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NEPTUNE PE/DE
Service Manual
Jetwash Direct ltd
NEPTUNE PE-DE_en_Ver.1.0_October 2010
A. Safety instructions 5
B. Technical data 6 - 9
10 -17 C. Construction
D. Function
E. Troubleshooting
18 -37
38 -41
F. Service / Repair 42-62
G. Adjustment / Test 63-71
H. Wiring diagrams
Jetwash Direct ltd
72-92
Index
A. Safety instructions ................................................... 5
B. Technical data........................................................... 6
C. Constrution
D. Function
-Electrical.................................................................... 18
-Funktion PCB ............................................................ 24
-Pumps ....................................................................... 28
-By-pass valves & Unloader………………………….... 31
E. Troubleshooting
-Table ......................................................................... 38
F. Service / Repair
-Electrodes ................................................................. 61
-Maintenance………… ............................................... 62
G. Adjustment / Test
-NA5 ........................................................................... 63
-C3.............................................................................. 66
-NP5 ........................................................................... 67
H. Wiring diagrams
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
3
Preface
This service manual contains detailed description of the main repair work on the Hot
Water High Pressure Washer, NEPTUNE PE—DE.
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.
Repair manuals and TSB (Technical Service Bulletin) sheets should be available at the site where repairs are carried out.
It is not permitted to give them to third parties.
Use original Nilfisk-ALTO spare parts only.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
4
Safety instructions A
For your own safety
Before using the cleaner, always read the operating instructions and keep them readily available.
Repair work should be carried out by persons instructed and trained in repairing this product.
The high-pressure cleaner should only be used by authorized persons who have been instructed in its use.
Although extremely easy to operate, children should not be allowed to use the cleaner.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
5
Technical data
NEPTUNE PE
NEPTUNE 5-46PE NEPTUNE 5-54PE
Motor Manufacturer and type
Power
Fuel type
CCM
Fuel tank capacity
Motor RPM, adjusted
Pulley size
Motor oil type
Motor oil capacity
HK/RPM
Cm3
Liter
RPM mm
Liter
Honda GX 340
9,5/3600
Petrol
337
6,1
3550
SPZ 55,4/1
SAE 15/40
1,1
Type
Pump pressure
Machine outlet pressure bar bar
Water Quantity, high pressure l/min
Water Quantity, low pressure l/min
Suction capacity (feeded)
Pump inlet temperature meter
°C
Fuel pressure
Fuel consumption dt = 45 °C
CO
2
content (min.)
Soot rating
Efficiency
Onboard fuel tank
Heater rating
Delta T @ working pressure bar kg/h
%
%
Litre kW
ºC
12
3,9
10,5
0
92
57
68
75
NA5
188
167
12
13,5
3
35-40
Type
Effect
RPM @ HP and Boiler
PUlley Size
Belt dimension Motor/Gen.
Length
Width
Height
Weight
Sound power level CE, Lwa
High-pressure hose DN8
HP nozzle
W
RPM mm mm mm kg
Db m t16W-75
1000
2825
SPZ 63/1
SPZ 670
970
780
1000
208
105
15
0400
10
3,9
10,5
0
92
57
81
81 t16W-75
1000
2825
SPZ 60/1
SPZ 670
970
780
1000
208
105
15
0450
Honda GX 390
11,0/3600
Petrol
389
6,1
3400
SPZ 55,4/1
SAE 15/40
1,1
NA5
198
170
13,5
15
3
35-40
B
6
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Technical data
NEPTUNE PE
NEPTUNE 7-61PE NEPTUNE 5-85PE
Motor Manufacturer and type
Power
Fuel type
CCM
Fuel tank capacity
Motor RPM, adjusted
Pulley size
Motor oil type
Motor oil capacity
HK/RPM
Cm3
Liter
RPM mm
Liter
Honda GX 390
11,0/3600
Petrol
389
6,1
3550
SPZ 55,4/1
SAE 15/40
1,1
Type
Pump pressure bar
Machine outlet pressure bar
Water Quantity, high pressure l/min
Water Quantity, low pressure
Suction capacity (feeded)
Pump inlet temperature l/min meter
°C
Fuel pressure
Fuel consumption dt = 45°
C
CO
2
content (min.)
Soot rating
Efficiency
Onboard fuel tank
Heater rating
Delta T @ working pressure bar kg/h
%
%
Litre kW
ºC
11
4,6
10,5
0
92
57
87
70
C3
202
192
16
18
3
35-40
Type
Effect
RPM @ HP and Boiler
PUlley Size
Belt dimension Motor/Gen.
Length
Width
Height
Weight
Sound power level CE,Lwa
High-pressure hose DN8
HP nozzle
W
RPM mm mm mm kg
Db m t16W-75
1000
2825
SPZ 63/1
SPZ 670
970
780
1000
210
105
15
0500
12
5,75
10,5
0-1
92
57
111
70 t16W-75
1000
2825
SPZ 60/1
SPZ 670
1130
910
1050
260
106
15
0650
Honda GX 630
20,8/3600
Petrol
670
20 (External tank)
3340
SPZ 80/4
SAE 15/40
1,9
NP5
210
195
20
21,5
5
35-40
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
B
7
Technical data
NEPTUNE PE
NEPTUNE 5-51DE NEPTUNE 7-66DE
Motor Manufacturer and type
Power
Fuel type
CCM
Fuel tank capacity
Motor RPM, adjusted
Pulley size
Motor oil type
Motor oil capacity
HK/RPM
Cm3
Liter
RPM mm
Liter
Type
Pump pressure bar
Machine outlet pressure bar
Water Quantity, high pressure l/min
Water Quantity, low pressure
Suction capacity (feeded)
Pump inlet temperature l/min meter
°C
Fuel pressure
Fuel consumption dt = 45°
C
CO
2
content (min.)
Soot rating
Efficiency
Onboard fuel tank
Heater rating
Delta T @ working pressure bar kg/h
%
%
Litre kW
ºC
Type
Effect
RPM @ HP and Boiler
PUlley Size
Belt dimension Motor/Gen.
