manualshive.com logo in svg

Alto Neptune 5, Service Manual, Page: 58 / 61

Share
Download
Alto Neptune 5 Service Manual Download Page 58

Neptune_GB_Ver.2.0_10/03

8.

Wiring diagrams

A1

B8

B9

S1

A2

Q

Y1

B2

B3

F1

F2

5 VDC

µP

X1a
X1b

Datalogger

X2

P

B6

B4

B1

B7

X5-13

X5-15

X4-21

X4-23

X4-17

X4-19

X4-15

X4-13

X4-11

X3-1

X3-9

X3-5

X4-7

X4-1

X4-3

X3-7

X3-3

X3-11

X7

Remote

4

4a

Temp.

Display

Operation

Fuel

Pump Oil

Service

Anti Stone

X5-5

X5-9

X6-9

X5-1

X6-1

X6-6

X6-7

X6-3

X5-3

X6-11

X5-11

X5-7

X4-9

X4-5

~

+

M

1~

A1

A2

K2

T1

11

4

14

13

12

8 VAC

24 VAC

U2 V2 W2

M

3~

V1 W1

U1

M1

L2 L3

L1

X11

T2

M2

PE

13 (17)

14 (18)

1

3

5

2

4

6

A1

A2

K1

1

02

S1

8a

7a

6a

5a

4a

3a

2a

1a

1

2

3

4

5

6

8

7

K1

S2

F11

11

14, 24

1a

2a

2

1

7

6

MT

7

9

Xma XMb

Xma

XMb

3

1

2

4

5

6

8

71261

3

Star / Delta

~

56.

S1
S2
T1
T2
X3-X6
X2
X3-X6
X7
X11
Xma-b
Y1

Switch on/off
Switch star-delta
Control transformer
Ignition transformer
Terminal strip
Pin contacts 5-pol. datalogger
Terminal strip
Connector remote control
Concentration terminal
Motor connector
Solenoid valve

A1
A2
B1
B2
B3
B4
B6
B7
B8
B9
F1/F2/F11
K1
K2
M1
M2
MT

Processor board
Display board
Temp. bensor
Flow switch
Safety thermal switch
Micro switch
Level switch pump oil
Light sensor
Level switch AntiStone
Level switch fuel
Fuse
Contactor
Relay
Motor 3~
Burner motor
Temp. switch motor

Summary of Contents for Neptune 5

Page 1: ...NEPTUNE 5 NEPTUNE 7 Service Manual...

Page 2: ...echnical data 3 8 3 Construction 9 15 4 Function 16 23 5 Trouble shooting 24 25 6 Service Repair 26 42 7 Adjustment Test 43 53 8 Wiring diagrams 54 56 9 1 Safety instructions 2 Special tools Spare par...

Page 3: ...ustrated spare parts lists during repairs They show the assembly position and the sequence in which the individual components should be assembled See Service Technical Information sheets They include...

Page 4: ...its use and who have been explicitly authorized to use it Repair work should be carried out by persons instructed in electrical installations or by trained electricians only ESD measures electrostatic...

Page 5: ...umption A 13 14 8 Fuse slow blow A 16 16 International Protection Class IP X5 IP X5 HP Nozzle NT 0530 NT 0450 Water inlet pressure bar 10 10 Water inlet temperature C 40 40 Water volume heat exchanger...

Page 6: ...ion A 15 8 9 1 Fuse slow blow A 20 16 International Protection Class IP X5 IP X5 HP Nozzle NT 0450 NT 0450 Water inlet pressure bar 10 10 Water inlet temperature C 40 40 Water volume heat exchanger l...

Page 7: ...21 7 12 5 Fuse slow blow A 25 16 International Protection Class IP X5 IP X5 HP Nozzle NT 0550 NT 0550 Water inlet pressure bar 10 10 Water inlet temperature C 40 40 Water volume heat exchanger l 4 78...

Page 8: ...6 International Protection Class IP X5 IP X5 HP Nozzle NT 0550 NT 0550 Water inlet pressure bar 10 10 Water inlet temperature C 40 40 Water volume heat exchanger l 4 78 4 78 Fuel consumption dt 45K kg...

