Neptune 500, 500-A, 500-D, 500-E, 5000 Installation Manual

500-S and 500-VS

NEP-ZL105638

INSTALLATION

OPERATION &

MAINTENANCE

NEPTUNE

SERIES 500/5000

PUMPS

Model 500/5000

500-A, 500-D, 500-E,

03.2018_REV 7

WARNING

SAFETY INSTRUCTIONS:

LOCKOUTS ARE REQUIRED BEFORE

SERVICING THIS EQUIPMENT.

Shut off/Lockout pump Power before Servicing.

Be certain pump isolation valves are

Closed and chemical is shut off.

Bleed pressure before servicing.

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture, malfunction and result in serious injury.

• This equipment is for professional use only.

• Do not allow pump to run dry.

PRESSURIZED EQUIPMENT HAZARD

• Shut off the pump and depressurize before performing any maintenance.

vacuum system. Take proper care to clean and handle them.

FIRE AND EXPLOSION HAZARD

Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in fire or explosion and serious injury.

• Ground the equipment. See motor installation instruction for grounding procedure.

the pump.

TOXIC FLUID HAZARD

Hazardous fluids or toxic fumes can cause serious injury or death if splashed in eyes or on the skin, swallowed, or inhaled.

• Know the specific hazards of the fluid you are using. Read the fluid manufactures warnings.

diaphragm pump. Also oil vapor may breathe out of the air breather installed on the gear box.

SOUND HAZARD

The sound pressure level of the pump may exceed 80dBA in some of the pumps.

• Observe all safety precautions when operating the pump within close proximity for extended periods by wearing hearing

other effects such as loss of balance and awareness.

MECHANICAL HAZARD

The pump may shake or vibrate during operation.

WARNING

Please read thoroughly before installation, operation or maintenance of any Neptune pump

• Read all instruction manuals, tags, and labels before operating the equipment.

• Use the equipment only for its intended use.

• Do not alter or modify this equipment.

• Be certain all operators of this equipment have been trained for safe working practices, understand it's limitations, and wear safety

goggles and or equipment when required.

• Do not exceed the maximum working pressure of the system as mentioned on the pump tag.

• Do not use the pump head or the suction or discharge piping to pull the equipment.

• Do not move pressurized pump.

• Use fluids or cleaning agents for cleaning that are compatible with the pump parts. Read the fluid and cleaning agent manufactures

warnings and also refer to the material compatibility chart

• Comply with all applicable local, state and national safety regulations.

Spray from leaks or ruptured components can splash fluid in the eyes or on the skin and cause serious injury.

• Do not tamper with or perform unspecified alteration of this device.

• Use only pipe, hose, and hose fittings rated for maximum rated pressure of the pump or the pressure at which the pressure relief

valve is set at.

• Always wear protective clothing, face shield, safety glasses and gloves when working on or near your metering pump.

• Additional precautions should be taken depending on the solution being pumped. Refer to SDS precautions from your solution

supplier.

• Do not stop or deflect fluid leaks with your hand, body, glove, or rag.

• Tighten all fluid connections before operating the equipment.

• Replace worn, damaged, or loose parts immediately.

• Before performing any maintenance requiring pump head and or valve (wetted parts) disassembly, be sure to relieve pressure from

the piping system and where hazardous process chemicals are present.

• Make the pump safe to handle for the personal and the environment by cleaning and chemically neutralizing the pump as
appropriate.

• Wear protective clothing and use proper tools as appropriate to avoid any injury.

• If the diaphragm has failed, process chemical may have contaminated the pump hydraulic oil. Handle with appropriate care. Clean

the pump and replace oil as necessary. Discard the contaminated oil as per the local code.

• If the diaphragm fails in a double diaphragm pump, pressurized process chemical can be present in the Neptune leak detection

• Do not pump non recommended flammable or explosive fluids.

• Static electricity may generate by fluid moving through pipes and hoses. A static spark could be produced by high fluid flow rate.

Earthing of the pump is a must.

• Provide fresh air ventilation to avoid the possible buildup of flammable fumes from the process chemicals.

• Keep the pump area free of debris, including cleaning agent, rags, and any flammable material.

• Follow the cleaning agent and other cleaning recommendations as mentioned in the operation and instruction manuals.

• Use cleaning agent with the highest possible flash point to clean the pump parts if needed.

• If there is any static sparking while using the equipment, stop operation at once. Identify and correct the problem before starting up

• Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.

• Wear the appropriate protective clothing, gloves, eyewear and respirator.

• Pipe and dispose of the exhaust air safely. If diaphragm fails, the fluid may be exhausted along with the air in mechanical

protectors.

• Extended exposure to elevated sound levels will result in permanent loss of hearing acuteness, tinnitus, tiredness, stress, and

TABLE OF CONTENTS

SECTION

PARAGRAPH

PAGE

I

—

GENERAL DESCRIPTION

1

LIMITED WARRANTY

2

PARTS ORDERING INSTRUCTIONS

3

II

—

INSTALLATION INSTRUCTIONS

4

1.0

GENERAL 4

2.0

SUCTION PIPING

5 3.0

DISCHARGE PIPING

6 4.0

ADJUSTMENT OF INTERNAL RELIEF VALVE

6 5.0

INSTALLATION OUTDOORS

8 6.0

START-UP, FLOODED SUCTION

8 7.0

START-UP, SUCTION LIFT

9 8.0

START-UP, AFTER SUCTION HAS RUN DRY

9

III

—

NORMAL MAINTENANCE AND

10

DISASSEMBLY INSTRUCTIONS

9.0

MAINTENANCE

10 10.0

REMOVAL OF VALVE CARTRIDGES

11 11.0

CLEANING OF VALVE CARTRIDGES

11 12.0

REPLACING OF VALVE CARTRIDGES

11 13.0

PROCEDURE FOR REPLACING CONTROL

12

ROD AND SEALING PLATE “O” RINGS

14.0

REMOVAL OF PUMP HEAD AND

13

REPLACEMENT OF DIAPHRAGM

15.0

REMOVAL OF STANDARD MOTOR

14

IV

16.0

MOTOR OPERATING CONDITIONS

15

V

—

TROUBLESHOOTING CHART

16

VI

—

INSTRUCTIONS FOR PUMPS WITH

18

ELECTRIC STROKE CONTROL

VII

18.0

PARTS LIST

19

VIII

—

DRAWINGS

22

APPENDIX

—

ADDITIONAL INSTRUCTIONS FOR VARIOUS MODEL OPTIONS

SERIES 500-E-AR “dia-PUMP”

25

SERIES 500-E “dia-PUMP”

26

SERIES 500-A “dia-PUMP”

22

SERIES 500-VS “dia-PUMP”

29

SERIES 5000 “dia-PUMP”

30

DOUBLE DIAPHRAGM OPTION

32

SECTION I

SERIES 500-E “dia” PUMP

WITH INTEGRAL TEFC MOTOR

SERIES 500-A “dia” PUMP

WITH INTEGRAL TEFC MOTOR

SERIES 500 “dia” PUMP

WITH INTEGRAL TEFC MOTOR

GENERAL DESCRIPTION

The Neptune Series 500 “dia-PUMP” is a reliable metering pump of the high-pressure diaphragm type. Under constant
conditions of temperature, pressure, and capacity adjustment settings, a +/-1% metered discharge volume is
maintained.

A plunger reciprocating at a fixed stroke displaces hydraulic fluid, which actuates a flexible, chemically inert, Teflon
diaphragm to create pumping action. The capacity of the pump is regulated by controlling the volume of hydraulic fluid,
which bypasses the diaphragm cavity.

Capacity adjustment can be made manually or automatically by instrument signal.

Metering accuracy is maintained by a control rod, which allows hydraulic fluid replacement and air venting automatically
with each stroke, while also taking into account temperature changes of the hydraulic fluid. Metering accuracy is also
insured by the use of double ball check valves on the suction and discharge of the pump.

PLEASE READ THE INSTRUCTION MANUAL COMPLETELY BEFORE INSTALLING THE PUMP.

®

The text and illustrations in the main body of this manual are based upon the Series 500 pump, shown at left above. The
Series 500-A and 500-E pumps are very similar to the Series 500 pump. The liquid ends are interchangeable.

Please refer to Appendix for all Models other than 500-S or 500-D.

Models 500-A, 500-E, 500-E-AR, 500-VS, 5003, 5005 and the Double Diaphragm Option are described in the Appendix.

