BASIC SERVICE MANUAL
Contents
1. Index pin retracts when lifted 34 www stenner com FEED RATE CONTROL WEAR Indication of wear is apparent when the feed rate control makes a skipping or ratcheting sound The pump output is less than the desired setting GROOVE IN CAM Worn groove in More cam is exposed to the rotation of the lifter at lower dial ring settings leading to cam wear and causing index malfunctioning Higher settings will reduce cam wear Inspect and replace cam as needed WORN LIFTER If the lifter arm wears and flattens it may not fully lift the pin out of the index plate The pin will make a ratcheting sound from Ester dragging across the plate The feed rate control will index inconsistently at different Should look like this settings Replace the lifter as needed 4 WORN INDEX PLATE di 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 Corrective Action To reduce wear the feed rate parts Index plate with elongated holes specify the pump closest to its maximum output capacity within the needs of th2. To reconnect the pump head to the feed rate control refer to Pump Head Replacement instructions page 33 14 wwwsstenner com PUMP TUBE BASICS The tube is the workhorse of the pump It is perishable and will eventually stop functioning from natural wear or when it reaches the end of its service life Indications of the end of service life are leaks Tube is fatigued causing a reduction or lack of output The pump tube service life can be reduced by 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 omm ra l PUMP TUBE 0 25 psi 0 1 7 bar 26 100 psi 1 8 6 9 bar Check valve required 6 1 7 2 2 1l Classic Single Head ONLY Tube number located on fitting For maximum pump tube life always identify the reasons for the failure and correct the problem be
3. Refer to the Trouble Shooting guide in the Classic Series Installation Manual for motor conditions and solutions 40 www stenner com ROTOR ASSEMBLY REPLACEMENT A rotor assembly includes D amp 1 Remove and set aside Two motor housing screws not shown Motor housing A Plastic fan B discard old fan Two coil screws and lock washers Coil keep wires connected E Remove and discard the rotor F and two amber bearing brackets D Press the new amber bearing bracket D onto the threaded brass inserts in the back of the gear case G 4 Install the new rotor by inserting the shaft 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 Correct Coil Orientation 6 Snap into place the second bearing bracket onto the rotor Copper Rods 1 Insert two coil screws with lock washers C and tighten Coil 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 tapping screws to secure the motor housing A Coil Lead Wire Opening USA and Canada 800 683 2378 International 904 641 1666 41 MOTOR COIL REPLACEMENT Disconnect power to pump 2 Remove motor base Remove two motor cover screws Invert the pump and use the pump head and feed rate control as
4. 17 20 IMPORTANT PUMP TUBE INFORMATION eeeeeene 21 TUBE REPLACEMENT 22 30 PUMP HEAD ini 31 33 SECTION V FEED RATE CONTROL FRC FEED ALE CONTROL preiei EN 34 WEAR EEEE E 35 36 FEED RATE PARTS 37 38 SECTION VI MOTOR Em 39 CAUSES OF MALFUNCTION 40 ROTOR ASSEMBLY REPLACEMENT 2 41 COIL REFEAC EMEND 42 45 GEARS amp GEAR SET IDENTIFICATION 46 47 48 BSME 1211 GENERAL INFORMATION SAFETY INFORMATION NOTICE Before installing or servicing the pump read the pump manual for all Safety information and complete instructions The pump is designed for installation and service by properly trained personnel WARNING HAZARDOUS VOLTAGE DISCONNECT power cord before removing motor cover for service Electrical service by trained personnel only WARNING HAZARDOUS PRESSURE CHEMICAL EXPOSURE N Use caution and bleed off all resident system pressure prior to attempting service or installation AN 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 persona
5. Prior to installation pre stretching lubricating the tube and or roller assembly or pinching during installation compromises the tube material Excessive pulling of the tube fitting during installation can result in compromising 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 allowing enough slack in the suction and discharge lines so the tube fittings can flex puts stress on the tube and fittings DO NOT use thread seal tape or pliers on pump tube threads USA and Canada 800 683 2378 International 904 641 1666 17 PUMP TUBE CONDITIONS THAT REDUCE TUBE LIFE continued CRACKED PUMP HEAD The tube housing and latches can crack from wear and long term chemical exposure due to incompatibility with the housing materia
