BDF Series

I N S TA L L AT I O N A N D MAINTENANCEMANUAL
Peristaltic Metering Pumps Since 1957

TableofContents

WarrantyandServicePolicy ............................................... 3
SafetyInformation ...................................................... 45
PumpIdentification ..................................................... 67
Outputs .............................................................. 8
MaterialsofConstruction................................................. 9
AccessoryChecklist ..................................................... 10
ProgrammingInstructions ................................................ 1117
Installation ............................................................ 1824
Troubleshooting ........................................................ 2527
SeparatingandReconnectingSubassemblies .................................. 28
TubeReplacement ...................................................... 2933
CleaningthePointofInjection ............................................. 3436
Motorexplodedviewandparts .......................................... 37
PumpHeadexplodedviewandparts ...................................... 3840
PumpTubes ........................................................... 41
CheckValves .......................................................... 42
ForYourRecords ....................................................... 43

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WarrantyandServicePolicy

LimitedWarranty StennerPumpCompanywillforaperiodofone(1)yearfromthe dateofpurchase(proofofpurchaserequired)repairorreplace atouroptionalldefectiveparts.Stennerisnotresponsiblefor anyremovalorinstallationcosts.Pumptubeassembliesand rubbercomponentsareconsideredperishableandarenot coveredinthiswarranty.Pumptubewillbereplacedeachtimea pumpisinforservice,unlessotherwisespecified.Thecostofthe pumptubereplacementwillbetheresponsibilityofthecustomer. Stennerwillincurshippingcostsforwarrantyproductsshipped fromourfactoryinJacksonville,Florida.Anytamperingwith majorcomponents,chemicaldamage,faultywiring,weather conditions,waterdamage,powersurges,orproductsnotused withreasonablecareandmaintainedinaccordancewiththe instructionswillvoidthewarranty.Stennerlimitsitsliabilitysolely tothecostoftheoriginalproduct.Wemakenootherwarranty expressedorimplied. Returns Stenneroffersa30dayreturnpolicyonfactorydirectpurchases. Exceptasotherwiseprovided,nomerchandisewillbeaccepted forreturnafter30daysfrompurchase.Toreturnmerchandise atanytime,callStennerat800.683.2378foraReturn MerchandiseAuthorization(RMA)number.A15%restocking feewillbeapplied.Includeacopyofyourinvoiceorpacking slipwithyourreturn. DamagedorLostShipments UPSandprepaidtruckshipments:Checkyourorderimmediately uponarrival.Alldamagemustbenotedonthedeliveryreceipt. CallStennerCustomerServiceat800.683.2378forallshortages anddamageswithinseven(7)daysofreceipt. Service&Repairs Beforereturningapumpforwarrantyorrepair,removechemical frompumptubebyrunningwaterthroughthetube,andthen runthepumpdry.Followingexpirationofthewarranty period, StennerPumpCompanywillcleanandoverhaulanyStenner meteringpumpforaminimumlaborchargeplusnecessary replacement parts and shipping. All metering pumps received for overhaul will be restored to their original condition. The customer will be charged for missing parts unless specific instructions are given. To return merchandise for repair, call Stenner at 800.683.2378 or 904.641.1666 for a Return Merchandise Authorization (RMA) number. Disclaimer The information contained in this manual is not intended for specific application purposes. Stenner Pump Company reserves the right to make changes to prices, products, and specifications at any time without prior notice.

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SafetyInformation

WarnsabouthazardsthatCANcausedeath, seriouspersonalinjury,orpropertydamageifignored. ELECTRICSHOCKHAZARD

ELECTRICSHOCKHAZARD: Pumpsuppliedwithgroundingpowercordandattachedplug. Toreduceriskofelectricalshock,connectonlytoaproperly grounded, grounding type receptacle. Install only on a circuit protected by a groundfault circuit Interrupter (GFCI).

RISKOFFIREHAZARD:
DONOTinstalloroperateonanyflammablesurface.
HAZARDOUSVOLTAGE: DISCONNECT powercordbeforeremovingmotorcoverfor service.Electricalservicebytrainedpersonnelonly. EXPLOSIONHAZARD:
Thispumpisnotexplosionproof.DONOT installoroperatein
anexplosiveenvironment.
Pumpisequippedwithasafetyinterlockswitch.Thisswitch
ensures that all supply voltage is disconnected from the timer
board in the event the cover is removed prior to unplugging the
power cord. DO NOT tamper with or alter this switch in any way.
Failure to follow this warning will void the warranty and can lead
to personal injury or property damage.
Electrical service by trained personnel only. Pump is not user
serviceable in regards to electrical components. Contact the factory
or an authorized service facility for repair.

