Pentair STA-RITE DURA-JET 5DJ Series User manual

50 Hz. DURA-JETTM SPA PUMP
5DJ Series
O W N E R’ S M A N U A L
INSTALLATION, OPERATION & PARTS
Sta-Rite Pool/Spa Group
293 Wright Street, Delavan, WI 53115
North America: 800-752-0183, FAX [phone]
International: 262-728-5551, FAX: [phone], TELEX: ITT 4970245
www.sta-ritepool.com
Union City, TN • Delavan, WI • Mississauga, Ont. • Murrieta, CA
Printed in U.S.A. ©2003, Sta-Rite Industries, Inc. SX377 (3/7/03)
This manual should be furnished to
the end user of this pump; its use
will reduce service calls, chance of
injury, and will lengthen pump life.

READ AND FOLLOW ALL
INSTRUCTIONS!
This is the safety alert symbol. When you see this
symbol on your system or in this manual, look for
one of the following signal words and be alert to the po-
tential for personal injury.
warns about hazards that will cause death,
serious personal injury, or major property damage if
ignored.
warns about hazards that can cause death,
serious personal injury, or major property damage if
ignored.
warns about hazards that will or can cause
minor personal injury or property damage if ignored.
NOTICE indicates special instructions not related to
hazards.
Carefully read and follow all safety instructions in this
manual and on equipment. Keep safety labels in good
condition; replace if missing or damaged.
Incorrectly installed or tested equipment
may fail, causing severe injury or property
damage.
Read and follow instructions in owner's
manual when installing and operating equipment. Have a
trained pool professional perform all pressure tests.
1. Do not connect system to a high pressure or city water
system.
2. Use equipment only in a pool or spa installation.
3. Trapped air in system can cause explosion. BE SURE
all air is out of system before operating or testing
equipment.
Before pressure testing, make the following safety
checks:
•Check all clamps, bolts, lids, and system accessories
before testing.
•Release all air in system before testing.
•Water pressure for test must be less than 25 PSI
(172 kPa).
•Water Temperature for test must be less than 100oF
(38oC).
•Limit test to 24 hours. After test, visually check system
to be sure it is ready for operation.
NOTICE: These parameters apply to Sta-Rite
equipment only. For non-Sta-Rite equipment,
consult manufacturer.
2
DURA-JET SPA PUMP
To avoid unneeded service calls, prevent possible injuries, and get the most out of your pump,
READ THIS MANUAL CAREFULLY!
The Sta-Rite ‘5DJ’ Series Spa Pump:
• Is designed to circulate hot water in spas and hot tubs.
• Is an excellent performer; durable, reliable.
IMPORTANT
SAFETY INSTRUCTIONS
Always follow basic safety precautions with this
equipment, including the following.
To reduce the risk of injury, do not per-
mit children to use this product unless they are closely
supervised at all times.
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 con-
structed so that it may be readily disassembled for stor-
age and reassembled to its original integrity.
SAVE THESE
INSTRUCTIONS

3
INSTALLATION
Installation and wiring of pump should only be done by
qualified, licensed personnel.
Pump mount must:
Be Solid - Level - Rigid - Vibration free. (To reduce vibra-
tion and pipe stress, bolt pump to mount.)
Be installed with pump suction inlet below water level at
all times (this allows pump to prime).
Be installed with pump discharge below water level at all
times (to avoid trapped air in discharge line).
Allow discharge line to be level or slope slightly up to
heater, spa, or pool.
Have adequate drainage to prevent flooding.
Be protected from excess moisture.
Allow adequate access for servicing pump and piping.
Ventilation:
Provide adequate ventilation to prevent motor overheat-
ing.
For continuous running, motor hot air exhaust must be
able to escape motor compartment.
Piping:
Use flexible or rigid PVC pipe for connections to pump.
Suction/discharge piping gate valves will allow removal
for servicing.
Use at least 1-1/2" IPS pipe.
Fittings restrict flow; for best efficiency use fewest possi-
ble fittings.
Pump will not prime if suction pipe leaks.
Unions are provided. Use as follows for leak-free connec-
tions to pump:
1. ‘O’ Ring and sealing surfaces must be clean.
2. Assemble handtight only! (NO WRENCHES!)
3. NO pipe compound or Teflon tape on unions.
4. Bond pipe to unions with PVC cement.
Use PVC cement only in a well ventilated
area away from flame; FOLLOW MANUFACTURER‘S
INSTRUCTIONS!
Spa Fittings:
Size and number of jets will have a major effect on jet
action.
Typical installations use up to four 7/8" or 3/4" diameter
jets or up to seven 1/2" diameter jets.
Spa fittings must meet International Association of
Plumbing and Mechanical Officials (IAPMO) standards.
Use only non-entrapping suction fittings or
double suction.
ELECTRICAL
Hazardous voltage. Can shock, burn,or
cause death. Ground pump before connecting to power
supply.
Ground motor before connecting to electrical
power supply! Failure to ground pump motor can
cause serious or fatal electrical shock hazard!
Do not ground to a gas supply line!
To avoid dangerous or fatal electrical shock, turn
OFF power to motor before working on electrical
connections.
GFCI tripping indicates an electrical problem. If
GFCI trips and will not reset, have a qualified elec-
trician inspect and repair electrical system.
Exactly match supply voltage to nameplate voltage
(110 Volt or 220 Volt 50 Hz single phase only)!
Incorrect voltage can cause fire or seriously damage
motor and voids warranty!
Grounding:
Install, ground, and wire motor according to local code
requirements.
Permanently ground motor; use size and type wire re-
quired by code.
Ground connection must be made to green grounding
terminal.
Connect motor ground terminal to electrical service
ground.
Install and bond pump according to local codes and ordi-
nances; use bonding lug on motor (see Figure 1). Use
solid copper conductor 8.4mm2or larger.

