Alto Neptune 5 User manual

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
NEPTUNE 5-25 / GB NEPTUNE 5-27 / EU
Water volume Qmax l/h 720 700
Water volume QIEC 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
C02content 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
NEPTUNE 5-42 / NO, BE NEPTUNE 5-42 / EU
Water volume Qmax l/h 860 860
Water volume QIEC 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
C02content 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
NEPTUNE 5-49 / NO, BE NEPTUNE 5-49 / EU
Water volume Qmax l/h 970 970
Water volume QIEC 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
C02content 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 Qmax l/h 1080 1080
Water volume QIEC 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
C02content 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 Qmax l/h 720
W ater volum e QIEC l/h / l/min. 660 / 11
Pressure P1 (working pressure) bar 90
Pressure P2 / Q2 bar / l/m in. 25 / 6,7
Pressure P m ax. I bar 200
Pressure P m ax. II bar 32
Tem perature t max. 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
F us e (s low blow ) A 13
International Protection Class IP X5
HP-Nozzle NT 0550
W ater inlet pressure bar 10
W ater inlet tem perature °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 tem perature °C 170
C02content 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/m in 1450
Piston Ceramic
Piston diam eter m m 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 Qmax l/h 1260 1260
Water volume QIEC 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
C02content 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.