1

IMPORTANT NOTICE

SECTION I

NEPTUNE CHEMICAL PUMP COMPANY

LIMITED WARRANTY

All Neptune Pumps are tested at the factory prior to shipment. Each part used in their construction has been carefully
checked for workmanship.

If the pump is installed properly, Neptune Chemical Pump Company warrants to the purchaser of this product for a
period of three years from the date of shipment, this product shall be free of defects in material and/or workmanship, as
follows:

1. Neptune Chemical Pump Company will replace, at no charge, any part that fails due to a defect in material and/or
workmanship during the warranty period, FOB our factory, North Wales, Pennsylvania. To obtain warranty service,
you must forward the defective parts to the factory for examination, freight pre-paid.

2. This warranty period does not cover any product or product part, which has been subject to accident, misuse, abuse
or negligence. Neptune Chemical Pump Company shall only be liable under this warranty if the product is used in the
manner intended by the manufacturer as specified in the written instructions furnished with this product.

Any express warranty not provided in this warranty document, and any remedy for breach of contract that, but for this
provision, might arise by implication or operation of law, is hereby excluded and disclaimed. Under no circumstances
shall Neptune Chemical Pump Company be liable to purchaser or any other person for any charge for labor, repairs, or
parts, performed or furnished by others, nor for any incidental consequential damages, whether arising out of breach of
warranty, express or implied, a breach of contract or otherwise. Except to the extent prohibited by applicable law, any
implied warranty of merchantability and fitness for a particular purpose are expressly limited in duration to the duration of
this limited warranty.

Some states do not allow the exclusion or limitation of incidental or consequential damages, or allow limitations on how
long any implied warranty lasts, so the above limitations may not apply to you. This warranty gives you specific legal
rights, and you may have other rights, which may vary from state to state.

1

IMPORTANT

SHOULD IT BE NECESSARY TO SEND THE PUMP TO THE FACTORY FOR REPAIR OR MAINTENANCE
REBUILDING; DRAIN ALL OIL AND CHEMICAL FROM PUMP BEFORE SHIPPING. FAILURE TO DO SO CAN
CAUSE EXTENSIVE DAMAGE TO THE MOTOR.

1

SEE IMPORTANT NOTICE - RETURN GOODS AUTHORIZATION

RETURN GOODS AUTHORIZATION

(1) All equipment returned to Neptune Chemical Pump Company, Inc. requires proper Returned

Goods Authorization Number (RGA) and tags.

(2) All equipment returned to the factory for repair or service must first be thoroughly flushed and have

all chemical contact areas neutralized.

(3) All equipment, which has been in contact with chemicals, must be accompanied by a copy of the

chemical product material Safety Data Sheet (SDS).

(4) Failure to comply with the above instructions will result in equipment being returned to sender,

freight collect, without service.

2

PARTS ORDERING INSTRUCTIONS

The complete model number and serial number of the pump must be furnished to insure prompt and
accurate parts service. These numbers are found on the name plate (sample below) located on the side of
the pump. Refer to Section VII for complete parts lists.

Send all orders or inquiries for parts to:

Parts Department
Neptune Chemical Pump Company
295 Dekalb Pike
North Wales, PA 19454
Tel.: [phone]
1 -888-3NEPTUNE (888-363-7886)
FAX: [phone]
Web: www.neptune1.com
Email: [e-mail]

NOTE: PLEASE SUPPLY BOTH MODEL AND SERIAL NUMBERS.

3

SECTION II

INSTALLATION INSTRUCTIONS

1.0 GENERAL

1.0.1 When unpacking a pump or chemical feed system, be certain that no parts are thrown away.

Examine the equipment for possible damage. If damage has occurred, file claim with the common
carrier within 24 hours. Neptune will assist in estimating the repair costs.

1.0.2 The ‘‘dia-PUMP’’ should be located so as to avoid an ambient temperature above 120°F, 50°C. Free

air circulation is important when considering the location of the pump.

1.0.3 The ‘‘dia-PUMP’’ should be located on a level surface. Three mounting holes are provided to anchor

the pump securely to the mounting surface. PVC head pumps must be mounted on three, one-inch
spacers provided.

1.0.4 Neptune recommends a 4” to 6” inch clearance above mounting surface (on most models) to allow

access to the Suction Valve. Please refer to model and valve location prior to installation.

1.0.5 All piping to the pump should be supported to prevent stress on the pump input and output fittings.

1.0.6 Before connecting the pump, make sure that all fittings are completely clean by flushing thoroughly.

Any foreign matter entering the pump can damage the internal parts and severely limit the life of the
pump.

1.0.7 A ‘‘Y’’ STRAINER MUST BE INSTALLED IN THE SUCTION LINE OF THE PUMP TO INSURE

AGAINST FOREIGN MATTER ENTERING THE PUMP. ALL SUCTION LIFT APPLICATIONS
REQUIRE A FOOT VALVE STRAINER TO PREVENT LOSS OF PRIME, AND TO PREVENT
FOREIGN MATERIAL FROM ENTERING THE PUMP.

1.0.8 Shut-off valves and unions should be placed in the suction and discharge lines to facilitate servicing

the pump.

1.0.9 Care should be exercised when piping to PVC head pumps. In cases where vibration or stress is

unavoidable, flexible connections should be used.

1.0.10 The electrical supply to the pump must match the motor name plate characteristics. The motor

rotation is counter clockwise when viewed from the top of the motor, looking down on the pump. (See
Figure 1).

1.0.11 Discharge Piping should be the same size or larger than the discharge connection. Suction Piping

should be one size larger than the suction connection (1/2” pipe minimum). Limit the total length of
the suction line to 3-4 feet suction lift or 6-7 feet flooded suction. Minimum bends, elbows, or other
restrictions.

Important

On single phase integral motors, the rotation is set at the factory and must not be changed.

On three phase integral motors, rotation is determined by noting the fan rotation.

Pump body is grounded to earth. Ground connection MUST penetrate to bare metal. Ground
to be clearly marked.
Check external pressure relief valve setting.

On some flange mounted motors, the motor rotation may be viewed by removing the cap on
the side of the flange. There is no viewing port or coupling access on the close coupled flange
mount motors. Rotation is checked by removing the oil fill plug an observing the gear. Correct
rotation is indicate by the gear teeth moving downward away from the oil fill hole.

Please note Figure 1, indicating the correct rotation. (An arrow on the gear box also indicates
proper rotation.) Operation with the incorrect rotation will damage the pump and motor.

Models 5003 and 5005 must be installed with a flooded suction. These models will not operate with
suction lift.

4

Alternate

Oils For Standard

Mfg.

Alternate

High Pressure Oils

Mobil Gear #626

Mobil Oil

Mobil Gear #629

Sun EP #68

Sun Oil

Sun Oil #220

Meropa #68

Texaco

Meropa #220

Mobil 1 0W30/5W30 for
5003/5005 Pumps only

Mobil Oil

FIGURE 1A

FIGURE 1

OIL LEVEL.DWG

1.0.12 Set capacity knob to zero and remove Air Bleed Plug from the top of Oil Chamber, refer to drawings HP-1102 (page 22)

for Series 500 and drawing 5024 (page 28) for Series 500-A and 500-E for location of plug. Fill gear box and pump by
pouring the hydraulic fluid supplied through the fill opening at the rear of the pump. Pour fluid in slowly until it has
reached the correct level per Figure 1A. Do not over fill as this can cause damage to the motor.

Allow a few minutes for the hydraulic fluid work through the oil head and appear at the oil bleed plug. Recheck oil level.
When air is purged, reinstall the Air Bleed Plug.

The hydraulic fluid supplied by Neptune is:

EP 68 Gear Oil, consult the parts listing in the back of this manual for the Neptune part number.

Heavier hydraulic fluid is supplied by Neptune for Hi Pressure Systems is EP SAE 90.

The 90 weight gear oil is used for high-pressure pumps using 1/2 horsepower motors or larger and rated for operation
over 1000 PSI except 5003 and 5005 pumps which uses Mobil 0W30 synthetic oil.

The 90-weight gear oil is also provided for the 500 pump models at all pressures.

2.0 SUCTION PIPING

2.0.1 The suction piping to the pump must be absolutely air tight. It is suggested that the suction piping be tested with

low air pressure and a soap solution to assure that no leaks exist.

