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.: 215-699-8700
1 -888-3NEPTUNE (888-363-7886)
FAX: 215-699-0370
Web: www.neptune1.com
Email: neptune.sales@psgdover.com
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
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