than one metallic strap per tension strap rows, assemble the straps together using 4 bolts and nuts (BB) 1/4" #20 X 5/8" (6,35 mm X 15,88 mm), taking care of placing the bolt head on top.
3) Attach the assembled tension straps to foot beams on both sides, using 4 standard screws #14.
POOL SIZE 10x16 10x21 13x18 13x23 15x20 15x26 15x31 18x33 18x38 18x44
TENSION STRAPS QUANTITY (TOTAL) 356 10 6 15 21 21 27 33
ROWS TO ASSEMBLE 3 5 35257 7 9 11
STRAPS PER ROW 1 1 22333 3 3 3
Chart
TENSION STRAPS ASSEMLBY
6
BUTTRESS ASSEMBLY
Illustration 6.1
Start with round sections, refer to illustration 7.1 :
Place the end of the first round section bottom track on the foot beam of the last pillar of the straight section. At the other end, place the first foot plate of the round section.
Round section, refer to Illustration 7.1 and 7.2 :
Using the round section bottom tracks and the foot plates, start with the first plate of the round section. Repeat this procedure until the half circle is completed.
Lock the track to the right pool
diameter by snapping the key on the corresponding posts.
Refer to Illustration 7.3. :
Before going to next step, make sure that the centre of the pool is properly squared and metallic tension straps are stretched.
ROUND SECTIONS BOTTOM TRACKS ASSEMBLY
7
WALL INSTALLATION
8
SAND
PLANKS
SUPPORT BAR
SAND
BAR
SUPPORT
PLANKS
JOINER PLATE
BOTTOM TRACK
PUMP RETURN HOLE
WALL
SKIMMER HOLE
1ST TRACK ROUND SECTION
1
ST
FOOT PLATE
ROUND SECTION
BOTTOM TRACK STRAIGHT SECTION
Illustration 7.3
Illustration 7.1
Illustration 7.2
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Key
Before pulling the liner up against the wall, insert a vacuum cleaner hose down into the pump return hole to approximately 15 cm (6") from the ground.
Maintain the hose in place with adhesive tape. Don't forget to block the skimmer hole with adhesive tape to prevent air from leaking in.
Place the unfolded liner in the center of the pool area at right angles with the skimmer hole. Make sure you wear light, flat­soled shoes to walk on the sand as the slightest heel mark could be visible once the pool is filled.
Carefully unfold the liner, bringing the bottom-sidewall seam close to the wall base. Make sure that the side with the protruding seams faces downward or that the patterned side faces upward. Lift up a section of the liner over the top of the wall leaving a 10 cm to 15 cm (4" to 6") fringe outside the wall. Secure the liner with a plastic coupler. Install the resine stabiliser strack on the wall then install the joiner plates on top of each upright.
At this point, the liner may be too tight, making it difficult to drape the overlap or, on the contrary, too loose. In such cases, you will have to redistribute the tension in the liner by remo-ving some of the couplers and readjusting the liner.
Installation detail of the u-bead liner.
Hang the liner on the top of the wall and install thesquare
stabiliser to secure.
Start the vacuum cleaner to allow the liner to adhere to the wall
and check for excess tension at the bottom or for wrinkles.
Adjust the liner by removing couplers if needed, to lift or lower it
in order to ensure a perfect fit.
Fill the pool up to the base of the wall before stopping and
removing the vacuum cleaner.
PUMP RETURN FITTING
After you remove the vacuum cleaner, you may install the return
fitting. Place the return fitting ring against the liner and adjust it
so that it is perfectly aligned with the hole in the wall.
When the ring is properly positioned and secured, cut the liner in
the middle of the ring. Insert the return fitting from the inside,
placing the first gasket between the return fitting and the liner
and the second between the wall and the liner. Then tighten the
outside ring with large pliers, taking care not to crease the liner.
BOTTOM DRAIN (optional)
Find the holes through the middle of the liner and screw the ring
and gasket in against the liner before cutting the liner in the
middle of the ring, then screw on the drain cover.
VINYL LINER INSTALLATION
10
LINER
RESINE STABILISER
TRACK
WALL
PLASTIC COUPLER
(SOLD SEPARATELY)
LINER
WALL TRACK
WALL
You can now spread approximately 10 cm (4") of compacting sand all around the inside base of the wall in order to protect the liner from the cutting edges of the bottom wall tracks and the stone dust (if applicable). Or install a prefabricated cove, if available.
