Stenner® Basic Service Manual
Contents
1. Motor mum 27 Gear Case How it worke The metal reduction gear and phenolic gear control the rpm of the feed rate and pumping head The 45 series delivers 26 rpm and 44 rpm for the 65 series The motor shaft with gear drives the feed rate control PHENOLIC p Lu 45 Series 8b Series I 9 16 4 lt 11 4 gt 1 i Continued 38 Maintenance Basics Motor Gear Case Wear Definition Gear failure in general can be caused by misalignment mainly due to wear water or chemical intrusion inside the gear case insufficient tooth engagement or wear and or damage to other components F TEETH MISSING BEST PRACTICE Factory recommended Apply generous amounts of grease AquaShield to gear posts gear rings pinions and output shaft Gear Case Parts Replacement when doing service in the gear case 1 Replace gears that show visible wear or corrosion 2 Replace gear posts that are worn rusted or corroded e To remove gear posts grasp with pliers and pull straight out To install gear posts insert in hole and press until bottomed Inspect gear case and cover for cracks and cup bearing for corrosion Replace as needed 59 Motor How it works A cylindrical rotor with shaft is encased within a magnetic coil When power ie applied to the coil the rotor rotates The rotor s directional rotation is determined by the orientation of the copper shade2. 6 Grease AquaShield the cover bushing ONLY and replace the cover and the screws leaving the front screw in between the fittings loose enough to rotate the tube fitting in order to center tube on rollers Centering the Pump Tube 1 To center 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 5 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 29 4 Turn the pump off let go of fitting and tighten the cover screws The cover ie not on securely if there ie between 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 30 Maintenance Basics Feed Rate Control FRC Feed Rate Control How it works SPIDER Ja E MERDA The feed rate control adjusts the output by utilizing a cam and lifter system to control the rotation of the roller assembly according to the setting on the dial ring Inside the FRC ie a brass spider and index pin assembly that consists of a pin with carbid
3. 7 DISASSEMBLED VIEW DISASSEMBLED j VIENI P I E lt lt gp 2 OUT 500998 p j Scare LINE gt n INJECTION LINE v maran FITTING amp CHECK ETC ee VALVE O 25 pei k e i WALW 5 SHUT OFF VALVE 26 100 psi CA SOLUTION TANK Spill Recovery In case of tube rupture chemical drains back into solution tank reducee or limite epillage on the ground or floor and prevente chemical from collecting in tube housing SPILL RECOVERY BAEk PARTIAL BOLE P THRO WITH HEAD amp 2 e Use section 44 DISCHARGE TUBING iM Vertical Wall Installation Thie type of installation ie recommended by factory to keep chemical away from pump parte Ouction Line Suction line should be 3 from tank bottom to prevent picking up eediment which can cause blockage in the check valve duckbill and discharge line Allow slack suction discharge tubing pump tube fittings can flex This prevents stress on tubing and tube fittings reducing the chance for breakage and leaks WEIGHTED STRAINER Compression Seal ferrules Beveled ends of ferrules face tube fittings Tubing should bottom into all fittings NOTE Additional information For 3 8 connections only While stabilizing the tu
4. BIEN PUMPS Basic Service Manual Classic Series Basic Service Manual Classic Series STENNER SECTION I General Information Safety Frecautione Icone 2 2 Tool List amp Cleaning eR DEP o e eo 3 Arb ldenbiicablotn wits qus deers e n hae 4 SECTION II Installation Review sess eara OR ea ORO RO REG p 5 Spill REG RE EU EA PORE 6 Vertical Wall Installation 6 SUCTION Line Compression Seal 7 ROOT eens Re eoa Rx CR REA UR RU eee is e SECTION III Separating amp Reconnecting Subassemblies Rivet arid Identification sse rr Ee eas 9 Ceparating Gubassembll b eR Wr e 10 Reconnecting Feed Rate to MOTOF kana ECOLE UE OY RR 11 Reconnecting Pump Head to Feed Rate 12 SECTION IV Maintenance Basics Tube Tube How It Worke 52 oss e eth d 15 Tube Failure cocer one eee Y OC Des 14 Fundamentale xoc cheese t et e 15 Tube Failure Causes amp Corrective Action 16 22 Tube Replacement amp Centering 23 29 SECTION Y Maintenance Basics Feed Rate Control FRC Feed Rate Control How It 2 2 2 1 50 Feed Ra
