Neptune NSP-M User manual

Neptune solenoid pump
NSP-M
Operating instructions
Read the operating manual!
The user is responsible for installation and operation related mistakes!

Table of Contents 3
Subject to technical changes.
Neptune solenoid pump NSP-M Operating instructions
Table of Contents
1 Notes for the Reader ..........................................................4
1.1 General non-discrimination......................................................4
1.2 Explanation of the signal words ................................................4
1.3 Explanation of the warning signs ..............................................4
1.4 Identification of warnings.........................................................4
1.5 Instruction for action identification ...........................................4
2 Safety .................................................................................5
2.1 General warnings.....................................................................5
2.2 Hazards due to non-compliance with the safety instructions .....6
2.3 Working in a safety-conscious manner .....................................6
2.4 Personal protective equipment.................................................6
2.5 Personnel qualification.............................................................6
3 Intended use ......................................................................8
3.1 Notes on product warranty .......................................................8
3.2 Intended purpose.....................................................................8
3.3 Device revision ........................................................................8
3.4 Principles ................................................................................8
3.5 Prohibited dosing media...........................................................8
3.6 Foreseeable misuse.................................................................8
4 Product description .........................................................10
4.1 Properties..............................................................................10
4.2 Scope of delivery ...................................................................10
4.3 Structure of the dosing pump .................................................10
4.4 Function description ..............................................................11
4.5 Rating plate ...........................................................................11
5 Technical data..................................................................12
5.1 Delivery capacity data............................................................12
5.2 Operating conditions and limits ..............................................12
5.3 Electrical specifications .........................................................13
5.4 Other data .............................................................................13
6 Dimensions ......................................................................14
7 Installing the Dosing Pump..............................................15
7.1 Set up information .................................................................15
7.2 Installation examples .............................................................15
8 Hydraulic installations.....................................................16
8.1 Design of the system..............................................................16
8.2 System piping........................................................................16
8.3 Aligning the dosing head ........................................................17
8.4 Hydraulic connections............................................................17
8.5 Connecting a leakage drain ....................................................18
8.6 Connecting the dosing head venting facility ............................19
8.7 Hydraulic accessories ............................................................19
9 Electrical installation.......................................................21
9.1 Principles ..............................................................................21
9.2 Conductive rubber band.........................................................21
9.3 Description of the connection sockets ....................................22
9.4 Assignment of the connection port..........................................22
10 Operation..........................................................................23
10.1 Commissioning the dosing pump..........................................23
10.2 Signal LED...........................................................................24
10.3 External On / Off via Release input ........................................24
10.4 Decommissioning the dosing pump......................................24
10.5 Shutting down in an emergency ...........................................24
10.6 Storage ...............................................................................24
10.7 Transportation......................................................................24
10.8 Disposal of old equipment ....................................................24
11 Maintenance ....................................................................25
11.1 Maintenance intervals..........................................................25
11.2 Tighten up dosing head bolts................................................25
11.3 Change the diaphragm.........................................................25
11.4 Clean suction and pressure valves........................................26
12 Troubleshooting ...............................................................27
12.1 Type of fault .........................................................................27
13 Spare parts.......................................................................29
13.1 Diaphragm spare parts kits ..................................................29
13.2 Dosing head spare parts kits including valves .......................29
14 Delivery characteristic curves.........................................30
15 Index.................................................................................31

Notes for the Reader
Instruction for action identification
4
Neptune solenoid pump NSP-M Operating instructions
1 Notes for the Reader
These Operating instructions contain information and behaviour rules for
safe and designated operation of the dosing pump NSP-M.
Observe the following principles:
nRead the entire operating manual prior to starting-up the device.
nEnsure that everyone who works with or on the dosing pump has read
the operating instructions and follows them.
nKeep the operating instructions for the entire service life of the dosing
pump.
nPass on the operating instructions to any subsequent owner of the
dosing pump.
1.1 General non-discrimination
In this operating manual, only the male gender is used where grammar
allows gender allocation. The purpose of this is to make the text easy to
read. Men and women are always referred to equally. We would like to
ask female readers for understanding of this text simplification.
1.2 Explanation of the signal words
Different signal words in combination with warning signs are used in this
operating manual. Signal words illustrate the gravity of possible injuries if
the risk is ignored:
Signal word Meaning
DANGER Refers to imminent danger. Ignoring this sign may
lead to death or the most serious injuries.
WARNING
Refers to a potentially hazardous situation. Failure
to follow this instruction may lead to death or
severe injuries.
CAUTION
Refers to a potentially hazardous situation. Failure
to follow this instruction may lead to minor injury
or damage to property.
NOTE Refers to a danger which, if ignored, may lead to
risk to the machine and its function.
Table 1: Explanation of the signal words
1.3 Explanation of the warning signs
Warning signs represent the type and source of a danger:
Warning sign Type of danger
General danger zone
Danger of electric shock
Danger of caustic or other burns
Danger of electromagnetic radiation
Danger of automatic start up
Danger of damage to machine or functional
influences
Table 2: Explanation of the warning signs
1.4 Identification of warnings
Warnings are intended to help you recognise risks and avoid negative
consequences.
This is how warnings are identified:
Warning sign SIGNAL WORD
Description of danger.
Consequences if ignored.
ðThe arrow signals a safety precaution to be taken to eliminate
the danger.
1.5 Instruction for action identification
This is how pre-conditions for action are identified:
üPre-condition for action which must be met before taking action.
@A resource such as a tool or auxiliary materials required to perform
the operating instructions.
This is how instructions for action are identified:
èSeparate step with no follow-up action.
1. First step in a series of steps.
2. Second step in a series of steps.
4Result of the above action.
üAction completed, aim achieved.

