PB460 - Pump POLARIS - Free user manual and instructions

USER MANUAL PB460 POLARIS

FOR YOUR SAFETY - This product must be installed and serviced by a contractor who is licensed and qualied in pool equipment by the jurisdiction in which the product will be installed, where such state or local requirements exist. In the event no such state or local requirement exists, the maintainer must be a professional with sufcient experience in pool equipment installation and maintenance, so that all of the instructions in this manual can be followed exactly. Improper installation and/or operation can create dangerous electrical hazards, which can cause high voltages to run through the electrical system. Before installing this product, read and follow all warning notices and instructions that accompany this product. Failure to follow warning notices and instructions may result in property damage, personal injury, or death. Improper installation and/or operation will void the warranty. If these instructions are not followed exactly, a re or explosion may result, causing property damage, personal injury, or death. ATTENTION INSTALLER: This manual contains important information about the installation, operation and safe use of this product. This information should be given to the owner/operator of this equipment. WARNING H0344400 REVD Pressure Cleaner Booster Pump Installation and Operation Manual For Polaris PB4-60 Booster Pumps with Serial Numbers beginning with "PB" and a manufacturing date on or after Dec 1, 2011. ENGLISH

1.2 Pool Pump Suction Entrapment

Section 6. Troubleshooting and Repair ........ 12

Section 7. Product Specications and Techni-

Installation and Operation Manual

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

pumps are powered by a high voltage electric motor and must be installed by a licensed or certied electrician or a qualied swimming pool service technician. WARNING 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 qualied 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 owing, indicating the possibility of electrical shock. Do not use the pump. Disconnect the pump and have the problem corrected by a qualied service representative before using. Due to the potential risk of re, electric shock, or injuries to persons, Zodiac Pumps must be installed in accordance with the National Electrical Code

), 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

) online at www.nfpa.org or call 617-770-3000, or contact your local government inspection agency. WARNING Incorrectly installed equipment may fail, causing severe injury or property damage. WARNING

• 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 lter 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. WARNINGPage 4 ENGLISH Polaris® PB4-60 Booster Pump | Installation and Operation Manual

SAVE THESE INSTRUCTIONS

Chemical spills and fumes can weaken pool/spa equipment. Corrosion can cause lters and other equipment to fail, resulting in severe injury or property damage. Do not store pool chemicals near your equipment. WARNING Do not start pump dry! Running the pump dry for any length of time will cause severe damage and will void the warranty. CAUTION To minimize the risk of severe injury or death the lter 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 lters or pumps. Zodiac

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 lter 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. WARNING 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. CAUTION 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. CAUTIONPage 5 ENGLISH Polaris PB4-60 Booster Pump Installation and Operation Manual

1.2 Pool Pump Suction Entrapment Prevention Guidelines

At least three (3) feet Suction Outlet (Main Drain) Suction Outlet (Main Drain) No valves between Tee and Main Drains Listed/certified to latest published version of ANSI/ASME A112.19.8 - 2007 or its successor, ANSI/APSP-16Anti-entrapmentCover/Grate or Suction Fitting, screw-fastened to Main Drain SumpListed/certified to latest published version of ANSI/ASME A112.19.8 - 2007 or its successor, ANSI/APSP-16Anti-entrapmentCover/Grate or Suction Fitting, screw-fastened to Main Drain Sump Valves OK between pump and Tee Pump Figure 1. Number of Suction Outlets Per Pump 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/certied to the latest version of ANSI

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 tting 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 tting’s maximum designed ow rate. If 100% of the pump’s ow 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 ow 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 Certication - 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 ow; for best efciency use fewest possible ttings (but at least two (2) suction outlets). Avoid ttings which could cause an air trap. Pool cleaner suction ttings must conform to applicable International Association of Plumbing and Mechanical Ofcials (IAPMO

) standards. WARNINGPage 6 ENGLISH Polaris PB4-60 Booster Pump Installation and Operation Manual

Section 2. General Description

This manual contains information for the proper installation, operation and maintenance of the Polaris PB4-60 pump. Procedures in this manual must be followed exactly. To obtain additional copies of this manual contact Zodiac Pool Systems, Inc. ("Zodiac") at 800.822.7933. For address information, see the back cover of this manual.

