Alto Poseidon 7 User manual

1
Service Manual
Poseidon

A TechnicalData
B Construction
C Function
D Trouble-shooting
E Service/Repair
F Adjustment/Test
G WiringDiagrams
H SparePartsProposal
I SpecialInformation
Index
Poseidon

Poseidon_GB01
Technical Data A
1
Poseidon 1200
Primary data Unit General Nominal values Tolerances
Voltage VAC 200 240 400 415 440 440 +6/-10%
Frequency Hz 50 50 50 50 60
Motor coupling
Number of phases Pce. 3333
Power consumption A 12 +-1.5
High voltage KV 2.4 in 2 sec.
Leakage current mA 0.75
Resistance in ground circuit Ohm 0.2
Absorption power kW 6.7
Axel power kW 5.5
Revolutions Min-1 1440 1420-1470
Control voltage VAC 200 240 400 415 440 440 +-10%
Signal voltage microprocessor VAC 5 +-10%
IP classification 45
Bypass time auto start/stop Sec 20
Bypass time manual Min 5
Water volume, high-pressure l/min 17.6
Water volume, low-pressure l/min 19.1
Machine's pressure gauge Bar 175 +-8.5%
Pump pressure, high-pressure Bar 158
Pressure, h-p pump outlet Bar 152
Opening pressure, pump outlet Bar 185 +-7
Bypass pressure Bar 11 +-4
Suction capacity Bar 0.17
Suction height, primed m 3
Max. water inlet temperature °C 85
Max. water inlet pressure Bar 10
Reaction force, max. N 54
Acoustic pressure level dBA 75.4
Oil volume Litre 0.5
Oil type Pump oil 100

Poseidon_GB01
Technical Data A
2
Poseidon 1280
Primary data Unit General Nominal values Tolerances
Voltage VAC 200 240 400 415 440 440 +6/-10%
Frequency Hz 50 50 50 50 60
Motor coupling
Number of phases Pce. 3 3 3 3
Power consumption A 13 +-1.5
High voltage KV 2.4 in 2 sec.
Leakage current mA 0.75
Resistance in ground circuit Ohm 0.2
Absorption power kW 8.3
Axel power kW 6.5
Revolutions Min-1 1440 1420-1470
Control voltage VAC 200 240 400 415 440 440 +-10%
Signal voltage microprocessor VAC 5 +-10%
IP classification 45
Bypass time auto start/stop Sec. 20
Bypass time manual Min 5
Water volume, high-pressure l/min 18.6
Water volume, low-pressure l/min 20.3
Machine's pressure gauge Bar 195 +-8.5%
Pump pressure, high-pressure Bar 178
Pressure, h-p pump outlet Bar 170
Opening pressure, pump outlet Bar 200 +-7
Bypass pressure Bar 12 +-4
Suction capacity Bar 0.17
Suction height, primed m 3
Max. water inlet temperature °C85
Max. water inlet pressure Bar 10
Reaction force, max. N
Acoustic pressure level dBA 75.4
Oil volume Litre 0.5
Oil type Alphasyn T 150

Poseidon_GB01
Technical Data A
3
Poseidon 720
Primary data Unit General Nominal values Tolerances
Voltage VAC 230 +6/-10%
Frequency Hz 50
Motor coupling 3
Number of phases Pce. 1
Power consumption A 12 +-1.5
High voltage KV 2.4 in 2 sec.
Leakage current mA 0.75
Resistance in ground circuit Ohm 0.2
Absorption power kW 2.9
Axel power kW 2.1
Revolutions Min-1 1430 1420-1470
Control voltage VAC 230 +-10%
Signal voltage microprocessor VAC 5 +-10%
IP classification 45
Bypass time auto start/stop Sec 20
Bypass time manual Min 5
Water volume, high-pressure l/min 11.5
Water volume, low-pressure l/min 12.5
Machine's pressure gauge Bar 105 +-8.5%
Pump pressure, high-pressure Bar 101
Pressure, h-p pump outlet Bar 93
Opening pressure, pump outlet Bar 125 +-7
Bypass pressure Bar 10.5 +-4
Suction capacity Bar 0.17
Suction height, primed m 3
Max. water inlet temperature °C85
Max. water inlet pressure Bar 10
Reaction force, max. N 54
Acoustic pressure level dBA 75.4
Oil volume Litre 0.5
Oil type Pump oil 100