Safety
General warnings 5
Neptune solenoid pump NSP-M Operating instructions
2 Safety
2.1 General warnings
The following warnings are intended to help you to eliminate the dangers
that can arise while handling the dosing pump. Risk prevention measures
always apply regardless of any specific action.
Safety instructions warning against risks arising from specific activities
or situations can be found in the respective sub-chapters.
DANGER
Mortal danger from electric shock!
Wrongly connected or located cables or damaged ones can injure you.
ðConnect the device only to a SCHUKO socket outlet protected by a
ground fault circuit interrupter (GFCI).
ðReplace damaged cables without delay.
ðDo not use extension cables.
ðDo not bury cables.
ðSecure cables to avoid being damaged by other equipment.
DANGER
Danger to life through explosions!
The use of dosing pumps without ATEX certification in a potentially
explosive atmospheres can result in potentially-fatal explosions.
ðNever use the dosing pump in potentially explosive areas.
WARNING
Danger from unsuitable materials
The materials of the dosing pump and hydraulic parts of the system
must be suitable for the dosing medium that is used. Should this not
be the case, the dosing media may leak.
ðMake sure that the materials you are using are suitable for the
dosing medium.
ðMake sure that the lubricants, adhesives, sealants, etc. that you
use are suitable for the dosing medium.
WARNING
Caustic burns or other burns through dosing media!
While working on the dosing head, valves and connections, you may
come into contact with dosing media.
ðUse sufficient personal protective equipment.
ðRinse the dosing pump with a liquid (e.g. water) which does not
pose any risk. Ensure that the liquid is compatible with the dosing
medium.
ðRelease pressure in hydraulic parts.
ðNever look into open ends of plugged pipelines and valves.
WARNING
Danger of automatic start up!
After connecting the mains supply, residual dosing media in the
dosing head can spray out.
ðBefore connecting the mains supply, connect the dosing lines.
ðCheck that all the screw connections have been tightened
correctly and are leak-proof.
WARNING
Danger from electromagnetic radiation!
Solenoid diaphragm dosing pumps In operation, solenoid diaphragm
dosing pumps emit a stray magnetic field. If you do not keep far
enough away, the function of a pacemaker can be negatively affected.
ðPeople with pacemakers must always keep at least 19.7 inch
away from the dosing pump.
CAUTION
Danger when changing the dosing medium!
Changing the dosing media can provoke unexpected reactions,
damage to property and injury.
ðClean the dosing pump and the system parts in contact with the
media thoroughly before changing the dosing medium.

Safety
Personnel qualification
6
Neptune solenoid pump NSP-M Operating instructions
CAUTION
Increased risk of accidents due to insufficient qualifica-
tion of personnel!
Dosing pumps and their accessories may only be installed, operated
and maintained by personnel with sufficient qualifications. Insufficient
qualification will increase the risk of accidents.
ðEnsure that all action is taken only by personnel with sufficient and
corresponding qualifications.
ðPrevent access to the system for unauthorised persons.
2.2 Hazards due to non-compliance with the safety
instructions
Failure to follow the safety instructions may endanger not only persons,
but also the environment and the device.
The specific consequences can be:
nFailure of vital functions of the dosing pump and the system.
nFailure of required maintenance and repair methods.
nDanger for individuals through dangerous dosing media.
nDanger to the environment caused by substances leaking from the
system.
2.3 Working in a safety-conscious manner
Besides the safety instructions specified in this operating manual, further
safety rules apply and must be followed:
nAccident prevention regulations.
nSafety and operating provisions.
nSafety provisions for handling dangerous substances (mostly the
safety data sheets to dosing media).
nEnvironmental protection provisions.
nApplicable standards and legislation.
2.4 Personal protective equipment
Based on the degree of risk posed by the dosing medium and the type of
work you are carrying out, you must use corresponding protective
equipment. Read the Accident Prevention Regulations and the Safety
Data Sheets to the dosing media find out what protective equipment you
need.
You will require the minimum of the following personal protective
equipment:
Personal protective equipment required
Protective goggles
Protective clothing
Protective gloves
Table 3: Personal protective equipment required
Wear the following personal protective equipment when performing the
following tasks:
nCommissioning
nWorking on the dosing pump while running
nShutdown
nMaintenance work
nDisposal
2.5 Personnel qualification
Any personnel who work on the dosing pump must have appropriate
special knowledge and skills.
Anybody who works on the dosing pump must meet the conditions below:
nAttendance at all the training courses offered by the owner.
nPersonal suitability for the respective activity.
nSufficient qualification for the respective activity.
nTraining in handling of the dosing pump.
nKnowledge of safety equipment and the way this equipment functions.
nKnowledge of this operating manual, particularly of safety instructions
and sections relevant for the activity.
nKnowledge of fundamental regulations regarding health and safety
and accident prevention.
All persons must generally have the following minimum qualification:
nTraining as specialists to carry out work on the dosing pump
unsupervised.
nSufficient training that they can work on the dosing pump under the
supervision and guidance of a trained specialist.