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 ltration pump will damage the booster pump. Improper operation of the booster pump will void the warranty. CAUTION

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 7.1, Replacement Parts List.

Section 3. Installation

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

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. CAUTION

3.1.2 Bonding and Grounding

1. The motor frame must be grounded to a reliable

grounding point using a solid copper conductor, No. 8 AWG (8.4mm

) or larger. In Canada, No. 6 AWG (13.3mm

) 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.

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. CAUTION 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. WARNING 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 tting the equipment can be turned off. This location must not be in the same area as the pool pump, lter, and other equipment. WARNING

Installation and Operation Manual

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.

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

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 guidelines for specific equipment.

1. Plumb the dedicated line upstream of all air

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

) 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. Minimumof 3 feet(1 meter) From Pool Filtration PumpPool FilterHeaterPolarisPlumb the booster pump up-stream of all air inducing equipment.

*Assumes three (3) copper conductors in a buried conduit and 3% maximum voltage loss in branch circuit. All National Electrical Code

) and local codes must be followed. Table shows minimum wire size and branch fuse recommendations for a typical installation per NEC. Table 1. Maximum Wire Size and Overcurrent ProtectionPage 8 ENGLISH Polaris PB4-60 Booster Pump Installation and Operation Manual

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.

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 conrm that it will continue to safely operate when any check valves are installed. WARNING

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

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.

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. Refer to Figures 3 and 4. Figure 3. Preferred Plumbing Configuration From Filter or Heater Horizontal Leg To Booster Pump Polaris Reinforced Hose Street Ell Option #1 Pool Return To Spa Ground Level Figure 4. Alternate Plumbing Configuration Pool Return From Filter or Heater Option #3 Option #2 To Spa Ground Level Leave 6"Page 9 ENGLISH Polaris

Installation and Operation Manual 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.

3.3.6 Check the Water Flow

NOTE This pump must have minimum outlet pressure of 45 psi. Lower pressure may cause an over- current 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:

3.3.4 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. See Figure 5 (a). CAUTION 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. See Figure 6.

3.3.5 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 Figure 5. Prep and install Quick Connect barb and connector nut

Connector BarbConnector NutPump BodyConnector BarbReinforced HoseConnector BarbBarb FaceConnector NutReinforced HoseNut Gap Figure 6. Tighten Connector Nut to Secure Hose Polaris Reinforced Hose 1-1/2" Rigid PVC Pipe Dedicated return line to pool Expansion Anchor Inlet Supply Line Figure 7. Complete InstallationPage 10 ENGLISH Polaris PB4-60 Booster Pump Installation and Operation Manual

1. Verify that the installation is correct. Refer to

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.

3.3.7 Conduct Pressure Test

When pressure testing a system with water, air is often trapped in the system during the lling 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 lter and loosening the pump basket lid on the lter pump while lling the pump. WARNING Trapped air in system can cause lter 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. WARNING When pressure testing the system with water, it is very important to make sure that the pump basket lid on the lter pump is completely secure. WARNING 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. WARNING

1. Fill the system with water, using care to eliminate

2. Pressurize the system with water to no more than

3. Close the valve to trap pressurized water in the

4. Observe the system for leaks and/or pressure

5. For technical support, contact Zodiac

technical support at 800.822.7933.