AVERTISSEMENT RISQUEDECHOCELECTRIQUE: Cettepompeestquipedunefichedemiseterre.Pour rduirelerisquedechoclectrique,sassurerquelaficheest bien raccorde une prise de courant avec une connexion de mise terre. Installer seulement sur un circuit proteger par un interrupteur proteger par une mise la terre.
DO NOT alter the power cord or plug end. DO NOT use receptacle adapters. DO NOT use pump with a damaged or altered power cordor plug.Contactthefactoryoranauthorizedservicefacilityfor repair. RISKOFCHEMICALEXPOSURE: Potentialforchemicalburns,fire,explosion,personalinjury,or propertydamage.Toreduceriskofexposure,theuseofproper personal protective equipment is mandatory.
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SafetyInformationcontinued
NOTICE: Indicatesspecialinstructionsorgeneral mandatoryaction. NOTICE:Thismeteringpumpisportableanddesignedto beremovablefromtheplumbingsystemwithoutdamageto the connections. NOTICE: This metering pump and its components have been tested for use with the following chemicals: Sodium Hypochlorite (1015%), Muriatic Acid (2022% Baume, 31.5% Hcl), and SodaAsh. NOTE: Cetteapompededosageetsescomposantsontt testspourutilisationaveclesproduitschimiquessuivants; HypochloritedeSodium(solutionde1015%);AcideMuriatique (2022%Baume,31.5%Hcl);CendredeSoude. Thisisthesafetyalertsymbol.Whendisplayedinthis manualorontheequipment, look for one of the following signal words alerting you to the potential for personal injury or property damage. Electricalinstallationshouldadheretoallnationalandlocal codes.Consultalicensedprofessional for assistance with proper electrical installation. PUMP INTENDED FOR INDOOR USE. Cettepompeestprvuepourutilisationlintrieur.

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PumpIdentification
Identifyyourpumpusingthelabelontheboxorthepump.

BoxLabel

25BDF5 02050503955 120 5/18.9 4/15.1 25/1.7 1/4"White 1/4"Blanco BDFHL5F1SQAA

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PumpIdentificationcontinued
DataLabel WarningLabel

25BDF5 BDFHL5F1SQAA 25psi/1.7bar120V60Hz 1.2amp4gpd/15.1lpd 02050503955

NOTE:Agencylistingsvarybymodel.

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Outputs

PumpOutputperDoseHour BankofDoseSwitches
Model Pressure Timer Pump Tube #1 Min.toMax. Min.toMax. Ounces Millimeters NumberofDoses 1 2 3 4 5 6

25BDF1HP* 25BDF1 25BDF1HP7* 25BDF17 25BDF2HP* 25BDF2 25BDF2HP7* 25BDF27 25BDF3 25BDF37 25BDF4 25BDF47 25BDF5 25BDF57

100psi(6.9bar) 25psi(1.7bar) 100psi(6.9bar) 25psi(1.7bar) 100psi(6.9bar) 25psi(1.7bar) 100psi(6.9bar) 25psi(1.7bar) 25psi(1.7bar) 25 psi (1.7 bar) 25psi(1.7bar)r 25 psi (1.7 bar) 25 psi (1.7 bar) 25 psi (1.7 bar)

24hour 24hour 7day 7day 24hour 24hour 7day 7day 24hour 7day 24hour 7day 24hour 7day

#1 #1 #1 #2 #2 #2 #2 #3 #3 #4 #4 #5 #5

0.06to1.3

2to39

Ounces Milliliters

0.06 0.12 2 4

0.18 0.24 6 8

0.3 10

0.36 12

0.21to4.5

6to134

Ounces Milliliters Ounces Milliliters Ounces Milliliters Ounces Milliliters

0.21 0.42 6 12

0.63 0.84 1.05 1.26 18 24 30 36

0.48to10 0.71 to 15 1 to 21

14to302 21 to 449 30 to 625

0.48 0.96 14 21 1 30 28 42 2 60 0.71 1.42

1.44 1.92 2.40 2.88 42 63 3 90 56 96 4 120 70 105 5 150 84 126 6 180 2.13 2.84 3.55 4.26

*Pumpsuppliedwithinjectioncheckvalvefor26100psi(1.76.9bar)applications
WithintheBankofDoseSwitcheseachnumberrepresentsthenumberofdoses 1 dose represents approximately 25 seconds of run time Any dip switch in the UP position represents a programmed dose amount ThesumofthedipswitchesintheUPpositionequalsthedoseamountforexample,switches2,4and5intheUPpositionwillgive11doses All dip switches in the UP position will pump the maximum dosage amount for the pump (21 doses) Bankof Dose Switches

NOTICE: Theinformationwithinthischartissolelyintendedforuseasaguide.Theoutputdataisanapproximationbasedonpumpingwaterunderacontrolledtestingenvironment.
Manyvariablescanaffecttheoutputofthepump.StennerPumpCompanyrecommendsthatallmeteringpumpsundergofieldcalibrationbymeansofanalyticaltestingtoconfirmtheiroutputs.

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MaterialsofConstruction

AllHousings ................... Polycarbonate PumpHeadLatches ............. Polypropylene PeristalticTube ................. Santoprene*, FDAApproved CheckValveDuckbill Suction/DischargeTubing ......... Polyethylene,FDAApproved Ferrules(1/4"&6mm) Tube Fittings ................... Polypropylene, NSF listed Connecting Nuts ............... Type 1 Rigid PVC or Polypropylene Check Valve Fittings ............. Type 1, Rigid PVC, NSF listed Weighted Suction Line Strainer..... PP or Type 1 Rigid PVC body with Type 1 Rigid PVC cap, NSF listed; ceramic weight All Fasteners ................... Stainless Steel
*Santoprene isaregisteredtrademarkofExxonMobilCorporation.

