SM_Neptune8_en.pdf

NEPTUNE 8

Supplement to Service Manual NEPTUNE 5 / 7

A. Safety instructions

B. Technical data

C. Construction

D. Function

E. Troubleshooting

F. Maintenance / repair

G. Adj Adjustm ustment ents s

H. Wiring diagrams

I. Special tools / spare parts

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Index Index

Preface

... 1

A. Safety Instructions

... 2

B. Technical Data 1. Neptune 8-103 *EU*

C. Construction

... 3 ... 4

D. Function 1. Soft start

E. Troubleshooting

... 7 ... 8

F. Maintenance / Repair 1. Maintenance 2. HP pump (N8) 2.1. Survey 2.2. Collar set 2.3. Connecting rod 2.4. Torque values 3. Electrical system 3.1. Soft start 3.2. Motor supply line

G. Adjustments

... 9 ... 10 ... 11 ... 11 ... 12 ... 13 ... 13 ... 14

H. Wiring Diagrams 1. Wiring diagram parts list 2. 3~ star (71342)

... 15 ... 16

I. Special Tools / Spare Parts

... 17

Notes

... 18

Neptune 8_EN_V 8_EN_Ver.1.0_01/ er.1.0_01/05 05

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Preface Preface

There Ther e ar are e on only ly mi mino norr di diff ffer eren ence ces s be betw twee een n th the e NEPTUNE 8 hot-water high-pressure cleaner and the NEPTUNE 5 / 7 line of products. This service manu ma nual al th ther eref efor ore e on only ly de desc scrib ribes es th the e di diff ffer erin ing g components and is intended as a supplement to the th e NE NEPT PTUN UNE E 5 / 7 se serv rvic ice e ma manu nual al.. Repair work requires a suitable testing workplace with wit h the nec necess essary ary pow power er sup supply ply.. If opera operating ting errors are evide evident, nt, refer the customer customer to th the e us user er ma manu nual al.. A fault in the cleaner can have a number of causes. Refer Ref er to Cha Chapte pterr E for tro troubl ublesh eshoot ooting ing.. Also refer to the illustrated spare parts list (part number: 301002064) for your repairs. This shows you the location of the individual parts and the sequence in which they are assembled. Read the "Se Read "Servi rvice ce / Tech echnic nical al Inf Inform ormati ation" on" she sheets ets.. The They y inc includ lude e inf inform ormati ation on on tec techni hnical cal mod modific ificati ations ons that th at ha have ve be been en ma made de af afte terr th this is se serv rvic ice e ma manu nual al wa was s pr prin inte ted. d. "Service / Technical Information" sheets are also valid as a supplement to the spare parts list until public pub licati ation on of a new edi editio tion. n. Service manuals and “Service / Technical Information” sheets should be available at the site where repair rep airs s are car carrie ried d out out.. It is no nott pe perm rmitt itted ed to gi give ve th them em to th thir ird d pa part rtie ies. s. Use or original Nilfisk


parts on only! ALTO AL TO spare pa

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Safety instructions

A Safety instructions

For your own safety

Observ Obse rve e na nati tion onal al sa safe fety ty di dire rect ctiv ives es an and d regulation regul ations s for the elect electrical rical engin engineerin eering g trade, tra de, in pa partic rticula ular: r: IEC 6033 60335-2-6 5-2-69 9 EN 60335 60335-2-69 -2-69

Repai Rep airs rs sh shou ould ld on only ly be mad ade e by so som meo eon ne who h as a s r ec e c ei e i ve v e d p ro r o pe pe r instructions for the job or w ho i s a q ua li fi ed electrician.

ESD (elec (electros trostat tatic ic discharge)

The eq The equi uipm pmen entt sh shou ould ld on only ly be us used ed by persons who have been instructed in its use us e an and d ar are e au auth thor oriz ized ed to do so so..

Observe the following ESD precautions before any repair of or near electronic elect ronic part parts: s: 


Before starting the equipment, be sure to read the accompanying operator manual, and an d ke keep ep it cl clos ose e as re read ady y re refe fere renc nce. e.

Touc ouch h the pro protec tectiv tive e con conduc ductor tor to dis discha charge rge you yourr own bod body y.



Possib Pos sibly ly wea wearr an ant anti-s i-stat tatic ic wri wrist st str strap. ap.



Use a con conduc ductin ting g flo floor or or tab tableto letop. p.



Never tou Never touch ch a cir circui cuitt boa board rd or ele electr ctroni onic c com compon ponent ents s alw always ays hol hold d it by th the e pl plas astic tic or in insu sula lati tion on..