5. which could be caused by calcium blockage clogged duckbill 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 Tube Roller DIAMOND TEAR DROP OVAL Excessive TUBE PRESSURE COMPONENTS BLOCKAGE KEN The tube can rupture or break rupture normally occure at the point between the diecharge tube fitting and the area where the roller leaves the tube A break or rip occurs just past the euction fitting The tube ie the workhoree of the pump It ie perishable and eventually has to be changed Tube Fundamentals ror maximum tube life Determine cause of tube failure before installing new tube e Natural wear end of service life Blockage excessive pressure worn damaged parte identity and correct problem IMPORTANT for optimum performance Remember to check tube psi rating against application psi Tube sizes 1 2 5 4 5 amp 7 are rated from 0 25 psi 1 2 amp 7 are rated from 26 100 psi when used with the injection check valve EU HA ASPR Maw 44 PFPE MAK STEMN R RHej 25P5 ETE DD M Mi Continued 16 Maintenance Basics Tube Tube Failures Causes and Corrective Action Excessive back pressure at the point of injection Blockage or restrictio
6. Tube fitting flange cracks are normal on the discharge tube fitting They DO NOT indicate a failure or defect J NOTE Additional information Continued 22 Maintenance Basics Tube Other tube failures e Using pump componente not provided by Stenner can cause pump to malfunction Chemical incompatibility petroleum and oil based products not compatible with Santoprene tube material Storage of tubes in high ambient temperatures and long term exposure from direct sunlight Overpressure due to crushed over tightened 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 Points to Be Greased 2 BEST PRACTICE Factory recommended Every time pump is serviced or tube is replaced apply grease AquaShield to the pump head cover bushing and main shaft ONLY Tube Replacement and Centering 2 BEST PRACTICE Factory recommended Prior to tube removal pump water through Removing the Old Pump Tube 1 2 tube to remove chemical Turn pump off Kemove ecrewe and then the cover by lifting the eide opposite the tube fittings Set the feed rate dial on a low setting and leave on this setting until finished Turn the pump on and let it run until one of the thr
7. dial ring boss onto the cam e 90 end 11 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 Generously grease AquaShield bottom of FRC housing before placing index plate inside Grease the top of the index plate 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 55 14 To secure mounting plate align ite arrow with the FRC housing arrow and install the three ecrewe 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 NOTE Additional information The dial 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 56 Maintenance Basics amm Feed Rate Control Manufactured before 2002 NOTE Additional information An arrow doesn t exist on older feed rate control mounting plates Place the plate the bump is to the left of the two adjacent holes that 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 tela Maintenance Basics
8. ard Continued 42 Maintenance Basics Motor gt _ gt 9 Install new coil over rotor on the remaining amber bracket The correct orientation ie with two copper rode 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 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 15 Crimp the etripped lead wiree to each of the new coil lead wires 14 Tuck wire nute into bottom of motor cover and eecure cover back in place Before tightening reveree cover ecrewe to catch original threade 15 Apply power to motor and test 44 Maintenance Basics Motor Correct Coil Orientation Rotor Assembly Replacement A new rotor assembly includes B D amp F 1 Remove and set aside e Two motor housing screws not shown Motor housing A Plastic fan discard old fan Two coil screws and lock washers C 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 Install the new rotor F by inserting th
9. be 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 TIGHTEN of adapter If leak occurs gradually tighten the 5 8 connecting nut as required 6 lInstallation_ PIN Rain Roof Recommended in all outdoor or wet environmente Fump motor is ventilated and water intrusion can cause motor damage JM Separating amp Reconnecting 9 Subassemblies Rivet and Slot Identification PLATE 10 Separating amp Reconnecting Subassemblies Separating Subassemblies 1 Turn the pump off and unplug the power cord 2 Hold the feed rate control section and turn the pump head clockwige 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 1 Reconnecting Feed Rate to Motor 1 Before reconnecting the feed rate control to the motor confirm preeeure epring ie in place and place feed rate control on the shaft 2 Turn the feed rate control counterclockwise to line up the flat side of the motor shaft d shaft 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 th
