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Stenner Classic Series Basic Service Manual

Chemical feed pump
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Basic Service Manual
Classic Series

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  • Page 1 Basic Service Manual Classic Series...

  • Page 2: Table Of Contents

    ........... . 45 INTRODUCTION The Stenner Classic Series chemical feed pumps are mechanical and will, during their service life, require scheduled maintenance. The purpose of this manual is to identify the five wear parts (pump tube, roller assembly, lifter, cam, and index plate) that will eventually require replacement, along with other maintenance basics.

  • Page 3: Section I - Ge Neral Information

    Section I General Information Safety Precautions Before Working on a Stenner Chemical Feed Pump 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.

  • Page 4: Tool List/Cleaning Supplies

    Tool List/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-citrus) all purpose cleaner • Needle-nose pliers • Utility knife...

  • Page 5: Part Identification

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

  • Page 6: Section Ii - Installation

    Section II Installation Review Proper Installation 0-25 psi 26-100 psi...

  • Page 7: Spill Recovery

    6 Installation Spill Recovery In case of tube rupture, 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: Suction Line, Compression Seal

    Suction Line Suction line is 3" from tank bottom. This prevents picking up sediment, which can cause blockage in the check 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.

  • Page 9: Rain Roof

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

  • Page 10: Section Iii - Separating & Reconnecting Subassemblies

    Section III Separating & Reconnecting Subassemblies Rivet and Slot Identification...

  • Page 11: Separating Subassemblies

    10 Separating & 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 clockwise until it stops. 3. Pull the pump head straight out. 4.

  • Page 12: Reconnecting Feed Rate To Motor

    Reconnecting Feed Rate to Motor 1. Before reconnecting the feed rate control to the motor, confirm pressure spring is 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.

  • Page 13: Reconnecting Pump Head To Feed Rate

    12 Separating & Reconnecting Subassemblies 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 shaft falls into place. 2. Push the pump head (toward the feed rate), while turning it counterclockwise, to line up the rivet holes on the pump head with the rivets on the feed rate control.

  • Page 14: Section Iv - Maintenance Basics - Tube

    Section IV Maintenance Basics – Tube 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.

  • Page 15: Tube Failure Definition

    14 Maintenance Basics – Tube 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, which could be caused by calcium blockage, clogged duckbill, or system pressure in excess of pump tube rating.

  • Page 16: Tube Fundamentals

    Tube Fundamentals For maximum tube life Determine cause of tube failure before installing new tube • Natural wear, end of service life. • Blockage, excessive pressure, worn/damaged parts: locate and correct problem. IMPORTANT! Key for optimum performance Remember to check tube psi rating against application psi.

  • Page 17: Tube Failure - Causes & Corrective Action

    16 Maintenance Basics – Tube Tube Failures Causes and Corrective Action Excessive back pressure at the point of injection Blockage or restriction located inside the injection fitting portion of the check valve due to calcification or mineral deposits. Corrective Action 1.
  • Page 18 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.
  • Page 19 18 Maintenance Basics – Tube Frozen rollers in roller assembly (wear part) Chemical intrusion. A cracked pump head housing Wear, chemical exposure, or incompatibility. Corrective Action 1. Pump head housing and roller assembly must be cleaned and wiped free of chemical residue or replaced if corroded or cracked.
  • Page 20 BEST PRACTICE Factory recommended Mount pump vertically and use spill recovery to run chemical back to tank in the event of tube failure. Chemical drains back into solution tank, preventing spillage on the ground/floor and keeps chemical from collecting in tube housing. Spill Vertical Recovery...
  • Page 21 20 Maintenance Basics – Tube Tube leaks around the fitting • Using pliers which can break internal seals and twist the tube. • Turning the fitting inside the tube when centering a replacement tube or when connecting suction/discharge lines. • Using Teflon Tape preventing ferrules from seating into tube fitting.
  • Page 22 Tube fittings pulling out of the tube • Pulling excessively on the tube fitting when installing a replacement tube. Allow rollers to stretch tube into position and follow tube replacement instructions. • Pre-stretching the tube before replacement. NOTE Additional information Due to wear, the used tube will have stretched and will be longer than the new tube.
  • Page 23 22 Maintenance Basics – Tube Other tube failures • Using pump components 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.