2.0.2 NEPTUNE RECOMMENDS THAT THE ‘‘dia-PUMP’’ BE OPERATED WITH A FLOODED SUCTION, AS THIS

WILL FACILITATE START UP AND INCREASE THE SERVICE LIFE OF THE PUMP. It is, however, possible to
operate the ‘‘dia-PUMP’’ with a suction lift of up to 5 feet, if absolutely necessary. A FOOT VALVE STRAINER
must be used on this type of application. Model 5003 and 5005 require a flooded suction.

2.0.3 It is highly recommended that all solution tanks be furnished with a low level cut off switch or low level alarm and

cut off switch to prevent the pump from running dry. OPERATION AGAINST A DRY SYSTEM WILL CAUSE
DAMAGE TO THE PUMP DIAPHRAGM AND REDUCE THE OPERATING LIFE OF THE PUMP.

2.0.4 The single, safest rule of thumb for selecting suction pipe size is to use the same size or one size larger than

the pump suction connection (1/2” pipe minimum).

5

FIGURE II

FIGURE III

ANTI-SIPHON
SPRING
P/N 000257

ANTI-SIPHON
SPRING
P/N 100198
P/N 100199

3.0 DISCHARGE PIPING

3.0.1 It is recommended that the ‘‘dia-PUMP’’ operate against a minimum discharge pressure of 50 psig. A

back pressure spring is supplied loose with the pump. If 50 psig back pressure is not provided by the
application, the back pressure spring should be installed on the pin under the discharge valve cap.
Installation of the back pressure spring artificially creates a discharge head. (Refer to Figures II and
III.) Note: Spring is not provided in 500-E Series.

3.0.2 Take care to use piping suitable for the discharge pressure.

IN METAL HEAD PUMP

IN PVC HEAD PUMP

4.0 ADJUSTMENT OF INTERNAL RELIEF VALVE

4.0.1 All Neptune Series 500/5000 dia-PUMPs are supplied with an internal relief valve preset to 200 psi.

The internal relief valve is designed to protect the pump itself should a discharge pressure beyond the relief
valve setting occur.

If a customer order specifies a relief valve setting above those indicated above, the specified setting will be
set at the factory. All pumps are tagged with the relief valve setting used by the factory.

6

4.0.1 (Continued)

FIGURE IV

4.0.2 To reset the relief valve to a higher pressure, (the relief valve setting cannot be reduced because of

To protect the external piping system, it is recommended that a relief valve as manufactured by
Neptune Chemical Pump Company, or equal, be placed in the discharge line of the pump. It is
further recommended that this relief valve be piped into return of the tank with clear PVC tubing so
that it can be determined if the solution is by-passing through the valve and returning to the tank,
indicating a line blockage.

Drawing HP-1102 (page 22) illustrates the location of the Internal Relief Valve for Series 500 (FIG.
#527 through #530). See drawing 5024 (page 28) for Series 500-A and 500-E.

The drawing shows a passage connecting the hydraulic fluid reservoir with the hydraulic fluid side of
the diaphragm.

The passage is interrupted by the Relief Valve Poppet (FIG. #527) which is backed up by a Relief
Valve Spring (FIG. #528).

If, during the pump operation, the pressure on the hydraulic fluid side of the pump exceeds the set
pressure of the internal relief valve, the poppet is forced from its seat allowing the hydraulic fluid to
flow back to the reservoir.

design considerations) instructions are as follows:

4.0.21 Connect a test set-up as shown in Figure IV below.

4.0.22 Start and run the pump until all air is relieved from the discharge liquid (hand valve open).

4.0.23 Remove Relief Valve Plug (Fig. #530).

4.0.24 Close hand valve; pressure gauge will read the internal relief valve setting which should
agree with the pressure setting on the tag if the pump is new. The desired setting is 100 psi
above the operating pressure of the system into which the pump is injecting. Do not adjust
lower than 200 psi.

4.0.25 To change the relief valve pressure setting, use the 3/16” Allen Wrench to adjust spring
tension by turning Relief Valve Adjusting Screw (FIG. #529).

(1) To increase pressure, turn Relief Valve Adjusting Screw (Fig. #529) in.
(2) To decrease pressure, turn Relief Valve Adjusting Screw (Fig. #529) out.

4.0.26 After resetting or adjusting pressure, replace Relief Valve Plug (Fig. #530).

Never turn Relief Valve Adjusting Screw (Fig. #529) completely in.

Do not attempt to set the internal relief valve more than 200psi in excess of name plate rating.

CAUTION

7

4.0.3

1 Pc.

1/2” Pipe Nipple 6” Long

2 Pcs.

1/2” Pipe Nipple 2” Long

1 Pc.

1/2” Hand Valve

2 Pcs.

1/2” Tee

1 Pc.

1/2” NPT X 1/2” Hose (Fitting)

1 Pc.

1/2” Hose, As Required

1 Pc.

1/2” Pressure Gauge (Minimum Gauge Pressure 500 psi)

1 Pc.

Allen Wrench 3/16”

1 Pc.

External Relief Valve (optional)

Parts required to test or adjust Relief Valve Pressure.

NOTE

The above parts must have a working pressure rating above the required set pressure.

5.0 INSTALLATION OUTDOORS

The “dia-PUMP” is a totally enclosed pump which can be used outdoors or indoors. When installed outdoors, make sure
that the pump is protected against extremes of nature as follows:

5.0.1. Running of the pump when exposed to tropical sunshine, with ambient temperature above 100ºF, 38ºC would
cause excessive oil and motor temperatures. The pump should be shaded and located in such a way as to
permit a high degree of air circulation.

5.0.2 Under cold conditions, the pump should be insulated and a heater should be supplied in order to maintain the
hydraulic fluid at an ambient temperature above 30ºF, -1ºC. Heat may be provided by a 100 watt bulb or a
heater tape, etc.

6.0 START-UP PROCEDURE (FLOODED SUCTION)

The following start-up procedure is complete and does repeat instructions on filling the gear box and pump.

6.0.1 The gear box should be filled with hydraulic fluid per the instructions in paragraph 1.0.12. Let the pump stand for
30 minutes and then recheck fluid level. Be certain that pump discharge lines are open.

6.0.2 Confirm that the liquid head is flooded and no air remains per the following paragraphs. Pumps should not be
running. Wear appropriate protective gear when performing any step that involves contact with the chemical.

6.0.2.1 SERIES 500 and 500-A METAL HEAD

Make certain that pumping chamber is flooded and air is purged by loosening Discharge Valve Cap (FIG. #536
on page 22) approximately 2 to 3 turns and allowing solution to appear. Then, tighten discharge valve cap. This
procedure will also allow air to vent from pumping chamber. THE “dia-PUMP” WILL NOT FUNCTION IF AIR IS
TRAPPED IN THE HYDRAULIC FLUID OR LIQUID PUMP CHAMBERS.

PVC Head Pumps –Discharge Valve Cap (P/N 000256 on page 23) is loosened by loosening Valve Cap Screws

6.0.2.2 SERIES 500 AND 500-A PVC HEAD

(P/N 100250).

6.0.2.3 SERIES 500-E (See page 26)

6.0.3 Follow the procedure below:

1. Make certain that the suction line, liquid end and discharge cartridge chamber are filled with water or

system fluid.

2. Set the capacity control knob to approximately 30-40% of maximum capacity.

3. On initial start-ups: Check for proper motor rotation (Refer to Paragraph 1.0.11). Run the pump for 10-20

seconds, then stop for 20-30 seconds. Repeat a few times. During these short runs, listen for any abnormal
motor or crank noises, and if present, refer to Trouble Shooting Chart.

8

4. On initial gearbox fill or after replacing hydraulic fluid, run pump for one-half to one hour to warm

up oil and allow air bubbles to dissipate. Check discharge line for indication of flow.

®Teflon – A registered trademark of the DuPont Company.

5. Once discharge flow is observed proceed to paragraph number 6; if no flow, repeat steps 3 and 4.

7.0 START-UP PROCEDURE (SUCTION LIFT) SERIES 500 AND 500-A.

(See page 26 for SERIES 500-E) MODELS 5003, 5005 AND 510 REQUIRE A FLOODED SUCTION.

Use the following procedure only if required:

8.0 START-UP AFTER SUCTION HAS RUN DRY

6. Increase capacity adjustment setting to 70% of maximum capacity and operate for 10-20 minutes.

7. Reduce capacity adjustment setting to 30-40% of maximum capacity and operate for several
minutes, then increase capacity adjustment back to 100% for approximately 10 minutes. Repeat
several times to insure that the air is bled from the hydraulic fluid side and the liquid side.

