Dover PSG Neptune, Installation Operation & Maintenance

Page 1: ...INSTALLATION OPERATION MAINTENANCE POLYMASTER LIQUID POLYMER BLEND FEED SYSTEM 05 2018 NEP ZL104791 ...

Page 2: ...p 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 Bleed pressure before servicing ...

Page 3: ... or deflect fluid leaks with your hand body glove or rag Check all fluid connections before operating the equipment Replace worn damaged or loose parts immediately Before performing any maintenance be sure to relieve pressure from the piping system and the equipment Wear protective clothing and use proper tools as appropriate to avoid any injury FIRE AND EXPLOSION HAZARD Improper grounding poor ai...

Page 4: ...DED SPARE PARTS FACTORY ASSISTANCE 16 TROUBLE SHOOTING 17 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 Parts Drawing Model PAD PMD 600 Parts Drawing Model PAD PMD 1200 Parts Drawing Model PAD PMD 1200R Parts Drawing Model PAD PMD 3000 Parts Drawing Model PAD PMD 3000R Standard Polymaster electrica...

Page 5: ...o 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 d...

Page 6: ...Cet équipement doit être installé et exploité seulement P N 104600 SEE INSTALLATION INSTRUCTIONS BEFORE CONNECTING TO THE SUPPLY VOIR LA NOTICE D INSTALLATION AVANT DE RACCORDER AU RÉSEAU P N 104604 MAX VOLTAGE 120 VAC 60 Hz 1 PHASE TOTAL FLA 5 AMP Polymaster www neptune1 com FUSE TAG FUSE TYPE F1 GDB 5A SIZE AMPS WORKING VOLTAGE 5 120 VAC P N 104603 120 VOLTS MET C US CSA C22 2 No 108 Complies Wi...

Page 7: ...the point of application 5 Install strainer shipped loose in the polymer line Connect the polymer feed first through the line strainer then to the connection marked Polymer In For remote pump models PAD 1200R and PAD 3000R the polymer feed line should be fed through the line strainer then connected directly to the suction of the remote feed pump Polymer suction line should be kept as short as poss...

Page 8: ...sed The cord may be removed and the unit hardwired to the power supply as long as a disconnect with lockout is provided For the proper handling of liquid polymers or other chemicals contact the chemical supplier IMPORTANT NOTE The pump stroke length should only be adjusted while it is operating Damage to the pump can occur if adjustments are attempted when pump is not cycling IMPORTANT NOTES All P...

Page 9: ...to the motor driven GATLIN distribution head where it is introduced to the dilution water 2 GATLIN DISTRIBUTION HEAD The mechanical distribution head is a patented design which is designed to hydraulically and mechanically spread the incoming polymer into extremely thin sheets thus maximizing polymer surface area exposed to water By creating thin sheets the water contacts a larger surface area of ...

Page 10: ...STRUCTIONS BEFORE CONNECTING TO THE SUPPLY VOIR LA NOTICE D INSTALLATION AVANT DE RACCORDER AURÉSEAU P N 104604 REMOTE LOCAL OFF FAULT ON TYPICAL FRONT PANEL WITH ELECTRONIC PUMP TYPICAL FRONT PANEL WITH SPEED CONTROL FOR REMOTE PUMP MODELS POLY002 ...

Page 11: ...sure is 100 psi 5 The solenoid valve will open when the system power is ON The polymer pump will also be energized but individual speed or stroke control settings may cause it to operate anywhere from 0 100 of capacity i e the pump can be turned OFF by its own control knobs even when the systems power is ON FLUSH WATER 1 Normally the Polymaster is flushed before shutdown To flush turnoff the polym...

Page 12: ...oth For motor driven diaphragm metering pumps this will be by manual stroke length adjustment only All other motor driven pumps including progressive cavity or rotary gear pumps are provided with a variable drive for speed adjustment Model numbers beginning with PAD are AUTOMATIC UNITS control the polymer flow rate automatically in response to a 4 20 mA signal Electronic metering pumps use the 4 2...

Page 13: ... and discharge lines by filling with mineral oil Simply connect the suction line into a source of mineral oil or fill the calibration column with mineral oil and allow the unit to run until mineral oil has been drawn completely through the suction line pump head discharge line and polymer injection valve at the Gatlin Turn off the chemical feed pump as soon as these lines are filled with mineral o...

Page 14: ...ss may vary slightly see pump manufacturer s recommended procedure For installations that are especially difficult to prime a hand operated vacuum pump has been included to assist the polymer feed pump in initially pulling in the polymer 5 Turn the polymer pump to the desired setting ADJUST PUMP ONLY WHEN THE PUMP IS RUNNING RECOMMENDED OPERATION IS TO SELECT THE CONVENIENT STROKE LENGTH SETTING A...

Page 15: ...10 POLY003 ...

Page 16: ... ensures the proper polymer percentage make down Set the pump stoke length to 100 and the stroke speed to 25 Open the polymer cylinder time the flow being pumped for 1 or more minutes close the valve and record the volume Never run the polymer metering pump without a supply of chemical Do not starve the pump When switching from the normal suction line to the calibration cylinder open the cylinder ...

