NEPTUNE 5 NEPTUNE 7
Contents
1. Dismount circlip ring 4 The wobble disc C is easily dismountable with puller P N 1205715 and special 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 hours Neptune GB _Ver 2 0_10 03 36 Motor Wobble disc 2 When mounting the D bearing cover completely protect the U A sleeve with tool P N 1206598 which is placed on the shaft before Noe Placing the cover Tool 1206598 Pic 6 9 Exploded view of wobble disc and its bearings When mounting the wobble disc lubricate the bearings with oil The big axial roller bearings 1 and 2 are identical Do not forget to mount the circlip ring 3 on the shaft Refill with 1 oil type Castrol Alphasyn T ISO 150 or BP Bartran HV ISO 100 Pic 6 10 Wobble disc amp bearings Pic 6 11 Bearing track amp piston Check the bearing surfaces for wear As long as the surface is even and shiny without pitting or grooves the wobble disc can be re used NB The illustrated bearing track Pic 6 11 has been working for more than 3000 hours with a pressure of 1802. A1 Datalogger 5 VDC F1 B B4 y x55 F A x5 7 i A X5 11 XY AZ B7 S g4 O uP an Bior e B8 Y X5 1 D A x53 B9 Y X6 1 a X6 3 S1 Y X6 6 i A X6 7 L X1a aia X1b X7 T Remote 3 Star 11246 v m L1 L2 L3 A Operation Neptune_GB_Ver 2 0_ 10 03 Fuel Display Z 47 7 y7 Pump Oil Service Anti Stone Processor board Display board Temp sensor 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 pr a ae te 1 l3 5 13 ee on 2 4 l6 14 F11 A1 11 K2 a ea es l A2 i 14 24 I Lea hi l M lt D B r7 db l I X11 s5 l l l Switch on off Control transformer Ignition transformer Connector display board Pin contacts 5 pol datalogger Terminal strip Connector remote control Concentration terminal Motor connector Solenoid valve 54 X5 13 e X5 15 A1 sl 5 VDC pots X5 7 X5 9 B7 X5 11 X6 11 X5 1 X6 1 j X6 3 S1 4 X6 6 Display PPE EE A1 Control board A2 Display board B1 Temp sensor B2 Flow switch
3. xt X7 l Remote eL Temp Display Y7 yh y7 yA y Operation Fuel u i Anti Stone More details about all sensors and the electrical system see page 22 23 Neptune _ GB _Ver 2 0_10 03 13 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 Flame sensor Electrodes Air distributor Ue NOZZE Exhaust Water outlet Water inlet __ dob a ja A R l lt Burner tube top plate Flame tube top part ii Burner tube Outer jacket Flame tube Inner jacket J plate p S Isolation ceramic fibres Isolation firebrick Note the heat exchanger tube arrangement in the the outer circle where the tube change position on its way up 1 2 3 4 5 to equalize the water temperature Neptune GB Ver 2 0_10 03 14 ALTO Construction Pump 7 5 The four piston axial pump C3 used in the Neptune 7 models is a compact unit with motor and pump
4. bar bar I min bar bar Ex 33 170 25 6 250 32 80 140 80 230 400 3 50 5 6 15 8 20 IP X5 NT 0450 10 40 4 78 3 9 12 170 12 0 1 gt 92 73 8 88 8 42 3 1450 Ceramic 18 12 8 SAE 15 W 40 1 180 1150 702 987 mae m5 170 25 6 7 250 32 80 140 80 400 415 3 50 5 6 9 1 16 IP X5 NT 0450 10 40 4 78 3 9 12 170 12 0 1 gt 92 73 8 88 8 42 3 1450 Ceramic 18 12 8 SAE 15 W 40 1 180 1150 702 987 ALTO Technical data 2 Neptune 5 49 ___ _ NEPTUNE 5 49 NO BE NEPTUNE 5 49 EU _ Water volume Qmax 970 Water volume Qtec E TAE mn 15 900 15 Pressure P1 working pressure bar 180 180 Pressure P2 Q2 bar min 25 6 7 251 6T Pressure Pmax bar 250 250 Pressure P max Il bar 32 32 Temperature t max I Il 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 2E 125 Fuse slow blow A 25 16 International Protection Class IP X5 IP X5 HP Nozzle NT 0550 NT 0550 Water inlet pressure 10 10 Water inlet temperature 40 40 Water volume heat exchanger 4 78 4 78 Fuel consumption dt 45K 4 3 4 3 Oilpressure 12 12 Flue gas temperature 170 170 C0 content min 12 12 Soot rating 0 1 0 1 Efficiency burner gt 92 gt 92 Sound pressure 1m 75 8 75 8 Sound power LWA 90 2 90 2 Reactive force 47 47 Motor sia Sia RPM i 1450 1450 Piston Ceramic Ceramic Piston diameter 18 18 Stroke 14 6 14 6 Pump oil SAE 1
5. The internal faults require a systematic inspection of the motor pump by an ALTO technician In order to establish the reason of the fault with certainty it may be a help to use the yes no diagram or the flowchart on page 29 Neptune_GB_Ver 2 0 10 03 25 Trouble shootin Error codes Display Symptom Outer Cause Inner Check Hot Safety temperature switch B3 Wire defective opens when temp is higher than 106 C 222 F Pump Oil Low Switch B6 open Light sensor B7 sees Light when Y1 is not activated Flame sensor short circuit Cold water operation not possible Hot Motor Protector HOP Motor winding gt 160 C 320 F Flow Failure No Light Fuel Enabled Light sensor B7 sees no flame when Y1 is open Flow switch open B2 and FLG microswitch B4 close Fuel Empty Level switch B9 Open Leakage Three times start without flow Microprocessor failure Temperature Sensor B1 Open Temperature Sensor B1 Closed Neptune_GB _ Ver 2 0_10 03 Fre Flow switch B2 closed and B4 open Use of long hoses at steam with leaky valves Wire defective Sensor not in place Wire defective Pump pressure too high Temp in room gt 40 C 104 F Wire defective Wire defective Spark failure Oil filter blocked soot on glass Wire defective Leaky system Water in electric system Wire defective Wire defective Air in suction wat
