First Generation Plunge - DC80 to CJ07 Water Pump Retrofit
Updated
Applies to:First Generation Plunge replacing a DC80 water pump with a CJ07 water pump. Technician Note:Use accompanying step-by-step photos and video clips for visual reference.
Tools Required
8mm flex head hex nut driver
Drill with 8mm nut driver
Flathead screwdriver / Chisel
Utility knife or snips (for cutting zip ties)
Zip ties
Hose (if necessary)
Inline/immersion pump (if necessary)
Towel
First Generation Plunge DC80 to RJ07 Water Pump Replacement
Power Down The Plunge
Unplug the plunge from the wall
Drain The Plunge
Locate the external drain under the electrical box.
Turn the ball valve so the red valve is perpendicular to the tub
If the water needs to be drained to a different location use a hose and inline pump to move the water to a different location.
Disconnect Chiller Connections from Chiller
Disconnect the two chiller connections from the "in" and "out" ports on the chiller.
Set the chiller aside.
Set Plunge on Its Side
🚨There will still be water in the underneath plumbing so tipping the Plunge will result in water flowing out of the tub.🚨
Lay down a towel to protect the side of the plunge.
Slowly lay the Plunge on its side so that the component side of the Plunge is facing up.
First Generation Plunge DC80 to RJ07 Water Pump Replacement
Remove Water Pump Transformer
Disconnect the male and female connectors that is connecting the water pump and water pump transformer.
Using a flathead screwdriver carefully pry the transformer off the electrical box
NOTE:If you have a heater on your Plunge you will need to remove the Inkbird Relay from the inside of the electrical box before removing the water pump transformer.
Using an 8mm flex head nut driver remove the 4 bolts securing the Inkbird Relay
Replace Inkbird Outlet box , after the pump transformer has been removed.
Remove Water Pump From Tub
Using an 8mm nut driver remove the 4 screws that are securing the water pump to the tub.
If removing a DC80 pump:
Using an 8mm nut drive remove the 2 screws that are securing the pump controller the tub. (small black box near the water pump)
Disconnect the chiller connection that is attached to the top threads of the pump by unscrewing the union
Disconnect the water pump from the tub union.
Loosen Pump Elbow Bulkhead Nut
Locate under the tub where the water pump elbow connects to plumbing under the tub.
Using a flathead screw driver, or chisel, and dig out the insulation foam that surrounds the nut and threads.
Once enough foam is removed use a pair of pliers to loosen the nut securing the water pump bulkhead to the tub.
Install Water Pump to Tub
Screw the white union to the threads on the head of the water pump.
🚨Before securing the water pump to the tub with screws it must first be rotated up. The CJ07 pump is bigger than the DC80 and will hit the ground if it is not rotated.🚨
Once the pump is rotated enough that it will not rest on the ground when set upright:
Place the blue pad in between the pump mount and tub.
Using a drill and 8mm nut driver secure the pump to the tub using the 4 screws.
The screws are self tapping screws, so you do not need to pre drill holes in the tub.
Tighten Water Pump Elbow Bulkhead Nut
Using the pliers tighten the nut on the back side of the water pump elbow to secure the bulkhead to the tub.
Attach Water Pump Transformer to Outside of Electrical Box
🚨The water pump transformer must be mounted to the outside of the electrical box. DO NOT mount inside the electrical box.🚨
Plug the water pump plug into the lowest outlet of the power strip in the electrical box.
Locate the strip of tape on the back of the water pump transformer and remove the protective layer.
Attach the water pump transformer to the left exterior wall of the electrical box.
Press and hold the water pump transformer firmly against the left external wall of the electrical box for 20 seconds.
Attach Male & Female Water Pump Connections
Connect the cord coming from the water pump and the cord coming from the top of the water pump transformer.
Role up the extra wire and zip tie together.
Set Up and Fill Plunge with Water
Slowly and carefully set the tub right side up.
Connect the water pump chiller connection to the "in" port on the chiller.
Connect the filter chiller connection to the "out" port on the chiller
Using the hose filter fill the Plunge up with water
Test the Water Pump
Once the water is above the jets and side drain, power on the Plunge.
Confirm that water is flowing out of the jets and water is circulating in the tub.
Comments
3 comments
What about priming the pumps? Maybe add more instructions for that too for everyone?
Great suggestion Jasmine Sagner, we'll include that in the next revision.
How do you prime the pumps be for starting it. What happens if you don’t prime the pumps
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