Transport electronic parts in conductive packaging (e.g. special ESD pac package kages). s).

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B

Technical data

1. NEPTU NEPTUNE NE 8-103 Neptune 8-103 *EU*

NEPTUNE 8 a t a d e n i h c a m l a c i n h c e T

M a c h in e p r o te c t io n c a t e g o r y C u r r e n t c o n s u m p tio n V o lta g e F re q u e n c y C o n n e c te d lo a d S o u n d p re s s u re H P n o z z le P re s s u re P 1 / P 1 m a x . P re s s u re P 2 / P 2 m a x . M a x . r e c o il f o r c e W a te r th ro u g h p u t (m a x .) W a te r th ro u g h p u t (E N 6 0 3 3 5 -2 -7 9 ) W a te r in ta k e p re s s u re (m a x .) W a te r in ta k e te m p e ra tu re (m a x .)

r o t o M

V o lta g e F re q u e n c y C o n n e c te d lo a d M o to r in s u la tio n I n g re s s p r o t e c t io n RPM

p m u P

Type P lu n g e r P lu n g e r d ia m e t e r P lu n g e r s t ro k e P u m p o il A m o u n t o f o il

mm mm

F u e l p re s s u re F u e l c o n s u m p t io n d t = 4 5 K E x h a u s t te m p e ra tu re C O 2 c o n t e n t ( m i n . )

bar k g /h °C %

S o o t r a tin g E f f ic ie n c y W a t e r c o n t e n t ( c o il) H e a t in g p o w e r

% l kW

1 2 ,5 6 ,0 185 1 0 ,5 (+ 0 ,8 ) 0 - 1 > 92 6 ,1 2 115

L e n g th W id th H e ig h t W e ig h t

mm mm mm kg

1190 702 1020 228

m m l l

10 5 35 A: 15 / B: 10

r e g n a h c x e t a e H

- d t n n h e a g s i m i n e o w D i s a l l s e u c o s e i n M

IP A V Hz kW d B (A ) bar bar N l/ h l/ h bar °C V Hz kW IP U /m in

ml

H ig h - p r e s s u r e h o s e E le c tr ic a l le a d F u e l ta n k D e te rg e n t ta n k

X5 2 2 ,4 400 - 415 50 12 8 0 ,2 1200 180 / 250 25 / 32 103 2000 1950 10 40 230 - 400 50 11 CL. F 44 1450 N 8 3 0 .2 0 c e ra m ic 22 1 9 ,8 SAE 15 W 40 2150

Table B.1: Neptune 8-103


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Construction

C Construction

5

The outer design design of the Neptune Neptune 8 hot hot-wa -water ter hig highhpressu pre ssure re cle cleane anerr is com comple pletel tely y ide identi ntical cal to the Nep Neptun tune e 7 li line ne of pro rodu duct cts s. As fa farr as sen enso sors rs,, con ontr trol ol,, functionality and electronics are concerned, there are also al so no di diff ffer eren ence ces s to th the e Ne Nept ptun une e 5 / 7 se serie ries. s. Forr fu Fo furt rthe herr de deta tail ils s ab abou outt th the e co cons nstr truc ucti tion on of th the e mach ma chin ine, e, re refe ferr to th the e Ne Nept ptun une e 5 / 7 Se Serv rvic ice e Ma Manu nual al..

Fig. C.1: Neptune C.1: Neptune 8-103

Due to the higher performance specifications of the Neptune 8, the main differences to the Neptune 5 / 7 series ser ies are fou found nd in a mod modifie ified, d, larg larger er dim dimens ension ioned ed motor/pump unit. In detail, this results in the following constructional differences:

1

2

so soft ft st star artt (1 (1)) fo forr th the e pu pump mp mo moto tor r pum pump p mot motor or (2) wit withou houtt att attach achmen mentt plu plug g pumping set (3) with modified water and detergent intake 4 3

Fig. C.2: Neptune 8-103 with cover hood and side panel removed

In ad addi ditio tion n to th the e ba basi sic c de desi sign gn ch chan ange ges s fro from m th the e Nept Ne ptun une e 5 / 7 se seri ries es li list sted ed ab abov ove, e, th ther ere e ar are e fu furt rthe herr le less ss evident evide nt cons constructi tructional onal diff differenc erences: es:

 con control trol saf safety ety blo block ck (4)  flo float at val valve ve

The Th e Ne Nept ptun une e 8 ma mach chin ine e is av avai aila labl ble e in on one e ve vers rsio ion n on only ly:: Neptune Neptu ne 8-103 8-103::

3~

This ma This mach chin ine e is eq equi uipp pped ed wi with th a st stor orag age e tr tray ay (5 (5)) fo forr ac acce cess ssor orie ies, s, to tool ols, s, et etc. c. as st stan anda dard rd.. Up Upgr grad adin ing g wi with th a ho hose se re reel el or ho hose se an and d ca cabl ble e re reel els s is po poss ssib ible le..