6. Water inlet pressure Water inlet temperature Water volume heat exchanger Fuel consumption dt 45K Oilpressure Flue gas temperature C0 content min Soot rating Efficiency burner Sound pressure 1m Sound power LWA Reactive force Table 1 1 Neptune 5 25 5 27 Neptune_GB_ Ver 2 0_ 10 03 ET TR EOT 11 bar bar I min bar 80 140 62 230 240 1 50 3 NT 0530 10 40 4 78 3 2 12 170 12 0 1 gt 92 71 8 86 9 25 1 1450 Ceramic 18 9 8 SAE 15W40 1 175 1150 702 987 or JTE 110 25 6 7 200 32 80 140 62 230 240 1 50 3 3 14 8 16 IP X5 NT 0450 10 40 4 78 3 2 12 170 12 0 1 gt 92 71 8 86 9 26 1 1450 Ceramic 18 9 8 SAE 15W40 1 175 1150 702 987 ALTO Technical data Neptune 5 42 eee SRE a Pees HAMEN Water volume Qmax Water volume Qc Pressure P1 working pressure Pressure P2 Q2 Pressure Pmax Pressure P max Il Temperature t max Il Heating power Electrical data Current consumption Fuse slow blow International Protection Class HP Nozzle Water inlet pressure Water inlet temperature Water volume heat exchanger Fuel consumption dt 45K Oilpressure Flue gas temperature CO0 content min Soot rating Efficiency burner Sound pressure 1m Sound power LWA Reactive force Motor RPM Piston Piston diameter Stroke Pump oil Pump oil quantity Weight LxWxH Table 1 2 Neptune 5 42 Neptune_GB_ Ver 2 0_ 10 03 l h 7 TAR
7. Water volume heat exchanger 6 12 6 12 Fuel consumption dt 45K 5 6 5 6 Oilpressure 12 12 Flue gas temperature 12 12 0 1 0 1 Efficiency burner gt 92 gt 92 Sound pressure 1m 76 6 76 6 Sound power LWA 91 7 91 7 Reactive force 61 61 Motor 3 Sa RPM 1450 1450 Piston Ceramic Ceramic Piston diameter 24 24 Wobble disc 12 12 Pump oil Alphasyn T ISO 150 Alphasyn T ISO 150 Pump oil quantity 1 1 Weight 217 217 LxWxH 1150 702 1020 1150 702 1020 Table 1 6 Neptune 7 63 Neptune GB Ver 2 0 10 03 8 Neptune 5 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 ii 1 Stone 3 piston radial __ 3 motor pump NP5 motor pump Pic 3 1 Neptune 7 C3 motor pump amp heat exchanger Pic 3 2 Neptune 5 NP5 motor pump amp heat exchanger NEPTUNE 7 variants NEPTUNE 5 variants 1 phase 7 25 1 phase 5 25 5 27 3 phase 7 63 3 phase 5 42 5 49 5 57 Extended versions Standard models basket for accessories X models hose reel X2 models hose reel amp cable reel Pic 3 3 Neptune GB Ver 2 0 10 03 9 Service side With the service doors open there is free access to all technical parts that require service Pic 3 4 and Pic 3 5 Fuel suction pipe Fuel gauge Fuel return pipe Pressure
8. B3 Safety thermal switch B4 Micro switch B6 Level switch pump oil B7 Light sensor B8 Level switch AntiStone B9 Level switch fuel C1 Operating capacitor C2 Startingcapacitor F1 F2 F11 Fuse K1 Contactor K2 Relay K3 Starting relay M1 Motor 1 M2 Burner motor MT Temp switch motor Neptune_GB_Ver 2 0_ 10 03 X11 X12 X13 Xma b Y1 1 phase 71250 bea Le Discharge resistor Switch on off Control transformer Ignition transformer Connector display board Pin contacts 5 pol datalogger Terminal strip Connector remote control Terminal Concentration terminal Motor connector Solenoid valve 55 A1 Datalogger X2 SEA B1 3 Star Delta 11261 L1 L2 L3 PE X4 11 X5 11 Xma XMb B7 g tt y y y y7 y Pump Oil Servi Anti Stone A1 Processor board S1 A2 Display board S2 B1 Temp bensor T1 B2 Flow switch T2 B3 Safety thermal switch X3 X6 B4 Micro switch X2 B6 Level switch pump oil X3 X6 B7 Light sensor X7 B8 Level switch AntiStone X11 B9 Level switch fuel Xma b F1 F2 F11 Fuse Y1 K1 Contactor K2 Relay M1 Motor 3 M2 Burner motor MT Temp switch motor Neptune_GB_Ver 2 0_ 10 03 l l l l l l 1 13 sl 13 17 14 18 Switch on
9. GB Ver 2 0_10 03 29 ALTO service Repair 6 C3 Survey SAN ITT ITA a j NLLLL L 111 A D7 yee DON YE goen non q N BARRE SS OSs BS N N NANN 2 Unloader valve Page 31 Cylinder head Page 32 33 Cylinder block Page 34 35 Motor and wobble disc Page 36 37 30 Neptune_GB_ Ver 2 0_ 10 03 ALTO If any pitting or scratches are found on the unloader piston and seat or on the non return valve and seat these parts must be renewed The safety valve has been set at the factory and can t be adjusted Check that the printed pressure corresponds to the specification 25 Nm _ _
10. and parts necessary for service and maintenance For a detailed view have a look in the spare parts list of Neptune 5 7 P N 301001054 Neptune_GB Ver 2 0_ 10 03 58 Further material Zz 41455 Grease 15 C till 130 C 50g ele tube Table 9 3 Further material To lubricate sleeves O Rings and other parts always use the grease in table 9 3 Never use grease containing silicon for parts that get in touch with water Neptune_GB Ver 2 0_ 10 03 59
11. cover Mount the lifting tool over the two coil ends and fix it with the nuts Dismount the 4 jf nuts see arrows at Pic 6 21 hook up the crane and lift out the coil Pic 6 22 When landing on the floor press over to the side Pic 6 23 or protect the machine with a piece of cardboard Pic 6 21 Hooking up the heat exchanger coil Pic 6 23 Bringing down the heat exchanger coil Attention Be aware of the fact that the machine can tip over Keep the coil close to the machine Pic 6 22 Lifting up the heat ETE coil Check the flame tube X and Y It is important that they are solid and complete Parts X and Y are part of the coil 8 and can t be separated Clean the coil with an alkaline detergent by using high pressure Afterwards rinse with clear water Pic 6 oA EA look meds thie coil from underneath Pic 6 25 Aok inside the heat exchanger jacket from top Clean up deposits and change the isolation 9 if needed Neptune GB Ver 2 0_10 03 44 Pic 6 26 Electrodes amp Pic 6 27 Electrodes amp fuel nozzle fuel nozzle To insert and remove tank meter carefully pull back Gees SUCtION pipe dont bend it aera Float switch moves from point A to B Pic 6 28 Also make sure to pull back the cable of the float switch Now insert remove the whole i unit Don t forget to bring I back float switch to operating position A after and make sure that the s