Length
Width
Height
Weight
Sound power level CE, Lwa
High-pressure hose DN8
HP nozzle
W
RPM mm mm mm kg
Db m
10
3,9
10,5
0
92
57
81
81 t16W-75
1000
2825
SPZ 63/1
SPZ 670
970
780
1000
220
110
15
0450
Yanmar
10/3600
Diesel
406
5,5
3530
SPZ 80/3
SAE 15/40
1,65
NP5
185
176
13,5
15
3
35-40
12
4,85
10,5
0-1
92
57
111
76 t16W-75
1000
2825
SPZ 60/1
SPZ 670
1130
910
1050
315
112
15
0650
Ruggerini
16/3500
Diesel
-
20 (External tank)
3500
-
SAE 15/40
1,8
C3
185
170
18,7
20
5
35-40
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
B
8
Technical data
NEPTUNE PE
NEPTUNE 7-72DE
Motor Manufacturer and type
Power
Fuel type
CCM
Fuel tank capacity
Motor RPM, adjusted
Pulley size
Motor oil type
Motor oil capacity
HK/RPM
Mitsubishi
16/1630
Diesel
1318 Cm3
Liter 20 (External tank)
RPM 1600 mm -
SAE 15/40
Liter 4,2
Type
Pump pressure bar
Machine outlet pressure bar
Water Quantity, high pressure l/min
Water Quantity, low pressure
Suction capacity (feeded)
Pump inlet temperature l/min meter
°C
Fuel pressure
Fuel consumption dt = 45°C
CO
2
content (min.)
Soot rating
Efficiency
Onboard fuel tank
Heater rating
Delta T @ working pressure bar kg/h
%
%
Litre kW
ºC
12
5
10,5
0-1
92
57
111
76
C3
200
185
19,5
21,5
5
35-40
Type
Effect
RPM @ HP and Boiler
PUlley Size
Belt dimension Motor/Gen.
Length
Width
Height
Weight
Sound power level CE, Lwa
High-pressure hose DN10
HP nozzle
W
RPM mm mm mm kg dB m t16W-75
1000
2825
SPZ 63/1
SPZ 670
1130
910
1050
510
99
15
0640
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
B
9
NA5 pump
Construction C
Overview NEPTUNE 5-46PE and 5-54PE
The NEPTUNE 5-46PE is designed with a
NA5 high pressure pump, a NEPTUNE 5 boiler and a HONDA GX340 motor.
5-54PE has a Honda GX390 motor
A small special hexagon key for easy adjustment of the fuel pressure is placed in the electric box in all
NEPTUNE PE/
DE machines
Fuel pump access through the square hole on the right side of the fuel tank.
Honda motor
230V Generator
Water regulation—pump
By-Pass valve
Temperature sensor—pump
Oil container w/ oil level switch
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Temperature sensor exhaust
Temperature sensor water outlet
Flow switch 1 and 2
10
NEPTUNE 7-61PE, front side
Construction C
Overview NEPTUNE 7-61PE
The NEPTUNE 7-,61PE is designed with a C3 high pressure pump, a Honda
GX390 motor with 13 HP, control system same as on the NEPTUNE 3, and a
NEPTUNE 5 boiler
A small special hexagon key for easy adjustment of the fuel pressure is placed in the electric box in all
NEPTUNE PE/
DE machines
Fuel pump access through the square hole in the fuel tank.
Water outlet
Honda Motor
C3 pump
Water Break tank, OPTIONAL
Water regulator
Anti Scale container, OPTIONAL
Wheels, OPTIONAL
NEPTUNE 7-61PE, front side
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
11
NEPTUNE 7-61PE, boiler top
Construction C
Overview NEPTUNE 7-61PE
IN
OUT
Flow- switch
Flow- switch
Temperature
Sensor
Electrodes
Temperature sensor, boiler exhaust
Flame sensor
Fuel nozzle
12
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
NEPTUNE 7-61PE, backside
Construction C
Overview NEPTUNE 7-61PE
Generator, 230V Charging relay Top cover
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
13
Construction C
Overview NEPTUNE 5-85PE
The NEPTUNE 5-85PE is designed with a NP5 high pressure pump, a Honda GX630 motor with
20 HP, control system same as on the NEPTUNE
3, and a NEPTUNE 7 boiler
Fuel pump access through the square hole on the right side of the fuel tank.
A small special hexagon key for easy adjustment of the fuel pressure is placed in the electric box in all
NEPTUNE PE/
DE machines
Honda motor
NP5 pump
Temperature sensor—pump
Oil glass w/level switch
Water inlet
Unloader
Safety valve.
(This safety valve is used only on 5-
85PE and 5-
51DE, becasue the unloader does not have a safety valve).
Generator
Battery—12V
NEPTUNE PE-DE_en_Ver.1.0_October 2010
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Construction C
Fuel pump access through the square hole fuel tank.
Overview NEPTUNE 5-51DE
The NEPTUNE 5-51DE is designed with a NP5 high pressure pump, a Yanmar motor with 10 HP, control system same as on the NEPTUNE 3, and a NEPTUNE
5 boiler.
A small special hexagon key for easy adjustment of the fuel pressure is placed in the electric box in all
NEPTUNE PE/
DE machines on the right side of the
Battery 12V Generator
230V
Yanmar motor
Safety valve (only on 5-51DE & 5-85DE)
Unloader & water regulator
NP5 pump
Oil container w/level switch
Thermal dump valve
Temperature sensor exhaust
Temperature sensor water outlet
Flow switch 1 and 2
15
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Construction C
Overview NEPTUNE 7-66DE
The NEPTUNE 7-66DE is designed with a
C3 high pressure pump, a Ruggerini motor with 16 HP, control system same as on the
NEPTUNE 3, and a NEPTUNE 7 boiler.
Fuel pump access through the square hole on the right side of the fuel tank.
