Polaris Air Blowers Workbook

Zodiac Pool Systems, Inc. 1-800-822-7933 Regional ext. ______________ www.ZodiacPoolSystems.com Instructor_________________________________________________________________ext._________ Sales Representatives_______________________________________________________ext._________ _________________________________________________________________________ext._________ Service Manager___________________________________________________________ext._________ _________________________________________________________________________ext._________

TABLE OF CONTENTS
MODELS ......................................................................................................... BLOWER SIZING ............................................................................................. INSTALLATION ............................................................................................... TROUBLESHOOTING ..................................................................................... 5 6-9 10,11 12

Blower Models

Series 400 Qt Residential Blower

Model 1-460-01 1-460-02 1-470-01 1-470-02 1-480-01 1-480-02

Volts 120 240 120 240 120 240

Horsepower 1.0 HP 1.0 HP 1.5 HP 1.5 HP 2.0 HP 2.0 HP

Amps 6.8 3.8 7.5 4.0 9.0 5.6

Exhaust Direction Bottom Bottom Bottom Bottom Bottom Bottom

Series 500 Metal Residential Blower

120V Models 1-521-01 1-516-01 1-566-01 240V Models 1-521-03 1-516-03 1-566-03 Horsepower 1.0 HP 1.5 HP 2.0 HP Horsepower 1.0 HP 1.5 HP 2.0 HP Amps 6.8 7.5 9.0 Amps 3.8 4.0 9.0 Exhaust Direction Bottom Bottom Bottom Exhaust Direction Bottom Bottom Bottom

Blower Sizing Information

Sizing matches the proper blower with a specific set of air holes in a spa Blower motors are air-cooled. The amount of air required is determined by: the blower H.P the system back pressure and the number and size of the air holes/jets.

Measuring Air Flow

The air flow is measured in cubic feet per minute (CFM). Too little airflow over the motor will cause it to overheat and shut off. Too little airflow can damage the motor and reduce the brush life.

System Back Pressure

Measured in inches of water system back pressure (SBP) is the sum of the forces that restrict the ability of air to flow freely over the blower motor and through the spa plumbing.

These limiting forces include: Pipe diameter Number and type of elbows Length of run Check valves Number of spa jets Size of spa jets
As back pressure increases, airflow decreases, reducing the ability of the blower motor to stay within its normal operating temperatures.

Airflow Range for Blowers

Blower HP

Min Airflow

Max Airflow

Max Back Pressure

1.0 HP 1.5 HP 2.0 HP

30 SCFM 45 SCFM 50 SCFM

90 SCFM 90 SCFM 90 SCFM

45 water 45 water 50 water

Sizing A New Spa Blower

To size a blower for a new spa a formula is used which uses the system back pressure, the airflow required by the blower & the number and size of the holes required in the spas air channel

Sizing A New Spa Blower

STEP ONE: Calculate Back Pressure

Convert the spas Back Pressure as an inches of water measurement, Use the formula below and write the number in the box. Measure from water surface to air line in inches 30 divide by 10 = + No. of feet of 2" pipe ___ + No. of 90 elbows______ 4 x .5 = + No. of 45 elbow ______ x .125 = + No. of lb. check valves ______ 1 x4= Total Back Pressure (inches of water) =

30 ________ 3 ________ 2 ________ ________ ________ 4 39

Sizing A New Spa Blower

STEP TWO: Determine the Airflow Locate the Total Back Pressure on the left side of the chart and draw a horizontal line. Note where your drawn line intersects at each dashed line. Read directly down to determine the necessary airflow for that size blower.

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Sizing A New Spa Blower

STEP THREE: Calculate the Required Number of Air Holes Choose an air hole size from the Hole Sizing Chart on the next slide. Record the adjacent Conversion Factor on the second line of the formula. Multiple the Total Airflow by the Conversion Factor to determine how many holes of that size are needed to achieve the necessary air flow.

Air Hole Sizing Chart

Air Hole Size 1/8" 5/32" 3/16" 1/4" 3/8" 1/2" Jet Conversion 2.4 1.5 1.1 0.6 0.27 0.15 0.1

Sizing A New Spa Blower

Total Airflow (SCFM) From Step 2 Conversion Factor for 1/8 Number of Holes Required

39 ________ 2.4 X ________

=

94

Note: Fewer holes than required will cause increased back pressure along the dashed line. Do not increase back pressure beyond minimum airflow for your blower!

Sizing An Existing Spa Blower

STEP ONE: Calculate Back Pressure

Too many holes will result in no air blowing from them.