6. PUMPS PERISTALTIC METERING PUMPS SINCE 1957 BASIC SERVICE MANUAL CLASSIC SERIES WITH QuickPro PUMP HEAD BASIC SERVICE MANUAL CLASSIC SERIES WITH QuickPro PUMP HEAD The Stenner Classic Series peristaltic metering pumps are mechanical and during 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 0009009909900990909000099090000909090000900990090090090009090009090009099090900000000009000000900990909000900990090090900900009000990000000000009909000090090900000090900009090900000009000000909090099 ICONS USED IN THIS MANUAL Factory Instructions Important Information Additional Information TABLE OF CONTENTS SECTION GENERAL INFORMATION INFORMANON MR D TOOL LIST AND CLEANING 6 CLASSIC SERIES PUMP 7 SECTION II INSTALLATION POINTS INSTALLATION DIAGRAM iE oiT 8 VERNGAL EE s M 9 SUCTION AND DISCHARGE LINES 10 0 11 SECTION SUBASSEMBLY CONNECTIONS RIVET AND SLOT IDENTIFICATION 2 12 13 RECONNECTING FEED RATE TO MOTOR 0 14 SECTION IV PUMP TUBE PUMP TUBE BASICO EA 15 8 16 CONDITIONS THAT REDUCE PUMP TUBE LIFE _
7. protected by Ground Fault Circuit Interrupter GFCI Disassembled View ot eee Disassembled View 4 i 27 Injection Injection i CheckValve Fitting p 26 100 psi 0 25 psi i 2 Pad Discharge Line 27 ld 727 Injection Check Valve i Thh or Injection Fitting e i E l I 1 i 1 Flow direction 1 I of solution 0 2 Optional Flow Indicator to confirm solution is pumping Discharge Line 8 www stenner com VERTICAL INSTALLATION Mount the pump vertically and use the spill recovery to drain chemical back to the tank in the event of tube failure This will help prevent chemical from collecting in the tube housing and reduces spillage on the floor The pump motor is ventilated and water intrusion can cause motor damage A rain roof is recommended for outdoor and wet environments Spill Recovery Set up Vertical Mount with Rain Roof Rain roof optional slips into wall bracket Poi Wall Bracket Spill Recovery Pump Head Tube drains solution back to tank Partial hole is punched t
8. point of injection and check valve duckbill for blockages Clean and or replace as required Reconnect the suction and discharge lines Turn the pump on and verify operation 30 www stenner com PUMP HEAD PUMP HEAD REPLACEMENT ADJUSTABLE MODEL REMOVE PUMP HEAD amp INSTALL QuickPro PUMP HEAD 1 Turn off the pump and unplug the power cord a remove the pump head hold the feed rate securely grasp the head and turn it clockwise until it stops Figure A b Remove the head by pulling it straight out from the pump The main shaft will come out with the pump head c Using a pair of pliers grasp the main shaft and rock it back and forth clockwise and counter clockwise while pulling it straight out of the pump head Set aside the shaft to be reinstalled later Discard the old tube housing 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 clockwise Line up the rivet holes on the pump head with the rivets on the feed rate control adjustable pump OR motor fixed output pump Figure D 3 Continue to push until the rivets are inside the holes Turn the pump head co
9. a stand to work on the motor See illustration 4 Remove fan and set aside Motor Motor Screws Pump Head Feed Rate Control 3 gt Gear Case Shaft Fan Coil Screw and Washer Motor Cover NS Coil Copper Rods Screw Boss 4 v Amber Bearing Bracket Motor Cover Screw Boss Motor Cover Pump Head 42 www stenner com COIL REPLACEMENT continued Disconnect ground wire with eyelet and set screw aside Cut 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 amber bearing bracket 8 Remove coil and discard Set Screw Ground Wire Screw Boss Ground Wire Lead Wire crimp type Wire Nuts qu USA and Canada 800 683 2378 International 904 641 1666 43 MOTOR COIL REPLACEMENT continued 9 Install new coil over rotor on the remaining amber bracket The correct orientation is with two copper rods in the upper right 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 Rotor Copper Rods Amber Bearing Bracket Coil Coil Lead Wire Coil Lead Wire Vent Opening 44 www stenner com COIL R
