Stenner Pumps Classic Series Basic Service Manual

BASIC SERVICE MANUAL
CLASSIC SERIES WITH QuickPro®PUMP HEAD
PERISTALTIC METERING PUMPS SINCE 1957
TO BE INSTALLED BY PROPERLY TRAINED PROFESSIONAL INSTALLER ONLY. READ MANUAL & LABELS FOR ALL SAFETY INFORMATION & INSTRUCTIONS.
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.
ICONS USED IN THIS MANUAL
Factory Instructions
Additional Information
Important Information
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 ............................................................................... 11
SECTION III – SUBASSEMBLY CONNECTIONS
RIVET AND SLOT IDENTIFICATION .............................................................. 12
SEPARATING SUBASSEMBLIES ................................................................. 13
RECONNECTING FEED RATE TO MOTOR ..................................................... 14
SECTION IV – PUMP TUBE
PUMP TUBE BASICS ................................................................................. 15
VISUAL REFERENCE ................................................................................. 16
CONDITIONS THAT REDUCE PUMP TUBE LIFE ...................................... 17-20
IMPORTANT PUMP TUBE INFORMATION .................................................... 21
TUBE REPLACEMENT ........................................................................... 22-30
PUMP HEAD REPLACEMENT ................................................................ 31-33
SECTION V – FEED RATE CONTROL (FRC)
FEED RATE CONTROL ................................................................................ 34
FEED RATE WEAR ................................................................................ 35-36
FEED RATE PARTS REPLACEMENT ....................................................... 37-38
SECTION VI – MOTOR
MOTOR .................................................................................................... 39
CAUSES OF MOTOR MALFUNCTION .......................................................... 40
ROTOR ASSEMBLY REPLACEMENT ............................................................ 41
COIL REPLACEMENT ........................................................................... 42-45
GEARS & GEAR SET IDENTIFICATION ......................................................... 46
GEAR WEAR ............................................................................................. 47
GEAR REPLACEMENT ............................................................................... 48
BSME 0814
TABLE OF CONTENTS
5
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.
HAZARDOUS PRESSURE/CHEMICAL EXPOSURE
Use caution and bleed off all resident system pressure prior to attempting service or installation.
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, personal 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.
www.stenner.com
6
TOOL LIST AND CLEANING SUPPLIES
GENERAL INFORMATION
#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
USA and Canada 800.683.2378, International 904.641.1666.
7
CLASSIC SERIES SINGLE HEAD ADJUSTABLE PUMP
THREE BASIC SUBASSEMBLIES
Use subassemblies in field for quick replacement.
GENERAL INFORMATION
Motor
Pump Head
Feed Rate Control
(FRC)
8
INSTALLATION POINTS
Optional Flow Indicator, to confirm solution is pumping.
www.stenner.com
Discharge Line
INSTALLATION DIAGRAM FOR SINGLE HEAD PUMP
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)
Discharge Line
Disassembled View
Suction Line
Solution Tank
Shut-Off Valve
Grounded Power Outlet; protected by Ground-Fault Circuit-Interrupter (GFCI)
Always use Rain Roof for outdoor use or if metering pump is subject to washdowns.
Injection Fitting 0-25 psi
Injection Check Valve 26-100 psi
Flow direction of solution
Disassembled View
Duckbill
Injection Check Valve or Injection Fitting
9
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.
VERTICAL INSTALLATION
INSTALLATION POINTS
USA and Canada 800.683.2378, International 904.641.1666.
Spill Recovery
Rain roof
(optional) slips
into wall bracket
Wall Bracket
Vertical Mount with Rain Roof
Pump Head
Spill Recovery Set-up
Tube drains solution back to tank.
Partial hole is punched through with a #2 Phillips head screwdriver.
Use section of 1/4" suction/discharge tubing and insert in hole.
10
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.
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.
3"
INSTALLATION POINTS
www.stenner.com
Suction Line
3.5"
(9 cm)
Weighted
Suction Line
Strainer
11
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.
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.
INSTALLATION POINTS
USA and Canada 800.683.2378, International 904.641.1666.
DO NOT use thread seal tape on pump tube threads
DO NOT use pliers
Finger tighten 1/4" nut
Ferrules
Connecting Nut
NOTE: Beveled ends of ferrules face pump. Tubing should bottom into all fittings.
12
RIVET AND SLOT IDENTIFICATION
The pressure spring is not used with the fixed output pump.
SUBASSEMBLY CONNECTIONS
www.stenner.com
Motor shaft and pressure spring coated with Aquashield
®
Indentation
Rivets (3)
Bump
Mounting Plate
Rivet Slots (3) Plate Screws (3)
13
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.
SUBASSEMBLY CONNECTIONS
USA and Canada 800.683.2378, International 904.641.1666.
Feed Rate Control
Pump Head
Feed Rate Control
Motor
14
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.
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.
To reconnect the pump head to the feed rate control refer to Pump Head Replacement instructions page 33.