10. d poles on the coil The helical end of the rotor engages the series of gears in the gearbox MOTOR 7 BEST PRACTICE Factory recommended Avoid mounting pump over an open chemical solution tank Proper ventilation will extend motor life Use a Stenner Rain Roof for outdoor Motor Failure Definition installations or if pump is subject to washdown Fower is applied to the motor and the rotor fails to rotate Motor Failure causes Water intrusion Install rainroof to protect fan cooled motor against water intrusion while allowing for ventilation Chemical vapore Can corrode or ruet the motor parte Inetall pump with adequate ventilation and avoid mounting over an open solution tank Faulty electrical supply or power source Motor voltage must match power supply Use volt meter to confirm 40 Maintenance Basics Motor Coil Replacement 1 Disconnect power to pump 2 Remove motor base Remove two motor cover screws 3 Invert the pump and use the pump head as a stand to work on the motor See illustration 4 Remove fan and set aside AMDER Ac BRACKET MOTOR COVER SCREEN Boss 41 Dieconnect ground wire with eyelet and eet ecrew aside Cut the power cord and coil lead wiree from motor cover at the wire nut four cute total et cover to the eide Remove and set aside e Two coil screws and washers from the rotor bracket Plastic bearing bracket amber Remove coil and disc
11. e bump on the feed rate mounting plate fits into the indentation in the gear case cover NOTE Additional information A The arrow on the feed rate control should be on top and confirm the bump is in the indentation 12 Separating 8 Reconnecting SubassemblicS Reconnecting Pump Head to Feed Rate 1 Put the pump head with main shaft into the feed rate control and turn it counterclockwise until the ehaft falle into place 2 Push the pump head toward the feed rate while turning it counterclockwiee to line up the rivet holes on the pump head with the rivete 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 ela Maintenance Basics 13 TUBE wear part How it works The tube is squeezed by two of 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 14 Maintenance Basics Tube amm Tube Failure Definition The general cause of most tube failures is a lack of routine maintenance A tube failure is indicated by a leak or a lack of output A diamond pattern where the tube presses against the pump head housing indicates excessive back pressure
12. e shaft helical gear onto the amber bearing bracket Place the coil E see Correct Coil Orientation over the rotor F onto the bearing bracket D Snap into place the second bearing bracket onto the rotor 7 Insert two coil screws with lock washers and tighten Starting at an angle press fan with hub side down onto the rotor ehaft Reinstall the two motor housing screws and tighten the self tapping screws to secure the motor housing 45 a Quick Tips Three Basic Subassemblies e Use subassemblies in field for quick replacement Repair and refurbieh parte at shop e Use Stenner Tank System for quick installation Establish application specific maintenance schedule Install parte poster in shop for quick part reference e Use UV black suction discharge tubing rain roof and UV gray tanks for outdoor applications Contact factory for help 800 683 2578 or 904 641 1666 e Visit our website at www stenner com STENNER CSM208 STENNER Peristaltic Metering Pumps Since 1957 www stenner com Phone 904 641 1666 US Toll Free 800 683 2378 Fax 904 642 1012 Hours of Operation EST Monday 7 5 Tues Fri 7 5 30 3174 DeSalvo Road Jacksonville Florida 32246 sales stenner com 9Stenner Pump Company All Rights Reserved Illustrations by David Stiles www stilesdesigns com
13. e 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 UFTER HOLDER INDEX PIN WITH an index plate hole The roller assembly rotates creating the CARBIDE TIP SPRING ENCLOSED pumping action When the lifter rides on the cam the pin ie lifted inside the holder The roller assembly does not rotate resulting in no pumping action NOTE Additional information Pin retracts when lifted 51 Feed Rate Wear Definition 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 Feed Rate Wear Causes 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 Index pla i The lifter riding on the cam causes a groove in the cam x plate with etongated holes WORM Th PLASTIC CARA fa Continued 22 Maintenance Basics Worn lifter wear part Continuous repetition of the lifter riding on the cam can cause 2 a flat epot on the rounded point of the lifter The flat epot contributes
