Nilfisk-ALTO NEPTUNE 5 FA, Service Manual

Page 1: ...Service Manual NEPTUNE 5 FA NEPTUNE 5 FA_EN_Ver 2 0_25 11 ...

Page 2: ...parts lists during repairs They show the assembly position and the sequence in which the individual components should be assembled See Service Technical Information STI 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 ...

Page 3: ...B C D E F G H I Special tools Spare parts Wiring diagrams 54 61 Adjustment Test 49 53 Service Repair 36 48 Troubleshooting 32 35 Function 25 31 Construction 19 24 Technical data 5 18 Safety instructions 4 ...

Page 4: ...rsons 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 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 ...

Page 5: ...2 Type NA5 NA5 Piston type Cermic Cermic Piston diameter mm 20 0 20 0 Stroke Wobble disc angle 10 2 10 2 Pump oil type Oil BP Energol GR XP220 Oil BP Energol GR XP220 Oil volume l 0 8 0 8 Electrical Power supply 400V 3 50Hz 400V 3 50Hz Current consump hot A 12 2 1 0 3 0 12 3 1 0 3 0 Current consump cold A 12 4 1 0 3 0 12 5 1 0 3 0 Power Consumption hot kW 6 0 0 5 0 5 6 1 0 5 0 5 Fuse size A 16 0 1...

Page 6: ... 0 0 10 0 0 5 0 0 Nozzle size oil 1 75 60 H 1 75 60 H CO2 content min 10 5 0 5 0 0 10 5 0 5 0 0 Efficiency burner 92 0 1 5 0 5 92 0 1 5 0 5 Soot picture 0 1 0 1 Exhaust outlet temperature C 175 0 10 0 10 0 175 0 10 0 10 0 Exhaust temperature cut off C 270 0 0 0 12 0 270 0 0 0 12 0 Fuel consump dT 45 deg kg h 4 0 4 0 Fuel consumption kg h 12 C inlet 6 7 6 7 Water volume in coil l 4 8 4 8 Fuel tank ...

Page 7: ...A5 NA5 Piston type Cermic Cermic Piston diameter mm 20 0 20 0 Stroke Wobble disc angle 9 2 12 0 Pump oil type Oil BP Energol GR XP220 Oil BP Energol GR XP220 Oil volume l 0 8 0 8 Electrical Power supply 400V 3 50Hz 400V 3 50Hz Current consump hot A 8 0 1 0 3 0 15 4 1 0 3 0 Current consump cold A 8 2 1 0 3 0 16 0 1 0 3 0 Power Consumption hot kW 4 1 0 5 0 5 7 6 0 5 0 5 Fuse size A 16 0 16 0 Cord ty...

Page 8: ...zzle size oil 1 35 60 H 1 75 60 H CO2 content min 10 5 0 5 0 0 10 5 0 5 0 0 Efficiency burner 92 0 1 5 0 5 92 0 1 5 0 5 Soot picture 0 1 0 1 Exhaust outlet temperature C 160 0 10 0 10 0 175 0 10 0 10 0 Exhaust temperature cut off C 270 0 0 0 12 0 270 0 0 0 12 0 Fuel consump dT 45 deg kg h 3 5 0 0 0 1 4 6 Fuel consumption kg h 12 C inlet 5 7 0 0 0 0 7 3 Water volume in coil l 4 8 4 8 Fuel tank l 17...

Page 9: ... 0 3 0 3 Type NA5 NA5 Piston type Cermic Cermic Piston diameter mm 20 0 20 0 Stroke Wobble disc angle 12 0 12 0 Pump oil type Oil BP Energol GR XP220 Oil BP Energol GR XP220 Oil volume l 0 8 0 8 Electrical Power supply 400V 3 50Hz 400 230V 3 50Hz Current consump hot A 15 8 1 0 3 0 15 6 25 1 0 3 0 Current consump cold A 16 0 1 0 3 0 15 8 25 1 0 3 0 Power Consumption hot kW 7 8 0 5 0 5 7 6 7 4 0 5 0...

