Polaris 480 Workbook

Welcome to the Polaris 480 Course

There are several types of pool cleaners In-Floor- Fittings Mounted in the pool floor that use filtered water to clean the pool. Electric - Cleaners that are plugged into electric with a cable. Suction- Cleaners mounted on the suction side of a pools pump and filter system. Pressure - Cleaners mounted on the return side of a pools pump and filter system and may use a booster pump for extra pressure. The Polaris 480 is a pressure cleaner which requires a booster pump. There are several models of pressure cleaners offered by Zodiac under the Polaris brand. It is easy to identify each model. If you remove the bag and look down the throat of each unit, you will see small jets. The number of jets is the first number in the description of the unit. If the unit requires a booster pump for proper pressure it will have an 8 or 9 as the second number. If a booster pump is not required and the unit operates off the regular pool returns, it will have a 6 as the second number. Example: 480 has four jets and requires a booster pump.

TTo take this course you will need a 480 cleaner as well as a Phillips head and straight edge screw driver. It is recommended that you obtain and read the Polaris 480 Owners Manual, TL-1150. Four jets provide greater vacuum power and faster cleaning (3 hours or less). Sweeps and scrubs the bottom and walls of any size or shape pool. Runs off a separate booster pump, working independently from the rest of your pool system.

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Features & Benefits

Runs

off a separate booster pump (operates independently from the rest of your pool system, always operates at 100% efficiency) No sweeping or vacuuming by hand Collects debris in its own bag before it reaches the filter (reduces filter cleaning by up to 80% per year) Four Vacuum Jets Ideal for large debris pools 31 feet of Hose comes in the box One Year Standard Warranty, 5 years on the Frame (Excluding wear items such as bags, tires, sweep hose or scrubbers)

Operation and Performance

Vacuums, sweeps and scrubs pool floor and walls Automatic in-line back-up valve frees 480 from obstructions and increases its randomness In-Line filter, standard with the Super Bag Zippered Double Filter Bag, as well as three

EZ Bags ( disposable fine filter bags ). Works under a pool cover Cleans the pool within 1-1/2 to 3 hours

Finished Good Part Number: F4 Zodiac Premium Points: 300

Opening the Box Sweep Hose Complete Extra Spare Wear Items Owners Manual Warranty Card License Plate Order Accessory Brochure

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Notes:

Additional Options for the 480

BlackMax 480PRO TankTrax 480PRO

480PRO BlackMax Black Max model is available to complement dark bottom pools

480PRO Tank Trax Designed for vinyl and other challenging in-ground pools. It easily climbs walls, and maneuvers over stairs or steep breaks.

The 480 comes standard with both : Super Bag (48-057) Plus Three EZ Bags (K42)

Extra Capacity Disposable Bag

Easy open clam bag clip assembly Same micron rating as a cartridge filter

UWF restrictor discs, red and blue UWF removal tool Spare Wear Items 3 EZ bags 1 extra filter screen for in-line filter 3 sweep hose scrubbers

MaxTrax Tires
Provides maximum traction without damage to pool finishes. WideTrax Tire is standard #48-032 WideTrax Tire, Black available #48-232 TankTrax Tire for TT models, #48-037

Dedicated Booster Pump Line

The 180 requires a dedicated pool cleaner line located equidistant from the two furthest points in the pool. ( More technical information on the booster pump is covered in the booster pump course )

Pressure
FILTER

Pressure
HEATER

Pressure Suction
(vacuum)
PUMP

Polaris Booster Pump Skimmer Main Drain Dedicated Cleaner Line

Return Lines

Install the Universal Wall Fitting

Installs in minutes on pools with a dedicated cleaner return line and a threaded 1-1/2" female pipe fitting. 1 Turn on the filtration pump and flush out the plumbing line. Turn pump off. 2 Remove the UWF from the Quick Disconnect and screw the UWF with the blue restrictor disk into the return opening. 3 Turn the Quick Disconnect clockwise into the UWF and pull away to secure.

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UWF- Universal Wall Fitting

Standard wall fitting ( UWF ) comes with blue restrictor disc installed. If pressure is low, below 28 psi, remove blue. If pressure is over 32 psi, remove blue and install the red.

