Dover NEPTUNE PSG NEP-131906 Owner's manual

INSTALLATION
OPERATION &
MAINTENANCE
NEPTUNE
Electronic Stroke
Controller
NEP-131906
NEP-ZL131906
06-2022_REV 1

1
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
▪Follow all warnings, cautions and instructions marked on, and supplied with, the product
▪Inform and educate personnel in the proper installation, operation and maintenance of the
product
▪Install equipment as specified in Neptune installation instructions and per applicable local and
national codes. Connect all products to the proper electrical sources
▪To ensure proper performance, use qualified personnel to install, operate, update and maintain
the unit
▪When replacement parts are required, ensure that the qualified service technician uses
replacement parts specified by Neptune. Substitutions may result in fire, electrical shock, other
hazards, or improper equipment operation
▪Keep all product protective covers in place (except when installing, or when maintenance is
being performed by qualified personnel), to prevent electrical shock, personal injury or actuator
damage
▪Operation of actuator in an inappropriate fashion may cause harm or damage to unit or other
equipment surroundings

2
Section
TABLE OF CONTENTS
PAGE
1
Introduction
3
2
Product Specification
4
Electrical Spec
4
Mechanical Spec
4
Performance Spec
5
3
Warranty Information
6
4
Part and Repair Instruction
7
5
Warning & Safety
8
6
Unboxing & Unit Overview
9
Unboxing inspection
9
Identification Label
9
Tools & Equipment Required (General Guideline Only)
9
Dimension & Components
10
Inside the Unit
11
7
Retrofitting Existing Neptune Diaphragm pump
13
Retrofitting series 500 & 560 diaphragm pumps
13
Retrofitting series 600 diaphragm pumps
15
Retrofitting series 6000 diaphragm pumps
16
8
Electrical Installation
19
Cable Entry
19
Connecting to Terminal
19
Wiring
21
Overcurrent Protection Fuses
21
Relays
21
CPT Feedback
22
Demand
22
9
Set Up & Calibration
23
10
Appendix
34
Flame Path Chart
34
Power Rating Table
34

3
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.
The electrical installation, maintenance and use of these actuators should be carried out in accordance with the
National Legislation and Statutory Provisions relating to the safe use of this equipment applicable to the site of
installation.
Access to live electrical conductors is forbidden in a Hazardous Area unless it is done under a special permit to
work, otherwise all power should be isolated, and the actuator moved to a non-hazardous area for repair or
attention
For the USA: NFPA70, National Electrical Code® is applicable. Only persons competent by virtue of their
training or experience should be allowed to install, maintain and repair Neptune actuators. Work undertaken
must be carried out in accordance with instructions in the manual. The user and those persons working on this
equipment should be familiar with their responsibilities under any statutory provisions relating to the Health and
Safety of their workplace.
The mechanical installation should be carried out as outlined in this manual and also in accordance with any
relevant national standard codes of practice. If the actuator nameplate indicates that it is suitable for use in a
Potentially Explosive Atmospheres (Hazardous Areas) then the actuator is suitable for use in Zone 1 and Zone 2
(or Div 1 and Div 2) hazardous area classifications, as defined by the actuator’s nameplate marking.
The enclosures on the Neptune actuator is manufactured from aluminum alloy with stainless steel fasteners.
The user must ensure that the operating environment and any materials surrounding the actuator cannot lead to a
reduction in the safe use of, or the protection afforded by, the actuator. Where appropriate the user must ensure
the actuator is suitably protected against its operating environment
Any equipment connected to the actuator should be of an equivalent (or better) hazardous area certification. The
installation, maintenance and use of the actuator installed in a hazardous area must be carried out by a
competent person and in accordance with all relevant codes of practice for the particular Hazardous Area
certification.
Should further information and guidance relating to the safe use of the Neptune actuator be required, it will be
provided on request.
Any inspection or repair of Hazardous Area approved actuators should not be undertaken unless it conforms to
National Legislation and Statutory Provisions relating to the specific Hazardous Area.