To determine the spa's Back Pressure as an inches of water measurement, use the formula below.

Measure from water surface to air line (inches) ________ + No. of feet of 2" pipe ___ divide by 10 = + No. of 90 elbows______ x .5 = + No. of 45 elbow ______ x .125 = + No. of lb. check valves ______ x 4 = Total Back Pressure (inches of water) = ________ ________ ________ ________

Sizing An Existing Spa Blower

STEP TWO: Calculate the airflow that the spa will allow

Count the number of spa jets Total Airflow spa will allow

number of jets ________ X 10 =

OR
Measure the size AND count the number of air holes in the spa Number of existing air holes _______ Conversion Factor of Air hole size Total Airflow spa will allow = _______

Sizing An Existing Spa Blower

STEP THREE: Determine the Proper Blower Refer to the Blower Performance Chart on the next slide Draw a horizontal line across from your calculated Back Pressure. Draw a vertical line up from your calculated Airflow Select the blower closest to the intersection of the two lines If the intersection occurs between dashed lines, select the blower whose curve is below the intersection If there is no curve below the intersection point, choose the first curve to the right of the intersection point. Remember: Improper sizing can cause blower damage that is not covered under warranty. Remember that bigger is not necessarily better.

Sizing A Existing Spa Blower

STEP TWO: Determine the Airflow
Locate the Total Back Pressure on the left side of the chart and draw a horizontal line. Note where your drawn line intersects at each dashed line. Read directly down to determine the necessary airflow for that size blower.

Installation Guidelines
Series 400 Aboveground QT Blowers Polaris aboveground residential blowers are specially designed for installation in noise-sensitive environments. Like other Polaris blowers, the QT is thermally protected by a patented thermal valve. This valve prevents overheating from excessive back pressure, and reduces the chance of motor damage or blower shutdown. Please Note: It is necessary to use 2" PVC pipe. As sizing is based on 2" PVC piping, the use of 11/2" PVC can cause problems. 1. 2. 3. Ensure the blower is properly sized. Improper sizing will reduce the life of the blower. Pressure test the system prior to installation. This will prevent potential leakage or loss of air. Please Note: This is especially important when using a Hartford loop. To install above the water level, the blower airloop or standpipe must stand at least 12" above the water level. Installing at a lower level can cause water damage, and is contrary to U.L. requirements. When using the Polaris blower to supercharge the jets, a 1/2 lb. U.L. listed check valve must be installed between the blower and the jets to prevent possible damage to the blower.

4.

Installation 5-25 From Spa

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Installation Over 25 From Spa

5. If the blower is to be installed more than 25 feet from the spa, an air loop must be installed 12" above the spa as close to the spa as possible. The air loop will prevent the entire blower line from filling with water and overworking the blower. 6. Always install a check valve in an accessible location for ease of service.

Installation Below Water Level

7. If the blower is to be installed below the water level, or if the blower air line drops below the bottom of the spa, a special plumbing configuration known as the Hartford Loop must be used to prevent the air line from filling with water. This installation method will require a 1/2 lb. U.L. listed check valve with no plumbing leaks and the top of the loop must be within 4" of the surface of the spa.

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Installation Guidelines
8. Do not install adjustable jets with the Polaris blower. Adjusting the jets can cause excessive back pressure. 9. Do not remove the surge protector, as this will cause damage to the blower. 10. Do not glue the blower to the standpipe. Glue fumes can potentially cause the blower to explode upon startup. If necessary, install a self-tapping screw to secure the blower to the standpipe. 11. Measuring the current draw under load using an amp meter. The maximum acceptable amp reduction due to back pressure is 1.0 amp for 120V motors or 0.5 amp for 240V motors.

Troubleshooting

PROBLEM
Water Damage

SYMPTOM
Corrosion on winding side of motor Calcium deposits inside blower

CAUSE
Blower or Hartford loop too low No check valve Too close to sprinklers Mounted upside down without protection

Back Pressure

Separation of housing Black carbon build-up Melting of housing Motor Failure Blower shuts off

Too small OR too few air holes More than 8-90 elbows in line Blockage Plumbed with less than 2 pipe Very long run Improperly sized Check valve greater than 1/2lb

Motor worn out

Brushes worn out quickly Installed on commercial spa

Residential blower on commercial spa Wired into circulation system

Explosion

Fan locked / Puffed on top Casing separated

PVC glue fumes ignited

110V wired 220V

Brushes gone

Improper wiring

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Polaris Blower Workbook 3-2012 16