SUBASSEMBLY CONNECTIONS
www.stenner.com
15
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:
Tube 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 T UBE PRE SSURE RATING
PUMP TUBE 0-25 psi (0-1.7 bar) 26-100 psi (1.8-6.9 bar)
Check valve required
#1 ✔✔
#2 ✔✔
#3
#4
#5
#7
*
*
Classic Single Head ONLY
For maximum pump tube life, always identify the reasons for the failure and correct the problem before a new tube is installed.
PUMP TUBE
USA and Canada 800.683.2378, International 904.641.1666.
Tube number located on fitting
16
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.
The most common tube problems are from a lack of routine maintenance. Always establish an application specific maintenance schedule.
PUMP TUBE
www.stenner.com
Roller
DIAMOND PATTERN
Excessive pressure
or blockage
TEAR DROP PATTERN
Normal
OVAL PATTERN
Fatigued tube or
worn components
(rollers)
Tube
17
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.
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.
PUMP TUBE
USA and Canada 800.683.2378, International 904.641.1666.
18
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.
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.
Normal roller wear can cause a lack of output as a result of the rollers’ inability to fully squeeze the tube.
PUMP TUBE
www.stenner.com
Confirm rollers turn freely
19
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.
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.
EXCESSIVE BACK PRESSURE AT THE POINT OF INJECTION
Insoluble sediments 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.
PUMP TUBE
USA and Canada 800.683.2378, International 904.641.1666.
Areas that clog
Injection Check Valve Duckbill
Clean out accumulated deposits with a #2 phillips head screw driver
Replace duckbill
20
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.
The tube will not center if it twists during installation or if the rollers are worn. The tube can also twist if the connections are 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.
PUMP TUBE
www.stenner.com
Rollers
Tube off center on rollers
21
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. 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.
DO NOT allow tube fittings to turn inside the pump housing when connecting suction and
discharge tubing. Tube will be forced off center towards cover and can wear a groove in the tube, leading to leaks.
For maximum tube life, always identify the reasons for the failure and correct the problem before a new tube is installed.
PUMP TUBE
USA and Canada 800.683.2378, International 904.641.1666.
22
TUBE REPLACEMENT
PUMP TUBE
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. 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
2. Depressurize and disconnect the suction and discharge lines.
3. 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.
4. Remove the tube housing cover and flip to use as a tool in the next step. Figure C
5. 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.
www.stenner.com
A B
C D
23
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. Figure E NOTE: Counter-clockwise is viewed from facing the head of the pump.
7. 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 a non-citrus all-purpose cleaner to clean chemical residue from the tube
housing, roller assembly and cover.
10. Check the housing, cover and roller assembly for cracks and replace if 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.
PUMP TUBE
TUBE REPLACEMENT continued
USA and Canada 800.683.2378, International 904.641.1666.
Tube replacement instructions for pumps manufactured before May 2011 are found on the website in the Downloads section.
E F G
24
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 I
3. Place the tube housing cover on the tube housing, affix the front latches to the
cover lip and then press the latches back to secure. Figure J
Identify the cause of tube failure prior to installing a 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.
PUMP TUBE
TUBE REPLACEMENT continued
www.stenner.com
H I J
25
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. Turn the pump off and unplug the power cord.
6. Remove the tube housing cover and flip to use as a tool in the next step. Figure L
7. 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 housing wall.
PUMP TUBE
TUBE REPLACEMENT continued
USA and Canada 800.683.2378, International 904.641.1666.
K L
M
26
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.
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 & O Proceed to step 9 on page 29. NOTE: Clockwise is viewed from facing the head of the pump.
PUMP TUBE
TUBE REPLACEMENT continued
www.stenner.com
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.
N O
27
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. 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 & 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.
PUMP TUBE
TUBE REPLACEMENT continued
USA and Canada 800.683.2378, International 904.641.1666.
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.
Fan Brake Tool
N O
28
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 will be pressed against the tube housing wall. Figure N & O. 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.
PUMP TUBE
TUBE REPLACEMENT continued
www.stenner.com
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.
N O
29
PUMP TUBE
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
TUBE REPLACEMENT continued
USA and Canada 800.683.2378, International 904.641.1666.
P Q
30
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
2. 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 S
3. DO NOT let go of fitting until tube rides approximately in center of rollers.
4. 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.
5. Inspect the suction and discharge lines, point of injection, and check valve duckbill for blockages. Clean and/or replace as required.
6. Reconnect the suction and discharge lines. DO NOT allow tube fittings to turn inside the pump housing.
7. Turn the pump on and verify operation.
TUBE REPLACEMENT continued
www.stenner.com
R S T
31
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. 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.
4. Turn the pump head counter-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.
A B
C D
32
PUMP HEAD
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. 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. Put the 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.
4. Turn the pump head counter-clockwise to secure the rivets in the rivet slots, firmly
attaching the pump head. Proceed to page 33.
PUMP HEAD REPLACEMENT continued
www.stenner.com
A D
33
PUMP HEAD
EXPAND THE ROLLER ASSEMBLY
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.
PUMP HEAD REPLACEMENT continued
USA and Canada 800.683.2378, International 904.641.1666.
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.
Expand the roller assembly
34
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.
Index pin retracts when lifted.