Page 17: ...s allows a finer plot on low volume pumps The right axis allows plotting curves for higher flow rate pumps Low Flow High Flow 0 10 GPH 0 60 MLM 10 20 GPH 60 120 MLM 20 30 GPH 120 180 MLM 30 40 GPH 180 240 MLM 40 50 GPH 240 300 MLM 50 60 GPH 300 360 MLM 60 70 GPH 360 420 MLM 70 80 GPH 420 480 MLM 80 90 GPH 480 540 MLM 90 100 GPH 540 600 MLM 100 GPH 600 MLM 0 10 20 30 40 50 60 70 80 90 100 Stroke fr...

Page 18: ...ndicator to provide the balance of dilution water required It is recommended that both primary and post dilution flow indicators be set to approximately the same flow rate unless the total water exceeds 2400gph in which case the maximum of 1200gph of water is added by the primary dilution flow meter and the balance is added by the post dilution flow meter The post dilution flow control valve is po...

Page 19: ...14 POST DILUTION STATIC MIXER POST DILUTION RATE SET VALVE POST DILUTION FLOW METER POLY004 ...

Page 20: ...ieved 4 Lubrication No lubrication required other than may be called for in the pump instruction manual 5 Flush After Each Use A The Polymaster should be flushed before shutdown To flush turn off the polymer feed pump or set the stroke speed to 0 using the controls on the face of the pump Now only dilution water is flowing through the system Allow the water to run for 10 minutes while the Gatlin i...

Page 21: ...mplete model number and serial number of the Polymaster must be furnished to insure prompt and accurate parts service These numbers are found on the name plate sample below located on the front panel 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 Email www pu...

Page 22: ...tion line or missing defective foot valve Tighten solution clamps using teflon tape Install foot valve on end of suction hose Use drum suction wand with foot valve Refer to all remedies under pump won t prime section of pump instruction manual Pump starts then stops Insufficient differential water pressure turning off pump power Check available water pressure flow rate and back pressure at outlet ...

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Page 24: ... 22 3 8 24 HEX NUT SELF LOCKING 2 100556 50 107461 54 1 POLYMASTER NAMEPLATE 1 108071 1 ROUND CAPS 4 107434 3 8 FLAT WASHER 2 106439 51 53 52 10 32 KEP NUT WA170873 10 32 X 7 8 LG PAN HD SCREW 107701 Y STRAINER WARNING LABEL 107836 2 4 4 45 46 49 48 5 8 ID X 12 LG HOSE 1 105529 101955 102152 1 1 43 42 44 1 2 MNPT X 5 8 HOSE BARB 16 15 107314 107796 10 X 1 2 LG SELF TAPPING SCREW FENDER WASHER 1 1 ...

Page 25: ...not installed on inlet line WARNING This equipment shall only be installed and operated ATTENTION Cet équipement doit être installé et expl oité seulement P N 1 046 00 SEE INSTALLATION INSTRUCTIONS BEFORE CONNECTING TO THE SUPPLY VOIR LA NOTICE D INSTALLATION AVANT DE RACCORDER AU RÉSEAU P N 104604 POLY007 ...

Page 26: ...not installed on inlet line WARNING This equi pment shall only be installed and operated ATTENTION Cet équipement doit être installé et expl oité seulement P N 104 600 SEE INSTALLATION INSTRUCTIONS BEFORE CONNECTING TO THE SUPPLY V OIR LA NOTICE D INSTALLATION AVANT DE RACCORDER AU RÉSEAU P N 104604 POLY008 ...

Page 27: ...strainer not installed on inlet line WARNING This equipmen t shall only be installed and operated ATTENTION Cet équipement doit être installé et exploité seulement P N 104 600 SEE INSTALLATION INSTRUCTIONS BEFORE CONNECTING TO THE SUPPLY VOIR LA NOTICE D INSTALLATION AVANT DE RACCORDER AU RÉSEAU P N 104604 ...

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Page 30: ...not i nstalled on inlet line WARNING Warranty void if Y strainer not installed on inlet line ON WARNING This equipment shall only be installed and operated ATTENTION Cet équipement doit être inst allé et exploité seulement P N 104600 POLY012 ...

Page 31: ...NG Warranty void if Y strainer not installed on inlet line ON WARNING This equipment shall only be installed and operated ATTENTION Cet équipement doit êt re ins tallé et ex ploité seulement P N 104600 POLY013 ...

Page 32: ...27 p Ne u t ne POLYMASTER ...

Page 33: ...28 p Ne u t ne POLYMASTER ...

Page 34: ... Tel 215 699 8700 FAX 215 699 0370 DATE SERVICED BY MAINTENANCE PERFORMED Polymaster Model______________________ Pump Model __________________________ Pump Maximum Flow___________________ Serial _______________________________ Maximum Water Flow___________________ Maximum Water Pressure________________ ...