Page 10: ... 0 5 0 0 12 0 0 5 0 0 Nozzle size oil 1 75 60 H 1 75 60 H CO2 content min 10 5 0 5 0 0 10 5 0 5 0 0 Efficiency burner 92 0 1 5 0 5 92 0 1 5 0 5 Soot picture 0 1 0 1 Exhaust outlet temperature C 175 0 10 0 10 0 175 0 10 0 10 0 Exhaust temperature cut off C 270 0 0 0 12 0 270 0 0 0 12 0 Fuel consump dT 45 deg kg h 4 6 4 6 Fuel consumption kg h 7 3 7 3 Water volume in coil l 4 8 4 8 Fuel tank l 17 0 ...

Page 11: ... 0 3 0 3 Type NA5 NA5 Piston type Cermic Cermic Piston diameter mm 20 0 20 0 Stroke Wobble disc angle 12 0 8 9 11 3 9 9 8 9 11 3 Pump oil type Oil BP Energol GR XP220 Oil BP Energol GR XP220 Oil volume l 0 8 0 8 Electrical Power supply 400 230V 3 50Hz 220V 440 3 60Hz Current consump hot A 15 8 25 1 0 3 0 12 5 21 8 1 0 3 0 Current consump cold A 16 25 1 0 3 0 12 7 22 1 0 3 0 Power Consumption hot k...

Page 12: ... 0 5 0 0 12 0 0 5 0 0 Nozzle size oil 1 75 60 H 1 75 60 H CO2 content min 10 5 0 5 0 0 10 5 0 5 0 0 Efficiency burner 92 0 1 5 0 5 92 0 1 5 0 5 Soot picture 0 1 0 1 Exhaust outlet temperature C 175 0 10 0 10 0 175 0 10 0 10 0 Exhaust temperature cut off C 270 0 0 0 12 0 270 0 0 0 12 0 Fuel consump dT 45 deg kg h 4 6 4 6 Fuel consumption kg h 12 C inlet 7 3 7 3 Water volume in coil l 4 8 4 8 Fuel t...

Page 13: ...0 2 0 2 Type NA5 NA5 Piston type Cermic Cermic Piston diameter mm 20 0 20 0 Stroke Wobble disc angle 12 0 8 9 11 3 10 2 Pump oil type Oil BP Energol GR XP220 Oil BP Energol GR XP220 Oil volume l 0 8 0 8 Electrical Power supply 400V 3 50Hz 200V 3 50Hz Current consump hot A 15 4 1 0 3 0 18 7 1 0 3 0 Current consump cold A 16 0 1 0 3 0 18 9 1 0 3 0 Power Consumption hot kW 7 6 0 5 0 5 5 4 0 5 0 5 Fus...

Page 14: ... 0 0 5 0 0 Nozzle size oil 1 75 60 H 1 35 60 H CO2 content min 10 5 0 5 0 0 10 5 0 5 0 0 Efficiency burner 92 0 1 5 0 5 92 0 1 5 0 5 Soot picture 0 1 0 1 Exhaust outlet temperature C 175 0 10 0 10 0 160 0 10 0 10 0 Exhaust temperature cut off C 270 0 0 0 12 0 270 0 0 0 12 0 Fuel consump dT 45 deg kg h 4 8 3 9 Fuel consumption kg h 12 C inlet 7 3 5 7 Water volume in coil l 4 8 4 8 Fuel tank l 17 0 ...

Page 15: ...5 NA5 Piston type Cermic Cermic Piston diameter mm 20 0 20 0 Stroke Wobble disc angle 8 4 10 2 Pump oil type Oil BP Energol Oil BP Energol Oil volume l 0 8 0 8 Electrical Power supply 200V 3 60Hz 230V 1 60Hz Current consump hot A 16 6 1 0 3 0 28 0 1 0 3 0 Current consump cold A 17 5 1 0 3 0 26 8 1 0 3 0 Power Consumption hot kW 5 1 0 5 0 5 8 0 0 5 0 5 Fuse size A 20 0 30 0 Cord type Power cord VCT...

