Polaris PB4-60 Manual

General Description

Description

The Polaris booster pump, PB4-60, supplies high pressure water to the Polaris pool cleaner to optimize cleaner efficiency. The pump is not self-priming and should only be used when the pool filtration pump is on.

Running the booster pump without a filtration pump will damage the booster pump. Improper operation of the booster pump will void the warranty.

Preparation

1. Upon receipt of the pump, check the carton for damage. Open the carton and check the pump for concealed damage, such as cracks, dents or a bent base. If damage is found, contact the shipper or distributor where you purchased the pump.
2. Inspect the contents of the carton and verify that all the parts are included. See Section Replacement Parts List.

Installation

Electrical Installation

Voltage Checks

The correct voltage, as specified on the pump data plate, is necessary for proper performance and long motor life. Incorrect voltage will decrease the pump's ability to perform and could cause overheating, reduce the motor life, and result in higher electric bills.
It is the responsibility of the electrical installer to provide data plate operating voltage to the pump by ensuring proper circuit sizes and wire sizes for this specific application.
The National Electrical Code^® (NEC^®, NFPA-70^®) requires all pool pump circuits be protected with a Ground Fault Circuit-Interrupter (GFCI). Therefore, it is also the responsibility of the electrical installer to ensure that the pump circuit is in compliance with this and all other applicable requirements of the National Electrical Code (NEC) and any other applicable installation codes.

Failure to provide data plate voltage (within 10%) during operation will cause the motor to overheat and void the warranty.

Bonding and Grounding

1. The motor frame must be grounded to a reliable grounding point using a solid copper conductor, No. 8 AWG (8.4mm²) or larger. In Canada, No. 6 AWG (13.3mm²) or larger must be used. If the pump is installed within five 5 feet (1,5 meter) of the inside walls of the swimming pool, spa, or hot tub, the motor frame must be bonded to all metal parts of the swimming pool, spa, or hot tub structure and to all electrical equipment, metal conduit, and metal piping within five (5) feet (1,5 meter) of the inside walls of the swimming pool, spa, or hot tub.
2. Bond the motor using the provided external lug.

To avoid the risk of property damage, severe personal injury, and/or death, always disconnect the power source before working on a motor or its connected load.

To avoid the risk of property damage, severe personal injury, and/or death, make sure that the control switch or time clock is installed in an accessible location so that in the event of an equipment failure or a loose plumbing fitting the equipment can be turned off. This location must not be in the same area as the pool pump, filter, and other equipment.

The pump must be permanently connected to a dedicated electrical circuit. No other equipment, lights, appliances or outlets may be connected to the pump circuit, with the exception of devices that may be required to operate simultaneously with the pump, such as a chlorinating device or heater.

Electrical

Table 1. Maximum Wire Size and Overcurrent Protection

Electrical Wiring

1. The pump motor must be securely and adequately grounded using the green screw provided. Ground before attempting to connect to an electrical power supply. Do not ground to a gas supply line.
2. Wire size must be adequate to minimize voltage drop during the start-up and operation of the pump. See Table 1 for wire sizes.
3. Insulate all connections carefully to prevent grounding or short-circuits. Sharp edges on terminals require extra protection. To prevent wire nuts from loosening, tape them using a suitable, listed (UL^®, ETL^®, CSA^®) electrical insulating tape. For safety, and to prevent entry of contaminants, reinstall all conduit and terminal box covers. Do not force connections into the conduit box.
4. To configure the internal wiring of the pump motor for the correct voltage, refer to the diagram on the motor data plate.
5. The starting current of the booster pump motor may exceed 15 amps on 115 VAC voltage line. It is recommended that a 20 amp service breaker be used for the pump connected to 115 VAC.
6. The booster pump motor is factory wired for 230 volts, but can be wired for either 115 or 230 volts. To rewire to 115 volt, follow the instructions on the name plate located on the back of the motor or the sizing plate on the side of the motor.
7. A separate time clock (in addition to the filtration system time clock) is recommended to control the On/Off functions of the booster pump. A manual switch can also be used.
8. If a time clock is used, set it to turn the pump on at least a half an hour after the pool filtration pump is turned on, and turn the pump off at least half an hour before the filtration pump shuts off. Periodically check the time clock settings to make sure they are properly synchronized.

