Basic Service Manual BW Cover PDF
Basic Service Manual BW Cover PDF
Classic Series
Safety Precautions/Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tool List/Cleaning Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Part Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SECTION II Installation Review Proper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Spill Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Vertical Wall Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Suction Line, Compression Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Rain Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SECTION III Separating & Reconnecting Subassemblies Rivet and Slot Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Separating Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Reconnecting Feed Rate to Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Reconnecting Pump Head to Feed Rate . . . . . . . . . . . . . . . . . . . . . . . 12 SECTION IV Maintenance Basics Tube Tube How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Tube Failure Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Tube Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Tube Failure Causes & Corrective Action . . . . . . . . . . . . . . . . . 16-22 Tube Replacement & Centering . . . . . . . . . . . . . . . . . . . . . . . . . . 23-29 SECTION V Maintenance Basics Feed Rate Control Feed Rate Control (FRC) How It Works . . . . . . . . . . . . . . . . . . . . . 30 Feed Rate Wear Definition & Causes . . . . . . . . . . . . . . . . . . . . 31-32 Feed Rate Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-36 SECTION VI Maintenance Basics Motor Gear Case How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Gear Case Wear Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Gear Case Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Motor How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Motor Failure Definition & Causes . . . . . . . . . . . . . . . . . . . . . . . . . 39 Rotor Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41-44 SECTION VII Quick Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. Best practice tips, such as a spill recovery to eliminate chemical leakage, as well as corrective action techniques will be covered.
Factory recommended
IMPORTANT!
Key for optimum performance
4 General Information
0-25 psi
26-100 psi
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.
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.
Compression Seal
8 Installation
Rain Roof
Recommended in all outdoor or wet environments. Pump motor is ventilated, and water intrusion can cause motor damage.
Section III Separating & Reconnecting Subassemblies Rivet and Slot Identification
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.
11
13
Tube Roller
The tube can rupture or break. A rupture normally occurs at the point between the discharge tube fitting and the area where the roller leaves the tube. A break or rip occurs just past the suction fitting. The tube is the workhorse of the pump. It is perishable and eventually has to be changed.
15
IMPORTANT!
Key for optimum performance Remember to check tube psi rating against application psi. All tubes (1, 2, 3, 4, 5 & 7) are rated to 0-25 psi; 1, 2 & 7 are rated to 26-100 psi.
Continued...
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. Position suction weight 3" from tank bottom. 3. Use strainer. 4. Replace duckbill.
BEST PRACTICE
Split along tube side Rubbing along roller assembly and pump head housing edge. Corrective Action 1. Center tube at time of new tube installation.
Continued...
19
Vertical Mount
Spill Recovery
Continued...
21
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.
Normal tube failures Pin hole at discharge side; tube will leak. Breakage at the suction side. Fatigued, no longer completely compresses, no rupture evident, doesnt 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.
Continued...
Points to Be Greased
BEST PRACTICE
Factory recommended Every time pump is serviced or a tube is replaced, apply grease (AquaShield) to the pump head cover bushing and main shaft ONLY.
23
Factory recommended Prior to tube removal, pump water through tube to remove chemical.
Continued...
7. Turn pump on and allow roller assembly to jog while guiding the tube with tension up and out of the housing. 8. Turn the pump off. Completely remove the tube assembly.
25
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. 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.
Continued...
3. Turn dial ring to L setting. While holding the threaded tube fitting, turn the pump on and allow it to jog the roller assembly. Guide the tube with slight tension (toward the center) to prevent pinching between the housing and roller assembly.
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.
4. 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. 5. Turn the pump off.
Continued...
29
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. Replace ferrules with every tube change.
30
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. When the pump is on, the index spider assembly rotates. When the lifter drops into the FRC channel, the pin engages an index plate hole. The roller assembly rotates, 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.
31
Continued...
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.
BEST PRACTICE
Factory recommended Mount pump in vertical position with spill recovery tube to allow chemicals to drain away from internal parts.
33
4. Flip worn index plate over OR install new index plate. 5. Clean out FRC channel before installing new cam. 6. Use grease (AquaShield) to lubricate the cams angled tip. 7. Install the cam. 8. Feed the angled tip into the FRC channel and keep the 90 end in the up position. Place thumb over the cam to guide as it is inserted in the channel.
9. 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. Continued...
10. Place dial ring boss onto the cams 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. 12. Generously grease (AquaShield) bottom of FRC housing before placing index plate inside. Grease the top of the index plate. 13. 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.
BEST PRACTICE
Factory recommended Add grease (AquaShield) to dial ring for easier turning.
35
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.
37
45 Series
85 Series
3/8"
1 3/8"
9/16"
1 1/4"
Continued...
BEST PRACTICE
Factory recommended Apply generous amounts of grease (AquaShield) to gear posts, gear rings, pinions, and master shaft when doing service in the gear case.
39
BEST PRACTICE
Factory recommended Avoid mounting pumps over an open chemical solution tank. Proper ventilation will extend motor life. Use a Stenner Rain Roof for outdoor installations or in a moist environment.
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 coil (keep wires connected) D 2. Remove and discard the rotor E and two plastic brackets C. 3. Press the new plastic bearing bracket onto the threaded brass inserts in the front of the motor case. 4. Install new rotor assembly by inserting the shaft (helical gear side) onto the gear case. 5. Place the coil over the rotor and keep the copper-shaded poles on the right-hand side (same side as the on/off switch). 6. Snap into place the second plastic bearing bracket on the rotor. 7. Insert two self-tapping screws (w/lock washers). 8. Starting at an angle, press fan (with hub side down) onto the rotor shaft. 9. Reinstall two motor housing screws and tighten the self-tapping screws to secure the motor housing cover.
41
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. 4. Remove fan and set aside.
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 bearing bracket (amber) 8. Remove coil and discard.
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. Install screws and washers and fasten bracket to coil. 10. With the metal band facing the bracket, press fan flush on rotor shaft.
43
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. Continued...
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. 16. Reconnect subassembly(s).
45
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. Use UV black suction/discharge tubing, rain roof, and UV gray tanks for outdoor applications.
Contact factory for help: 800.683.2378 or 904.641.1666. Visit our website at www.stenner.com.
46 Notes
www.stenner.com Phone: 904.641.1666 US Toll Free: 800.683.2378 Fax: 904.642.1012 Hours of Operation (EST): Monday 7 am - 5 pm Tues.-Fri. 7 am - 5:30 pm
3174 DeSalvo Road Jacksonville, Florida 32246 [email protected] Stenner Pump Company All Rights Reserved
CSM