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Pool Cover Specialists National, Inc.

8553 South 2940 West


West Jordan, Utah 84088
www.poolcovers.com
Infinity 4000 Installation
Reference Packet
A quick guide supplying important reference materials for pool
builders and Infinity 4000 installers.
800-369-5152
800-568-6955 Fax:
Phone:
Table of Contents
1. Infinity 4000 Features
2. Toptrack Styles
3. Deckmount System Enclosure
4. Undertrack Styles
5. PCS Coping Forms
6. Excavation Guides
7. Electrical Requirements
8. Mechanism Housing Options
9. System Clearance Specs
10. Lid Options
11. Infinity 4000 Specifications
Please Note: This document constitutes a quick reference guide to PCS products and
methodologies. For full details and instructions, please consult the appropriate
documentation.
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2
4
5
6
7
8
10
14
18
19
21
Infinity 4000 Features
1
- 2 -
- 3 -
Toptrack Styles
2
The original PCS Track. Stands about 3/4
above the deck. Can be used with any pool
cover application. For free-form pools, this
and the Snap-down Toptrack are the best
options.
An update on the Universal Toptrack. Easy
to install and featuring a sleeker look, the
patented Snap-down Toptrack has become
the standard Toptrack application.
Standing only 1/8 above the deck, the
Horizontal Flush Toptrack is an attractive
and less obtrusive style. Because the track
must be set below deck, it is only available
on new decks.
The Horizontal Flush Track can be installed
without a Retainer. Screw heads will be
visible on the track, but will effectively
anchor the track.
Introduced in 2006, the Vertical Flush is a
great option for new pools. The Track snaps
easily into the Retainer and sits nearly flush
with the deck. The best low-visibility
Toptrack on the market.
- 4 -
Deckmount System Enclosure
3
For existing pools where recessed systems are not practical, the Infinity 4000 Deckmount System is an affordable and reliable
option. To increase the safety and enhance the appearance of Deckmount Systems, Pool Cover Specialists recommends covering the
mechanism with our Vinyl Bench Enclosure. The Enclosure is also an effective barrier, protecting the mechanism from harsh
weather and other potential interferences.
The Vinyl Bench is custom-built to fit each system. The
bench can be constructed for pools with a Track Space of
up to 28 feet.
PCS Part #s DB1002 - DB1009 Vinyl Bench, Exploded Diagram
To ease shipment and transport, the Bench is shipped as a
modular product. The diagram above shows the separate
pieces included in a Bench of average length.
FIG. A
FIG. B
Some notes on installing the Enclosure:
The system is installed and anchored to
the deck first.
The Back Panel is assembled and placed
in position at the back (non-pool side) of
the mechanism. (FIG. A)
The Back Panel is anchored to the deck.
(FIG. B)
The Front Panel is assembled and placed
in position. Side Panels are secured to
the Front and Back Panels.
Specially designed Lid Brackets are then
installed to the inside back wall of the
Bench.
The Lid panels are then placed over the
Bench and secured.
- 5 -
Undertrack Styles
4
Installed on 3 sides of the pool, this retainer
can be used with PCS Reusable Forms to
create an elegant and sturdy coping.
NOTE: It can also be used when a channel
is created in the deck and a raised pool-
wall is desired.
This retainer overhangs the pool wall to
create the popular cantilevered look.
NOTE: It can also be used with stone
coping applications.
Deck-on-Deck retainer raises the track 1/2
above the pool deck. This retainer is ideal
for non-rectangular pools and free-form
fiberglass pool-cover applications.
NOTE: Also available in a high-profile
configuration.
Our newest retainer is perfect for vinyl liner
pools. Built specifically for the new PCS
Housing, available early 2009. This retainer
can be used with the easy Snap-in Coping.
The standard gunite Retainer (above) can be
modified for use in Raised Wall Pools. In
these applications a pocket is created in the
raised wall. The retainer is placed in the
pocket and secured to the back wall. It is
then mortared into place.
- 6 -
PCS Coping Forms
5
PCS Re-usable Coping Forms come in many styles and can be used in conjunction with any of our retainer options. The images
below illustrate how the forms fit in the retainer, held in place by a shim. After the deck is formed, the forms can be removed and re-
used for the next application. Below is a sampling of our Coping Form applications.
- 7 -
Excavation Guides
6
Excavation Instructions For Rectangular Undertrack Pools