Fig. C.1 & C.2: 1.) Soft start 2.) Pump motor Neptune 8_EN_V 8_EN_Ver.1.0_01/0 er.1.0_01/05 5

3.) Pumping set (N8) 4.) Contr Control ol safet safety y block

5.) Storage tray

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C

Construction

Construction Soft So ft st star artt of th the e pu pump mp mo moto tor r 4

The so The soft ft st star artt el elec ectro troni nic c ci circ rcui uitry try is lo loca cate ted d in a se sepa para rate te housing (1) mounted with a bracket (2) to the central tube (3) of the machine. The connecting line (4) is led from fr om th the e ho hous usin ing g (1 (1)) di dire rect ctly ly in into to th the e re rear ar of th the e el elec ectr tric ic box bo x of th the e ma mach chin ine. e.

3

2

For fur furthe therr det detail ails, s, refe referr to Cha Chapte pterr F.3. .3.1. 1. 1

Fig. C.3: Sof Softt sta start rt hou housin sing g mo moun untedto tedto cen centra trall tub tube e

Pump Pum p mot motor or wit withou houtt att attach achmen mentt plu plug g Due to th Due the e hi high gher er cu curre rrent nt co cons nsum umpt ptio ion n co comp mpar ared ed to th the e Nept Ne ptun une e 5 / 7 li line ne of pr prod oduc ucts ts an and d in inco comp mpat atib ibil ilit ity y of th the e motor (5) to the existing cold-water series, the motor line (6) is not provided with an attachment plug. The motor line (6) is led directly into the rear of the electric box of th the e mach chin ine e. Th The e star con onn nect ctiion is implem imp lement ented ed in the mot motor or (5) (5)..

6

For fur furthe therr det detail ails, s, refe referr to Cha Chapte pterr F.3. .3.2. 2.

5 Fig. C.4: Pump Pumpmoto motorr witho without ut atta attachme chment nt plug

Pumping set (N8) with modified water and detergent intake

10

10

9

The N8 pump (7) is basically constructed similar to the NP5 pump, only being dimensioned larger. larger. The weight of th the e pu pump mp (7 (7)) is th ther eref efor ore e su supp ppor orte ted d by a su supp ppor ortt fo foot ot (8). Detergent is taken in directly behind the outlet of the water break tank (Fig. C.5; detail) and not from the valve val ve blo block ck (9) (9).. The water feed hose (10) to the pump (7) is connected to th the e va valv lve e bl bloc ock k (8 (8)) at th the e mo moto torr si side de..

7 8

For fur furthe therr det detail ails s see Cha Chapte pterr F.2.

Fig. C.5: Pump Pumping ing set (N8)

Fig. C.3 - C.5: 1.) Soft start housing 2.) Soft start housing bracket 3.) Central tube 4.) Connecting line Neptune 8_EN_V 8_EN_Ver.1.0_01/0 er.1.0_01/05 5

5.) Motor 6.) Motor line 7.) N8 pump 8.) Support foot

9.) Valve block 10.) Water feed hose

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C

Construction

Construction Contro Con troll saf safety ety blo block ck The fo The follo llowi wing ng mo modi dific ficat atio ions ns we were re ma made de to th the e co cont ntro roll sa safe fety ty bl bloc ock k comp co mpar ared ed to th the e Ne Nept ptun une e 5 / 7 se seri ries es::

1

The pressure hose (1) to the heat exchanger was changed to Neve verr us use e th the e pr pres essu sure re hose hose of th the e Ne Nept ptun une e 7 DN10. Ne machine. Th The e ho hous usin ing g (2 (2)) fo forr th the e ma magn gnet etic ic co cont ntac actt pi pist ston on of th the e flo flow w sensor sens or was lengt lengthene hened. d. Th The e ma magn gnet etic ic co cont ntac actt pi pist ston on wa was s re repl plac aced ed by a la larg rger er on one e (diame (di ameter ter:: 13 mm) mm)..

2

Forr fu Fo furth rther er de deta tails ils,, re refe ferr to th the e Ne Nept ptun une e 8 lis listt of sp spar are e pa part rts. s.