Page 9: ...um ption A 13 F us e s low blow A 13 International P rotec tion C las s IP X5 H P N oz z le N T 0550 W ater inlet pres s ure bar 10 W ater inlet tem perature C 40 W ater volum e heat ex c hanger l 4 7...

Page 10: ...International Protection Class IP X5 IP X5 HP Nozzle NT 0680 NT 0680 Water inlet pressure bar 10 10 Water inlet temperature C 40 40 Water volume heat exchanger l 6 12 6 12 Fuel consumption dt 45K kg...

Page 11: ...1 phase 5 25 5 27 3 phase 5 42 5 49 5 57 Extended versions Standard models basket for accessories X models hose reel X2 models hose reel cable reel Pic 3 3 9 Pic 3 1 Neptune 7 C3 motor pump heat exch...

Page 12: ...draulic accumulator Anti stone valve Suction connection filter inside Water quantity regulator Pump oiltank Detergent A B valve Exhaust Detergent A B suction hose Fuel tank Detergent A tank Water tank...

Page 13: ...1l Fuel tank Detergent A tank Fuel tank gauge Fuel return pipe Fuel suction pipe Water tank Suction hose AntiStone tank Inlet valve B9 Frame 5 7 The frames of Neptune 5 and 7 are identical and built u...

Page 14: ...nnection terminals The cover plate is mounted with the main switch the display the temperature adjustment and five status warning lights Pic 3 6 The cover is sealed around the edge the manometer and t...

Page 15: ...F11 13 14 11 14 24 8 6 5 4 1 2 3 X11 MT Xma Xmb 9 7 Xma Xmb T2 M 1 M2 O N 1 2 X7 remote B8 B4 B6 B1 B9 S1 B7 K 1 K 2 Y 2 Y 1 B 2 M T B 3 2 4 V 8 V Electric system K1 K2 Fuse F2 Fuse F1 X2 datalogger...

Page 16: ...he combustion chamber An insulating material placed in the bottom of the heat exchanger makes sure that the inner bottom among other things is protected from superheating Water inlet Air distributor F...

Page 17: ...valve Oil Oil Motor shaft Crankshaft Motor Piston In Out Suction valve Pressure valve 15 Pump 7 5 The four piston axial pump C3 used in the Neptune 7 models is a compact unit with motor and pump buil...

Page 18: ...he plug icon only and the pressure gauge shows max pressure Now the machine is on stand by in cold water mode By switching to hot water mode the machine remains in stand by mode When the spray handle...

Page 19: ...lt code will be shown on the display When the machine and heat exchanger are operating properly the flame touches against the insulated bottom The temperature is here approximately 1100 C The hot exha...

Page 20: ...are driven by a wobble disc which transforms the rotating power from the rotor into the reciprocating pump pistons The angle of the disc and the diameter of the pistons decide the volume of water suc...

Page 21: ...y of the crank A and the diameter of the pistons decide the volume of water sucked into the suction valves and pressed out through the pressure valves The inlet and the outlet are connected directly t...

Page 22: ...is pressurized in the heat exchanger the high pressure hose and the HP chamber under the unloader valve piston When the unloader valve opens there is a lower pressure in the green area and the non re...

Page 23: ...microswitch B4 closes and starts the motor The pressure drops a little more but will build up until the working pressure approximately 165 bar in this example is reached As long as the spray handle is...

Page 24: ...motor stops B6 Oil level sensor stops the machine if the pump is low on oil Activates red light on panel B7 Flame sensor detects light of the flame If the flame is not detected when it should be the...

Page 25: ...sensors and 24 VAC to supply the actors contactor relay solenoid valve To run the machine on hot water the following must be o k on the front panel S1 and the temperature setting on hot and the spray...

Page 26: ...motor thermal protection switch may open and stop the motor 5 Variation in the mains voltage supply must be within 7 of the rated value at the machine long or undersized extension cords can be a prob...

Page 27: ...too hot 13 Fuel filter blocked 14 Air adjustment faulty 15 Fuel level low or water in fuel tank The require a systematic inspection of the motor pump by an ALTO technician In order to establish the re...