Plumbing

Be careful not to overtighten any pipe fitting on the inlet or outlet of the booster pump. Overtightening can cause the housing to crack.

Requirements

The Polaris Booster Pump requires a dedicated return line. Plumb the booster pump into the system so that it always receives flow from the filtration pump.
To ensure proper function of the pump and the cleaner, refer to Figure 2 and adhere to the following g uidelines for specific equipment.

1. Plumb the dedicated line upstream of all air inducing equipment.
2. If a heater is installed on the system, tap the inlet for the booster pump into the return line downstream and at least three (3) feet (1 meter) from the heater discharge. See Figure 2. Do not tap the booster pump inlet into the three-foot (1 meter) section of heat sink pipe that comes directly out of the heater.
3. Some solar heating systems utilize the entire water flow when the panels are being purged of air. If the pump is installed in a non-flow pipe during solar panel purges, install an automatic override to shut off the pump.
4. Plumb the booster pump inlet higher, upstream and as far away as possible from a chlorinator.

Pipe Sizing

1. Use rigid PVC pipe with a minimum diameter of 3/4", 1-1/2" is recommended, for the dedicated return line. Flexible PVC piping is not recommended for the dedicated pool return line underground as it can be damaged by expansion and movement caused by the surge of pump pressure.
   
2. The booster pump inlet connection line should be at least 3/4" pipe. The Softube Quick Connect fittings are designed to work with the Polaris reinforced hose (part #P19) only.
3. Do not tap into the top of a horizontal line.
4. Use 90° street ells to minimize bends and loops in the Polaris reinforced hose.

Pump Location

1. Zodiac Pool Systems, Inc. recommends installing the pump within one 1 foot (30 cm) above the water level. The pump should not be elevated more than a few feet above the water level of the pool.
2. If the pump is located below water level, isolation valves must be installed on both the suction and return lines to prevent back flow of pool water during any routine or required servicing.
   
   Some Safety Vacuum Release System (SVRS) devices are not compatible with installation of check valves. If the pool has an SVRS device, be sure to confirm that it will continue to safely operate when any check valves are installed.
3. The pump and other circulation equipment must be located more than 5 feet (1,5 meter) from the water. Choose a location that will minimize turns in the piping.
   NOTE
   In Canada, the pump must be located a minimum of 3.0 meters [approximately 10 feet] from the water (CSA C22.1).
4. The pump must be placed on a solid foundation that will not vibrate. To further reduce the possibility of vibration noise, bolt the pump to the foundation.
   NOTE
   Zodiac^® recommends bolting the pump directly to the foundation.
5. The pump foundation must have adequate drainage to prevent the motor from getting wet. The pump needs to be protected from the rain and sun.
6. Proper ventilation is required for the pump to operate normally. All motors generate heat that must be removed by providing proper ventilation.
7. Provide access for future service by leaving a clear area around the pump. Allow plenty of space above the pump for servicing.
8. If the equipment is under cover, provide adequate lighting.

Install the Pump

1. Mount the pump using two (2) concrete expansion anchors to ensure stability.
2. Apply four (4) to six (6) wraps of Teflon^® tape to the tapered thread of the connecter barb.
   
   
   Pipe dope should NEVER be used on barb threads. Pipe dope will severely weaken the plastic, causing leakage and may cause the plastic to fracture. DO NOT OVERTIGHTEN.
3. Thread and tighten the tapered thread of the connector barb into the pump port on the pump body. See Figure 5 (b).
4. Trim reinforced hose to required length. Make sure cut is clean and square. Avoid unnecessary loops or bends in the hose.
5. Slide connector nut onto the trimmed end of the hose with threaded end toward the cut end of the hose. See Figure 5 (c).
6. Apply water to connector barb to help hose slide over barbs. Push trimmed edge of hose fully onto the connector barb. See Figure 5 (d).
7. Slide/Rotate the connector nut to the barb to engage threads correctly, do not cross thread connector nut. Tighten the connector nut until threads are no longer visible (gap about 1/8" or just less than the width of two dimes), or until it touches the barb face.
   