Fig. C.6: Control C.6: Control safety block of Neptune 8

Float valv valve e 3

4

6 5

Compared to the Neptune 5 / 7 series, a float valve (3) with larger nominal width (Neptune 5 / 7: DN10; Neptune 8: DN17) is used. Therefore, the water inlet filter (4), float (5) and membrane (6) are also diffe different. rent. Forr fu Fo furt rthe herr de deta tail ils, s, re refe ferr to th the e Ne Nept ptun une e 8 li list st of sp spar are e pa part rts. s.

Fig. C.7: Water C.7: Water break tank with new float valve

Although the Neptune 8 and the Neptune 5 / 7 series are largely identical, be sure to use the Nept Ne ptun une e 8 lis listt of sp spar are e par artts wh when en or orde deri ring ng par arts ts fo forr th this is ma mach chin ine! e!

Fig. C.6 & C.7: 1.) Pressure hose 2.) Housing Neptune 8_EN_V 8_EN_Ver.1.0_01/0 er.1.0_01/05 5

3.) Float valve 4.) Water inlet filter

5.) Float 6.) Membrane

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D

Function

1. Soft start There Ther e ar are e no fu func nctio tiona nall di diff ffer eren ence ces s be betw twee een n th the e Ne Nept ptun une e 5 / 7 se seri ries es an and d th the e Ne Nept ptun une e 8. Ho Howe weve verr, du due e to the higher capacity of its motor/pump unit, the Neptune 8 must be started up using a so-called soft startt funct star function. ion. A1

1 2

Datalogger

X2 B1

F1

5V DC +

T1

X4-21

~

X4-23 X4-17

X5-13 X5-15

24V AC

B4

1

1 a

2

2 a

L1 L2 L3

12

400V AC

13

X4-19 X5-5

7

11

8V AC

PE

S1

4

14

X4-15

B3

P

X4-13

X5-7 X5-9

B6

F2

MT

X4-9 X4-11

X5-11

B7

X3-1

µP

X6-9 X6-11

X3-9

X5-1

B8

A1

13

5

13

A2

24

6

14

K1

F11

X3-5 X5-3

Q

X6-1

B9

B2

X4-5

A1

X4-7

11

K2 A2

X6-3

S1

X4-1

X6-6

4

Y1

L1 L2

X6-7

X1a X1b

X7

M2

T1 T2

X4-3 X3-7 X3-3 X3-11

4a

14, 24

A3

X11

X12

M 1~

T2

X13

Remote

A2

Temp.

Display

U1 V1 W1

M1 O pe pe ra ra titi on on

F ue ue l

P um um p O il

S er er vi vi ce ce

A nt nt i S to to ne ne

M 3~

U2 V2 W2

Fig. D.1: Wiring D.1: Wiring diagram of Neptune 8

The so The soft ft st star artt fu func ncti tion on pr prov ovid ides es cu curr rren entt li limi mita tati tion on du duri ring ng th the e star st artt-up up ph phas ase e (1 se seco cond nd). ). Th This is is re real alis ised ed by ph phas ase e co cont ntro roll to 2 phases (Fig. D.1.; red border). A potentiometer (1) installed on the soft start board may be used to set the starting torque of the machine. The torque is preset in the factor fac tory y and nor normal mally ly nee needs ds not be cha change nged. d. Forr fu Fo furth rther er de deta tails ils ab abou outt th the e fu func ncti tion onal ality ity,, re refe ferr to th the e Nept Ne ptun une e 5 / 7 Se Serv rvic ice e Ma Manu nual al..

1

Fig. D.2: Neptune D.2: Neptune 8 soft start board

Fig. D1 & D2: 1.) Potentiometer Neptune 8_EN_V 8_EN_Ver1.0_01/05 er1.0_01/05

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Troubleshooting

E Troubleshooting

The mi The micr crop opro roce cess ssor or co cont ntro roll of th the e Ne Nept ptun une e 8 is id iden entic tical al to th that at of th the e Ne Nept ptun une e 5 / 7 se serie ries. s. Th The e ma mach chin ine e shows the same error codes on its display, which may to be used to find out the cause of a possible malfunction. Other troub troublesho leshooting oting proce procedures dures are also ident identical. ical. For det detail ailed ed tro troubl ublesh eshoot ooting ing inf inform ormati ation, on, ref refer er to the Nep Neptun tune e 5 / 7 Ser Servic vice e Man Manual ual.. Fur Furthe therr use useful ful lea leads ds and information for troubleshooting the machine can be found in the respective Service / Technical Info In form rmat atio ion n sh shee eets ts (S (STI TIs) s) fo forr th the e Ne Nept ptun une e 5 / 7 se seri ries es..


