Nilfisk-ALTO NEPTUNE 5 FA Bedienungsanleitung

Service Manual

NEPTUNE 5 FA

NEPTUNE 5 FA_EN_Ver.2.0_25/11

NEPTUNE 5 FA_EN_Ver.2.0_25/11 2

This service manual contains detailed description of the main repair work on the hot HPW

NEPTUNE 5.

Repair work requires a suitable testing workplace with the necessary water and power supply.

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.

See ”Service Technical Information” (STI) sheets. They include information on technical

modifications that have been made after this repair manual was printed.

”Service Technical Information” sheets are also valid as a supplement to the spare parts list until

publication of a 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 original Nilfisk-ALTO spare parts only.

Preface

I. Special tools /

Spare parts

Wiring diagrams 54-61

Adjustment / Test 49 -53

Service / Repair 36 -48

Troubleshooting 32-35

Function 25-31

Construction 19 -24

Technical data 5-18

Safety instructions 4

Safety instructions

NEPTUNE 5 FA_EN_Ver.2.0_25/11

For your own safety

ESD measures

(electrostatic discharge)

Observe valid safety regulations

for electrical equipment. In

particular, observe the following

regulations:

IEC 60335-2-79

EN 60335-2-79

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.

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 necassary.

 Use a conductive floor covering or a conductive table cover.

 Never touch the printed circuit board or electronic components

( always hold on to plastic ).

 Transport electronic components in conductive packaging

( e.g. ESD bag ).

Technical data

NEPTUNE 5 FA_EN_Ver.2.0_25/11

NEPTUNE 5 FA

Description

5-50FA EU

400V/3 ~50Hz 16A

5-50FAX EU

400V/3 ~50Hz 16A

Item no.

Tol. 107146650 107146651

Technical data Test result Tol.+ Tol.- Test result Tol.+ Tol.-

Pump-Data

Max. inlet pressure (bar) 10,0 10,0

Max. Inlet temperature (°C) 40,0 40,0

Pressure at pump head 0 175 10 10 180 10 10

Pressure @ Cylinder Head (bar) 0 180 10 10 185 10 10

Pressure @ Outlet (bar) 0 163 9 9 166 9 9

Pressure @ Gun (bar) 0 140 8 8 144 8 8

Pressure cut off

@ Cylinder Head (bar) 200 5 5 205 5 5

Pressure Pmax safety valve @

Cylinder Head (bar) 250,0 5,0 5,0 250,0 5,0 5,0

Flow. Qiec (l/min) 2,5% 13,6 0,3 0,3 13,6 0,3 0,3

Flow. Qmax (l/min) 5% 14,6 0,7 0,7 14,6 0,7 0,7

Flow. Qmin, steam (l/min) 3% 6,3 0,2 0,2 6,3 0,2 0,2

Type NA5 NA5

Piston type Cermic Cermic

Piston diameter (mm) 20,0 20,0

Stroke / Wobble disc angle 10,2 10,2

Pump oil type

Oil BP Energol

GR-XP220

Oil BP Energol

GR-XP220

Oil volume (l) 0,8 0,8

Electrical

Power supply 400V/3~/50Hz 400V/3~/50Hz

Current consump. - hot (A) 12,2 1,0 3,0 12,3 1,0 3,0

Current consump. - cold (A) 12,4 1,0 3,0 12,5 1,0 3,0

Power Consumption - hot (kW) 6,0 0,5 0,5 6,1 0,5 0,5

Fuse size (A) 16,0 16,0

Cord type H07RN-F 4G1,5 x 6m H07RN-F 4G1,5 x 6m

Plug type CEE 3P+N+G / 16A CEE 3P+N+G / 16A

Control PCB 24 volt PCB 24 volt

Contactor 100-C16KJ10 24 100-C16KJ10 24

Electrical diagram 106427171 106427171

Eletrical test data

Highvoltage (HV) test (V) 1000 Vac 1000 Vac

HV-Resistance (MΩ) ≥1MΩ/ 500Vdc ≥1MΩ/ 500Vdc

Cord-resistance (Ohm) 0,2 0,2

Motor-Data

Motortype 3~ Induction 3~ Induction

Rotational speed (min-1) 1450 1450

Insulation Class F Class F

Protection Class IP 54 IP 54

Nominal power [kW] 5,5 3,0 3,0 5,5 3,0 3,0

Cos j 0,7 0,7

Technical data

NEPTUNE 5 FA_EN_Ver.2.0_25/11

NEPTUNE 5 FA

Description

5-50FA EU

400V/3 ~50Hz 16A

5-50FAX EU

400V/3 ~50Hz 16A

Item no.