Safety
Personnel qualification 7
Neptune solenoid pump NSP-M Operating instructions
These operating instructions differentiate between these user groups:
2.5.1 Specialist staff
Thanks to their professional training, knowledge, experience and
knowledge of the relevant specifications, specialist staff are able to
perform the job allocated to them and recognise and/or eliminate any
possible dangers by themselves.
2.5.2 Trained persons
Trained persons have received training from the operator about the tasks
they are to perform and about the dangers stemming from improper
behaviour.
In the table below you can check what qualifications are the pre-condi-
tion for the respective tasks. Only people with appropriate qualifications
are allowed to perform these tasks!
Qualification Activities
Specialist staff nAssembly
nHydraulic installations
nElectrical installation
nMaintenance
nRepairs
nCommissioning
nTaking out of operation
nDisposal
nFault rectification
Trained persons nStorage
nTransportation
nControl
nFault rectification
Table 4: Personnel qualification

Intended use
Foreseeable misuse
8
Neptune solenoid pump NSP-M Operating instructions
3 Intended use
3.1 Notes on product warranty
Any non-designated use of the product can compromise its function or
intended protection. This leads to invalidation of any warranty claims!
Please note that liability is on the side of the user in the following cases:
nThe dosing pump is operated in a manner which is not consistent with
these operating instructions, particularly safety instructions, handling
instructions and the section "Intended Use".
nIf people operate the product who are not adequately qualified to carry
out their respective activities.
nNo original spare parts or accessories of Neptune are used.
nUnauthorised changes are made to the device.
nThe user uses different dosing media than those indicated in the
order.
nThe user does not use dosing media under the conditions agreed with
the manufacturer such as modified concentration, density, tempera-
ture, contamination, etc.
3.2 Intended purpose
The dosing pump NSP-M is intended for the following purpose: the
conveying and dosing of liquids.
3.3 Device revision
This operating manual applies to the following devices:
Device Month / year of
manufacture Firmware
NSP-M 03/2017 01:01
Table 5: Device revision
3.4 Principles
nBefore delivery, the manufacturer inspected the dosing pump and
operated it under specific conditions (with a specific dosing medium
with a specific density and temperature, with specific pipe dimen-
sions, etc.) Since these conditions differ at every location of usage,
the delivery capacity of the dosing pump should be measured by
gauging it at the operating company's installation. For details on the
approximate values and the capacity of the dosing pump, refer to the
chapter 14 “Delivery characteristic curves” on page30.
nComply with the information regarding the operating and environmen-
tal conditions (see chapter "Technical data").
nAny restrictions regarding the viscosity, temperature and density of
dosing media must be followed. You must only use dosing media at
temperatures above freezing point or below the boiling point of the
respective medium.
nThe materials of the dosing pump and hydraulic parts of the system
must be suitable for the dosing medium that is used. In this connec-
tion, note that the resistance of these components can change in
dependence on the temperature of the media and the operating
pressure.
i
Information on the suitability of materials combined with
different dosing media can be found in the Compatibility Chart
of Neptune.
The information in this resistance list is based on information
from the material manufacturers and on expertise obtained by
Neptune from handling the materials.
As the durability of the materials depends on many factors,
this list only constitutes initial guidance on selecting material.
In all cases, test the equipment with the chemicals you use
under operating conditions.
nThe dosing pump is not intended for outdoor use unless appropriate
protective measures have been taken.
nAvoid leaks of liquids and dust into the casing and avoid direct
exposure to sunlight.
nYou must never operate dosing pumps in a potentially explosive
atmosphere if they do not have corresponding nameplates or an
appropriate EU Declaration of Conformity for potentially explosive
atmospheres.
3.5 Prohibited dosing media
The dosing pump must not be used for these media and substances:
nGaseous media,
nradioactive media,
nsolid substances,
ncombustible media,
nall other media that are not suitable for delivery using this dosing
pump.
3.6 Foreseeable misuse
Below, there is information about the applications of the dosing pump or
associated equipment that are not considered to be intended use. This
section is intended to allow you to detect possible misuse in advance and
to avoid it.