4
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 –Local)
Zero and Span Position - (Factory Setting –0% & 100%)
Limit, Lower and Upper - (Factory Setting –0% & l00%)
Terminals: 18 AWG wire recommended
Conduit Entry: 4 Places, ¾”-14NPT
Mechanical
Stroke: (Output Shaft Linear Travel)
500 Series Pump: 0.714”(18.14mm)
600 Series Pump: 1.428”(36.27mm)
Shaft Motion: Extend or retract on command Signal (adjustable)
Speed: 0.125 to 0.25 in/sec (6.35 mm/sec)
Thrust: 100 lbf
Temperature Limit: -4°F to 150°F (-20°C to 65°C)
Altitude: Up to 5000m
Housing: Casted aluminum alloy with gasketed window for stroke Position Indicator
Local Control: Handwheel, Manual Operation: Push to engage, Spring Return on Release
Environmental Rating:
Canadian Hazardous Area –Factory Mutual Canada (FMC) Certified Explosionproof to Canadian electrical Code (CEC)
Enclosure types 4, IP67
Note: Reliability in respect to fatigue or long-term operation against CSA C22.2 No. 139 standard is not included in the Approval

5
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

6
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:
1. Neptune Chemical Pump Co. 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, Grand Terrace, CA. 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 Co. 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.
IMPORTANT NOTICE- RETURN GOODS AUTHORIZATION
1. All equipment returned to - Neptune Chemical Pump Company requires proper Returned Goods
Authorization Number (RGA) and tags.
2. If returned goods is a pump, or is to be shipped attached to a pump, drain all oil and chemicals. All chemical
contact areas must be thoroughly flushed and 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 (MSDS).
4. Failure to comply with the above instructions; will result in equipment being returned to sender, freight
collect, without service.

7
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
Grand Terrace, CA 92313
USA
Tel: [phone]
Email: [email protected]
3. Mechanical Stroke Control repairs may be made by purchaser. Refer to Figure 1 for parts identification.
Order from Neptune Customer Service by description.
4. Existing Neptune 500 & 600 & 6000 series manual diaphragm pumps can be upgraded by adding Stroke
Control. See Section 7 for self-retrofitting instruction. It is suggested to bring the unit to our local representative
or distributor for the service. Find your local distributor at:
https://www.psgdover.com/neptune/contact-us/representative-locator
5. If purchaser desires to perform a field pump upgrade by adding Stroke Control, a kit consisting of a Stroke
Controller-Positioner and an appropriate pump Connector Rod Assembly will be prepared. See retrofitting
instruction at later section in this document. Prior to ordering, consult with Customer Service Department to
review required tools and consumables.
6. Electrical repairs are limited to replacing the stepper motor, and factory repairing or replacing the two printed
circuit boards. The upper and lower printed circuit boards are interconnected and are replaced as a single
assembly. The Purchaser may send the faulty Printed Circuit Board Assembly to Neptune for evaluation and
repair or replace it with a new assembly. Replacement PC Board Assemblies are shipped with “Factory
Settings” (configuration, calibration, and adjustments) to match the pump the Stroke Control is mounted on.
Stepper motors are not repairable.
IMPORTANT NOTICE - RETURN GOODS AUTHORIZATION
1. All equipment shipped to Neptune Chemical Pump Company for repair, evaluation or upgrade requires
proper Returned Goods Authorization Number (RGA) and tags.
2. If shipped goods are a pump, or is to be shipped attached to a pump, drain all oil and chemicals. All chemical
contact areas must be thoroughly flushed and 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 (MSDS).
4. Failure to comply with the above instructions, will result in equipment being returned to sender, freight
collect, without service ...