12. gauge connection safety switch z TZA a gt IN ag Flame sensor Fuel nozzle connection Temperature sensor Pic 3 4 Neptune top view Pipe for lifting hook Ignition transformer and service crane Detergent A B valve Exhaust 7 Fuel tank A r at Fuel pump Tem Anti stone valve Water tank Os Detergent A tank Hydraulic accumulator me Pic 3 5 Neptune Detergent A B suction hose Pump oiltank side view Control Safety Block Suction connection filter inside Water quantity regulator Neptune GB _Ver 2 0_10 03 10 ALTO Construction Frame 5 7 The frames of Neptune 5 and 7 are identical and built up in a straightforward form all bolted together see drawings Fuel return pipe Fuel tank m7 Fuel suction pipe AntiStone tank Fuel tank Detergent A tank Neptune GB Ver 2 0 10 03 11 Operator side The electric box Pic 3 8 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 Display Temperature setting Error message O Operation Running hours Fuel Sevice interval setting O Anti Stone a Service p amd Li Pump
13. lock nut slowly turn adjustment screw g 5 to right until machine shuts off Then turn 2 3 4 additional turns in the same direction Lock adjustment screw 5 with nut and sealing paint 6 N UUs SN Check After closing gun the lever of the microswitch does not touch the housing Adjusting minimum operating pressure nam Turn adjustment screw 1 to left until minimum operating pressure is reached see Table 7 1 If 5 necessary loosen lock nut 6 and turn union nut 8 a counterclockwise Then turn union nut 8 to right until it contacts j 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 seal with sealing paint Fitadjustment knob and secure with cap Also lock cap with sealing paint Turn Control Safety Block to max pressure Work after adjustments Remove test bolt and mount safety valve 4 Check function at high pressure Remove jumper on X10 and close electrical box Set dip switch 1 back to O only if temperature indication has to be set to F Note Flow sensor needs to be adjusted with the burner in operation see burner adjustment procedure Neptune GB Ver 2 0 10 03 49 Heat exchanger adjustment Adjusting the burner 1 Remove heat exchanger at least once a year and clean it with high pressure and an alkaline detergent Combi aktiv 2 Descale coil if n
14. nut Torque 13 Nm Distance spacer Oil seal 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 rod when re installing hexagon nut and a torque of 13 Nm Oil seals must be changed if there are any signs of leaks or if they are removed The recommended way to remove the oil seals which are pressed into the pump body is to puncture the seal with an awl and pry down When installing new seals a light coating of lubricant on the seals may ease the installation Make sure it is pressed in using equal pressure around the entire circumference Neptune GB Ver 2 0_ 10 03 42 ALTO Service Repair Pump house amp motor Replace the motor completely if 1 One or more 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 Replace the pump X completely y if Is Q YY 1 1 The pump has been running without oil or with water in oil 2 The bearings are abnormally worn Neptune GB Ver 2 0_10 03 43 Heat exchanger removal With a special designed service crane P N 301001078 it s no longer necessary to remove the coil by hand Just put up the crane to the central tube and disconnect all connections attached to the heat exchanger and burner Then remove burner and outer heat exchanger
15. 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 56 ALTO special tools Spare parts 9 Special tools P N Name comparison chart 17243 17246 Oil pressure testing 1 1249 CO measurement equipment with Oe etestigue 1206150 1206168 49473 60141 Pressure gauge HP hose test pressure gauge Table 9 1 Special tools With the datalogger P N 301000 383 you can read out motor starts motor running hours run mode by pass mode burner running hours and the current service intervall The CO measurment equipment P N 1220429 is a manual measuring instrument Nowadays there s electronic equipment available like the TESTO 352 2 plus flue gas sensor 352 2 that makes it much easier to measure all relevant data incl temperature Neptune_GB Ver 2 0_ 10 03 57 ALTO special tools Spare parts 9 Spare parts 62730 Safety valve compl 200 bar 1 49 7 25 111957 0 1119571 Repair kit gasket 0 111982 301001130 Extension kit hose cable reel 30100113 301001146 Piston kit dia 18 301001147 Piston kit dia 20 301001148 Piston sealing kit dia 18 301001149 Piston sealing kit dia 20 301001153 Valve kit for pump 6x Repair kit CSB 5 57 7 63 Table 9 2 Spare parts Table 9 2 includes all important repair kits
16. oil Main switch 1 6 Off Cold Hot pTO Adjust NEPTUNE gaye Temperature setting Service intervals Py on fs ff SB HS a Pic 3 6 Operator panel S1 main switch Detergent A B valve The cover is hinged in the lower left side and secured with a strap to avoid stress on the display connection cable Neptune_GB_ Ver 2 0_ 10 03 12 Electric system 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 XT remote X2 datalogger S ye Fuse F11 Pic 3 9 Electrical box Fuse F2 Fuse F1 A1 a T1 sa PE L1L21L3 Datalogger 5V DC F1 ee S1 T l X2 i La 4 o ve t B1 X4 23 12 Ol OEE X4 17 13 4oovac i l q X5 15 l X4 19 AMAS a ie k Nt X l B4 X5 5 J X4 15 xt I l i ai A x5 7 A aS B6 Y X5 9 Ez Y x9 MT l l A X5 11 Xma Xmb l B7 P aa ae coal oe j A1 l 1 3 5 13 eye a ee Rr L aaa a a i I i 4 J6 A 14 7 O X5 3 x5 B2 B9 Y X61 ma i E o z o r T p 14 24 A X6 3 AV l s1 h M2 T2 X4 3 A a TO 4a l L X3 7 a L aa 2 X1a EA en
17. the inlet to the heat exchanger Switches off the machine if temperature becomes gt 106 C 222 F Will switch off if the burner keeps burning without water flow through the heat exchanger Can not be reset but must be replaced after correcting the fault B4 NC Microswitch controls the motor start stop When pressure is higher than working pressure the switch will open and the 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 machine will be stopped B8 Level switch AntiStone liquid If low yellow light will light up B9 Level switch fuel stops the fuel valve when low on fuel and yellow light appears on the panel MT Temperature switch stops the motor if the temperature in the windings becomes gt 160 C 320 F Automatic reset of MT S1 Main switch Functions on off cold water mode hot water mode Actors T2 Ignition transformer is on when burner fan is running Y1 Solenoid opens closes the fuel for the burner 22 Electric system The machine is supplied with main power which is transformed into 8 VAC to supply the microprocessor and 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 an