6.0.4 The pump is now ready for “on line” service. Calculate what the desired capacity as a percentage of
either the maximum capacity rating on the pump data plate, or the nominal capacity at the required
system pressure.

7.0.1 If the “dia-PUMP” is to be used where suction lift is required, A FOOT VALVE STRAINER MUST BE
INSTALLED on the end of the suction line. A pipe tee is installed on the top end of the suction line
with one leg to the pump suction, one leg to the suction line and one leg pointing straight up and
plugged. Remove plug and fill piping assembly with liquid. Replace plug. Start pump and follow
procedure per Paragraph 6.0.3.

7.0.2 Remove Discharge Valve Cap (FIG. #536). Then, using Allen wrench provided, remove Discharge
Valve Nut (FIG. #543). The Discharge Valve Nut (FIG. #543) is stamped with the letter “T” to indicate
the face which should be installed toward the top on reassembly. Finally, remove Discharge Valve
Cartridge (FIG. #539) using special blade provided. Fill the pumping chamber with liquid to check
operation of the suction valve. Reinstall / replace parts and then follow instructions per Section II,
Paragraph 6.0.3. Repeat entire procedure if pump loses prime or runs dry. (See Figures VI and VII.)

NOTE

PVC Head Pumps (Refer to page #23) – Remove Discharge Valve Cap (P/N 000256) by removing
Valve Cap Screws (P/N 100250). Next, remove Discharge Valve Cartridge (P/N 000259) using
special round lug tool provided. Fill pumping chamber with liquid to check operation of the suction
valve. Reinstall / replace parts and then follow instructions per Section II Paragraph 6.0.3. (Refer to
Figure VII.)

CAUTION

Do not over tighten PVC valves as the PVC material is not able to withstand excessive force and can
fail. Teflon® paste is an excellent thread lubricant and may be applied.

In applications where the suction tank does not have a low level cut-off interconnected into the pump
motor circuit, the pump may occasionally run dry. THIS MUST BE AVOIDED BECAUSE DAMAGE
TO THE PUMP CAN RESULT AND THE SERVICE LIFE WILL BE SIGNIFICANTLY REDUCED
WHEN THE PUMP IS ALLOWED TO RUN WITH A DRY LIQUID END.

Before restarting a pump that has run dry and which has not damaged itself, follow the procedure in
Paragraph 6.0 through 6.0.3 of Section II, except it is not necessary to warm up the oil.

9

SECTION III

NORMAL MAINTENANCE AND DISASSEMBLY INSTRUCTIONS

Recommended Maintenance Schedule

Weekly Interval

• Check oil level

Check for leaks

Check ground connection for corrosion

• Clean pump surfaces and surrounding area of dust and debris

First 250 hours of operation

• Change oil

Every 4000 hours or six months

Change oil

• Clean inlet piping strainer & check external pressure relief valve

Replace worm shaft oil seal

If equipped, check coupling insert. Replace if necessary.

Tighten all fasteners

Annual

Clean check valves. Replace O-rings.

Replace diaphragm

• If equipped, replace coupling insert.

• Replace rolling element bearings

Replace O-rings

Replace check valves

9.0 MAINTENANCE

Under normal conditions, the “dia-PUMP” does not require any significant amount of maintenance. It is
advised that periodic visual observations be made of the oil level. See Page 5 (Figure 1A) for correct oil
level. The liquid end of the pump should also be inspected for leakage. These observations should be made
regularly, at least every 48 hours.

•

•

•

•

•

•

•

•

•

•

10

10.0

REMOVAL OF VALVE CARTRIDGES (See page 26 for SERIES 500-E; Page 29 for 500-VS)

The “dia-PUMP” incorporates a unique check valve design whereas the discharge and suction piping NEED

NOT be disturbed in order to service the valve cartridges.

Should the valves need cleaning, remove as follows:

10.0.1 Suction Valve: Remove Suction Valve Cap (FIG. #550) and using Allen Wrench provided, remove

Suction Valve Cartridge (FIG. #544).

NOTE for PVC Head Pumps

Remove Suction Valve Cap (P/N 000256) by removing the Valve Cap Screws (P/N 100250) and

remove Suction Valve Cartridge (P/N 000259) using the special round lug tool provided. Caution:
PVC is fragile – do not use excessive force.

10.0.2 For removal of discharge valve, refer to instruction in Section II, Paragraph 7.0.2.

10.0.3 Please refer to Figures VI and VII showing valve cartridge removal.

11.0 CLEANING OF VALVE CARTRIDGES

11.0.1 The valve cartridge is a complete and integral unit and should not be disassembled for cleaning. If
the valves are found to be worn and in need of replacement, an entire valve cartridge, either suction
or discharge, should be ordered. The suction valve is the longer of the two valve cartridges.

11.0.2 To clean the valve cartridges, soak in strong detergent and then blow dry with compressed air.

12.0 REPLACING OF VALVE CARTRIDGES (See page 25 for SERIES 500-ER)

12.0.1

Be certain that the Valve Seat O-Ring (FIG. #549 for Metal Head Pumps, P/N 100185 for PVC Head
Pumps) is removed with the valve and that no other foreign matter is in the valve cavity.
Use a small amount of grease to hold the o-ring in the groove in the end of the valve cartridge on
reassembly.

Reverse the procedure used to remove the valve cartridge. Do not over-tighten valve cartridge. Firm
tightening is enough to cause the O-Ring to seal.

11

FIGURE V

CUT-AWAY VIEW OF VALVE SECTION, METAL HEAD PUMP

FIGURE VI

VALVE CARTRIDGE REMOVAL, METAL HEAD PUMP

FIGURE VII

VALVE CARTRIDGE REMOVAL, PVC HEAD PUMP

12.0 REPLACING OF VALVE CARTRIDGES (Continued)

13.0 PROCEDURE FOR REPLACING CONTROL ROD O-RING (fig. #517)
AND SEALING PLATE O-RING (FIG. #516).

Refer to Figure VIII

1. Remove Drain Plug (FIG. #510) and drain hydraulic fluid.

2. Remove Indicator Plate (FIG. #520) by removing two holding screws.

3. Remove control rod assembly with Control Rod (FIG. #’s 515, 523,524) attached, by turning counter

clockwise and pulling out.

4. Insert 11/16” Hex Socket onto the Sealing Nut (FIG. #526) and screw out of pump in a counter clockwise

direction. Then, remove Sealing Plate (FIG. #518) using a small brass hook to pull loose.

12

FIGURE VIII

REMOVAL OF CONTROL ROD ASSEMBLY

5. Replace Control Rod O-Ring (FIG. #517) and Sealing Plate O-Ring (FIG. #516).

Remove and examine Teflon Diaphragm (FIG. #533). Remove and examine the Liquid Side

6. Take care when replacing Sealing Plate, (FIG. #518) so as to not damage the Sealing Plate O-Ring

(FIG. #516).

7. Replace all parts and fill pump with hydraulic fluid per previous instructions.

8. Follow start-up procedure as if starting a new pump.

14.0 REMOVAL OF PUMP HEAD AND REPLACEMENT OF DIAPHRAGM (REFER TO FIGURES IX AND X)

14.0.1 Remove Drain Plug (FIG. #510), and drain hydraulic fluid.

14.0.2 Remove Long and Short Pump Head Bolts [(FIG. #’s 551 and 552) or (P/N 101135 and P/N 101136)
on PVC pumps.] Lift Pump Head [(FIG. #535) or (P/N 000255, P/N 000258) on PVC pump] away from
pump.

14.0.3
Diaphragm Backup Place [(FIG. #532) or (P/N 000254, 100245) on PVC pumps.] Replace with new
part, if required. When replacing the Teflon diaphragm, be certain to line it up properly with the sealing
grooves.

14.0.4 To reassemble, reverse the above procedure. Reassembly is facilitated by laying the pump on its side.
Be certain to tighten all bolts evenly. Tighten to 25 ft. lbs. (15ft. lbs. On PVC pump).