4
Wiring:
See the wiring diagram on the motor housing for wiring
connection information. Pump must be permanently con-
nected to circuit.
Install a Ground Fault Circuit Interrupter (GFCI) in circuit;
it will sense a short-circuit to ground and disconnect
power before it becomes dangerous to pool users. For
size of GFCI required and test procedures for GFCI, see
manufacturer’s instruction.
In case of power outage, check GFCI for tripping (which
will prevent normal pump operation). Reset if necessary.
NOTICE: If you do not use conduit when wiring motor,
be sure to seal wire opening on end of motor to prevent
dirt, bugs, etc., from entering.
Voltage:
Voltage at motor must be not more than 10% above or
below motor nameplate rated voltage or motor may over-
heat, causing overload tripping and reduced component
life. If voltage is less than 90% or more than 110% of
rated voltage when motor is running at full load, consult
power company.
Motor Black (Common) Black (Common)
Hi-Speed
Line
Brown
White
Blue
Low-Speed
Line
Hi-Speed
Capacitor
Low-Speed
Capacitor
Ground Wire
Left Side Right Side
Green
Blue
(4 Poles)
Brown
(2 Poles)
4349 0303
Motor Black Black
Line
Blue
Line
Brown
White
Capacitor
Ground Wire
Left Side Right Side
Figure 1: Single speed electrical connections.
Figure 2: Two speed electrical connections.

5
OPERATION
Priming Pump:
NEVER run pump dry! Running pump dry
may damage seals, causing leakage and flooding! Fill
pump with water before starting motor.
Do not add chemicals to spa system directly in
front of pump suction. Adding undiluted chemicals
may damage pump and voids warranty.
Open gate valves before starting system.
Pump will prime itself when used in flooded suction
system.
Be sure to release all air from filter and piping system; see
spa/filter owner’s manual.
On two speed models, low speed is used for filtration and
heating; high speed provides therapy jet action.
Do not block pump suction! To do so with body
may cause severe or fatal injury. Small children
using spa must ALWAYS have close adult supervision!
•Tub should have dual suction outlets to prevent body
or hair entrapment.
•Use only tub suction fittings certified to meet
ASME/ANSI standard A112.19.8M-1987.
NOTICE: Do not block jets! To do so may flood area
causing damage to equipment and water damage to sur-
rounding area.
Water:
Keep water level at least two inches above bottom of
skimmer opening when system is not in use. Failure to do
so can allow air to enter system, causing pump to lose its
prime.
Keep water temperature at 104°F (40°C) or below.
Keep an accurate thermometer in spa; check it before
getting in.
Age or health conditions may require a lower tempera-
ture; consult a physician for more information.
If in doubt, start at a lower temperature and gradually in-
crease it according to your experience, but do not in-
crease it above 104°F.
Do not use or allow the use of the tub by anyone
using alcohol or drugs. The effects of hot water, al-
cohol and/or drugs can cause dizziness and falling, loss
of consciousness, or heart attack.
A long bath in hot water may cause hyperthermia
(too much heat in the body) which can be fatal.
Some symptoms of hyperthermia are:
• Nausea
• Dizziness
• Fainting
If these symptoms appear while in the spa, GET OUT AT
ONCE!
Cool the body at once with cold towels or a cool shower.
Call a doctor if symptoms do not go away.
Too much heat
can cause nausea,
dizziness,
fainting, or death.
Check temperature.
before using tub.
Hazardous suction.
Can trap hair or
body parts, causing
severe injury
or death.
Do not block
suction.