Page 16: ... 10 0 0 5 0 0 Nozzle size oil 1 35 60 H 1 75 60 H CO2 content min 10 5 0 5 0 0 10 5 0 5 0 0 Efficiency burner 92 0 1 5 0 5 92 5 1 5 0 5 Soot picture 0 1 0 1 Exhaust outlet temperature C 160 0 10 0 10 0 175 0 10 0 10 0 Exhaust temperature cut off C 270 0 0 0 12 0 270 0 0 0 12 0 Fuel consump dT 45 deg kg h 3 9 4 8 Fuel consumption kg h 12 C inlet 5 7 6 7 Water volume in coil l 4 8 4 8 Fuel tank l 17...

Page 17: ... 3 Type NA5 NA5 Piston type Cermic Cermic Piston diameter mm 20 0 20 0 Stroke Wobble disc angle 12 0 12 0 Pump oil type Oil BP Energol GR XP220 Oil BP Energol GR XP220 Oil volume l 0 8 0 8 Electrical Power supply 400V 3 50Hz 400V 3 50Hz Current consump hot A 15 4 1 0 3 0 15 8 1 0 3 0 Current consump cold A 16 0 1 0 3 0 16 0 1 0 3 0 Power Consumption hot kW 7 6 0 5 0 5 7 8 0 5 0 5 Fuse size A 16 0 ...

Page 18: ...Nozzle size oil 1 75 60 H 1 75 60 H CO2 content min 10 5 0 5 0 0 10 5 0 5 0 0 Efficiency burner 92 0 1 5 0 5 92 0 1 5 0 5 Soot picture 0 1 0 1 Exhaust outlet temperature C 175 0 10 0 10 0 175 0 10 0 10 0 Exhaust temperature cut off C 270 0 0 0 12 0 270 0 0 0 12 0 Fuel consump dT 45 deg kg h 4 6 0 0 0 1 4 6 0 0 0 1 Fuel consumption kg h 12 C inlet 7 3 0 0 0 0 7 3 0 0 0 0 Water volume in coil l 4 8 ...

Page 19: ...he Neptune 5 FA is build with a NA5 pump The by pass system is flow activated unlike the pressure activated by pass system known from previous Neptune machines The frame cabinet detergent tank and fuel tank is identical to previous Neptune 5 models Fuel gauge Boiler inlet Flame sensor Fuel nozzle Exhaust thermal safety sensor Fig C 1 Side view Boiler Fuel pump Flow control Pressure water regulatio...

Page 20: ...ame cabinet parts Fig C 3 NEPTUNE 5 FA 11 5 6 7 4 12 1 3 2 8 9 10 1 Lance holder 2 Detergent tank 3 Fuel tank 4 Fuel filter 5 Top cover 6 Side cabinet right 7 Handle 8 Detergent tank 9 Water break tank 10 External detergent filter 11 Frame 12 Side cabinet left ...

Page 21: ... 4 The cover is sealed around the edge and around the manometer and the detergent valve Display Temperature setting Error mesage Running hours Sevice interval setting Operation Fuel Anti stone Service Main switch S1 Display board A2 Main switch S1 OFF COLD HOT Adjustment Temperature settings Service interval settings Detergent A B Pressure Gauge Fig C 4 Operation panel Fig C 5 Panel inside Fig C 6...

Page 22: ... is the connector to a remote control which is available as an accessory X2 is the connector to the Nilfisk Alto Datalogger and to service interval settings Detailed function is described in chapter D Detailed adjustment is described in chapter G Electrical diagrams can be found in chapter H Fig C 7 PCB A1 Y2 K2 K1 X2 Data logger X7 Remote control B 7 S 1 B 9 B 1 B 6 B 4 Y1 B2 MT B3 24V 8V Fuse F1...

Page 23: ... and top in a sandwich construction between which the combustion air is routed into the combustion An insulating material placed in the bottom of the boiler makes sure that the inner bottom among other things is protected from super heating Insolation Mounting plate Fixation spacer Inner jacket Outer jacket Burner tube Top plate Water outlet Exhaust Fuel nozzle Electrodes Flame sensor Air distribu...