18. 3 1 For your own safety ESD measures electrostatic discharge Neptune_GB_ Ver 2 0_ 10 03 Repair work should be carried out by persons instructed in electrical installations or by trained electricians only Safety instructions Observe valid safety regulations for electrical equipment n particular observe the following regulations IEC 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 Take the following ESD precautions before carrying out any repairs to the electronics e Touch the earth conductor before repairing the cleaner to discharge electrostatic charge from your body e Wear wrist band if necessary e Use a conductive floor covering or a conductive table cover e Never touch the printed circuit board or electronic components always hold at plastic e Transport electronic components in conductive packaging e g ESD bag ALTO Technical data Neptune 5 25 5 27 ee a ee RER Se ea Pressure P1 working pressure Pressure P2 Q2 Pressure Pmax Pressure P max Il Temperature t max Il Heating power Electrical data Current consumption Fuse slow blow International Protection Class HP Nozzle
19. 5 W 40 SAE 15 W 40 Pump oil quantity 1 1 184 184 1190 702 987 1190 702 987 Table 1 3 Neptune 5 49 Neptune GB Ver 2 0_10 03 5 ALTO Technical data Neptune 5 57 NEPTUNE 5 57 NO BE NEPTUNE 5 57 EU Water volume Qmax Water volume Qc Pressure P1 working pressure Pressure P2 Q2 Pressure Pmax Pressure P max Il Temperature t max Il Heating power Electrical data Current consumption Fuse slow blow International Protection Class HP Nozzle Water inlet pressure Water inlet temperature Water volume heat exchanger Fuel consumption dt 45K Oilpressure Flue gas temperature C0 content min Soot rating Efficiency burner Sound pressure 1m Sound power LWA Reactive force Motor RPM Piston Piston diameter Stroke Pump oil Pump oil quantity Table 1 4 Neptune 5 57 Neptune_GB_ Ver 2 0_ 10 03 h I h l min bar bar I min 1080 1000 16 7 200 25 6 7 250 32 80 140 80 230 400 3 50 7 9 24 8 32 IP X5 NT 0550 10 40 4 78 4 8 12 170 12 0 1 gt 92 14 1 89 1 55 3 1450 Ceramic 20 12 8 SAE 15 W 40 1 184 1150 702 987 1080 1000 16 7 200 25 6 7 250 52 80 140 80 400 415 3 50 7 9 14 3 16 IP x5 NT 0550 10 40 4 78 4 8 12 170 12 0 1 gt 92 74 1 89 1 55 3 1450 Ceramic 20 12 8 SAE 15 W 40 1 184 1150 702 987 W ater volume Q max W ater volume Qtec Pressure P1 working pressure Pressure P2 Q2 Pressure Pmax P
20. A nee Neptune_GB_ Ver 2 0_ 10 03 Service Repair Control Safety Block 0009 c cae Dis 20 18 21 O z z Can SN ee YY 24 SS 25Nm ff i Q 31 C3 Cylinder head 1 Kit P N 1119571 Pressure valve LP pressure Suction valve HP pressure sleeve Kit P N 107120700 Kit P N 1119310 Dismounting and mounting by hand Attach the big O ring using grease Note position of the casting smile the eight 10 mm nuts with 27 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 hand Mandrel P N 1216506 Pic 6 1 C3 pump with removed HEr Pic 6 2 Dismounting suction valves head Neptune GB Ver 2 0_10 03 32 C3 Cylinder head 2 DERIB ack up ring 7 LP sleeve rubber 6 gt ALLA O Ring Sy collar 5 Back up ring 4 HP sleeve textile O en Nylonring 2 gt Lon a SY ZZ Lnn LL RR SSS SSS Suction valve Duct Pressure valve Mounting of textile sleeves by means of tool P N 1220090 It is an advantage if the sleeves have been in a water bath for 3 4 hours before mounting them Do not forget to blow through the ducts and grease all sleeves before mounting D
21. NEPTUNE 5 NEPTUNE 7 Auto ny Compromise Service Manual TECHNOLOGIES 1 Safety instructions 2 Technical data 3 8 3 Construction 2 fe 4 Function 16 23 Index 5 Trouble shooting 24 25 6 Service Repair 26 42 7 Adjustment Test 43 53 8 Wiring diagrams 54 56 Special tools Spare parts ALTO 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 A fault 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 anew edition Repair manuals and Service Technical Information sheets should be available at the site where repairs are carried out Itis not permitted to give them to third parties Use original ALTO spare parts only Neptune_GB_Ver 2 0 10 0
22. The inlet and the outlet are connected directly to the Control Safety Block Neptune_GB_Ver 2 0 10 03 18 NPS pump The NP5 three piston radial pump used in the Neptune 5 models Crankshaft ol Pressure valve Motor 7 11 Motor shaft gt RO Piston Suction valve Three pistons are driven by connecting rods which are attached to a crankshaft which is in turn driven by the electric motor The eccentricity 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 to the Control Safety Block Neptune _ GB _Ver 2 0_10 03 19 Neptune_GB_ Ver 2 0_ 10 03 HP hose to boiler Flow switch B2 ae Magnet piston Non return valve Control Safety Block 1 Low volume adjustment Main ajustment nut Low volume spring Unloader spring B4 s Microswitch B4 NC Unloader valve piston Safety valve Unloader valve seat ve t HP outlet from pump Water inlet suction side When the machine is started with a closed spray gun The pressure rises until the cutoff pressure is reached set by the unloader spring The unloader valve piston is forced upwards and will open the microswitch B4 which signals the PCB A1 to start the timer which will stop the machine in 20 s During that 20 s