Installation Recommendations

1. If the pump is located below water level, isolation valves must be installed on both sides of the pump to prevent back flow of pool water during any routine or required servicing.
2. To help prevent difficulty in priming, install the suction pipe without high points (above inlet of pump - inverted "U"s in plumbing), which can trap air.
3. The piping must be well supported and not forced together where constant stress will be experienced.
4. Always use properly sized valves. Jandy^® Pro Series diverter valves and ball valves typically have the best flow capabilities.
   
5. Use the fewest fittings possible. Every additional fitting has the effect of moving the equipment farther away from the water.

NOTE
If more than 10 suction fittings are needed, the pipe size must be increased.

Check the Water Flow

NOTE
This pump must have minimum outlet pressure of 45 psi. Lower pressure may cause an overcurrent motor condition.
After the system is plumbed, verify water flow to the booster pump by disconnecting the inlet supply line at the booster pump and then turning on the filtration pump. Water should flow from the line.
If there is no water flow, check the following:

1. Verify that the installation is correct. Refer to Figure 6.
2. Use smaller eyeball fittings in the pool return lines or plug a return line.

Once flow is established, the pump is ready for operation.

Conduct Pressure Test

When pressure testing a system with water, air is often trapped in the system during the filling process. This air will compress when the system is pressurized. Should the system fail, this trapped air can propel debris at a high speed and cause injury. Every effort to remove trapped air must be taken, including opening the bleed valve on the filter and loosening the pump basket lid on the filter pump while filling the pump.

Trapped air in system can cause filter lid to be blown off, which can result in death, serious personal injury, or property damage. Be sure all air is properly out of system before operating. DO NOT USE COMPRESSED AIR TO PRESSURE TEST OR CHECK FOR LEAKS.

When pressure testing the system with water, it is very important to make sure that the pump basket lid on the filter pump is completely secure.

Do not pressure test above 35 PSI. Pressure testing must be done by a trained pool professional. Circulation equipment that is not tested properly can fail, which could result in severe injury or property damage.

1. Fill the system with water, using care to eliminate trapped air.
2. Pressurize the system with water to no more than 35 PSI.
3. Close the valve to trap pressurized water in the system.
4. Observe the system for leaks and/or pressure decay.
5. For technical support, contact Zodiac^® technical support at 800.822.7933.

Operation

Start-up

Never run the booster pump without water. Running the pump "dry" for any length of time can cause severe damage to both the pump and motor and will void the warranty.

Never run the booster pump without the cleaner connected. Running the pump without the cleaner connected will cause damage to the pump impeller and will void the warranty.
If this is a new pool installation, make sure all piping is clear of construction debris and has been properly pressure tested. The filter should be checked for proper installation, verifying all connections and clamps are secure according to the manufacturer's recommendations.

To avoid risk of damage or injury, verify that all power is turned off before starting this procedure.

1. Turn filtration pump ON.
2. Open the filter pressure release to relieve the system pressure until water comes out.
3. If the filter pump is located below the water level of the pool, opening the filter pressure release valve will prime the pump with water.
4. Once all the air has left the filter, close the pressure release valve.
5. Turn on the power to the booster pump. Then turn on the booster pump.
6. The booster pump should prime. The time it takes to prime will depend on the elevation and length of pipe used on the suction supply pipe. See Section Check the Water Flow for proper elevation and pipe size.
7. If the booster pump does not prime and all the instructions to this point have been followed, check for a suction leak.

Maintenance

Winterizing the Pump

The pump must be protected when freezing temperatures are expected. Allowing the pump to freeze will cause severe damage and void the warranty.

