Nilfisk-ALTO NEPTUNE 4 User manual

NEPTUNE 4
Supplement
to Service Manual
NEPTUNE 3 and NEPTUNE 5 / 7

A. Safety instructions
B. Technical data
C. Construction
D. Function
E. Troubleshooting
F. Maintenance / repair
G. Adjustments
H. Wiring diagrams
I. Special tools / spare parts

Nilfisk
ALTO
Index
Preface
A. Safety instructions
B. Technical data
C. Construction
D. Function
E. Troubleshooting
F. Maintenance / repair
Notes
1. NEPTUNE 4-25 / NEPTUNE 4-28
2. 4-30
3. N 4-42
4. 4-49
5. 4-54
... 1
... 2
... 3
... 4
... 5
... 6
... 7
... 8
... 9
... 10
... 11
... 19
NEPTUNE
EPTUNE
NEPTUNE
NEPTUNE
G. Adjustments
H. Wiring diagrams
I. Special tools / spare parts
... 12
... 13
... 14
... 15
... 16
... 18
1. Wiring diagram parts list
2. 3~ star (71305)
3. 3~ star / delta (71306)
4. 1~ with Klixon relay (71307a)
5. 1~ with starting electronic (71418) ... 17
Index
Neptune 4_EN_Ver.1.0_04/06

Nilfisk
ALTO
There are only minor differences between the
NEPTUNE 4 hot-water high-pressure cleaner and
NEPTUNE 3 and NEPTUNE 5 line of products.
This service manual mainly refers to the
concerning sections in the service manuals
NEPTUNE 3 and NEPTUNE 5
Repair work requires a suitable testing workplace
with the necessary power supply.
If operating errors are evident, refer the customer
to the user manual.
A fault in the cleaner can have a number of causes.
Refer to Chapter E for troubleshooting.
Also refer to the illustrated spare parts list (p
301002627) for your repairs. This shows you the
location of the individual parts and the sequence in
which they are assembled.
Read the ”Service / Technical Information” sheets. They include information on technical modifications
that have been made after this service manual was printed.
”Service / Technical Information” sheets are also valid as a supplement to the spare parts list until a new
edition is published.
Service manuals and “Service / Technical Information” sheets should be available at the place where
repairs are carried out.
Transfer to third parties is not allowed.
Use original spare parts only!
/7.
/n
Nilfisk ALTO
Preface
Neptune 4_EN_Ver.1.0_04/06
Preface
1/21

A
Nilfisk
ALTO
Safety instructions
For your own safety
Repairs should only be
made by someone who
has received proper
instructions for the job or
who is a qualified
electrician.
Observe national safety directives and
regulations for the electrical engineering
trade, in particular:
IEC 60335-2-69
EN 60335-2-69
Before starting the equipment, be sure to
read the accompanying operator manual,
and keep it close as ready reference.
The equipment should only be used by
persons who have been instructed in its
use and are authorized to do so.
ESD (electrostatic
discharge)
Observe the following ESD precautions before any repair of or near
electronic parts:
Touch the protective conductor to discharge your own body.
Possibly wear an anti-static wrist strap.
Use a conducting floor or tabletop.
Never touch a circuit board or electronic components always hold
it by the plastic or insulation.
Transport electronic parts in conductive packaging (e.g. special
ESD packages).
l
l
l
l
l
Neptune 4_EN_Ver.1.0_04/06
Safety instructions
2/21