23. areful when you dismount thrust collar Pic 6 15 because you can easily damage the surface inside Give the thrust collar an inspection before mounting 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 Pic 6 19 Mounting thrust collar 5 Inspect the the thrust collar for marks lubricate and mount it with your fingers Pic 6 19 Neptune_GB_ Ver 2 0_ 10 03 w _ 4 M p i y yE fi F s I Pic 6 16 Mounting HP sleeve amp support ring 2 When mounting the sleeves and the support ring Pic 6 16 remember lubricating Pic 6 18 Mounting LP sleeve 4 Clean the thrust collar and lubricate before mounting the sleeves Pic 6 18 Pic 6 20 Mount cylinder head 6 When you mount the cylinder head tighten the bolts in the shown sequence Pic 6 20 Use a 6 mm hexagon wrench with a torque of 20 Nm 41 Piston amp oilseal To inspect the plunger for cracks Spray the inside of the plunger with fast evaporating cleaner such as a brake cleansing agent The brake cleansing agent will take a second longer to evaporate from the crack thus making the crack visible Carefully inspect and replace as needed O Rings and support rings on the plunger rod prior to re installing the plungers Support ring O Ring y Packing ring A ne p Hexagon
24. bar It is now ready to be changed Neptune GB Ver 2 0 10 03 37 ALTO Neptune_GB_ Ver 2 0 10 03 Motor Page 43 arvice Repair 6 Pump housing Page 43 NP5 Survey Control Safety Block Page 39 Valve cover amp seals Page 40 41 Pistons amp oil seals Page 42 38 ALTO Service Repair Control Safety Block If any pitting or scratches are found on the unloader piston and seat or on the non return valve and seat these parts must be renewed D The safety valve has been set at the factory and can t be adusted 11 Check that the printed B4 pressure corresponds TE Ts to the specification 25 Nm FT l CD O45 L Sz 18 O21 O22 23 e we ZY 24 SS 25Nm My i NS Neptune GB _Ver 2 0_10 03 39 ALTO service Repair oF NP5 Pump head 1 Pressure valve 3 O Ring 1 O Ring HP sleeve 4 Support ring 5 Suction valve O Ring 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 removal Pic 6 12 NP5 Cylinderhead When you replace the valves give the O Rings an inspection for damage before mounting Pic 6 13 Pressure valve Pic 6 14 Suction valve Neptune_GB_Ver 2 0_ 10 03 40 Pic 6 15 Dismounting thrust collar 1 Be c
25. built together in line axial LLLL LAL l s A By iLL ae Em Out n eee Pressure valve UOT n J Suction valve Fan Stator Rotor Wobble disc Piston The three piston radial pump NP5 used in the Neptune 5 models is a compact unit with motor and pump Crankshaft Pressure valve Motor gt Motor shaft Suction valve Neptune _ GB _Ver 2 0_10 03 15 Neptune_GB_ Ver 2 0_ 10 03 Operation Start cold water mode Start hot water mode Main switch S1 Temperature setting N Suction from pump Status indicators Pic 4 1 Operator panel Detergent A Detergent Pressure gauge 7 Connected to water tank If the machine and power supply a
26. d the spray handle open If all the sensors are closed and o k K1 will start the motor and K2 the ignition and fan Y1 will open and let in fuel to the combustion chamber If the flow stops B2 will open and the 24 VAC supply to the solenoid Y1 will be interrupted and the combustion will stop A1 o 5 ay B1 F L B B6 an fj i uP SS Remote 4a A2 B1 Temperature sensor B2 Flow switch B3 Safety thermal switch B4 Microswitch B6 Oil level switch B7 Flame sensor B8 AntiStone level switch B9 Fuel level switch MT Motor temp switch S1 Main switch T2 Ignition transformer Y1 Solenoid valve Neptune GB Ver 2 0 10 03 23 ALTO Trouble shootin Functional requirements 1 Water supply must be able to deliver the needed water at a min of 1bar pressure 2 The water inlet temperature must not exceed 40 C 104 F 3 The water must be without impurities as for instance floating sands gt 50 wu 4 If the ambient temperature exceeds 40 C when running constant the 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 problem 6 Diesel fuel must be of a standard as used on diesel engines Ker
27. eal is in place Suction pipe Pic 6 28 Tank meter amp fuel float switch Neptune_GB _ Ver 2 0_ 10 03 Electrodes tank meter How to handle the burner insert Always remove electordes 18 first while dismounting burner insert Tighten fuel nozzle 17 only with a hexagonal wrench and a torque of 18 Nm Otherwise the fuel nozzle can be damaged and a proper combustion cant be guarantied Always measure the electrode 18 set up first and re adjust if necessary before re installing burner insert values see Pic 6 26 and 6 27 aac The flame sensor 9 must be fixed with a screw 5 in the right position Don t over tighten Check and clean the glass 8 45 Maintenance Maintenance plan NEPTUNE 5 only anal Six As After the first 50 van required 500 operating operating hours Four Waterfilters o Oilfiter o o S O Changing the pump oil Maintenace work A water filter is fitted on the water inlet to prevent large particles of dirt from entering into the pump Water filters 1 Unscrew Quick GEKA coupling 2 Remove filter with tool and clean it 3 Clean filter at the pump inlet hose Oil filter To clean or replace filter 1 Unscrew filter cap 1 2 Clean replace oil filter 2 3 Dispose of cleaning solution replaced filter in accordance with regulations Further maintena