Intended use
Foreseeable misuse 9
Neptune solenoid pump NSP-M Operating instructions
Foreseeable misuse is assigned to the individual stages of the product
lifetime:
3.6.1 Incorrect assembly
nUnstable or unsuitable bracket
nDosing pump bolted wrongly or loosely
3.6.2 Incorrect hydraulic installation
nSuction and pressure lines dimensioned incorrectly
nUnsuitable connection of the pipes due to wrong material or
unsuitable connections.
nSuction and pressure lines mixed-up
nDamage to threads due to them being tightened too much
nBending of pipelines
nNo free return flow of the pressure relief valve
nExcessive demand due to the pressure differences between the
suction and pressure valves
nThrough-suction at installation without back-pressure valves
nDamage due to undamped acceleration mass forces
nExceeding the admissible pressure on the suction and discharge sides
nUsing damaged parts
3.6.3 Incorrect electrical installation
nConnecting the mains voltage without a protective earth
nUnsecured mains or one that does not conform to standards
nNot possible to immediately or easily disconnect the power supply
nWrong connecting cables for mains voltage
nDosing pump accessories connected to wrong sockets
nDiaphragm monitoring not connected or defective
nProtective earth removed
3.6.4 Incorrect start-up
nStart-up with damaged system
nShut-off valves closed at commissioning
nClosed suction or pressure line, e.g. due to blockages
nPersonnel was not informed before the start-up
nSystem was recommissioned after maintenance without all the
protective equipment and fixtures, etc. being reconnected.
nInadequate protective clothing or none at all
3.6.5 Incorrect operation
nProtective equipment not functioning correctly or dismantled
nModification of the dosing pump without authority
nIgnoring operational disturbances
nElimination of operational disturbances by personnel without
adequate qualifications
nDeposits in the dosing head due to inadequate purging, particularly
with suspensions
nBridging the external fuse
nOperation made more difficult due to inadequate lighting or machines
that are difficult to access
nOperation not possible due to dirty or illegible display of the dosing
pump
nDelivery of dosing media for which the system is not designed
nDelivery of particulate or contaminated dosing media
nInadequate protective clothing or none at all
3.6.6 Incorrect maintenance
nCarrying out maintenance during ongoing operation
nCarrying out work that is not described in the operating manual
nNo adequate or regular inspection of correct functioning
nNo replacement of damaged parts or cables with inadequate
insulation
nNo securing against reactivation during maintenance work
nUsing cleaning materials that can cause reactions with the dosing
media
nInadequate cleaning of the system
nUnsuitable purging medium
nUnsuitable cleaning materials
nDetergents left in system parts
nUsing unsuitable cleaning equipment
nUsing the wrong spares or lubricants
nContaminating the dosing medium with lubricant
nInstalling spare parts without following the instructions in the
operating manual
nBlocking venting orifices
nPulling off sections of the plant
nContamination at installation without a dirt trap
nMixing up the valves
nMixing up the sensor lines
nNot reconnecting all the lines
nDamaging or not installing all the seals
nNot renewing seals
nNot paying attention to safety data sheets
nInadequate protective clothing or none at all
3.6.7 Incorrect decommissioning
nNot completely removing the dosing medium
nDismantling lines while the dosing pump is running
nDevice not disconnected from the power supply
nUsing the wrong dismantling tools
nInadequate protective clothing or none at all
3.6.8 Incorrect disposal
nIncorrect disposal of dosing media, operating resources and other
materials
nNo labelling of hazardous substances

Product description
Structure of the dosing pump
10
Neptune solenoid pump NSP-M Operating instructions
4 Product description
4.1 Properties
The NSP-M is a solenoid diaphragm dosing pump that is used when
precise dosing results are required.
They are characterized by the following properties:
nOutput range from 0.09 to 3.43 gph, up to 232 psig.
nReproducible dosing precision of ±2%.
nInfinitely variable dosing rate from 0 to 100 %.
nSignal LED for display of the operating state.
nMaterial finishes PVC, PP, PVDF.
nIntegrated automatic dosing head ventilation.
nSuitable for highly aggressive or poisonous dosing media.
nFloor- and wall-mounting options.
nConnections: M12x1 plug, A-coded.
nCSA and UL certified.
4.2 Scope of delivery
Please compare the delivery note with the scope of delivery. The
following items are part of the scope of delivery:
nDosing pump NSP-M,
nOne set each of hose clamping connections for the suction and
discharge sides for hoses with diameters of 4/6 mm, 1/4 x 3/8” (made
of PVC, PP and PVDF),
nCover cap for the electrical connection
nMains cable,
nOperating instructions,
nInspection report and test certificate (optional),
nAccessory kit (optional).
4.3 Structure of the dosing pump
4.3.1 General Overview
Fig. 1:
a
b
c
Dosing pump overview NSP-M
No. Description
1Dosing head
2Drive unit
3Control box
4.3.2 Dosing head
Fig. 2:
a
c
d
b
Dosing head
No. Description
1Valve and connection on the discharge side
2integrated dosing head venting facility (plastic version only)
3Arrow indicating the direction of throughflow of the dosing
medium (plastic version only)
4Valve and connection on the suction side

Product description
Rating plate 11
Neptune solenoid pump NSP-M Operating instructions
4.3.3 Control elements
Fig. 3:
a
c
b
Controller of dosing pump NSP-M
No. Description
1Stroke frequency adjustment for setting the dosing capacity (in
per cent)
2Connection sockets for external operation or connecting
accessories
3Mains cable for power supply
Table 6: Designation of components
4.4 Function description
Dosing pumps are positive displacement pumps. They are used if
precisely defined delivery of a medium is necessary. A constant volume
per stroke or time is delivered.
The system delivers or meters the dosing medium by means of a
repeated sequence of suction strokes followed by pressure strokes. This
results in a pulsing flow.
If the dosing pump is in the suction stroke phase, the diaphragm is pulled
into the rear final position. Due to the resulting vacuum in the dosing
head, the pressure valve closes, the suction valve opens and dosing
medium flows from the suction line into the dosing head.
If the dosing pump is in the pressure stroke phase, the diaphragm is
moved into the front final position. Due to the pressure in the dosing head,
the suction valve closes and the dosing medium flows through the
pressure valve from the dosing head into the pressurised pipe.
4.5 Rating plate
There is information on the equipment about safety or the product's way
of functioning. The information must stay legible for the duration of the
service life of the product.
T
Fig. 4: Rating plate NSP
No. Description
1Product, type, nominal size
2Maximum delivery capacity at average backpressure
3Maximum delivery capacity at maximum backpressure
4Protection class
5Voltage supply
6CSA certificate
7WEEE label
8 Frequency
9Power consumption
10 Serial number
11 Month / year of manufacture
12 Material of the dosing head/seals
Table 7: Rating plate
NSP 11
10
2
1
45
6
7
89
12
3