10. helical end of the rotor engages the series of gears in the gear case Rotor Assembly Gears USA and Canada 800 683 2378 International 904 641 1666 39 MOTOR CAUSES OF MOTOR MALFUNCTION WATER INTRUSION The motor is fan cooled and needs proper ventilation while protecting it from water intrusion Corrective Action Mount the single head pump vertically with pump head downward and use the rain roof in outdoor installations in areas subject to wash downs or in moist environments CHEMICAL 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 s result in rotor mis alignment that can cause the rotor to bind to the magnetic coil that may be evident by a humming sound Corrective Action 1 Check the condition of the brackets and phenolic gear 2 Replace parts as needed POPS OOOH
11. into the tube fitting Fi tighten Ferrules NY NOTE Beveled ends of ferrules face pump Tubing should bottom into Connecting Nut all fittings DO NOT use thread seal tape on pump tube threads DO NOT use pliers For 3 8 connections only 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 USA and Canada 800 683 2378 International 904 641 1666 11 SUBASSEMBLY CONNECTIONS RIVET AND SLOT IDENTIFICATION Indentation Motor shaft and pressure spring coated with Aquashield Mounting Plate Rivet Slots 3 Plate Screws 3 0090090099099900909009290000099090000909090000900990000909009009099099000090990900000099000000090090099099900090090900009090000090090000909000909909090099099009090900900090900900000090900000090909900999 The pressure spring is not used with the fixed output pump 12 wwwsstenner com SUBASSEMBLY CONNECTION
12. maximum tube life always identify the reasons for the failure and correct the problem before a new tube is installed USA and Canada 800 683 2378 International 904 641 1666 21 PUMP TUBE TUBE REPLACEMENT 33338 8 7 8 88 PREPARATION 1 2 Follow all safety precautions prior to tube replacement Prior to Service pump water or a compatible buffer solution through the pump and suction and discharge lines to remove chemical and avoid contact REMOVE THE PUMP TUBE 1 Turn the pump off and unplug the power cord On the adjustable model ensure that the feed rate control is set to 10 Figure A Depressurize and disconnect the suction and discharge lines 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 Remove the tube housing cover and flip to use as a tool in the next step Figure C 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 tube fittings Figure D NOTE The roller assembly needs to be collapsed to remove the tube 22 www stenner com PUMP TUBE TUBE REPLACEMENT continued 6 the adjustable pump hold the feed rate control securely On the fixed output pump hold the p
13. will be pressed against the tube housing wall Figure amp 0 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 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 28 www stenner com PUMP TUBE TUBE REPLACEMENT continued 9 Apply a small amount of AquaShield to the cover bushing ONLY DO NOT 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 USA and Canada 800 683 2378 International 904 641 1666 29 PUMP TUBE CENTER THE TUBE 1 Ensure the pump is off Lift the latch located between the tube fittings leaving the end of the latch engaged with the lip on the tube housing cover Leave the latch on the opposite side engaged Figure R Plug the pump in and turn it on Turn the tube fitting on the suction side not more than 1 8 of a turn in the direction tube must move Figure DO NOT let go of fitting until tube rides approximately in center of rollers 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 Inspect the suction and discharge lines
14. EPLACEMENT 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 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 Wire Stripper Strip Approx 1 2 Lead Wire Ground Wire USA and Canada 800 683 2378 International 904 641 1666 45 MOTOR GEARS Located in the gear case the metal reduction gear and phenolic gear control the rom of the feed rate and pump head The 45 and 100 series delivers approximately 26 rom and approximately 44 rpm for the 85 and 170 series The motor shaft with gear drives the feed rate control Motor Phenolic Gear Motor Shaft with Gear Metal Reduction Gear GEAR SET IDENTIFICATION The illustrations show the diameters of the gears and pinions 45 amp 100 SERIES GEARS 85 amp 170 SERIES GEARS Phenolic Gear Phenolic Gear 3 8 9 16 1 3 8 13 8 Metal Reduction Gear Metal Reduction Gear 9 16 9 16 E 1 3 8 1 1 4 46 www stenner com GEAR WEAR Generally gear failure can be caused by misalignment mainly due to the wear over the service life of the pump Check for the following conditions that can contribute to t