8
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
▪Electric Shock Hazard: Installation and Servicing must be performed only by qualified personnel
▪Electrostatic Discharge: This equipment houses static sensitive devices. To protect the internal
components never touch the printed circuit boards without using electrostatic (ESD) control procedure
▪Actuator castings are manufactured from aluminum alloy with stainless steel fasteners. The user must
ensure that the operating environment and any materials surrounding the actuator cannot lead to a
reduction in the safe use of, or the protection afforded by the actuator
▪Note that under no circumstances should any additional lever device such as a wheel key or wrench be
applied to the hand-wheel in order to develop more force when closing or opening the valve. This may
cause damage to the valve and/or actuator and it may also cause the valve to become stuck in the seated
or back seated position.
▪The screws securing the outer window frame maintain the integrity of the flame proof enclosure and
must NOT be removed
▪Do not remove the top cover assembly or conduit entry blanking plugs when an explosive environment
is present.
▪The equipment utilizes a non-metallic outer coating and has a potential static hazard. Clean only with a
damp cloth.

9
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. Examine the equipment for possible damage. If damage has occurred, file a claim
with the common carrier within 24 hours. Neptune will assist in estimating the repair costs.
Stroke Controller-Positioners are normally shipped mounted on, and configured for, the pump with which it will
be used. Unless the customer order specifically instructs otherwise, the stroke controller will be shipped with
standard "Factory Settings". See Calibration and Adjustments in next section.
Identification Label
An identification tag is attached to each actuator. When ordering parts, requestion information or service
assistance, please provide all of the tag information.
Tools & Equipment Required (General Guideline Only)
Top Cover Fixings - 6 mm Allen Wrench
Electrical Connections - Terminal Screwdriver
Command & Feedback - 4 to 20 mA Command source/meter
Actuator to Valve fixings - As required

10
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. Stroke position can be found at the local display window

11
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.

12
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’
Used to navigate menus in view mode. Decrease parameter values in Edit Mode.
‘MODE/CANCEL’
Used to exit and go to previous Menu.
ENTER
Used to enter and save changes to configuration parameters.
FAULT
NON-CRITICAL FAULT
An alarm condition exists which does not prohibit actuator movement.
Non-critical faults are:
STALL
Torque / Thrust Overload
Loss of Communications
Loss of Demand Signal
Over Temperature
Power Loss
CRITICAL FAULT
An alarm exists which prohibits actuator movement.
Critical faults are:
Loss of Feedback
EEPROM Fault

13
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. It is suggested to bring the unit to our local representative or distributor for the service. Find your local
distributor at: https://www.psgdover.com/neptune/contact-us/representative-locator
FIELD RETROFIT: If a field retrofit is planned, the appropriate instructions should be reviewed for required
manuals, tools, connector rod assembly, replacement gaskets and consumables (e.g. hydraulic oil, Loctite). The
process should be analyzed to see if a precise determination of the pump ZERO setting is required.
CLEARANCE: Examine pump location for clearances to install Stroke Controller-Positioner. If Stroke
Positioner is to be installed with pump remaining in pipeline, verify clearances required for draining oil and
process fluids.
7.1 RETROFITTING SERIES5000, 500 & 560 DIAPHRAGM P U M P S
REQUIRED EQUIPMENT:
▪Small Screwdriver
▪11/16" 6-point socket wrench
▪Analog Signal Generator
▪Valve (on pump discharge )
▪Calibrated Measuring Cylinder (on pump suction) Pipe Stand with Drain
7.1.1 PUMP MODIFICATION: Refer to illustrations in the Series 5000, 500 or 560 Pump Operating &
Instruction Manual for parts identification and other information referenced in the instructions. Individual parts
are identified by "Figure Numbers" (F/N). Manual includes tables that cross reference Figure Numbers to part
descriptions and Neptune Part Numbers (P/N). Replacement parts are ordered by their Part Number (P/N).
Note: Control Rod Assemblies for Series 5000/500 & 560 pumps are not interchangeable. Correct control rod
Assembly will be included with a Stroke Controller-Positioner purchased for retrofit.
7.1.2 Remove gear box drain plug F/N 510 from gear box F/N 500 and allow hydraulic oil to drain completely
from the gear box. Replace the drain plug.
7.1.3 Remove two slotted head screws F/N 521 from pump body F/N 513 allowing the indicator plate F/N 520
to hang loosely.
7.1.4 Turn control knob F/N 524 counterclockwise until the threads disengage from the sealing nut F/N 526.
Pull the control knob and attached metering rod from the pump body .
7.1.5 With an 11/16" 6-point socket wrench, remove the sealing nut .
7.1.6 Parts 520, 521, 524, and 526 are no longer needed.
7.1.7 The sealing plate F/N 518 remains in position Within the pump body.