Page 24: ...ss valve The NA 5 three piston axial pump used in Neptune 5 FA is build in line with the electrical motor as one compact unit Fig C 11 Flow control The start stop system in Neptune 5 FA is flow Activated The flow control checks if there is flow in the system to stop and start the machine ...

Page 25: ...e By switching to hot water mode the machine is then in stand by in hot water mode When the spray handle is activated flow will activate the flow switch and start the motor pump unit At the same time anti scale pump starts up and the fan for the burner starts ventilating the com bustion chamber for 3 sec before the fuel is pumped into the boiler and the combustion takes place The temperature will ...

Page 26: ...s through the magnetic solenoid valve to the nozzle in the air distributor if combustion is required 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 a flame sensor placed on top of the boiler will secure that fuel pump is automatically stopped and a fault cod...

Page 27: ...Level switch Anti Stone 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 is 160 deg C 320 deg F Automatic reset Actors Y1 Solenoid opens closes the fuel for the burner T2 Ignition transformer is on when burner fan is running The machine i...

Page 28: ...he wobble disc C decides the volume of water which is sucked through the suction valves E and pressed out through the pressure valves F The inlet I and the outlet J are connected directly to the By pass valve G The water volume can be adjusted by the regulation valve H A B C D E F A Stator B Rotor C Wobble disc D Ceramic piston E Suction valve F Pressure valve G BY pass housing H Water regulation ...

Page 29: ...nd the seat E is closed Machine is started and the gun is closed By pass pressure When the gun J closes the pressure inside the by pass housing equalizes and the by pass piston B is pressed down by the tension of it s spring The seat E in the top of by pass piston opens The water runs from the pump outlet A into the by pass housing C Due to the closed gun J and the opening in the by pass seat E th...

Page 30: ...g it the pressure will drop The safety valve C has no function under normal circumstances The pressure of the safety valve is set to about 25 30 bar above the cut off pressure The safety valve will open if the by pass valve is stocked and lead water to the suction side of the pump A B I C D E F G H K When the water regulation G is turned counter clock wise the seat H opens and the water runs both ...

Page 31: ...ich gives a signal to the PC board which starts up the motor pump unit The flow from the pump lifts up piston G To secure the flow is all right the magnet in piston G closes the reed contact NC H which gives the signal to the PC board In hot water mode this signal controls the fuel solenoid valve and the anti scale pump The fuel solenoid valve and the anti scale pump will activate when the PC boar...

Page 32: ... water too hot 13 Fuel filter blocked 14 Air adjustment faulty 15 Fuel level low Water in tank 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 parti cularly straining conditions External faults usually represent the following...

Page 33: ...sensor for start open flow sensor for hot water closed Flow failure FLF Flow sensor open while motor is running Flow problem or less water FLO Leakage detect by micro sw flow sens Leakage LEA Safety temperature switch open Hot safety temp switch HOS Pumpoil switch open LED indication Pump oil error POL Light indication burner with fuel disabled Light fuel not activated LHL No light indication burn...

Page 34: ...ssure Nozzle Electrode Flame sensor HOP Hot Motor Protector Motor winding 160degC 320degF Pump pressure too high Temp in room 40degC 104degF Fan on motor de fective Fuse F1 2amp Sensor in win dings FLF Flow Failure Flow switch B2 closed and B4 open Wire defective Flow piston han ging Reed switch LHE No Light Fuel Enabled Light sensor B7 see no light when Y1 is open Wire defective Spark failure Oil...

Page 35: ...e increased flue gas loss Other symp toms are that the machine smokes during steady operation Cause 1 Air deficiency Remedy Check air adjustment and fan attachment to boiler Cause 2 Bad oil air mixture Remedy Check oil pressure and oil quality Replace the oil nozzle Adjust air diffuser Cause 3 Unfinished combustion Remedy Check bottom insulation boiler top gasket between tube and inner boiler jack...