28. ecessary using a descaling agent 3 Adjust burner insert dimensions see page 45 4 Connect fuel pressure gauge Pic 7 3 and run machine in hot water mode continuous operation 5 Adjust fuel pressure to 12 bar at fuel pump Pic 7 4 Caution Always use a new fuel nozzle for adjustment Table 7 2 Mount the nozzle with a hexagonal wrench and a torque of 18 Nm 6 Disconnect fuel pressure gauge Pic 7 3 Measuring fuel pressure Fuel nozzi 5 25 27 7 25 135 _ ENTER NEPTUNE 5 42 49 57 1 75 60 H 301000886 60 H NEPTUNE 7 63 250 301000887 Fuel pressure 12 bar Table 7 2 Neptune fuel nozzles Adjusting the flow switch 1 Machine has to run continuously in hot water mode 2 Push in reed switch completly and pull it back until burner switches off Green signal light on operator panel flashes 3 Slowly push in reed switch within 2 s until burner starts again Green signal light is on 4 Repeat procedure if necessary 5 Adjust machine to min waterflow pressure Solenoid valve Reed switch must not close in this setting 6 Finally test the proper function by simulating water shortage f Solenoid valve has to close and shut off the burner Magnet piston Neptune _GB_Ver 2 0_10 03 fuel pressure 50 Combustion Caution Higher CO concentrations at atmospheric pressure differences different altitudes or temperatures and low quality of the used fuel can lead to a faster accumulation o
29. er No water Heat exchanger security adjustment Flow and pressure switch out of adjustment Switch B3 must be Oil residue in heat changed if open exchanger Oil seals worn out B6 switch Oil residue in heat Oil pressure exchanger is burning Nozzle Y1 Leaky Electrode Ignition failure Flame sensor Fan on motor Sensor in defective windings Fuse F1 Flow piston hanging Reed switch Flow switch off Fuse F11 Sensor B7 Leaky non return B4 switch valve Detergent valve 26 ALTO Trouble shootin Electrical tests Before you change the control board run through these tests 1 Power On Check Turn to cold Stand by Check all three phases 400 VAC Pic 5 2 K1 amp K2 2 K2 Check Start relay to power up the burner e the Machine Turn switch to start and further to hot mode Check visually that the N K2 is switching on within the time 20 s the machine is running in by pass Neptune _GB_Ver 2 0_10 03 3 Power Off Check Disconnect machine from mains power With Ohm meter in sound mode Power off Pressure O O k if If not o k check K1 X Connection to coil A1 A2 K2 Go to power On Check Y1 X Coil on fuel pump B2 o Flow switch position MT X Connections in motor pl
30. f soot on the heat exchanger coil C02 02 Soot NEPTUNE 11 5 12 5 3 4 6 0 Table 7 2 CO O and soot setting values Measuring and adjustment of soot rate The lateral mounted air flap at the blower is easy to adjust from top with an Allen wrench or a hexagon socket screwdriver by a spindle Pic 7 5 The spindle is retained by friction Turning clockwise means more air turning counterclockwise means less air 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 Wait until the burner has been running for at least 2 minutes before starting the measurements Air flap needs to be adjusted until the values of table 7 2 are reached CO O measurement Set to 11 5 12 If necessary readjust air flap and repeat soot measurement Temperature measurement Flue gas temperature t minus intake temperature t gives the temperature differential At At t t Calculating flue gas loss an flue gas loss t flue gas temperature t Intake temperature CO Carbon dioxide content in the flue gass A1 Constant for fuel oil 0 5 B Constant for fuel oil 0 007 gt a t t x AT co B Neptune GB Ver 2 0_10 03 51 ALTO AntiStone device The ALTO AntiStone device is set at the factory to water hardness class 2 Adjustment steps 1 Measure the water hardness or ask your wa
31. lay 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 Neptune_GB_Ver 2 0 10 03 17 Function C3 pump The C3 four piston axial pump used in the NEPTUNE 7 models nal O U t Pressure Fan Wobble disc Piston 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
32. lve in off position as shown it draws in water from the water break tank to clean the valve and the hose to the pump 16 Heat exchanger 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 y 1 K 5 dg gt YY N Pnn mi ani T mE Ti i i i oon ooo e a IT i i eal iLL ay ine a J J gt A e Z ar ii i N LY J _ RZ h NA I N Y TS 3 7 z In hot water mode fuel is drawn from the tank through the fuel filter to the pump If combustion is required fuel 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 disp
33. nce work see at the users manual in chapter 7 Neptune GB Ver 2 0_10 03 46 Electronic setup Machine cut off with pressure release Function used in connection with remote mode If 2 is on machine switches off after 20 min in by pass mode A restart is only possible with mainswitch S1 At the same time the ouput of the optional valve Y2 gets power for 10s to release pressure at the HP outlet Change temperature display When 1 is on it shows temperature in Fahrenheit on display NB it s not possible to cancel by pass time when temp display is set to Fahrenheit Hour display setting Jumper between 2 3 on X9 shows the total running hours for 5 s on the display during start up Cancel by pass time Jumper on X10 eliminates by pass time of 20 s which is necessary when adjusting microswitch B4 Service interval setting Bridge 3 and 5 on X2 while changing service interval with the temperature adjustment knob 100 to 600 hours Change to hotwater mode to set new setting Pic 7 1 Detail of PCB A1 Neptune_GB _ Ver 2 0_ 10 03 47 Attention Adjustments have to be done with correct nozzle for the machine Preparation Make sure machine is switched off and pressure is released Mount test pressure gauge directly on the outlet hose of the pump see Pic 7 2 or alternatively connect gauge P N 49473 with hose P N 60141 at the water input of the coil where built in gauge is c