Technical data
Operating conditions and limits
12
Neptune solenoid pump NSP-M Operating instructions
5 Technical data
5.1 Delivery capacity data
Please note that some of this data only represents guide values. The actual capacity of a dosing pump depends on various factors. For approximate
values of the delivery capacity at different pressures, refer to chapter "”14 Delivery characteristic curves” on page 30.
Information Value
NSP-M Size
NSP-M09 NSP-M20 NSP-M50 NSP-M89 NSP-M160 NSP-M240 NSP-M343
Delivery capacity at max. backpressure
gph 0.09 0.20 0.5 0.89 1.60 2.40 3.43
ml/stroke 0.05 0.05 0.2 0.32 0.57 0.83 0.87
Max. delivery pressure psig 232 116 87 43
Delivery capacity at average backpressure
gph 0.14 0.29 0.61 1.00 1.80 2.64 4.00
ml/stroke 0.08 0.08 0.24 0.35 0.63 0.92 1
Average delivery pressure psig 116 58 43 14
Max. stroke frequency rpm 120 250 160 180 250
Table 8: Output data
5.2 Operating conditions and limits
Information Value NSP-M Size
Approved ambient temperature °F 41 – 113 (with PVC components 41 – 104)*
Relative humidity %max. 90
Max. sound pressure level (depressurised) dB(A) 68 – 75
Max. sound pressure level (at test pressure) dB(A) 65 – 70
Max. supply pressure mbar 800
Viscosity limits mPa∙s 300** / 1000***
Adjustable dosing range %0 – 100
Table 9: Operating conditions and limits
* Use of the dosing pump at ambient temperatures below 41 °F must be checked individually. In such cases, please contact the manufacturer.
** With a viscosity of ~300 mPa∙s and above, you must use spring-loaded valves.
*** If the viscosity is above 1000 mPa∙s, this must be checked individually and the stroke frequency must be between 50 and 100 strokes/min.
5.2.1 Approved media temperature
Information Value NSP-M (Sizes)
Dosing head made of PVC °F 32 – 95
Dosing head made of PP °F 32 – 140
Table 10: Approved media temperature

Technical data
Other data 13
Neptune solenoid pump NSP-M Operating instructions
Information Value NSP-M (Sizes)
Dosing head made of PVDF °F 32 – 176
Table 10: Approved media temperature
5.3 Electrical specifications
Information Value
NSP-M Size
NSP-M09 NSP-M20 NSP-M50 NSP-M89 NSP-M160 NSP-M240 NSP-M343
Voltage supply 110 – 240 V AC, -10 % / +5 %, 50/60 Hz
Power consumption W 10 15 21 27 28 29 26
Max. current consumption during dosing
stroke A 2.0 3.0 3.7 3.8 4.1 3.6
Table 11: Electrical specifications
5.4 Other data
Information Value
NSP-M Size
NSP-M09 NSP-M20 NSP-M50 NSP-M89 NSP-M160 NSP-M240 NSP-M343
Weight (with dosing head made of PVC, PP,
PVDF) Ib 6.6 approx.
Diameter of diaphragm in 0.94 1.3 1.54
Electrical cable feet 5.9 m (with mains plug)
Protection class IP65 (with covering caps on the connections)
Insulation class F
Valve connection G 5/8 male
Valve size DN3 DN4
Table 12: Other data

Dimensions
Other data
14
Neptune solenoid pump NSP-M Operating instructions
6 Dimensions
NSP-M with dosing head made of PVC, PP or PVDF
Fig. 5:
7.09"
2.32"
L L
4.72"
7.36"
6.30"
1.70" 3"
2.76"
0.26"
3.94"
3.15"
4.57"
Dimensioned drawing of NSP-M with dosing head made of PVC, PP or PVDF (all
dimensions in inches)
Connection Material Scale Nominal width L
Hose clamp connector PVC / PP / PVDF
4/6 mm DN4 31
1/4 x 3/8" 1/4" 34
Table 13: Hose connections