Tol. 107146650 107146651

Technical data Test result Tol.+ Tol.- Test result Tol.+ Tol.-

Heating Unit

Boilerpower_input (kW) 78,0 78,0

Temperature t max, @ inlet 12°C 87,7 0,0 3,0 87,7 0,0 3,0

Delta temp. variance at 50 °C

set point, at @ gun (°C) 30,0 0,0 3,0 30,0 0,0 3,0

Boiler on time at 50 °C set point,

@ inlet 12° (sec) 30,0 5,0 5,0 30,0 5,0 5,0

Steam temp. t II @ outlet and v.

Steam nozzle(°C) 140,0 10,0 30,0 140,0 10,0 30,0

Pressure P2 @ outlet with

standard nozzle (bar) 27,0 5,0 5,0 27,0 5,0 5,0

Fuel pump type Diesel Diesel

Oil pressure ( bar ) 10,0 0,5 0,0 10,0 0,5 0,0

Nozzle size, oil 1,75 60°H 1,75 60°H

CO2 content min ( % ) 10,5 0,5 0,0 10,5 0,5 0,0

Efficiency burner ( % ) 92,0 1,5 0,5 92,0 1,5 0,5

Soot picture 0-1 0-1

Exhaust outlet temperature (°C) 175,0 10,0 10,0 175,0 10,0 10,0

Exhaust temperature, cut off (°C) 270,0 0,0 12,0 270,0 0,0 12,0

Fuel consump. @ dT=45 deg(kg/h) 4,0 4,0

Fuel consumption (kg/h)

@ 12°C inlet 6,7 6,7

Water volume in coil (l) 4,8 4,8

Fuel tank (l) 17,0

Others

Gun ST ERGO 2000 ST ERGO 2000

Lance TORNADO PLUS TORNADO PLUS

Hose DN 8x10m 3/8" DN 8x20m

High Pressure Nozzle NT 0500 NT 0500

Noise level 1m Lpa( dBA) 76,6 1,5 1,5 76,6 1,5 1,5

Noisepower LWA (dB) A 93,0 1,5 1,5 93,0 1,5 1,5

Impact force N 44,0 45,0

Vibration ISO 5349 ( m/s² ) ≤2,5 ≤2,5

Protection Class IP X5 IP X5

Max detergent flow

from full internal tank (%) 4,0 1,0 1,0 4,0 1,0 1,0

Max detergent flow

from full internal tank (L/min) 0,5 0,2 0,2 0,5 0,2 0,2

Technical data

NEPTUNE 5 FA_EN_Ver.2.0_25/11

NEPTUNE 5 FA

Description

SB FA EU

400V/3 ~50Hz 10A

5-61FA EU

400V/3 ~50 16A

Item no.

