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Home My WebLink AboutFile Documents.1201 Tiehack Rd.0033.2018 (6).ARBK SUNDANCE SPA COVER SPECIFICATIONS SP-001 Revision: Rev R DESCRIPTION SPECIFICATIONS Top Side Material Vinyl Spa grade (marine grade with additional performance against UV, abrasion, cracking and mildew) with polyester backing. Environmental Conditions This product is intended for use in a portable spa application, which includes both indoor and outdoor environments. It will be exposed to weather conditions exterior to the spa cabinet. The spa cover may experience sub-zero temperatures in places like Alaska and extreme heat, up to 185°F, in the Southwestern United States during transit. It may experience high and low ambient temperatures during normal operation and may be exposed to direct sunlight. -60°F to 185°F ambient environment 0 to 100% environment with condensation Covers will be exposed to spa chemicals (chlorine, bromine, ozone, H2O2, Baqua Spa (polyhexamethyl biguanide), pH modifiers, minerals, and salts, soaps, oils, and creams of personal hygiene products. Resistance to these chemicals, their aqueous solutions, and their vapors is required. Performance The purpose of the cover is to provide an effective means of insulation and heat retention of the contents of the spa, while preventing the introduction of airborne debris inside the spa. The cover also is a safety feature preventing accidental drowning. Design/ Material Materials used should have an established history of successful use in similar applications. Otherwise, rigorous testing is required. Any test program proposed should be approved by Sundance Spas in advance. Proven technology is preferred. Vendors using unproven materials will be responsible for costs Sundance Spas incurs as a consequence. Vendor is also responsible for defects of design, assembly, and workmanship. That responsibility includes, but is not limited to, cost of parts, labor, rework, shipping, and warranty. See cover drawing for color options. Changes not more than 2 units DE as per ASTM G155 after Xenon arc or a comparable weathering test. No appreciable chalking allowed. Vinyl Spa grade (marine grade with additional performance against UV, abrasion, cracking and mildew) vinyl, polyester backing, mold, mildew and UV resistant. -20°F or lower cold crack rating. Must pass 1500 hours of weatherometer exposure. Based upon a (54" wide) linear yard, minimum 26.6 oz per linear yard and minimum .030" thick. Flame retardant added. Fade resistant. Must pass Wyzenbeek abrasion resistance test with 200,000 double rubs with # 8 cotton duck cloth. Minimum 10 ounce per square yard, scuff resistant double laminated vinyl with polyester, cross woven; - 40°F or lower cold crack rating; fire and mildew retardant included. Minimum .016" thick. polyethylene, minimum 4 mil thick . Has fire retardant. The moisture barrier shall be heat sealed to prevent water accumulation. Standard Cover Closed cell Expanded Polystyrene (EPS); minimum 1-1/2 lb. per ft3 density +/-10%; virgin material , no re- grind; R-value of 13.5 or better. Fire retardant included. The design of the cover skin shall be such that no water can enter and accumulate between the moisture barrier encased foam core and the cover skin. Additionally, the design shall be such that no water can enter and accumulate inside any flap, skirt, pocket, or other potential water retaining space defined by the cover skin. It is preferred that the construction keep water out of any enclosed space bounded by the cover skin. Providing a means of drainage is less desirable, but acceptable. Commercial Grade Zipper # 5 to #8 nylon black Acetyl nylon Polyester Grommet General Cover Assembly Spa grade (marine grade with additional performance against UV, abrasion, cracking and mildew). Extreme Cover Closed cell Expanded Polystyrene (EPS); minimum 2 lb. per ft3 density +/-10%; virgin material, no re-grind; R-value of 13.5 or better. Fire retardant included. Storage Temperature Range Moisture Barrier Bottom Side Material Chemical Exposure FoamSpa grade polyester fabric. UV, mildew, mold, water, and abrasion resistant. 