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Poseidon 7 Service Manual TsJ 6-03.02 Index 1 A TechnicalData B Construction C Function D Trouble-shooting E Service/Repair F Adjustment/Test G WiringDiagrams H SparePartsProposal I SpecialInformation Index Poseidon Technical Data A Poseidon 1200 Primary data Voltage Frequency Motor coupling Number of phases Power consumption High voltage Leakage current Resistance in ground circuit Absorption power Axel power Revolutions Control voltage Signal voltage microprocessor IP classification Bypass time auto start/stop Bypass time manual Water volume, high-pressure Water volume, low-pressure Machine's pressure gauge Pump pressure, high-pressure Pressure, h-p pump outlet Opening pressure, pump outlet Bypass pressure Suction capacity Suction height, primed Max. water inlet temperature Max. water inlet pressure Reaction force, max. Acoustic pressure level Oil volume Oil type Poseidon_GB01 Unit VAC Hz Pce. A KV mA Ohm kW kW Min-1 VAC VAC Sec Min l/min l/min Bar Bar Bar Bar Bar Bar m °C Bar N dBA Litre General 200 240 50 Nominal values 400 415 440 50 50 50 3 12 3 3 440 60 Tolerances +6/-10% 3 +-1.5 2.4 in 2 sec. 0.75 0.2 200 240 6.7 5.5 1440 400 5 45 20 5 17.6 19.1 175 158 152 185 11 0.17 3 85 415 440 440 1420-1470 +-10% +-10% +-8.5% +-7 +-4 10 54 75.4 0.5 Pump oil 100 1 Technical Data A Poseidon 1280 Primary data Voltage Frequency Motor coupling Number of phases Power consumption High voltage Leakage current Resistance in ground circuit Absorption power Axel power Revolutions Control voltage Signal voltage microprocessor IP classification Bypass time auto start/stop Bypass time manual Water volume, high-pressure Water volume, low-pressure Machine's pressure gauge Pump pressure, high-pressure Pressure, h-p pump outlet Opening pressure, pump outlet Bypass pressure Suction capacity Suction height, primed Max. water inlet temperature Max. water inlet pressure Reaction force, max. Acoustic pressure level Oil volume Oil type Poseidon_GB01 Unit VAC Hz Pce. A KV mA Ohm kW kW Min-1 VAC VAC Sec. Min l/min l/min Bar Bar Bar Bar Bar Bar m °C Bar N dBA Litre General 200 240 50 Nominal values 400 415 440 50 50 50 3 13 3 3 440 60 Tolerances +6/-10% 3 +-1.5 2.4 in 2 sec. 0.75 0.2 200 240 8.3 6.5 1440 400 5 45 20 5 18.6 20.3 195 178 170 200 12 0.17 3 85 415 440 440 1420-1470 +-10% +-10% +-8.5% +-7 +-4 10 75.4 0.5 Alphasyn T 150 2 Technical Data A Poseidon 720 Primary data Voltage Frequency Motor coupling Number of phases Power consumption High voltage Leakage current Resistance in ground circuit Absorption power Axel power Revolutions Control voltage Signal voltage microprocessor IP classification Bypass time auto start/stop Bypass time manual Water volume, high-pressure Water volume, low-pressure Machine's pressure gauge Pump pressure, high-pressure Pressure, h-p pump outlet Opening pressure, pump outlet Bypass pressure Suction capacity Suction height, primed Max. water inlet temperature Max. water inlet pressure Reaction force, max. Acoustic pressure level Oil volume Oil type Poseidon_GB01 Unit VAC Hz Pce. A KV mA Ohm kW kW Min-1 VAC VAC Sec Min l/min l/min Bar Bar Bar Bar Bar Bar m °C Bar N dBA Litre General Nominal values 230 50 3 1 12 Tolerances +6/-10% +-1.5 2.4 in 2 sec. 0.75 0.2 2.9 2.1 1430 230 5 45 20 5 11.5 12.5 105 101 93 125 10.5 0.17 3 85 1420-1470 +-10% +-10% +-8.5% +-7 +-4 10 54 75.4 0.5 Pump oil 100 3 Construction B Frame The frame is built of Ø25mm steel pipes. One nozzle can be stored on each side of the machine. 