Stenner Classic Series Basic Service Manual Download Page 37 | Manualshive

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36 Maintenance Basics – FRC

NOTE

Additional information

An arrow doesn’t exist on
older feed rate control
mounting plates. Place the
plate so the “bump” is to
the left of the two adjacent
holes that are in between
two screw bosses. Align the
screw holes on the mounting
plate and feed rate control
and the mounting plate will
be re-installed at the proper
orientation.

Feed Rate Control

Manufactured before 2002

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Summary of Contents for Classic Series

Page 1: ...Basic Service Manual Classic Series ...

Page 2: ...l Recovery 6 Vertical Wall Installation 6 Suction Line Compression Seal 7 Rain Roof 8 SECTION III Separating Reconnecting Subassemblies Rivet and Slot Identification 9 Separating Subassemblies 10 Reconnecting Feed Rate to Motor 11 Reconnecting Pump Head to Feed Rate 12 SECTION IV Maintenance Basics Tube Tube How It Works 13 Tube Failure Definition 14 Tube Fundamentals 15 Tube Failure Causes Correc...

Page 3: ...ing service or installation Use caution when disconnecting discharge tubing from pump Discharge tubing may be under pressure and may contain chemical Please refer to Stenner Installation and Maintenance Manual for safety hazards and notices NOTICE BEST PRACTICE Factory recommended NOTE Additional information IMPORTANT Key for optimum performance Important icons used in this manual Section I Genera...

Page 4: ...rewdriver Flat blade screwdriver 3 8 open end wrench to change index pin lifter Stenner grease AquaShield Fantastik or similar non citrus all purpose cleaner Needle nose pliers Utility knife 3 Tool List Cleaning Supplies ...

Page 5: ...4 General Information Part Identification Stenner Classic Series Chemical Feed Pump Three Basic Subassemblies ...

Page 6: ...5 Review Proper Installation Section II Installation 26 100 psi 0 25 psi ...

Page 7: ...ure chemical drains back into solution tank preventing spillage on the ground floor and keeps chemical from collecting in tube housing Vertical Wall Installation This type of installation is recommended by factory to keep chemical away from pump parts ...

Page 8: ...valve duckbill and discharge line Allow slack in suction discharge tubing so pump tube fittings can flex This prevents stress on tubing and tube fittings reducing the chance for breakage and leaks Compression Seal NOTE Additional information Beveled ends of ferrules face tube fittings Tubing should bottom into all fittings ...

Page 9: ...8 Installation Rain Roof Recommended in all outdoor or wet environments Pump motor is ventilated and water intrusion can cause motor damage ...

Page 10: ...9 Section III Separating Reconnecting Subassemblies Rivet and Slot Identification ...

Page 11: ...e pump off and unplug the power cord 2 Hold the feed rate control section and turn the 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 ...

Page 12: ...aft with the flat side of the spider in the feed rate control and push straight on 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 counterclockwise until it locks into place and the bump on the feed rate mounting plate fits into the indentation in the gear case cover NOTE Additional information The arrow on the feed rate co...

Page 13: ...ile turning it counterclockwise to line up the rivet holes on the pump head with the rivets on the feed rate control 3 Continue to push until the rivets are inside the holes and the snap lock engages 4 Turn the pump head counterclockwise to secure the rivets in the rivet slots firmly attaching the pump head Reconnecting Pump Head to Feed Rate NOTE Additional information Tubes must be horizontal wh...

Page 14: ...f the three rollers that move along the tube As the roller moves the compressed section generates a vacuum creating a self priming function The remaining two rollers repeat the process and the rotation creates a pumping action Section IV Maintenance Basics Tube ...

Page 15: ...ill or system pressure in excess of pump tube rating An oval pattern indicates worn rollers and or the tube reaching the end of its service life Tubes can rupture without either pattern apparent The tube can rupture or break A rupture normally occurs at the point between the discharge tube fitting and the area where the roller leaves the tube A break or rip occurs just past the suction fitting The...

Page 16: ...e Blockage excessive pressure worn damaged parts locate and correct problem Tube Fundamentals For maximum tube life IMPORTANT Key for optimum performance Remember to check tube psi rating against application psi All tubes 1 2 3 4 5 7 are rated to 0 25 psi 1 2 7 are rated to 26 100 psi Continued ...

Page 17: ...e due to calcification or mineral deposits Corrective Action 1 Insert a round shank screwdriver through injection fitting into the pipe to locate or break up 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 Tube Failures Causes and Corrective Action ...

Page 18: ...rom tank bottom 2 Position suction weight 3 from tank bottom 3 Use strainer 4 Replace duckbill Split along tube side Rubbing along roller assembly and pump head housing edge Corrective Action 1 Center tube at time of new tube installation BEST PRACTICE Factory recommended Replace duckbill with every tube change NOTE Additional information Tube will not center if wrist twists during installation sh...