1
Poseidon_GB01
Construction B
Frame
The frame is built of Ø25mm steel pipes. One nozzle can be stored on each side of the machine.
2,Ø250mmwheelsand1,Ø100mmswivelwheelaremountedtotheframe.
A bent bar is attached to the front of the frame to protect hose attachments. The bar is also used for lifting the
machineboth manually and by crane.
Thebackbarisequippedwith fixtures for mounting hose reel, a U-bar for placing nozzles, and winding reel for
electrical cable.
The steering handle is made of plastic.
Cabinet
Thecabinetismadeofvacuum-shapedplastic.
On the cabinet’s top side there is room for storing small auxiliary articles.
All hoses are connected through the hole at the front of the cabinet.
Motor/pump
Themotor/pumpunitisattachedtotheframewithfourtaptitescrewsintheelectricmotor’sstator.This
waythepumpcanbeaccessedfromthefrontofthemachine,andthosepartsofthepumpsusceptible
towearare easilyserviced.
Thepumpisa4-cylinderaxialpistonpumpwithawobblediscsystemandsolidceramicpistons.Suction
andpressurevalvesaremadeofstainlesssteel.
The oil system is closed, and the oil level can be checked through a liquid indicator on the side of the
cabinet.
Thepump’swaterconnectionis mounted using ¾” quick-acting coupling.
The pump’s pressure outlet is mounted with a 3/8”quick-acting coupling
nipple.
Thepumppressurecanbereadinbars(CPA)onanadaptedpressuregauge.
Start/stop system
Themachine’sstart/stopsystemiscontrolledbyamicroprocessorthatstops/interruptsthesignalfrom
areedswitch.Thereedswitchisactivatedbytheflowofamagneticpistonmountedinthepumpoutlet’s
flowcontrolthroughthepump.
The start switch has 3 settings:
0= Machine stopped.
I= Aut. start/stop. Machine stopped with automatic stop function if the spray handle is not activated
after20seconds.
Man=Manuel.Machinestartedinmanualposition. Themachinestops automatically,however,ifthe
spray handle is not activated after 5 minutes.
Use the manual position if the machine is set to suction without water inlet pressure.

2
Poseidon_GB01
Construction B
Electrical system
The electrical system is located in electrical casing placed on the motor/pump unit.
All automatic functions are controlled by a microprocessor built into a circuit board.
Equipment
Themachine’sstandardequipmentconsistsof:
Ergo3000sprayhandle.
10mtr. Double wirehigh-pressurehose.
Tornadonozzle.
¾” quick coupling nipple.

Poseidon_GB01
Function C
1
Pump Function
Theillustration below shows a cross-section ofthe Poseidon pump.
Thepump’sjobisto move a givenamountofwaterfromthesuction side to thehigh-pressurenozzle.
Thevolumeofwaterdependsonthepistons’quantity,diameter,impactlength,andnumberofimpacts
perminute.
WhenwobblediscAisturned,thepistonispulleddownwith thehelpof retractingspringB, andwater
issuckedthroughsuction valve C.
Whenthepistonrisesagain,thesuctionvalvecloses,andpressure valve D opens.
Fromhere,waterispropelledtowardsthepump’sbypassvalve.
Becauseofthehigh-pressurenozzle’ssmallopening,considerableforceisneededtomovethepistons
forward.
Inordertoreducelostfriction, the force ofthemotoristransferredtothepistons via the wobbledisc’s
oil-soakedErollerbearings.
The pistons are composed of a stainless steel portion, which is controlled by the cylinder and sealed
withoilsleeveF.Theupperportionofthepistonisceramic,thesealonthewatersideconsistsofagasket
system.
At the top is textile sleeve G, which seals out high-pressure. A smaller leakage current passes down
tolow-pressuresleeveH,andbetweenthesetwosleeves,thelubricationisdrainedbacktothesuction
side through a small channel.

Poseidon_GB01
Function C
2
Bypass Valve Function
The bypass valve has 4 functions:
1. Protect the machine against excess pressure.
2. Relievethepressureinbypass.
3. Fastconversiontohigh-pressure.
4. Ensure 0 pressure when the machine is stopped.
Operation:
ThewaterfromthepumpisledintochamberAofthebypassvalve.
From there, the water passes through hole B in piston C and out of the machine.
This leads to a pressure imbalance in piston C, which keeps valve disc D closed to valve seat E.
Bypass:
Whenwaterconsumptionstops(the spray handle is released), pressure increases briefly until safety valve F
opensuponreachingthepressuresetting,whichshouldbeadjustedto25-30barsoverworkingpressure.This
causesthepressuredrop in piston C to disappear,andvalvediscD moves from valve seat E. The machine is
nowrunninginbypass.

