NEPTUNE 5
NEPTUNE 7
Service Manual
Index
2. Technical 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 parts
57 - 59
Neptune_GB_Ver.2.0_10/03
Preface
Preface
This service manual contains a detailed description of the main repair work on the hot HPW
NEPTUNE 5 and NEPTUNE 7.
Repair work requires a suitable testing workplace with the necessary power supply.
If operating errors are evident, refer the customer to the operating instructions.
Afault in the cleaner can have several causes as described in the section on troubleshooting.
Refer to the illustrated 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 information on technical modifications
that have been made after this repair manual was printed.
“Service / Technical Information” sheets are also valid as a supplement to the spare parts list until
publication of a new edition.
Repair manuals and “Service / Technical Information” sheets should be available at the site where
repairs are carried out.
It is not permitted to give them to third parties.
Use originalALTO spare parts only.
1.
0.
Neptune_GB_Ver.2.0_10/03
1.
Safety instructions
Safety instructions
For your own safety
Observe valid safety regulations
for electrical equipment.In
particular, observe the following
regulations:
lEC 60335-2-69
EN 60335 -2-69
Additionally:
Also see national regulations.
Before using the cleaner, always
read the operating instructions
and keep them readily available.
Only allow the high pressure
cleaner to be used by persons
who have been trained in 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 discharge)
Take the following ESD precautions before carrying out any repairs to
the electronics:
• Touch the earth conductor before repairing the cleaner (to discharge
electrostatic charge from your body).
• Wear wrist band if necessary.
• Use a conductive floor covering or a conductive table cover.
• Never touch the printed circuit board or electronic components (always
hold at plastic).
• Transport electronic components in conductive packaging (e.g. ESD
bag).
2.
Neptune_GB_Ver.2.0_10/03
2.
Technical data
3.
Table 1.1: Neptune 5-25 / 5-27
Neptune 5-25 / 5-27
NEP TUNE 5-25 / GB NEP TUNE 5-27 / EU
Water volume Q
max
l/h 720 700
Water volume Q
IEC l/h/ l/min. 660/11 630/10,5
Pressure P1 (working pressure) bar 90 110
Pressure P2 / Q2 bar / l/min. 25 / 6,7 25 / 6,7
Pressure Pmax. I bar 200 200
Pressure P max. II bar 32 32
Temperature t max. I / II °C 80 / 140 80 / 140
Heating power kW 62 62
Electrical data V/Ph/Hz/kW 230-240/1/50/3 230-240/1/50/3,3
Current consumption 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 l 4,78 4,78
Fuel consumption dt=45K kg/h 3,2 3,2
Oilpressure bar 12 12
Flue gas temperature °C 170 170
C0
2
content min. % 12 12
Soot rating 0-1 0-1
Efficiency burner % >92 >92
Sound pressure 1m dB(A) 71,8 71,8
Sound power LWA dB(A) 86,9 86,9
Reactive force N 25 26
Motor 1 ~ 1 ~
RPM 1/min 1450 1450
Piston Ceramic Ceramic
Piston diameter mm 18 18
Stroke mm 9,8 9,8
Pump oil SAE 15W40 SAE 15W40
Pump oil quantity l 1 1
Weight kg/h 175 175
L x W x H mm 1150/702/987 1150/702/987
Neptune_GB_Ver.2.0_10/03
2.
Technical data
4.