B
Nilfisk
ALTO
Table B.1: Neptune 4-25 / Neptune 4-28
1. NEPTUNE 4-25 / NEPTUNE 4-28
Neptune Neptune
4-25 4-28
*GB* *GB*
Machine protection category IP X5 X5
Current consumption A 30 13
Voltage V 110 230
Frequency Hz 50 50
Connected load kW 3 3
Sound pressure dB (A) 72,4 72,4
HP nozzle 500 640
Pressure P1 / P1 max. bar 90 / 200 90 / 200
Pressure P2 / P2 max. bar 25 / 32 25 / 32
Max. recoil force N 25 27
W ater throughput (max.) l/h 720 770
W ater throughput (EN 60335-2-79) l/h 660 720
W ater intake pressure (max.) bar 10 10
W ater intake temperature (max.) °C 40 40
Voltage V 110 230
Frequency Hz 50 50
Connected load kW 2 2,2
Motor insulation CL. F CL. F
Ingress protection IP 54 54
RPM U/min 1450 1450
Type NP5 10.12 NP5 11.14
Plunger ceramic ceramic
Plunger diameter mm 18 18
Plunger stroke mm 9,8 10,8
Pump oil SAE 15 W 40 SAE 15 W 40
Amount of oil ml 1000 1000
Fuel pressure bar 15 (- 0,5) 15 (- 0,5)
Fuel consumption dt = 45 K kg/h 3,2 3,5
Exhaust temperature °C 185 185
CO2content (min.) % 10,5 (+ 0,5) 10,5 (+ 0,5)
Soot rating 0 - 1 0 - 1
Efficiency % > 92 > 92
W ater content (coil) l 3,5 3,5
Heating power kW 55 55
Length mm 1053 1053
W idth mm 685 685
Height mm 750 750
W eight kg 128 128
High-pressure hose DN 8 x 10 m DN 8 x 10 m
Electrical lead m 5 5
Fuel tank l 16 16
Detergent tank l 10 10
Heat exchanger
Dimen-
sions and
weight
Miscella-
neous
NEPTUNE 4
Technical machine dataMotorPump
Note: Neptune 4-28 *GB* is also available as X-model.
Technical data
Neptune 4_EN_Ver.1.0_04/06
3/21

B
Nilfisk
ALTO
Table B.2: Neptune 4-30
Note: Neptune 4-30 *EU* and Neptune 4-30 *EXP* are also available as X-models.
2. NEPTUNE 4-30
Neptune Neptune
4-30 4-30
*EU* *EXP*
Machine protection category IP X5 X5
Current consumption A 15,6 15
Voltage V 230 220
Frequency Hz 50 60
Connected load kW 3,4 3,3
Sound pressure dB (A) 72,4 72,4
HP nozzle 530 500
Pressure P1 / P1 max. bar 110 / 200 105 / 200
Pressure P2 / P2 max. bar 25 / 32 25 / 32
Max. recoil force N 30 27
W ater throughput (max.) l/h 750 720
W ater throughput (EN 60335-2-79) l/h 700 670
W ater intake pressure (max.) bar 10 10
W ater intake temperature (max.) °C 40 40
Voltage V 230 220
Frequency Hz 50 60
Connected load kW 2,2 2,2
Motor insulation CL. F CL. F
Ingress protection IP 54 54
RPM U/min 1450 1750
Type NP5 11.14 NP5 2,8G22
Plunger ceramic ceramic
Plunger diameter mm 18 18
Plunger stroke mm 10,8 8,5
Pump oil SAE 15 W 40 SAE 15 W 40
Amount of oil ml 1000 1000
Fuel pressure bar 15 (- 0,5) 15 (- 0,5)
Fuel consumption dt = 45 K kg/h 3,45 3,3
Exhaust temperature °C 185 185
CO2content (min.) % 10,5 (+ 0,5) 10,5 (+ 0,5)
Soot rating 0 - 1 0 - 1
Efficiency % > 92 > 92
W ater content (coil) l 3,5 3,5
Heating power kW 55 55
Length mm 1053 1053
W idth mm 685 685
Height mm 750 750
W eight kg 128 128
High-pressure hose DN 6 x 10 m DN 6 x 10 m
Electrical lead m 5 5
Fuel tank l 16 16
Detergent tank l 10 10
Heat exchanger
Dimen-
sions and
weight
Miscella-
neous
NEPTUNE 4
Technical machine dataMotorPump
Technical data
Neptune 4_EN_Ver.1.0_04/06
4/21

