Polaris 380 Workbook
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Welcome to the Polaris 380 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 380 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: 380 has three jets and requires a booster pump. To take this course you will need a 380 cleaner as well as a Phillips head and straight edge screw driver. It is recommended that you obtain and read the Polaris 380 Owner’s Manual, TL-850 . Three 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) • Three 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 backup valve frees 380 from obstructions and increases its randomness • In-Line filter, now standard along with Zipper Filter Bag • Works under a pool cover • Cleans the pool within 1-1/2 to 3 hours
Finished Good Part Number: F3 Zodiac Premium Points: 200
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Additional Options for the 380 • BlackMax 380 • Filter Bags • Tires
380 BlackMax Model BlackMax model is available to complement dark bottom pools
Filter Bags Filter bags to custom clean in any application from heavy debris (Leaf Bag) to the fine debris (EZ Bag ) disposable filter bags with micro-rating equivalent to cartridge filters, as well as ones for BlackMax models. Standard on Polaris 380 is 9-100-1021 Zippered All Purpose Filter Bag.
MaxTrax Tires Provides maximum traction without damage to pool finishes. Standard MaxTrax Tire is Part Number C10 PosiTrax for tile pools is Part Number C13 Black for BlackMax models is Part Number C11
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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
Pressure
HEATER FILTER
Pressure Suction
PUMP
(vacuum)
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.
31 Feet of Hose
Quick Disconnect Fitting with Black pressure release
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• • • •
In-line Filter Transparent filter housing Easy access to filter screen Built-in swivel
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 backup valve (A) 30 inches from the end of the hose that attaches to the mast of the cleaner (B).
A-Back Up Valve
C- One Foot Section
B-Cleaner End
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.
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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? Separate hose at the strainer. Cut the overage from feed hose section. • 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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Cleaner Assembly
Head Float Adjustment Standard position of the Head float is pushed all the way in towards the cleaner.
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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 11 o’clock, but depending on the pool, other settings may be helpful.
Sweep Hose Adjustment The proper operation of the sweep hose is to gently sweep the pool and put debris into suspension where it can be removed by the filter system. A sweep hose with too much pressure will “whip” and wear out quickly as well as spray outside the pool. The standard setting is to screw the sweep hose adjustment screw all the way in and back out 1-1/2 to 2 turns.
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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Cleaning And Attaching The Bag Remove the bag collar from the feed hose. Push the tabs on the bag collar and twist the bag away from the feed pipe. Pull off the filter bag, open the closure 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.
With the Cleaner On… • Check Wheel RPM • 28 – 32 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 ¾” 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 ¾” 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 it’s 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
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Verification of Water Flow Diagram
You can test all water function to verify no debris has clogged the unit. Either attached in the pool, or with the use of a G110 Wet Function Bench Tester.
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If during the test or by a quick look it appears that one of the jets is clogged with debris. The simple use of a paper clip and a back-flush through the water management should solve the problem.
Always make sure the jet that supplies the paddle wheel and wheel spin of the unit is clear as well.
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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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 ½ minutes.
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 ½ 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 9-100-9010 Tune-up Kit includes all wear parts but does not include a top or bottom.
Rebuild Kit 9-100-9030 Rebuild Kit includes all wear parts and includes the top and bottom.
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Polaris 380 Tear Down
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Polaris 180 Tear Down Remove the bag. Twist the bag connector until it disengages with a clicking sound from the throat.
Remove the float. It is not threaded on. Pull straight back to remove.
Remove the top. Use a Phillips head screw driver to remove the two screws on the back of the unit.
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Tear Down Once the two screws have been removed and plate pulled back off the unit you can proceed with removing the top.
With pressure on the tabs holding the top in place, you can pull the top up and off the unit.
If the unit is prior to 2003, there is a screw mounted on the double wheel side of the top. Unscrew it and pry the two sections of the top apart.
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Tear Down Remove the sweep hose. Plastic clamp is split. Separate the split from side to side (straight edge screw driver will help) and the clamp may be removed. Once clamp is off, pull the sweep hose off.
Remove the sweep hose adjustment screw. A typical flat head screw driver will fit the screw or use a pair of pliers. It unscrews counter clockwise.
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Tear Down Remove the three screws from the feed mast and pull it out of the unit.
When you remove or install the feed pipe it is critical to the operation of the unit to note the o-ring on the bottom of the feed pipe. The o-ring must fit flush in the bottom fitting or the it will leak power away from the operation of the unit.
O-ring bottom of the feed pipe
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Tear Down Four screws hold the frame in place. Remove the three that are exposed.
To remove the fourth screw under the front axle. Loosen the two screws holding the front axle enough to allow you to move the axle plate back out of the way. Then take out the final frame screw under the plate.
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Tear Down Remove the frame. It is a tight fit and you must remove the frame by first pulling back toward the hoses and lifting the back of the frame.
Grab frame here
Lift a very little, push back towards thrust jet. Lift straight up. Note: There is a disc between the belts on the drive axle. Front belt should always be mounted closest to the frame.
To adjust the belts you can loosen the two screws on the front and rear axle. Adjust belt tension and tighten axles back down. You should be able to place your finger on the belt and it will flex less than ¼”.
