The Plunge (Generation 1) — DC60/DC80 to CJ07 pump conversion — Plumbing modification

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.

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
• If you temporarily removed the Inkbird outlet module, reinstall it in its original position after the old pump transformer has been removed, using its original mounting hardware.

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. 
• "Warning" After water pump is removed, line up the new pump to check if the plumbing lines connect. If it does, follow these steps DC60/DC80 to CJ07 conversion — direct fit
• If plumbing doesn't line up, proceed to the next steps.

Remove Insulation Foam to Expose Plumbing

• 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.

Remove Water Pump Elbow & Bulkhead

• Cut the flex hose 6" back from where it is glued into the back of the bulkhead.
• Using pliers unscrew the nut from the threads on the back side of the bulkhead.
• Remove the elbow and 6" of flex hose that you cut by pulling it out of the hole in the side of the tub.

Install Water Pump Elbow Bulkhead

• Apply the adhesive manufacturer’s required surface preparation to every solvent-welded joint below before applying cement, including the hard pipe, elbow, union and bulkhead joints.
• Prepare the pipe or hose and mating fitting surfaces according to the adhesive manufacturer’s instructions, using only the cleaner and primer specified for the actual materials. Do not treat acetone as a substitute for a required primer. If the compatible products or preparation instructions are unclear, stop and obtain them from Repairs before bonding.
• Glue the coupler to the underneath plumbing
  • Thoroughly coat the outside of the flex hose with the PVC cement glue
  • Thoroughly coat the inside of the coupler with PVC cement glue
  • Slide the coupler onto the flex hose until it stops and twist the coupler a quarter twist.
  • Allow the joint to set for assembly as directed by the adhesive manufacturer. The two-minute set interval shown in the original procedure is not a cure time or permission to refill, pressurize or use the Plunge.
• Prepare the pipe or hose and mating fitting surfaces according to the adhesive manufacturer’s instructions, using only the cleaner and primer specified for the actual materials. Do not treat acetone as a substitute for a required primer. If the compatible products or preparation instructions are unclear, stop and obtain them from Repairs before bonding.
• Glue spare flex hose into the backside of the new bulkhead
  • Thoroughly coat the outside of the flex hose with the PVC cement glue
  • Thoroughly coat the inside of the bulkhead with PVC cement glue
  • Slide the flex hose into the backside of the bulkhead until it stops and twist the flex hose a quarter twist.
  • Allow the joint to set for assembly as directed by the adhesive manufacturer. The two-minute set interval shown in the original procedure is not a cure time or permission to refill, pressurize or use the Plunge.
• Using hose cutters, cut the spare flex hose to a length that allows it to be glued into the other side of the coupler
• Prepare the pipe or hose and mating fitting surfaces according to the adhesive manufacturer’s instructions, using only the cleaner and primer specified for the actual materials. Do not treat acetone as a substitute for a required primer. If the compatible products or preparation instructions are unclear, stop and obtain them from Repairs before bonding.
• Glue the spare flex hose into the coupler
  • Thoroughly coat the outside of the flex hose with the PVC cement glue
  • Thoroughly coat the inside of the coupler with PVC cement glue
  • Slide the coupler onto the flex hose until it stops and twist back and forth to seal cement glue.
  • Allow the joint to set for assembly as directed by the adhesive manufacturer. The two-minute set interval shown in the original procedure is not a cure time or permission to refill, pressurize or use the Plunge.
• Tighten bulkhead nut using pliers. 

Assemble Elbow & AB Union

• Glue the hard pipe into the 90 degree elbow. 
  • Thoroughly coat the outside of the hard pipe with the PVC cement glue
  • Thoroughly coat the inside of the 90 degree elbow with PVC cement glue
  • Slide the hard pipe into the 90 degree elbow until it stops and twist the hard pipe a quarter twist.
  • Allow the joint to set for assembly as directed by the adhesive manufacturer. The two-minute set interval shown in the original procedure is not a cure time or permission to refill, pressurize or use the Plunge.
• Glue the AB union onto the other end of the elbow.
  • Thoroughly coat the outside of the elbow with the PVC cement glue
  • Thoroughly coat the inside of the AB union with PVC cement glue
  • Slide the AB union onto the elbow until it stops and twist the AB union a quarter twist.
  • Allow the joint to set for assembly as directed by the adhesive manufacturer. The two-minute set interval shown in the original procedure is not a cure time or permission to refill, pressurize or use the Plunge.
      

Install Water Pump to Tub

Glue the 90 degree elbow into the front of the bulkhead. The elbow will be facing left when looking at the side of the tub.

🚨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.🚨

• Thoroughly coat the outside of the PVC pipe with the PVC cement glue
• Thoroughly coat the inside of the bulkhead with PVC cement glue
• Slide the PVC pipe into the bulkhead until it stops and twist the coupler a quarter twist.
• Allow the joint to set for assembly as directed by the adhesive manufacturer. The two-minute set interval shown in the original procedure is not a cure time or permission to refill, pressurize or use the Plunge.
• 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.

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.

Confirm adhesive cure before refilling

Before adding water, follow the adhesive manufacturer’s full cure and return-to-service instructions for the actual adhesive, pipe materials, joint size and installation conditions. If the product or applicable instructions cannot be identified, stop and obtain them from Repairs. Do not substitute the original two-minute assembly interval for this check.

Set Up and Fill Plunge with Water

Follow the matching Generation 1 setup guide for the final fill level and power sequence: Hot/Cold or Cold Only.

• Reconnect the chiller-hose union removed from the top of the old pump to the replacement pump's matching outlet. Confirm that the union is seated before refilling.
• Slowly and carefully set the tub right side up.
• Connect the water pump chiller connection to the "in" port on the chiller.
• Close the external drain valve before adding water.
• Using the hose filter, fill the Plunge until it is half full. Do not connect the filter-side OUT connection before the Plunge is half full.
• Connect the filter chiller connection to the "out" port on the chiller
• After connecting the OUT connection, finish filling to the level specified in the matching Generation 1 setup guide.
• Inspect the disturbed plumbing connections for leakage before restoring power. Do not power the Plunge if a leak is present.

Test the Water Pump

• With the main supply still unplugged, disconnect the chiller and heater (if fitted) supply plugs from their verified outlets for the first circulation check. Confirm that the electrical connections and enclosure are dry. Close the electrical enclosure before reconnecting wall power.
• With the Plunge filled to the setup-guide level and the heater/chiller supply plugs still disconnected, restore main power to run the circulation pump as directed by the matching Generation 1 setup guide.
• Confirm that water is flowing out of the jets and water is circulating in the tub. Do not enable cooling or heating until flow is confirmed. If no water flows from the jets, stop and obtain Support instructions.
• With water circulating, inspect the disturbed plumbing connections again for leakage. If a leak appears, switch off and unplug the Plunge before making any adjustment.
• Only after flow and leak checks pass, switch off and unplug the main supply again before opening the enclosure to reconnect the chiller and heater (if fitted) to their verified outlets according to the matching Generation 1 setup guide. Close the dry enclosure, restore power and confirm flow continues before normal heating or cooling. Set the intended temperature using that guide.