Installing the Dosing Pump
Installation examples 15
Neptune solenoid pump NSP-M Operating instructions
7 Installing the Dosing Pump
DANGER
Mortal danger from electric shock!
Electrically conductive liquid can enter pump housings, cable screw
connections and mains connectors.
ðMake sure that all protective measures comply at least with the
requirements of protection class IP65.
ðAlways set up the dosing pump such that water cannot enter the
housing.
CAUTION
Danger of personal injury and material damage!
A dosing pump that is difficult to access represents a danger due to
incorrect operation and faulty maintenance.
ðInstall the dosing pump such that it is accessible at all times.
7.1 Set up information
When installing, follow the basic principles below:
nThe valves must be vertical: Pressure valve at top, suction valve at
bottom. In this connection, pay attention to the arrow on the dosing
head. The dosing head must be aligned such that the arrow points
vertically upwards.
nYou should install the dosing pump at a convenient height for
operation.
nIt must not be installed under the ceiling.
nThe frame of foundation for fixing the dosing pump must not be
subjected to jolts. The pump must be vibration-free and stable.
nThere must be enough free space in the area of the dosing head and
the suction and pressure valves for these parts to be easily dismantled
if required. The entire space requirement for installation and
maintenance is approximately 1 m².
nThe distance from the sides of the dosing pump to the wall or other
dosing pumps or equipment must be at least 1.2 inch. There must be
a guaranteed flow of circulating air.
nThe maximum ambient temperature must be complied with, see
chapter 5.2 “Operating conditions and limits” on page12. If
necessary, radiant heat from surrounding equipment must be
screened.
nAvoid exposure to direct sunlight.
nThe dosing pump is not intended for use out of doors unless
appropriate protective measures have been taken to prevent dust and
water from entering the housing.
nFor the dimensions of the fastening holes, refer to chapter 6
“Dimensions” on page14.
nThe tightening torque for the fastening bolts is 1.5 – 2 Nm.
7.2 Installation examples
7.2.1 Installation on a wall console
Fig. 6: Installation on a wall console
To reduce the structure-borne noise, the dosing pump is bolted to the
wall bracket using rubber elements. The materials necessary for this are
included with the wall bracket.
7.2.2 Installation on the wall
Fig. 7: Installation on the wall
The dosing pump can be mounted to the floor or directly to the wall
without the need for additional elements. Turn the dosing head appropri-
ately to ensure the flow direction of the medium through the dosing head.

Hydraulic installations
System piping
16
Neptune solenoid pump NSP-M Operating instructions
8 Hydraulic installations
In this chapter, you will find information about the hydraulic parts of a
system that you should install or that can install additionally. In many
cases, you must install hydraulic accessories to be able to use all the
functions that the dosing pump NSP-M offers, to guarantee functional
safety or to achieve a high level of dosing precision.
WARNING
Caustic burns or other burns through dosing media!
A diaphragm rupture, blocked pressure lines or the use of material not
suitable for the dosing medium can result in the discharge of dosing
medium. Depending on the type and hazardousness of the dosing
medium, this can result in injury.
ðWear the recommended personal protective equipment.
ðMake sure that the materials you are using are suitable for the
dosing medium.
ðMake sure that the lubricants, adhesives, sealants, etc. that you
use are suitable for the dosing medium.
ðInstall a leakage drain.
ðInstall pressure relief valves.
CAUTION
Danger of personal injury and material damage!
High peak pressures can lead to piping vibrating and cause them to
snap. This can result in injury from piping or escaping dosing media.
ðInstall pulsation dampeners.
NOTE
Damage to drives due to overloading
The pressure conditions between the suction and discharge sides
must be balanced; otherwise, overloading can result. This can lead to
uncontrolled dosing processes, damage to the piping and to the
dosing pump.
ðEnsure that the pressure on the discharge side is at least 14.5 psig
than on the suction side.
NOTE
Locking of threads
Stainless steel and plastic parts (particularly those made of PVC) that
are bolted together in a detachable connection (e.g. the dosing head
and the valves) can lock. This makes them difficult to release.
ðBefore bolting, grease the corresponding parts with a lubricant
(e.g. PTFE spray). Ensure that the lubricant is compatible with the
dosing medium.
8.1 Design of the system
nThe dosing pumps technical data (see chapter 5 “Technical data” on
page12) must be taken into account and the plant s layout must
be set up appropriately (e.g. pressure loss when rating the lines with
regard to their nominal diameter and length).
nThe entire system and its integrated dosing pump must be designed
in such a way that an escaping dosing medium (due to the failure of
wearing parts such as the diaphragm, or burst hoses) does not lead to
permanent damage to system parts or the premises.
nThe leakage opening of the dosing head must be visible so that you
can detect a diaphragm rupture. It must be possible for the outflow
from the leakage drain to be on a free downwards gradient.
nIf you use hazardous dosing media, the installation must be designed
such that no disproportionately high consequential damages arise
due to dosing media escaping.
nTo avoid dosing errors after the end of the process, the dosing pump
must be locked hydraulically.
nTo allow you to easily inspect the pressure conditions in the system,
you should provide connections for pressure gauges close to the
suction and pressure valves.
8.2 System piping
nThe system piping must not exert any force on the connections and
valves of the dosing pump.
nThis means that steel piping should be connected to the dosing pump
by means of flexible pipe sections.
nThe nominal diameters of the pipework and the installed fittings
should be rated the same as or greater than the nominal diameters of
the dosing pump's suction and pressure valves.
nThe suction line should be kept as short as possible.
nYou should avoid intertwined hoses.
nAvoid loops, since air bubbles can collect.