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Maintenance / repair

F 1. Maintenance

Maintenance plan

Maintenance task

Weekly

Aft fter er th the e fi firs rstt 50 operati ope rating ng hou hours rs

Every Ever y 6 mon onth ths s or 50 500 0 op oper erat atin ing g As req requir uired ed hours

Cleaning Cleani ng wat water er fil filter ter Clea Cl eani ning ng oi oill fi filt lter er Chec Ch ecki king ng pu pum mp oi oill quality Chan Ch angi ging ng pu pum mp oi oill Empt Em ptyi ying ng fu fuel el tan tank k Flam Fla me sen sensor sor Table F.1: Maintenance F.1: Maintenance plan

All maintenance tasks in accordance with the maintenance plan for the Neptune 8 are the same as requ re quire ired d fo forr th the e Ne Nept ptun une e 5 / 7 se seri ries es.. Th The e on only ly di diff ffer eren ence ce is th the e lo loca catio tion n of th the e pu pump mp in inle lett fil filte ter: r: 1. Unscrew the union nut (1) at the water wat er inl inlet et cou coupli pling. ng. 2. Re Remo move ve th the e fil filte terr (2 (2)) us usin ing g pl plie iers rs or another suitable tool and clean it. If necess nec essary ary rep replac lace e the filt filter er (2) (2).. 1 2 1

Fig. F.1: Water F.1: Water inlet at HP pump

In addition to the Neptune 5 / 7 Service Manual, also see the corresponding User Manual (p/n 301002 301 002099 099)) for fur furthe therr inf inform ormati ation on on mai mainte ntenan nance ce and mai mainte ntenan nance ce pla plan. n.

Fig. F.1: 1.) Union nut 2.) Filter Neptune 8_EN_V 8_EN_Ver1.0_01/05 er1.0_01/05

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F 2. HP pump (N8)

1. Survey

6 4

3 1

4

5 2

Fig. F.2: HP F.2: HP pump of Neptune 8 (exploded view)

7

4 2

Fig. F.3: HP F.3: HP pump of Neptune 8 (sectional model)

The HP pu The pump mp us used ed is a bi bidi dire rect ctio iona nall th thre reee-pi pist ston on straight-type pump with ceramic pistons (1). Its function and design are almost identical to the NP5 pump. The pump pum p hou housin sing g (2) is fla flange nge-mo -mount unted ed axi axiall ally y ont onto o the electr ele ctric ic mot motor or.. The rot rotor or sha shaft ft pro projec jects ts fro from m the mot motor or and is us used ed as a dr driv ive e sh shaf aftt (3 (3)) fo forr th the e HPpum HPpump. p. The Th e cr cran anks ksha haft ft (3 (3)) is se seat ated ed in tw two o id iden enti tica call ro roll ller er bearings (4). (Note: Different roller bearings are used in the NP5 HP pump.) They ensure smooth operation and long lon g ser servic vice e lif life. e. Multigrade oil is used for lubrication of the HP pump. (Not (N ote: e: Ab Abou outt 2150 2150 ml ar are e re requ quir ired ed fo forr th the e NP NP8 8 pu pump mp vs vs.. appr ap prox ox.. 10 1000 00 ml fo forr th the e NP NP5 5 pu pump mp.) .) Differences also exist in the design of the collar sets (5) and pum pump p con connec nectin ting g rod rods s (6) (6)..

Fig. F.2 & F.3: 1.) Ceramic piston (sleeve) 2.) Pump housing Neptune 8_EN_V 8_EN_Ver1.0_01/05 er1.0_01/05

3.) Crankshaft 4.) Roller bearing

5.) Collar set 6.) Pump connecting rod 10/21

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F


2. HP pump (N8) 2. Thrust collar set In contrast to the NP5 pump, the collar set of the N8 pu pump mp is co comp mpos osed ed of a tw twoo-pi piec ece e th thru rust st co colla llar r package. High-pressure package: 1.) Sup Suppor portt rin ring g 2.) HighHigh-press pressure ure sleev sleeve e 3.) Hig High-p h-pres ressur sure e thr thrust ust col collar lar

4 8

1

2

7

5

3

6

Fig. F.4: Thrust F.4: Thrust collar set of N8 pump

Low-pressure package: 4.) Support ring (not shown in lower part of Fig. F.4) 5.) Low-p Low-pressu ressure re sleev sleeve e 6.) Low Low-pr -press essure ure thr thrust ust col collar lar 7.) O-r O-ring ing For th For the e fit fittin ting g po posi siti tion ons, s, re refe ferr to th the e il illu lust stra rati tion ons s in Fig. F.4. Caution: Wh When en fi fitti tting ng or re remo movi ving ng th the e th thru rust st collar sets be sure not to scratch the thrust collar. Liberally grease the sleeves, their seats and Orings. Do not re-use a sleeve once it has been removed.