Do not use antifreeze solutions in the pool, spa, or hot tub systems! Antifreeze is highly toxic and may damage the circulation system. The only exception to this is Propylene Glycol. For more information see your local pool/spa supply store or contact a qualified swimming pool service company.

1. Drain all water from the pump, system equipment, and piping.
2. Remove the drain plug. Store the drain plug in a safe location and reinstall it when the cold weather season is over. Do not lose the o-ring. (Drain Plug with O-ring Set, R0537000).
3. Keep the motor covered and dry.
   NOTE
   Covering the pump with plastic will create condensation, and this moisture will damage the pump. The best way to protect your pump is to have a qualified service technician or electrician properly disconnect the electrical wiring at the switch or junction box. Once the power is removed, the two (2) quick connect fittings can be loosened and the pump stored indoors. For safety, and to prevent entry of contaminants, reinstall all conduit and terminal box covers.
4. When the system is reopened for operation, make sure all piping, valves, wiring, and equipment are in accordance with the manufacturer's recommendations. Pay close attention to the filter and electrical connections.
5. The pump must be primed prior to starting; refer to Section Start-up.

Product Specifications and Technical Data

Replacement Parts List

To order or purchase parts for Polaris^® pumps, contact your nearest Zodiac^® dealer. If they cannot supply you with what you need, contact Zodiac technical support at 800.822.7933 or www.zodiacpoolsystems.com.

Polaris PB4-60 Booster Pump Exploded View

Pump Dimensions

IMPORTANT SAFETY INSTRUCTIONS

READ AND FOLLOW ALL INSTRUCTIONS

Safety Instructions

All electrical work must be performed by a licensed electrician and conform to all national, state, and local codes. When installing and using this electrical equipment, basic safety precautions should always be followed, including the following:

To reduce the risk of injury, do not permit children to use this product.

To reduce the risk of property damage or injury, do not attempt to change the backwash (multiport, slide, or full flow) valve position with the pump running.

Polaris pumps are powered by a high voltage electric motor and must be installed by a licensed or certified electrician or a qualified swimming pool service technician.

RISK OF ELECTRIC SHOCK, FIRE, PERSONAL INJURY, OR DEATH. Connect only to a branch circuit that is protected by a ground-fault circuit-interrupter (GFCI). Contact a qualified electrician if you cannot verify that the circuit is protected by a GFCI. Make sure such a GFCI should be provided by the installer and should be tested on a routine basis. To test the GFCI, push the test button. The GFCI should interrupt power. Push the reset button. Power should be restored. If the GFCI fails to operate in this manner, the GFCI is defective. If the GFCI interrupts power to the pump without the test button being pushed, a ground current is flowing, indicating the possibility of electrical shock. Do not use the pump. Disconnect the pump and have the problem corrected by a qualified service representative before using.
Due to the potential risk of fire, electric shock, or injuries to persons, Zodiac Pumps must be installed in accordance with the National Electrical Code^® (NEC^®), all local electrical and safety codes, and the Occupational Safety and Health Act (OSHA^®). Copies of the NEC may be ordered from the National Fire Protection Association (NFPA^®) online at www.nfpa.org or call 617-770-3000, or contact your local government inspection agency.

Incorrectly installed equipment may fail, causing severe injury or property damage.

• Do not connect the system to an unregulated city water system or other external source of pressurized water producing pressures greater than 35 PSI.
• Trapped air in system can cause the filter lid to be blown off, which can result in death, serious personal injury, or property damage. Be sure all air is out of the system before operating.

To minimize the risk of severe injury or death the filter and/or pump should not be subjected to the piping system pressurization test.
Local codes may require the pool piping system to be subjected to a pressure test. These requirements are generally not intended to apply to the pool equipment such as filters or pumps.
Polaris pool equipment is pressure tested at the factory.
However, if the WARNING cannot be followed and pressure testing of the piping system must include the filter and/or pump, BE SURE TO COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS:

• Check all clamps, bolts, lids, lock rings and system accessories to ensure they are properly installed and secured before testing.
• RELEASE ALL AIR in the system before testing.
• Water pressure for test must NOT EXCEED 35 PSI.
• Water temperature for test must NOT EXCEED 100°F (38°C).
• Limit test to 24 hours. After test, visually check system to be sure it is ready for operation.