Hydraulic installations
Hydraulic connections 17
Neptune solenoid pump NSP-M Operating instructions
8.3 Aligning the dosing head
Fig. 8:
a
b
c
Aligning the dosing head
When connecting the dosing lines to the dosing pump, you must observe
the direction of through-flow (see arrow). The dosing head must be
aligned vertically. The alignment can be changed in 90° intervals.
The suction valve (3) must always point downwards. Accordingly, arrow
(2) and pressure valve (1) always point upwards. This is irrespective of the
positioning of the dosing head to the drive.
8.4 Hydraulic connections
8.4.1 Connecting hose clips
Choose the hose connection according to the condition of the hose
(material, inner diameter, wall thickness) in order to ensure maximum
pressure resistance.
8.4.1.1 Size 4/6
Fig. 9:
a
b
c
d
e
4/6
Hose clips 4/6 (internal and external diameters in mm)
Perform the following working steps:
1. Cut the hose (1) to the appropriate length neatly and at an exact right
angle.
2. Place a gasket that is suitable for the dosing medium between the
connection (5) and the valve.
3. Screw the connecting piece e to the dosing pump's valve using the
(2).
4. Thread the union nut (3) and the clamping ring (4) onto the hose.
5. Plug the hose all the way in to the grommet of connection piece.
6. Push the clamping ring onto the grommet of connection piece and
screw it to the union nut.
7. Carry out the same procedure with the connection to the dosing
pump's other valve.
üHose clip connected.
8.4.1.2 Size 6/12
Fig. 10:
a
b
c
d
Hose clip 6/12 (internal and external diameter in mm)
Size 6/12 hose clips only have a union nut. It clamps the hose onto the
grommet of the connection piece and at the same time fastens on the
dosing pump's valve.
Perform the following working steps:
1. Cut the hose (1) to the appropriate length neatly and at an exact right
angle.
2. Place a gasket that is suitable for the dosing medium between the
connection (4) and the valve.
3. Push the union nut (2) and the cutting ring (3) over the hose.
4. Press the end of the hose onto the grommet of connection piece. You
can do this more easily by moistening the end of the hose on the
inside or applying some lubricant to the grommet in the cone area.
You should push at least two thirds of the hose onto the grommet of
the connection piece.
5. Push the cutting ring over the hose into the cone area on the
grommet of connection piece.
6. Screw the union nut onto the valve of the dosing pump.
üHose clip connected.

Hydraulic installations
Connecting a leakage drain
18
Neptune solenoid pump NSP-M Operating instructions
8.4.2 Making the glue-in connection
Fig. 11:
a
b
Glue-in connection
Perform the following working steps:
1. Cut the PVC tube to length.
2. Push the union nut onto the tube.
3. Stick the bonded coupling sleeve (2) to the tube (follow the
instructions of the adhesive manufacturer).
4. Screw the union nut onto the valve of the dosing pump. Use a gasket
that is suitable for the dosing medium.
üGlue-in connection made.
8.4.3 Making the cemented connection
Fig. 12:
a
b
Cemented connection
Perform the following working steps:
1. Cut the tube to length.
2. Cut the thread (2) onto the end of the tube.
3. Push the union nut onto the tube.
4. Seal the thread. When choosing your sealing material, take into
account its resistance to material, temperature and pressure.
5. Screw the union nut onto the valve of the dosing pump. Use a gasket
that is suitable for the dosing medium.
üCemented connection made.
i
Under normal conditions, you only need to screw the hydraulic
connections finger-tight. However, due to the material settling,
the pre-tension of the screw connection can slacken. This
means that you must re-tighten the screw connection before
carrying out commissioning.
8.5 Connecting a leakage drain
Neptune dosing pumps are produced to the highest of quality standards
with a long service life. However, some parts are subject to operational
wear.This is the case particularly with the diaphragms that are continu-
ously subjected to forces during the suction and discharge strokes and to
the effects of the dosing medium.
If a diaphragm ruptures, the dosing medium starts to leak.This leakage is
drained via the leakage opening. On the flange of the dosing head, there
are three openings for this purpose. Depending on the alignment of the
dosing pump, the leakage is drained via the downward opening.
Fig. 13: Openings of the leakage drain
NOTE
Damage to drives due to effervescent media
If a hose is connected to the leakage drain and it is routed back into
the dosing tank, effervescent media can enter the drive and damage
it.
ðCollect the leakage in a collecting pan.
ðAs an alternative, you can route the leakage back to to the dosing
tank using a funnel. You should install the funnel at an adequate
distance from the leakage opening.