14
7.1.8 Screw adapter P/N 002705 into the pump body and tighten securely against the seal p l a t e .
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.
7.1.9 The control rod is supplied attached to the connector, P/N 002707. Apply 1 drop of low strength ( b l u e )
Loctite to the threads on the connector P/N 002707. Screw the connector completely into the threaded rod
projecting from the nose of the Electric Stroke Control. Allow the Loctite to set.
7.1.10 MOUNT ELECTRIC STROKE CONTROL: The Stroke Controller-Positioner is installed as a unit.
Do not disassemble or remove the cover from the unit.
7.1.11 If the output shaft of Stroke Controller-Positioner is not in the ZERO position (output shaft fully
retracted) turn the Manual Adjustment Handwheel clockwise until the shaft is fully retracted (see Section 6,
Handwheel Operation).
7.1.12 Turn the large Mounting Nut on the nose of the Stroke Controller-Positioner so that there is
1/4"between the face of the nut and the face of the stroke control unit (see Section 6, Handwheel Operation).
7.1.13 Coat the tip of the control rod F/N 515 with STP, or heavy machine oil, to allow it to slip easily into the
sealing plate O-ring.
7.1.14 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. This operation is best undertaken with two people,
one to position the Stroke Controller-Positioner and the other to apply the pressure.
7.1.15 Engage the threads on the Stroke Controller-Positioner with the threads in the adapter. Screw the
Stroke Controller-Positioner into the adapter until the jam nut contacts the pump body .
7.1.16 Orient the Stroke Controller-Positioner with the nameplate and viewing window up and parallel to the
pump mounting surface.
7.1.17 Tighten the Mounting Nut securely against the pump body.
7.1.18 PREPARE PUMP: Fill the pump gear box with hydraulic oil per Pump IOM
7.1.19 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 & Instruction
Manual.
7.1.20 The pump is now ready to be returned to service. Follow start-up procedure as if starting a new pump..
7.1.21 Review Warnings at the beginning of Operating Manual and at the beginning of this section.
7.1.22 Remove cover from Stroke Controller-Positioner.
7.1.23 Connect Analog Signal Generator to the appropriate Command Input terminals
7.1.24 Energize Stroke Controller-Positioner. Start pump motor. Increase simulated Command Input Signal