3. Connecting rods

A

A A

10

9 9

A

9

A

The th The thre ree e co conn nnec ecti ting ng ro rods ds (9 (9)) in th the e N8 HP pu pump mp are designed in two parts. Before removing the cranks cra nkshaf haftt (10 (10)) uns unscre crew w the hex hexago agon n scr screws ews (arrows A) and remove them together with the loos lo ose e pa part rt of th the e pu pump mp co conn nnec ectin ting g ro rod d (9 (9). ). Sh Shou ould ld the parts be re-used, mark the order of assembly and re-ins re-install tall them acco according rdingly ly.. When mounting the connecting rods (9) be sure to lubricate lubricate the bearing bearing faces faces of the rods rods (9) and not to jam the rods. Tighten the fastening screws (arrows (arrow s A) alter alternately nately and even evenly ly..

A

Fig. F.5: Pump F.5: Pump housing opened (view from the rear)

Fig. F.4 & F.5: 1.) Support ring 2.) HP sleeve 3.) HP thrust collar Neptune 8_EN_V 8_EN_Ver1.0_01/05 er1.0_01/05

4.) Support ring 5.) LP sleeve 6.) LP thrust collar

7.) O-ring 8.) Oil seal (piston) (piston) 9.) Pump connecting rod

10.) Crankshaft

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F


2. HP pump (N8) 4. Torque values

D

C

F

2

1

G

E B

D

A E

Fig. F.6: HP F.6: HP pump of Neptune 8 (exploded view)

Torque values Valve bl block sc screws: Piston nut: Housing co c over screws: Bearing co c over sc s crews: Valve plugs: Connecting ro r od bo b olts: Crankshaft (w/o oi o il filling):

A) 50Nm (arrow A) 12Nm (arrow B) 10Nm (arrow C) C) 24Nm (arrow D) D) 67Nm (arrow E) 10Nm (arrow F) F) 0.2-0.8Nm (arrow G) G) Adjusting washers (2 (2)) wi with th fo four ur different thickness (0.05 / 0.10 / 0.19 / 0.25) are ar e av avai aila labl ble e fo forr ad adju just stme ment nt of th the e to torq rque ue at th the e cr cran anks ksha haft ft (1 (1). ).

On ac acco coun untt of th the e si simi mila larr de desi sign gns s of th the e N8 an and d NP NP5 5 pu pump mps, s, in info form rmat atio ion n on as asse semb mbly ly of th the e comp co mpon onen ents ts ca can n al also so be ta take ken n fro from m th the e Po Pose seid idon on 5 or Ma Maxx xxii 4 Se Serv rvic ice e Ma Manu nual al,, in ad addi diti tion on to th the e de deta tails ils avai av aila labl ble e in th the e Ne Nept ptun une e 5 / 7 Se Serv rvic ice e Ma Manu nual al..

Fig. F.6: 1.) Crankshaft 2.) Adjusting washer Neptune 8_EN_V 8_EN_Ver1.0_01/05 er1.0_01/05

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F

3. Electr Electric ic system 1. Soft start

5

3

4

A

2 1

Fig. F.7: Soft F.7: Soft start housing mounted to central tube

The soft start circuitry is located in a housing (1) moun mo unte ted d on a br brac acke kett (2 (2)) cl clam ampe ped d to th the e ce cent ntra rall tube tu be (3 (3)) of th the e ma mach chin ine. e. When Wh en worki working ng on the soft soft star startt circui circuitry try - in particular when the housing cover (4) is opened - be sur ure e to fi firs rstt tu turn rn off th the e mac achi hine ne an and d pu pull ll out the mai mains ns plu plug. g. Before Bef ore rem removi oving ng the com comple plete te sof softt sta start rt box including its bracket (2), turn off and unplug the machin mac hine. e. The Then, n, as req requir uired, ed, dis discon connec nectt the connec con nectin ting g lin line e (5) of the ele electr ctroni onic c cir circui cuitry try (eith (e ither er di dire rect ctly ly at th the e el elec ectr tric ic bo box x or at th the e co cont ntro roll circ ci rcui uitr try) y).. Th Then en lo loos osen en th the e re reta tain inin ing g sc scre rew w (arrow A) and lift out the complete unit along the cent ce ntra rall tu tube be (3 (3). ). Fo Forr fu furt rthe herr de deta tail ils s ab abou outt assemb ass embly ly,, refe referr to the cor corres respon pondin ding g sp spare are pa parts rts list.