Table 1.2: Neptune 5-42
Neptune 5-42
NEP TUNE 5-42 / NO, BE NEP TUNE 5-42 / EU
Water volume Q
max
l/h 860 860
Water volume Q
IEC l/h / l/min. 800 / 13,3 800 / 13,3
Pressure P1 (working pressure) bar 170 170
Pressure P2 / Q2 bar / l/min. 25 / 6,7 25 / 6,7
Pressure Pmax. I bar 250 250
Pressure P max. II bar 32 32
Temperature t max. I / II °C 80 / 140 80 / 140
Heating power kW 80 80
Electrical data V/Ph/Hz/kW 230-400/3/50/5,6 400-415/3/50/5,6
Current consumption 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 4,78 4,78
Fuel consumption dt=45K kg/h 3,9 3,9
Oilpressure bar 12 12
Flue gas temperature °C 170 170
C0
2
content min. % 12 12
Soot rating 0-1 0-1
Efficiency burner % >92 >92
Sound pressure 1m dB(A) 73,8 73,8
Sound power LWA dB(A) 88,8 88,8
Reactive force N 42 42
Motor 3 ~ 3 ~
RPM 1/min 1450 1450
Piston Ceramic Ceramic
Piston diameter mm 18 18
Stroke mm 12,8 12,8
Pump oil SAE 15 W 40 SAE 15 W 40
Pump oil quantity l 1 1
Weight kg/h 180 180
L x W x H mm 1150/702/987 1150/702/987
Neptune_GB_Ver.2.0_10/03
2.
Technical data
Table 1.3: Neptune 5-49
Neptune 5-49
NEP TUNE 5-49 / NO, BE NEP TUNE 5-49 / EU
Water volume Q
max
l/h 970 970
Water volume Q
IEC l/h / l/min. 900 / 15 900 / 15
Pressure P1 (working pressure) bar 180 180
Pressure P2 / Q2 bar / l/min. 25 / 6,7 25 / 6,7
Pressure Pmax. I bar 250 250
Pressure P max. II bar 32 32
Temperature t max. I / II °C 80 / 140 80 / 140
Heating power kW 80 80
Electrical data V/Ph/Hz/kW 230-400/3/50/6,9 400-415/3/50/6,9
Current consumption A 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 4,78
Fuel consumption dt=45K kg/h 4,3 4,3
Oilpressure bar 12 12
Flue gas temperature °C 170 170
C0
2
content min. % 12 12
Soot rating 0-1 0-1
Efficiency burner % >92 >92
Sound pressure 1m dB(A) 75,8 75,8
Sound power LWA dB(A) 90,2 90,2
Reactive force N 47 47
Motor 3 ~ 3 ~
RPM 1/min 1450 1450
Piston Ceramic Ceramic
Piston diameter mm 18 18
Stroke mm 14,6 14,6
Pump oil SAE 15 W 40 SAE 15 W 40
Pump oil quantity l 1 1
Weight kg/h 184 184
L x W x H mm 1190/702/987 1190/702/987
5.
Neptune_GB_Ver.2.0_10/03
2.
Technical data
NEPTUNE 5-57 / NO, BE NEPTUNE 5-57 / EU
Water volume Q
max
l/h 1080 1080
Water volume Q
IEC l/h / l/min. 1000 / 16,7 1000 / 16,7
Pressure P1 (working pressure) bar 200 200
Pressure P2 / Q2 bar / l/min. 25 / 6,7 25 / 6,7
Pressure Pmax. I bar 250 250
Pressure P max. II bar 32 32
Temperature t max. I / II °C 80 / 140 80 / 140
Heating power kW 80 80
Electrical data V/Ph/Hz/kW 230-400/3/50/7,9 400-415/3/50/7,9
Current consumption A 24,8 14,3
Fuse (slow blow) A 32 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 4,78
Fuel consumption dt=45K kg/h 4,8 4,8
Oilpressure bar 12 12
Flue gas temperature °C 170 170
C0
2
content min. % 12 12
Soot rating 0-1 0-1
Efficiency burner % >92 >92
Sound pressure 1m dB(A) 74,1 74,1
Sound power LWA dB(A) 89,1 89,1
Reactive force N 55 55
Motor 3 ~ 3 ~
RPM 1/min 1450 1450
Piston Ceramic Ceramic
Piston diameter mm 20 20
Stroke mm 12,8 12,8
Pump oil SAE 15 W 40 SAE 15 W 40
Pump oil quantity l 1 1
Weight kg/h 184 184
L x W x H mm 1150/702/987 1150/702/987
Table 1.4: Neptune 5-57
Neptune 5-57
6.