15. IGN Roller assembly collapses and expands Before turning pump on CONFIRM ROLLER ASSEMBLY IS EXPANDED and tube is pressed against housing wall After the pump head has been replaced the roller assembly must be expanded Proceed to pages 26 to 29 in the TUBE REPLACEMENT INSTRUCTIONS to EXPAND THE ROLLER ASSEMBLY according to your model CENTER THE TUBE Proceed to page 30 in the TUBE REPLACEMENT INSTRUCTIONS to CENTER THE TUBE USA and Canada 800 683 2378 International 904 641 1666 33 FEED RATE CONTROL FEED RATE CONTROL FRC The feed rate control adjusts the output by utilizing a cam and spring loaded lifter system to control the rotation of the roller assembly according to the setting on the dial ring Inside the FRC is a brass spider assembly that consists of a pin with carbide tip and spring inside the holder 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 FRC Channel Cam Index Plate Brass Spider Assembly Lifter holder and index pin spring is enclosed POCO
16. NER FAN BRAKE TOOL SHOULD BE USED FOR THIS STEP a Insert the fan brake tool into the vent in the rear of the motor housing Refer to the figures below NOTE The fixed output pump doesn t have a clutch so the fan brake keeps the shaft from rotating when expanding the roller assembly b Holding the pump securely use the cover as a wrench 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 amp 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 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 USA and Canada 800 683 2378 International 904 641 1666 27 PUMP TUBE TUBE REPLACEMENT continued EXPAND THE ROLLER ASSEMBLY FIXED OUTPUT MODEL Motor vent with key slot manufactured after 4 29 11 8 Expand roller assembly a Slide one latch out to remove it from the tube housing Insert the latch end into the key slot in the vent in the rear of the motor housing While pressing the latch into the rear of the motor gently rotate the cover clockwise until it stops Refer to the figures below b Holding the pump securely use the cover as a wrench and quickly snap rotate the roller assembly clockwise to expand the roller assembly The tube
17. S SEPARATING SUBASSEMBLIES gt 7 n Turn the pump off and unplug the power cord Hold the feed rate control section and turn the pump head clockwise until it stops Pull the pump head straight out Hold the motor assembly grasp the feed rate control section and turn clockwise until it stops and pull it straight out 4 Pump Head Feed Rate Control USA and Canada 800 683 2378 International 904 641 1666 13 SUBASSEMBLY CONNECTIONS RECONNECTING FEED RATE TO MOTOR 1 Before reconnecting the feed rate control to the motor confirm pressure spring adjustable model only is in place and place feed rate control on the shaft 2 the feed rate control counter clockwise to line up the flat side of the motor shaft d shaft with the flat side of the brass 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 oo y Y UV
18. e application Check the lifter cam and index plate during scheduled maintenance USA and Canada 800 683 2378 International 904 641 1666 35 FEED RATE CONTROL FEED RATE CONTROL WEAR continued SEIZED INDEX PIN AND OR LIFTER ASSEMBLY Water or chemical intrusion will corrode the pin and lifter causing them to seize 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 36 www stenner com FEED RATE CONTROL FRC PARTS REPLACEMENT 1 Remove and set aside Three screws Feed rate mounting plate Dial ring observe installed cam Brass spider assembly Index plate 2 required remove index pin assembly by unscrewing with a 3 8 wrench and replace Flip worn index plate over OR install new index plate Clean out FRC channel before installing new cam Apply AquaShield to lubricate the cam s angled tip To install the cam feed the angled cam tip 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 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 Angled