Page 28: ...ensor not in place Wire defective Oil residue in heat exchanger is burning Y1 Leaky Ignition failure Oil pressure Nozzle Electrode Flame sensor Ho M P t otor rotector Motor winding 160 C 320 F Pump pr...

Page 29: ...tion Connections in motor plug Change sensor B3 Transformer Transformer Level switch anti scale Micro switch setting Level switch oil Temperature sensor Level switch in fuel tank Go to power On Check...

Page 30: ...eased flue gas loss Other symptoms are that the machine smokes after it is warmed up during steady operation Cause 1 Air deficiency Remedy Check air adjustment and fan attachment to heat exchanger Cau...

Page 31: ...ending on the actual consumption A test of the water pressure should therefore be carried through when there is a heavy consumption The pressure must under no circumstances drop below 1 bar NB If the...

Page 32: ...Neptune_GB_Ver 2 0 10 03 _ 6 Service Repair Ke nn ey C3 Survey Unloader valve Page 31 Cylinder head Page 32 33 Cylinder block Page 34 35 Motor and wobble disc Page 36 37 30...

Page 33: ...m 2 25 Nm 18 24 Control Safety Block 31 The safety valve has been set at the factory and can t be adjusted Check that the printed pressure corresponds to the specification B2 If any pitting or scratch...

Page 34: ...the casting smile Tighten the eight 10 mm nuts with 27 Nm Dismount suction valve seat with a mandrel Now press out the pressure valve with a 2 mm punch Check the surface of the seats Mounting only by...

Page 35: ...bath for 3 4 hours before mounting them Do not forget to blow through the ducts and grease all sleeves before mounting Don t scratch the brass cylinder head when removing the old HP sleeves 33 Duct D...

Page 36: ...Rings over the threads will cause oil leaks Always replace LP sleeves when replacing HP sleeves Check that the ducts are clear Kit 16 consists of two new parts the crown back up ring and the thrust c...

Page 37: ...emove any coating Before mounting the new sleeves it will be a good idea to moisten the sleeves with soapy water Mount new oil sleeves with punch P N 1220429 Carefully knock or press them home Careful...

Page 38: ...al legs P N 1206150 1206168 Pic 6 7 Do not forget to remove key 5 before dismounting the D bearing cover Check bearing surfaces for wear If in doubt replace kit completely after approximately 2000 hou...

Page 39: ...with tool P N 1206598 which is placed on the shaft before placing the cover Check the bearing surfaces for wear As long as the surface is even and shiny without pitting or grooves the wobble disc can...

Page 40: ...Neptune_GB_Ver 2 0 10 03 _ 6 Service Repair Valve cover seals Page 40 41 Pistons oil seals Page 42 Pump h Page 43 ousing Motor Page 43 NP5 Survey 38 Control Safety Block Page 39...

Page 41: ...3 7Nm 2 Control Safety Block The safety valve has been set at the factory and can t be adusted Check that the printed pressure corresponds to the specification 25 Nm 39 B2 If any pitting or scratches...

Page 42: ...ing Pic 6 13 Pressure valve Pic 6 14 Suction valve Dismount the brass plug on the cylinder head with a 21mm fixed spanner and remove the valves Do not scratch the inside of the valve chamber during re...

Page 43: ...Pic 6 17 Removing LP sleeve 3 When dismounting the LP sleeves use a screwdriver to tip out the sleeves Pic 6 17 Do not re use the them 6 When you mount the cylinder head tighten the bolts in the show...

Page 44: ...ing O Ring Packing ring Distance spacer Also clean the distance spacer before re installing the plungers Do not re use the packing rings Use one drop of medium strength thread locker on each plunger r...

Page 45: ...windings have burned or broken 2 Cable connection from motor plug to stator has been broken 3 Flash over to frame 4 Bearings abnormally worn Pump house motor Replace the pump X completely if 1 The pum...

Page 46: ...on the floor press over to the side Pic 6 23 or protect the machine with a piece of cardboard Check the flame tube X and Y It is important that they are solid and complete Parts X and Y are part of th...

