Stenner Pumps Classic Series Basic Service Manual Download Page 5

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TOOL LIST AND CLEANING SUPPLIES

GENERAL INFORMATION

•

#2 Phillips head screwdriver

•

Flat head screwdriver

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3/8" open end wrench (to change index pin lifter)

•

AquaShield

•

Fantastik

or similar (non-citrus) all purpose cleaner

•

Needle-nose pliers

•

Utility knife

Summary of Contents for Classic Series

Page 1: ...VICE MANUAL CLASSIC SERIES WITH QuickPro PUMP HEAD PERISTALTIC METERING PUMPS SINCE 1957 TO BE INSTALLED BY PROPERLY TRAINED PROFESSIONAL INSTALLER ONLY READ MANUAL LABELS FOR ALL SAFETY INFORMATION INSTRUCTIONS ...

Page 2: ... their service life will require scheduled maintenance The purpose of this manual is to identify the parts that will eventually require replacement along with other maintenance basics Best practice tips and corrective actions are also in this manual ICONS USED IN THIS MANUAL Factory Instructions Additional Information Important Information ...

Page 3: ...ECONNECTING FEED RATE TO MOTOR 14 SECTION IV PUMP TUBE PUMP TUBE BASICS 15 VISUAL REFERENCE 16 CONDITIONS THAT REDUCE PUMP TUBE LIFE 17 20 IMPORTANT PUMP TUBE INFORMATION 21 TUBE REPLACEMENT 22 30 PUMP HEAD REPLACEMENT 31 33 SECTION V FEED RATE CONTROL FRC FEED RATE CONTROL 34 FEED RATE WEAR 35 36 FEED RATE PARTS REPLACEMENT 37 38 SECTION VI MOTOR MOTOR 39 CAUSES OF MOTOR MALFUNCTION 40 ROTOR ASSE...

Page 4: ...vice by trained personnel only HAZARDOUS PRESSURE CHEMICAL EXPOSURE Use caution and bleed off all resident system pressure prior to attempting service or installation Use caution when disconnecting discharge line from pump Discharge may be under pressure Discharge line may contain chemical RISK OF CHEMICAL EXPOSURE Potential for chemical burns fire explosion personal injury or property damage To r...

Page 5: ...D CLEANING SUPPLIES GENERAL INFORMATION 2 Phillips head screwdriver Flat head screwdriver 3 8 open end wrench to change index pin lifter AquaShield Fantastik or similar non citrus all purpose cleaner Needle nose pliers Utility knife ...

Page 6: ...800 683 2378 International 904 641 1666 7 CLASSIC SERIES SINGLE HEAD ADJUSTABLE PUMP THREE BASIC SUBASSEMBLIES Use subassemblies in field for quick replacement GENERAL INFORMATION Motor Pump Head Feed Rate Control FRC ...

Page 7: ...ble this view Vertical Wall Mounting Bracket requires 2 screws Discharge Line Disassembled View Suction Line Solution Tank Shut Off Valve Grounded Power Outlet protected by Ground Fault Circuit Interrupter GFCI Always use Rain Roof for outdoor use or if metering pump is subject to washdowns Injection Fitting 0 25 psi Injection Check Valve 26 100 psi Flow direction of solution Disassembled View Duc...

Page 8: ...n cause motor damage A rain roof is recommended for outdoor and wet environments VERTICAL INSTALLATION INSTALLATION POINTS USA and Canada 800 683 2378 International 904 641 1666 Spill Recovery Rain roof optional slips into wall bracket Wall Bracket Vertical Mount with Rain Roof Pump Head Spill Recovery Set up Tube drains solution back to tank Partial hole is punched through with a 2 Phillips head ...

Page 9: ...ex The slack prevents stress on the pump tube and fittings to help reduce the chance for breakage and leaks The suction line should not be inserted to the bottom of the weighted strainer If the suction line becomes flush with the nose of the strainer the pump may not prime due to blockage Use Stenner suction and discharge tubing rain roof and UV gray tank for outdoor applications 3 INSTALLATION PO...

Page 10: ...nly While stabilizing the tube fitting attach female end of adapter to the tube fitting s ferrule inside Slide line through 3 8 connecting nut and finger tighten to male end of adapter If leak occurs gradually tighten the 3 8 connecting nut as required INSTALLATION POINTS USA and Canada 800 683 2378 International 904 641 1666 DO NOT use thread seal tape on pump tube threads DO NOT use pliers Finge...

Page 11: ...ATION The pressure spring is not used with the fixed output pump SUBASSEMBLY CONNECTIONS www stenner com Motor shaft and pressure spring coated with Aquashield Indentation Rivets 3 Bump Mounting Plate Rivet Slots 3 Plate Screws 3 ...