Neptune_GB_Ver.2.0_10/03
2.
Technical data
Table 1.5: Neptune 7-25
Neptune 7-25
NEPTUNE 7-25 / GB
W ater volum e Q
max
l/h 720
W ater volum e Q
IEC l/h / l/min. 660 / 11
Pressure P1 (working pressure) bar 90
Pressure P2 / Q2 bar / l/min. 25 / 6,7
Pressure Pm ax. I bar 200
Pressure P m ax. II bar 32
Tem perature t m ax. I / II °C 80 / 140
Heating power kW 80
Electrical data V/Ph/Hz/kW 230-240/1/50/3
Current consum ption A 13
Fus e (s low blow) A 13
International Protection Class IP X5
HP-Nozzle NT 0550
W ater inlet pressure bar 10
W ater inlet temperature °C 40
W ater volum e heat exchanger l 4,78
Fuel consum ption dt=45K kg/h 3,2
O ilpres s ure bar 12
Flue gas temperature °C 170
C0
2
content m in. % 12
Soot rating 0-1
Efficiency burner % >92
Sound pressure 1m dB(A) 72,5
Sound power LW A dB(A) 87,6
Reactive force N 25
Motor 1~
RPM 1/min 1450
Piston Ceramic
Piston diam eter mm 24
W obble disc #1
Pump oil Alphasyn-T ISO 150
Pum p oil quantity l 1
W eight kg/h 189
L x W x H m m 1150/702/987
7.
Neptune_GB_Ver.2.0_10/03
2.
Technical data
NEPTUNE 7-63 / NO, BE NEPTUNE 7-63 / EU
Water volume Q
max
l/h 1260 1260
Water volume Q
IEC l/h / l/min. 1170 / 19,5 1170 / 19,5
Pressure P1 (working pressure) bar 175 175
Pressure P2 / Q2 bar / l/min. 25 / 6,7 25 / 6,7
Pressure Pmax. I bar 250 250
Pressure P max. II bar 32 32
Temperature t max. I / II °C 100/140 100/140
Heating power kW 115 115
Electrical data V/Ph/Hz/kW 230-400/3/50/8,3 400-415/3/50/8,3
Current consumption A 23,4 13,5
Fuse (slow blow) A 25 16
International Protection Class IP X5 IP X5
HP-Nozzle NT0680 NT0680
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/h 5,6 5,6
Oilpressure bar 12 12
Flue gas temperature °C
C0
2
content min. % 12 12
Soot rating 0-1 0-1
Efficiency burner % >92 >92
Sound pressure 1m dB(A) 76,6 76,6
Sound power LWA dB(A) 91,7 91,7
Reactive force N 61 61
Motor 3 ~ 3 ~
RPM 1/min 1450 1450
Piston Ceramic Ceramic
Piston diameter mm 24 24
Wobbledisc #12 #12
Pump oil Alphasyn-T ISO 150 Alphasyn-T ISO 150
Pump oil quantity l 1 1
Weight kg/h 217 217
L x W x H mm 1150/702/1020 1150/702/1020
Table 1.6: Neptune 7-63
Neptune 7-63
8.
Neptune_GB_Ver.2.0_10/03
3.
Construction
Neptune5/7
In this manual two different models are described: the NEPTUNE 5 and the NEPTUNE 7. The two
models are built with the same frame and cabinet.
Visually they are different on two points - the height of the heat exchanger and the type of motor pump
used.
NEPTUNE 7 variants
1 phase: 7-25*
3 phase: 7-63*
NEPTUNE 5 variants
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 exchanger)
Pic. 3.2: Neptune 5 (NP5 motor pump & heat exchanger)
(*) These
numbers
refer to the theoretical total impact spraying water calculated by
the formula:
Impact = 0.024 x (l / min at max pressure) x Ö (nozzle pressure (bar) / 0.981)
Pic. 3.3: Neptune X2-model
Hose reel
Cable reel
Heat
exchanger
(115 kW)
4 piston axial
C3 motor pump
Heat
exchanger
(80 kW)
3 piston radial
NP5 motor pump
Neptune_GB_Ver.2.0_10/03
3.