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AccessoryChecklistpreinstallation

25psiunitincludes: 3ConnectingNuts1/4" 3 Ferrules 1 Injection Fitting 1 Weighted Suction Line Strainer 1/4" 1 20' Roll of Suction & Discharge Tubing 1/4" White 1 Installation and Maintenance Manual 100psiunitincludes: 3 ConnectingNuts1/4" 3 Ferrules 1 Injection Check Valve 1 Weighted Suction Line Strainer 1/4" 1 20' Roll of Suction & Discharge Tubing 1/4" White 1 Installation and Maintenance Manual

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ProgrammingInstructions

KEY
On: DipswitchintheUP position Off: DipswitchintheDOWN position Dose Hour: The programmed time when the dose amount is injected. Minimum is 1 hour per day and maximum is 24 hours per day 1Dose: Minimumvolumeofliquidinjected(#1dipswitchintheUPposition) IV. Program hours for dose event 21Doses: Maximumdoseamount V. Dose Amount: Thevolumeofliquidtobeinjectedperdosehour.Thedose amountis the sum of the dip switches in the UP position Example: The minimum dose amount is 1 dose and is the #1 dip switch in the UP position. 3 doses are the #3 dip switch in the UP position or #1 & #2 dip switches in the UP position. The maximum dose amount is 21 doses and is all of the switches in the UP position. Dip switch numbers 1+2+3+4+5+6 = 21 doses. Prime I.

SUMMARYOFSTEPS
Battery IA. 7daytimeronly, selectdaysoftheweek II. Settimeofday

III. Select doseamount

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ProgrammingInstructionscontinued
I.BATTERY
ELECTRICSHOCKHAZARD:
DONOTplugpowercordintoreceptacle;performprogrammingwithoutACpower.
1. Removethefourscrewstoremovepumpcoverandconfirmthatalldipswitchesonthe circuit board are in the down position. 2. Connect the supplied 9V battery. This will illuminate the green LED light. Replace battery if light does not illuminate. NOTE: ThebatteryonlyretainsthetimeofdayandwillnotrunthepumpifACpower is lost.

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ProgrammingInstructions continued
IA.7DAYTIMERONLY,SELECTDAYSOFTHEWEEK
NOTE: Skipthisstepifusing24hourtimerandproceedtostepII.
Onthe7daytimerboard,dipswitches17inthefirstbankofswitchesrepresentthedaysof
theweek.Switch1representsthedaythatthetimerisactivated. Forexample,ifthepumpisprogrammedonWednesday,thenthethirdswitchwouldrepresentFriday. 1. Pressandholdtheprimeswitch(locatedbeneaththepumphead)toilluminatethegreen LEDlighttoflashingindicatingthedayoftheweekmodeisactive. 2. Lift the dip switches to represent the days of the week that the pump is to dose. 3. Recordtheprogrammeddaysettingsbypressingtheredprimeswitchonceagain.Thegreen LED light will turn off. The7daytimerisnowset. 4. Setallswitchestothedownposition.ThegreenLEDlightwillilluminate.
Green LED Light DaysoftheWeek (7daytimeronly)

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ProgrammingInstructionscontinued
II.SETTIMEOFDAY
Fromlefttoright,thefirstbankofswitchesrepresents1a.m.tonoon.Thesecondbank represents 1 p.m. to midnight.
1stBankof Switches 2ndBankof
Switches

1. Setthetimeofdaybyliftingthedipswitchthatisclosesttothecurrenttimeofday. The green LED will turn off. The time of day is now set. NOTE: To erase the setting, push all dip switches down and return to the battery instructions.

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ProgrammingInstructions continued
III.SELECTDOSEAMOUNT
Fromlefttoright,usethethirdbankofswitches16. 1. Refertotheoutputchartonpage8.

3rdBankofSwitches

2.

Setthedoseamountperhourbyliftingthecorrespondingdoseswitches.

3. Doseamountsarecumulative. For example, switches 2, 4 & 6 in the UP position will feed 12 doses (2+4+6=12).

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ProgrammingInstructionscontinued
IV.PROGRAMHOURSFORDOSEEVENT
1. Leavedoseswitches(thirdbank:16)intheirprogrammedposition. 2. KeepthetimeofdayswitchintheUPposition(either1stor2ndbankofswitches),liftthedip switchestocorrespond withthehour(s)ofthedaythatthepumpwillfeedsolution. 3. AftersettingthedipswitchesintheUPposition,pushthetimeofdayswitchdownif solution is not to be pumped at that hour.
1stBankof Switches 2ndBankof Switches

GreenLEDLight

NOTICE: Ifall24hourlyswitchesaresetintheDOWNpositionatanytime,theboardwill loseitsprogrammedtimeofday.Ifthisoccurs,returntotheStepI. 4. Installthecoverbysecuringthefourcoverscrewsandplugtheunitintoaproperly groundedreceptacle. Moreonnextpage

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ProgrammingInstructions continued
V.PRIME
1. Presstheredprimebuttontoprimethepump.Thepumpwillautomaticallyshutoffafter60 seconds.Todiscontinuepumpoperationduringthe60secondprimecycle,presstheprime buttonagain. Cycleasnecessarytopumpsolutiontothepointofinjection. TheBDFisnowreadyforoperation.
MotorHousing Pump Head

2.