34. on t scratch the brass cylinder head when removing the old HP sleeves Pic 6 3 Mounting pressure sleeves 33 Neptune_GB_ Ver 2 0_ 10 03 C3 Cylinder block 1 Torque moment 37 Nm Pa Nar fy ar a O A T y m vaa va rem oe t Pee ey Pay ree et et yo oy gan pa ae ae Pere ame EFT pam fy FF Fe 0 TEN P PA P PON OR PA PAR PO N R N S PN DON PA P ON N P N PO PO R PAN PAN OO R T PA R P R P D PO R A P P N w 7 lt Stud parean m Me Oooo ar porono Y Oil sleeve lt O Ring 1 LP sleeve 6 Back up ring 7 en Soa Drain the oil Loosen the 8 nuts gradually and evenly because of the spring load Special extra deep 17 mm box head P N 1206762 may be used Mount new O Rings on studs with tool P N 1206812 Sliding the O Rings over the threads will cause oil leaks Back up ring 7 Always replace LP sleeves when replacing HP sleeves Check that the ducts are clear Kit 16 P N 107120700 LP sleeve 6 Pic 6 4 C3 pump pistons Back up ring 4 O Ring 1 Kit 16 consists of two new parts the crown back up ring and the thrust collar They must always be replaced at the same time Neptune GB Ver 2 0 10 03 34 C3 Cylinder block 2 Carefully tip out the oil sleeves with an adequate screwdriver and discard them Be careful not to scratch the
35. onnected Open electrical box and cancel by pass time 20 s by setting jumper on X10 temp setting has to be set to C otherwise by pass time can t be canceled Remove safety valve 4 and screw in test bolt P N 63138 Turn adjustment knob not shown in Pic 7 2 as far as possible 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 of the microswitch 3 Adjusting maximum operating pressure Switch on machine and open trigger gun Turn setscrew 7 clockwise until max operating pressure is reached see Table 7 1 Then turn setscrew counterclockwise until operating pressure starts dropping Turn setscrew 7 turn to right again Close trigger gun and check max cut off pressure see Table 1 If necessary readjust Lock setscrew 7 with lock nut 9 Check operating pressure again Operating Pressure v y g 5 zg E Min Max 6 Ta T B j 2 Pa bar 3 BE NIN Table 7 1 Neptune 5 7 pressure settings Neptune_GB_ Ver 2 0_ 10 03 ST Pic 7 2 CSB with test pressure gauge 48 Control Safety Block Adjusting microswitch 3 Switch on machine and open trigger gun When Operating pressure is reached close trigger gun machine does not shut off After loosening
36. osene can be used only in machines with a special fuel pump e g all US variants will have it 7 Exhaust gas must be led directly into the open air without restriction If these requirements are met and you still experience operational break downs there are faults on the system Neptune_GB _ Ver 2 0_ 10 03 24 ALTO Trouble shootin Check list When trouble shooting it will be a great help if you can locate the fault as being either an external fault or an internal fault External faults are due to either improper maintenance incorrect operation or operation under particularly straining conditions External faults usually represent the following The below mentioned conditions have been checked and found ok Comments S Z O 1 Installation fuse blown 2 Plug defective 3 Cable cracked or split 4 Too long too small or defective extension cables 5 High low pressure nozzle blocked or worn 6 Spray handle defective or leaky 7 High pressure hose too long or defective 8 Water inlet filter 2 blocked dirty water 9 Inadequate water supply 10 Air sucked into the pump empty detergent tank selected 11 Detergent system blocked dried up 12 Inlet water too hot 13 Fuel filter blocked 14 Air adjustment faulty 15 Fuel level low or water in fuel tank PELE LE ELE LE LE LE LEEW AT iT
37. re 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 va
38. ressure P max Il Temperature t max I I Heating power Electrical data Current consumption Fuse slow blow International Protection Class HP Nozzle W ater inlet pressure W ater inlet temperature W ater volume heat exchanger Fuel consumption dt 45K Oilpressure Flue gas temperature CO content min Soot rating Efficiency burner Sound pressure im Sound power LWA Reactive force Piston diameter W obble disc Pump oil Pump oil quantity Table 1 5 Neptune 7 25 Neptune_GB_ Ver 2 0_ 10 03 l h I min bar bar l min bar bar C k W V Ph Hz kW A A Neptune 7 25 NEPTUNE 7 25 GB 720 660 11 90 257 6 T 200 32 80 140 80 230 240 1 50 3 ales 13 IP X5 NT 0550 10 40 4 78 3 2 12 170 12 0 1 gt 92 72 5 87 6 25 1 1450 Ceramic 24 1 Alphasyn T ISO 150 1 189 1150 702 987 ALTO Technical data 2 Neptune 7 63 NEPTUNE 7 63 NO BE NEPTUNE 7 63 EU__ Water volume Qmax h 1260 1260 Water volume Qtec I 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 250 250 Pressure P max ll 32 32 Temperature t max Il 100 140 100 140 Heating power TIS 115 Electrical data 230 400 3 50 8 3 400 415 3 50 8 3 Current consumption 23 4 135 Fuse slow blow 25 16 International Protection Class IP X5 IP X5 HP Nozzle NT 0680 NT 0680 Water inlet pressure 10 10 Water inlet temperature 40 40
39. rki ng pressure Aemme E a a OE A ee een nS ae ae ee Starting pressure _ A _ __ __ _ A BC D E F Diagram 4 1 Pressure development Neptune 7 63 Mounted with an 0680 nozzle and connected to a hose of 10 m the machine is started with inactivated spray gun A The pressure is building up until the unloader valve opens and the microswitch B4 activates the timer B The pressure will rise a little more but will drop Point D immediately C After 20 s in by pass the motor stops D If the system is tight the pressure will remain At the same time the pressure in the pump drops to zero D the dashed line 18 TS D The spray handle is activated and the pressure drops The 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 E As long as the spray handle is activated and the nozzle is unchanged the pressure is steady Neptune GB Ver 2 0 10 03 21 Neptune_GB_ Ver 2 0_10 03 Sensors Actors Ce HL a Ca K la GB Sensors B1 Temperature sensor at the outlet of the heat exchanger Controls the combustion Y1 on off according to setting B2 Flow switch senses the flow out of the pump into the heat exchanger and with B1 controls solenoid Y1 on off B3 Safety thermal switch placed at