15
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
▪Analog Signal G e n e r a t o r
▪Valve ( on p u mp d i s c h a r g e )
▪Calibrated Measuring Cylinder ( o n pump s u c t i o n ) Pipe Stand with D r a i n
7.2.1 PUMP MODIFICATION: Refer to illustrations in the Series 600 Pump Operating & Instruction
Manual for parts identification and other information referenced in the instructions. Individual parts are
identified by "Figure Numbers" (F/N). Manual includes tables that cross reference Figure Numbers to part
descriptions and Neptune Part Numbers (P/N). Replacement parts are ordered by their Part Number (P/N).
Note: Control Rod Assemblies differ for the various Series 600 models. Correct control rod Assembly will be
included with a Stroke Controller-Positioner purchased for retrofit.
7.2.2 Remove gear box drain plug F/N 0130 from gear box F/N 0101 and allow hydraulic oil to drain
completely from the gear box. Replace the drain plug.
7.2.3 Remove two slotted head screws F/N 0142 from pump body F/N 1401 allowing the indicator plate F/N
0118 to hang loosely.
7.2.4 Turn control knob F/N 0117 counterclockwise until the threads disengage from the sealing plate retainer
F/N 0116. Pull the control knob and attached control rod from the pump body .
7.2.5 Remove the sealing plate retainer by removing the four (4) socket head cap screws F/N 0144. Pull the
sealing nut retainer out of the pump body.
7.2.6 Parts 0116, 0117, 0118, and 0143 are no longer needed.
7.2.7 The sealing plate F/N 1407 remains in position within the pump body.
7.2.8 Slide adapter F/N 002706 into pump body and secure with the 4 socket head cap screws F/N 0144.
7.2.9 The control rod is supplied as an assembly attached to the connector, P/N 002708. Apply 1 drop of low
strength (blue) Loctite the threads on the connector PIN 002708. Screw the connector completely into the
threaded rod projecting from the nose of the Electric Stroke Control. Allow the Loctite to set.
7.2.10 MOUNT ELECTRIC STROKE CONTROL: The Stroke Controller-Positioner is installed as a unit.
Do not disassemble or remove the cover from the unit.
7.2.11 If the output shaft of the Controller-Positioner is not in the ZERO position {output shaft fully retracted)
tu r n the Manual A d j u s t m e n t Handwheel clockwise until the shaft i s fully retracted.
7.2.12 Turn the large Mounting Nut on the nose of the Stroke Controller-Positioner so that there is 1/4"
between the face of the nut and the face of the stroke control unit (see Section 6, Handwheel Operation).

16
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. This operation is best undertaken with two people,
one to position the Stroke Controller-Positioner and the other to apply pressure.
7.2.15 Engage the threads on the Stroke Controller-Positioner with the threads in the adapter. Screw the Stroke
Controller-Positioner into the adapter until the jam nut contacts the pump body.
7.2.16 Orient the Stroke Controller-Positioner with the nameplate and viewing window up and parallel to the
pump mounting service. ·
7.2.17 Tighten the Mounting Nut securely against the pump body.
7.2.18 PREPARE PUMP: Fill the pump gear box with 4 quarts of hydraulic oil, (two P/N 002372)
containers. Refer to Series 600 Pump Instruction Manual.
7.2.19 Using the scale on the top of the stroke control unit and the manual control knob on the back of the unit,
follow the pump Start-up-Procedure, in the Pump Manual.
7.2.20 The pump is now ready to be returned to service. Follow start-up procedure as if starting a new pump..
7.2.21 Review Warnings at the beginning of Operating Manual and at the beginning of this section
7.2.22 Remove cover from Stroke Controller-Positioner
7.2.23 Connect Analog Signal Generator to the appropriate Command Input terminals
7.2.24 Energize Stroke Controller-Positioner. Start pump motor. Increase simulated Command Input Signal
7.2.25 Start pumping by opening discharge valve .
7.2.26 Confirm back pressure duplicates normal operation.
7.2.27 Refer to Section 9 of this manual on Configuration, Calibration and Adjusting the unit
7.3 RETROFITTING SERIES6000 DIAPHRAGM P U M P S
REQUIRED EQUIPMENT:
▪Small Screwdriver
▪15/16" 6-point socket wrench
▪Analog Signal Generator
▪Valve (on pump discharge )
▪Calibrated Measuring Cylinder (on pump suction) Pipe Stand with Drain
7.3.1 PUMP MODIFICATION: Refer to illustrations in the Series 6000 Pump Operating & Instruction
Manual for parts identification and other information referenced in the instructions. Individual parts are
identified by "Item Numbers" (I/N) on BOM page 20 & 22. Manual includes tables that cross reference Figure
Numbers to part descriptions and Neptune Part Numbers (P/N). Replacement parts are ordered by their Part