Poseidon_GB01
Function C
3
PO SEIDO N SPRAY
A
B
B
C
D
E
F

Poseidon_GB01
Function C
4
PO SEIDO N BY- PASS
F
A
B
C
B
E
D

Poseidon_GB01
Function C
5
Flow Control
Flowcontrolconsistsof:
1. Casing
2. Piston w/ magnet
3. Spring
4. Reedswitch
Operation:
A drop in pressure in the piston pushes the piston forward, causing the magnet to activate the reed switch.
A drop in pressure on the piston’s end face causes the piston to remain in this position.
Bypass:
When water is not being consumed, the drop in pressure in the piston stops, and the piston is pushed back
by the spring, deactivating the reed switch.
The pressure is balanced out through the hole in the piston, and the force of the spring holds the piston in a
neutralposition.
5 VO LT
SPRAY.
0 V O LT
BY- PASS.

Poseidon_GB01
Function C
6
PC Board
The circuit board has the following functions:
1. To start the electric motor when starting the machine.
2. To stop the electric motor when operation of the machine is finished.
3. To record and store data concerning the machine’s work situations, operation, and bypass.
The circuit board is protected against excess pressure thanks to a circuit breaker (0.63A- SLOW) placed on
theboard.
Startswitchpositions
0:
The machine is not in operation; there is no power from the Start/Stop switch to print and the contactor’s
magneticpole.
1:
The machine is set to automatic start/stop operation.
When you activate the spray handle and water is flowing through the machine, the flow sensor’s reed switch
signalsthecircuitboard’smicroprocessor,and themachinerunsuninterrupted.
When you release the spray handle, and water flow through the machine stops, the signal to the PC board’s
microprocessor is interrupted. After a 20-second delay, power to the contactor’s magnetic pole is cut off, and
the electric motor stops.
Man:
The machine is set to manual operation.
The flow sensor is monitored via the reed switch but is not active.
Theelectricmotorrunsuninterruptedregardlessofwhetherornotthereedswitchregisterswaterflow.
When you release the spray handle and the water flow through the machine stops, the power to the Start/Stop
switch and to the contactor’s magnetic pole is cut off after 5 minutes.
The machine must then be restarted using the Start/Stop switch.
Service functions:
1. Identificationofmachineandsoftwaretype.
2. Read-outofnumberofstarts.
3. Read-outinhours/minutesofoperatingtimeunder flow.
4. Read-outinhours/minutesofbypasstime.
Theseread-outsaremadewithALTOSB Datalogger .
A description of SB Datalogger will be added later.

Poseidon_GB02
Trouble-shooting D
1
Poss. cause/ Check
Circuit breakers Contactor + coil Electrical connections + plug Temperature sensor in motor Start switch Print + reed switch Piston for bypass valve Pump pressure + h-p nozzle Suction valve + seat Pressure valve + seat Leaks in hoses Bypass valve + disc O-ring in cylinder head Water filter Pressure sleeve Air in pump Safety valve Water supply Water temperature Suction height Suction cup on bypass valve Oil sleeve + oil hoses Suction sleeve Flow control
Symptom:
Motor doesn't start XXXXXX X
Motor doesn't stop X
Motor stops XXXX X X
Max. pressure too high X
Max. pressure too low XXXXXXXXXXXX
Max. pressure irreg. in suction X X X X XXX X
Max. pressure 50-70 bars XXX
Max. pressure pulsating XXX
Bypass pressure too high XX X
Oil consumption too high X
Pump run only bypass XX
Bypass valve "thumps" XX X
Uneven pressure during operation XX
Pump doesn't go into bypass XX
Operating Requirements
To ensure error-free operation, the following requirements must be met:
1. Machine and equipment must be free of air and without leaks.
2. Water temperature must not exceed 85°C when inlet pressure on water supply.
3. In suction mode, water temperature must be significantly lower, depending on the suction
height. Make sure the pump does not cavitate (water boils under vacuum).
4. Water quality must be free of impurities > 50 µ.
5. Water supply must be sufficient at all times.
6. Ambient temperature must not exceed 40°C.
7. Supply voltage must not vary by more than 6% of the given value.