Page 19: ...orroded or cracked Rollers need to turn freely but without rocking tilting from side to side 2 Replace roller assembly and or cracked housing NOTE Additional information Normal roller wear can cause a lack of output as a result of the rollers inability to fully squeeze the tube The wear is generally in the bore of the roller To check for roller bore wear hold each roller at the top and bottom betw...

Page 20: ...ng spillage on the ground floor and keeps chemical from collecting in tube housing Spill Recovery NOTE Additional information Screws are self tapping back off screws to find original threads If screw bosses are stripped use alternate bosses and position them opposite each other The pump housing must flex to avoid pump head cracking Do not use more than two screws Continued Vertical Mount ...

Page 21: ...ting ferrules from seating into tube fitting Stress on tube fitting from a tight radius in the suction discharge tubing Crushed ferrules from over tightening or use of pliers Corrective Action 1 Only finger tighten connecting nut Do not use pliers Do not use Teflon tape Hold tube fitting when tightening connecting nut to prevent fitting from turning 2 Change ferrules with every tube change Ferrule...

Page 22: ...on side Fatigued no longer completely compresses no rupture evident doesn t pump The above conditions are usually indications that the tube has reached the end of its service life If all other conditions wear have been checked and corrected determine maintenance schedule NOTE Additional information Due to wear the used tube will have stretched and will be longer than the new tube NOTE Additional i...

Page 23: ...ct sunlight Overpressure due to crushed over tightened duckbill Corrective Action 1 Use only Stenner accessories with Stenner pumps 2 Check the chemical resistance chart for chemical compatibility or call the factory 3 Do not store tubes in pump rooms or in direct sunlight 4 Do NOT lubricate the pump tube or roller assembly BEST PRACTICE Factory recommended Every time pump is serviced or a tube is...

Page 24: ...e tube fittings 3 Set the feed rate dial on a low setting and leave on this setting until finished 4 Turn the pump on and let it run until one of the three slots in the roller assembly lines up with the bottom tube fitting suction side BEST PRACTICE Factory recommended Prior to tube removal pump water through tube to remove chemical Continued ...

Page 25: ...assembly further lift the tube fitting out of the housing slot and pull it toward the center of the roller 7 Turn pump on and allow roller assembly to jog while guiding the tube with tension up and out of the housing 8 Turn the pump off Completely remove the tube assembly ...

Page 26: ...hemical residue from pump head housing roller assembly and cover 3 Check housing for cracks and replace if cracked 4 Ensure rollers turn freely 5 Check rollers for excessive side play from bore wear Replace roller assembly if worn IMPORTANT Key for optimum performance Identify the cause of tube failure prior to installing a new tube Continued ...

Page 27: ...ct the suction discharge tubing point of injection and check valve duckbill for blockages Clean and or replace as required 7 Install clean housing 8 Install and grease shaft 9 Install roller assembly Installing the New Pump Tube 1 Manually turn roller assembly counterclockwise to line up its slot with the tube housing slot 2 Place the tube fitting into the housing and roller assembly slot IMPORTAN...

Page 28: ...sed tube will stretch approximately 3 4 of an inch over its life The new tube will appear to be stiff and short Follow directions to allow rollers to stretch tube into place 4 When the tube reaches the top housing slot turn pump off Turn dial ring to 10 hold tube fitting firmly and turn pump on Allow rollers to stretch tube into place while guiding the tube into the slot 5 Turn the pump off Contin...

Page 29: ...r the pump tube on the rollers set the Feed Rate dial to a setting of 10 Turn pump on 2 Turn the IN suction tube fitting located on the bottom of the pump head not more than 1 8 of a turn in the direction the tube must move 3 Do not let go of fitting until the tube rides approximately in the center of the rollers NOTE Additional information If pump head housing screws are stripped use alternate bo...

Page 30: ... the screw boss and the cover BEST PRACTICE Factory recommended Trim 1 off suction discharge tubing before installing ferrules Replace ferrules with every tube change Fixed Rate Pump Tube Change To install a new tube in a fixed rate pump utilize the on off switch to jog the roller assembly in absence of the feed rate control ...

Page 31: ...d index pin assembly that consists of a pin with carbide tip and a spring inside the holder attached to a lifter When the pump is on the index spider assembly rotates When the lifter drops into the FRC channel the pin engages an index plate hole The roller assembly rotates creating the pumping action When the lifter rides on the cam the pin is lifted inside the holder The roller assembly does not ...