Construction
Fuel gauge
Pressure gauge connection
Fuel suction pipe
Fuel return pipe
Temperature
safety switch
Flame sensor
Fuel nozzle connection
Temperature sensor
Ignition transformer
Control Safety Block
Hydraulic
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
With the service doors open there is free access to all technical parts that require service (Pic.
3.4 and Pic 3.5).
Fuel pump
Service side
Pipe for lifting hook
and service crane
10.
OUT
IN
Pic. 3.4: Neptune top view
Pic. 3.5: Neptune
side view
Neptune_GB_Ver.2.0_10/03
3.
Construction
5
A
n
t
i-
S
t
o
n
e
8
4
6
6
(
6
x
1
l.)
Fuel tank
Detergent A tank
Fuel tank gauge
Fuel return pipe
Fuel suction pipe
Water tank
Suction hose
AntiStone tank
Inlet valve
B9
Frame5/7
The frames of Neptune 5 and 7 are identical and built up in a straightforward form, all bolted
together (see drawings).
11.
Neptune_GB_Ver.2.0_10/03
3.
Construction
Operator side
Display:
- Temperature setting
- Error message
- Running hours
- Sevice interval setting
Main switch S1:
Off / Cold / Hot
S1 main
switch
Detergent A/B valve
Data plate
Display board A2
Sealing
Sealing
The electric box contains the control board, the transformer, relays, fuses and
connection 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 the detergent valve (Pic. 3.7).
.
(Pic. 3.8)
The cover is hinged in the lower left side and secured with a strap to avoid stress on the display
connection cable.
Adjust:
- Temperature setting
- Service intervals
12.
Operation
Fuel
Pump oil
Service
Anti Stone
Pic. 3.6: Operator panel
Pic. 3.7: Operator panel (backside)
Pic. 3.8: Electrical box
Neptune_GB_Ver.2.0_10/03
3.
Construction
A1
B8
B9
S1
A2
12
S1
1a
1
2a
2
T1
Q
A1
A2
K1
A1
A2
K2
135
246
PE
L2 L3L1
Y1
B2
B3
11 7
414
13
12
8V AC
24V AC
400V AC
F1
F2
5V DC
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
~+
U2
V2
W2
M
3~
V1
W1
U1
M1
F11
13
14
11
14, 24
8 654 123
X11
MT
Xma Xmb
9
7
Xma
Xmb
T2
M
1~
M2
ON
12
X7: remote
B8 B4 B6 B1
B9 S1 B7
K1 K2 Y2
Y1 B2 MT B3 24V 8V
Electric system
K1
K2
Fuse F2
Fuse F1
X2: datalogger
X1a: display
Transformer T1
The electric control system is built up around the control board A1 (Pic. 3.10) which is divided
into two systems, a 5 VDC system on one side to supply the sensors B8, B4, B6, B1, B9, B7 and
on the other side 24 VAC, which supplies the actors (contactor, relay, solenoid valve).
The transformer T1 (Pic. 3.9) supplies the system with 24 VAC and 8 VAC.
13.
Fuse F11
More details about all sensors and the electrical system see page 22 / 23.
Pic. 3.10: PCB A1
Pic. 3.9: Electrical box
Neptune_GB_Ver.2.0_10/03
3.
Construction
1
2
3
4
5
Heat exchanger
The heat exchanger is the heat generating part of a hot water machine. It consists of a labyrinth-
constructed tube coil, which encloses the combustion chamber. The tube coil is enclosed by a
double container with boiler jacket, bottom and top in a sandwich construction, between which
the pre-heated air is routed into the 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
Flame sensor
Electrodes
Fuel nozzle
Exhaust
Water outlet
Burner tube top plate
Burner tube
Flame tube top part
Flame tube
Inner jacket
Outer jacket
Isolation (firebrick)
Isolation (ceramic fibres)
Mounting plate
Fixation spacer
14.