SAND BASE FINISHING
Level finishing sand one last time. Make sure that any sharp stones, debris or roots have been removed from the surface. For better protection, spray sand with water and pack it once more until the base is nicely even.
SAND BASE FINISHING
9
WALL INSTALLATION (continued)
8
LINER
WALL
30 cm (12")
10 cm (4")
SAND COVE (or PREFAB COVE)
BOTTOM TRACK
Begin inserting the wall into the bottom wall tracks in the middle of a joiner plate. At first, the wall is kept in place with one or two support bars (or extra persons). One person uncoils the wall on a beam or a plank, while a second person inserts it in the bottom wall tracks. Do not uncoil more than 3 m (10') of wall before you install a support bar to reinforce the structure.
Once the wall is completely uncoiled, you may find that it is too long or that both ends do not meet by a few centimetres. If such is the case, you must gently push the wall in or out. If this does not work, roll up the wall again, realign the grooves and uncoil the wall again. If the spread is too wide, measure the wall and check it against the following chart.
When you prepare to join the ends of the wall, make sure the end
that is reinforced by the fold is inside the circle, facing the liner
and that the other end faces outward (Illustration 8.1).
When the wall joint is secured, install the round stabilisers on top
of it.
IMPORTANT: Due to the enormous pressure exerted by the water on the steel wall, it is absolutely essential that all the bolts are screwed in tigh-tly and no hole is left open. All bolt heads must be inside with washer and nut outside. Cover all bolt heads with heavy fabric tape.
MODEL 10x16 10x21 13x18 13x23 15x20 15x26 15x31 18x33 18x38 18x44
42' 4-3/4" 53' 3-3/4" 48' 11" 59' 8" 56' 6" 67' 5" 78' 5" 86' 96' 11" 107' 11-1/2" (12,92m) (16,25m) (19,91m) (18,24m) (17,22m) (20,55m) (23,90m) (26,21m) (29,54m) (32,91m)
ACTUAL LENGHT
OF THE WALL
Chart
Illustration 8.1
Clip the uprights to the bottom joiner plates.
Make sure the post is well snaped into the bottom plate.
BUTTRESS POST INSTALLATION
11
UPRIGHT
BOTTOM PLATE
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Note: See 'Safety Information" Manual, Page 1.
As described in the manual, all components of the filtration system should be placed to prevent a child to climb on top and get access to the pool.
Using a little bit of stone dust (or sand), place at level a patio stone 61 cm x 76 cm (24" x 30") before installing the motor and filter
Position the motor on the stone and insert the two nozzles to connect the hoses.
Then, install the filter tank. Adjust the lateral assembly pro-perly in its channel. It is sometimes necessary to install the laterals.
Patch the center hole of the lateral assembly using the plug to allow filtering sand to flow into the tank.
Remove the plug. Install the joint in the cavity and secure the filter head by placing the back wash position on opposite side of the pool.
Position the Safety procedures panel on the outside of the pool. This panel must be at the most visible place from the yard on your pool.
Place the four (4) safety stickers inside the pool in a way that it’s
seen from any entry point of the swimmer (See positionning
drawing).
SECURITY SIGNS INSTALLATION
15
SEAT CAP INSTALLATION
14
Clip the top plate into the upright.
Make sure the T shaped key is well align in the upright front hole.
Make sure the top plate is well snaped into the post.
BUTTRESS POST TOP PLATE (STRAIGHT SECTIONS)
12
TOP SEAT INSTALLATION
13
Place the top seat on the upper side of the upright.
Align the holes on top seat with the right pool size on the top plate.
Secure the top seat with two (4) screws.
Snap the seat cap stating out side the top seat.
Clip the front nose of the seat in side the top seat.
FILTRATION SYSTEM ASSEMBLY
16
UPRIGHT
TOP PLATE
KEY
TOP PLATE
UPRIGHT
SCREW
TOP SEAT
SEAT CAP
UPRIGHT
FIXE THE FRONT HOOK FIRST
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PARTS LIST
18
Insert threaded nozzles, if applicable, in order to be able to screw the valve in the skimmer.
Connect the drain hose to the bottom nozzle. Connect the motor hose to the side nozzle.