14.0.5 Start up pump by following Start-Up Procedure per Section II Paragraph 1.0.12 and 6.0.3.

13

14.0 REMOVAL OF PUMP HEAD AND REPLACEMENT OF DIAPHRAGM (Continued)

FIGURE IX FIGURE X

15.0 REMOVAL OF MOTOR FROM STANDARD “dia-PUMP” (REFER TO FIGURE XI)

15.0.1 Disconnect all wires leading to the motor.

15.0.2 Remove Drain Plug (FIG. #510) and drain hydraulic fluid from pump.

15.0.3 Remove the fan cover and fan if the motor is a TEFC type. Remove retaining bolts from the top of the motor.

These bolts are threaded directly into the Pump Gear Box (FIG. #500).

15.0.4 Turn case of motor gently to break silicone seal between motor casing and Pump Gear Box (FIG. #500). Tilt

motor slightly forward and remove housing and remove internal part.

15.0.5 To replace motor, clean machined surface at top of Gear Box (FIG. #500) and apply silicone sealer. Place

motor back in position generally reversing the disassembly procedure.

FIGURE XI

14

SECTION IV

in thermal

MOTOR OPERATING CONDITIONS

16.0 The Standard Series 500/5000 “dia-PUMP” is supplied with a 1/3 HP or 1/2 HP/single phase/totally enclosed fan cooled

motor as an integral part of the pump itself.

The normal temperature rise for this motor is 40ºC above ambient temperature and thus, it might appear that the motor is
operating at a higher than normal temperature. This situation is normal and should not cause concern.

As a precaution against motor overheating, it is recommended that the pump be located where adequate ventilation is
available. It is also highly RECOMMENDED THAT A MOTOR STARTER WITH THE PROPER OVERLOAD
PROTECTION BE SUPPLIED AS AN ADDITIONAL SAFETY DEVICE.

The Standard Series 500/5000 “dia-PUMP” (1/3HP/1/115V/60C/TEFC) motor is supplied with built­protection. Automatic overload is provided on all pumps with standard motor with serial numbers higher than 9600-78D.

Should an overload occur on a standard motor unit which is not protected by a motor starter or on such a unit where the
starter has failed, the motor will shut down automatically. It will take approximately ½ hour for the automatic thermal
overload switch to reset itself.

15

SECTION V

TROUBLESHOOTING CHART

1. Pump Motor Will Not Operate.

A. Blown Fuse.

A. Check for short circuit or overload.

B. Open thermal overload device in

B. Reset.

C. Low liquid level in tank (where low

C. Fill tank.
D. Broken wire.

D. Locate and repair.

E. Low voltage.

E. Check for too light wiring.
F. Oil “frozen” in pump.

F. Thaw out.

*2. Pump Does Not Deliver Rated

A. Starved suction.

A. Replace suction piping with larger size,

B. Leaky suction piping.

B. Pressure test, repair or replace

C. Excessive suction lift.

C. Rearrange equipment location to

D. Liquid too close to boiling point.

D. Lower temperature or increase suction

E. Air or gas trapped in oil or pumpage.

E. Decrease capacity to 20% for 5 mins.,
F. Worn or dirty valves or seats, or both.

F. Clean or replace.

G. Viscosity of liquid too high (CPS).

G. (1) Reduce viscosity by heating or

H. Insoluble materials settling out, or

H. Check solution strength.
I. Low discharge pressure.

I. A minimum discharge pressure of 50
J. Capacity adjustment set above 100%

J. Reposition adjustment knob to 100%
K. Air in hydraulic or chemical systems.

K. Bleed system.

SYMPTOMS CAUSES REMEDIES

starter or motor.

Capacity

level cut-off is used).

or increase suction head.

defective piping.

reduce suction lift.

head pressure.

then increase to 100% for 5 mins.

other means;
(2) Increase size of suction piping;
(3) Increase suction pressure

crystallization of saturated solution.

capacity mark.

16

Flush and clean solution tank
periodically. Suction connection should
be 2 to 4” from bottom of solution tank.

psi is required to insure proper capacity
control.

mark.

SYMPTOMS CAUSES REMEDIES

L. No foot valve strainer.

L. Install one.

*3. Pump delivers erratically.

A. Leaky suction line.

A. Repair or replace piping.

B. Worn or dirty valves or seats, or

C. Excessive excursion of ball from

D. Liquid too close to boiling point.

D. Reduce temperature or raise

suction pressure.

E. Leaky internal or external relief

4. Motor Overheats Thermal

A. Overload caused by operating

A. Check operating pressure against

5. Noisy Operation

(1) In Pump

A. Pump Valves.

A. Valves must move to open and

(2) In Gear Reducer

A. Pounding noise at high discharge

A. Fluid compressibility causes

6. Improper Oil Level in

A. Increases and overflows.

A. Flexible diaphragm punctured by

7. Pump Delivery is Not

A. System pressure too low.

A. Install back-pressure spring,

8. Pump Does Not Develop

A. Internal relief valve leaking.

A. Check setting as per pressure

B. Internal relief valve being

B. System pressure exceeds relief

Overload Activates

both.

valve seats (indicated by ball
chatter).

valve.

pump beyond rated capacity.

pressure.

B. Clean or replace cartridges.

C. Replace cartridges.

E. Repair or replace relief valve.

pump manufacturer’s data plate
maximum rating.

close, and they will make a clicking
noise as they operate. These
noises are sometimes amplified by
natural resonances in piping
system. They are usually
indications of normal valve
functioning.

reversal of load on gears at end of
pressure stroke. Not considered
detrimental.

Reservoir.

Adjustable

Required Pressure

* Symptoms 2 and 3 ---- A Diaphragm may need replacing.

actuated.

foreign material – replace
diaphragm. Clean and flush
hydraulic system at once.

provided, into discharge cartridge.

B. Install Back-pressure valve.

change procedure, Paragraph 4.0.

valve set pressure.

Refer to Paragraph 4.0 for

adjustment procedure.

17

SECTION VI

SEE ELECTRIC STROKE CONTROL INSTRUCTION MANUAL P/N ZL106738

FOR PUMPS FURNISHED WITH OPTIONAL ELECTRIC STROKE CONTROL.

17.0 Typical Drawing of the Neptune dia-PUMP with Electric Stroke Control shown below.

18

SERIES 500 AND 500-A PUMP PARTS

FIG.
NO. DESCRIPTION

QTY.

PART

NO.

500

Gear Box*

1

000162

5005

Worm Gear 18 SPM*

1

003517

Worm Gear 37 SPM*

1

000164

Worm Gear 72 SPM*

1

000166

Worm Gear 117 SPM*

1

000163

Worm Gear 144 SPM*

1

002818

Worm Gear 175 SPM*

1

000165

502

Connecting Rod

1

000167

503

Gear Shaft*

1

106305

506

Worm 18 SPM

1

003516

Worm 37 SPM

1

000170

Worm 72 SPM

1

000172

Worm 117 SPM

1

000169

Worm 144 SPM

1

002817

Worm 175 SPM

1

000171

507

Bearing Cup

1

100179

508

Bearing Cone

1

100180

509

Worm Spring Pin

1

100181

510

Drain Plug

1

100182

511

Connecting Rod Pin

1

100183

512

Fill Plug

1

000191

513

Pump Body, Right Hand

1/2” Small Cavity††

1

000180

1/2” Standard Cavity††

1

000178

11/16” Standard Cavity††

1

000177

1-1/16” Standard Cavity††

1

000176

1-3/16” Standard Cavity††

1

003232

Pump Body, Left Hand

1/2” Small Cavity††

1

000179

1/2” Standard Cavity††

1

000175

11/16” Standard Cavity††

1

000174

1-1/16” Standard Cavity††

1

000173

1-3/16” Standard Cavity††

1

003235

514

Piston 1/2”

1

000181

Piston 11/16”

1

000182

Piston 1-1/16”

1

000183

Piston 1-3/16”

1

003234

515

Control Rod

1

000184

516

Sealing Plate O-Ring 1/2”

1

100184

Sealing Plate O-Ring 11/16”

1

100185

Sealing Plate O-Ring 1-1/16”

1

100186

Sealing Plate O-Ring 1-3/16”

1

100244

517

Control Rod O-Ring

1

100188

518

Sealing Plate 1/2”

1

000185

Sealing Plate 11/16”

1

000186

Sealing Plate 1-1/16”

1

000187

Sealing Plate 1-3/16”

1

003233

Capacity indicating scale

1

100192

Capacity indicating scale 5003

1

104802

Capacity indicating scale 5005

1

104799

FIG.

NO.

DESCRIPTION

QTY.