NOTICE: These parameters apply to Zodiac equipment only. For non-Zodiac equipment, consult equipment manufacturer.

Chemical spills and fumes can weaken pool/spa equipment. Corrosion can cause filters and other equipment to fail, resulting in severe injury or property damage. Do not store pool chemicals near your equipment.

Do not start pump dry! Running the pump dry for any length of time will cause severe damage and will void the warranty.

This pump is for use with permanently installed pools and may also be used with hot tubs and spas if so marked. Do not use with storable pools. A permanently installed pool is constructed in or on the ground or in a building such that it cannot be readily disassembled for storage. A storable pool is constructed so that it may be readily disassembled for storage and reassembled to its original integrity.

Do not install within an outdoor enclosure or beneath the skirt of a hot tub or portable spa. The pump requires adequate ventilation to maintain air temperature at less than the maximum ambient temperature rating listed on the motor rating plate.

Pool Pump Suction Entrapment Prevention Guidelines

Pump suction is hazardous and can trap and drown or disembowel bathers. Do not use or operate swimming pools, spa, or hot tubs if a suction outlet cover is missing, broken, or loose. The following guidelines provide information for pump installation that minimizes the risk of injury to users of pools, spas, and hot tubs:
Entrapment Protection - The pump suction system must provide protection against the hazards of suction entrapment.
Suction Outlet Covers - All suction outlets must have correctly installed, screw-fastened covers in place. All suction outlet (drain) covers must be maintained. Drain covers must be listed/certified to the latest version of ANSI^®/ASME^® A112.19.8 or its successor standard, ANSI/APSP-16. They must be replaced if cracked, broken, or missing.
Number of Suction Outlets Per Pump - Provide at least two (2) hydraulically-balanced main drains, with covers, as suction outlets for each circulating pump suction line. The centers of the main drains (suction outlets) on any one (1) suction line must be at least three (3) feet apart, center to center. See Figure 1.
The system must be built to include at least two (2) suction outlets (drains) connected to the pump whenever the pump is running. However, if two (2) main drains run into a single suction line, the single suction line may be equipped with a valve that will shut off both main drains from the pump. The system shall be constructed such that it shall not allow for separate or independent shutoff or isolation of each drain. See Figure 1.
More than one (1) pump can be connected to a single suction line as long as the requirements above are met.
Water Velocity - The maximum water velocity through the suction fitting or cover for any suction outlet must be 1.5 feet per second unless the outlet complies with the latest version of ANSI/ASME A112.19.8 or its successor standard, ANSI/APSP-16, the standard for Suction Fittings For Use in Swimming Pools, Wading Pools, Spas, and Hot Tubs. In any case, do not exceed the suction fitting's maximum designed flow rate.
If 100% of the pump's flow comes from the main drain system, the maximum water velocity in the pump suction hydraulic system must be six (6) feet per second or less, even if one (1) main drain (suction outlet) is completely blocked. The flow through the remaining main drain(s) must comply with the latest version of ANSI/ASME A112.19.8 or its successor standard, ANSI/APSP-16, the standard for Suction Fittings For Use in Swimming Pools, Wading Pools, Spas, and Hot Tubs.
Testing and Certification - Suction outlet covers must have been tested by a nationally recognized testing laboratory and found to comply with the latest version of ANSI/ASME A112.19.8 or its successor standard, ANSI/ APSP-16, the standard for Suction Fittings For Use in Swimming Pools, Wading Pools, Spas, and Hot Tubs.
Fittings - Fittings restrict flow; for best efficiency use fewest possible fittings (but at least two (2) suction outlets). Avoid fittings which could cause an air trap.
Pool cleaner suction fittings must conform to applicable International Association of Plumbing and Mechanical Officials (IAPMO^®) standards.