19. fore a new tube is installed USA and Canada 800 683 2378 International 904 641 1666 15 PUMP TUBE VISUAL REFERENCE A diamond pattern that forms where the tube presses against the tube housing indicates excessive back pressure Excessive back pressure can be caused by any blockage a clogged duckbill or when the system pressure exceeds the pump tube pressure 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 Tube dI ZI Koller Z DIAMOND PATTERN TEAR DROP PATTERN OVAL PAITERN Excessive pressure Normal Fatigued tube or or blockage worn components rollers The most common tube problems are from a lack of routine maintenance Always establish an application specific maintenance schedule 16 wwwsstenner com PUMP TUBE CONDITIONS THAT REDUCE TUBE LIFE IMPROPER TUBE HANDLING Not following factory tube replacement instructions Storing tubes in high ambient temperatures or long term exposure to direct sunlight weakens tube material
20. g wall USA and Canada 800 683 2378 International 904 641 1666 25 PUMP TUBE TUBE REPLACEMENT continued EXPAND THE ROLLER ASSEMBLY ADJUSTABLE MODEL 8 Expand roller assembly Hold the feed rate control securely use the cover as a wrench 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 amp O Proceed to step 9 on page 29 NOTE Clockwise is viewed from facing the head of the pump 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 2 At every tube change trim approximately 1 off the I end of both the suction and discharge lines before NN Tus installing new ferrules Replace duckbill 26 100 psi applications and ferrules with every new tube 26 www stenner com PUMP TUBE TUBE REPLACEMENT continued EXPAND THE ROLLER ASSEMBLY FIXED OUTPUT MODEL Manufactured before 4 29 11 8 Expand roller assembly N WARNING ONLY THE STEN
21. he phenolic gear stripping et Phenolic Gear Water or chemical intrusion Cracked bearing bracket Worn gear posts Worn gear case cover Rusted helical gear Insufficient lubrication Teeth missing Corrective Action 1 Review the vertical installation that includes using a rain roof in outdoor applications or wet environments Replace gears that show visible wear or corrosion Replace gear posts that are worn rusted or corroded Inspect the gear case and cover for cracks or corrosion and replace as needed 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 W Apply a generous amount of AquaShield to gear posts pinions gear rings and the main shaft with gear after doing service in the gear case USA and Canada 800 683 2378 International 904 641 1666 47 MOTOR GEAR REPLACEMENT Remove four Phillips head screws from gear case cover 2 Remove gear case cover Remove gears and inspect posts remove posts grasp with pliers and pull straight out 4 Wipe away old grease check for rust or corrosion on the rotor shaft and remove with wire brush any visible rust or corrosion prior to replacing gears Install gear posts by tapping with rubber mallet until bottomed Apply AquaShield on new gear posts before installing gears Install phenolic gear and spacer Install metal reduction gear and m
22. hrough with a 2 Phillips head screwdriver Use section of 1 4 suction discharge tubing and insert in hole USA and Canada 800 683 2378 International 904 641 1666 9 INSTALLATION POINTS SUCTION AND DISCHARGE LINES The suction line should be 3 from the tank bottom to prevent picking up sediment which can cause blockage in the check valve duckbill and discharge line Allow slack in both the suction and the discharge lines so the pump tube fittings can flex The slack prevents stress on the pump tube and fittings to help reduce the chance for breakage and leaks Suction Line 3 5 i 9 cm Weighted Suction Line Strainer 009009909909909900009909009099090900000909900900909090090000909000909909000900090900090009000900990000090090900009090900000909090000090009000009909099000909099000090900000999090000000900000099090990099 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 10 www stenner com INSTALLATION POINTS COMPRESSION SEAL The suction and discharge lines are installed to the pump tube fittings with a compression type seal consisting of the connecting nut and ferrule The beveled end of the ferrule should face the tube fitting and the suction and discharge lines should bottom