Note the heat exchanger tube arrangement in the the outer circle where the tube change position
onitswayup(1-2-3-4-5)toequalize the water temperature.
Neptune_GB_Ver.2.0_10/03
3.
Construction
A
K
e
n
n
e
y
K
e
n
n
e
y
Fan
Rotor
Stator
Wobble disc
Piston
Out
In
Pressure
valve
Suction
valve
Oil
Oil
Motor shaft
Crankshaft
Motor
Piston
In
Out
Suction valve
Pressure valve
15.
Pump7/5
The four piston axial pump C3 used in the Neptune 7 models is a compact unit with motor and
pump built together in line (axial).
The three piston radial pump NP5 used in the Neptune 5 models is a compact unit with motor and
pump.
4.
Function
Neptune_GB_Ver.2.0_10/03
Start cold water mode
Start hot water mode
Display
Temperature setting
Detergent valve A / B
Pressure gauge
Status indicators
If the machine and power supply are o.k. (depending on the electronic set-up) following will
happen doing start up:
When the main switch S1 is turned on to cold or hot water mode, the machine runs a self test (3
dashes are shown in the display). Optionally it’s possible to show the actual running hours of the
pump for 5 seconds by setting a jumper on X9 on PCB A1 before the self test.
Afterwards the motor will start building up pressure until cut off pressure and then by-pass for 20 s
before it stops. After the self test procedure the display shows the temperature setpoint C or F
(depending on dip switch setting on PCB A1).
The status indicator lights up the green light on the 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 is activated, the pump will deliver water. At the same time the fan for the
burner starts ventilating the combustion chamber for 3 s before fuel is pumped into the heat
exchanger and the combustion starts.
The water temperature will now raise until the setpoint has been reached. The combustion stops,
when the actual temp. value exceeds the setpoint, but the fan and ignition are still working. When
the temperture falls short of the setpoint combustion kicks-off again.
The detergent valve makes it possible to choose between detergent A from the built in tank or
detergent B from a canister. With the valve in off position as shown it draws in water from the
water break tank to clean the valve and the hose to the pump.
°°
Main switch S1
16.
Detergent
B
Detergent
A
Connected to water tank
Suction from pump
Pic. 4.1: Operator panel
Operation
4.
Function
Neptune_GB_Ver.2.0_10/03
Heat exchanger
In hot water mode f combustion is
required, fuel
fuel is drawn from the tank through the fuel filter to the pump. I
passes through the magnetic solenoid valve to the nozzle in the air distributor. Fuel
is returned to the tank if combustion is not required.
The ignition transformer is active in hot water mode and it will form sparks between the
electrodes. If the flame is not developed when it should be, a flame sensor placed on top of the
boiler will secure that the fuel pump is automatically stopped and a fault 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 exhaust gas is forced
further round the labyrinth-shaped combustion chamber, where the heat is absorbed by the water
in the tubes.
When the machine is running in hot water mode the fan draws in air and leads it into the side of
the heat exchanger around and between the two jackets up to the air distributor. On the way, the
air is preheated before it is mixed with the oil spray from the nozzle.
The cold water enters the boiler at the inner winding where the temperature is highest. By doing
so, it will minimize the condensation of water on the surface of the tube.
17.
4.
Function
Neptune_GB_Ver.2.0_10/03
K
e
n
n
e
y
Fan
Rotor
Stator
Wobble disc
Piston
Out
In
Oil
C3 pump
The C3 four piston axial pump used in the NEPTUNE 7 models
The four ceramic pistons 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 sucked through the suction valves and pressed out through the
pressure valves.
The inlet and the outlet are connected directly to the Control Safety Block.
Pressure
valve
Suction
valve
18.
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