Note: It is very important that the pool be formed square providing a true rectangle. To be sure the pool is
square check these dimensions:
width AB = width CD
length AC = length BD
diagonal AD = diagonal BC
Provisions:
1. Dig the trench at the cover housing end of the pool a minimum of one foot beyond the pool.
2. Extend the trench 36 past each side wall. Trench must be dug 18 - 20 inches deep and 18 inches wide
(front to back).
3. Do not dig out for skimmers along the cover housing end.
4. Determine which side of the trench will house the motor.
5. Form a vault inside the trench. The motor side of the vault will extend 36 beyond the track. The
opposite (non-motor) side will extend 12 beyond the track.
6. The finished vault should be dug at least 14 below bond beam height (not deck height). Vault width
(front to back) is determined by the track length: Track Lengths up to 65 require a 14 inside
dimension. Track Lengths above 65 require a 16 inside dimension. NOTE: If using gravel, form
vault 4 - 6 inches deeper. Inside dimensions of vault should be 4 feet longer than Track Space.
7. Make sure the vault has adequate drainage.
- 8 -
Excavation Instructions For Freeform / Toptrack Pools

Note: It is very important that the pool cover tracks be laid squarely providing a true rectangle around the pool.
To be sure the tracks are placed correctly, check these dimensions:
width AB = width CD
length AC = length BD
diagonal AD = diagonal BC
Provisions:
1. Dig the trench at the cover housing end of the pool a minimum of one foot beyond the pool.
2. Extend the trench 36 past each side wall. Trench must be dug 18 - 20 inches deep and 18inches wide
(front to back).
3. Do not dig out for skimmers along the cover housing end.
4. Determine which side of the trench will house the motor.
5. Form a vault inside the trench. The motor side of the vault will extend 36 beyond the track. The
opposite (non-motor) side will extend 12 beyond the track.
6. The finished vault should be dug at least 14 deep. Vault width (front to back) is determined by the
track length: Track Lengths up to 65 require a 14 inside dimension. Track Lengths above 65 require
a 16 inside dimension. NOTE: If using gravel, form vault 4 - 6 inches deeper. Inside dimensions of
vault should be 4 feet longer than Track Space.
7. Make sure the vault has adequate drainage.
- 9 -
- 10 -
WIRING A 110 VOLT UNIT: The electrician should bring 110VAC to the motor end of the housing.
Pull a hot wire, a neutral wire, and an unbroken ground wire (green) to the housing and terminate them in a UL
rated J box. The 7/8 Horsepower Motor is the standard motor as of 2003. It draws 13 amps under normal
running conditions. Wire to the motor should be no smaller than 12 AWG.
KEY SWITCH: (NOTE: When ordering your Infinity system you have an option for cover
controller: Key Switch or Touchpad. As of 2009, the Key Switch is standard.) Run a separate conduit to
the desired location and mount a water-tight single gang extra deep junction box. (NOTE: ASTM safety
requirements mandate that the key switch be in full view of the pool not more than thirty feet away and
5 above ground level out of reach of small children.) The Key Switch requires three wires, 16 - 22 AWG,
however, PCS recommends pulling five wires to simplify any future replacements or upgrades. The Key
Switch operates on 5 VDC.
NOTE: PCS recommends using a stranded wire instead of data cable. Data cable is not reliable for
pool cover applications.
Electrical Requirements
7
BONDING: All INFINITY 4000 systems require bonding. The electrician should provide an 8 AWG
(American Wire Gauge) solid copper ground wire from the pool equipment pad to a ground clamp on the
electrical conduit inside the housing, with a six foot long tail that will be attached to the mechanism ground
lug. Be sure to follow local codes in all instances. (NOTE: Place bonding wires at each end of the
housing.)
TOUCHPAD: Run a separate conduit to the desired location. A custom Touchpad enclosure will be
provided with the mechanism. This enclosure has been drilled for a NPT (National Pipe Thread)
connector in the bottom side. NOTE: ASTM safety requirements mandate that the touchpad be in full
view of the pool not more than thirty feet away and 5 above ground level out of reach of small children.
Pull five wires, 16-22 AWG, for the Touchpad. The Touchpad operates on 5 VDC.
GROUND FAULT CIRCUIT INTERRUPTER: A 20 Amp dedicated GFCI must be provided in
the electrical supply line for the motor.
MOTOR CONTROLLER CIRCUIT BOARD: The INFINITY 4000 control board is either
mounted in a water-tight box which is placed inside the cover housing next to the motor or it is mounted inside
the casing of the flood-proof motor itself. It changes motor rotation from forward to reverse and has limit
switch capabilities for added safety, stopping the cover in the fully opened and fully closed positions. The
control is operated by a momentary Key Switch or Touchpad.
TECHNICAL INFORMATION:
In most areas, high and low voltage wires can be run in the same conduit, if they are rated at a voltage
of 600 or greater.
Controller Options
- 11 -
Wiring Diagrams
- 12 -
Hall Effect Sensor Baldor Motor
Keyswitch or Touchpad
- 13 -
Mechanism Housing Options
8
Recessed Redwood* Housing - Undertrack
SIDE VIEW
Redwood Housing - Undertrack