Page 47: ...ert remove the whole unit Don t forget to bring back float switch to operating position A after and make sure that the seal is in place 45 Pic Electrodes fuel nozzle 6 26 Pic Electrodes fuel nozzle 6...

Page 48: ...into the pump 1 Unscrew Quick GEKA coupling 2 Remove filter with tool and clean it 3 Clean filter at the pump inlet hose 1 Unscrew filter cap 1 2 Clean replace oil filter 2 3 Dispose of cleaning solut...

Page 49: ...fter 20 min in by pass mode Arestart is only possible with mainswitch S1 At the same time the ouput of the optional valve Y2 gets power for 10 s to release pressure at the HPoutlet Change temperature...

Page 50: ...to right Remove adjustment knob after removing cap not shown in Pic 7 2 it s on top of the adjustment knob Turn setscrew 7 to left until it no longer contacts intermediate piece 2 Dismount setscrew 5...

Page 51: ...on nut 8 counterclockwise Then turn union nut 8 to right until it contacts adjustment screw 1 Close gun and check function of microswitch 3 Lock union nut 8 with lock nut 6 Lock lock nuts 6 and 9 and...

Page 52: ...ch and a torque of 18 Nm 6 Disconnect fuel pressure gauge Caution Fuel nozzle Part number NEPTUNE 5 25 27 7 25 1 35 60 H 301001068 NEPTUNE 5 42 49 57 1 75 60 H 301000886 NEPTUNE 7 63 2 50 60 H 3010008...

Page 53: ...ster accumulation of soot on the heat exchanger coil 2 Caution The values dictated by National Emmissions Control Ordinances have to be kept By adjusting the air flap the soot CO and O values change W...

Page 54: ...8 3 6 7 5 7 14 8 8 17 5 12 5 25 1 51 150 moderately hard 2 2 3 128 180 7 6 10 5 14 21 17 5 26 3 25 1 37 6 151 300 hard 3 3 4 180 10 5 21 26 3 37 6 300 very hard 4 4 The ALTO AntiStone device is set at...

Page 55: ...red line Three of the motor wires are connected in a star point thick purple line The burner motor and ignition transformer are connected to this star point and therefore supplied with 230 V only The...

Page 56: ...X5 11 X5 7 X4 9 X4 5 U2 V2 W2 M 3 V1 W1 U1 M1 F11 13 14 11 14 24 8 6 5 4 1 2 3 X11 MT Xma Xmb 9 7 Xma Xmb T2 M 1 M2 71246 54 Switch on off Control transformer Ignition transformer Connector display bo...

Page 57: ...A1 A2 K2 3 K3 X12 C1 X11 2 11 14 24 4 C2 R1 X13 Xma Xmb 2 4 8 3 1 71250 1 phase 55 Control board Display board Temp sensor Flow switch Safety thermal switch Micro switch Level switch pump oil Light se...

Page 58: ...2 K1 1 0 2 S1 8a 7a 6a 5a 4a 3a 2a 1a 1 2 3 4 5 6 8 7 K1 S2 F11 11 14 24 1a 2a 2 1 7 6 MT 7 9 Xma XMb Xma XMb 3 1 2 4 5 6 8 71261 3 Star Delta 56 S1 S2 T1 T2 X3 X6 X2 X3 X6 X7 X11 Xma b Y1 Switch on o...

Page 59: ...r spare l l 17239 Soot comparison chart l l 17241 CO2 test liquid l l 17242 Exhaust air thermometer Manual l l 17243 Measurement suitcase l l 17246 Oil pressure testing l l 17249 CO2 measurement equip...

Page 60: ...001130 Extension kit hose cable reel l l 301001131 Extension kit cable reel l l 301001146 Piston kit dia 18 l 301001147 Piston kit dia 20 l 301001148 Piston sealing kit dia 18 l 301001149 Piston seali...

Page 61: ...e Neptune 5 Neptune 7 41455 Grease 15 C till 130 C 50 g tube l l Further material Table 9 3 Further material To lubricate sleeves O Rings and other parts always use the grease in table 9 3 Never use g...

Reviews:

No comments