Proper Hose Length

31 feet of hose is standard in the box. A one foot section from wall fitting to strainer (C). Two 10 foot feed hose sections after the strainer that are attached by a swivel. The final 10 foot section is the leader hose and has the back-up valve (A) 30 inches from the end of the hose that attaches to the mast of the cleaner (B). A-Back Up Valve B-Cleaner End C- One Foot Section

The Black Pressure Release on the wall fitting is set to allow any pressure not needed by the cleaner to release out into the pool. Notes:

Adjust Feed Hose To Fit Pool Length

Measure the deepest part of the pool. Cut leader hose, from end that attaches to feed hose, so length is equal to the greatest depth of the pool. Attach leader hose to feed hose and connect hose to the pool wall at the return line. Extend hose to farthest point of pool. The hose end must be within 6" longer or shorter of the farthest point. See dotted circle. Hose too long? Cut excess length from the first hose section and reconnect hoses. Hose too short? Buy an additional feed hose section (part #9-100-3104), one swivel (part #D20) and two hose nuts (part #D15). After adjusting hose, position hose floats as shown.

Hose Cutting
When you cut the hose, take care to cut it clean and with a sharp knife. If you do not cut it clean the nut will be hard to push back on the end of the swivel (or cleaner). The nut always is put on the swivel first and then screwed back over the hose after it has been pushed on to swivel (or cleaner).

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Sweep Hose Adjustment

To set the water flow of the sweep tail. The sweep tail connector turns and clicks through 5 settings

Optional Hose Weight

For Sweep Hose When a consumer complains that the sweep hose at the proper setting is still spraying their windows, the use of a B2 hose weight may solve the issue. To remove sweep hose, leverage a flathead screwdriver between the jaws of the clamp and gently push apart. Cut 7" off the length and slide on the sweep hose weight.

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BagCleaning
Remove the bag clasp from the feed hose. Twist the bag connector until it disengages with a clicking sound from the feed pipe. Pull off the filter bag, open the both closures and dump out the debris. To reinstall align markings on the connector and feed pipe. Click connector into position on pipe and reattach bag collar to hose.

Empty the bag when it is half full, especially if the dirt load is sand. It is easier to empty the bag when it is dry. Alternate between two bags

Feed Hose Connector Assembly

Easy connection simplifies attachment of hose to cleaner

Bag Clasp Assembly

Positioned on feed hose for quick, accurate attachment Easy On/Off Snap

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Thrust Jet Adjustment

The thrust jet powers the direction of the cleaner and gives the Polaris a random pattern. Factory position is straight back, but depending on the pool, other settings may be helpful.

With Cleaner On ...

Check Wheel RPM for a reading between 34-36 RPM For an accurate reading, the Cleaner must be held

below Water level. RPM = Revolutions per Minute. Measure of Speed.

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Helpful Installation Options

G-12 Over the Deck Kit For Pools Without a dedicated cleaner return G-9 Reducing Bushing For pools with an old Polaris fitting still glued into the wall. ( It was a thread ) G-35 Pressure Stick Used at the end of the cleaner hose with both the pool pump and booster pump turned on to verify proper operating pressure for the cleaner 10-102-00 Removal Tool Removes UWF (Universal Wall Fitting) and removes pressure release from wall fitting.

Optional Over The Deck Kit

G-12 For pools without a dedicated cleaner line

Over The Deck Kit Installation

For older pools that do not have a dedicated cleaner return and the installer does not want to lower the water in the pool and drill a return through the pool wall .

G-12 The elbow and valve connects to the booster pump. Connector on valve is a hose bib to connect garden hose. The other end of the garden hose connects to hose bib on the pipe.

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Special Fittings
G-9 can be used for threaded outlets. Then the UWF (Universal Wall Fitting) can screw in.

With the Cleaner On Check Supply Pressure

Pressure should be between 28 to 32 PSI For an accurate reading, you must hold the tip of the Pressure Stick (#G-35) under the Water. PSI = pounds per square inch. Measure of Pressure.