Discharge Suction

NOTICE:Toretainthisprogramschedule,the9Vbatteryisabackupincase ACpower is lost. 7Day Model If AC power is lost and the 9V battery fails, the pump will default to OFF once the power is restored. To reprogram the settings, unplug the pump and replace the battery. 24Hour Model If AC power is lost and the 9V battery fails, the pump will default to 12 pm when power is restored and the pump will resume its dose schedule and dose amounts. If the dose schedule needs to correspond with the actual time of day, unplug the pump, replace the battery, and reprogram all settings.

PrimeButton

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Installationadditionalsafetyinstructions

NOTICE: Indicatesspecialinstructionsorgeneralmandatoryaction.

Readallsafetyhazardsbeforeinstallingorservicingthe pump.Thepumpisdesignedforinstallation and service by properly trained personnel. Use all required personal protective equipment when working on or near a chemical metering pump. Installthepumpsothatitisincompliancewith all national and localplumbingandelectricalcodes.

Usetheproperproducttotreatpotablewatersystems, useonlychemicalslistedorapprovedforuse. Installthepumptoworkinconjunctionwithwellpump orsystemcontrols.

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Installationcontinued mountpump
MOUNTPUMP
Selectadrylocation(toavoidwater intrusionandpumpdamage)abovethe solution tank. To prevent pump damage in the event of a pump tube leak, never mount the pump vertically with the pump head up. Toavoidchemicaldamagefromfumes, DONOTmountpumpdirectlyoveran opensolutiontank.Keeptankcovered. Avoidfloodedsuctionorpump mountedlowerthanthesolution container.Drawsolutionfromthetop ofthetank.Pumpcanrundrywithout damage. If pump is installed with a flooded suction, a shutoff valve or other device must be provided to stop flow to pump during service. DO NOT allow water intrusion into the motor or corrosion and damage will occur. Topreventmotordamage,verifywith avoltmeterthatthereceptaclevoltage correspondswiththepumpvoltage.

NOTICE: DONOTplugmeteringpumpintopowersourceunlessBDFhasbeenprogrammed.

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InstallationDiagram

GroundedPowerOutlet (GFCIRecommended)

Disassembled View

OUT (Discharge) IN(Suction)

DischargeLine

SuctionLine

Injection Check Valve

Duckbill Injection Fitting 025psi Injection CheckValve 26100psi

ShutOff Valve

Solution Tank

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Installationcontinued suction/dischargelines
INSTALLSUCTION/DISCHARGELINETOPUMPHEAD
1. Uncoilthesuction/dischargeline.Useoutsideofsolutiontankasaguidetocutproperlength ofsuctionlineensuringitwillbe23"abovethebottomofsolutiontank. Allowsufficientslacktoavoidkinksandstresscracks.Alwaysmakeacleansquarecut
toassurethatthesuctionlineisburrfree.Normalmaintenancerequirestrimming.
Suctionlinesthatextendtothebottomofthetankcanresultindebrispickup
leading to clogged injectors and possible tube failure.
2. Makeconnectionsbyslidingtheline(s)throughconnectingnutandferruleandfingertighten tothecorrespondingtubefittings.Suctionsidetubeconnectionisindicatedby INonthe tubehousingcover. 3. Finger tighten nut to the threaded tube fitting while holding the tube fitting. Overtighteningtheferruleandnutwithawrenchmayresultindamaged
fittings, crushed ferrules, and air pick up.
DO NOT use thread sealant tape on pump tube connections or tools to
tighten connections.

Finger tighten 1/4"nut OUT DONOT usepliers. DONOT usethread sealanttapeon pumptubethreads.

Discharge Line

Ferrules

SuctionLine

NOTE: Beveledends offerrulesfacepump. Tubingshouldbottom intoallfittings.

IN

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Installationcontinued suctionline
INSTALLSUCTIONWEIGHT
1. Drillaholeintothebungcaporsolutiontanklid.Slidethetubing through and secure the weighted strainer to the line. 2. To attach the strainer, slide approximately 3 1/2" of tubing through the collet and lock into place on strainer body. Pull tubing to make sure it is secure. 3. Suspend slightly above tank bottom to reduce the chance of sediment pickup.
3"

Weighted SuctionLine Strainer

DONOT mixchemicalsinthesolutioncontainer.Follow recommendedmixingproceduresaccordingtothemanufacturer. DO NOT operate pump unless chemical is completely in solution. Turn pump off when replenishing solution.

Suction/Discharge Tubing

3.5" (9cm)

DONOT slidetubing
allthewaytothe
bottomofthe weightedstrainer.
Tubingcouldbecome
flushwiththenoseof
thestrainerandthe
pumpmaynotprime
duetoblockage.