6
PUMP SERVICE
Hazardous voltage. Can shock, burn,or
cause death. Disconnect power before working on pump
or motor.
Pump should only be serviced by qualified personnel.
To avoid dangerous or fatal electrical shock haz-
ard, disconnect power to motor before working on
pump or motor!
No lubrication or regular maintenance are needed.
If shaft seal is damaged, repair as follows:
Removing Old Seal:
1. Disconnect power to pump motor.
2. Drain tub and pump; disconnect unions to allow ac-
cess to pump.
3. Remove four bolts holding front plate to seal plate; re-
move front plate.
4. Remove shaft cover or motor canopy; using screw-
driver in slot on motor end of shaft or wrench on flats
of shaft extension, hold pump shaft and unscrew im-
peller from shaft (turn counterclockwise). Rotating half
of seal will come off with impeller.
5. Carefully remove rotating part of seal from impeller
sleeve by pulling and turning on sealing washer and
spring (Figure 3). Do not damage impeller surface
where drive ring seats and seals.
6. Carefully remove four motor throughbolts from seal
plate (Figure 4); remove seal plate and use a screw-
driver to tap ceramic seat out from the rear (Figure 5).
Do not damage seal cavity in seal plate.
7. Clean cavity from which seal was removed and clean
motor shaft.
8. Inspect water slinger for damage. Replace if needed.
Installing New Seal:
1. Ceramic seat must be clean and free of dirt, grease,
dust, etc. Wet rubber cup gasket of ceramic seat with
small amount of water; press into cavity firmly and
squarely with finger pressure (Figure 6).
2. If ceramic seat will not locate properly, remove it,
place face up on bench, and reclean cavity. Ceramic
seat should now locate.
3. Seal must be free of dirt, grease, grit, scratches or
chips; be sure impeller sleeve is clean. Slide seal as-
sembly, rubber drive ring first, onto impeller sleeve
until drive ring bottoms on impeller back shroud.
4. Slip water slinger over motor shaft; remount seal plate.
Torque throughbolts to 25 inch-lbs. (29 cm-kg).
5. Screw impeller onto motor shaft until it seats against
motor shaft shoulder. Work water slinger over end of
impeller sleeve so it rides on sleeve (Figure 7).
6. Remount front plate to seal plate.
7. Reconnect unions; tighten hand tight only.
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7

7
STORAGE/
WINTERIZING
To prevent damage to components from
fumes, store spa chemicals away from pump and spa. If
possible, store chemicals in another room.
Allowing pump to freeze will damage pump and
void warranty!
Drain all water from pump and piping when expecting
freezing temperatures or when storing pump for a long
time (see instructions below).
Keep motor dry and covered during storage.
To avoid condensation/corrosion problems, do not cover
or wrap pump with plastic.
For outdoor/unprotected pump installations:
1. Enclose entire system in a weatherproof enclosure.
2. To avoid corrosion damage, allow ventilation; do not
wrap system in plastic.
Follow spa manufacturer’s directions for storage of spa.
Draining Pump:
Hazardous voltage. Can shock, burn,or
cause death. Disconnect power before working on pump
or motor.
To avoid dangerous or fatal electrical shock haz-
ard, turn OFF power to motor before draining
pump.
NOTICE: Do not use anti-freeze solutions (except propy-
lene glycol) in your spa system. Most anti-freezes are
hightly toxic and may damage plastic components in the
system. Propylene glycol is non-toxic and will not dam-
age pump components.
1. Close all valves on suction and return piping.
2. Remove drain plug in bottom of front plate.
3. Drain all piping and storage tanks exposed to freezing
temperatures.
4. Be sure no airlocks are holding water in system.
5. Consult spa and filter owner’s manuals for instructions
about draining the rest of the system.
NOTICE: We recommend a drain plug or valve at the
low point of the spa piping to help drain spa system.
6. Before restarting, replace all plugs and make sure all
pipe connections are tightly sealed.
Startup for Winterized Equipment:
1. Remove any temporary weather protection placed
around system for shutdown.
2. Follow filter manufacturer’s instructions for reactiva-
tion of the filter.
3. Inspect all electrical wiring for damage or deteriora-
tion over the shutdown period. Have a qualified ser-
viceman repair/replace wiring as needed. Inspect and
tighten all watertight connections.
4. Open all valves in suction and return piping.
5. Remove all winterizing plugs in spa system.
6. Remove all anti-freeze solutions from system.
7. Close all drain valves and replace all drain plugs in
spa system.
8. Fill spa with water to proper level (see spa manufac-
turer’s instructions).

8
TROUBLESHOOTING
GUIDE
Read and understand safety and operating
instructions in this manual before doing any work on
pump!
A. PUMP DOES NOT OPERATE
1. Check GFCI for proper operation according to GFCI
manufacturer’s instructions.
2. Check for plugged impeller. Follow disassembly/as-
sembly instructions under “ Pump Service”, Page 9.
3. Consult dealer/installer or service representative.
B. IMPROPER JET ACTION
1. Check for blocked fittings. Blocked fittings will cause
poor flow and poor jet action.
2. Consult dealer/installer or service representative.
C. EXCESSIVE AIR IN SYSTEM – PUMP LOSES PRIME
1. Make sure water level in spa is at least 2" (51 mm)
above top of jets with system not operating.
2. Make sure there are no leaks in suction piping.
3. Make sure there is no vortex (whirlpool) at the suction.
4. Consult dealer/installer or service representative.
D.CIRCUIT BREAKER IN HOME PANEL TRIPS
REPEATEDLY
1. Breaker must be of adequate capacity.
2. For GFCI breaker: test according to GFCI manufac-
turer’s instructions.
3. Make sure no other lights and appliances are on circuit.
4. Consult dealer/installer or service representative.