FEED RATE CONTROL
www.stenner.com
Cam
FRC Channel
Brass Spider AssemblyIndex Plate
Lifter, holder, and index pin spring is enclosed
Feed Rate Control
35
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
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 dragging across the plate. The feed rate control will index inconsistently at different settings. Replace the lifter as needed.
WORN INDEX PLATE
A 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 on the feed rate parts, specify the pump closest to its maximum output capacity within the needs of the application. Check the lifter, cam and index plate during scheduled maintenance.
USA and Canada 800.683.2378, International 904.641.1666.
Worn groove in plastic cam
Flat area
Should look like this
Index plate with elongated holes
36
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.
FEED RATE CONTROL
www.stenner.com
37
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.
3. Flip worn index plate over OR install new index plate.
4. Clean out FRC channel before installing new cam.
5. Apply AquaShield®to lubricate the cam’s angled tip.
6. To install the cam, feed the angled cam tip into the FRC channel and keep the
90º 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.
FRC PARTS REPLACEMENT
FEED RATE CONTROL
USA and Canada 800.683.2378, International 904.641.1666.
Angled tip
3/8" wrench
Angled end
90º angle
Installing New Cam
90º end
38
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.
FEED RATE CONTROL
www.stenner.com
39
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.
USA and Canada 800.683.2378, International 904.641.1666.
Rotor Assembly
Coil
Gears
Helical End
40
Refer to the Trouble Shooting guide in the Classic Series Installation Manual for motor conditions and solutions.
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.
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.
MOTOR
www.stenner.com
41
MOTOR
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
Coil (keep wires connected) E
2. Remove and discard the rotor F and two amber bearing brackets D.
3. 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 F 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.
6. Snap into place the second bearing bracket onto the rotor.
7. Insert two coil screws with lock washers C and tighten.
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.
ROTOR ASSEMBLY REPLACEMENT
USA and Canada 800.683.2378, International 904.641.1666.
A
D
B
C
E
F
G
D
Correct Coil Orientation
Copper Rods
Coil
Vent
Opening
Coil Lead Wire
Coil Lead Wire
42
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. Remove fan and set aside.
MOTOR
www.stenner.com
Motor
Gear Case Shaft
Motor Screws
Feed Rate Control
Pump Head
Rotor
Motor Cover
Motor Cover Screw Boss
Pump Head
Feed Rate Control
Co
i
l
Sc
r
ew
a
n
d
W
a
s
h
e
r
Coil Copper Rods
Amber Bearing Bracket
Motor Cover Screw Boss
Coil
Fan
Motor Screws
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:
Two coil screws and washers from the rotor bracket
Plastic amber bearing bracket
8. Remove coil and discard.
USA and Canada 800.683.2378, International 904.641.1666.
Ground Wire Screw Boss
Ground Wire
Lead Wire
2 Lead Wires
Wire Nuts
(crimp
type)
Set Screw
Eyelet
44
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.
MOTOR
www.stenner.com
Rotor
Copper Rods
Amber Bearing Bracket
Coil
Vent Opening
Coil Lead Wire
Coil Lead Wire
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. 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.
USA and Canada 800.683.2378, International 904.641.1666.
Lead Wire
Ground
Wire
Strip Approx, 1/2"
Wire Stripper
Lead Wire
Ground Wire
46
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.
MOTOR
www.stenner.com
Motor
Gear Case
Phenolic Gear with Spacer
Metal
Reduction
Gear
Motor Shaft
with Gear
GEAR SET IDENTIFICATION
The illustrations show the diameters of the gears and pinions.
45 & 100 SERIES GEARS 85 & 170 SERIES GEARS
Phenolic Gear Phenolic Gear
Metal Reduction Gear Metal Reduction Gear
3/8"
1 3/8"
9/16"
1 3/8"
9/16"
1 1/4"
9/16"
1 3/8"
47
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
Cracked bearing bracket
Worn gear posts
Worn gear case cover
Rusted helical gear
Insufficient lubrication
Corrective Action
1. Review the vertical installation that includes using a rain roof in outdoor
applications or wet environments.
2. Replace gears that show visible wear or corrosion.
3. Replace gear posts that are worn, rusted or corroded.
4. Inspect the gear case and cover for cracks or corrosion and replace as needed.
5. 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®.
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.
Phenolic Gear
Teeth missing
48
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.
5. Install gear posts by tapping with rubber mallet until bottomed.
6. Apply AquaShield®on new gear posts before installing gears.
7. Install phenolic gear and spacer.
8. Install metal reduction gear and motor shaft with gear.
9. Use remaining AquaShield®on top of the three gears.
10. Re-attach gear case cover with four screws and tighten. Screws must be backed in to
locate original threads before securing, to prevent stripping screw boss.
MOTOR
www.stenner.com
Gear Case
Motor Shaft
with Gear
Phenolic Gear with Spacer
Metal Reduction Gear
Gear Case
Thrust
Washer
Phenolic Gear
Gear Post
Phenolic Gear Spacer
Motor Shaft with Gear
Pressure Spring (adjustable models only)
Metal Reduction Gear
Gear Case Cover
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
BSME 0814
Loading...