Pressure Stick # G-35

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Removal Tool #10-102-00

Also removes pressure relief fittings

Removal Tool #10-102-00

Use with pins still existing in the wall fitting ( UWF )

Removal Tool #10-102-00

Use where pins are missing in the wall fitting (UWF)

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Quick Troubleshooting
Check if In-Line Strainer is Clean - This will not allow enough pressure for unit to work properly Check if Bag is Full - Unit will run on its side if bag is too heavy Check Head Float - Should be full of air not water. The cleaner will also be on its side when full of water Check Wheel Spin- All 3 should spin smoothly. If not bearings and gears could be blocked or worn. Check Water Flow - Wet Function Bench Test (G-110). Allows you to plug in at a sink or at a hose bib and verify that all jets are clear and working properly

Cleaning the Filter

Always disconnect the Polaris before cleaning or backwashing the pool filter, and let the filtration system run for at least five minutes before reconnecting the cleaner. To clean the filter screen, pull it out of the wall fitting assembly, rinse it and press it firmly back into place. Current Filter In-Line Hose Old Filter In Quick Disconnect Fitting

Wet Function Bench Tester

G110 is available so that a cleaner can be hooked to a sink faucet or a hose bib to test water flow through the unit and if the jets are all clear, allowing for proper flow.

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Verification of Water Flow Diagram

Back-Up Valve
The G-52 Backup Valve is mounted on the hose near the cleaner. Using a paddle wheel and gear system , it pulls the cleaner backwards Using water flow every 2 minutes.

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Back-Up Valve
The back-up valve mechanism may be changed.

Backup Valve
The paddle wheel and gear system in the mechanism changes water flow from the cleaner to the open port to pull the cleaner away from any obstructions.

Options for the Backup Valve

The G-56 is a booster valve seat for the G52 and that will increase the flow from the back up valve when it is in reverse mode. This will pull the cleaner farther back than the normal backup valve. The G-65 is a double acting mechanism (guts) for the G-52 backup valve. Normal G52 backs up every 2 min. If you replace the mechanism with a G-65 is will back up approximately every 1 min and 45 sec.

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Tune Up Kit
48-210 Tune-up Kit is for the standard 480. It includes all wear parts but does not include a top or bottom.

Tune Up Kit
48-210 Tune-up Kit includes all wear parts but does not include a top, bottom or frame.

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Tune Up Kit
48-211 Tune-up Kit is for the TankTrax 480. It includes all wear parts but does not include a top, bottom, or frame.

Tune Up Kit
48-211 Tune-up Kit includes all wear parts but does not include a top, bottom or frame.

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Tear Down: Remove Sweep Hose

Hold the sweep hose, and turn the sweep hose nut clockwise. Pull the sweep hose from the sweep hose adjustment barb.

Tear Down: Top Housing

Loosen the two screws securing top and lift off housing. Top housing is one-piece with an incorporated float (not sold separately) Screws on outer housings are captured screws.

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Tear Down: Vacuum Tube/Feed Pipe

Remove the four screws securing vacuum tube/feed pipe assembly Two on both sides of the tube/feed pipe assembly

Tear Down: Vacuum Tube/Feed Pipe

Lift off assembly

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Tear Down: Vacuum Plate Assembly

Turn cleaner upside down and loosen three screws holding vacuum plate (bottom plate) assembly in position

Tear Down: Vacuum Plate Assembly

Please note that the screws are captured

Tear Down: Vacuum Plate Assembly

Slide off lower housing and return cleaner to upright position.

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Tear Down: Drive Chain

Starting with double-wheel side, move chain forward and push off gearbox assembly. Chain can be completely removed without taking off wheels. Push chain off gearbox on single-wheel side. Leave chain until wheel is removed. Chain positioning label is installed on vacuum tube/ feed pipe assembly for reference.

Tear Down: Gearbox Assembly

Remove three screws securing gearbox assembly Lift off of frame Gearbox assembly is a sealed modular component sold as a unit. Part Number 48-020

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Tear Down: Water Management System (WMS)

Turn frame over and remove three screws holding WMS in place Remove WMS module (48-010)

Tear Down: Water Management System (WMS)

Adjustable Sweep Hose To increase motion of hose, move teardrop indicator clockwise towards more flow designation To decrease motion, move indicator counterclockwise

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Tear Down: WideTrax Wheels

Pop off hubcaps with flat-blade screwdriver There is an opening in each hub cab for the screw driver.