Page 12: ...he pump head clockwise until it stops 3 Pull the pump head straight out 4 Hold the motor assembly grasp the feed rate control section and turn clockwise until it stops and pull it straight out SUBASSEMBLY CONNECTIONS USA and Canada 800 683 2378 International 904 641 1666 Feed Rate Control Pump Head Feed Rate Control Motor ...

Page 13: ...ass spider in the feed rate control and push towards the motor 3 Push and turn the feed rate control until the rivets on the gear case are inside the rivet holes on the feed rate 4 Turn counter clockwise until it locks into place and the bump on the feed rate mounting plate fits into the indentation in the gear case cover The arrow on the feed rate control should be on top To reconnect the pump he...

Page 14: ...y conditions of the application or the installation These conditions are Calcium or mineral deposits Sediment blockages Chemical incompatibility Corrosion Improper handling PUMP TUBE PRESSURE RATING PUMP TUBE 0 25 psi 0 1 7 bar 26 100 psi 1 8 6 9 bar Check valve required 1 2 3 4 5 7 Classic Single Head ONLY For maximum pump tube life always identify the reasons for the failure and correct the prob...

Page 15: ...ure rating An oval pattern indicates worn rollers and or the pump tube has reached the end of its service life Pump tubes can rupture without either pattern apparent The most common tube problems are from a lack of routine maintenance Always establish an application specific maintenance schedule PUMP TUBE www stenner com Roller DIAMOND PATTERN Excessive pressure or blockage TEAR DROP PATTERN Norma...

Page 16: ... the material Allow the pump to run the roller assembly in its collapsed position for approximately one minute to relax the tube as indicated in the tube replacement instructions Using pliers to center or secure connections can damage ferrules The connecting nut must be finger tightened only Using thread seal tape prevents ferrules from seating properly into tube fitting and can cause leaks Not al...

Page 17: ...sult of atmosphere or tube failure can result in seizing the rollers Corrective Action 1 Confirm chemical compatibility with housing and pump tube material 2 Review factory recommended vertical pump installation 3 In the event of tube rupture rinse the chemical residue from the housing and roller assembly with factory recommended cleaners 4 If tube housing is cracked replace Normal roller wear can...

Page 18: ...p accumulated deposits If screwdriver can t be inserted drill the deposit out of the injection fitting Do not drill through the opposite pipe wall 2 Replace duckbill EXCESSIVE BACK PRESSURE AT THE POINT OF INJECTION Insoluble sediments or particulates drawn through the suction line from the bottom of the tank can cause blockage or restriction in the check valve duckbill These solids and excessive ...

Page 19: ...nstructions which include centering the tube on the rollers The tube will not center if it twists during installation or if the rollers are worn The tube can also twist if the connections are over tightened finger tighten only Refer to the Trouble Shooting guide in the Classic Series Installation Manual for more pump tube and pump head conditions and solutions PUMP TUBE www stenner com Rollers Tub...

Page 20: ...ver tightening may result in a twisted tube damaged fittings crushed ferrules and air pick up NOTE A twisted tube will not center and can decrease tube life For 26 100 psi applications inspecting and replacing the duckbill at every tube change is recommended Santoprene pump tubes are not compatible with petroleum or oil based products Refer to the Chemical Resistance Chart in the Catalog for compa...

Page 21: ...suction and discharge lines 3 Open the back and front of the latches on both sides of the head Carefully fold latches back to prevent contact with the cover Figure B For CE pump only Remove the safety screw on cover 4 Remove the tube housing cover and flip to use as a tool in the next step Figure C 5 Align the center of the inverted cover with the center of the roller assembly so that the three ho...

Page 22: ...r 9 Use a non citrus all purpose cleaner to clean chemical residue from the tube housing roller assembly and cover 10 Check the housing cover and roller assembly for cracks and replace if cracked 11 Ensure the rollers turn freely Replace the roller assembly if the rollers are seized or worn or if there is a reduction or lack of output from the pump Figure G 12 Reinstall the clean tube housing On a...

Page 23: ...gers to center it over the rollers Figure I 3 Place the tube housing cover on the tube housing affix the front latches to the cover lip and then press the latches back to secure Figure J Identify the cause of tube failure prior to installing a new tube A used tube will have stretched approximately 3 4 and the new tube will appear to be stiff and short Follow directions to allow rollers to stretch ...

Page 24: ...over and flip to use as a tool in the next step Figure L 7 Align the center of the inverted cover with the center of the roller assembly so that the three holes on the face of the cover align with the three knurled lugs on the roller assembly Position the cover feet near the bottom Figure M NOTE The roller assembly needs to be expanded so the tube is pressed against the tube housing wall PUMP TUBE...