Tol. 107146652 107146653

Technical data Test result Tol.+ Tol.- Test result Tol.+ Tol.-

Pump-Data

Max. inlet pressure (bar) 10,0 10,0

Max. Inlet temperature (°C) 40,0 40,0

Pressure at pump head 0 75 4 4 190 10 10

Pressure @ Cylinder Head (bar) 0 80 4 4 195 11 11

Pressure @ Outlet (bar) 0 72 4 4 193 11 11

Pressure @ Gun (bar) 0 67 4 4 168 9 9

Pressure cut off

@ Cylinder Head (bar) 100 5 5 215 5 5

Pressure Pmax safety valve @

Cylinder Head (bar) 120,0 5,0 5,0 250,0 5,0 5,0

Flow. Qiec (l/min) 2,5% 12,1 0,3 0,3 15,8 0,4 0,4

Flow. Qmax (l/min) 5% 13,1 0,7 0,7 16,9 0,8 0,8

Flow. Qmin, steam (l/min) 3% 5,6 0,2 0,2 9,2 0,3 0,3

Type NA5 NA5

Piston type Cermic Cermic

Piston diameter (mm) 20,0 20,0

Stroke / Wobble disc angle 9,2 12,0

Pump oil type

Oil BP Energol

GR-XP220

Oil BP Energol

GR-XP220

Oil volume (l) 0,8 0,8

Electrical

Power supply 400V/3~/50Hz 400V/3~/50Hz

Current consump. - hot (A) 8,0 1,0 3,0 15,4 1,0 3,0

Current consump. - cold (A) 8,2 1,0 3,0 16,0 1,0 3,0

Power Consumption - hot (kW) 4,1 0,5 0,5 7,6 0,5 0,5

Fuse size (A) 16,0 16,0

Cord type H07RN-F 4G1,5 x 6m H07RN-F 4G1,5 x 6m

Plug type CEE 3P+N+G / 16A CEE 3P+N+G / 16A

Control PCB 24 volt PCB 24 volt

Contactor 100-C12KJ10 5,5kW 100-C16KJ10 24

Electrical diagram 106427171 + 71371 106427171

Eletrical test data

Highvoltage (HV) test (V) 1000 Vac 1000 Vac

HV-Resistance (MΩ) ≥1MΩ/ 500Vdc ≥1MΩ/ 500Vdc

Cord-resistance (Ohm) 0,2 0,2

Motor-Data

Motortype 3~ Induction 3~ Induction

Rotational speed (min-1) 1450 1450

Insulation Class F Class F

Protection Class IP 54 IP 54

Nominal power [kW] 3,0 3,0 3,0 6,7 3,0 3,0

Cos j 0,8 0,7

Technical data

NEPTUNE 5 FA_EN_Ver.2.0_25/11

NEPTUNE 5 FA

Description

SB FA EU

400V/3 ~50Hz 10A

5-61FA EU

400V/3 ~50 16A

Item no.

Tol. 107146652 107146653

Technical data Test result Tol.+ Tol.- Test result Tol.+ Tol.-

Heating Unit

Boilerpower_input (kW) 67,0 85,0

Temperature t max, @ inlet 12°C 85,2 0,0 3,0 83,0 0,0 3,0

Delta temp. variance at 50 °C

set point, at @ gun (°C) 30,0 0,0 3,0 30,0 0,0 3,0

Boiler on time at 50 °C set point,

@ inlet 12° (sec) 30,0 5,0 5,0 30,0 5,0 5,0

Steam temp. t II @ outlet and v.

Steam nozzle(°C) 140,0 10,0 30,0 140,0 10,0 30,0

Pressure P2 @ outlet with

standard nozzle (bar) 27,0 5,0 5,0 27,0 5,0 5,0

Fuel pump type Diesel Diesel

Oil pressure ( bar ) 12,0 0,5 0,0 12,0 0,5 0,0

Nozzle size, oil 1,35 60°H 1,75 60°H

CO2 content min ( % ) 10,5 0,5 0,0 10,5 0,5 0,0

Efficiency burner ( % ) 92,0 1,5 0,5 92,0 1,5 0,5

Soot picture 0-1 0-1

Exhaust outlet temperature (°C) 160,0 10,0 10,0 175,0 10,0 10,0

Exhaust temperature, cut off (°C) 270,0 0,0 12,0 270,0 0,0 12,0

Fuel consump. @ dT=45 deg(kg/h) 3,5 0,0 0,1 4,6

Fuel consumption (kg/h)

@ 12°C inlet 5,7 0,0 0,0 7,3

Water volume in coil (l) 4,8 4,8

Fuel tank (l) 17,0 17,0

Others

Gun ST ERGO 2000 ST ERGO 2000

Lance TORNADO PLUS TORNADO PLUS

Hose DN 8x10m Quick 3/8" DN 8x10m Quick 3/8"

High Pressure Nozzle NT 0700 NT 0550

Noise level 1m Lpa( dBA) 76,4 1,5 1,5 78,2 1,5 1,5

Noisepower LWA (dB) A 92,0 1,5 1,5 96,0 1,5 1,5

Impact force N 26,0 53,0

Vibration ISO 5349 ( m/s² ) ≤2,5 ≤2,5

Protection Class IP X5 IP X5

Max detergent flow

from full internal tank (%) 4,0 1,0 1,0 4,0 1,0 1,0

Max detergent flow

from full internal tank (L/min) 0,5 0,2 0,2 0,6 0,2 0,2

Technical data

NEPTUNE 5 FA_EN_Ver.2.0_25/11

NEPTUNE 5 FA

Description

5-61FAX EU

400V/3 ~50 16A

5-61FA NO

400V/230/3 ~

50Hz 25/16A

Item no.

