Related Manuals for Dover PSG Neptune
Summary of Contents for Dover PSG Neptune
- Page 1 INSTALLATION, OPERATION & MAINTENANCE POLYMASTER LIQUID POLYMER BLEND & FEED SYSTEM NEP-ZL104791 05.2018...
- Page 2 WARNING LOCKOUTS ARE REQUIRED BEFORE SERVICING THIS EQUIPMENT. SAFETY INSTRUCTIONS: Shut off/Lockout pump Power before Servicing. Be certain pump isolation valves are Closed and chemical is shut off. Bleed pressure before servicing. SAFETY INSTRUCTIONS: Shut off/Lockout Polymaster Power before Servicing. Be certain Polymaster isolation valves are Closed and chemical is shut off.
- Page 3 WARNING Please read thoroughly before installation, operation or maintenance of any Polymaster Machine Only suitability trained personnel should work on the equipment. *CAUTION: Before performing any maintenance disconnect electric power. EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture, malfunction and result in serious injury. This equipment is for professional use only.
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Page 4: Table Of Contents
Polymaster ™ TABLE OF CONTENTS PAGE NO. INSTALLATION CAUTION! THEORY OF OPERATION OPERATING INSTRUCTIONS LONG TERM STORAGE INSTRUCTIONS START UP CALIBRATION CALIBRATION GRAPH POST DILUTION UNIT MODELS PMD-3000 AND PAD-3000 ONLY MAINTENANCE RECOMMENDED SPARE PARTS/FACTORY ASSISTANCE TROUBLE SHOOTING DRAWINGS Parts Drawing Gatlin Mixer Parts Drawing Model PAD/PMD-60 and PAD/PMD-100 Parts Drawing Model PAD/PMD-200 Parts Drawing Model PAD/PMD-300... - Page 5 NEPTUNE CHEMICAL PUMP COMPANY LIMITED WARRANTY All Neptune Polymaster units are tested at the factory prior to shipment. Each part used in their construction has been carefully checked for workmanship. If the Polymaster is installed properly, Neptune Chemical Pump Company warrants to the purchaser of this product for a period of twelve months from the date of first use or eighteen months from shipment, whichever occurs first, this product shall be free of defects in material and/or workmanship, as follows: 1.
- Page 6 TYPICAL BACK PANEL Solution Outlet Complies With UL 778 ® CSA C22.2 No. 108 E112964 SEE INSTALLATION INSTRUCTIONS BEFORE CONNECTING TO THE SUPPLY. VOIR LA NOTICE D’INSTALLATION AVANT DE RACCORDER AU RÉSEAU. P/N 104604 WARNING! This equipment shall only be installed and operated .......
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Page 7: Installation
INSTALLATION 1. Unpack Polymaster from shipping container. Inspect system for any shipping damage and report it to the freight company and to Neptune immediately. Save the shipping container. Identify all the parts within the container. As a minimum, there should be a strainer for the water line, a strainer for the polymer line and a priming kit with a hand pump. -
Page 8: Caution
CAUTION In addition to this instruction, there is a project specific mechanical drawings, a project specific electrical drawing and a metering pump instruction manual specific for the pump furnished with this unit. Refer to the metering pump instruction manual for pump start-up information. Check nameplate for power requirements. -
Page 9: Theory Of Operation
THEORY OF OPERATION The Neptune Polymaster polymer dilution system has three basic subsystems which are the water and Polymer feed/metering subsystem, the Gatlin distribution head subsystem and the mixing/activation subsystem. WATER & POLYMER FEED/METERING SUBSYSTEM The dilution water is connected to the bulkhead and labeled “Water/Inlet” at the back of the unit. Dilution water flows through a strainer (to be located outside of the unit), a NEMA 4X solenoid valve, a flow metering valve, with visual flowmeter, and then into pressure switch assembly. - Page 10 FAULT LOCAL REMOTE SEE INSTALLATION INSTRUCTIONS BEFORE CONNECTING TO THE SUPPLY. VOIR LA NOTICE D’INSTALLATION AVANT DE RACCORDER AU RÉSEAU. P/N 104604 TYPICAL FRONT PANEL WITH ELECTRONIC PUMP FAULT LOCAL REMOTE TYPICAL FRONT PANEL WITH SPEED CONTROL FOR REMOTE PUMP MODELS POLY002...