Separation Disc
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Tear Down Remove the belts from the wheels on the double wheel side of the frame. Just like a bicycle chain. Lift the belt off to one side and spin the wheel.
Remove the wheels. A flat head screw driver will in a small opening in each hub cap to pop them off.
Remove the wheels. There is an e-clip mounted on the end of each shaft. A flat head screw driver will help pop them out.
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Please note the look of the wheel bearings. One side has a solid blue face, while the other side exposes the ball bearings. When installing these bearings always make sure the blue face is out so that the balls are not exposed.
There are two bearings in each of the wheels on the double wheel side of the cleaner.
There are no bearings in the wheel on the single wheel side of the cleaner. Note that this wheel is different than the wheels on the double wheel side of the cleaner. Tires remain the same.
With the wheels off you can see that the axle blocks could be removed and replaced. You are down to the frame with the drive gear assembly and axles left in it.
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Note the spacers on each axle. They are hard to see when you first pull off the wheels because they will be tight up against the frame.
Remove the turbine cover.
Review this diagram of the drive assembly.
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In order to remove the drive axle, there is an e-clip to remove on the axle just inside the white plastic up against the turbine wheel. Remove the e-clip and pull axle out from the turbine pulley.
Turbine Pulley Do not remove the eclip on the pulley.
Pull out the transfer pulley drive shaft.
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You can remove the turbine wheel and drive gear. Please note that there is a bearing in the turbine wheel. It is embedded in the wheel and the only way to replace the turbine wheel bearing is to replace the entire turbine wheel. Turbine Wheel
Turbine Wheel Bearing
Drive Gear
Turbine Pulley/ Drive Shaft
To put the turbine pulley/drive shaft back in, remove the bearing on the single wheel side of the frame. Replace the turbine wheel and drive gear. Push the drive side ¾ of the way through the unit so that it is just sticking out of the bearing holder.
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Put the e-clip back on the drive shaft
This is why it is important to leave the bearing out to this point. You need to mount the e-clip before it is back in position, behind the frame. Now replace bearing. Remember, solid blue side out
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Lift shaft up and push all the way in so eclip is now behind frame
Replace the turbine cover
Remove the weight.
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Replace the wheels and belts. Don’t forget the spacers.
Front wheel belt first.
Frame with wheels should be all reassembled. Let’s take a look at the bottom.
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The water management system starts at the bottom of the feed pipe. It supplies water to the turbine to make the wheels turn, a hose to the thrust jet, and a hose to the sweep hose. To Turbine
To Thrust Jet
To Sweep Hose
The water management system also supplies two fittings on either side of the throat. These are held in place by two clips. They are covered by silicone when they leave the factory. This is to prevent dirt and sand from getting into the unit on initial start up. You can remove the silicone and clamps to replace the entire water management system.
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You could remove and/or replace the water management system by cleaning out the silicone. With pliers pull the clamps out on either side of the throat. .
Water Management Replacement.
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The most common mistake when rebuilding a unit is to leave the lower turbine cover out. Please replace it in the bottom now.
Replace the weight.
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Replace the frame. It is a tight fit and you must replace the frame by holding the back of the frame. Getting the front of the frame in place first. Then push back of frame down as close to the back of the unit as possible. Grab frame here
Four screws hold the frame in place. Remove the three that are exposed.
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Replace the three screws from the feed mast and pull it out of the unit. Making sure the o-ring at the base of the feed pipe is flush and clean. .
Replace the top.
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Replacing float. Head float gets pushed all the way forward to the cleaner.
Make sure the thrust jet is set at 11 o’clock.
Replace the sweep hose and sweep hose adjustment screw Screw it in until it bottoms out. Back it out 1 ½ to 2 turns. This will allow the sweep hose to sweep and not whip.
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Serial Number Serial Number is located on the frame and on the back of the unit.
Serial Number It is a bar code label
The product identifier.
It 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 won’t 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.
Cleaner only turns in one direction or is running in circles
Check the filter bag. If full, empty it or replace if needed.
Cleaner stays in one end of the pool, does not clean entire pool.
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 o’clock) (3900 = 7 o’clock)
Sweep hose sprays water out of the pool.
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Check WMS for obstructions.
Verify thrust jet is in the correct position. (180, 280, 480 = straight back), (360, 380 = 11 o’clock) (3900 = 7 o’clock) Verify thrust jet is in the correct position. (180, 280, 480 = straight back), (360, 380 = 11 o’clock) (3900 = 7 o’clock)
Verify thrust jet is in the correct position. (180, 280, 480 = straight back), (360, 380 = 11 o’clock) (3900 = 7 o’clock)
Check hoses, connections, and swivels for leaks.
Replace the sweep hose scrubber if it worn or missing.
With cleaner on, verify that vacuum jets have clear unobstructed flow.
Verify that all of the wheels are moving together. Check for broken belts.
With cleaner on, verify that vacuum jets have clear unobstructed flow.
Verify the back-up valve is cycling.
Check for proper flow by confirming proper PSI and than Proper RPM’s.
Check bearings are clear of debris and replace if worn.
Add a sweep hose weight, part #B2
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Polaris 380 - 3/11 46