D = 11 min.
W = 14 for TLs** up to 65
16 for TLs over 65
The diagrams that follow show cross-sections of the different housing options available. These diagrams are meant to give the
technician an idea of how the different housings work. For more detailed information, refer to the appropriate documents or call the
PCS Customer Service Department at 1-800-369-5152.
*The Housing can be
constructed with many wood
types. We recommend
redwood for its durability.

**TL = TRACK LENGTH
Provisions:
1. 2 x 12 redwood or pressure treated lumber should be used to build the housing. 16P box nails or 3 deck
screws should be used to assemble.
2. Inside housing dimensions are determined by the track length:
Track lengths up to 65 require a 14 inside dimension
Track lengths 65 to 85 require a 16 inside dimension
3. Motor end of cover housing must have a minimum of 36 from pool wall inside measurement and opposite
end must have a minimum of 12 from pool wall inside measurement.
4. Temporary bracing should be nailed to the top inside of housing to provide support until bond beam and
pool deck have been completed around housing. Spacing should be 2 to 3 apart.
- 14 -
Recessed Redwood Housing - Toptrack
SIDE VIEW
Redwood Housing - Toptrack

D = 11 min.
W = 14 for TLs up to 65
16 for TLs over 65
IMPORTANT NOTE: The inside measurements of the cover housing are determined by the width and length of the
pool. To determine the length of the cover housing for an Undertrack installation, the width of the pool from water line
to water line must be acquired. To this measurement add 36 for the motor end and 12 for the opposite end. (See
Diagram A). The inside width of the cover housing is determined by the length of the pool. For standard pool lengths,
PCS recommends an inside housing width of 14. (See Diagram C). Use 2 x 12 redwood or pressure-treated lumber to
construct the box.
Temporary bracing should be nailed to the top inside of the Housing, spaced about 2 to 3 apart.
Base boards are used to maintain Housing dimensions, spaced about 3 to 4 apart.
Recessed Redwood Housing - Construction
36 Motor End 12 Opposite End
Recessed Gunite Housing - Undertrack
SIDE VIEW
Gunite Housing - Undertrack

D = 14 min.
W = 14 for TLs up to 65
16 for TLs over 65
Recessed Concrete Housing - Toptrack
SIDE VIEW
Concrete Housing - Toptrack

D = 14 min.
W = 14 for TLs up to 65
16 for TLs over 65
36 Motor End 12 Opposite End
36 Motor End 12 Opposite End
- 16 -
(2009) Vacuum Formed Housing for Vinyl Liner Pools
SIDE VIEW
(2009) Vacuum Formed
Housing
The (2009) Vacuum Formed Housing offers a great improvement over Vinyl Liner Pool
Housings of the past.