17
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. Replace the drain plug.
7.3.3 Remove two slotted head screws I/N 45 from pump body I/N 29 allowing the indicator plate I/N 46 to
hang loosely.
7.3.4 Turn control knob I/N 44 counterclockwise until the threads disengage from the sealing nut I/N 39. Pull
the control knob and attached metering rod from the pump body .
7.3.5 With an 15/16" 6-point socket wrench, remove the sealing nut .
7.3.6 Parts 39, 44, 45, and 46 are no longer needed.
7.3.7 The sealing plate F/N 38 remains in position Within the pump body.
7.3.8 Screw adapter P/N 004252 into the pump body and tighten securely against the seal p l a t e .
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.
7.3.9 The control rod is supplied attached to the connector, P/N 004251. Apply 1 drop of low strength ( b l u e )
Loctite to the threads on the connector P/N 004251. Screw the connector completely into the threaded rod
projecting from the nose of the Electric Stroke Control. Allow the Loctite to set.
7.3.10 MOUNT ELECTRIC STROKE CONTROL: The Stroke Controller-Positioner is installed as a unit.
Do not disassemble or remove the cover from the unit.
7.3.11 If the output shaft of Stroke Controller-Positioner is not in the ZERO position (output shaft fully
retracted) turn the Manual Adjustment Handwheel clockwise until the shaft is fully retracted (see Section 6,
Handwheel Operation).
7.3.12 Turn the large Mounting Nut on the nose of the Stroke Controller-Positioner so that there is
1/4"between the face of the nut and the face of the stroke control unit (see Section 6, Handwheel Operation).
7.3.13 Coat the tip of the control rod I/N 53 with STP, or heavy machine oil, to allow it to slip easily into the
sealing plate O-ring.
7.3.14 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. This operation is best undertaken with two people,
one to position the Stroke Controller-Positioner and the other to apply the pressure.
7.3.15 Engage the threads on the Stroke Controller-Positioner with the threads in the adapter. Screw the
Stroke Controller-Positioner into the adapter until the jam nut contacts the pump body .
7.3.16 Orient the Stroke Controller-Positioner with the nameplate and viewing window up and parallel to the
pump mounting surface.

18
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 & Instruction
Manual.
7.3.20 The pump is now ready to be returned to service. Follow start-up procedure as if starting a new pump.
7.3.21 Review Warnings at the beginning of Operating Manual and at the beginning of this section.
7.3.22 Remove cover from Stroke Controller-Positioner.
7.3.23 Connect Analog Signal Generator to the appropriate Command Input terminals
7.3.24 Energize Stroke Controller-Positioner. Start pump motor. Increase simulated Command Input Signal
7.3.25 Start pumping by opening discharge valve .
7.3.26 Confirm back pressure duplicates normal operation .
7.3.27 Refer to Section 9 of this manual on Configuration, Calibration and Adjusting the unit

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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.
If the actuator is to be installed in a hazardous area, a suitably certified cable gland must be fitted with
the use of a certified thread adaptor where appropriate. Unused entries must be closed with a suitably
certified stopping plug. Wire type must meet local and certifying agency (FMC) requirements and have a
minimum temperature rating of 88 °C. Wiring installation must comply with local statutory regulations.
8.2 Connecting to Terminals
Uncovering
Ensure all power supplies are isolated before removing actuator covers.
The wiring diagram supplied is particular to each actuator and must not be interchanged with any other actuator.
If in doubt check the wiring diagram number with that on the actuator.
Refer to the wiring diagram to identify functions of terminals. Check that the supply voltage is the same as that
marked on the actuator nameplate.Check that the supply voltage agrees with that stamped on the actuator
nameplate. A fused switch or circuit breaker must be included in the wiring installation of the actuator. The
switch or circuit breaker must be installed as close as possible to the actuator and shall be marked to indicate
that it is the disconnecting device for that particular actuator. Actuator must be mounted such that it is not
difficult to operate the disconnecting device.
The actuator must be protected with an over current protection device