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Installationcontinued pointofinjection
INSTALLINJECTIONPOINT
1. Makeasecurefingertightconnectiononthedischargefittingofthepumpheadasinstructed inInstallSuctionLineinstructions. DONOTusethreadsealanttapeonpumptubeconnections or tools to tighten
connections.
HAZARDOUSPRESSURE:Shutoffwater orcirculationsystemand
bleedoffany systempressure.
Locateapointofinjectionbeyondallpumpsandfiltersorasdetermined by
the application.
2. A 1/4" or 1/2" Female NPT (FNPT) connection is required for installing the injection fitting. If thereisnoFNPTfittingavailable,provideonebyeithertappingthepipeorinstallingFNPTpipe tee fitting. 3. Wrap the Male NPT (MNPT) end of injection fitting with 2 or 3 turns of threading tape. If necessary,trimtheinjectionfittingquillasrequiredtoinjectproductdirectlyintoflowofwater.
DONOT usethread sealanttapeonpump tubethreads.

DONOT usepliers.

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TrimInjectionFitting

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Installationcontinued pointofinjection

4. Handtightentheinjectionfittingintothe FNPTfitting.
TypicalPointofInjection

025psiModels
(includes injection fitting)
a. Install connecting nut and ferrule to
the pump discharge tubing. Insert
discharge tubing into injection fitting
until it reaches base of fitting.
b. Fingertightenconnectingnuttofitting. 26100 psi Models
(includes injection check valve)
a. Prior to connection, test injection check valve and NPT threads for leaks by pressurizing system. If necessary, tighten an additional 1/4 turn. b. Install connecting nut and ferrule to the pump discharge tubing. Insert discharge tubing into check valve body until it reaches base of body. c. Finger tighten connecting nut to fitting.

5. Turn pump on and repressurize system. Observe chemical flow as actuated by system and check all connections for leaks. 6. After suitable amount of dosing time, perform tests for required solution levels Theinjectionpointandfittingrequire periodicmaintenancetocleanany depositsorbuildup.Toallowquick accesstothepointofinjection, Stennerrecommendstheinstallation of shutoff valves.

Injection Check Valve 1/4"or1/2" FNPT Reduction Bushing ShutOff Valve

HAZARDOUSPRESSURE:

Shutoffwaterorcirculationsystem
andbleedoffanysystempressure.

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Troubleshootingmotor

PROBLEMPOSSIBLECAUSESOLUTION
Motor
HAZARDOUSVOLTAGE: DISCONNECT powercordbeforeremovingmotorcoverforservice. Electricalserviceshouldbebytrainedpersonnelonly. LEDdoesntilluminate. Batteryisdead. Dip switches are up (ON). Replace9Vbattery.DO NOT hook up battery until at the job site. Dip switches should be down (OFF) before connecting battery. (NOTE: If all dip switches are down and the battery is good, possible board problem. Consult factory.) Pump not dosing the proper schedule. No power at the receptacle. Longterm power outage/low 9V battery caused pump to lose program. Pump rollers not turning when prime button is pressed. Motor is bad or interlock switch not working because motor cover is not secured. Confirm power is restored, check battery, and if necessary, replace and reprogram. Replace battery and reprogram. If the battery is disconnected from the pump, the programs will be lost. Replace motor or secure motor cover to base.

NOTICE:Toretainthisprogramschedule,the9VbatteryisabackupincaseACpowerislost. 7Day Model IfACpowerislostandthe9Vbatteryfails,thepumpwilldefaulttoOFFoncethepowerisrestored.Toreprogramthesettings, unplugthepumpandreplacethebattery. 24Hour Model IfACpowerislostandthe9Vbatteryfails,thepumpwilldefaultto12pmwhenpowerisrestoredandthepumpwillresumeits dosescheduleanddoseamounts.Ifthedosescheduleneedstocorrespondwiththeactualtimeofday,unplugthepump, replace thebattery,andreprogramallsettings.

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Troubleshootingcontinued pumphead
PROBLEMPOSSIBLECAUSESOLUTION
Componentscracking Pumpheadleaking No pump output, pump head rotates Chemicalattack Pumptuberupture Depleted solution tank Pump suction line weight is above solution Leak in the suction line Ferrulesinstalledincorrectly,missingordamaged Injectionpointisclogged Cloggedsuction/dischargetubingand/or injectioncheckvalve Lifeofpumptubeexhausted Suctiontubingisflushwiththenoseofthe weightedstrainer Low pump output, pump head rotates Life of pump tube exhausted Rollers worn or broken Injection point is restricted Incorrect tube size High system back pressure No pump output;pump head doesnt rotate Stripped roller assembly Motor problem Pump output high Incorrect tube size or setting Roller assembly broken Checkchemicalcompatibility Replace pumptube,ferrules;centertube Replenish solution Replenish solution Inspect or replace suction line Replaceferrules Inspectandcleaninjectionpoint Cleanand/orreplaceasneeded Replacepumptube,ferrules;centertube Pullsuctiontubingapproximately1"frombottomofstrainer Cutbottomofsuctiontubingatanangle Replace pump tube, ferrules; center tube Replace roller assembly Inspect and clean injection point Replace tube with correct size Verify system pressure against tube psi, replace tube if needed Replace roller assembly Refer to motor section Replace tube with correct size or adjust settings. Replace roller assembly