A small special hexagon key for easy adjustment of the fuel pressure is placed in the electric box in all
NEPTUNE PE/
DE machines
Rugerinni motor
Oil container w/level sensor
Gera box between motor and pump
C3 pump
By-pass valve W/water regulator
Temperature sensor—pump
Temperature sensor exhaust
Temperature sensor water outlet
Flow switch 1 and 2
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
16
Construction C
Overview NEPTUNE 7-72DE
The NEPTUNE 7-72DE is designed with a C3 high pressure pump, a Mitsubishi motor with 15 HP, control system same as on the NEPTUNE 3, and a
NEPTUNE 7 boiler.
Fuel pump access through the square hole on the right side of the fuel tank.
A small special hexagon key for easy adjustment of the fuel pressure is placed in the electric box in all
NEPTUNE PE/
DE machines
Mitsubishi motor
Oil container w/level sensor
Temperature sensor—pump
By-pass valve w/ water regulator
C3 pump
Temperature sensor exhaust
Temperature sensor water outlet
Flow switch 1 and 2
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
17
Function D
Functional desription of NEPTUNE 5-46PE, 5-54PE and 7-61PE
Start the motor by shortly turning the key (5) into the start position. When you let go the key, the key moves back to the ”ON” position.
When the key is turned to the start position, the start relay (13) is pulled, and the start motor is turning the motor.
In the ”ON” position the battery is continuously charged by the AC generator (9) through the rectifier
(2).
With the key in “ON” position, the hour counter will count, no matter if the motor is running or not.
18
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Function D
Functional desription of NEPTUNE 5-46PE, 5-54PE and 7-61PE
Circuit board (A2) is monitoring the thermostat on the high pressure pump (15), the motor oil switch (8) and the oil level switch in the high pressure pump.
If the thermostat on the pump or the motor oil switch is closing (failure) is respectively input 9 and input 8 connected to ground, which causes the LED to light, and at the same time output 15 is connected to ground.
If the oil level switch closes (failure) input 5 is connected to ground, output 15 is also connected to ground, which pulls the relay (6) and the motor stops. Also the LED for low oil level will light up.
On this model it is important that the jumper on A2 (2A) is NOT mounted.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
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19
Function D
Functional desription of NEPTUNE 5-51DE
Start the motor by shortly turning the key (5) into the start position. When you let go the key, the key moves back to the ”ON” position.
When the key is turned to the start position, the start relay (13) is pulled, and the start motor is turning the motor.
Circuit board (A2) is monitoring the thermostat (E) on the high pressure pump, the motor oil switch
(D) and the oil level switch in the high pressure pump.
If the thermostat (E) on the pump is closing (failure) is input 8 connected to ground, which causes the LED to light, and at the same time output 15 is connected to ground.?????????????????????
If the charging generator (I) is not charging, wire (Y) in the regulator (O) is getting 12V and also the input 7 on A2 is then getting 12V, which makes the charging light lighten.
On this model it is important that the jumper on A2 (2A) is NOT mounted, for the charging system to work properly.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
20
Jetwash Direct ltd
Function D
Functional desription of NEPTUNE 7-66DE
When the key (S1) is turned to start, the start relay is pulled and the motor starts. Then let go the key, and it moves back to the ”ON” position.
The motor oil pressure switch (B10) is a normally closed switch. In closed position (motor not running) the switch is connected to ground. When the motor starts and the RPM increases the motor oil pressure increases the switch opens and there is no connection to ground anymore. When no connection to ground there is no ground on output 15, which means the motor runs.
If output 15 is connected to ground 5 sec. after the key is turned back to “ON” position, contactor K3 is pulled, and the fuel pump is disconnected for 9 sec. (done by TIM 2—Timer for motor stop) — motor stops.
If there is a failure on sensor B5, B 10 or B11, and by that output 15 is connected to ground, the fuel pump will be disconnected in 9 sec., and the motor will stop.
If the 12V charging is not functioning input 6 on A2 will be connected to ground.
IMPORTANT: JUMPER ON A2 MUST BE MOUNTED
NEPTUNE PE-DE_en_Ver.1.0_October 2010
21
Jetwash Direct ltd
Function D
Functional desription of NEPTUNE 7-72DE
When the key (S1) is turned to the ”ON” position, the glow timer (Tim1), and the glow relay (K3) is activated, and the glow plugs (R1) are heating, and also the glow lamp on A2 is lightening. After a short while the timer runs out and the glow relay opens.
Now the key can be turned to the start position, and the starter coil (Y2—red wire), together with the holding coil (Y2—white wire) is pulled and runs the starter motor, and the motor will start.
Now release the key, so it goes back to the “ON” position, the starter coil (Y2—red wire) is no longer pulled, but the holding coil (Y2—white wire) is kept hold through the contactor (K3).
If there is a failure on B5 (oil level switch pump oil), B10 (Motor oil switch), B11 (thermo switch motor) or B12 (thermo switch high pressure pump), output 15 on A2 is connected to ground, contactor
K3 opens and the holding coil Y2 opens and the motor stops.
It is important that the jumper is mounted on the circuit board (A2). When jumper mounted there is
12VDC on output 7 on A2. Output 7 is connected to connection “R” on the generator. The generator
(G1) can only give output, if there is 12VDC present on connection “R”. If the generator is “worn/ defect” the DC voltage on connection “L” drops down to 0 VDC, and input 6 on A2 in then connected to ground, and the charging LED will light up.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
22
Jetwash Direct ltd
Function D
Functional desription of NEPTUNE 5-85PE
If there is a failure on B5 (oil level switch pump oil), B10 (motor oil switch) or B12 (thermo switch high pressure pump) is output 15 on A2 connected to ground. At the same time input “F” on the
Honda motor is connected to ground, and the Honda motor will stop.
IMPORTANT: JUMPER ON A2 MUST BE MOUNTED
NEPTUNE PE-DE_en_Ver.1.0_October 2010
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23
Function D
Functional desription of Circuit Board, A1
The circuit board used in all NEPTNE PE/DE machines is the same as used in NEPTUNE 3.
The only difference is the following bridges which are mounted on the circuit board in the NEPTUNE
PE/DE machines.