Section 4. Operation

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. CAUTION 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. CAUTION 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. WARNING

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

3.3.6 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.Page 11 ENGLISH Polaris PB4-60 Booster Pump Installation and Operation Manual

Section 5. Maintenance

The pump must be protected when freezing temperatures are expected. Allowing the pump to freeze will cause severe damage and void the warranty. CAUTION 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 qualied swimming pool service company. CAUTION

1. Drain all water from the pump, system equipment,

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 4.1, Start-up.Page 12 ENGLISH Polaris

Installation and Operation Manual

Section 6. Troubleshooting and Repair

strongly recommends that you call a licensed and qualified service professional in to perform any repairs on the filter/pump system. To locate an independent service company, check your local yellow pages or visit: www.zodiacpoolsystems.com.

Symptom Possible Problem/Solution The cleaning/circulating system is not operating correctly. Verify that skimmer baskets, pump basket and other screens are clean. Clean as necessary. Check filter and clean as necessary. Check valve positions. Adjust as necessary. NOTE Multiple pieces of equipment operating at one time (for example, waterfalls, spa jets, and surface returns) may prevent the cleaning system from working properly. Check the cleaning system manually to ensure that the system is adjusted according to the manufacturer's recommendations. Bubbles present in the filtration pump basket. Air in system. Check the pool or spa water level to ensure it is at the proper level and that air is not being drawn into the suction piping. If the water is at normal level, turn off the pump. Remove the lid and check for debris around the lid o-ring seat or improper installation of the lid seal, as this either of these conditions will cause air to leak into the system. Clean the lid o-ring and place on the lid. Hand-tighten the lid to make an air tight seal. Do not use any tools to tighten the lid. Turn the pump back on. Air leaks are still present. Check the suction side piping union. While the pump is running, try to tighten the union. If this does not stop the air leak, turn off the pump. Loosen both unions and slide the pump out of the way. Remove, clean and re-install both union o-rings on the filtration pump. Reposition the pump next to the piping and secure the union nuts to the pump. With clean union o-rings, hand-tightening of the unions should create a seal. If the unions still do not seal, gently tighten with a large pair of tongue-and-groove pliers. Do not over-tighten. There is no air in the system, but the pressure is still low. It is possible that debris is caught in the pump impeller. The pump impeller moves the water, and the vanes in the impeller can become blocked with debris. See Section 6.2, Service Technician Maintenance, 6.2.1, Blocked Impeller, for more information. There is no debris blocking the impeller and the pressure is still low. The pump impeller is showing signs of normal wear. Have a qualified service technician check the impeller and replace as necessary. If the pump is part of a relatively new installation, it could be an electrical problem. Contact a qualified service technician. Have the technician check for loose electrical connections and check the voltage at the pump motor while it is in operation. The voltage must be within 10% of the motor's data plate rating. If the voltage is not within 10%, contact a qualified electrician and/or the local power service provider. Pump seal is leaking air. Have a qualified service technician replace the seal. The pump is leaking water between the motor and pump body. This is caused by a damaged or failed mechanical seal. Replace the seal. See Section 6.2, Service Technician Maintenance, 6.2.4, Mechanical Seal Replacement. The pump gets hot and shuts off periodically. Ensure that there is adequate room around the motor to circulate air and keep the motor cool. Have a qualified electrician check for loose connections and check the voltage at the pump motor while it is in operation. The voltage must be within 10% of the motor's data plate rating. If the voltage is not within 10%, contact a qualified electrician and/or the local power service provider.Page 13 ENGLISH Polaris PB4-60 Booster Pump Installation and Operation Manual

6.2 Service Technician Maintenance

This pump must be serviced by a professional service technician, qualied in pool/spa installation. The following procedures must be followed exactly. Improper installation and/or operation can create dangerous electrical hazards, which can cause high voltages to run through the electrical system, possibly causing property damage, serious injury, or death. Improper installation and/or operation will void the warranty. WARNING

6.2.1 Blocked Impeller

While servicing the pump, switch off the circuit breakers at the power source. Severe personal injury or death may occur if the pump starts while your hand is inside the pump. WARNING

1. Turn off the pump. Switch off the circuit breaker

2. Look inside the pump for any debris. Remove any

debris found inside.