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Troubleshootingcontinued pumptube
PROBLEMPOSSIBLECAUSESOLUTION NOTICE: Aleakingpumptubedamagesthemeteringpump.Inspectpumpfrequentlyforleakageandwear.
Refer to Tube Replacement section for additionalsafetyprecautionsandinstructions. Tubeleaking Pumptuberuptured Calciumormineraldeposits Excessivebackpressure Tubeistwisted Tubenotcentered Tube life is shortened Chemical attack Mineral deposits at injection point Sediment blockage at check valve Degraded check valve duckbill Duckbill in wrong orientation Tube manually stretched or pinched during replacement Seized rollers caused abrasion on tube Exposure to heat or sun Tube connection is leaking Missing ferrule on 1/4" line Crushed ferrule Ferrule in wrong orientation Replace pump tube, ferrules; center tube Clean injection fitting, replace pump tube, ferrules; center tube Verify system pressure against tube psi, replace tube if needed Replace pump tube, ferrules; center tube Replace pump tube, ferrules; center tube Check chemical compatibility Remove deposits, replace pump tube, ferrules; center tube Maintain suction line 23" above bottom of tank Replace duckbill at every tube change Reverse duckbill orientation Follow tube replacement instructions and allow roller assembly to stretch tube into place Clean roller assembly or replace Do not store tubes in high temperatures or in direct sunlight Replace ferrule Replace ferrule Reverse orientation of ferrule

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SeparatingandReconnectingSubassemblies

SeparatingSubassemblies
1. Turnoffthepumpandunplugthepowercord. 2. Holdthemotorsectionandturnthepumpheadclockwise,untilitstops. 3. Pullthepumpheadstraightoutandoff.
Separating

NOTE: Older pumps or pumps that have hadatuberupturemayrequiretheuseofa flat bladescrewdrivertoassistinpumpheadremoval.Turnpumpheadcounterclockwiseuntilit stops.Insertthescrewdriverbehindthepumpheadandcarefullyprythepumpheadoff themotorshaftwhilepulling.

ReconnectingPumpHeadtoMotor
1. Holdthepumpmotorsectionandinsertthemotorshaftintothepumpheadmakingsure theflatofthemotorshaftalignswiththethecorrespondingflatofrollerassembly. 2. Rotatethepumpheaduntilthelockingrivetsonthefrontofthepumpmotoralignwith the corresponding mounting locations of the pump head.
Reconnecting

3. Push the head onto the motor shaft until it bottoms. 4. Turn counterclockwise to engage mounting rivets.

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TubeReplacementsafetyinformation

RISKOFCHEMICALEXPOSURE: Toreduceriskofexposure,checkthepumptuberegularlyfor leakage.Atthefirstsignofleakage,replacethepumptube. To reduce risk of exposure, the use of proper personal protective equipment is mandatory when working on or near chemical metering pumps. Toreduceriskofexposure,andalsopriortoservice,shipping, or storage, pump generous amounts of water or a compatible buffer solution to remove chemical from pump. Consult chemical manufacturer and MSDS sheet for additional information and precautions for the chemical in use. Personnel should be skilled and trained in the proper safety and handling of the chemicals in use. PINCHPOINTHAZARD: Useextremecautionwhenreplacingpumptube.Becarefulof yourfingersandDONOTplace fingers near rollers. HAZARDOUSPRESSURE/ CHEMICALEXPOSURE: Usecautionandbleedoffallresidentsystempressurepriorto attemptingserviceorinstallation. Usecautionwhendisconnecting discharge tubing from pump. Dischargemaybeunderpressure.Tubingmaycontainchemical. NOTICE: Indicatesspecialinstructionsorgeneral mandatoryaction. NOTICE: DONOTapplygrease,oil,orlubricantstothepump tubeorhousing. NOTICE: Prior to pump tube replacement, inspect the entire pump head for cracks or damaged components. Ensure rollers turn freely. NOTICE: Rinseoffchemicalresidualandcleanallchemicaland debrisfrompumpheadcomponentspriortotubereplacement. ApplyStennergreasetomainshaftandtubehousingcover bushingduringtubereplacement. NOTICE: DO NOT pull excessively on pump tube. Avoid kinks or damage during tube installation. NOTICE: Inspect the suction/discharge tubing, injection point (into pipe), and injection check valve duckbill for blockages after any tube rupture. Clear or replace as required.
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TubeReplacementcontinued preparation
1. Followallsafetyprecautionspriortotubereplacement. 2. Priortoservice,pumpwateroracompatiblebuffersolutionthroughthepumpandsuction/discharge line to remove chemical and avoid contact. 3. Turn pump off. 4. Disconnect the suction and discharge connections from pump head. 5. Plug power cord into constantly energized, properly grounded receptacle for service.