2, Ø250mm wheels and 1, Ø100mm swivel wheel are mounted to the frame. A bent bar is attached to the front of the frame to protect hose attachments. The bar is also used for lifting the machine both manually and by crane. The back bar is equipped with fixtures for mounting hose reel, a U-bar for placing nozzles, and winding reel for electrical cable. The steering handle is made of plastic. Cabinet The cabinet is made of vacuum-shaped plastic. On the cabinet’s top side there is room for storing small auxiliary articles. All hoses are connected through the hole at the front of the cabinet. Motor/pump The motor/pump unit is attached to the frame with four taptite screws in the electric motor’s stator. This way the pump can be accessed from the front of the machine, and those parts of the pump susceptible to wear are easily serviced. The pump is a 4-cylinder axial piston pump with a wobble disc system and solid ceramic pistons. Suction and pressure valves are made of stainless steel. The oil system is closed, and the oil level can be checked through a liquid indicator on the side of the cabinet. The pump’s water connection is mounted using ¾” quick-acting coupling. The pump’s pressure outlet is mounted with a 3/8” quick-acting coupling nipple. The pump pressure can be read in bars (CPA) on an adapted pressure gauge. Start/stop system The machine’s start/stop system is controlled by a microprocessor that stops/interrupts the signal from a reed switch. The reed switch is activated by the flow of a magnetic piston mounted in the pump outlet’s flow control through the pump. The start switch has 3 settings: 0 = Machine stopped. I = Aut. start/stop. Machine stopped with automatic stop function if the spray handle is not activated after 20 seconds. Man = Manuel. Machine started in manual position. The machine stops automatically, however, if the spray handle is not activated after 5 minutes. Use the manual position if the machine is set to suction without water inlet pressure. Poseidon_GB01 1 Construction B Electrical system The electrical system is located in electrical casing placed on the motor/pump unit. All automatic functions are controlled by a microprocessor built into a circuit board. Equipment The machine’s standard equipment consists of: Ergo 3000 spray handle. 10 mtr. Double wire high-pressure hose. Tornado nozzle. ¾” quick coupling nipple. Poseidon_GB01 2 Function C Pump Function The illustration below shows a cross-section of the Poseidon pump. The pump’s job is to move a given amount of water from the suction side to the high-pressure nozzle. The volume of water depends on the pistons’ quantity, diameter, impact length, and number of impacts per minute. When wobble disc A is turned, the piston is pulled down with the help of retracting spring B, and water is sucked through suction valve C. When the piston rises again, the suction valve closes, and pressure valve D opens. From here, water is propelled towards the pump’s bypass valve. Because of the high-pressure nozzle’s small opening, considerable force is needed to move the pistons forward. In order to reduce lost friction, the force of the motor is transferred to the pistons via the wobble disc’s oil-soaked E roller bearings. The pistons are composed of a stainless steel portion, which is controlled by the cylinder and sealed with oil sleeve F. The upper portion of the piston is ceramic, the seal on the water side consists of a gasket system. At the top is textile sleeve G, which seals out high-pressure. A smaller leakage current passes down to low-pressure sleeve H, and between these two sleeves, the lubrication is drained back to the suction side through a small channel. Poseidon_GB01 1 Function C Bypass Valve Function The bypass valve has 4 functions: 1. Protect the machine against excess pressure. 2. Relieve the pressure in bypass. 3. Fast conversion to high-pressure. 4. Ensure 0 pressure when the machine is stopped. Operation: The water from the pump is led into chamber A of the bypass valve. From there, the water passes through hole B in piston C and out of the machine. This leads to a pressure imbalance in piston C, which keeps valve disc D closed to valve seat E. Bypass: When water consumption stops (the spray handle is released), pressure increases briefly until safety valve F opens upon reaching the pressure setting, which should be adjusted to 25-30 bars over working pressure. This causes the pressure drop in piston C to disappear, and valve disc D moves from valve seat E. The machine is now running in bypass. Poseidon_GB01 2 Function C P O S E ID O N S P R A Y D F E A B B C Poseidon_GB01 3 Function C P O S E ID O N B Y - P A S S D F E C B Poseidon_GB01 A B 4 Function C Flow Control Flow control consists of: 1. 