Page 25: ...te the roller assembly clockwise to expand the roller assembly The tube will be pressed against the tube housing wall Figure N O Proceed to step 9 on page 29 NOTE Clockwise is viewed from facing the head of the pump PUMP TUBE TUBE REPLACEMENT continued www stenner com NEW PUMP HEAD DESIGN Roller assembly collapses and expands Before turning pump on CONFIRM ROLLER ASSEMBLY IS EXPANDED and tube is p...

Page 26: ...quickly snap rotate the roller assembly clockwise to expand the roller assembly The tube will be pressed against the tube housing wall Figure N O NOTE Clockwise is viewed from facing the head of the pump c Remove the fan brake tool Proceed to step 9 on page 29 PUMP TUBE TUBE REPLACEMENT continued USA and Canada 800 683 2378 International 904 641 1666 NEW PUMP HEAD DESIGN Roller assembly collapses ...

Page 27: ...h and quickly snap rotate the roller assembly clockwise to expand the roller assembly The tube will be pressed against the tube housing wall Figure N O NOTE Clockwise is viewed from facing the head of the pump c Remove the latch from the vent and re attach it to the tube housing Proceed to step 9 on page 29 PUMP TUBE TUBE REPLACEMENT continued www stenner com NEW PUMP HEAD DESIGN Roller assembly c...

Page 28: ...T lubricate the pump tube Figure P 10 Place the tube housing cover feet first on the tube housing affix the front of the latches to the cover lip and then press the latches back to secure Figure Q TUBE REPLACEMENT continued USA and Canada 800 683 2378 International 904 641 1666 P Q ...

Page 29: ...ove Figure S 3 DO NOT let go of fitting until tube rides approximately in center of rollers 4 Turn the pump off let go of the fitting and secure the latch between the fittings Figure T For CE pump only Reinstall the safety screw on the cover 5 Inspect the suction and discharge lines point of injection and check valve duckbill for blockages Clean and or replace as required 6 Reconnect the suction a...

Page 30: ... and cover If the shaft will not come out remove the cover from the pump head and use a hammer to tap the shaft from the front of the roller assembly to dislodge it Figure B d Insert the shaft back into the feed rate control Figure C e Put the new pump head onto the feed rate control and turn it counter clockwise until the shaft falls into place 2 Push the pump head in while turning it counter clo...

Page 31: ...river between the pump body and the head Gently pry the head forward ensuring the rivets on the pump body remain disengaged from the tube housing c Put the new pump head onto the motor and turn it counter clockwise until the shaft falls into place Figure D 2 Push the pump head in while turning it counter clockwise Line up the rivet holes on the pump head with the rivets on the feed rate control ad...

Page 32: ...page 30 in the TUBE REPLACEMENT INSTRUCTIONS to CENTER THE TUBE PUMP HEAD REPLACEMENT continued USA and Canada 800 683 2378 International 904 641 1666 NEW PUMP HEAD DESIGN Roller assembly collapses and expands Before turning pump on CONFIRM ROLLER ASSEMBLY IS EXPANDED and tube is pressed against housing wall CAUTION Use care when expanding roller assembly excessive force can crack the hub and lead...

Page 33: ... attached to a lifter When the pump is on the spider assembly rotates When the lifter drops into the FRC channel the pin engages the index plate rotating the roller assembly creating the pumping action When the lifter rides on the cam the pin is lifted inside the holder The roller assembly does not rotate resulting in no pumping action Index pin retracts when lifted FEED RATE CONTROL www stenner c...

Page 34: ...across the plate The feed rate control will index inconsistently at different settings Replace the lifter as needed WORN INDEX PLATE A worn cam or lifter can cause the index pin to drag across the index plate and elongate the holes The pin will skip across the holes and cause index malfunction The plate can be flipped to use the other side or it may be replaced Remember to grease with AquaShield C...

Page 35: ... the feed rate will malfunction Corrective Action 1 Replace the index pin and or lifter assembly as needed 2 Review the factory recommended vertical installation 3 Schedule a pump tube replacement at regular intervals according to the specific application For 26 100 psi applications replace the duckbill at every tube change FEED RATE CONTROL www stenner com ...

Page 36: ... Apply AquaShield to lubricate the cam s angled tip 6 To install the cam feed the angled cam tip into the FRC channel and keep the 90º end in the up position Place thumb over the cam to guide as it is inserted in the channel 7 Continue to feed the cam in the channel until there is approximately a 1 2 gap between the cam tip and the beginning of the channel FRC PARTS REPLACEMENT FEED RATE CONTROL U...