X4,5 to X5,6—oil level switch high pressure pump. Oil level switch is moved to circuit board A2
X4,1 to X4,2—Anti-stone
X3,5 to X3,6—Thermal switch in high pressure pump motor.
24
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Function D
Functional desription of Circuit Board, A1
Control Circuit Board (A1) is functioning the same way in all the NEPTUNE PE/DE models. The power supply to A1 is supplied by the 230V generator G2, which is driven by the motor. This means that the motor must be running—and running at full RPM—before the A1 is working. In cold water mode the S1 main switch can be in position ON or OFF. If S1 is turned to the temperature area (red) the hot water mode is activated.
When S1 is turned to ON power is supplied through the fuse F1 to the microprocessor. The microprocessor is starting up, and the 5 status LED’s is lightening up for 1 sec. If there is a failure during start up, the control circuit board goes into failure mode.
If the S1 main switch is turned to “hot water mode”, and the spay gun is open, and desired temperature set at S1, B1 temperature sensor is measuring lower temperature that the set point at S1, and
B9 fuel level sensor is measuring fuel in the tank, and B2 flow switch, and B4 flow switch is registering water flow, the burner motor M2 is started, and the ignition transformer T2 is started over the burner relay K3. A high voltage spark is generated between the electrodes in the burner.
The burner motor M2 is driving the burner fan, which is blowing pre-heated air into the boiler. The self-sucking fuel pump is pumping fuel pressure up to the fuel solenoid valve Y1. When the burner motor/fan has been running in 1 sec., the fuel solenoid valve Y1 opens, and the fuel is pumped under pressure to the fuel nozzle. The atomized fuel is leaving the fuel nozzle and is ignited.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
25
Jetwash Direct ltd
Function D
Functional desription of Circuit Board, A1—Continued
The flame sensor B7 is controlling if the fuel is ignited, and if it is (the flame sensor can see the flame) it “allows” the burner to burn.
If the flame sensor don’t see the flame after 4 sec. (when S1 is in hot water mode), the fuel solenoid valve will close, and the burner will be stopped.
If the display is flashing in the LED’s, it can be due to too low RPM on the motor.
If the LED’s are flashing, it means that the voltage is too low to maintain the circuit board.
The flashing LED’s means that the display is “re-starting” all the time.
26
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Function D
Functional desription of Circuit Board, A1—Continued
Circuit Board A2 (A1)
Circuit board (A2) has LED’s for the motor, e.g. water temperature, motor oil level etc.
Control Circuit Board A1
Control Circuit Board:
Pos. 1: The heating and ON/OFF switch (S1)
Pos. 2: Heating Relay (K2)
Pos. 3: LED’s
Pos. 4: Fuse—Self-resetting ”Pico fuse”
Pos. 5: Fuse
Pos. 6: Fuse
On the above picture is the correct setting of the circuit board.
Arrow 1
Setting is WITHOUT JUMPER = By-pass time active
Arrow 2:
Setting is JUMPER MOUNTED ON PIN 2 AND 3
= Flame Sensor active.
27
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Function D
Cam shaft
NEPTUNE PE/DE—NP5 PUMP
The 3piston radial pump NP5 is used in the NEPTUNE 5-85PE and 5-51DE
OUT
OIL
Pressure valve
Shaft
IN
Suction valve
The three pistons are driven by the motor via a belt drive. The cam shaft transforms the rotation power into the pistons reciprocating movements.
The movement and the diameter of the pistons decide the water volume which can be sucked into the suction valves and pressed out through the pressure valves.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
28
Function D
NEPTUNE PE/DE—NA5 PUMP
The 3piston NA5 pump is used in the NEPTUNE 5-46PE and 5-54PE
Honda motor and D-bearing cover
Pistons, cylinder block,cylinder head and sealings
Water inlet
By-pass valve with water regulator
The NA5 pump is connected to the Honda motor with a direct drive.
By-pass valve function is described later in this service manual.
29
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Function D
NEPTUNE PE/DE—C3 PUMP
The 4 piston C3 pump is used in the NEPTUNE 7-61PE, 7-66DE and 7-72DE
The wobble disc is mounted directly on the motor shaft.
Water is sucked through the suction valves and out through the pressure valves and the piston in the by-pass valve. The piston has two small holes where the water is running through in order to create a pressure drop, which make sure the valve cone is closed during operation.
When water flow is interrupted, the pressure rises until the safety valve opens. Because of the achieved pressure drop, the valve cone is pressed to open so the water re-circulates at a pressure < 10 bar.
Water quantity is regulated by a handle in the end of the by-pass valve. When turning the handle clockwise, the by-pass valve cone will be forced open, so some of the water is recirculating in the pump.
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Function D
B
A
By-Pass valve function NEPTUNE 5-46PE and 5-54PE
G
F
H
E
D
I
K
J
C
Working pressure
Machine is started and the gun ”J” with correct lance/nozzle is open -
Machine runs in working pressure ”K”:
The water is pressed from the pump outlet ”A” into the by-pass housing ”C”.
The water runs through the bottom of by-pass housing ”C” and directely to the outlet ”I”.
Due to the water pressure the by-pass piston ”B” is pressed up and the seat ”E” is closed.
G
F
E
D
H
K
I J
C
B
A
By-pass pressure
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”, the water runs back into the suction side of the pump through the valve ”D”.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
31
Jetwash Direct ltd
Function D
By-Pass valve function NEPTUNE 5-46PE and 5-54PE
C
B
A
By-pass pressure
The by-pass pressure is determined of the spring tension in valve ”A”.
The tension is fixed and will bring out a by-pass pressure in about 30 - 35 bar.
Valve ”A” also secures the self suction ability.
The cut off pressure when the gun is released, is determined of the adjustment screw ”B”.
When the screw is tightened the cut off pressure will rice and by loosening it the pressure will fall.
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.
G
F
E
D
C
B
A
Water reduction
H
I
K
When the water regulation ”G” is turned counter clock wise, the seat ”H” opens and the water runs both to the outlet of the by-pass housing and in by-pass to the suction side of the pump.
The pressure ”K” will fall depending of the size of the opening in seat ”H”.