PART

NO.

519

Control Rod Spring Pin

1

100189

520

Indicator Plate

1

000188

521

Indicator Plate Screws

2

100190

522

Control Knob Set Screw

1

100191

523

Control Rod Positioner

1

000189

Control Rod Positioner 5003

1

004839

Control Rod Positioner 5005

1

004834

524

Control Knob

1

002071

Control Knob for 5003

1

004841

Control Knob for 5005

1

004836

526

Sealing Nut

1

002069

Sealing Nut for 5003

1

004840

Sealing Nut for 5005

1

004835

527

Relief Valve Poppet Except Model 547

1

000193

Relief Valve Poppet Model 547 Only

1

003531

528

Relief Valve Spring Except Model 547

1

100193

Relief Valve Spring Model 547 Only

1

107948

Relief Valve Spring-

Model No. After Material Code-Example: 515-S-N3HP

1

106319

529

Relief Valve Adjusting Screw

1

105164

530

Relief Valve Plug

1

100196

531

Oil Side Backup Plate

Small Diameter Models 500, 5003, 5005††

1

000197

Standard Diameter Except Models 53X and 54X††

1

000194

Standard Diameter Models 53X and 54X††

1

003946

533

Teflon Diaphragm

Small Cavity ††

1

000231

Standard Cavity ††

1

000200

534

Pump Body Cap Screws

2

100197

538

Valve Cap O-Rings

2

100200

Valve Cap O-Rings-Teflon

2

100213

549

Valve Seat O-Rings

2

100204

Valve Seat O-Rings-Teflon

2

100203

553

Pipe Plug

1

100210

554

Cover Plate

1

000229

555

Cover Plate Screws

2

100211

556

Std. Motor Assembly 18 SPM**

1

003618

Std. Motor Assembly 37 SPM**

1

002400

Std. Motor Assembly 72 SPM**

1

002401

Std. Motor Assembly 117 SPM**

1

002402

Std. Motor Assembly 144 SPM**

1

002836

Std. Motor Assembly 175 SPM**

1

002407

557

Hydraulic Fluid (2 qts.) ISO68

1

003089

Hydraulic Fluid (2 qts.) SAE90

1

002372

Hydraulic Fluid (1 qt.) SAE 0W30 Synthetic

1

104807

590

Gasket or Sealer

1

106290

591

Gasket or Sealer

2

106291

5002

Shaft Retainer Assembly*

1

002722

5004

Thrust Washers

3-4

100252

5025

Shaft Retainer Screws

3

100254

5699

Knob Friction O-Ring

1

100417

STD motor assemblies include figure numbers 506, 508, 509.

1/3-1-115-60-TEFC-CAP-48Y.

SECTION VII PARTS LIST

High Pressure Denoted by “HP” in

††Models 5003, 5005, 500 are small cavity. All others are standard cavity.
Right hand pump body is standard on all Simplex Pumps.
* Items not to be used on 500-A pumps (page 2)
** Includes Part Nos. 506, 508 and 509.

19

PARTS FOR PUMP WITH METAL HEADS

FIG.
NO. DESCRIPTION

QTY.

PART

NUMBER

539

Discharge Valve Cartridge

1

000209

544

Suction Valve Cartridge

1

000217

549

Valve Seat O-Ring

4

100204

538

Valve Cap O-Ring

4

100200

533

Diaphragm (Models 500, 5003 & 5005 Only)

1

000231

533

Diaphragm (All Other Models)

1

000200

517

Control Rod O-Ring

2

100188

516

Sealing Plate O-Ring (Models 500/5005/510/515)

2

100184

516

Sealing Plate O-Ring (Models 520/522/525/527)

2

100185

516

Sealing Plate O-Ring (Models 530/532/535/537/538)

2

100186

516

Sealing Plate O-Ring (Models 547)

2

100244

FIG.
NO. DESCRIPTION

QTY.

PART

NUMBER

539

Discharge Valve Cartridge

1

000210

544

Suction Valve Cartridge

1

000218

549

Valve Seat O-Ring

4

100204

538

Valve Cap O-Ring

4

100200

533

Diaphragm (Models 500, 5003 & 5005 Only)

1

000231

533

Diaphragm (All Other Models)

1

000200

517

Control Rod O-Ring

2

100188

516

Sealing Plate O-Ring (Models 500/5005/510/515)

2

100184

516

Sealing Plate O-Ring (Models 520/522/525/527)

2

100185

516

Sealing Plate O-Ring (Models 530/532/535/537/538)

2

100186

516

Sealing Plate O-Ring (Models 547)

2

100244

FIG.
NO. DESCRIPTION

QTY.

PART

NUMBER

P-539-C

Discharge Valve Cartridge

1

000259

P-544-C

Suction Valve Cartridge

1

000262

P-549-C

Valve Seat O-Ring

4

100185

P-538-C

Valve Cap O-Ring

4

100244

533

Diaphragm (Models 500, 5003 & 5005 Only)

1

000231

533

Diaphragm (All Other Models)

1

000200

517

Control Rod O-Ring

2

100188

516

Sealing Plate O-Ring (Models 500/5005/510/515)

2

100184

516

Sealing Plate O-Ring (Models 520/522/525/527)

2

100185

516

Sealing Plate O-Ring (Models 530/532/535/537/538)

2

100186

516

Sealing Plate O-Ring (Models 547)

2

100244

P-571-C

Vent Plug O-Ring

2

100080

FIG

NO.

DESCRIPTION

QTY.

N3

PART NO.

N4

PART NO.

532

Diaphragm Back Up Plate Liquid Side (Standard Cavity)

1

000195

000196

Diaphragm Back Up Plate Liquid Side (Small Cavity)

1

000198

000199

535

Liquid Head (Standard Cavity)

1

000202

000203

Liquid Head (Small Cavity)

1

000205

000206

536

Discharge Valve Cap

1

002073

002072

537

Anti-Siphon Spring 18, 37, 72 or 117 SPM Pumps

1

100198

100199

539

Discharge Valve Cartridge

1

000209

000210

543

Discharge Valve Nut

1

000215

000216

544

Suction Valve Cartridge

1

000217

000218

550

Suction Valve Cap

1

000207

000208

551

Short Pump Head Bolts

6

100206

100206

552

Long Pump Head Bolts

2

100208

100208

SPARE PARTS KIT (N3 CONSTRUCTION) MODELS 500 THROUGH 547, 5003 & 5005

KIT NUMBER 002712

DUPLEX PUMPS
REQUIRE 2 KITS

SPARE PARTS KIT (N4 CONSTRUCTION) MODELS 500 THROUGH 547, 5003 & 5005

SPARE PARTS KIT (N5 CONSTRUCTION) MODELS 500 THROUGH 547, 5003 & 5005

KIT NUMBER 002713

DUPLEX PUMPS
REQUIRE 2 KITS

KIT NUMBER 002714

DUPLEX PUMPS
REQUIRE 2 KITS

20

PARTS FOR PUMPS WITH MOTOR FLANGE ADAPTER, (REFER TO PARTS DRAWING 000911 ON PAGE 24)

FIG.
NO. DESCRIPTION

QTY.

PART

NUMBER

507

Bearing Cup 1 100179

508

Bearing Cone 2 100180

558

Motor Flange Adapter

1

000227

559

Worm Shaft with Retaining Ring attached (Part #107952)

1

000228

560

Lovejoy Coupling

1

100053

561

Oil Seal 1 100214

562

Adapter to Gear Box Bolts

4

100215

563

Adapter to Motor Bolts

4

100216

564

Lock Washer 4 100217

565

Coupling Key 2 100218

566

Lock Washers 4 100219

509

Spring Pin 1 100181

FIG.
NO. DESCRIPTION

QTY.

PART

NUMBER

570

Control Rod “P”

1

000273

571

Control Mount 1 000274

572

Short Mounting Bolt

3

100259

573

Plexiglass Shell

1

000275

576

Piston 1 000276

578

Range Spring, 3-15 psi (9 psi Span) Standard

1

100260

578

Range Spring, 3-9 or 9-15 psi (6 psi Span)

1

100261

578

Range Spring, 5-25 psi (20 psi Span)

1

100262

578

Range Spring, 3-27 psi (24 psi Span)

1

100263

579

Housing 1 000277

580A

Moore 73N Control Valve – Forward Acting

1

100265

580B

Moore 73N Control Valve – Reverse Acting

1

100266

581

Retainer Bolt 1 100267

583

Pneumatic Diaphragm

1

100268

584

Control Rod Adapter

1

000280

585

Control Spring Pin

1

100269

586

Long Mounting Bolt

3

100270

587

Operating Spring

1

100271

589

Retaining Plate and Stop Bushing

1

000281

FIG.
NO. DESCRIPTION

QTY.

