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Summary of Contents for Dover NEPTUNE PSG NEP-131906
- Page 1 INSTALLATION OPERATION & MAINTENANCE NEPTUNE Electronic Stroke Controller NEP-131906 NEP-ZL131906 06-2022_REV 1...
- Page 2 Manual Introduction The following instructions must be followed and integrated with your safety program when installing and using Neptune products ▪ Read and save all instructions prior to installing, operating and servicing this product ▪ If you don’t understand any of the instructions, contact Neptune for clarification ▪...
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Page 3: Table Of Contents
Section TABLE OF CONTENTS PAGE Introduction Product Specification Electrical Spec Mechanical Spec Performance Spec Warranty Information Part and Repair Instruction Warning & Safety Unboxing & Unit Overview Unboxing inspection Identification Label Tools & Equipment Required (General Guideline Only) Dimension & Components Inside the Unit Retrofitting Existing Neptune Diaphragm pump Retrofitting series 500 &... -
Page 4: Introduction
1. Introduction This manual has been produced to enable a competent user to install, operate, adjust and inspect the Neptune actuator. Only Neptune approved actuator replacement parts should be used. Under no circumstances should any modification or alteration be carried out on the actuator, as this could invalidate the conditions under which its certification was granted. -
Page 5: Product Specification
2. Product Specifications Electrical Line Voltage:120/240 VAC (tolerance ± 10%) Frequency: 60 Hz (tolerance ± 10%) Power: 2.37W (Stationary) / 44.5W (Moving Full Load) (Full Power Rating Table at the end of the manual) Command Signal Inputs: 4-20mADC Command Signal Adjustability Local/Remote Control - (Factory Setting –... -
Page 6: Performance Spec
Performance Linearity 1.0% Deadband 0.00% to 10.0% Adjustable Repeatability 0.5% Hysteresis 0.70% Resolution 0.2% Linear Features: Permanently Lubricated Absolute encoder LCD user Interface DC brushless electric motor Motor Controller with travel and thrust adjustment Manual Override Hazardous Area certification Explosion Proof... -
Page 7: Warranty Information
3. Warranty Information LIMITED WARRANTY All Neptune products are tested at the factory prior to shipment. Each part used in their construction has been carefully checked for workmanship. If the Electric Stroke Controller-Positioner is installed properly, Neptune Chemical Pump Co. 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:... -
Page 8: Part And Repair Instruction
4. Parts and repair instructions 1. Complete model number and serial number of both the Stroke Control AND pump must be provided to insure. prompt and accurate parts and repair service. 2. Address all inquiries and purchase orders for parts and factory repair to: Customer Service Department Neptune PSG California 22069 Van Buren Street... -
Page 9: Warning & Safety
5. Warning & Safety Please read thoroughly before installation, operation, or maintenance of any Neptune pump ▪ Correct installation, operation and servicing of Stroke Controller-Positioner, and associated pump, in Hazardous areas is entirely the responsibility of the user ▪ Protection provided by the equipment may be impaired if used in a manner not specified in this document ▪... -
Page 10: Unboxing & Unit Overview
6. Unboxing & Unit Overview Unboxing Inspection Receiving inspection: Carefully inspect for shipping damage. Damage to the shipping carton is usually a good indication that it has received rough handling. When unpacking a pump or chemical feed system, be certain that no parts are thrown away. -
Page 11: Dimension & Components
Knowing your controller Dimension & Components Handwheel Operation The handwheel is located on the top cover. Push and hold the handwheel down and rotate to extend/retract or rotate the actuator output drive. Verify direction of output shaft rotation for clockwise operation of the handwheel. -
Page 12: Inside The Unit
Inside the unit Main Printed Circuit Board (PCB) Layout LCD Display The main PCB has a LCD Display used to show STATUS and configuration information. On power up the default screen is the POSIT parameter. See Basic Menu structure for the rest of the parameters The actuator will indicate Local or Remote mode selected in top left-hand corner of the LCD. - Page 13 Setup Pushbuttons Four push button switches are located on the main PCB below its LCD Display and are used to view and change the actuator configuration parameters. The Switch Functions are as follows: ‘UP’ Used to navigate menus in view mode. Increase parameter values in Edit Mode. ‘DOWN’...
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Page 14: Retrofitting Existing Neptune Diaphragm Pump
7. Retrofitting Existing Neptune Diaphragm pump WARNING! Do not perform pump retrofit in a Hazardous Area or a damp / wet location. WARNING! Verify pump power is disconnected (de-energized) and Locked-Out. WARNING! Close isolation valves (shut off process fluid). Bleed Pressure. Drain all oil and process fluids. FACTORY RETROFIT: Existing manual Neptune diaphragm pumps can be upgraded with an Electric Stroke Control. - Page 15 7.1.8 Screw adapter P/N 002705 into the pump body and tighten securely against the seal plate. NOTE: A small hole is drilled in the side of the adapter. This hole must face down to allow any oil leakage to drain out of the adapter. Shims are provided to position the adapter. If, when the adapter is tightened the hole is not between 5 o'clock and 7 o'clock, unscrew the adapter and add shims between the adapter and the sealing plate to reposition the drip hole.
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Page 16: Retrofitting Series 600 Diaphragm Pumps
7.1.25 Start pumping by opening discharge valve. 7.1.26 Confirm back pressure duplicates normal operation. 7.1.27 Refer to Section 9 of this manual on Configuration, Calibration and Adjusting the unit 7.2 RETROFITTING SERIES 600 DIAPHRAGM PUMPS REQUIRED EQUIPMENT: ▪ Small Screwdriver ▪... -
Page 17: Retrofitting Series 6000 Diaphragm Pumps
7.2.13 Coat the tip of the control rod with STP, or heavy machine oil, to allow it to slip easily into the sealing plate O-ring. 7.2.14 Center the control rod in the sealing plate and, using hand pressure on the back of the control housing, push the control rod through the O-ring in the sealing plate. - Page 18 Number (P/N). Note: Control Rod Assemblies for Series 6000 pumps are not interchangeable. Correct control rod Assembly will be included with a Stroke Controller-Positioner purchased for retrofit. 7.3.2 Remove gear box drain plug I/N 67 from gear box I/N 1 and allow hydraulic oil to drain completely from the gear box.