Tear Down: WideTrax Wheels

Remove wheel lock screw

Tear Down: WideTrax Wheels

Unique wheel lock screw is smaller with blue marking

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Tear Down: WideTrax Wheels

Inner Wheel Assembly Plastic wheel spines

Inside thread on shaft

Chain Guard Keeps chain on pulley

Tear Down: Axle Block Assembly

Remove two screws holding axle block assembly. Note: longer screws also have star washers.

Slide axle block out of slot in frame

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Tear Down: Idler Tensioner Assembly

Remove screws to release tensioner Spring automatically adjusts chain tension on double-wheel side of cleaner

Tear Down: Tension Adjustment

Elongated screw receptacle channel on the singlewheel side provides manual tension adjustment Adjust position of axle block in receptacle

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Tear Down: Frame

Now, put the cleaner back together.

Tear Down: Replace Axles and Tensioner

Replace the tensioner assembly and axles. Be sure to get the spring in place in the tensioner.

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Tear Down: Replace Wheels and Hub Caps

Tear Down: Replace Water Management System (WMS)

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Tear Down: Replace Gearbox Assembly

Gearbox assembly is a sealed modular component sold as a unit. Part Number 48-020

Tear Down: Replace Drive Chain

Chain positioning label is installed on vacuum tube/feed pipe assembly for reference.

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Tear Down: Replace Bottom and the Vacuum Plate Assembly

Turn cleaner upside down and place the bottom assembly on the unit. Put the vacuum plate in place and screw the three screws in place.

Tear Down: Replace the Vacuum Tube/Feed Pipe

Make sure o-ring is clean and in place when pushing the pipe in place.

Replace the four screws securing vacuum tube/feedpipe assembly

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Tear Down: Replace the Top Housing

Tear Down: Attach the Sweep Hose

Put the nut on the adjustment barb first. Then push hose onto the barb. Screw the nut back over the hose counter clockwise.

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Serial Number 480Pro

Located on both the frame and on the back of the cleaner body.

Serial Number 480Pro

It is a bar code label located on the lower right of the back of the unit.

Product identifier

This is the date the unit was produced.

This is the number of the unit that was built on that date.

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Troubleshooting Quick Troubleshooting

Check if In-Line Strainer is Clean- This will not allow enough pressure for unit to work properly Check if Bag is Full - Unit will run on its side if bag is too heavy Check Head Float - Should be full of air not water. The cleaner will also be on its side when full of water Check Wheel Spin - All 3 should spin smoothly. If not the belts and /or drive for the belts are broken or blocked.

Troubleshooting
Back-up Valve is always on or wont engage. Check wheel RPM and pressure to verify proper flow. Check Back-up valve for debris or damage.

Cleaner is not moving.

Check wheel RPM and pressure to verify proper flow.

Verify WMS hose is attached and clamp is secure.

Check WMS for obstructions.

Cleaner only turns in one direction or is running in circles Cleaner stays in one end of the pool, does not clean entire pool.

Check the filter bag. If full, empty it or replace if needed.

Verify thrust jet is in the correct position. (180, 280, 480 = straight back), (360, 380 = 11 oclock) (3900 = 7 oclock) Verify thrust jet is in the correct position. (180, 280, 480 = straight back), (360, 380 = 11 oclock) (3900 = 7 oclock)

With cleaner on, verify that vacuum jets have clear unobstructed flow. With cleaner on, verify that vacuum jets have clear unobstructed flow.

Verify that all of the wheels are moving together. Check for broken belts. Verify the back-up valve is cycling.

Verify that feed hose is within 6 longer or shorter of the farthest point of the pool.

Cleaner is slow or sluggish, running with less power than normal.

Verify thrust jet is in the correct position. (180, 280, 480 = straight back), (360, 380 = 11 oclock) (3900 = 7 oclock)

Check hoses, connections, and swivels for leaks.

Check for proper flow by confirming proper PSI and than Proper RPMs. Add a sweep hose weight, part #B2

Check bearings are clear of debris and replace if worn.

Sweep hose sprays water out of the pool.

Verify thrust jet is in the correct position. (180, 280, 480 = straight back), (360, 380 = 11 oclock) (3900 = 7 oclock)

Replace the sweep hose scrubber if it worn or missing.

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Polaris 480 - 3/11 38