40. surface 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 Pic 6 6 Mounting oil sleeves Oil sleeve LP sleeve HP sleeve lt Check the piston for wear in the pressure area and the area of the oil sleeves Check the ceramic for cracks Remove any coating Pressure area Ceramic rides on wobble disc Stainless steel Neptune GB _Ver 2 0_10 03 35 Motor Wobble disc 1 The motor consists of a stator with windings and a rotor with shaft which is kept in the right place by a bearing in the N bearing cover and the inner needle bearing of the wobble disc in the D bearing cover The fan blade has been pressed on to the rotor with an internal locking ring A B 5 The bearing track A is fixed with a guide pin 1 The washer 2 ensures that the needle bearing B is kept free of the oil sleeve 3
41. t between tube and inner heat exchanger jacket in top cover Check burner tube Cause 4 Unstable ignition Remedy Check electrodes Adjust the air quantity less air Cause 5 Leaky solenoid valve on pump Y1 Remedy Check replace solenoid valve Y 1 Low fuel pressure Cause 1 Incorrect adjustment Remedy Adjust pump pressure 12 bar see page 50 Cause 2 Filter blocked defective pump Remedy Replace filter pump Empty and clean tank Full water volume at steam stage Cause Mechanical defect of by pass valve or adjustment Remedy Check by pass valve Neptune_GB_Ver 2 0 10 03 28 ALTO Trouble shootin Pressure ls Ane working pressure o k yes a o the preasure gt no 4 steady yes Vv isok The pressure of the machine drops the machine vibrates and makes a noise Reason Water supply inadequate water temperature too high or water filter 2 dirty NB The pressure of most water supplies varies depending 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 The machine starts stops by itself Reason Leak on the high pressure side or in the non return valve NB If the machine has been operated with hot water a cooling of the hose may cause the machine to start stop a couple of times before stability has been reached Neptune
42. ter supply company Read off setting for ALTO AntiStone from the table below and set the adjusting knob to required position mg l ppm Ca Description Settin NEPTUNE 5 NEPTUNE 7 0 7 0 8 8 0 12 5 0 50 slightly hard Neptune_GB _ Ver 2 0_ 10 03 52 Electrical connection Some models are equipped with a star delta switch S2 to change between 230 V and 400 V Caution Before connecting devices with voltage changeover Check that the pre selected voltage on the machine corresponds with the voltage of the electrical installation Otherwise the electrical devices of the machine can be destroyed ee On this diagram the switch S2 is turned into star connection for 400 V In this position the transformer is connected to the primary pin 7 red un line MA Three of the motor wires are connected in a star point thick purple ae e call Io F11 line The burner motor and ignition ng transformer are connected to this star point and therefore supplied with 230 V only l l Worst case The machine is set for 230 V but ee eee eee Se supply is 400 V The motor windings i l a which are made for 230 V are now fed 3 1 gt Jels lais with 400 V The burner motor and the ignition transformer are now fed with 400 V Star delta switch S2 is located on the backside of the electrical box and easy to adjust with a slotted screwdriver Neptune GB Ver 2 0_ 10 03 53
43. the water being pumped will flow through the unloader valve seat and return to the pump Also during the initial start water 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 return valve is forced onto its seat trapping high pressure in the heat exchanger and HP hose When the pump stops pressure in the green area goes to O bar High pressure is shown with blue in this drawing and low or no pressure with green When the spray gun trigger is squeezed the pressure trapped in the heat exchanger and HP hose is reduced and the unloader spring forces the piston down allowing the microswitch B4 to close which signals the PCB A1 to start the pump motor You can also see in this drawing that the magnet piston has moved up with water flow and will signal the PCB A1 to turn on the burner if hot water is selected The safety valve will only open if the pressure in the system exceeds P 10 such as might be caused by a blocked unloader valve 20 Control Safety Block 2 There are four purposes of the Control Safety Block 1 To secure the machine against an excess of pressure 2 To ensure a quick start 3 To reduce the pressure in the pump when in by pass mode 4 Allow regulation of water volume A Safety Valve eee S ee eee ee ee ee Cut Off Pressure Wo
44. ug B3 X Change sensor B3 24V X Transformer 8V X Transformer B8 X Level switch anti scale B4 X Micro switch setting B6 X Level switch oil B1 X Temperature sensor B9 X Level switch in fuel tank S1 o Go to power On Check B7 o Wire and flame sensor 27 ALTO Trouble shootin Heat exchanger performance The symptom is reduced performance of the pump effect or the heat exchanger effect The symptom of reduced heat exchanger effect is a lower water outlet temperature than the set value The possible causes for this are as follows Scale deposits in heat exchanger tube Scale formation acts as insulation and reduces heat transfer to the water The result is raised flue gas temperature increased flue gas loss Cause The hardness of the water no AntiStone or AntiStone dosing too low Remedy Descale heat exchanger tube Sooted heat exchanger tube Soot has the same effect as scale deposits i e that they are both insulating against the heat transfer to the water and results in increased flue gas temperature increased 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 Cause 2 Bad fuel air mixture Remedy Check fuel pressure and quality Replace the fuel nozzle Adjust air diffuser Cause 3 Unfinished combustion Remedy Check bottom insulation boiler top gaske
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