INSTALLATION, OPERATION AND MAINTENANCE MANUAL Polymaster ™ Liquid Polymer Blend & Feed System NEPTUNE MEMBER OF A COMPANY 204, Dekalb Pike, Lansdale, PA 19446 TM P U MP S O L U T I O N S G R O U P A DOVER COMPANY Tel.
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. Bleed pressure before servicing.
WARNING Please read thoroughly before installation, operation or maintenance of any Polymaster Machine EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture, malfunction and result in serious injury. • This equipment is for professional use only. • 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.
Polymaster ™ TABLE OF CONTENTS PAGE NO.
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.
TYPICAL BACK PANEL Solution Outlet Polymer Inlet Water Inlet WARNING! Warranty void if "Y"strainer not installed on inlet line WARNING! Warranty void if "Y"strainer not installed on inlet line 1
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. Record model number and serial number in spaces provided in front cover of this manual for future reference.
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. Be certain power supply matches these requirements. Electrical requirements available are: 115Y-1 phase-50/60 Hz or 220Y- 1 phase.-50/60 Hz depending on how the unit was ordered.
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. 1. WATER & POLYMER FEED/METERING SUBSYSTEM The dilution water is connected to the bulkhead and labeled “water/inlet” at the back of the unit.
FAULT ON OFF LOCAL REMOTE Polymaster CHEMICAL PUMP CO., INC. TYPICAL FRONT PANEL WITH ELECTRONIC PUMP FAULT ON OFF LOCAL REMOTE CHEMICAL PUMP CO., INC.
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. When the power switch is in the “REMOTE” position, the unit is unable to run if a remote switch permits operation.
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. The feed pump controls the amount of polymer being metered into the system. Depending upon the type of feed pump, there may be pump speed and/or stroke length control. These adjustments are both on the pump for the electronic solenoid pumps.
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 set up. If the Polymaster is to be shut down for more than three (3) days, flush carefully per the following procedure. 1. .Begin water flush as described in step 5 under maintenance on page 15. 2.
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. This is normal when there is no water flow. The system requires a minimum of 25 psi applied back pressure to sustain the Run mode otherwise the amber “FAULT” light will come on. 2. Allow water to flow into the system. Turn the water flow to maximum.
10
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. The dilution water flowmeter requires no calibration. 2.
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.
INSTRUCTIONS FOR OPERATION OF POST-DILUTION UNIT (Applies to 2 stage dilution furnished on models PA/PM-3000 and PA/PM-3000R only) The models PA/PM-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.
14
MAINTENANCE 1. Inspect for polymer or water leakage at the 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. Inspect light and switches for proper operation. A. If a light or switch is inoperative, replace the defective part. 3. Re-calibrate the pump. A.
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 Polymaster unit 220 volt Kit No.
TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION Pump running but not pumping chemical. Air leak in suction line. Tighten hosing and clamps. Empty polymer drum Check a-ring in strainer cap to see if dislodged or cracked. Replace if cracked or missing. Check polymer supply. Pump loses prime after operation. Plugged suction line. Clean suction line, check strainer basket. Pump check valves dirty. Inspect or clean pump valves. Clogged or missing foot valve.
18
19 WARNING! Warranty void if "Y"strainer not installed on inlet line "ATTENTION! FAULT P/N 104600 Cet équipement doit être installé et exploité seulement ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, OFF REMOTE CHEMICAL PUMP CO., INC.
20 WARNING! Warranty void if "Y"strainer not installed on inlet line FAULT P/N 104600 Cet équipement doit être installé et exploité seulement ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, "ATTENTION! OFF REMOTE CHEMICAL PUMP CO., INC.
21 WARNING! Warranty void if "Y"strainer not installed on inlet line FAULT P/N 104600 Cet équipement doit être installé et exploité seulement ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, "ATTENTION! OFF REMOTE CHEMICAL PUMP CO., INC.
22 WARNING! Warranty void if "Y"strainer not installed on inlet line FAULT P/N 104600 Cet équipement doit être installé et exploité seulement ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, "ATTENTION! OFF REMOTE CHEMICAL PUMP CO., INC.
23
24
25 WARNING! Warranty void if "Y"strainer not installed on inlet line "ATTENTION! FAULT P/N 104600 Cet équipement doit être installé et exploité seulement ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, OFF REMOTE CHEMICAL PUMP CO., INC.
26 CHEMICAL PUMP CO., INC.
27 32/@0$ 67(5 L 1L
28 32/@0$ 67(5 L 1L
Polymaster MAINTENANCE LOG Polymaster Model______________________ Serial #_______________________________ Pump Model __________________________ Maximum Water Flow___________________ PumpParts Maximum Flow___________________ Spare Kit #__________________________ Maximum Water Pressure________________ NEPTUNE CHEMICAL PUMP CO., INC. Tel.