  • Page 24: Tube Replacement & Centering

    Tube Replacement and Centering BEST PRACTICE Factory recommended Prior to tube removal, pump water through tube to remove chemical. Removing the Old Pump Tube 1. Turn pump off. 2. Remove screws and then the cover by lifting the side opposite the tube fittings. 3.
  • Page 25 24 Maintenance Basics – Tube 5. Turn pump off. 6. Without moving the roller 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.
  • Page 26 After Removing Old Tube IMPORTANT! Key for optimum performance Identify the cause of tube failure prior to installing a new tube. 1. Remove roller assembly, shaft, and housing. 2. Use Fantastik ® or similar (non-citrus) all purpose cleaner to clean all chemical residue from pump head housing, roller assembly, and cover.
  • Page 27 26 Maintenance Basics – Tube 6. Inspect 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.
  • Page 28 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. 4. When the tube reaches the top housing slot, turn pump off. •...
  • Page 29 28 Maintenance Basics – Tube 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. NOTE Additional information If pump head housing screws...
  • Page 30 4. Turn the pump off, let go of fitting, and tighten the cover screws. The cover is not on securely if there is a gap between the screw boss and the cover. BEST PRACTICE Factory recommended Trim 1" off suction/discharge tubing before installing ferrules.

  • Page 31: Section V Maintenance Basics - Feed Rate Control

    Section V Maintenance Basics – Feed Rate Control Feed Rate Control (FRC) How it works The feed rate control adjusts the output by utilizing a cam/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 and index pin assembly that consists of a pin (with carbide tip) and a spring inside the holder attached to a lifter.

  • Page 32: Feed Rate Wear - Definition & Causes

    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.
  • Page 33 32 Maintenance Basics – FRC Worn lifter (wear part) Continuous repetition of the lifter riding on the cam can cause a flat spot on the rounded point of the lifter. The flat spot contributes to the premature wear of the cam and index plate. A seized or corroded index pin and lifter assembly Usually caused by water or chemical intrusion.

  • Page 34: Feed Rate Parts Replacement

    Feed Rate Parts Replacement 1. Remove screws. 2. Remove feed rate mounting plate and dial ring. 3. Remove cam, spider assembly, and index plate. • If required, remove index pin assembly by unscrewing with box wrench and replace. 4. Flip worn index plate over OR install new index plate. 5.
  • Page 35 34 Maintenance Basics – FRC NOTE Additional information Spread AquaShield ® on bottom step of ring. 10. Place dial ring boss onto the cam’s 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.
  • Page 36 14. To secure mounting plate, align its arrow with the FRC housing arrow and install the three screws. 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 36 Maintenance Basics – FRC Feed Rate Control Manufactured before 2002 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.

  • Page 38: Section Vi - Maintenance Basics - Motor

    Section VI Maintenance Basics – Motor Gear Case How it works The metal reduction gear and phenolic 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.

  • Page 39: Gear Case Wear - Definition

    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. BEST PRACTICE Factory recommended Apply generous amounts...

  • Page 40: Motor - How It Works

    Factory recommended Avoid mounting pumps over an open chemical solution tank. Proper ventilation will extend motor life. Use a Stenner Rain Roof for Motor Failure outdoor installations or in Definition a moist environment. Power is applied to the motor and the rotor fails to rotate.

  • Page 41: Rotor Assembly Replacement

    40 Maintenance Basics – Motor Rotor Assembly Replacement 1. Remove and set aside: • two motor housing screws (not shown) • motor housing (not shown) • plastic fan A (discard old fan) • two coil screws and lock washers B •...

  • Page 42: Coil Replacement

    Coil Replacement 1. Disconnect power to pump. 2. Remove the feed rate control with 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.
  • Page 43 42 Maintenance Basics – Motor 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 General Information 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 motor housing. Place bracket back on the rotor and securely seat into new coil.
  • Page 45 44 Maintenance Basics – Motor 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.

  • Page 46: Quick Tips

    Three Basic Subassemblies • Use subassemblies in field for quick replacement. Repair and refurbish parts at shop. • Use Stenner Tank System for quick installation. • Establish “application specific” maintenance schedule. • Install parts poster in shop for quick part reference.
  • Page 47 46 Notes...
  • Page 48 3174 DeSalvo Road Jacksonville, Florida 32246 Phone: 904.641.1666 sales@stenner.com US Toll Free: 800.683.2378 Fax: 904.642.1012 © Stenner Pump Company All Rights Reserved Hours of Operation (EST): Monday 7 am - 5 pm Illustrations by David Stiles Peristaltic Metering Pumps Tues.-Fri.

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