Some notes about the Housing:
Modular Design - the Housing is
shipped in 6 sections. This makes
transport and installation easier.
Compatibility - works with the new
and improved PCS Vinyl Liner
Retainer (PCS Part #52001).
New Lid - adds a sleeker look to the
mechanism cover.
Mounting - can be mounted to
polymer and steel wall pools.
T Slot Mechanism Mounting
System - allows for easier
installation and position adjustment
12 Opposite End 36 Motor End
- 17 -
System Clearance Specs
9
- 18 -
Standard System (110v AC, 220v AC, 24v DC)
Single Gang
Junction Box
Brushless DC System (110v AC)
Hydraulic System (110v AC, 220v AC)
3 - 4 Open
Conduit
Mini Infinity System, using Mounting Plates (all motor options available)
Lid Options
10
Our standard lid in an Undertrack application. The
installation is made easy with the PCS Drop-In Lid Bracket
Brace. These Braces are installed to the back wall of the
Housing, approximately one every 2 - 3 feet. The Lid
Brackets slide into the Braces and sit flush with the deck.
This is the standard lid in a Toptrack application. Drop-In
Lid Braces are used here as well. The Toptrack Lid Bracket
is formed with an angle to elevate the lid over the Toptrack.
Undertrack Lid Bracket Toptrack Lid Bracket Drop-In Lid Bracket Brace
Lid Bracket w/ Mounting
Holes (22742)
Side View
Standard Lids:
- 19 -
Adjustable Lids:
11 Adjustable Lid
Bracket
(LB2100)
14 Adjustable Lid Bracket
-for flush lids-
(VL2100)
15 Adjustable Lid Bracket
(LB2300)
Front View
(dimensions are for all Adjustable
Lid Bracket models)
PCS Adjustable Lid Brackets can be adjusted 5 degrees up or
down. These Brackets are extremely sturdy and can hold up
to 1200 pounds when properly installed. The Bracket is
secured directly to the Housing wall.
Made for larger lids, the 24 Bracket is ideal for Vanishing
Leading Edge applications, as illustrated above. This
Bracket, when installed properly, can hold up to 600 pounds.
24 Adjustable Lid Bracket
(LB2400)
- 20 -
Infinity 4000 Specifications
11
Pool Cover Fabric
7-Year Manufacturers Limited Prorated Warranty
Low shrink, non-wicking yarns
Specially-formulated vinyl for chlorine resistance, UV resistance, abrasion resistance, and mildew
resistance
10 color options
Custom cover colors and designs available
Economic Specs
The U.S. Dept. of Energy has established that heating costs can be reduced 60 to 80 percent by
covering a pool when it is not in use.
A PCS pool cover can increase the daytime water temperature by 10 - 15 degrees. Night-time heat loss
is reduced by 70%.
A covered pool allows much less chemical evaporation; this means less chlorine and other chemicals
are needed, thereby reducing pool care costs.
Mechanism
Manufacturers Lifetime Limited Warranty
Machined and Hard-anodized End-castings
Hard-anodized aluminum brackets
Powder-coated, anodized reel system
Electrical
3-Year Manufacturers Limited Warranty on all electrical components
Standard IDEC Keyswitch Controller
Standard .84 horsepower, 34 rpm Gearmotor
Optional - Touch-sensitive Touchpad; Backlit Touchpad
Optional Hydraulic Motor
Optional water-feature shutoff
Safety Credentials
Meets or exceeds all ASTM F 1346 - 91 requirements
Electrical bonding included with all systems to ensure electrical grounding
Full UL listing
- 21 -
Notes:
POOL COVER SPECIALISTS NATIONAL, INC.
VISIT US ON THE WEB:
www.poolcovers.com
116 West Morgan
Knightstown, IN 46149
765-345-9000
8553 South 2940 West
West Jordan, Utah 84088
801-255-6124
1-800-369-5152

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