B
Nilfisk
ALTO
Table B.3: Neptune 4-42
Note: Neptune 4-42 *EU* is also available as X-model.
3. NEPTUNE 4-42
Neptune
4-42
*EU*
Machine protection category IP X5
Current consumption A 10
Voltage V 400
Frequency Hz 50
Connected load kW 5,6
Sound pressure dB (A) 76,5
HP nozzle 0475
Pressure P1 / P1 max. bar 170 / 250
Pressure P2 / P2 max. bar 25 / 32
M ax. recoil force N 43
W ater throughput (max.) l/h 860
W ater throughput (EN 60335-2-79) l/h 800
W ater intake pressure (max.) bar 10
W ater intake temperature (max.) °C 40
Voltage V 400
Frequency Hz 50
Connected load kW 4,5
Motor insulation CL. F
Ingress protection IP 54
RPM U/min 1450
Type NP5 13.20
Plunger ceramic
Plunger diameter mm 18
Plunger stroke mm 12,8
Pump oil SAE 15 W 40
Amount of oil ml 1000
Fuel pressure bar 15 (- 0,5)
Fuel consumption dt = 45 K kg/h 3,9
Exhaust temperature °C 185
CO2content (min.) % 10,5 (+ 0,5)
Soot rating 0 - 1
Efficiency % > 92
W ater content (coil) l 3,5
Heating power kW 70
Length mm 1053
W idth mm 685
Height mm 750
W eight kg 132,5
H igh-pressure hose D N 8 x 10 m
Electrical lead m 5
Fuel tank l 16
Detergent tank l 10
Heat exchanger
Dimen-
sions and
weight
Miscella-
neous
NEPTUNE 4
Technical machine dataMot orPump
Technical data
Neptune 4_EN_Ver.1.0_04/06
5/21

B
Nilfisk
ALTO
Table B.4: Neptune 4-49
4. NEPTUNE 4-49
Neptune Neptune
4-49 4-49
*EU* *NO, BE*
Machine protection category IP X5 X5
Current consumption A 12,5 21,7 / 12,5
Voltage V 400 230, 400
Frequency Hz 50 50
Connected load kW 6,9 6,9
Sound pressure dB (A) 76,6 76,6
HP nozzle 0550 0550
Pressure P1 / P1 max. bar 180 / 250 180 / 250
Pressure P2 / P2 max. bar 25 / 32 25 / 32
Max. recoil force N 47 47
W ater throughput (max.) l/h 950 950
W ater throughput (EN 60335-2-79) l/h 900 900
W ater intake pressure (max.) bar 10 10
W ater intake temperature (max.) °C 40 40
Voltage V 400 230, 400
Frequency Hz 50 50
Connected load kW 5,5 5,5
Motor insulation CL. F CL. F
Ingress protection IP 54 54
RPM U/min 1450 1450
Type NP5 15.20 NP5 15.20
Plunger ceramic ceramic
Plunger diameter mm 18 18
Plunger stroke mm 14,6 14,6
Pump oil SAE 15 W 40 SAE 15 W 40
Amount of oil ml 1000 1000
Fuel pressure bar 15 (- 0,5) 15 (- 0,5)
Fuel consumption dt = 45 K kg/h 4,4 4,4
Exhaust temperature °C 185 185
CO2content (min.) % 10,5 (+ 0,5) 10,5 (+ 0,5)
Soot rating 0 - 1 0 - 1
Efficiency % > 92 > 92
W ater content (coil) l 3,5 3,5
Heating power kW 70 70
Length mm 1053 1053
W idth mm 685 685
Height mm 750 750
W eight kg 137,5 137,5
High-pressure hose DN 8 x 10 m DN 8 x 10 m
Electrical lead m 5 5
Fuel tank l 16 16
Detergent tank l 10 10
Heat exchanger
Dimen-
sions and
weight
Miscella-
neous
NEPTUNE 4
Technical machine dataMotorPump
Note: Neptune 4-49 *EU* and Neptune 4-49 *NO, BE* .are also available as X-models
Technical data
Neptune 4_EN_Ver.1.0_04/06
6/21