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TubeReplacementcontinued removeoldtube
REMOVEOLDTUBE
1. Turnthemeteringpumpoff. 2. Removeandsetasidecoverandscrews. 3. PressthePRIMEbuttontojogtheroller assembly until one of the three slots in the roller assembly lines up with the bottom tube fitting (suction side). Illustration A 4. Turn pump off. 5. Lift tube fitting out of housing slot and pull it toward center of roller assembly. Illustration B 6. Press the PRIME button to jog the roller assembly while guiding the tube, with tension, up and out of housing. Illustration C 7. Turnpumpoff.Whentheslotintheroller assemblyalignswiththeOUT(discharge) tubefitting,removeanddiscardpumptube. 8. Remove roller assembly and housing. 9. Use noncitrus allpurpose cleaner to clean chemical residue from pump head housing, roller, and cover. 10. Check housing for cracks. Replace if cracked. 11. Ensure rollers spin freely. Illustration D 12. Replace roller assembly if: seized, excessive side play from bore wear, or if rollers are visibly worn. 13. Reinstall clean tube housing. 14. Install roller assembly.
PullOut PullOut

Check Rollers

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TubeReplacementcontinued installnewtube
IMPORTANT!DONOTlubricate pumptubeorrollerassembly.

INSTALLNEWTUBE
1. PressthePRIMEbuttonuntiloneoftheslots intherollerassemblyalignswiththeIN (suction) tube fitting slot in the housing. Press again to stop. 2. Place tube fitting into suction side slot of the housing and the roller assembly slot. Illustration E 3. Press the PRIME button to jog the roller assembly while guiding the tube to prevent it from getting pinched between the housing and roller assembly. IMPORTANT! Avoid rotating wrist, which can result in a twisted tube that will not center. DO NOT force tube and be careful of your fingers. 4. Guidetube,withslighttension(toward the center) to prevent pinching between housing and roller assembly. Illustration F 5. Whentherollerassemblyslotreaches the housing slot that the fitting inserts into, depress the PRIME button to aid in stretching the tube assembly until it can be inserted into the housing.

Tube Housing Slot RollerAssembly Slot

NOTE: A used tube will have stretch approximately 3/4" and the new tube will appear to be stiff and short. Follow directions to allow rollers to stretch tube into place. 6. 7. Allow rollers to stretch tube into place while guiding tube into slot. Illustration G Press the prime button to turn off.

Guide

G
Guide

Tube Housing Slot

RollerAssembly Slot

8. Apply a small amount of grease (AquaShield)tocoverbushingONLYand replace cover and two screws, leaving front screw inbetween the fittings loose.

NOTE: CoverScrewsareselftappingand mustbebackedintolocateoriginalthread before securing. If a screw boss is stripped, use alternate bosses and position opposite from each other. Never secure the cover plate with more than 2 screws.

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TubeReplacementcontinued centernewtube
CENTERNEWTUBE
1. Tocenterthetubeontherollers,pressthePRIME buttontocontinuallyrotatetherollers. IllustrationH 2. Turnthetubefittingonthesuctionsidenotmorethan1/8ofaturn in the direction tube must move. 3. DO NOT let go of fitting until tube rides approximately in center of rollers. 4. Press the PRIME button to turn Off. Tighten cover screws. Cover is not on securely if there is a gap between screw boss and cover. Illustration I
Leavethisscrewloose.

H
1/8Turn

Cover

Gap Screwboss

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CleaningthePointofInjectionsafetyinformation

NOTICE: Indicatesspecialinstructionsorgeneral
mandatoryaction. WarnsabouthazardsthatCANcause death,seriouspersonalinjury,orpropertydamage ifignored. Thisisthesafetyalertsymbol.Whendisplayedinthis manual or on the equipment, look for one of the following signal words alerting you to the potential for personal injury or property damage. HAZARDOUSPRESSURE/ CHEMICALEXPOSURE:

NOTICE:025psimodelsareinstalledusinganinjection
fittingand26100psimodelsuseaninjectioncheckvalve. Both allow the extension tip to be installed in the center of the pipe directly in the flow of water to help reduce deposit accumulation.
InjectionCheckValve

Injection Fitting

Usecautionandbleedoffallresidentsystempressureprior toattemptingserviceorinstallation.
Duckbill (Rubber) CheckValve Body

Usecautionwhendisconnecting discharge tubing from pump. Discharge line may be under pressure. Tubing may contain chemical. To reduce risk of exposure, the use of proper personal protective equipment is mandatory when working on or near chemical metering pumps.

AreasThatClog

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CleaningthePointofInjectioncontinued
1. Turnmeteringpumpoffandunplug cord.Disablewaterpumporauxiliary equipmentelectricalsupply. 2. Depressurize system and bleed pressure from pump discharge tubing. 3. Loosenandremoveconnectingnut andferrulefromtheinjectioncheck valve or injection fitting to disconnect discharge tubing. 26100 psi models: Unscrew the top fitting (check valve body) todisassemble.Thebottomfitting (injectionfittingwitharrow)should remainattachedtothepipe. Remove duckbill from check valve body and replace if deteriorated or swollen. If clogged, clean or replace (yearly replacement recommended). Examine ORing on the injection fitting and replace if deteriorated or damaged. More on next page 4. Inserta#2 Phillips head screwdriver throughinjection fitting into the pipe to locate or break up accumulated deposits. If screwdriver cannot be inserted, drill the deposit out of the injection fitting (DO NOT drillthrough theoppositepipewall).
ReplaceDuckbill

Cleanoutaccumulated depositswitha#2Phillips headscrewdriver. Periodicinspectionandcleaningof thepointofinjectionwillmaintain proper pump operation and provide maximum tube life.

