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Summary of Contents for Stenner Pumps QuickPro QP25T2-1
- Page 1 PERISTALTIC METERING PUMPS SINCE 1957 BASIC SERVICE MANUAL CLASSIC SERIES WITH QuickPro ® PUMP HEAD TO BE INSTALLED BY PROPERLY TRAINED PROFESSIONAL INSTALLER ONLY. READ MANUAL & LABELS FOR ALL SAFETY INFORMATION & INSTRUCTIONS.
- Page 3 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.
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Page 4: Table Of Contents
TABLE OF CONTENTS SECTION I – GENERAL INFORMATION SAFETY INFORMATION ................5 TOOL LIST AND CLEANING SUPPLIES ............6 CLASSIC SERIES PUMP ................7 SECTION II – INSTALLATION POINTS INSTALLATION DIAGRAM ................8 VERTICAL INSTALLATION ................9 SUCTION AND DISCHARGE LINES ............. 10 COMPRESSION SEAL ................ -
Page 5: Section I - General Information
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. HAZARDOUS VOLTAGE: DISCONNECT power cord before removing motor cover for service. Electrical service by trained personnel only. -
Page 6: Tool List And Cleaning Supplies
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 •... -
Page 7: Classic Series Pump
GENERAL INFORMATION CLASSIC SERIES SINGLE HEAD ADJUSTABLE PUMP THREE BASIC SUBASSEMBLIES Motor Feed Rate Control (FRC) Pump Head Use subassemblies in field for quick replacement. USA and Canada 800.683.2378, International 904.641.1666. -
Page 8: Section Ii - Installation Points
INSTALLATION POINTS INSTALLATION DIAGRAM FOR SINGLE HEAD PUMP Always use Rain Roof for outdoor use or if metering pump is subject to washdowns. Rain Roof slides into 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;... -
Page 9: Vertical Installation
INSTALLATION POINTS 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. -
Page 10: Suction And Discharge Lines
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. -
Page 11: Compression Seal
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 into the tube fitting. -
Page 12: Section Iii - Subassembly Connections
SUBASSEMBLY CONNECTIONS RIVET AND SLOT IDENTIFICATION Indentation Motor shaft and pressure spring coated with Aquashield ® Rivets (3) Bump Mounting Plate Rivet Slots (3) Plate Screws (3) The pressure spring is not used with the fixed output pump. www.stenner.com... -
Page 13: Separating Subassemblies
SUBASSEMBLY CONNECTIONS SEPARATING SUBASSEMBLIES 1. Turn the 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 14: Reconnecting Feed Rate To Motor
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. Turn 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. -
Page 15: Section Iv - Pump Tube
PUMP TUBE 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: •... -
Page 16: Visual Reference
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. -
Page 17: Conditions That Reduce Pump Tube Life
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. • Prior to installation, pre-stretching, lubricating the tube and/or roller assembly or pinching during installation, compromises the tube material. - Page 18 PUMP TUBE CONDITIONS THAT REDUCE TUBE LIFE continued CRACKED PUMP HEAD The tube housing and latches can crack from wear, long term chemical exposure or due to solution incompatibility with the housing material (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.
- Page 19 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.
- Page 20 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.
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Page 21: Important Pump Tube Information
PUMP TUBE IMPORTANT TUBE INFORMATION • Always follow factory tube replacement and centering instructions. • Schedule a tube replacement at regular intervals according to the needs of the specific application. • A used tube will have stretched approximately 3/4" and the new tube will appear to be stiff and short. -
Page 22: Tube Replacement
PUMP TUBE TUBE REPLACEMENT PREPARATION 1. Follow all safety precautions prior to tube replacement. 2. 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. - Page 23 PUMP TUBE TUBE REPLACEMENT continued 6. On the adjustable pump, hold the feed rate control securely. On the fixed output pump hold the pump 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.
- Page 24 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.
- Page 25 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 5.
- Page 26 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.
- Page 27 PUMP TUBE TUBE REPLACEMENT continued EXPAND THE ROLLER ASSEMBLY – FIXED OUTPUT MODEL (Manufactured before 4/29/11) 8. Expand roller assembly ONLY THE STENNER 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.
- Page 28 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.
- Page 29 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.
- Page 30 PUMP TUBE TUBE REPLACEMENT continued 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.
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Page 31: Pump Head Replacement
PUMP HEAD PUMP HEAD REPLACEMENT ADJUSTABLE MODEL REMOVE PUMP HEAD & INSTALL QuickPro PUMP HEAD ® 1. Turn off the pump and unplug the power cord. a. To remove the pump head, hold the feed rate securely, grasp the head and turn it clockwise until it stops. - Page 32 PUMP HEAD PUMP HEAD REPLACEMENT continued FIXED RATE MODEL REMOVE PUMP HEAD & INSTALL QuickPro PUMP HEAD ® 1. Turn off the pump and unplug the power cord. a. To remove the pump head, hold the pump securely, grasp the head and turn it clockwise until it stops.
- Page 33 PUMP HEAD PUMP HEAD REPLACEMENT continued Expand the roller assembly EXPAND THE ROLLER ASSEMBLY 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 to failure of the roller assembly.
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Page 34: Section V - Feed Rate Control (Frc)
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. -
Page 35: Feed Rate Wear
FEED RATE CONTROL 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 plastic cam More cam is exposed to the rotation of the lifter at lower dial ring settings leading to cam wear and causing index malfunctioning. - Page 36 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.
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Page 37: Feed Rate Parts Replacement
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. If required, remove index pin assembly by unscrewing with a 3/8" wrench and replace. - Page 38 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.
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Page 39: Section Vi - Motor
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 helical end of the rotor engages the series of gears in the gear case. -
Page 40: Causes Of Motor Malfunction
MOTOR CAUSES OF MOTOR MALFUNCTION LIQUID 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. -
Page 41: Rotor Assembly Replacement
MOTOR ROTOR ASSEMBLY REPLACEMENT A rotor assembly includes B, D & F. 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 C •... -
Page 42: Coil Replacement
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 and feed rate control as a stand to work on the motor. See illustration. 4. - Page 43 MOTOR COIL REPLACEMENT continued 5. Disconnect ground wire (with eyelet) and set screw aside. 6. 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: •...
- Page 44 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.
- Page 45 MOTOR COIL REPLACEMENT 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.
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Page 46: Gears & Gear Set Identification
MOTOR GEARS Located in the gear case, the metal reduction gear and phenolic gear control the rpm of the feed rate and pump head. The 45 and 100 series delivers approximately 26 rpm and approximately 44 rpm for the 85 and 170 series. The motor shaft with gear drives the feed rate control. -
Page 47: Gear Wear
MOTOR 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 the phenolic gear stripping. • Water or chemical intrusion Phenolic Gear •... -
Page 48: Gear Replacement
MOTOR GEAR REPLACEMENT 1. Remove four Phillips head screws from gear case cover. 2. Remove gear case cover. 3. Remove gears and inspect posts. To 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. - Page 50 STENNER PUMP COMPANY 3174 DeSalvo Road Jacksonville, Florida 32246 USA 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 Made in the USA © Stenner Pump Company All Rights Reserved Illustrations by David Stiles www.stilesdesigns.com...
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