2. Motor supply line

6

7

The mo The moto torr lin line e (6 (6)) is co conn nnec ecte ted d wi with thou outt an attachmen atta chmentt plug to the motor (7). There Therefore, fore, the motor (7) must be disconnected at the electric box for removal. First turn off the machine and discon dis connec nectt it from the mai mains ns sup supply ply (un (unplu plug). g). If the complete motor/pump assembly has to be pull pu lled ed ou outt fo forr re repa pair ir or ma main inte tena nanc nce e wo work rk,, discon dis connec nectin ting g the mot motor or lin line e (6) is not nec necess essary ary because the line has sufficient length to allow t hi hi s. s. H ow ow ev ev er er, b ef ef or or e p ul ul lili ng ng o ut ut t he he motor/p mot or/pump ump ass assemb embly ly ens ensure ure tha thatt the mot motor or line li ne (6 (6)) is fr free eely ly mo mova vabl ble. e. For further details about assembly, refer to the correspon corre sponding ding spar spare e part parts s list.

Fig. F.8: Pump F.8: Pump motor without attachment plug

Fig. F.7 & F.8: 1.) Housing 2.) Bracket Neptune 8_EN_V 8_EN_Ver1.0_01/05 er1.0_01/05

3.) Central tube 4.) Housing cover

5.) Connecting line 6.) Motor supply line

7.) Motor 13/21

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G

Adjustments Adjustment s

Adjustments Electronic Elect ronic circu circuitry: itry:

Adjustments see Neptune 5 / 7 Service Manual.

Control Contr ol safety block block::

Adjustment procedure see Neptune 5 / 7 Service Manual or STI 390.

Heat exchanger system: Adjustment procedure see Neptune 5 / 7 Service Manual or STI MPW005. Settings:

NEPTUNE

8-103

CO2 content

%

Fuel pressure Soot rating

bar

10.5 (+ 0.8) 12,5 0-1

Flow contr control: ol:

Adjustment procedure see Neptune 5 / 7 Service Manual.

AntiStone AntiS tone devic device: e:

Parame Para mete ters rs fo forr ad adju just stme ment nt se see e Ne Nept ptun une e 5 / 7 Se Serv rvic ice e Ma Manu nual al.. (N (Nep eptu tune ne 8 is sett si se simi mila larr to Ne Nept ptun une e 7. 7.))

Softt sta Sof start: rt:

The st The star arti ting ng to torq rque ue of th the e el elec ectr tric ic mo moto torr ha has s be been en se sett co corr rrec ectl tly y in th the e fa fact ctor ory y. Furthe Fur therr adj adjust ustmen mentt is gen genera erally lly not req requir uired. ed.

Neptune 8_EN_V 8_EN_Ver1.0_01/05 er1.0_01/05

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Wiring diagrams

H

1. Wiring diagram parts list Note:

The com compon ponent ents s lis listed ted in Tabl able e H.1 rel relate ate to the fol follow lowing ing Nep Neptun tune e 8 wir wiring ing dia diagra gram. m.

Code

A1 A2 A3 B1 B2 B3 B4 B6 B7 B8 B9 F1/F F1 /F2/ 2/F1 F11 1 K1 K2 M1 M2 MT S1 T1 T2 X1a/ X1 a/b b X2 X3-X6 X7 X11/ X1 1/12 12/13 /13 Y1

Component designation

Processor Board Display Board Softstarter Temp. Sensor Flow switch Safety thermal switch Micro switch Level switch pump oil Light sensor Level switch anti stone Level switch fuel Fuse Fu se Contactor Relay Motor 3~ Burner motor Temp. switch motor Switch on/off Control transformer Ignition transformer Conn Co nnec ecto torr di disp spla lay y bo boar ard d Pin co con nta tact cts s 5po pol. l. dat ata a lo logg gger er Terrminal strip Te Connect cto or remote co con ntrol Term Te rmin inal al Magnet valve