14. ed 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 between your thumb and index finger If it rocks back and forth replace the roller assembly Vertical Mount 19 BEST PRACTICE Factory recommended Mount pump vertically and use spill recovery to drain chemical back to tank in the event of tube failure Thie will help prevent chemical from collecting in the tube housing and reducee epillage on the floor Spill Recovery SPILL RECOVERY TIBE SOLUTION BASE TAME PaRTLAL HOLE IS THES WITH FILLES HEAD amp 2 F use SECTION J4 s SUCTION DISCHARGE TUBING IM HALE NOTE Adaditional information Screws are self tapping back off screws to find original threads If screw bosses are stripped use screws to cut new threads in unused bosses Fosition them opposite one another The pump housing must flex to avoid pump head cracking Do not use more than two screws Continued 20 Maintenance Basics mmm Tube leaks around the fitting can result from Using pliers which can break internal seals and t
15. ee slots in the roller assembly lines up with the bottom tube fitting Suction side PE 1 l 701 5 gak TT CRIT Continued 25 24 Maintenance Basics 5 Turn pump off 6 Without moving the roller assembly further lift the tube fitting out of the housing elot and pull it toward the center of the roller 7 Turn pump on and allow roller assembly to jog while guiding the tube with teneion up and out of the housing 65 Turn the pump off Completely remove the tube assembly 25 After Removing Old Tube IMPORTANT Key for optimum performance ldentify the cause of tube failure prior to installing a new tube 1 Remove roller assembly shaft and housing 2 Use Fantastik or similar non citrue all purpose cleaner to clean all chemical 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 Hes TILT amp Continued 26 Maintenance Basics mmm Inepect the euction diecharge tubing point of injection and check valve duckbill for blockages Clean and or replace ae required 7 Install clean housing amp Inetall and grease ehaft 9 Install roller assembly Installing the New Pump Tube 1 Manually turn roller assembly c
16. ined personnel A WARNING Hazardous Pressure Chemical Exposure To reduce risk of chemical exposure the use of proper personal protective equipment is mandatory when working on or near chemical metering pumps A Shut off water source Use caution and bleed off all resident system pressure prior to attempting service or installation A Use caution when disconnecting discharge tubing from pump Discharge tubing may be under pressure and may contain chemical Important icons used in this manual BEST PRACTICE Factory recommended NOTE Additional information FE IMPORTANT Key for optimum performance Tool List amp Cleaning Supplies 2 Phillips head screwdriver Flat blade screwdriver 3 8 open end wrench to change index pin lifter Stenner grease AquaShield Fantastik or similar non citrue all purpose cleaner Needle noge pliers Utility knife 4 General Information Part Identification Stenner Classic Series Chemical Feed Pump DAL RING NOTE Additional information A Use subassemblies in field for quick replacement Repair and refurbish parte at ehop 210 Installation m 5 Review Proper Installation RAIN E ONTS SLOTS IN L AUTIN G BRACKET GROUNDED Oki GFF wma rupek ROOF Fewer VISIBLE THIS view CUTLET eFic s RECOMMENDED WALL MOUNTING BRACKET REQUIRES SCREWS IN SUCTION
17. n located inside the injection fitting portion of the check valve 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 2 Replace duckbill BEST PRACTICE Factory recommended Replace duckbill with every tube change ral PERIIT I Pos LAMA fa HEAD 17 Excessive back pressure at the point of injection Blockage or restriction of the check valve duckbill due to insoluble sediments or particulates from the bottom of the tank Corrective Action 1 Replace suction discharge tubing and clean sediment from tank bottom 2 Fosition suction weight 3 from tank bottom 3 Use strainer 4 Replace duckbill if necessary Split along tube side Rubbing along roller assembly and pump head housing edge Corrective Action 1 Center tube at time of new tube installation NOTE Additional information Tube will not center if wrist twists during installation or if rollere are worn Continued 18 Maintenance Basics Tube mme Frozen rollers in roller assembly Chemical intrugion A cracked pump head housing Wear chemical exposure or incompatibility Corrective Action 1 Pump head housing and roller assembly must be ringed and wiped free of chemical residue or replaced if corroded or crack