2. 3. 4. Casing Piston w/ magnet Spring Reed switch Operation: A drop in pressure in the piston pushes the piston forward, causing the magnet to activate the reed switch. A drop in pressure on the piston’s end face causes the piston to remain in this position. Bypass: When water is not being consumed, the drop in pressure in the piston stops, and the piston is pushed back by the spring, deactivating the reed switch. The pressure is balanced out through the hole in the piston, and the force of the spring holds the piston in a neutral position. 5 V O L T S P R A Y . 0 V O L T B Y - P A S S . Poseidon_GB01 5 Function C PC Board The circuit board has the following functions: 1. To start the electric motor when starting the machine. 2. To stop the electric motor when operation of the machine is finished. 3. To record and store data concerning the machine’s work situations, operation, and bypass. The circuit board is protected against excess pressure thanks to a circuit breaker (0.63A- SLOW) placed on the board. Start switch positions 0: The machine is not in operation; there is no power from the Start/Stop switch to print and the contactor’s magnetic pole. 1: The machine is set to automatic start/stop operation. When you activate the spray handle and water is flowing through the machine, the flow sensor’s reed switch signals the circuit board’s microprocessor, and the machine runs uninterrupted. When you release the spray handle, and water flow through the machine stops, the signal to the PC board’s microprocessor is interrupted. After a 20-second delay, power to the contactor’s magnetic pole is cut off, and the electric motor stops. Man: The machine is set to manual operation. The flow sensor is monitored via the reed switch but is not active. The electric motor runs uninterrupted regardless of whether or not the reed switch registers water flow. When you release the spray handle and the water flow through the machine stops, the power to the Start/Stop switch and to the contactor’s magnetic pole is cut off after 5 minutes. The machine must then be restarted using the Start/Stop switch. Service functions: 1. 2. 3. 4. Identification of machine and software type. Read-out of number of starts. Read-out in hours/minutes of operating time under flow. Read-out in hours/minutes of bypass time. These read-outs are made with ALTO SB Datalogger . A description of SB Datalogger will be added later. Poseidon_GB01 6 Trouble-shooting D Operating Requirements To ensure error-free operation, the following requirements must be met: Water quality must be free of impurities > 50 µ. 5. Water supply must be sufficient at all times. 6. Ambient temperature must not exceed 40°C. 7. Supply voltage must not vary by more than 6% of the given value. Poss. cause/ Check Symptom: Suction sleeve Flow control 4. Water temperature Suction height Suction cup on bypass valve Oil sleeve + oil hoses In suction mode, water temperature must be significantly lower, depending on the suction height. Make sure the pump does not cavitate (water boils under vacuum). Air in pump Safety valve Water supply 3. Pressure sleeve Water temperature must not exceed 85°C when inlet pressure on water supply. Piston for bypass valve Pump pressure + h-p nozzle Suction valve + seat Pressure valve + seat Leaks in hoses Bypass valve + disc O-ring in cylinder head Water filter 2. Electrical connections + plug Temperature sensor in motor Start switch Print + reed switch Machine and equipment must be free of air and without leaks. Circuit breakers Contactor + coil 1. Motor doesn't start X X X X X X X Motor doesn't stop X Motor stops X X X X X X Max. pressure too high X Max. pressure too low X X X X X X X X X X X X Max. pressure irreg. in suction X X X X X X X X Max. pressure 50-70 bars X X X Max. pressure pulsating X X X Bypass pressure too high X X