PART

NUMBER

562

Adapter to Gearbox Bolts

4

100215

563

Adapter to Motor Bolts

4

100216

564

Lock Washers 4 100217

566

Lock Washers 4 100219

611

Motor Flange Adapter

1

004157

612

Motor Worm Shaft

1

004156

613

Wave Spring 1 107599

614

Bearing 1 106180

615

Retaining Ring

1

106593

PARTS UNIQUE TO PUMPS SUPPLIED WITH NEPTUNE PNEUMATIC STROKE CONTROL

PARTS UNIQUE TO PUMPS SUPPLIED WITH “FALP” (REFER TO PARTS DRAWING FALP ON PAGE 24)

SECTION VII

PARTS ORDERING INSTRUCTIONS

Note: For Prompt entry of parts orders; your order must include both model number and serial number.

21

Drawing HP-1102

22

.

SERIES 500 PVC HEAD ASSEMBLY WITH SMALL CAVITY

(ASSEMBLY P/N 002074)

SERIES 500 PVC HEAD ASSEMBLY WITH STANDARD CAVITY

(ASSEMBLY P/N 002075)

Kynar liquid end material code [N8] is available in the style used for Series 500-E only. See Page 26

23

DRAWING #000911

DRAWING # FALP

24

APPENDIX

SERIES 500-E-AR

“dia-PUMP” INSTRUCTIONS

Addendum to Operating and Instruction Manual for the 500 dia-PUMP and 500-A dia-PUMP

This sheet describes the differences in liquid head design of the Series 500-E-AR “dia-PUMP”. This sheet is intended to
be used with the Operating and Instruction Manual for Neptune Series 500 and 500-A “Dia-pumps”.

The Series 500-E-AR Pumps are identical to the Series 500-A except for an economy liquid head. All parts of the
instruction manual relating to Series 500-A are applicable to 500-E except for liquid head parts and valve instructions.
The 500-E-AR consists of: (1) liquid head casting, (1) suction valve
and (1) air release valve (P/N: 104412).

Installation: Refer to installation instructions of the 500, 500-A and 500 E for proper set up of pump.
of the "AR" liquid head allows you to vent off gases that may accumulate in the
(P/N: 104412). You must connect tubing (3/16” ID X 5/16” OD) to
back to the supply tank or drain.

(P/N: 004498), (1) discharge valve (P/N: 004503)

The unique design

pump head from the air release valve

the connection on the air release valve and return it

004586---- Complete Spare Parts Kit*
*Includes suction and discharge valve cartridges, diaphragm and all O-rings.

25

CAST IRON & 316SS

PVC & KYNAR

DISCHARGE
VALVE
CARTRIDGE

SUCTION
VALVE
CARTRIDGE

BACKUP
PLATE

LIQUID
HEAD

PUMP HEAD
SCREWS

DISCHARGE
VALVE
CARTRIDGE

SUCTION
VALVE
CARTRIDGE

LIQUID
HEAD

PUMP HEAD
SCREWS AND
WASHERS

APPENDIX

CODE N3

Part #

CODE N5

Part #

CODE N8

Part #

SERIES 500-E

316SS

“dia-PUMP” INSTRUCTIONS

Addendum to Operating and Instruction Manual for the 500 dia-PUMP and 500-A dia-PUMP

This sheet describes the differences in liquid head design of the Series 500-E “dia-PUMP”. This sheet is intended to be used with the
Operating and Instruction Manual for Neptune Series 500 and 500-A “dia-PUMP”.

The Series 500-E Pumps are identical to the Series 500-A except for an economy liquid head. All parts of the instruction manual
relating to Series 500-A are applicable to 500-E except for liquid head parts and valve instructions. The 500-E liquid head consists of:
(1) liquid head casting, (1) back-up plate (on metal head models only), and (2) valve cartridges. The valve cartridges are replaced as
a unit; they cannot be disassembled.

The following parts are unique to Series 500-E Models:

DESCRIPTION QTY.

Pump Head 1 003276 003278 003326

Valve Cartridge Suction 1 003321 003279 003332

Back-Up Plate 1 000195 NA NA

Valve Cartridge Discharge 1 003321 003279 003332

Pump Head 5/16-18 Screws 8 100205 107697 107697

Pump Head 5/16 Washers 8 NA 106857 106857

Complete Spare Parts Kit* 1 003385 003386 003387

*Includes suction and discharge valve cartridges, diaphragm and all O-rings.

NOTE: PRIMING PROCEDURE
Series 500-E pumps have no anti-siphon spring to defeat when priming, they also do not have a valve cap to vent and bleed air.
To bleed air on initial start-up it will be necessary to open a valve to the atmosphere in the discharge line before the first isolation
valve. If there is no valve in the particular installation, then breaking the piping connection at tubing joint or union will allow the air to
escape while the pump is primed. This is only required when first starting a new installation. Since there is no anti-siphon spring, it is
necessary to install a backpressure valve in the line when pumping to atmospheric or low-pressure injection points.

316SS

PVC

KYNAR

Valve cartridges remove as one piece. Apply pipe dope or Teflon paste to threads to reinstall.

26

APPENDIX

PAGE

SECTION

PARAGRAPH

7

4.0.1

2

Drawing number 5024 illustrates the location of the internal

7

4.0.21

Location of 500-A “dia-PUMP” Internal Relief Valve is on

13

15.0.3

Remove retaining bolts … (FIG. #5016, 5018, 5019, 5020)

13

15.0.4

Turn Case (FIG. #5016, 5018, 5019, 5020)

13

15.0.5

To replace motor … (FIG. #5016, 5018, 5019, 5020)

FIG.
NO.

DESCRIPTION

QTY.

PART

NUMBER

5002

Shaft Retainer Assembly

1

000242

5003

Gear Shaft

1

100251

5005

Worm Gear 37 SPM

1

000292

5006

Worm Gear 72 SPM

1

000293

5007

Worm Gear 117 SPM

1

000291

5008

Worm Gear 175 SPM

1

000294

5016

Gear Box (Model 500 Only)

1

000288

5018

Gear Box (Model 510/515 Only)

1

000282

5019

Gear Box (Model 520/522/525 Only)

1

000283

5020

Gear Box (Model 530/532/535/538 Only)

1

000284

SERIES 500-A

THE FOLLOWING CHANGES IN TEXT MUST BE CONSIDERED WHEN USING THIS MANUAL
FOR THE SERIES 500-A “dia-PUMP”. EXCEPT FOR THE DIFFERENCES LISTED BELOW,
THIS INSTRUCTION MANUAL APPLIES COMPLETELY TO BOTH THE SERIES 500 AND
SERIES 500-A “dia-PUMP”.

relief valve (FIG. #527 thru #530).

top of the Pump Body, not as shown in Figure IV.

Parts for Series 500-A “dia-PUMP” not common to Series 500 “dia-PUMP”. Refer to Drawing 5024

RECOMMENDED SPARE PARTS

The Spare Parts Kits listed on page 20 of this manual comprise the recommended

spare parts for all Series 500 dia-PUMPS.

27

Drawing 5024

28

Series 500VS (High Viscosity)

RECOMMENDED SPARE PARTS

FIG.
NO. DESCRIPTION

QTY.

PART

NUMBER

533

Diaphragm

1

000200

539

Discharge Valve Assembly

1

000209

Check Valve Assembly

1

003117

538

Valve Cap O-Ring

2

100200

516

Sealing Plate O-Ring (Model 515)

2

100184

516

Sealing Plate O-Ring (Models 520, 522, 525)

2

100185

516

Sealing Plate O-Ring (Models 530, 532, 535, 537)

2

100186

516

Sealing Plate O-Ring (Model 547)

2

100244

549

Valve Seat O-Ring

2

100204

APPENDIX

SERIES 500-VS

HIGH VISCOSITY

INTRODUCTION

The Neptune Series 500 “dia-PUMP” is available with a special liquid end to handle higher viscosity liquids.
Model numbers of pumps are for example 515-VS-N3 or 535-VS-N3.