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Function D
By-Pass valve function NEPTUNE 7-61PE, 7-66DE, 7-72DE
Operation:
The water from the pump is lead into the chamber ”A” in the by-pass valve.
From here the water passes through the holes “B” in the by-pass valve piston “C” and out to the high pressure nozzle. When water is pressed through holes in the piston “C”, there is a pressure drop over the piston (this means the pressure is higher on one side of the piston). This will keep the valve cone “D” closed against its seat
“E”, because the piston “C” is fixed to the valve cone.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
By-Pass:
When the water consumption stops
(spray handle is released/closed), the pressure drop over piston “C” disappears, the pressure in the by-pass valve increases briefly until the safety valve “F” opens. The safety valve just opens briefly, and closes again. The safety valve opens when the pump pressure overcomes the tension of the spring in the safety valve. (The safety valve is adjusted to open 25-30 bar above normal working pressure). Now the valve cone “D” lift from its seat “E”, and water runs in by-pass.
Jetwash Direct ltd
33
Function D
Unloader valve function NEPTUNE 5-85Pe AND 5-51DE
Unloader mounted on pump
Unloader function:
On the assumption that the black handle
(adjustment handle) on the unloader is turned all the way to max. pressure (clockwise).
When the pump is running the unloader piston (2) is pressed down it its seat (1), and all the water volume is going through the gun and out to the high pressure nozzle.
When the gun is released (no water flow out), the pressure in the unloader will rise, and the increased pressure will overcome the adjusted tension of the unloader spring (6), and the unloader piston (2) will be lifted up from its seat.
Water will now return through the seat (1) to the suction side of the pump (by-pass) mode.
Unloader disassembled
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
34
Function
Flow switch function NEPTUNE PE
D
Flow switch
Plug with Shaft
Water supply connected to the machine.
Water from the pump is pressed through the high pressure hose to the first flow switch.
When water is entering the first flow switch, the piston with magnet is pressed to the top of the flow switch housing, and the reed switch is making contact and closing the circuit.
(Reed switch is a NO contact)
Water is now pressed through the second flow switch, the piston with magnet is pressed to the far end of the housing, and the reed switch is making contact and closing the circuit.
When the spray handle is released and the water flow stops, the flow switch pistons will move away from the reed switches, and the will brake off the circuit and the burner will stop.
When the water flow stops, the piston in the first flow switch will fall down and be stopped by the plug with the shaft. The plug with shaft is installed to reduce the movement of the piston.
The signals from the two flow switches must come simultaneously. (MAX. difference between the two signals are 4 seconds)
The signals from the flow switches are controlling the fuel pump solenoid valve. This to make sure that the burner is not starting if there is no flow of water through the heating coil.
35
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Heat exchanger (schematic)
Fig. D.19:
1) Burner fan
2) Baffle plate
3) Fuel nozzle
4) Heating coil
5) Fuel pump
6) Fuel filter
7) Solenoid valve
8) Nozzle stock
9) Fuel return line
10) Ignition transformer
11) Ignition electrodes
12) Flame probe
13) Flue
14) Flame sheath
15) Flame funnel
16) Insulation
17) Water inlet
18) Water outlet
Function D
Heat exchanger NEPTUNE PE
The heat exchanger is the functional link between the heating subsystem and the water subsystem.
In "Hot water" mode the burner fan
(1) draws in air and conducts it laterally into the heat exchanger where it is routed upwards between the two jackets to the baffle plate
(2). This preheats the air before it mixes with the fuel spray from the fuel nozzle (3).
Cold water is fed to the inner circuit in which the temperature is highest.
This reduces in as much as possible any condensation on the surface of the heating coil (4).
At the same time fuel is drawn in from the fuel tank by the fuel pump
(5) through the filter (6). The fuel is conducted by the solenoid valve (7) to the nozzle stock (8) with the fuel nozzle (3). If no combustion is needed, the fuel goes back to the tank on the return line (9).
The ignition transformer (10) activated in "Hot water" mode generates ignition sparks across the electrodes (11) to ignite the fuel spray.
This process is monitored by the flame sensor (12).
In normal operation the hot exhaust flows downwards and upwards between the piping of the heating coil
(4) thus warming the water in the system.
The exhaust exits through the flue
(13).
36
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Function D
Safety Thermal Temperature Sensor in boiler exhaust
Located in the heat exchanger outlet (flue) is a temperature-dependent resistor (Pt 100) functioning as a temperature sensor.
If the temperature in the heat exchanger outlet (actual temperature) exceeds the temperature set-point, the solenoid valve Y1 closes to interrupt the fuel feed. The temperature sensor is only activated in "Hot water" mode.
The safety thermal release mounted on the heat exchanger water inlet, is an absolute safety element on the heat exchanger.
If a fault is present, e.g. all control and safety devices fails, and hot water flows at high pressure from the heat exchanger back through the safety valve into the high pressure pump, the thermal release responds and shuts down the entire machine through the control circuit. Before restarting, the machine must cool down, the fault causing the heated water to flow in the wrong direction must be corrected, and a new thermal release fitted.
The flame sensor is a light-sensitive phototransistor.
The flame sensor checks for the presence of a flame.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
37
Fault
Green LED illuminates.
⇒
Troubleshooting
Cause Remedy
Machine ready to opeate.
All LEDs flash once before the motor is turned on.
Yellow LED illuminates.
⇒ Fuel level is low.
•
Refill fuel. "Cold water" mode is possible.
Yellow LED flashes.
⇒ Alto Anti Stone level is
•
Refill Alto Anti Stone. low. "Hot water" and "Cold water" mode is possible.
Red LED illuminates.
⇒
Red LED flashes. ⇒
Pump oil level is low.
•
Refill pump oil (Chapter
F.1.3). The burner and
Jetwash Direct ltd motor are cut out. The green
hes.
LED extinguis-
Service interval: service
•
Service the machine. due in 20 hours. "Hot water" and "Cold water" mode is possible.
Red LED illuminates.
⇒
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service interval elapsed.
•
Service the machine.
"Hot water" and "Cold water" mode is possible.