The threads on all threaded nozzles must be covered with teflon tape prior to installing in order to prevent water leaks. Teflon is applied to the threads as follows: little or none on the first few threads (to facilitate introduction) and several layers toward the end threads (for better watertightness).
DRAIN VALVE ASSEMBLY (if applicable)
17
Install necessary nozzles, then connect hoses using collars.
1. The first hose runs from the top of the pump to the side of the filter head;
2. The second one goes from the pump to the skimmer (or to the bottom drain valve);
3. The third goes from the front of the filter head to the water return or from the front of the chlorinator to the water return.
A back wash hose may be placed behind the filter head.
If there is a chlorinator and/or heat pump, they must be assembled at the filter exit.
FILTRATION SYSTEM ASSEMBLY
16
ITEMDESCRIPTION 10x16 10x2113x18 13x23 15x20 15x26 15x3118x33 18x38 18x44
Number of curved section
8 8 10 10 12 12 12 14 14 14
Number of straight section
4 8 4 8 4 8121216 20
POOL WALL (finished lenght, inch)
42' 4-3/4"
(12,92m)
53' 3-3/4" (16,25m)
48' 11"
(19,91m)
59' 8"
(18,24m)
56' 6"
(17,22m)
67' 5"
(20,55m)
78' 5"
(23,90m)
86'
(26,21m)
96' 11"
(29,54m)
107' 11-1/2"
(32,91m)
BOLT & NUT FOR 52" (OR 54") WALL
25 (29) 25 (29) 25 (29) 25
(29) 25 (29) 25 (29) 25 (29) 25 (29) 25 (29) 25 (29)
POOL LINER
111111111 1
PLASTIC COUPLER (SOLD SEPARATELY)
111111111 1
TOP SEAT - ROUND SECTIONS
8 8 10 10 12 12 12 14 14 14
TOP SEAT- STRAIGHT SECTIONS
4
8 4 8 4 8121216 20
FOOT PLATE
6 6 8 8 10 10 10 12 12 12
UPRIGHT 52'' or UPRIGHT 54''
6 6 8 8 10 10 10 12 12 12 TOP PLATE ROUND SECTION SEAT CAP
BTM TRACK - ROUND SECTIONS
446 6 8 8 8 10 10 10 BTM TRACK - STRAIGHT SECTIONS
4 8 4 8 4 8121216 20 TOP TRACK - ROUND SECTIONS
8 8 10 10 12 12 12 14
14 14
TOP TRACK - STRAIGHT SECTIONS
4 8 4 8 4 8121216 20
BUTTR
ESS ASSEMBLY
BUTTRESS POST
61061061014 14 18 22 TOP PLATE OVALE SECTION
61061061014 14 18 22 FOOT BEAM
61061061014 14 18 22 SPLICE BRACKET
12 20 12 20 12 20 28 28 36 44 PRESSURE PLATE
4 8 4 8 4 8121216 20 SPOO
L SLEEVE
244024402440565672 88 BOLT 1/2" X 3" X #13 (12,7 mm X 76,2 mm)
244024402440565672 88 NUT 1/2" (12,7 mm)
244024402440565672 88 WASHER 1/2" (12,7 mm)
72 120 72 120 72 120 168 168 216 264 BOLT CAP COVER
244024402440565672 88 FOOT BEAM STYROFOAM CAP
12 20 12 2
012202828
36 44
TENS
ION STRAP
3 5 6 10 6 15 21 21 27 33 1/4" #20 X 5/8" (6,35 mm X 15,88 mm) SCREW & FLANGE NUT
12 20 2440565672 88
STANDARD SCREW ( SCREW #14 , 1" LENGHT)
AA
BB
DD
CC
A B
C D
E
F
G
J K L
O P Q R S
T
U UU
V W X Y BB
Z
6 6 8 8 10 10 10 12212 12 12 16 14 18 16 20 24 26 30 34
100
156 108 164 116 172 228 236 292 348
6
10 6 10 6 10 14 14 18 22
A
C
U
W
T
X
E
DD
O
Z
G
J
Q
V
B
Z
AA
L
S
T
Z
R
F
D
UU
P
Y
X
Z
BB
K
BB
CC
F
Z
BB
M
Z
T
U
UU
V
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