STA-RITE DURA-JET 5JSAC-A User manual

DURA-JETTM 230 VOLT, 50Hz SPA PUMP
O W N E R’ S M A N U A L
INSTALLATION, OPERATION & PARTS
MODELS
1/2 HP 3/4 HP 3/4 HP
5JSAC-A 5JSAD-A 5JSAYD-A
(2-Speed)
Sta-Rite Pool/Spa Group
293 Wright Street, Delavan, WI 53115
International: 262-728-5551, FAX: [phone]
www.starite.com
Union City, TN • Delavan, WI • Mississauga, Ont. • Murrieta, CA
© 2005, Sta-Rite Industries S223 (Rev. 1/26/06)
This manual should be furnished to
the end user of this pump; its use
will reduce service calls and chance
of injury and will lengthen pump life.

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 ‘JS’ Series Spa Pump:
• Is designed to circulate hot water in spas and hot tubs.
• Is an excellent performer; durable, reliable.
Table of Contents
Safety Instructions ......................................................................................3
Installation ..................................................................................................4
Electrical-Grounding ...................................................................................5
Wiring .....................................................................................................5-6
Operation ...................................................................................................7
Pump Service...........................................................................................8-9
Storing/Winterizing ................................................................................9-10
Troubleshooting Guide..............................................................................11
Repair Parts List.........................................................................................12

3
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 potential for personal injury.
warns about hazards that will cause death, serious personal in-
jury, or major property damage if ignored.
warns about hazards that can cause death, serious personal in-
jury, 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 equip-
ment. 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 per-
form 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. Remove trap lid and retighten hand tight only.
NOTICE: These parameters apply to Sta-Rite equipment only. For
non-Sta-Rite equipment, consult manufacturer.
To reduce the risk of injury, do not permit children to use this
product unless they are closely supervised at all times.

4
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 vibration 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 overheating.
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" (48mm) IPS pipe.
Fittings restrict flow; for best efficiency use fewest possible fittings.
Pump will not prime if suction pipe leaks.
Unions are provided. Use as follows for leak-free connections 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 fitting or dou-
ble suction.

5
ELECTRICAL
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 electrician inspect and repair electrical system.
Exactly match supply voltage to nameplate voltage (230 Volt, 50Hz,
single phase only)! Incorrect voltage can cause fire or seriously
damage motor and voids warranty!
Grounding:
Install, ground, and wire motor according to local or National Electrical Code
requirements.
Permanently ground motor; use size and type wire required by code.
Ground connection must be made to green grounding terminal under motor
canopy or access plate (see Figure 1).
Connect motor ground terminal to electrical service ground.
Install and bond pump according to local codes and ordinances; use bonding
lug on motor (see Figure 1). Use solid copper conductor No. 8 AWG (8.4mm2)
or larger.
Wiring:
Pump must be permanently connected to circuit. Table I, Page 6, gives correct
wire and circuit breaker sizes for the pump alone. If other lights or appliances
are also on the same circuit, be sure to add their amp loads to pump amp load
before figuring wire and circuit breaker sizes. (If unsure how to do this or if
this is confusing, consult a licensed electrician.) Use the load circuit breaker
as the master on-off switch.
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 manufac-
turer’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.
Hazardous voltage.
Can shock, burn,
or cause death.
Ground pump before
connecting to
power supply.
BONDING
LUG
MOTOR NAMEPLATE
GREEN
GROUND
SCREW
MOTOR
CANOPY
THROUGH
BOLTS 499 0993
Figure 1A: Typical ground screw and
bonding lug locations.
White
230
Volt
Lines
A
B
L2
L1
Bl
ue
Figure 1B. Motor terminal block
connections.
230 Volt Hookup

6
Voltage:
Voltage at motor must be not more than 10% above or below motor name-
plate rated voltage or motor may overheat, causing overload tripping and re-
duced 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.
Values given in tables below are for PUMP MOTOR ONLY. If addi-
tional spa accessories are installed on pump motor circuit (heater,
blower, etc.), include their amperage draw when figuring wire and circuit
breaker sizes.
L2
B
A
L1
Lo
Hi
Timer Motor
Supply
Lo
Hi
Circuit
Protector
Remote
SPDT
Switch
Ground
(Green)
Common
Remote Switching For 2-Speed Pumps
Timer (optional)
Low Speed Only
Minimum switch and timer amp rating must equal Branch Fuse Rating
given in "Recommended Circuit Breaker Size and Wiring Data" table.
TABLE I - RECOMMENDED CIRCUIT BREAKER SIZE AND WIRING DATA FOR 50 Hz MOTORS
Branch AWG (mm2) Wire Gauge Size
Max Circuit Dist in Ft. (M) - Service to Motor
Model Motor Load Breaker 0-100 101-200 201-300 Temp
No. HP Volts Amps Amp Rating (0-30) (31-60) (61-90) Deg. C.
Single Speed Pumps:
5JSAC-A 1/2 230 4.0 15 14 (2.0) 14 (2.0) 14 (2.0) 75
5JSAD-A 3/4 230 4.7 15 14 (2.0) 14 (2.0) 14 (2.0) 75
Two Speed Pumps:
5JSAYD-A 3/4 230 4.7 15 14 (2.0) 14 (2.0) 14 (2.0) 75