1
Poseidon_GB01
Service/Repair E
Safety valve
Thesafetyvalve’sfactorysettingforopeningpressure=working pressure + 25 to +30 bars.
Upon each service inspection the setting must be tested and, if necessary, adjusted.
When mounting, affix ball and pressure plate to the spring with lubrication.
The seat is screwed on using a 10mm socket wrench (no gasket required).
Before testing with a pressure gauge, make sure that two threads are visible behind the locknut.
Warning: Before starting the pump, check that the test manometer valve is open. Close the valve slowly;
pressuremustneverexceed250bars.
Pressure side
Suction side
10mm special wrench
no.: 1206754
6mm Allen wrench
o
1
Man
M ax. 250 bar.

2
Poseidon_GB01
Service/Repair E
Valve cylinder head 1
Kenney
Lubrication duct Pressure valve seat
Suction valve seat
Nylon ring
Textile sleeve (hard)
Back-up ring
Rubber sleeve (soft)
Removethesuctionvalveseatusingimpactpiercerno.1216506.
Pressout the pressure valve usinga 2 mm piercer.
Checkvalveseats.
Mountagainwithfingers.
Removalandmountingisdonemanually.
LubricatethelargeOringwithgrease.

3
Poseidon_GB01
Service/Repair E
Lock/back-up ring
Rubber sleeve secondary
Thrust collar
Back-up ring
Textile sleeve
Expansion/back-up ring
O-ring
Suction valve Pressure valve
O-ring
When mounting textile sleeves, use tool no.: 1220090.
Ithelps to place the sleeves in a water bath 3-4 hoursbefore mounting.
Remembertoblowthroughthelubricationducts with compressed air.
Valve cylinder head 2
Kenney

4
Poseidon_GB01
Service/Repair E
O-ring
Oil sleeve
Plate
Back-up ring
Torque: 37 Nm
Oil filling
Oil draining
Alwaysreplacesecondarysleeveswhen
replacingpressuresleeves.
Check for free passage in the thrust
collar’sdrainageholes.
Draintheoilbylooseningtheplugatthebottomofthecylinder
block.
Loosenthe8nutsevenlyinconsiderationofthepressurefrom
the piston springs.
Usespecialheadno.1206762.
Mount new O rings on stay bolts using tool no. 1206812.
Whenchangingtheoil,loosenthehoseconnectionabove
the cylinder block.
Oil (0.5 litres) is poured into the threaded hole.
Testing has shown that the pump does not consume oil
duringnormaloperation.
In other words, under normal circumstances you do not
need to refill oil in the pump.
Nevertheless, the oil level and quality must be checked
regularlythroughtheliquidindicator.
Cylinder block 1

5
Poseidon_GB01
Service/Repair E
Oil sleeve Low-pressure High-pressure
Contact surface Stainless steel Ceramic
Inspectthepistonfor
wearonthecontact
surfaceandin the
areafor oilsleeves.
Examinethe ceramic
for cracks, and wipe
cleananydeposits.
Cylinder block 2
Carefullylifttheoil
sleevesoutwith a
suitablescrewdriverand
disposeof them.
Becareful not toscrape
thesurface.
Beforeinsertingthe new
sleeves, it is a good idea
tomoistenthe sleeves
withsoapywater.
Insertnewoilsleeves
usingpiercer no.
1220429.
Gentlytapor press in.

6
Poseidon_GB01
Service/Repair E
Motor / wobble disc 1
Themotor consists of a stator with windings,a rotor with an axel that isheld in place with a bearing in
theN-bearingcoverandthewobbledisc’sinnermostneedlebearingintheD-bearingcover.
Ventilator 4 is pressed onto the rotor over locking bush 5 and is mounted with two screws.
Thewobbledisc’spressureplate23isheldinplacewithpeg22.Plate21ensuresthatneedlebearing
24isheldapartfromoil sleeve X.
Removelockingring27.
Thewobblediscis easily removedwith
wheeldresserno.1205715andspecial
legno.1206150/1206168.
Remembertoremoveparallelkey17before
removingD-bearingcover.
Checkbearingsurfacesforwear.
If in doubt, replace set 28 completely.
4ND
5
stator ro to r
x
22
21
27
23