Page 32: ...s Worn index plate wear part If there is a groove in the cam and or the lifter point has a flat spot the lifter cannot raise the index pin high enough inside the holder The pin will drag across the index plate and accelerate the wear by elongating the plate holes The pin can no longer engage in the holes Groove in cam wear part The lifter riding on the cam causes a groove in the cam Continued ...

Page 33: ...eized or corroded index pin and lifter assembly Usually caused by water or chemical intrusion NOTE Additional information The lower the feed rate control setting the more wear on the cam lifter and plate To reduce FRC parts wear select the pump model that will operate at the desired maximum gpd BEST PRACTICE Factory recommended Mount pump in vertical position with spill recovery tube to allow chem...

Page 34: ...all new index plate 5 Clean out FRC channel before installing new cam 6 Use grease AquaShield to lubricate the cam s angled tip 7 Install the cam 8 Feed the angled tip into the FRC channel and keep the 90 end in the up position Place thumb over the cam to guide as it is inserted in the channel 9 Continue to feed the cam in the channel until there is approximately a 1 2 gap between the cam tip and ...

Page 35: ... FRC channel in a clockwise motion place the dial ring onto the FRC housing and snap into place 12 Generously grease AquaShield bottom of FRC housing before placing index plate inside Grease the top of the index plate 13 Place the spider with index pin assembly on the index plate The lifter tip should be positioned in the 1 2 gap in the FRC channel NOTE Additional information Spread AquaShield on ...

Page 36: ...ial ring will be stiff or difficult to rotate if it lacks lubrication AquaShield or the screws are over tightened If the screws are too loose the dial ring can inadvertently be turned to 10 by the motor IMPORTANT Key for optimum performance If the dial ring does not rotate from L to 10 the FRC mounting plate is in the wrong orientation ...

Page 37: ...ol mounting plates Place the plate so the bump is to the left of the two adjacent holes that are in between two screw bosses Align the screw holes on the mounting plate and feed rate control and the mounting plate will be re installed at the proper orientation Feed Rate Control Manufactured before 2002 ...

Page 38: ...nolic gear control the rpm of the feed rate and pumping head The 45 series is 26 rpm and the 85 series is 44 rpm The motor shaft with gear drives the feed rate control 45 Series 85 Series 37 Section VI Maintenance Basics Motor 3 8 9 16 1 3 8 1 1 4 Continued ...

Page 39: ...ottomed Inspect gear case and cover for cracks and cup bearing for corrosion Replace as needed BEST PRACTICE Factory recommended Apply generous amounts of grease AquaShield to gear posts gear rings pinions and master shaft when doing service in the gear case Gear Case Wear Definition Gear failure in general can be caused by misalignment mainly due to wear water or chemical intrusion inside the gea...

Page 40: ...entilation to the fan cooled motor while protecting against water intrusion Chemical vapors Can corrode or rust the coil rotor and bearings resulting in the motor s inability to rotate freely Burned motor coil Motor voltage must match power supply Use volt meter to confirm Damaged bearing brackets Cracked or broken bearing brackets result in rotor misalignment which causes the rotor to bind to the...

Page 41: ...s inserts in the front of the motor case 4 Install new rotor assembly by inserting the shaft helical gear side onto the gear case 5 Place the coil over the rotor and keep the copper shaded poles on the right hand side same side as the on off switch 6 Snap into place the second plastic bearing bracket on the rotor 7 Insert two self tapping screws w lock washers 8 Starting at an angle press fan with...

Page 42: ...th the pump head attached and set on a flat surface to be used as a stand for the motor case 3 Remove two motor cover screws and invert the motor by inserting the gear case shaft into the feed rate control 4 Remove fan and set aside Continued Coil Replacement 41 ...

Page 43: ... the power cord and coil lead wires from motor 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 bearing bracket amber 8 Remove coil and discard 42 Maintenance Basics Motor ...

Page 44: ...he motor housing 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 Continued 11 With wire strippers set at 16 gauge strip approximately 1 2 from the power cord and on off switch lead wires in the motor housing 12 Secure ground wire with eyelet to motor coil ...

Page 45: ... 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 16 Reconnect subassembly s 44 Maintenance Basics Motor ...

Page 46: ...p Use Stenner Tank System for quick installation Establish application specific maintenance schedule Install parts poster in shop for quick part reference Use UV black suction discharge tubing rain roof and UV gray tanks for outdoor applications Contact factory for help 800 683 2378 or 904 641 1666 Visit our website at www stenner com ...

Page 47: ...46 Notes ...

Page 48: ... 642 1012 Hours of Operation EST Monday 7 am 5 pm Tues Fri 7 am 5 30 pm 3174 DeSalvo Road Jacksonville Florida 32246 sales stenner com Stenner Pump Company All Rights Reserved Illustrations by David Stiles www stilesdesigns com CSM Peristaltic Metering Pumps Since 1957 ...

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