18. ounterclockwise to line up IMPORTANT its slot with the tube housing slot Key for optimum performance 2 Flace the tube fitting into the housing and roller ly slot DO NOT lubricate pump tube or roller assembly YAN TUBE SLOT 3 Turn dial ring to L setting e While holding the threaded tube fitting turn the pump on and allow it to jog the roller assembly e Guide the tube with slight tension toward the center to prevent pinching between the housing and roller assembly 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 Turn the pump off TUBE HOUSING SLOT TURN THE PUMP ON WALK TUBE IM ROLLER ASSEMBLY SLOT 27 IMPORTANT Key for optimum performance Avoid rotating wrist which can result in a twisted tube that will not center DO NOT force the tube and be careful of your fingers NOTE Additional information A used 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 Continued 28 Maintenance Basics Tube NOTE Additional information If pump head housing screws are stripped use alternate bosses and position them opposite each other Use only two at a time
19. te Wear Definition amp Causes 51 52 Feed Rate Farts Replacement koe Ope See a 55 56 SECTION VI Maintenance Basics Motor Gear Caee How If WorkS ass cece 37 Gear Case Wear Definition csse 38 Gear Case Farts Replacement 38 Motor How lt Work i eie t Ro dag Rs 59 Motor Failure Definition amp CAUSES 39 Goll Replacement Voices Ver ek 40 43 Rotor Assembly Replacement 44 SECTION VII Quick TIPS HA 45 INTRODUCTION FEX S 4 a eagle ME mi Me ui E D Tuus The Stenner Classic Series peristaltic metering pumps are mechanical and will during their service life require scheduled maintenance The purpose of this manual ie to identify the five wear parte pump tube roller assembly lifter and index plate that will eventually require replacement along with other maintenance basics Best practice tips euch as a spill recovery to eliminate chemical leakage ae well ae corrective actione are covered 2 General Information OT Safety Precautions o NOTICE Before installing or servicing the pump read the pump manual for all safety information and equipment instructions The pump is designed for installation and service by properly tra
20. to the premature wear of the cam and index plate seized or corroded index pin and lifter assembly BEST PRACTICE Usually caused by water or chemical intrusion Factory recommended Mount pump in vertical position with spill recovery NOTE Additional information tube to allow chemicals to drain away from internal parte The lower the feed rate control setting the more wear on the cam lifter and plate To reduce FRC parte wear select the pump model that will operate at the desired maximum Feed Rate Farte Replacement 1 Remove screws Remove feed rate mounting plate and dial ring Remove cam epider aesembly and index plate If required remove index pin aesembly by unecrewing with box wrench and replace ew N Flip worn index plate over OR install new index plate Clean out FRC channel before installing new cam 4 5 6 Use grease qua9hiela to lubricate the cam e angled tip 7 Install the cam 6 Installing New Feed the angled tip into the FRC channel and keep the 2 90 end in the up position Place thumb over the cam to guide ae it ie ineerted in the channel 9 Continue to feed the cam in the channel until there ie approximately a 1 2 gap between the cam tip and the beginning of the channel Continued 4 20 24 Maintenance Basics FRC BEST PRACTICE Factory recommended Spread AquaShield on bottom step of ring for easier rotation 10 Place
21. wist the tube Turning the fitting inside the tube when centering a replacement tube or when connecting suction discharge lines Using thread sealant tape which prevents ferrules from seating into tube fitting Stress on tube fitting from a tight radius the suction discharge tubing Crushed ferrules from over tightening or use of pliers Corrective Action 1 Finger tighten connecting nut DO NOT pliers DO NOT use thread eealant tape Hold tube fitting when tightening connecting nut to prevent fitting from turning 2 Change ferrules with every tube change Ferrules make the seal between tube fitting and the connecting nut DO NOT a Lisa PLIERS Tube fittings pulling out of the tube can result from Fulling excessively on the tube fitting when installing a replacement tube Allow rollere to etretch tube into position and follow tube replacement instructions e Fre etretching the tube before replacement NOTE Additional information Due to wear the used tube will have stretched and will be longer than the new tube Normal tube failures Pin hole at discharge side tube will leak Breakage at the suction 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
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