7
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!
NOTICE: Do not block jets! To do so may flood area causing damage to
equipment and water damage to surrounding 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.
Age or health conditions may require a lower temperature; consult a physi-
cian for more information.
If in doubt, start at a lower temperature and gradually increase it according to
your experience.
Keep an accurate thermometer in bath; check it before getting in.
Do not use or allow the use of the spa by anyone using alcohol or
drugs. The effects of hot water, alcohol and/or drugs can cause dizzi-
ness 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.
Hazardous suction.
Can trap hair or
body parts, causing
severe injury
or death.
Do not block
suction.
Too much heat
can cause nausea,
dizziness,
fainting, or death.
Check temperature.
before using tub.

8
PUMP SERVICE
Pump should only be serviced by qualified personnel.
To avoid dangerous or fatal electrical shock hazard, 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 spa and pump; disconnect unions to allow access to pump.
3. Remove six bolts holding front plate to seal plate; remove front plate.
4. Remove shaft cover or motor canopy; using screwdriver in slot on motor
end of shaft or wrench on flats of shaft extension, hold pump shaft and un-
screw impeller 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 2). Do not damage impeller
surface where drive ring seats and seals.
6. Carefully remove four motor throughbolts from seal plate (Figure 3); remove
seal plate and use a screwdriver to tap ceramic seat out from the rear
(Figure 4). Do not damage seal cavity in seal plate.
7. Clean cavity from which seal was removed and clean motor shaft.
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 liquid detergent; press into
cavity firmly and squarely with finger pressure (Figure 5).
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 assembly, rubber drive ring first, onto impeller
sleeve until drive ring bottoms on impeller back shroud.
4. Slip slinger over shaft; remount seal plate. Torque throughbolts to 25 inch-
lbs. (29 cm-kg).
Hazardous voltage.
Can shock, burn,
or cause death.
Disconnect power
before working
on pump or motor.
Figure 2
Figure 3
Figure 4
Figure 5

9
5. Screw impeller onto shaft until it seats against shaft shoulder. Work slinger
over end of impeller sleeve so it rides on sleeve (Figure 6).
6. Remount front plate; using pattern, shown in Figure 7, torque bolts to 30
inch-lbs. (34.5 cm-kg). BE SURE to start with bolt in 3 o’clock position as
shown.
7. Reconnect unions; tighten hand tight only.
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.
Figure 6
Figure 7 – Torque Sequence
#1
#6
#2
#5 #3
#4
Start
Here

10
Draining Water
To avoid dangerous or fatal electrical shock hazard, turn OFF power to
motor before draining pump.
NOTICE: Do not use anti-freeze solutions (except propylene glycol)
in your spa system. Most anti-freezes are highly toxic and may dam-
age plastic components in the system. Propylene glycol is non-toxic
and will not damage 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 the 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 shut-
down.
2. Follow filter manufacturer’s instructions for reactivation of the filter.
3. Inspect all electrical wiring for damage or deterioration over the shutdown
period. Have a qualified serviceman 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 manufacturer’s instructions).
Hazardous voltage.
Can shock, burn,
or cause death.
Disconnect power
before working
on pump or motor.

11
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 in-
structions.
2. Check for plugged impeller. Follow disassembly/assembly instructions
under “ Pump Service”, Page 8.
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 sys-
tem 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 manufacturer’s instructions.
3. Make sure no other lights and appliances are on circuit.
4. Consult dealer/installer or service representative.

12
1
2
3
4
5
6
78
9
10
11
12
13
14
14B
5
4
3
• Not illustrated.
REPAIR PARTS LIST
DURA-JETTM
230 VOLT, 50Hz,
SPA PUMP
Parts are common to all models listed except as noted;
Key Nos. 1, Motor; and 8, Impeller, are listed below.
Model Motor No. Impeller No.
No. HP (Key No. 1) (Key No. 8)
230 Volt Single Speed
5JSAC-A 1/2 C218-297 C105-228PB
5JSAD-A 3/4 C218-298 C105-229PA
230 Volt Two Speed
5JSAYD-A 3/4 C218-299 C105-229PA
Key Part
No. Description Qty. Number
1 Motor 1 Chart at Right
2 Slinger 1 C69-23
3 Collar, Union 2 U11-182P1
4 Adapter, Union 2 U11-183P1
5 “O” Ring, 2 U9-226P
6 Seal Plate 1 C1-260P
7 Seal 1 U9-358SS
8 Impeller 1 Chart at Right
9 “O” Ring 1 U9-357
10 Front Plate 1 C101-262P
11 Washer, 1/4 Flat 6 U43-117SS
12 Washer, 1/4 Lock 6 U43-10SS
13 Screw, 1/4-20x1-3/4 6 U30-873SS
14 Drain Plug 1 U178-920P
14B Pipe Plug 2 WC78-40T
• Nameplate 1 U33-155
• Decal - “For Use with Pools
and Spas” 1 U27-635
• Voltage Label - 230V 1 U27-68
• Warning Tag 1 C63-12
• Caution Tag 1 U27-599