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Page 11: Operating Instructions
OPERATING INSTRUCTIONS Please refer to system specific mechanical and electrical drawings and schematics for full information about the particular unit purchased for this site. CONTROL PANEL 1. The power switch supplies power to the entire system when turned to “LOCAL” red run light will be lighted. - Page 12 DILUTION WATER FLOW CONTROL 1. The flowmeter indicates the dilution water flow rate. The water flowing through the flowmeter does not contain any polymer. 2. The flowmeter control knob is used for adjusting the dilution water flow rate. POLYMER FLOW CONTROL 1.
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Page 13: Long Term Storage Instructions
LONG TERM STORAGE INSTRUCTIONS If the system will not be operating for an extended period of time, all the polymer should be purged from the system. Polymer that is left in the pump head for three or more days may start to harden. If the Polymaster is to be shut down for more than three (3) days, flush carefully per the following procedure. -
Page 14: Start Up
START-UP 1. Apply power to the unit by turning the switch at the top right of the unit to “LOCAL”. The red “ON” light should come on. Since water has not yet been turned on, expect the amber “FAULT” light to illuminate immediately. - Page 15 POLY003...
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Page 16: Calibration
CALIBRATION 1. Calibration of the polymer pump is recommended once the system is operational. Differences in the specific gravity and viscosity of polymers, as well as the specific piping arrangement used, require calibration of the pump to determine the precise polymer feed rate at a particular pump setting. A chart is developed to show the flow rates at various pump settings specific to the polymer and the installation site. -
Page 17: Calibration Graph
CALIBRATION GRAPH For your convenience, the vertical scales on this graph are labeled for English Units (gallons per hour) or Metric Units (milliliters per minute). You cannot use both on the same graph since the scales are not related. The left axis allows a finer plot on low volume pumps. The right axis allows plotting curves for higher flow rate pumps. -
Page 18: Post Dilution Unit Models Pmd-3000 And Pad-3000 Only
INSTRUCTIONS FOR OPERATION OF POST-DILUTION UNIT (Applies to 2 stage dilution furnished on models PAD/PMD-3000 and PAD/PMD-3000R only) The models PAD/PMD-3000 include two separate water flow indicators with separate water flow adjustment knobs. The primary dilution flow meter is located on the front face for the Polymaster. The second dilution or post dilution flow indicator is inside the unit with the rate setting valve at the top of the flow meter. - Page 19 POST DILUTION POST DILUTION FLOW METER STATIC MIXER POST DILUTION RATE SET VALVE POLY004...
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Page 20: Maintenance
MAINTENANCE 1. Inspect for polymer or water leaks in the system components. A. If joint leakage is observed, tighten carefully. Most joints are plastic (i.e. PVC, Delrin, acrylic) and over-tightening will lead to breakage. B. If component leakage is observed, replace the defective part. Contact Neptune for part replacement. 2. -
Page 21: Recommended Spare Parts/Factory Assistance
RECOMMENDED SPARE PARTS Polymaster unit 120 volt Kit No. 003896 Contains: (3) replacement fuses (3) spare indicating lamp bulbs (1) spare Gatlin mechanical seal (1) spare polymer injection valve Kit No. 003866 Contains: Polymaster unit 220 volt (3) replacement fuses (3) spare indicating lamp bulbs (1) spare Gatlin mechanical seal (1) spare polymer injection valve... -
Page 22: Troubleshooting
TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION Air leak in suction line. Pump running but not Tighten hosing and clamps. pumping chemical. Check o-ring in strainer cap to see if dislodged or cracked. Replace if cracked or missing. Empty polymer drum Check polymer supply. Clean suction line, check strainer Plugged suction line. - Page 24 POLY001...
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- Page 34 Polymaster MAINTENANCE LOG Polymaster Model______________________ Serial #_______________________________ Pump Model __________________________ Maximum Water Flow___________________ Pump Maximum Flow___________________ Maximum Water Pressure________________ Spare Parts Kit #__________________________ NEPTUNE CHEMICAL PUMP CO., INC. Tel.: 215-699-8700 • FAX: 215-699-0370 DATE SERVICED BY MAINTENANCE PERFORMED...
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