This liquid end, which is only available in 316SS, is different than the standard liquid end as the suction valve,
back up plate, and liquid head are modified to allow oversized porting to enable thick liquids to be drawn into
the pump on the suction stroke. All other parts of the pump are identical to the standard pump.

Note, the suction connection is directly up from below and the normal suction connection is plugged. The
pump must be elevated as the inlet connection is plugged. The pump must be elevated as the inlet
connection extends below the plane of the gear box seat.

Maintenance instructions are identical to the standard pump. The four parts which are different from the
standard unit are shown below.

003139----Complete Spare Parts Kit, Includes Diaphragm and all O-Rings.

Head Parts Drawing

C-003105

29

APPENDIX

MODEL 5003 and 5005

LOW VOLUME PUMP

INTRODUCTION

A special version of the Neptune Series 500 Pump is the Model 5003 and 5005. This pump is different than the
standard pump due to the unique Low-Flow design and uses a Metering Device with extremely close tolerances.
(Correct installation is critical for proper pump operation). Refer to Parts Drawing S00126 for cross-sectional
details. This drawing also indicates each part of the Model 5003 and 5005 that is not common to the other pumps
within the Series 500.

Generally, the maintenance and repair procedures for the Model 5003 and 5005 are the same as those shown in
the Operating and Instruction Manual for the Series 500 and 500-A Pumps. Failure to follow these instructions
could cause pump output to become erratic, or stop altogether.

PUMP CALIBRATION

Each pump is tested at the factory prior to shipment to assure proper operation without leakage at the maximum
capacity and discharge pressure specified, with a constant flooded suction of 2 feet of water. For precise capacity
control in the field, a calibration test under actual operating conditions with the actual piping arrangements is
frequently desirable. Use a calibration drawdown cylinder in the suction line.

After the suction and discharge lines are piped with a convenient sampling point in the suction line, and the pump
has been suitably primed, test samples are collected at 25%, 50% 75% and 100% capacity settings. A straight line
results when these points are plotted on graph paper. This graph can be used as a calibration curve for an
intermediate setting as long as suction and discharge conditions remain constant.

It is important to realize that the sample at 50% will not necessarily be 1/2 that of 100%, nor will any other sample
points be to a specific percentage of the 100% value, but the pump will give repetitive samples at the same setting.
This is due to the extremely low volume of the pump which results in a shifting zero flow point as pressure
increases and can be seen in the curve below.

THIS MODEL MUST BE INSTALLED WITH FLOODED SUCTION.

The hydraulic fluid for “5003” and “5005” Pump supplied by Neptune is Mobil Synthetic Oil 0W30.
Common sources for hydraulic fluid are listed on page 5.

30

Drawing S00126

SERIES 5000 "dia PUMP"

FIG.

NO.

DESCRIPTION

QTY.

PART

NUMBER

Control Rod Positioner for 5003

1

004839

Control Rod Positioner for 5005

1

004834

Control Knob Assembly for 5003

1

004845

Control Knob Assembly for 5005

1

004844

Sealing Nut for 5003

1

004840

Sealing Nut for 5005

1

004835

PERFORMANCE CURVE

Drawing S000126
SERIES 5000 “dia-PUMP”

Parts for Series 5000 “dia-PUMP” not common to Series 500 “dia-PUMP
Refer to Drawing S00126

1

”.

2

3

RECOMMENDED SPARE PARTS – same as 500 Series, see page 20

PARTS ORDERING INSTRUCTIONS
Note: For prompt entry of parts orders; your order must include model number and serial number.

31

APPENDIX

The instructions below are for Neptune’s optional Double

Use of a double diaphragm allows diaphragm to be

diaphragm allowing repairs to be made before

Neptune’s double diaphragm is a kit which may be
retrofitted to any pump currently in service or may be

charge piping. Remove drain plug and drain

re. Be

DOUBLE DIAPHRAGM OPTION

FIGURE 1

ADDENDUM: Special instructions for Series 500, 500-A & 560 “dia-PUMPs” with Double Diaphragm

THEORY OF OPERATION

Diaphragm Kit which is available for the Neptune Series
500 and 500-A “dia-PUMPs”.

monitored and provides an early warning upon failure of
either
process fluid mix with the pump hydraulic fluid.

installed on a new pump at the factory.

Figure 1 illustrates a Double Diaphragm Assembly. An
intermediate plate is located between the oil and liquid
heads with one diaphragm on each side of the
intermediate plate. The Intermediate Plate is connected
to a rupture alarm or pressure switch via a capillary
system. The area between the diaphragms is
evacuated. Rupture in either diaphragm produces an
increase in volume and, therefore, a pressure increase,
which can be sensed by a pressure switch for alarm
purposes.

DISASSEMBLY OF INTERMEDIATE PLATE

1.0.0 Shut pump off and disconnect suction and dis-

1.0.1 Remove 8 Screws and remove the liquid head

1.0.2 The intermediate plate, which is between the

1.0.3 Remove the rupture alarm (pressure switch) and

1.0.4 Replace one or both diaphragms if needed.

hydraulic fluid from the gearbox.

assembly. Some hydraulic oil and process fluid
will spill out when the head is removed.

pump heads can be removed easily.

clean the capillary system.

1.0.5 To reassemble reverse above procedu

certain that parts align properly.

VACUUM AIR FROM INTERMEDIATE SPACE

1.0.6 Open valve Item No. 5 (Figure 2).

1.0.7 To remove air, attach the vacuum pump with a
hose connection Item No. 6 to the valve Item No.
5 (Figure 2) and pump until resistance is felt,
for normal operating conditions.

32

APPENDIX

ITEM NO.

DESCRIPTION

QTY.

PART NO.

1

INTERMEDIATE PLATE ASSEMBLY

1

003190

2

1/8 NPT NIPPLE

1

101475

3

1/8 NPT TEE

1

101898

4

PRESSURE SWITCH, NEMA 4

1

107021

PRESSURE SWITCH, NEMA 7

1

107022

5

VALVE

1

106599

6

HOSE CONNECTOR

1

WA170782

7

VACUUM PUMP (SOLD SEPARATLEY)

1

108233

8

TUBE CONNECTOR, 1/8 NPT STRAIGHT

1

WD170746

9

1/4 X 1/8 NPT REDUCER BUSHING

1

101804

10

1/4-20 X 1" LG. HEX HEAD SCREW

2

100159

11

1/4-20 HEX NUT

2

100448

12

1/8 NPT PIPE PLUG, 316SS

1

101859

13

1/4" FLAT WASHER

2

108426

14

1/4" LOCK WASHER

2

100169

15

1/8 NPT NIPPLE (FOR METAL HEADS)

1

101477

1/8 NPT NIPPLE (FOR PLASTIC HEADS)

1

101479

16

BRACKET ASSEMBLY

1

003577

BRACKET ASSEMBLY (FOR DUPLEX)

1

003600

17

DIAPHRAGM

1

000200

18

VACUUM TUBE

1

004433

19

TUBE CONNECTOR, 1/8 NPT ELBOW

1

104614

DOUBLE DIAPHRAGM OPTION

FIGURE 2

ADDENDUM: Special instructions for Series 500, 500-A & 560 “dia-PUMPs” with Double Diaphragm

1.0.8 Close valve Item No. 5

1.0.9 Remove the vacuum pump. Plug valve Item No. 5 with a 316SS pipe plug Item No. 12

1.0.10 Reinstall the Pump

1.0.11 Follow procedure in Neptune Standard Operating and Instruction Manual for Initial Pump Startup

NOTE: Neptune furnishes a Mityvac



vacuum pump from

automotive parts stores. (Unit furnished by Neptune is less gauge and automotive adapters)

Mityvac

33



No. 6810 automotive test kit available at many

34 35

Pump Model___________________________

Serial #_______________________________

MAINTENANCE LOG

Strokes Per Minute______________________

Piston Diameter________________________

Spare Parts Kit #____________________________________________________________

NEPTUNE CHEMICAL PUMP CO., INC. Tel.: [phone] • FAX: [phone]

DATE SERVICED BY MAINTENANCE PERFORMED

Maximum Flow________________________

Maximum Pressure_____________________

.

Revised 2-13-2013
Rev 5, Revised 6-16-2014
Rev 6, Revised 5/18/2015
Rev 7, Revised 03/15/2018

© Copyright 2012 Neptune Chemical Pump Company, Printed in U.S.A NEP-ZL105638

36