23. l refer to Chemical Resistance Guide SEIZED ROLLERS IN THE ROLLER ASSEMBLY Corrosive chemicals that collect on the roller bushings as a result 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 Confirm rollers turn freely Normal roller wear can cause a lack of output as a result of the rollers inability to fully squeeze the tube 18 www stenner com PUMP TUBE CONDITIONS THAT REDUCE TUBE LIFE continued EXCESSIVE BACK PRESSURE AT THE POINT OF INJECTION Calcium or mineral deposits in the injection fitting section of the check valve can cause blockage or restriction creating back pressure that exceeds the pump tube pressure rating 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 Injection Check Valve Duckbill Clean out accumulated deposits with a 2 phillips head screw driver EXCESSIVE BACK PRESSURE AT THE POINT OF INJECTION Insoluble sedimen
24. l injury or property damage To reduce risk of exposure the use of proper personal protective equipment is mandatory USA and Canada 800 683 2378 International 904 641 1666 5 GENERAL INFORMATION TOOL LIST AND CLEANING SUPPLIES 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 6 www stenner com GENERAL INFORMATION CLASSIC SERIES SINGLE HEAD ADJUSTABLE PUMP THREE BASIC SUBASSEMBLIES Motor Feed Rate Control FRC Pump Head ES 8 Use subassemblies in field for quick replacement USA and Canada 800 683 2378 International 904 641 1666 7 INSTALLATION POINTS INSTALLATION DIAGRAM FOR SINGLE HEAD PUMP Always use Rain Roof for outdoor use or if metering pump is Rain Roof slides into subject to washdowns wall mounting bracket no tools necessary On Off Switch under roof not visible this view Vertical Wall Mounting Bracket requires 2 screws Grounded Power Outlet
25. otor shaft with gear moe om Use remaining AquaShield on top of the three gears 10 Re attach gear case cover and four new screws finger tighten the screws Screws must be backed in to locate original threads before securing to prevent stripping screw boss Gear Post Phenolic Gear Metal Reduction Gear Pressure Spring adjustable models only Thrust Washer Phenolic Gear Motor Shaft Spacer with Gear Gear Case Gear Case Cover Gear Case Phenolic Gear with Spacer Motor Shaft Metal Reduction Gear with Gear 48 www stenner com STE NNER STENNER PUMP COMPANY 3174 DeSalvo Road Jacksonville Florida 32246 Phone 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 Stenner products are proudly made in the USA Stenner Pump Company All Rights Reserved Illustrations by David Stiles www stilesdesigns com BSME Rev1211
26. r on the tube housing affix the front latches to the cover lip and then press the latches back to secure Figure J POCO Identify the cause of tube failure prior to installing 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 tube into place 24 www stenner com PUMP TUBE TUBE REPLACEMENT continued INSTALL TUBE continued 4 With the cover latched plug the pump in and turn the power on Allow the pump to run the roller assembly in its collapsed position for approximately one minute to relax the tube Figure K Turn the pump off and unplug the power cord Remove the tube housing cover and flip to use as a tool in the next step Figure L 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 housin
27. re 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 20 wwwsstenner com IMPORTANT TUBE INFORMATION gt Always follow factory tube replacement and centering instructions Schedule a tube replacement at regular intervals according to the needs of the specific application used tube will have stretched approximately 3 4 and the new tube will appear to be stiff and short 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 Replace ferrules with every tube change ferrules are the seal between the tube fitting and the connecting nut Only finger tighten the nut and ferrule Over 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 compatibility or call the factory 96090000900900000009000000000000000000000900000000000000090000000000000000000000900000090000000000000090000000000000000090090000900909000000900000900000000000000000000009000900009 For