B
Nilfisk
ALTO
Table B.5: Neptune 4-54
Note: All three Neptune 4-54 variants .are also available as X-models
5. NEPTUNE 4-54
Neptune Neptune Neptune
4-54 4-54 4-54
*EU* *NO, BE* *EXP*
Machine protection category IP X5 X5 X5
Current consumption A 14 24 / 14 22,5 / 14
Voltage V 400 230, 400 220, 460
Frequency Hz 50 50 60
Connected load kW 7,9 7,9 7,9
Sound pressure dB (A) 76,9 76,9 76,9
HP nozzle 0500 0500 0500
Pressure P1 / P1 max. bar 200 / 250 200 / 250 200 / 250
Pressure P2 / P2 max. bar 25 / 32 25 / 32 25 / 32
Max. recoil force N 56 56 52
Water throughput (max.) l/h 1050 1050 1050
Water throughput (EN 60335-2-79) l/h 1000 1000 1000
Water intake pressure (max.) bar 10 10 10
Water intake temperature (max.) °C 40 40 40
Voltage V 400 230, 400 220, 460
Frequency Hz 50 50 60
Connected load kW 5,5 5,5 5,5
Motor insulation CL. F CL. F CL. F
Ingress protection IP 54 54 54
RPM U/min 1450 1450 1750
Type NP5 15.20 NP5 15.20 NP5 4G30
Plunger ceramic ceramic ceramic
Plungerdiameter mm181818
Plunger stroke mm 14,6 14,6 12
Pump oil SAE 15 W 40 SAE 15 W 40 SAE 15 W 40
Amount of oil ml 1000 1000 1000
Fuel pressure bar 15 (- 0,5) 15 (- 0,5) 15 (- 0,5)
Fuel consumption dt = 45 K kg/h 4,9 4,9 4,9
Exhaust temperature °C 185 185 185
CO2content (min.) % 10,5 (+ 0,5) 10,5 (+ 0,5) 10,5 (+ 0,5)
Sootrating 0-1 0-1 0-1
Efficiency % >92 >92 >92
Water content (coil) l 3,5 3,5 3,5
Heating power kW 70 70 70
Length mm 1053 1053 1053
Width mm 685 685 685
Height mm 750 750 750
Weight kg 137,5 137,5 137,5
High-pressure hose DN 8 x 10 m DN 8 x 10 m DN 8 x 10 m
Electrical lead m 5 5 5
Fuel tank l 16 16 16
Detergent tank l 10 10 10
Heat exchanger
Dimen-
sions and
weight
Miscella-
neous
NEPTUNE 4
Technical machine dataMotorPump
Technical data
Neptune 4_EN_Ver.1.0_04/06
7/21

C
Nilfisk
ALTO
1
2
1
2
Construction
Neptune 4_EN_Ver.1.0_04/06
Construction
The external design of the Neptune 4 hot-water
high-pressure cleaner is identical to the Neptune 3
line of products. As far as sensors, control,
functionality and electronics are concerned, there
are no differences to the Neptune 3 series as well.
There are only two differences compared to
Neptune 3:
The Neptune 4 series has the NP5 hp-pump (1)
installed (like the Neptune 5) and the machine is
equipped with an additional hydraulic accumulator
(2)(see also STI MPW-040).
For further details about the construction of the
machine, refer to the Neptune 3 and Neptune 5 / 7
Service Manuals (chapter C resp. chapter 3).
Fig. C.1: Neptune 4
Fig. C.2: NP5 pump & Control Safety Block with hydraulic
accumulator
The Neptune 4 HPC is available in following versions:
Neptune 4-25:
Neptune 4-28:
1~
1
The machine comes as standard- (with storage tray for accessories, tools, etc.) or X-model (with hose
reel instead of the storage tray). Upgrading with a hose reel is possible.
~
1~
3~
3~
3~
Neptune 4-30:
Neptune 4-42:
Neptune 4-49:
Neptune 4-54:
Fig. C.1 & C.2:
1.) NP5 hp-pump 2.) Hydraulic accumulator
8/21

D
Nilfisk
ALTO
There are no functional differences between the Neptune 3 line of products and the Neptune 4 series.
For further details on the subject of function refer to the Neptune 3 Service Manual (chapter D) as well as
the user manual of the respective machine.
For details about the function of the NP5 hp-pump refer to the Neptune 5 / 7 Service Manual (chapter 4).
Further valuable information can be found in the Service / Technical Information (STI) sheets for
Neptune 3 / 5 / 7.
Function
Neptune 4_EN_Ver1.0_04/06
Function
9/21

E
Nilfisk
ALTO
Based on the same microprocessor control as the Neptune 3 line of products, the Neptune 4 shows the
same error codes for verification of the cause of a malfunction of the machine.
This also applies to other troubleshooting procedures.
For further details on the subject of troubleshooting refer to the Neptune 3 Service Manual (chapter E)
as well as the user manual of the respective machine.
For details about troubleshooting the NP5 hp-pump refer to the Neptune 5 / 7 Service Manual (chapter
5).
Further valuable information can be found in the Service / Technical Information (STI) sheets for
Neptune 3 / 5 / 7.
Troubleshooting
Troubleshooting
Neptune 4_EN_Ver.1.0_04/06
10/21