100% solution dyed polyester weighing 7 ounces/square yard. -20°F or lower cold crack rating. Must pass 1500 hours of weatherometer exposure. Must pass 50,000 cycles Wyzenbeek. Fade resistant. Urethane coated back. DefinitionREQUIREMENT Zipper Water Retention SpacesTop Side MaterialHumidity Environment Color Stability Colors Polyester Sundance Spas Inc. Confidential SP-001 9/14/2017 Page 1 2/16/18 DESCRIPTION SPECIFICATIONS DefinitionREQUIREMENT Design/ Material The top side material and the bottom side material shall not show any air pockets or material gathering. The material shall be stretched tight with the seam on the corner. The material shall be smooth with no bumps from the plastic wrapper beneath it. Vinyl Double stitched locking backstitch. Preferred minimum 4 stitches per inch (i.e., a maximum stitch length of .25"). 4 to 6 stiches per inch is acceptable. 2" hinge width to be measured between stitching. Stitching to be straight and not deviate from centerline more than .050". *Dimensions not applicable to the wide hinge of three-piece covers. Polyester Double stitched locking backstitch. Preferred minimum 3-1/2 stitches per inch (i.e., a maximum stitch length of .25"). 3-1/2 to 6 stiches per inch is acceptable. 2" hinge width to be measured between stitching. Stitching to be straight and not deviate from centerline more than .050". *Dimensions not applicable to the wide hinge of three-piece covers. 135#, tex; sunlight and UV resistant; severe abrasion resistant; rot-proof and color fast Dacron polyester. Thread to match color of top side material. An oversized hole and 92# thread may be used on skirt hems (to allow for water drainage). All seam allowances must be at least a .25 inch. Seams are 4-ply. C-channel construction type. Preferred channel shall be 2.1" minimum height by 1.1" minimum flanges length. The preferred material shall be .040" minimum thickness galvanized steel sheet. C-channel construction different than the preferred configuration may be supplied with prior written Sundance Engineering approval. The flanges shall be embedded in foam at hinged sides. The manufacturer shall certify that the cover complies with ASTM F1346-91 specification. No part of web shall protrude out of foam more than .100" Standard Cover The foam panels shall have a minimum thickness of 2.50" and a minimum hinge-to-outer edge height difference of 1.25". The bottom surface of the foam panels shall be flat or contoured as required to prevent air flow in or out of the spa. Extreme Cover The foam panels shall have a minimum thickness of 3.00" and a minimum hinge-to-outer edge height difference of 2.00". The bottom surface of the foam panels shall be flat or contoured as required to prevent air flow in or out of the spa. SewingSeams Thread Foam TaperSupports Material Fit 2" ±1/8" 1 1/2" ±1/16" 2X 1/4" ±1/16" 1/4" ±1/16" Unacceptable Material gathering Stretched tight Seam on the corner Smooth with no bumps Unacceptable Bump from plastic 1/4" ±1/16" 2X 1/4" ±1/16"1 1/2" ±1/16" 2" ±1/8" Sundance Spas Inc. Confidential SP-001 9/14/2017 Page 2 2/16/18 DESCRIPTION SPECIFICATIONS DefinitionREQUIREMENT Design/ Material If speaker pockets are required, the pockets shall be cut into the bottom side of the expanded polystyrene foam according to the drawing. The pockets shall be filled with flexible polyurethane foam 19/45 that is white with a 1.8 minimum support (sag) factor. Pockets shall be covered with top side material. Hinges shall be 4-layer, quadruple stitched, and reinforced (with the supports). Spa side edges of the hinge areas shall be made with bottom side material. Top side material is limited to the seam at the top of the hinge area. Hinges shall be equipped with compression seals that are squeezed when the hinge closes to reduce heat loss through the space between the foam panels. The seals shall be made of bottom side material on the outside and a high-rebound, compressible core material on the inside. The design shall not allow the high- rebound, compressible core material to accumulate water. The seals shall occupy a minimum of 95% of the theoretical air volume between foam panels and shall not extend below the cover bottom surface. Seals may be tapered for spas with non-flat top rails. The exterior handles shall be made of top side material. Each cover shall be equipped with 6 exterior handles. There shall be one on the front, one on the back, and two on each side. Each of the three exterior edges of both cover panels shall be equipped with one handle. Covers may be equipped with rubber molded handles or alternative handle locations if indicated on the drawing. See cover drawing for handle dimensions. Interior handles shall be made of woven nylon. There shall be two interior handles on the inside of the hinge area. Each cover panel shall have a handle on its inside hinge