Page 36: ...de the Electrical Box Fig F 01 Data Plate Fig F 02 Water filter Cleaning Fig F 03 Oil extention As required clean the water filter Unscrew connector for water break tank Pull out the filter by use of a nose pliers Clean the filter and inspect for damages Clean the filter Replace if necessary Check the pump oil quality and quantity Refill if necessary Change the oil at major repairs Type of oil ref...

Page 37: ...tom of the knob Drag the knob out from the shaft Note When closing the electrical box leave the wiring diagram inside Fig F 06 E box knob disassembly Fig F 07 Electrical box Exploded view The components in the E box are shown by numbers in the wiring diagrams chapter H Fig F 08 Electrical box Back side Before connecting devices with voltage changeover Check that the pre selected voltage on the mac...

Page 38: ...ts in the by pass system be aware of the order of the components Fig F 11 By pass water regulation By reassembling of the water regulation knob special tool no 1211697 can be used By pass system Fig F 10 By pass valve cone By reassembling of the valve cone inside the water regulation special tool no 1210558 can be used 1210558 ...

Page 39: ...t collar Inspect the thrust collar for damages before mounting Puller used in the picture is Bahco 4521N F Fig F 13 Thrust collar Fig F 12 Valve housing Fig F 14 Valve housing Fig F 15 Valve housing Carefully tip out the sleeves with an adequate screwdriver and replace them Be careful not to scratch the surface Knock carefully on the back side of the valve seat to demount it or use an 8mm threaded...

Page 40: ... of the placement of pressure valve parts Take out the pressure valve seats with an adequate puller Replace with new parts if necessary Puller used in the picture is Bahco 4521N 00 Picture of piston guides The pressure valves can easily be taken out of the cylinder head Replace with new parts if necessary Pic F 16 Suction valves Pic F 17 Pressure valves Valves ...

Page 41: ...k Take out the oil sleeves using an adequate puller Be careful not to damage the surface of the cylinder block Puller used in the picture is Bahco 4521N F Oil seal and piston To make replacement easier moisten the sleeves with soapy water Mount the sleeves using a 19mm box spanner and a fiber hammer Place sleeves pistons and springs as shown Mount the cylinder block to the D bearing cover by the t...

Page 42: ...header ring must be placed in groove against the centre of the cylinder head If the header ring is mounted wrongly and not according to instruction there is a big risk of damaging the header ring and parts of it will block pistons and valves in the pump or get stucked in the non return valve in the unloa der Fig F 24 Header ring Fig F 25 Damaged header ring ...

Page 43: ...ig F 26 Pump head Fig F 27 D bearing cover and wobble disc Fig F 29 Wobble disc removal Fig F 28 Wobble disc Demount the wobble disc screwing a 16mm bolt into the threads Tighten the bolt against the motorshaft and pull the wobble disc out The center bolt is fixing the wobble disc to the motor shaft and ensure the rotor to be kept in the right position in proportion to the stator Overview of the p...

Page 44: ...d according to instructions Fig 32 Fig 33 pos A B A The curved edge A of the bearing tracks must be mounted against the D bearing cover and the wobble disc B The sharpe edge B of the bearing track must be mounted against the bearings Fig F 30 Bearing track removal Fig F 31 Bearing system woble disc Fig F 32 Bearing track Fig F 33 Bearing track Bearing system B A ...

Page 45: ... bolts When the bearing is damaged always replace the complete D bearing cover Fig F 37 fan The oil sleeve in the D bearing cover can be demounted carefully using a screwdriver Mount the oil sleeve by using an adequate box spanner and a fiber hammer Overview of the motor parts The fan can be demounted by taking off the lock ring and carefully push the fan with a screwdriver Electrical motor ...

Page 46: ... tank 1 Detergent tank 2 Fuel tank 3 Strainer 4 Float valve 5 gasket Fig F 38 Fuel tank Overview A B C D E Fig F 49 Boiler top 2 1 3 4 5 6 1 Ignition Transformer 2 Ignition cords 3 Ignition electrodes 5mm 4mm Fig F 40 Fuel nozzle 5mm Fig F 41 Fuel nozzle Heating system Fig F 39 Heating system Overview ...

Page 47: ...exhaust If the exhaust temperature reaches 270 C 518 F the machine cuts out The relay pla ced in the E box can be reset by pressing the green button Fig F 42 Temperatur sensor Fig F 43 Temperatur relay 1 2 3 4 5 6 7 Fig F 44 Burner unit Burner Unit 1 Fuel solenoid 2 Fuel pump 3 Burner motor 4 Burner housing 5 Fuel filter 6 Fan 7 Fan cover ...

Page 48: ...g on the floor press over to the side or protect the machine by a piece of card board Attention Be aware of the fact that the machi ne can tip over Keep the coil close to the ma chine Check the flame tube A and B It is important that they are solid and whole Clean up deposits and change the isolation if needed A B Heat exchanger Fig F 45 Dismounting coil Fig F 46 Dismounting coil Fig F 47 Dismount...

Page 49: ...m 20 Nm 65 Nm 10 Nm 40 Nm 25 Nm By hand Torque specifications Fig G 01 Wobble disc Fig G 02 Cylinder block Fig G 03 Cylinder head Fig G 04 Venting valve Fig G 05 By pass housing 40 Nm Fig G 08 Water regulation Fig G 07 Outlet fittings Fig G 06 Venting valve ...

Page 50: ...1206358 to the machine water outlet Check the working pressure in data sheets chapter B Close the safety valve completely Turn pressure bolt B Fig G12 1 to 2 turns out to ensure that a too high cut off pressure will not damage the by pass valve Adjust the test tap A Fig G 09 G 10 and the pressure bolt B so it couples 20 30 bars higher than working pressure when the pres sure gun is closed CUT OFF ...

Page 51: ...d hard movements during the change from working pressure to by pass pressure Let the machine run 5 bars lower than the cut off pressure working adjustment and adjust the safety valve out Counter clockwise until it couples out go into bypass Then you turn the adjusting screw a turn back Clockwise and lock it with the counter nut Open and close the pressure gun a couple of times to check the adjustm...

Page 52: ...ine the soot rating with a soot pump and soot rating reference scale The figure should not exceed 1 Otherwise open the air flap a little and repeat the measurement Repeat the procedure until the specified value is obtained 4 Then the CO2 content in the exhaust the intake and exhaust temperature are determined This can be done with conventional meters or with an electronic meter like the TESTO 327 ...

Page 53: ...rating with a soot pump 1 and soot rating reference scale The figure should not exceed 1 Otherwise open the air flap Fig G 07 a little and repeat the measure ment Repeat the procedure until the specified value is obtained Fig G 17 Soot raiting Fig G 19 Service settings Burner settings The CO2 content in the exhaust the intake and exhaust temperature are determined This can be done with conventiona...

Page 54: ...H Wiring diagrams NEPTUNE 5 FA_EN_Ver 2 0_25 11 54 ...

Page 55: ...H Wiring diagrams NEPTUNE 5 FA_EN_Ver 2 0_25 11 55 ...

Page 56: ...H Wiring diagrams NEPTUNE 5 FA_EN_Ver 2 0_25 11 56 ...

Page 57: ...H Wiring diagrams NEPTUNE 5 FA_EN_Ver 2 0_25 11 57 ...

Page 58: ...H Wiring diagrams NEPTUNE 5 FA_EN_Ver 2 0_25 11 58 ...

Page 59: ...H Wiring diagrams NEPTUNE 5 FA_EN_Ver 2 0_25 11 59 ...

Page 60: ...H Wiring diagrams NEPTUNE 5 FA_EN_Ver 2 0_25 11 60 ...

Page 61: ...H Wiring diagrams NEPTUNE 5 FA_EN_Ver 2 0_25 11 61 ...

Page 62: ...62 NEPTUNE 5 FA_EN_Ver 2 0_25 11 Notes ...

Page 63: ...NEPTUNE 5 FA_EN_Ver 2 0_25 11 63 ...