Page 37: ...AquaShield to the top of the index plate 12 Place the spider assembly on the index plate The lifter tip should be positioned in the 1 2 gap in the FRC channel 13 To secure mounting plate align its arrow with the FRC housing arrow and install the three screws If the dial ring does not rotate from L to 10 the FRC mounting plate is in the wrong orientation The dial ring will be stiff or difficult to ...

Page 38: ...is applied to the coil the rotor rotates The rotor s directional rotation is determined by the orientation of the copper shaded poles on the coil The helical end of the rotor engages the series of gears in the gear case USA and Canada 800 683 2378 International 904 641 1666 Rotor Assembly Coil Gears Helical End ...

Page 39: ...AL VAPORS The motor won t be able to rotate freely if the coil rotor and bearing are rusted or corroded Corrective Action 1 Avoid mounting the pump over an open solution tank 2 Review vertical installation INCORRECT VOLTAGE The motor voltage must match power supply to avoid a burned coil Corrective Action Use a volt meter for confirmation DAMAGED BEARING BRACKETS Cracked or broken bearing bracket ...

Page 40: ...t helical gear side onto the amber bearing bracket D 5 Place the coil E see Correct Coil Orientation over the rotor F onto the bearing bracket D 6 Snap into place the second bearing bracket onto the rotor 7 Insert two coil screws with lock washers C and tighten 8 Starting at an angle press fan B with hub side down onto the rotor shaft 9 Reinstall the two motor housing screws and tighten the self t...

Page 41: ...rate control as a stand to work on the motor See illustration 4 Remove fan and set aside MOTOR www stenner com Motor Gear Case Shaft Motor Screws Feed Rate Control Pump Head Rotor Motor Cover Motor Cover Screw Boss Pump Head Feed Rate Control Coil Screw and Washer Coil Copper Rods Amber Bearing Bracket Motor Cover Screw Boss Coil Fan Motor Screws ...

Page 42: ...or cover at the wire nut four cuts total Set cover to the side 7 Remove and set aside Two coil screws and washers from the rotor bracket Plastic amber bearing bracket 8 Remove coil and discard USA and Canada 800 683 2378 International 904 641 1666 Ground Wire Screw Boss Ground Wire Lead Wire 2 Lead Wires Wire Nuts crimp type Set Screw Eyelet ...

Page 43: ...corner and the vent opening at the bottom of the gear case Place bracket back on the rotor and securely seat into new coil Install screws and washers and fasten bracket to coil 10 With the metal band facing the bracket press fan flush on rotor shaft MOTOR www stenner com Rotor Copper Rods Amber Bearing Bracket Coil Vent Opening Coil Lead Wire Coil Lead Wire ...

Page 44: ...th eyelet to motor coil 13 Crimp the stripped lead wires to each of the new coil lead wires 14 Tuck wire nuts into bottom of motor cover and secure cover back in place before tightening reverse cover screws to catch original threads 15 Apply power to motor and test USA and Canada 800 683 2378 International 904 641 1666 Lead Wire Ground Wire Strip Approx 1 2 Wire Stripper Lead Wire Ground Wire ...

Page 45: ...nd 170 series The motor shaft with gear drives the feed rate control MOTOR www stenner com Motor Gear Case Phenolic Gear with Spacer Metal Reduction Gear Motor Shaft with Gear GEAR SET IDENTIFICATION The illustrations show the diameters of the gears and pinions 45 100 SERIES GEARS 85 170 SERIES GEARS Phenolic Gear Phenolic Gear Metal Reduction Gear Metal Reduction Gear 3 8 1 3 8 9 16 1 3 8 9 16 1 ...

Page 46: ...ludes using a rain roof in outdoor applications or wet environments 2 Replace gears that show visible wear or corrosion 3 Replace gear posts that are worn rusted or corroded 4 Inspect the gear case and cover for cracks or corrosion and replace as needed 5 Inspect the helical gear at the end of the rotor Buff off the rotor if rusted or replace the rotor assembly 6 Lubricate with AquaShield Apply a ...

Page 47: ...aShield on new gear posts before installing gears 7 Install phenolic gear and spacer 8 Install metal reduction gear and motor shaft with gear 9 Use remaining AquaShield on top of the three gears 10 Re attach gear case cover with four screws and tighten Screws must be backed in to locate original threads before securing to prevent stripping screw boss MOTOR www stenner com Gear Case Motor Shaft wit...

Page 48: ... 904 641 1666 US Toll Free 800 683 2378 Fax 904 642 1012 sales stenner com www stenner com Hours of Operation EST Mon Thu 7 30 am 5 30 pm Fri 7 00 am 5 30 pm Made in the USA Stenner Pump Company All Rights Reserved Illustrations by David Stiles www stilesdesigns com BSME 0814 ...

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