E
38
Fault
Green LED flashes.
Green LED and red LED flash simultaneously.
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
Troubleshooting
Cause
Flow sensor fault.
Water tap closed or water flow inadequate.
Detergent tank empty.
Pressure rate control or
Vario Press set for too small amount of water.
Machine scaled up.
Remedy
•
See Chapter F.3.3,
F.3.5 and G.3.4."Cold water" mode is possible.
•
Requirements in Chapter B.
•
Refill detergent or set the SDR valve to "0".
•
Set the pressure rate control or Vario Press for a higher water flow.
•
Descale the machine.
Leakage or impermissible operating status through brief operation.
Spray pistol leaking.
HP hose, HP coupling or pipe leaking.
Detergent tank empty.
Filter clogged in water intake.
HP pump sucking in air.
•
The machine cuts out after being briefly operated three times. Reset: set the main switch to
"Off". Operate the pistol for > 3 s.
•
Check the spray pistol.
•
Tighten the screws, replace the HP hose or pipe.
•
Refill detergent.
•
Clean the filter
•
Correct leaking points.
E
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
39
Troubleshooting
Cause Remedy Fault
Green LED and red LED flash alternately
⇒ Motor/machine overheated (MT has triggered).
⇒ Thermal release B3 has
⇒ tripped.
⇒ 24 Vac fine-wire fuse F2 has blown.
Green LED flashes slowly & red LED flashes fast
⇒
⇒
Fault in fuel or ignition system, burner fault.
Flame probe (option) sooted up.
•
Set the main switch to
"Off". Allow the machine to cool.
•
Work without an extension cable or use an extension cable with a larger cross-section.
•
Possibly a phase failure: have the electrical connection checked.
•
Correct the cause of the fault (Chapter D.2.3.5) and replace the thermal release (Chapter F.7.4).
•
Correct the cause of the fault and replace the fine-wire fuse (Chapter
F.8.1).
•
See Chapter F.2.6 and
F.7. "Cold water" mode is possible.
•
If this option is fitted, remove it and clean it.
E
40
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Fault
Green LED does not illuminate.
Pressure too low.
Machine runs jerkily.
⇒
⇒
⇒
⇒
⇒
Troubleshooting
Cause Remedy
No power to microprocessor.
•
Make sure the machine is plugged in.
•
Operate main switch S1.
•
Check the primary and secondary voltage (8
Vac) on transformer T1.
•
Pico fuse F1 has blown
(self-resetting). Wait un-
HP nozzle worn. til F1 is reset or, if the fault persists, replace electronic controller A1
(Chapter F.8.1).
•
Replace the HP nozzle.
•
Turn the pressure rate Pressure rate control or
Vario Press set for too low a pressure. control on the unloader valve in the direction
"+", or set the Vario
Press rotary knob
(accessory) on the pistol for a larger amount of water.
Flexo Power nozzle
Close the Flexo Power open. nozzle.
HP pump taking air in
•
Close the detergent dosfrom empty detergent ing valve. Take the tank spray pipe off the spray pistol. Operate the spray pistol and let the machine run until the air is expelled from the system and the pump works smoothly.
E
41
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Service / Repair F
NA5 Pump
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
42
Valves
Service / Repair F
NA5 Pump
Fig.F.13: Valve housing
•
•
Dismount the valve housing from the cylinder block by the three M12 bolts.
Be aware of the o-rings and valve parts.
Fig.F.14: Thrust collar
•
•
Be carefull not to damage the surface inside when dismounting the thrust collar.
Inspect the thrust collar for damages before mounting.
Fig.F.15: Valve housing
• Carefully tip out the sleeves with an adequate screwdriver and replace them. Be careful not to scratch the surface.
Fig.F.16: Valve housing
•
•
Knock carefully on the back side of the valve seat to demount it or use an 8mm threaded pin and pull it out.
Replace with new parts.
43
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Valves
Service / Repair F
NA5 Pump
Pic. F.17: Suction valves
• Overview of the placement of suction valve
parts.
Pic. F.18: Pressure valves
• Overview of the placement of pressure valve parts
Picture of piston guides
Fig.F.19: Pressure valves
•
•
The pressure valves can easily be taken out of the cylinder head.
Replace with new parts if necessary.
Fig.F.20: Pressure valve seat
• Take out the pressure valve seats with an adequate puller or use an 8mm
• Replace with new parts if necessary.
44
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Cylinder Block
Service / Repair
NEW !
F
NA5 Pump
Fig.F.21: Cylinder block
• Overview of the placement of the parts in the cylinder block.
Fig.F.22: Oil Sleeves
• Take out the oil sleeves using an
• Be careful not to damage the surface of the cylinder block.
Oil seal and piston
Fig.F.23: Valve Kit 3~ - Exploded View
• To make replacement easier moisten the sleeves with soapy water.
• the spanner and a fiber hammer.
Fig.F.24: Pistons
•
•
Place sleeves, pistons and springs as shown.
Mount the cylinder block to the D-bearing cover by the two 6mm mounting screws.
45
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Wobble disc
Service / Repair F
NA5 Pump
Fig.F.25: Pump head
• The cylinder head and the cylinder block is fastend to the D-bearing cover by two
6mm mounting bolts for the cylinder block and three 12mm bolts for the cylinder head.
Fig.F.26: D-bearing cover and wobble disc
• Overview of the parts inside the D-
Fig.F.27: Wobble disc
• 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.
Fig.F.28: Wobble disc removal
• Demount the wobble disc screwing a 1
6mm bolt into the threads. Tighten the bolt against the motorshaft and pull the wobble disc out.
46
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
D-bearing cover
Service / Repair F
NA5 Pump
Fig.F.29: D-bearing cover
• The D-bearing cover is mounted to the
Motor by four 6mm bolts.
• When the bearing is damaged, always replace the complete D-bearing cover.