Hydraulic installations
Hydraulic accessories 19
Neptune solenoid pump NSP-M Operating instructions
8.6 Connecting the dosing head venting facility
NSP-M dosing heads have an integrated dosing head venting facility.
Fig. 14: Dosing head venting facility with hose connection
Perform the following working steps:
1. Connect a 4/6 hose to the dosing head venting facility.
2. Route the other end of the hose into the dosing tank or a collecting
tank.
üDosing head venting facility connected.
8.7 Hydraulic accessories
The following chapter is intended to give you an overview of installation
options.
Please note that these operating instructions are no substitute for the
instructions supplied with the accessories in each case. The correspond-
ing documentation supplied with the product applies to safety informa-
tion and provides exact instructions on assembly.
8.7.1 Injection nozzle
If the pressure line enters a main line, it is advisable to install an injection
nozzle.
Injection nozzles have three main functions:
nDosing the medium into a main line.
nPreventing flowback into the pressure line through a non-return valve.
Notes on assembly:
nDouble-ball injection nozzles must be installed into the main line
vertically from the bottom. You can install hose and spring-loaded
injection nozzles any way you like.
nWith dosing media that tend to crystallize, it is advisable to carry out
installation into the main line from the bottom. This prevents air
bubbles from being trapped.
nMany dosing media tend to contaminate the injection nozzles, which
can lead to blockages. In cases like this, it is advisable to install an
injection nozzle that is easy to dismantle and block off.
8.7.2 Pressure-relief valve
Pressure relief valves have an important safety function for protecting the
dosing pump and the associated pipes and fittings. The dosing pump can
generate a pressure that is many times the rated one. A blocked pressure
line can lead to dosing medium escaping.
An improperly high pressure can occur if:
nThe shut-off valves are closed even though the dosing pump is
running.
nPipes block.
At an appropriate pressure, a pressure relief valve opens a bypass line
and protects the system in this way from damage caused by over-pres-
sure.
Notes on assembly:
nThe line for returning dosing medium from the pressure relief valve
must be routed to the dosing tank or to a collecting pan.
nThe pressure in the dosing tank must not be too high so that it is
possible to accommodate the returned dosing medium.
nAs an alternative, the system can return dosing medium into the
suction line in front of the dosing pump. In this case, there must not be
a non-return valve or a foot valve in the suction line.
nYou should install the pressure relief valve as close as possible to the
dosing head.
8.7.3 Back-pressure valve
Back-pressure control valves are necessary if:
nThere are considerably fluctuating system pressures.
nThe pressure on the suction side is higher than on the discharge side
or if you intend to carry out dosing into depressurized lines.
In cases like this, if you do not use a back-pressure valve, imprecise
dosing results will occur or overloading will result. The back-pressure
valve solves these problems by generating a defined, constant backpres-
sure.
In some circumstances, a back-pressure valve is unnecessary if you use
a hose injection nozzle and if the backpressure that it generates is
adequate.
8.7.4 Pulsation dampener
Pulsation dampeners have the following functions:
nDamping pulsating delivery flows for processes that require
low-pulsation dosing.
nReducing the throughflow resistance with long pipelines.
When installed on the suction side:
nDamping of acceleration mass forces and with this reduction of wear
on the dosing pump.
nPreventing cavitation (pull-off of the liquid column) due to too high
acceleration.
However, pulsation dampeners also have important safety functions,
since they prevent pressure peaks from arising that lead to piping
vibrating and cause them to snap.

Hydraulic installations
Hydraulic accessories
20
Neptune solenoid pump NSP-M Operating instructions
This problem can occur:
nWith the high amplitudes of the vibrations.
nWhen using long pipes (the severity of the pulsation increases with
the length of the pipe).
nWhen using rigid piping instead of elastic hoses.
Notes on assembly:
nYou should carry out assembly in the direct vicinity of the location
where you want to damp the pressure peaks (directly in front of the
suction valve or directly behind the pressure valve).
nPulsation dampeners should be installed with throttle valves or
back-pressure valves installed directly behind them. By setting the
valves appropriately, you can further-optimise damping of the
pulsations.
nTo prevent unnecessary pipe friction losses, you should lay the
connecting line straight and in accordance with the rated width of the
pulsation dampener.
nYou must separately fasten relatively large pulsation dampeners and
ones with hose connections.
nPipelines must not transfer any mechanical tensions onto the
pulsation dampener.
8.7.5 Priming aid
Priming aids are particularly advisable:
nIn the case of dosing pumps with small volumetric displacements per
stroke or with low stroke length settings.
nWith high suction hights.
nWith highly dense dosing media.
nAt priming for the first time due to dry valves and air in the suction line
and the dosing head.
nIn dosing systems with frequent downtimes.
Further advantages resulting from priming aids:
nPreventing cavitation in the suction line.
nGas removal.
nOptical dosing control with small amounts.
nSmoothing of the suction flow.
8.7.6 Level monitoring
Level monitoring of suction-side feeding of the dosing medium to prevent
the tank being sucked dry and to ensure that it can be topped up again in
good time.
8.7.7 Dosing of suspensions
When dosing suspensions, the dosing head must be rinsed regularly to
prevent depositing. To do this, you install a feed line for the rinsing
medium (water) in the suction side installation.
8.7.8 Suction pressure regulator
A suction pressure regulator may be necessary if the suction-side
installation of the system demonstrates a varying suction pressure or
supply pressure:
nDosing pumps that are installed above dosing tanks deliver less as the
tank empties, since the suction head increases.
nDosing pumps that are installed below dosing tanks deliver less as the
tank empties, since the positive delivery pressure reduces.
Further problems that can occur:
nGreater wear on the dosing pump, e.g. diaphragm rupture due to the
effects of heavy forces with particularly high tanks and high-density
dosing media.
nIdling of the dosing tank in the case of a diaphragm rupture or pipe
breakage.
nImpermissibly high forces in the pump transmission that occur when
dosing pumps receive the dosing medium directly from the pressure
line.
nReduced performance or destruction of fittings due to cavitation with
long suction lines.
Installing a suction pressure regulator is a remedy for the problems
above. The suction pressure regulator is opened by the dosing pump's
suction pressure. This ensures that no dosing medium can flow if the
dosing pump is not running or no vacuum can be generated following a
pipe fracture.
Notes on assembly:
nWhen using a large suction pressure regulator, you should provide a
pulsation dampener on the suction side.