edge. The handles on the hinge side edges shall be staggered so that a single person can lift the folded cover using them. The center of each hinge side handle shall be approximately 24" away from the centerline of the opposing hinge side handle. Additionally, each hinge side handle shall be approximately 12" away from the cover centerline that is perpendicular to the hinge edge. See cover drawing for handle dimensions. Interior Handles Exterior Handles Hinge Seal, Exterior The ends of the hinges shall be equipped with seals to prevent air flow when the cover is closed. When the cover is closed, the seals shall completely seal the gap between the foam panels, blocking air flow in or out of spa. The seals shall be made of top side material and shall have a highly compliant compressible core. The seals shall not extend below the bottom surface of the cover. Seals may be tapered for spas with non-flat top rails. *Dimensions not applicable to the wide hinge of three-piece covers. Hinge Seal, Interior Hinges Speaker Pockets HINGE SPACER (INTERIOR SEAL) HINGE SIDE EDGE HANDLE HINGE SIDE EDGE HANDLE Bottom Side Material Top Side Material HINGE END CAP (EXTERIOR SEAL) Sundance Spas Inc. Confidential SP-001 9/14/2017 Page 3 2/16/18 DESCRIPTION SPECIFICATIONS DefinitionREQUIREMENT Design/ Material Covers may come with or without skirts depending on the model. Skirts must flow smoothly and may not bunch, or pull to the side, or gather unevenly. Vinyl The skirt shall be made of 2 layers of vinyl material sewn back-to-back. If the skirt does not have enough body, a stiffener, such as, a layer of thin foam padding may be added between the layers. Polyester The skirt shall be made of 2 layers of polyester material sewn back-to-back with a stiffener added for body. The stiffener may be a 1/8 inch layer of thin foam padding added between the layers of fabric. Corners may be rounded or square. See drawing for details. Top side material, tie-down straps required per cover, 1" wide with center release fasteners or equivalent. Example center release fastener are shown at the right. Refer to drawing for quantity, strap lengths, and locations. Top side material with Nylon mesh bottom, stitching consistent with cover. Velcro latch with nylon strap on double layered flap. See drawing for dimensions. See applicable cover drawing. The drawing shall take precedence over any conflicts between information. Vinyl Vinyl covers shall have a heat impressed logo, centered on the front and back skirt. Polyester Polyester covers shall use a fabric tag with the brand logo. The top of the logo shall be sewn in the skirt seam and located 1" towards the cover centerline from the right-front strap. A waterproof tag shall be sewn under the skirt as shown, 1" towards the center from the left-rear strap. The tag shall include the cover model number, traceability information, such as serial number, and other relevant details. The tag is to be tear- and fade-resistant. Remote Pouch Skirts Tags Dimensions CornersSkirt StiffnessLogos Tie-Down Straps Round Corner (Example only) Square Corner (Example only) Non-Skirt (Example only) Skirt (Example only)Unacceptable Material gathering Back Layer Foam Padding 1/8" Front Layer 1 3/4" Sundance Spas Inc. Confidential SP-001 9/14/2017 Page 4 2/16/18 DESCRIPTION SPECIFICATIONS DefinitionREQUIREMENT Design/ Material Bilingual (French and English in equal prominence) regarding compliance with ASTM F1341-91 and a statement of warning at the front and back edges of the cover: See cover drawings for the areas allocated to warning labels. Label information shall comply with the requirements of ASTM standard for safety covers ( F 1346-91). The Cover manufacturer is responsible for determining the information required for safe use of the cover. A label specifying material ( vinyl, polyester) may be located to the left side of the front left strap as indicated on the print. Example warning labels for english and french are below. ⚠WARNING: AVOID DROWNING RISK FAILURE TO FOLLOW ALL INSTRUCTIONS MAY RESULT IN INJURY OR DROWNING. NON-SECURED OR IMPROPERLY SECURED COVERS ARE A HAZARD. KEEP COVER ON SPA AND LOCKED WHEN NOT IN USE. MANUAL SAFETY SPA COVER. In accordance with ASTM F1346-91 ⚠ATTENTION!: ÉVITER LES RISQUES DE NOYADE. Á DÉFAUT DE NE PAS SIUIVRE TOUTES LES INSTRUCTIONS CORRECTMENT, CELA PEUT ENGENDRER UNI BLESSURE OU NOYADE. RISQUE DE DANGER SI LE COUVERT N'EST PAS SÉCURISÉ OU PROPREMENT INSTALLÉ. GRADER LE COUVERT DE SPA FERMÉ ET VERROUILLÉ LORSQUE NON UTILISÉ LE MANUEL DE SECURITE DE COUVERT. SELON L'ASTM F1346-91 Literature and inscriptions shall be bilingual, French and English in equal prominence. Vendor shall identify their covers by permanently printing their Sundance assigned vendor number near the front label. Testing/ Inspection Completed Assembly Visual and dimensional inspection • Exterior hinge seals fit tight in the gap. They cannot slide around. Gaps may be found using lights. • Long skirts have a tendency to wrinkle and may need stiffeners added. • Plastic around the foam cannot cause bulges when folded up on the corners. • Covers must perform well using a cover lifter. Added Water Accumulation Accumulated water shall not exceed 12.5% of the cover's dry weight during 48 hours of continuous simulated moderate rain fall. Per applicable UL and ASTM standards Vendor shall develop and present to Sundance Spas a program of reliability testing. Once approved by Sundance Spas, vendor shall conduct the approved test program and report the raw data and analysis to Sundance Spas. Quality Compliance Not to exceed 2% failures in 3 yrs. Not to exceed 0.4% failures in 1 yr. Complies with safety standard ASTM F1346-91 Per ASTM Vendor shall provide to Sundance Spas written assurance that components are within the specified dimensions, tolerances, and materials. Foam certification shall be sent with each shipment. Vendor shall have a QC program and provide details to Sundance Spas. Vendor shall retain records for 5 years for future audits Vendor shall analyze failed units and provide a written report to Sundance Spas. Vendor shall develop corrective action plan to correct the failure and provide Sundance Spas with the plan. Vendor shall respond to request for CA with a plan, provide plan to Sundance Spas, conduct CA, and notify Sundance Spas of the results of the corrective action with details of testing. Cover shall be coded to be traceable to date of manufacture, lot, serial number, etc. The coding method shall be permanent so that it will remain readable and affixed over the cover's entire useful life. Vendor shall provide adequate protection from handling and transportation damage, as well as environmental storage variables. Vendor shall supply details of the packaged part/assembly to Sundance Spas (for approval). Inscriptions shall be in English and French given equal prominence. The packaging shall be coded to show cover date of manufacture, lot, etc. visibly from outside the sealed package. Recitals This specification is subject to change due to corrections that need to be made, new information that comes or new requirements. Engineering Manager/ R&D Manager Vendor Signatures Specification Standards Validation testing Approvals Vendor Identification Specific points of concern for detailed first article inspections Reliability Packaging Product Lot Traceability Records Test methods Vendor Certification Labels Corrective Action (CA) Failure Analysis Inserts, Brochure, Instructions, etc. QC Program Sundance Spas Inc. Confidential SP-001 9/14/2017 Page 5 2/16/18 Revision History Revision Description DATE APPROVED A Document release B Remove speaker cutout CA/OP C Major modifications to materials, dimensions, and required features incorporating the best features of a variety of existing manufacturer's covers. D ADDED TOLERANCE TO FOAM DENSITY 1/28/2010 PV/WW E MODIFIED SKIRT, HANDLE AND TOP SIDE VINYL SPECIFICATION 3/19/2010 PV/LS F MODIFY "C" CHANNEL AND HINGE SPECIFICATION 4/19/2010 PV/TS G ADDED DIMENSIONS TO SEWING SPECIFICATION 5/18/2010 PV/LB H MODIFIED THREAD AND SUPPORT REQUIREMENT 6/23/2010 PV/LB J ADDED CALLOUTS FOR J-LX SERIES AND SUNDANCE ELITE SERIES ON SKIRT REQUIREMENT.1/31/2011 FR/ER K ADDED CALLOUTS FOR CORNERS AND UPDATED SKIRT CALLOUT. 2/14/2011 FR/ER L ADDED EXCEPTION TO "SEWING"5/22/2012 W2/TS M ADDED WATER RETENTION SPACES TO DESIGN/MATERIALS. ADDED WATER ACCUMULATION TESTING REQUIREMENT. ADDED 92# THREAD ALLOWANCE TO THE "THREAD" REQUIREMENT OF THE DESCRIPTION "DESIGN/MATERIAL" SECTION. 8/8/2014 FEH/TS N MERGED THE VINYL, SUNBRELLA, SPECIFICATIONS INTO ONE DOCUMENT. ADDED POLYESTER INFORMATION TO THE DOCUMENT. 3/17/2015 WR/TS O REMOVED SUNBRELLA, ADDED EXTREME COVER FOAM & TAPER 1/11/2016 JRW P REVISED "LOGOS" AND "TAGS" SECTIONS, BOTTOM OF PAGE 4 5/6/2016 JRW R REVISED "LOGOS", "SEWING", "HINGE SEAL, INTERIOR/EXTERIOR"8/31/2016 JRW 6873 9334 6866 6851 6779 6726 9334 unreleased 9800 ECO Number 9334 unreleased 8987 7838 7201 7155 6298 5762 6927 2/16/18