Table H.1: Wiring H.1: Wiring diagrams parts list for Neptune 8


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H

Wiring diagrams

2. ThreeThree-phase phase star (71342)

3 1

4 1

2 T

4 2 , 4 1

1 1

M

5

2 L

2 1 X

3 A

6

3 1

1 L

3 1 X

2 M

1 1 F

3 L

~ 1

4 2

2 L

2 T

1 L

1 T

1 W 1 V

1 U 1

1 1 X

E P

1a

1

2 W 2 V 2 U

M

7

2 K 4

1 A 2 1

3 1

C A V 8

2 A

2

C A V 0 0 4

1 S

1 T 1 1

~ 3

2a 1 A

12

M

T M

4 1

C A V 4 2

2 A

1 K

3 B

2 B

1 Y

Q

1 2 4 X

3 2 4 X

7 1 4 X

9 1 4 X

3 1 4 X

5 1 4 X

1 1 4 X

9 - 4 X

2 1 F

1 3 X

9 - 3 X

5 - 3 X

5 - 4 X

7 4 X

1 3 - 7 - 3 - 1 4 3 3 3 X X X X

1 4 X

F

y a l p s i D

7 X e t o m e R

~

+

C D V 5

e n o t S i t n A

e c i v r e S l i O p m u P

P µ

l e u F

r e g g o l a 2 t a X D 3 1 5 X

5 1 5 X

7 5 X

5 - 5 X

9 - 5 X

1 1 5 X

9 - 6 X

1 1 6 X

a b 1 1 X X 1 5 X

3 - 5 X

3 - 6 X

1 6 X

6 - 6 X

. p m e T

7 6 X

1 A

2 A

4

P

1 B


4 B

6 B

7 B

8 B

9 B

1 S

a 4

n o i t a r e p O

r a t s e s a h p - e e r h t m a r g a i d g n i r i W : 1 . H . g i F

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I

Special tools / spare parts

Special Spec ial tools / spa spare re par parts ts / servic service e access accessories ories

Part number 17237 17238 17239 17240 17241 17242 17243 17246 40471 40472 63138 301000383 301001078 301001089 301002067 301001875 301001090 301000911 301002071 310001130 301001131 301002050 301002053 301002051 301002055 301002039 3812385 24499 3812625

Description Special tools (1)

Remarks

Soot pump with filter paper and soot rating scale Filter paper Soot rating scale CO2 meter with refill fluid CO2 metering fluid

Gas thermome thermometer ter (pointe (pointer) r) Test case (empty) Fuel pressu pressure re meter Gas thermomet thermometer er (LCD) Exhaust loss calculator Test bolt Datalogger Service crane Chimney adapter TESTO exhaust air probe TESTO central unit Crane eye

see also STI MPW /SPW -011 see also STI MPW /SPW -011

Spare parts / repair kits Safety valve Repair kit CSB Attachment Attachme nt set: hose & cable drum Attachment Attachme nt set: hose drum Kit piston 22 mm Kit piston sealin sealing g 22 mm Kit oil sealin sealing g Kit support ring 22 mm Kit valv valve e (x6) Fuse 5 x 20; 6,3A/250V Fuse 5 x 20; 315 m Fuse 5 x 20; 2,0A/250V

(2)

F11 F1 F2

(3)

41455 33397 33667

Service accessories Grease (-15 to +130°C +130°C), ), 50 g tube; foodsafe Loctite 242, 50 ml bottle Silicone Silico ne greas grease, e, 100 g tube Sealing varnish, commercial standard Silicone spray, commercial standard Copper paste, commerc commercial ial standa standard rd

Table I.1: Special I.1: Special tools, spare parts and service accessories

Further details concerning special tools, spare parts and service accessories can be found in the Nept Ne ptun une e 3 an and d Ne Nept ptun une e 5 / 7 Se Serv rvic ice e Ma Manu nual als s as we well ll as in di dive vers rse e ST STI’ I’s. s.


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Notes Notes

____________________ ____________________ ____________________ __________________ __ ____________________ __________________ __ ____________________ __________________ __ ____________________ __________________ __ __________________________ ____________________ ______ __________________________ ____________________ ______ __________________________ ______________________ ____ __________________________ ____________________ ______ __________________________ ____________________ ______ __________________________ ____________________ ______ __________________________ ____________________ ______ __________________________ ____________________ ______ __________________________ ____________________ ______ __________________________ ____________________ ______ __________________________ ____________________ ______ __________________________ ____________________ ______ Neptune 8_EN_V 8_EN_Ver.1.0_01/ er.1.0_01/05 05

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Notes Notes


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Notes Notes


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Notes Notes


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SM_Neptune8_en.pdf

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