28. tip 3 8 wrench Angled end Installing New 90 end A 90 angle USA and Canada 800 683 2378 International 904 641 1666 37 FEED RATE CONTROL FRC PARTS REPLACEMENT continued 8 Apply Aquashield to the inside of the dial ring for easier turning 9 Place dial ring boss onto the cam s 90 end 10 While keeping the 90 end in the boss and the cam in the FRC channel in a clockwise motion place the dial ring onto the FRC housing and snap into place 11 Apply AquaShield to bottom of the FRC housing before placing index plate inside Apply 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 rotate if it lacks AquaShield or the screws are over tightened If the screws are too loose the dial ring can inadvertently be turned to setting 10 by the motor 38 www stenner com MOTOR MOTOR The motor has a cylindrical rotor with shaft that is encased within a magnetic coil When power 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
29. ts 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 pressure can damage the pump tube Corrective Action 1 Replace suction and discharge tubing and clean sediment from tank bottom 2 Position weighted strainer 3 from tank bottom 3 Replace duckbill At every tube change trim approximately 1 off the end of both the suction and discharge lines before installing new ferrules Replace duckbill 26 100 psi applications and ferrules with every new tube USA and Canada 800 683 2378 International 904 641 1666 19 PUMP TUBE CONDITIONS THAT REDUCE TUBE LIFE continued SPLIT ALONG SIDE OF THE TUBE The tube rubbing against the edge of the tube housing can cause the side to split Corrective Action Always follow the factory s tube replacement instructions which include centering the tube on the rollers Rollers Tube off center on 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 a
30. ump securely Use the tube housing cover as a wrench and quickly Snap rotate the cover counter clockwise to collapse the roller assembly The tube will no longer be pressed against the tube housing wall Figure E NOTE Counter clockwise is viewed from facing the head of the pump Remove and discard the pump tube Figure F 8 Remove the roller assembly and the tube housing On the adjustable pump also remove the shaft Set them aside to reinstall later 9 Use anon citrus all purpose cleaner to clean chemical residue from the tube housing roller assembly and cover 10 Check the housing for cracks and replace it if it is 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 an adjustable pump also install the shaft into the feed rate control 13 Apply AquaShield to the shaft tip 14 Install roller assembly USA and Canada 800 683 2378 International 904 641 1666 23 PUMP TUBE TUBE REPLACEMENT continued INSTALL TUBE IMPORTANT DO NOT LUBRICATE PUMP TUBE OR ROLLER ASSEMBLY 1 Ensure the power to the pump is off and the power cord is unplugged On the adjustable model ensure that the feed rate control is set to 10 Figure H 2 Place the new tube in the pump head use your fingers to center it over the rollers Figure 3 Place the tube housing cove
31. unter clockwise to secure the rivets in the rivet slots firmly attaching the pump head Proceed to page 33 USA and Canada 800 683 2378 International 904 641 1666 31 PUMP HEAD PUMP HEAD REPLACEMENT continued FIXED RATE MODEL REMOVE PUMP HEAD amp INSTALL QuickPro PUMP HEAD 1 Turn off the pump and unplug the power cord a remove the pump head hold the pump securely grasp the head and turn it clockwise until it stops Figure A b Remove the tube housing and roller assembly together by pulling it straight out from the pump The shaft will remain in the pump Discard the tube housing and cover If the housing and roller assembly are difficult to remove insert a large flat blade screwdriver 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 Putthe 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 adjustable pump OR motor fixed output pump Figure D 3 Continue to push until the rivets are inside the holes Turn the pump head counter clockwise to secure the rivets in the rivet slots firmly attaching the pump head Proceed to page 33 32 www stenner com PUMP HEAD PUMP HEAD REPLACEMENT continued NEW PUMP HEAD DES
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