Tol. 107146654 107146655

Technical data Test result Tol.+ Tol.- Test result Tol.+ Tol.-

Pump-Data

Max. inlet pressure (bar) 10,0 10,0

Max. Inlet temperature (°C) 40,0 40,0

Pressure at pump head 0 195 11 11 190 10 10

Pressure @ Cylinder Head (bar) 0 200 11 11 195 11 11

Pressure @ Outlet (bar) 0 197 11 11 193 11 11

Pressure @ Gun (bar) 0 170 9 9 168 9 9

Pressure cut off

@ Cylinder Head (bar) 220 5 5 215 5 5

Pressure Pmax safety valve @

Cylinder Head (bar) 250,0 5,0 5,0 250,0 5,0 5,0

Flow. Qiec (l/min) 2,5% 15,8 0,4 0,4 15,8 0,4 0,4

Flow. Qmax (l/min) 5% 16,9 0,8 0,8 16,9 0,8 0,8

Flow. Qmin, steam (l/min) 3% 9,3 0,3 0,3 9,2 0,3 0,3

Type NA5 NA5

Piston type Cermic Cermic

Piston diameter (mm) 20,0 20,0

Stroke / Wobble disc angle 12,0 12,0

Pump oil type

Oil BP Energol

GR-XP220

Oil BP Energol

GR-XP220

Oil volume (l) 0,8 0,8

Electrical

Power supply 400V/3~/50Hz 400/230V/3~/50Hz

Current consump. - hot (A) 15,8 1,0 3,0 15,6 / 25 1,0 3,0

Current consump. - cold (A) 16,0 1,0 3,0 15,8 / 25 1,0 3,0

Power Consumption - hot (kW) 7,8 0,5 0,5 7,6 / 7,4 0,5 0,5

Fuse size (A) 16,0 28 / 16

Cord type H07RN-F 4G1,5 x 6m H07RN-F 4G2,5x6,0

Plug type CEE 3P+N+G / 16A -

Control PCB 24 volt PCB 24 volt

Contactor 100-C16KJ10 24 100-C23KJ10

Electrical diagram 106427171 106427177

Eletrical test data

Highvoltage (HV) test (V) 1000 Vac 1000 Vac

HV-Resistance (MΩ) ≥1MΩ/ 500Vdc ≥1MΩ/ 500Vdc

Cord-resistance (Ohm) 0,2 0,2

Motor-Data

Motortype 3~ Induction 3~ Induction

Rotational speed (min-1) 1450 1450

Insulation Class F Class F

Protection Class IP 54 IP 54

Nominal power [kW] 6,7 3,0 3,0 6,7 3,0 3,0

Cos j 0,7 0,8

Technical data

NEPTUNE 5 FA_EN_Ver.2.0_25/11

NEPTUNE 5 FA

Description

5-61FAX EU

400V/3 ~50 16A

5-61FA NO

400V/230/3 ~

50Hz 25/16A

Item no.

Tol. 107146654 107146655

Technical data Test result Tol.+ Tol.- Test result Tol.+ Tol.-

Heating Unit

Boilerpower_input (kW) 85,0 85,0

Temperature t max, @ inlet 12°C 83,0 0,0 3,0 83,0 0,0 3,0

Delta temp. variance at 50 °C

set point, at @ gun (°C) 30,0 0,0 3,0 30,0 0,0 3,0

Boiler on time at 50 °C set point,

@ inlet 12° (sec) 30,0 5,0 5,0 30,0 5,0 5,0

Steam temp. t II @ outlet and v.

Steam nozzle(°C) 140,0 10,0 30,0 140,0 10,0 30,0

Pressure P2 @ outlet with

standard nozzle (bar) 27,0 5,0 5,0 27,0 5,0 5,0

Fuel pump type Diesel Diesel

Oil pressure ( bar ) 12,0 0,5 0,0 12,0 0,5 0,0

Nozzle size, oil 1,75 60°H 1,75 60°H

CO2 content min ( % ) 10,5 0,5 0,0 10,5 0,5 0,0

Efficiency burner ( % ) 92,0 1,5 0,5 92,0 1,5 0,5

Soot picture 0-1 0-1

Exhaust outlet temperature (°C) 175,0 10,0 10,0 175,0 10,0 10,0

Exhaust temperature, cut off (°C) 270,0 0,0 12,0 270,0 0,0 12,0

Fuel consump. @ dT=45 deg(kg/h) 4,6 4,6

Fuel consumption (kg/h) 7,3 7,3

Water volume in coil (l) 4,8 4,8

Fuel tank (l) 17,0 17,0

Others

Gun ST ERGO 2000 ST ERGO 2000

Lance TORNADO PLUS TORNADO PLUS

Hose DN 8x20m 3/8" DN 8x20m 3/8"

High Pressure Nozzle NT 0550 NT 0550

Noise level 1m Lpa( dBA) 78,2 1,5 1,5 78,2 1,5 1,5

Noisepower LWA (dB) A 96,0 1,5 1,5 96,0 1,5 1,5

Impact force N 54,0 53,0

Vibration ISO 5349 ( m/s² ) ≤2,5 ≤2,5

Protection Class IP X5 IP X5

Max detergent flow

from full internal tank (%) 4,0 1,0 1,0 4,0 1,0 1,0

Max detergent flow

from full internal tank (L/min) 0,6 0,2 0,2 0,6 0,2 0,2

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