3. Switch on the circuit breaker to the pump motor.

4. Turn on the pump, and see if the problem is

5. If the impeller is still blocked with debris and it is

not possible to remove the debris, the pump will need to be disassembled in order to access the inlet and outlet of the impeller.

6.2.2 Impeller Removal

While servicing the pump, switch off the circuit breakers at the power source. Severe personal injury or death may occur if the pump starts while your hand is inside the pump. WARNING

1. Turn off the pump. Switch off the circuit breaker

to the pump motor. If you are not replacing the motor, do not disconnect the electrical wiring. NOTE If you are replacing the motor, Zodiac

strongly recommends that a qualified service technician or electrician properly disconnect the electrical wiring at the pump motor.

2. Turn off any valves to prevent pool water from

reaching the pump. Drain the water from the pump by loosening the unions or removing the drain plugs.

3. Using a 9/16" wrench, loosen the bolts connecting

the pump volute to the motor backplate. See Figure 8.

4. Pull the volute from the backplate. The impeller is

connected to the motor shaft. NOTE At this point you have access to the inlet and outlet of the impeller to remove any debris.

5. Remove the motor shaft cover on the back of the

motor by twisting the hex-head screw with a 90° crescent wrench. See Figure 8. The motor shaft will be exposed.

6. Hold the motor shaft with a ½" wrench while

unscrewing the impeller from the motor shaft with your hand. NOTE The impeller is a right-handed thread, therefore turn the impeller counter-clockwise to unscrew.

7. Inspect the impeller for signs of rubbing and/or

Installation and Operation Manual

6.2.4 Mechanical Seal Replacement

NOTE This is a two (2) part replacement process. The mechanical seal must be replaced as a set. NOTE Refer to Figure 10 for an illustration of the location of the mechanical seal and impeller. Do not damage the ceramic or carbon surfaces of the seals. If surfaces are damaged, leaks will occur. WARNING

1. To access the mechanical seal, follow steps 1

through 6 of Section 6.2.2, Impeller Removal.

2. Remove the carbon face seal half from the motor

shaft. Refer to Figure 9. This is a spring-loaded seal. Grasp the portion of the seal closest to the impeller body and pull the seal off using a twisting motion.

3. Remove the motor from the backplate following

the steps in Section 6.2.5, Motor Replacement.

4. Place the backplate o-ring side down and force the

ceramic seal out using a screwdriver or drift pin.

5. Turn the backplate o-ring side up and insert the

new ceramic seal side into the backplate. Use great care to press the seal in squarely with your fingers. The ceramic is easily damaged and must be pressed in using only your fingers or soft tools. Do not use any lubricant other than water and soap solution.

6. Install the motor following the steps in

Section 6.2.5, Motor Replacement.

7. Install the backplate following the steps in

1. Press the new carbon face seal half (see Figure

9) on the motor shaft using a twisting motion.

Make sure the carbon surface is facing toward the ceramic ring in the backplate. VERY IMPORTANT! Grasp the lower portion of the seal (opposite the carbon face) when installing the seal, or it will be damaged. CAUTION NOTE To assist assembly, only use water and soap solution as a lubricant. Any other lubricant will destroy the seal after a short period of time. NOTE Exercise great care to keep the seal and mating parts clean.

2. While holding the motor shaft with a ½" wrench,

thread the impeller onto the motor shaft. Hand-tighten the impeller until it is secure. Do not overtighten.

3. Replace the motor shaft cover by inserting the

cover tabs into the slots and rotating the cover 90º clockwise.

4. Install and tighten the screws lightly in a crossing

“X” pattern using a 9/16" wrench, starting with the inner (middle) four (4) then the outer (top and bottom) four (4) to draw the backplate to the body in an even manner. Once all the screws are snug, torque in the same order to 18 ft-lbs.

5. Open the pressure release valve on the filter, and

make sure it is clean and ready for operation.