- Page 19 7.3.17 Tighten the Mounting Nut securely against the pump body. 7.3.18 PREPARE PUMP: Fill the pump gear box with hydraulic oil per Pump IOM 7.3.19 Using the scale on the top of the stroke control unit and the Manual Adjustment Handwheel on the back of the Stroke Controller-Positioner, follow the pump Start-up Procedure, in the Pump Operating &...
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Page 20: Electrical Installation
8. Electrical Installation 8.1 Cable Entries The cable entries are tapped ¾” NPT. Remove any transit plugs. Make off cable entries appropriate to the cable type and size. Ensure that threaded adaptors, cable glands or conduit are tight and fully waterproof. Seal unused cable entries with steel or brass threaded plugs. - Page 21 Earth Ground Connections A lug is cast adjacent to the conduit entries for attachment of an external protective Earth (Ground) cable. An internal earth terminal is also provided. Consult local and certifying agency codes to determine which earth connectors is to be used. Removing Terminal Cover Using a 6 mm Allen key loosen the captive fixings securing the terminal compartment cover.
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Page 22: Wiring
8.3 Wiring Installation Wiring Route cabling through the most appropriate conduit entry making sure that cables will not foul on the cover assembly or internal components after refitting. Refer to the actuator wiring diagram for connection details. Wire type must meet local and certifying agency (FMC) requirements and have a minimum temperature rating of 88 °C. -
Page 23: Cpt Feedback
of the Low Voltage Directive, the maximum allowable voltage that can be applied to the relay terminals is 150 VAC. For DC however, the maximum voltage that can be applied is 30 VDC. Rated Current is 3 A 8.6 CPT Feedback The Loop-powered transmitter provides 4 to 20 mA signal that corresponds to position. -
Page 24: Set Up & Calibration
9. Set Up and Calibration 9.1 Basic Setup Basic setup is required once the actuator has been mounted on to the valve. Procedures include: Step 1 Select Local Operation Step 2 Set Output Torque/Thrust Step 3 Select Action at End of Travel (Limit or Force) Step 4 Set Close Limit of Travel Step 5 Set Open Limit of Travel Step 6 Calibrate Command Signal Zero Setpoint... - Page 25 9.2 Basic Menu Structure...
- Page 26 9.3 Basic Setup Flowchart Default Setting recommended unless customer specified Default Setting recommended unless customer specified Default Setting recommended unless customer specified Default Setting recommended unless customer specified...
- Page 27 9.4 Select Local Operation Screen shows the actuator set to Remote operation mode with alarms active. The actuator must be set to Local operation mode before the travel limits can be set. Using the 4 push button switches mounted below the LCD. PRESS ‘DOWN’...
- Page 28 9.5 Set Output Torque/Thrust Before operating the actuator electrically, it may be necessary to reduce the output torque or thrust of the actuator to prevent valve becoming jammed at the end of travel during setup. Note that the default value (100%) thrust is sufficient to be used in Neptune application.
- Page 29 9.6 Select Action at End of Travel The actuator can be configured to stop on position limit at the end of travel where valves do not require torque or thrust to be applied to the valve seat. To provide tight shut off at end of travel the actuator can be configured to apply its configured torque or thrust to the valve seat in either direction.
- Page 30 9.7 Set Closed Limit of Travel (0% Flow / 4mA Position) To set the Closed limit of travel for the actuator press the DOWN button until CL LIM is displayed. Press ENTER to put the actuator in to EDIT Mode. This will allow parameter changes to be made.
- Page 31 9.9 Calibrate Command Signal Zero Setpoint After the open/close limit is set the 4 to 20 mA signal is automatically calibrated to those positions. The 4 mA input command will send you to CLOSED LIMIT, the 20 mA and will send you to OPEN LIMIT. 9.9.1 Basic Setup The controller enables the actuator to automatically position a valve or actuated device in proportion to an analogue mA current.
- Page 32 9.10 Set Command Signal Invert Note that the default value is ready to operate in Neptune application. No change is needed. Move on to Step 9.11 if necessary Press the DOWN arrow until the CMD IV menu is displayed. Press ENTER until ‘EDIT’ is displayed. Screen shows Command Signal Invert set to OFF.
- Page 33 9.12 Set Deadband Note that the default value is ready to operate in Neptune application. No change is needed. Press the DOWN arrow until the DBAND menu is displayed. Press ENTER until ‘EDIT’ is displayed. Screen shows the Deadband set to 0.1%. Deadband is adjustable between 0 to 10% of the Analogue signal.
- Page 34 9.13 Completing Basic Setup (cont'd) Ensure that the spigot face is clean and greased with the o-ring seal fitted and in good condition. Note: Carefully align the cover assembly and handwheel shaft. Ensure that all wiring is fitted correctly and will not foul the top cover assembly once fitted.
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Page 35: Appendix
10. Appendix Flame Path chart In accordance with clause 5.1 of CAN/CSA C22.2 No. 60079-1 (2016), the critical dimensions of the flamepath are: Flamepath Maximum Gap (mm) Minimum Length (mm) Lid/Base 0.15 12.8 Base/screw shaft 0.145 13.5 Base/feedback shaft bush -0.02 13.7 Feedback shaft/lid...
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