Fig.F.30: Oil sleeve
• 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.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
47
Service / Repair F
C3 Pump
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
48
Service / Repair F
C3 Pump
Mandrel no.: 1216506
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
49
Service / Repair F
C3 Pump
Ke n n ey
Duct
Mounting of textile sleeves by means of tool no. 1220090. It is an advantage if the sleeves havebeen in a water bath for 3-4 hours before mounting them. Do not forget to blow air through the ducts.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
50
Service / Repair
Washer
O-ring
Thrust collar
Torque: 37 Nm
F
C3 Pump
Oil sleeve
Secondary sleeve
Spacer ring (Crovn)
Drain off the oil. Loosen the 8 bolts gradually (because of the spring load). Special box head no.1206762 may be used.
Mount new O-rings on studs with tool no. 1206812.
Always replace secondary sleeves when replacing pressure sleeves. Check that there is a free passage from the drain holes.
Spacer ring
Secondary sleeve
Back-up ring O-ring
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
51
Service / Repair F
C3 Pump
Carefully tip out the oil sleeves with an adequate screwdriver and discard them. Be careful not to scratch the 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 no.1220429. Carefully knock or press them home.
Oil sleeve LP HP
Check the piston for wear in the pressure area and the area fPressure area
(rides on wobble disc) or oil sleeves. Check the ceramic for cracks. Remove any coating.
Pressure area, touches the bearing disk
Stainless steel
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Ceramic
Jetwash Direct ltd
52
Service / Repair
Dismount locking ring on the rotor shaft.
The wobble disc is easily dismounted with puller no. 1205715 and special legs no. 1206150/1206168. Do not forget to remove the key before dismounting the
D-bearing cover.
Check bearing surfaces for wear. If in doubt, replace kit complete after approx.
2000 hours.
When mounting the D-bearing cover complete,protect the U sleeve with tool no.
1206598 which is placed on the shaft, before placing the cover.
Tool : 1206598
F
C3 Pump
Pittings
Check the bearing surfaces for wear. As long as the wear is even and shiny without pittings or grooves, the wobble disc can be
When mounting the wobble disc, lubricate the bearings with oil. The big roller bearings are identical. Do not forget to mount the circlip on the rotor shaft. Refill with 1 l oil type Castrol Alphasynt ISO 150.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
53
Service / Repair F
NP5 Pump
Motor
Pump h ousing .
Valve cover & seals.
Pistons & oil seals.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
54
Service / Repair F
NP5 Pump
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!
When you replace the valves give the o-rings an inspection for damage before mounting.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
55
Service / Repair F
NP5 Pump
Be careful when you dismount thrust collar because you can easily damage the surface inside. Give the thrust collar an inspection before mounting.
When mounting the sleeves and the spacer, remember lubricating.
When dismounting the suction sleeves, use a screwdriver to tip out the sleeves.
Do not reuse the sleeves.
Clean the thrust collar and lubricate before mounting the sleeves as shown in the ilustration.
5
8
2
4
6
Inspect the the thrust collar for marks, lubricate and mount it with your fingers.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
When you mount the cylinder head tighten the bolts in the shown sequence Use a 6mm hexagon wrench.
Jetwash Direct ltd
56
Service / Repair F
NP5 Pump
Piston & Oil Seal
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, Orings and backup rings on the plunger rod prior to reinstalling the plungers.
Backup-ring
O-ring
Copper washer
Oil seal
Brass slinger plate
T orque
106 Inch pounds
8,8 ft.lbs
13NM
Also clean the brass slinger plates before reinstalling the plungers.
Do not re-use the copper washers!
Use one drop of medium strength thread locker on each plunger rod when reinstalling plunger nut and torque to specifications.
Oil seals must be changed if there 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 sew 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 PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
57
Service / Repair F
NP5 Pump
NP5 Unloader valve
NP5 Unloader valve
NP5 Unloader valve parts
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
58
Service / Repair F
Boiler
The boiler 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 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 superheating.
Flame sensor Electrodes Fuel nozzle
Exhaust
Water outlet
Water inlet
Top plate
Air distributor
Flame tube top part
Burner tube
Flame tube
Air inlet Fixation spacer
Outer jacket
Inner jacket
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
Insolation
Mounting plate
59
Service / Repair F
Boiler
5
4
2
4
3
6
7
X
8
Check the flame tube marked with X and Y. It is important that they are solid and complete.
Y is a part of the coil
8 and cannot be separated.
Clean the coil.
Remove the outer top cover and mount the lifting tool over the two coil ends and fix it with the nuts. Dismount the 4 nuts
"Arrows"and hook up the crane and lift out the coil.
Y
10
Burner Unit.
6. Fan
1
2
3
4
5
6
7
9
Clean up deposits and change the isolation if needed.
Burner fan and fuel pump.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
60
Electrodes
6mm
Service / Repair F
Burner Electrodes
5 mm
4 mm
Spring washer
The electrode is adjusted from factory.
If the distance between the legs becomes greater than 4 mm, the electrode must be changed.
The electrode 18 is self adjusting the position on the nozzle by a spring washer 19 under the fixing screw 20.
11
12
13
4
6
7
5
10 9
14
17
18
19
20
21
22
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
The flame sensor 9 must be fixed with 5 in the right position.
Clean the flame sensor
61
Service / Repair F
Maintenance plan
Water filters
Oil filter
Checking the pump oil quality
Changing the pump oil
Emptying the fuel oil tank
Weekly
NP 5 pump only:
After the first 50 operating hours
C3 and Na5 pump every six months or
500 operating hours
As required
Maintenance
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
62
Adjustment / Test G
IMPORTANT:
When torque settings are made, all parts — Pump, screws etc. must have a temperature at 20°C.
NA5 pump
Torque specifications
20 Nm
20 Nm
Fig.G.01: Wobble disc
Fig.G.02: Cylinder block
65 Nm
25 Nm
Fig.G.03: Cylinder head Fig.G.04: Venting valve
10 Nm
By hand
Fig.G.05: By-pass housing Fig.G.06: Venting valve
40 Nm
Fig.G.07: Outlet fittings
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Fig.G.08: Water regulation
Jetwash Direct ltd
40 Nm
63
Adjustment / Test G
NA5 pump
Adjustment of by-pass system.