F
Nilfisk
ALTO
Maintenance / repair
Maintenance and repair works to be performed on the Neptune 4 are the same as for the Neptune 3 line
of products, except the hp-pump.
Further details concerning maintenance / repair can be found in the Neptune 3 (chapter F) & Neptune 5 /
7 (chapter 6) Service Manuals as well as in the respective User Manual (part number 301002531).
1. Maintenance
For details refer to the Neptune 3 Service Manual chapter F.1.
2. Periphery
3. Control Safety Block
4. Motor
5. Pump
6. SDR valve
7. Heating subsystem
8. Electrical subsystem
For details refer to the Neptune 3 Service Manual chapter F.2.
For details refer to the Neptune 3 Service Manual chapter F.3.
For details refer to the Neptune 3 (chapter F.4.) and Neptune 5 / 7 (chapter 6) Service Manual.
For details refer to the Neptune 5 / 7 Service Manual chapter 6.
For details refer to the Neptune 3 Service Manual chapter F.6.
For details refer to the Neptune 3 Service Manual chapter F.7.
For details refer to the Neptune 3 Service Manual chapter F.8.
Neptune 4_EN_Ver1.0_04/06
Maintenance / repair
11/21

G
Nilfisk
ALTO
Table G.1: Heat exchanger settings
1. Control board
2. Control Safety Block
3. Heat exchanger system
For adjustment refer to the Neptune 3 Service Manual (chapter G.1).
The adjustment procedure is described in the Neptune 3 Service Manual (chapter G.2) or STI MPW-
030.
The adjustment procedure is described in the Neptune 3 Service Manual (chapter G.3) or STI MPW-005
/ STI MPW-028.
Adjustments
4
CO2content %10.5 (+ 0.5)
Fuel pressure bar 15 (- 0.5)
Soot rating 0-1
NEPTUNE
4. Flow control
5. Automatic AntiStone
6. Electrical connection
The adjustment procedure is described in the Neptune 3 Service Manual (chapter G.3).
The parameters for adjustment are described in the Neptune 3 Service Manual (chapter G.4).
The adjustment of the star / delta switch is described in the Neptune 3 Service Manual (chapter G.5).
Neptune 4_EN_Ver1.0_04/06
Adjustments
12/21

H
Nilfisk
ALTO
1. Wiring diagrams parts list
Table H.1: Wiring diagrams parts list for Neptune 4
Note: The components listed in Table H.1 relate to the following Neptune 4 wiring diagrams.
Code Component designation
A1 Control board
A3 Starting electronic
B1 Temperature sensor
B2 Reed switch
B3 Thermo fuse
B4 Microswitch
B6 Float switch, pump oil
B7 Flame sensor
B8 Float switch, AntiStone
B9 Float switch, fuel
C1 Capacitor
C2 Starting capacitor
F1 Pico fuse
F2 / F3 Fine-wire fuse
K1 Contactor
K2 Relay
K3 Klixon relay
M1 Motor, three-phase
M2 Burner fan motor
MT Thermal protector
R1 Discharge resistor
R2 Inrush current limiter
S1 Switch on / off + temperature setting
S2 Switch star / delta
T1 Transformer
T2 Ignition transformer
X1 Flat connector
X2-X4 Terminal block
X5 Plug connector, 5-way, datalogger
X11 – X13 Omnibus terminal
Xma-b Motor connector
Y1 Solenoid valve
Wiring diagrams
Neptune 4_EN_Ver.1.0_04/06
13/21

H
Nilfisk
ALTO
2. 3 star (71305)~
Fig. H.1: Wiring diagram 3 star~
Wiring diagrams
Neptune 4_EN_Ver.1.0_04/06
14/21

H
Nilfisk
ALTO
4. 1 with Klixon relay (71307a)~
Fig. H.3: Wiring diagram 1 with Klixon relay~
Wiring diagrams
Neptune 4_EN_Ver.1.0_04/06
15/21

H
Nilfisk
ALTO
3. 3 star / delta (71306)~
Fig. H.2: Wiring diagram 3 star / delta~
Wiring diagrams
Neptune 4_EN_Ver.1.0_04/06
16/21

H
Nilfisk
ALTO
5. 1 with starting electronic (71418)~
Fig. H.4: Wiring diagram 1 with starting electronic~
Wiring diagrams
Neptune 4_EN_Ver.1.0_04/06
17/21