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CleaningthePointofInjection continued
5. Replacedischargetubingifcrackedor deteriorated.Iftheendisclogged,cutoff thecalcifiedorblockedsectionoftubing. 025 psi models: Replace ferrule and insert the discharge tubingintotheinjectionfitting approximately3/4"1"untilitstops. 26100 psi models:
Cutoffthecalcifiedorblockedsection.

6.

Tightentheconnectingnutfingertight.

7. Enable the water pump electrical supply and pressurize the water system. 8. Putthemeteringpumpbackinserviceand inspect all connections for leaks.

Reassemble the injection check valve in reverse order. Replaceferruleandinsertthedischarge tubing into the injection check valve approximately 3/4" until it stops.

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Motorexplodedview

Contactfactoryforpartnumbers.
Motor Cover

Cover ScrewB Timer Board Switch Mounting ScrewJ

SafetyInterlock Switch

MotorBaseScrewD BatteryStrap Battery 9V

Contact SwitchBracket

Coil Ground ScrewE

Gear Motor Motor Housing

PCBCard Guide

PowerCord10' 120V

Motor Base Motor ScrewH

StrainRelief Bushing

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PumpHeadexplodedview

TubeHousing

Roller Housing Pump Tube TubeHousing Cover Cover ScrewB

Roller

Contactfactoryforpartnumbers. 38 www.stenner.com

PumpHeadcontinued servicekits
PUMPHEADSERVICEKITS
DESCRIPTION
SANTOPRENE Kit 025psi(01.7bar)

PARTNUMBER
PSKL0_*_ *selecttubenumber1,2,3,4,5 PSKH0_*_ *selecttubenumber1,2 PSKLT* *selecttubenumber2,5 PSKHT2

UM
KIT KIT
Ferrules1/4"

025psi(1.7bar)
RollerAssembly Connecting Nuts1/4"

SANTOPRENE Kit 26100psi(1.76.9bar) TYGOTHANE Kit 025psi(01.7bar) Kit26100psi(1.76.9bar)includes TYGOTHANE #2PumpTube&PELLATHANE duckbill

KIT KIT
PumpTube

Cover ScrewB

26100psi(6.9bar)
Roller Assembly Connecting Nuts1/4" Duckbill Ferrules1/4"
CoverScrewB

PumpTube

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PumpHeadcontinued subassemblies
PUMPHEADS
PumpHead

DESCRIPTION
PumpHead includesSANTOPRENE pumptube, ferrules1/4" PumpHead includesSANTOPRENEpumptube &duckbill,ferrules1/4" PumpHead includesTYGOTHANEpumptube, ferrules1/4" PumpHead includesTYGOTHANE#2pumptube, PELLATHANE duckbill,ferrules1/4"

PARTNUMBER

UM

PARTNUMBER UM
PKof2

UCTHC*D EA MCTHC*D *selecttubenumber1,2,3,4,5 UCPH*FD EA n/a *selecttubenumber1,2 UCPHT0* EA n/a *selecttubenumber2,5 UCPHTD2 EA n/a

Pump Tube Numbers #1and#2for26100psipump (whenusedwithcheckvalve). #1,2,3,4, 5 for 025 psipump.

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PumpTubes
PUMPTUBES
DESCRIPTION
SANTOPRENE PumpTube, ferrules1/4" SANTOPRENE PumpTube&Duckbill, ferrules1/4" TYGOTHANE PumpTube, ferrules1/4" TYGOTHANE #2 PumpTube& PELLATHANEDuckbill,ferrules1/4"

PARTNUMBER

UM

PARTNUMBER UM
PKof5

UCCP20* PKof2 MCCP20* *selecttubenumber1,2,3,4,5 UCCP*FD PKof2 n/a *selecttubenumber1,2 UCTYG0* PKof2 MCTYG0* *selecttubenumber2,5 UCTY2FD PKof2 n/a

PKof5

PumpTubeNumbers #1and#2for26100psipump (whenusedwithcheckvalve). #1, 2, 3, 4, 5 for 025 psi pump.

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CheckValves
CHECKVALVES
DESCRIPTION
InjectionCheckValve1/4" CheckValve includesSANTOPRENE duckbill;ferrules1/4" CheckValve includesPELLATHANE duckbill;ferrules1/4"

PARTNUMBER
UCDBINJ UCTYINJ

UM
EA EA

PARTNUMBER UM
MCDBINJ MCTYINJ PKof5 PKof5

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ForYourRecords

Model:
SerialNumber:
DateofInstallation:

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StennerPumpCompany 3174DeSalvoRoad Jacksonville,Florida32246 Phone: 904.641.1666 US Toll Free: 800.683.2378 Fax: 904.642.1012 sales@stenner.com www.stenner.com
Peristaltic Metering Pumps Since 1957

Hours of Operation (EST): Monday 7:00 am5:00 pm Tues.Fri.7:00am5:30pm

StennerPumpCompany AllRightsReserved

BDF308B