A
Fig.G.09: Pressure gauge
Dismount the test plug in the by-pass housing and mount a pressure gauge instead.
Fig.G.10: Test tap
Connect a test tap (A), hose and pressure gun to the outlet of the machine.
B
Fig.G.11: Safety valve Fig.G.12: Pressure bolt
Close the safety valve completely.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Adjust the test tap (A) and the pressure bolt
(B) so it couples 20-30 bars higher than working pressure, when the pressure gun is closed— CUT OFF PRESSURE. After the cut off pressure is reached the machine runs in by-pass untill the pressure gun is opened.
The working pressure is stated in the technical data sheets chapter B.
64
Jetwash Direct ltd
Adjustment / Test G
NA5 pump
Adjustment of by-pass system.
Pressure bolt
When adjustment is done, lock the bolt with the counter nut.
Safety valve
Then let the machine run just below the cut off pressure (working + adjustment) and adjust the safety valve out until it couples out
(go into bypass). Then you adjust the adjusting “screw” a ½ turn back and lock it with the counter nut.
Finalize the adjustment with locking glue/ paint on both the bolt and the safety valve.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
65
Adjustment / Test G
C3 pump
Adjustment of by-pass system.
Pos. 1 Safety valve adjustment
Pos. 2 Set screw for min. Water adjustment
Pos. 3 Min. Water adjustment screw
Minimum water volume (and pressure) adjustment:
First mount test manometer with correct high pressure test nozzle.
Turn the black handle on the water regulator all the way clockwise. (Min. Water volume)
Start the motor and run at full RPM.
Test manometer must show approx. 30 bar. If this is not the case, loosen set screw (pos. 2), and then turn the min. Water adjustment screw (pos. 3) untill you reach approx. 30 bar.
Safety valve adjustment:
First mount test manometer without test nozzle—just open outlet.
Turn the black handle on the water regulator all the way counterclockwise. (Max.. Water volume)
Start the motor and run at full RPM.
Slowly close the valve on the test manometer, and read the pressure when the safety valve opens. (That will be the pressure just before the pressure drops)
The opening pressure for the safety valve must be 25-30 bar above normal working pressure.
To adjust the opening pressure, loosen the lock nut (pos. 1) with a 22 mm Open/ring spanner.
Then adjust the safety valve by turning the adjustment screw with a 6 mm. Allen Key, When turning clockwise—opening pressure increases, and counterclockwise it decreases.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
66
Adjustment / Test G
NP5 pump
Adjustment of Unloader system.
Turn the black handle clockwise as far as it can.
This is max. pressure adjustment.
13 mm Box spanner
Using a screwdriver or similar tool, to remove the cap on top of the unloader.
Loosen the lock nut on the pressure adjustment bolt. Use a 13 mm. box spanner.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Adjust the pressure with a 7 mm. Hexagon
Allen Key the following way.
Start machine with correct HP nozzle.
Loosen unloader until pressure drops, then turn ½ turn clockwise, to obtain full pressure again.
67
Jetwash Direct ltd
Adjustment / Test G
NP5 pump
Adjustment of Unloader system.
When the correct pressure is adjusted, tighten the lock nut with a
13 mm. Box Spanner.
Mount the cap on top of the unloader. Now the correct adjustment of the unloader is done. By turning the handle counterclockwise, you can reduce the pump water volume and pressure.
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
68
Adjustment / Test G
Burner settings.
Note: Higher CO2 concentrations at different barometric pressure, altitude or temperature and poor quality of the used fuel can lead to faster soot deposition on the heating coil of the heat exchanger.
Preparation
1. Set the fuel pressure.
2. Let the machine run in "Hot water" mode for at least two minutes so that it reaches operating temperature and meaningful results can be measured.
Note: Machines that are primarily used for a brief period should run continuously for about half an hour in "Hot water" mode before an exhaust measurement.
Measurement
3. Determine 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 325, which measures and displays all relevant data.
If the measured value is too low, close the air flap a little and check the soot rating and Co2 content again.
Repeat all settings until all specified values are obtained.
5. Finally seal the set screw (arrow A) of the air flap with varnish.
Fuel pressure setting.
• Mount pressure gauge on the fuel pump.
• Adjust the fuel pressure according to the values in Technical data chapter A.
Air flap.
• The air flap on the side of the burner fan is adjusted by a self-locking spindle on a set screw. Turning clockwise increases the air intake, turning counterclockwise reduces it.
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Burner settings.
Adjustment / Test G
Fig.G.17: Soot raiting
Determine the soot 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 measurement. Repeat the procedure until the specified value is obtained.
Fig.G.18: Burner measurements.
The CO2 content in the exhaust, the intake and exhaust temperature are determined.
This can be done with conventional meters or, as in Fig. G.08, with an electronic meter like the TESTO 325 (4), which measures and displays all relevant data.
If the measured value is too low, close the air flap (Fig.G.06) a little and check the soot rating and Co2 content again.
1. BR1
2. BR2
3. X5—For Datalogger and Service Interval
4. ”Fuel” LED
5. ”Antistone” LED
6. ”Service” LED
7. ”Pump Oil” LED
8. ”Operation” LED
Service time setting:
Switch off machine with S1. install a jumper on X5 between pin 3 and 5. Switch on machine
(cold water mode). With the temperature setting knob it is now possible to set a new service interval. The reading is done by the LED’s (4,5,6,7 and 8), where (4) is 100 hours, 4+5 is 200 hours and so on, up to 500 hours when all LED’s are on. If setting is not changed for 3 sec., the setting is saved. This can be seen when the chosen LED’s are flashing. Machine must now be switched off, and the jumper removed from X5. Default service setting from factory is 200 hours.
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Adjustment / Test
Boiler
G
1.
2.
3.
4.
5.
6.
Fig.F.49. Boiler top
Heating system - Overview.
1. Ignition Transformer.
2. Ignition cords.
3. Ignition electrodes
4. Flame sensor.
5. Fuel nozzle.
6. Air distributer.
4mm
5mm
5mm
Fuel nozzle. Fuel nozzle.
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Notes
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