6. Switch on the circuit breaker to the pump motor.

7. Turn on the pump and check the system for normal

8. Once all the air has left the filter, close the

Installation and Operation Manual

6.2.5 Motor Replacement

To ensure continued safety and reliable operation, Zodiac Pool Systems, Inc. requires that you replace the motor with a motor that has the identical HP rating and service factor (Zodiac Pool Systems, Inc. approved only). CAUTION To avoid the risk of property damage, severe personal injury, or death, turn off the pump and switch off the circuit breaker to the pump motor before beginning this procedure. WARNING

1. Have a qualified service technician or electrician

properly disconnect the electrical wiring at the pump motor.

2. To disassemble the pump volute from the motor,

follow steps 1 through 6 in Section 6.2.2, Impeller Removal.

3. Remove the four (4) 9/16" screws and remove the

motor. NOTE Before removing the backplate, note the alignment of the backplate to the motor. Label is facing upward. See Figure 11.

4. If installing a new motor, remove the protective

plastic cap from the motor shaft. Place the motor on the backplate. The label should be facing upward. The starting capacitor on the motor should be at the 12 o'clock position.

5. Replace the four (4) bolts and washers holding the

backplate to the motor. Bolts with Washers (Qty 4) Motor Assembly Backplate Label Location Impeller Figure 10. Remove Back Plate

6. To reassemble the pump after replacing the motor,

follow steps 1 through 9 of Section 6.2.3, Impeller Replacement.

7. Have a qualified service technician or electrician

properly connect the electrical wiring at the pump motor. NOTE Zodiac Pool Systems, Inc. recommends that the mechanical seals be replaced at the same time the motor is replaced. See Section 6.2.4, Mechanical Seal Replacement, for details.Page 16 ENGLISH Polaris® PB4-60 Booster Pump | Installation and Operation Manual

Section 7. Product Specifications and Technical Data

7.1 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. Key No. Description Qty Order Part No. Comments 1 Replacement Motor for Booster Pump 1 P61 2 O-Ring, Backplate, PB4-60 1 R0536600 3 Seal, Ceramic and Spring 1 R0445500 4 Impeller, PB4-60 1 R0536400 5 Volute, PB4-60 1 R0536300 (Includes Drain Plug with O-Ring) 6 Bolts with Washers and Nuts 6 R0536900 7 Drain Plug with O-Ring, Common 1 R0537000 8 Base, Booster, PB4-60 1 R0537100 9 Bolts and Washers, Stainless, Motor, PB4-60 4 R0536800 10 Quick Connect Install Kit 1 R0617100 Kit includes 1 ea 6' length of reinforced hose and 4 ea Quick Connect fittings. 11 Quick Connect Fittings 4 R0621000 Comes with 4ea Quick Connect Fittings and Installation Instructions. 12 Pump Hose 6FT Reinforced 1 P19 6' Length 13 Backplate PB4-60 1 R0536700 Includes Seal and Backplate O-ring

Installation and Operation Manual NOTE When installing pump, leave a minimum of 2.0 feet (60 cm) of clearance above the pump for service.

Bolt Holes, Center to Center Front Edge of Union to Center of Bolt Holes 4 "

For Polaris PB4-60 Booster Pumps with Serial Numbers beginning with "PB" and a manufacturing date on or after Dec 1, 2011. Figure 13. New Polaris PB4-60 Booster Pump Figure 14. Discontinued Older Model of PB4-60 Booster Pump Older models of the PB4-60 Booster Pumps discontinued as of Nov 30, 2011.Page 19 ENGLISH Polaris

is a registered trademark of Zodiac International, S.A.S.U., used under license. Polaris® and the Polaris 3-wheeled cleaner design are registered trademarks of Zodiac Pool Systems, Inc. All trademarks referenced herein are the property of their respective owners. ©2014 Zodiac Pool Systems, Inc. H0344400 REVD Zodiac Pool Systems Canada, Inc. 2115 South Service Road West, Unit 3 Oakville, ON L6L 5W2

3.3.5 Recommandations relatives

Section 3. Installation

TENSION TENSION TENSION