X Oil consumption too high X Pump run only bypass X X Bypass valve "thumps" X X X Uneven pressure during operation X X Pump doesn't go into bypass X X Poseidon_GB02 1 Service/Repair E Safety valve The safety valve’s factory setting for opening pressure = working pressure + 25 to +30 bars. Upon each service inspection the setting must be tested and, if necessary, adjusted. When mounting, affix ball and pressure plate to the spring with lubrication. The seat is screwed on using a 10mm socket wrench (no gasket required). Before testing with a pressure gauge, make sure that two threads are visible behind the locknut. Warning: Before starting the pump, check that the test manometer valve is open. Close the valve slowly; pressure must never exceed 250 bars. Pressure side 10mm special wrench no.: 1206754 6mm Allen wrench Suction side M a x . 2 5 0 b a r. M a n o 1 Poseidon_GB01 1 Service/Repair E Valve cylinder head 1 Removal and mounting is done manually. Lubricate the large O ring with grease. Lubrication duct K en ne y Pressure valve seat Suction valve seat Nylon ring Textile sleeve (hard) Back-up ring Rubber sleeve (soft) Remove the suction valve seat using impact piercer no. 1216506. Press out the pressure valve using a 2 mm piercer. Check valve seats. Mount again with fingers. Poseidon_GB01 2 Service/Repair E Valve cylinder head 2 Lock/back-up ring O-ring Rubber sleeve secondary Thrust collar Back-up ring Textile sleeve Expansion/back-up ring ey nn K e Suction valve Pressure valve O-ring When mounting textile sleeves, use tool no.: 1220090. It helps to place the sleeves in a water bath 3-4 hours before mounting. Remember to blow through the lubrication ducts with compressed air. Poseidon_GB01 3 Service/Repair E Cylinder block 1 Oil filling Plate O-ring Torque: 37 Nm Oil sleeve Back-up ring Oil draining Always replace secondary sleeves when replacing pressure sleeves. Check for free passage in the thrust collar’s drainage holes. Drain the oil by loosening the plug at the bottom of the cylinder block. Loosen the 8 nuts evenly in consideration of the pressure from the piston springs. Use special head no. 1206762. Mount new O rings on stay bolts using tool no. 1206812. When changing the oil, loosen the hose connection above the cylinder block. Oil (0.5 litres) is poured into the threaded hole. Testing has shown that the pump does not consume oil during normal operation. In other words, under normal circumstances you do not need to refill oil in the pump. Nevertheless, the oil level and quality must be checked regularly through the liquid indicator. Poseidon_GB01 4 Service/Repair E Cylinder block 2 Carefully lift the oil sleeves out with a suitable screwdriver and dispose of them. Be careful not to scrape the surface. Before inserting the new sleeves, it is a good idea to moisten the sleeves with soapy water. Insert new oil sleeves using piercer no. 1220429. Gently tap or press in. Oil sleeve Contact surface Poseidon_GB01 Stainless steel Low-pressure Ceramic High-pressure Inspect the piston for wear on the contact surface and in the area for oil sleeves. Examine the ceramic for cracks, and wipe clean any deposits. 5 Service/Repair E Motor / wobble disc 1 The motor consists of a stator with windings, a rotor with an axel that is held in place with a bearing in the N-bearing cover and the wobble disc’s innermost needle bearing in the D-bearing cover. Ventilator 4 is pressed onto the rotor over locking bush 5 and is mounted with two screws. The wobble disc’s pressure plate 23 is held in place with peg 22. Plate 21 ensures that needle bearing 24 is held apart from oil sleeve X. 4 N s ta to r ro to r D 23 2 2 x 2 1 2 7 5 Remove locking ring 27. The wobble disc is easily removed with wheel dresser no. 1205715 and special leg no.1206150/1206168. Remember to remove parallel key 17 before removing D-bearing cover. Check bearing surfaces for wear. If in doubt, replace set 28 completely. Poseidon_GB01 6 Service/Repair E Motor / wobble disc 2 When mounting complete D bearing cover, protect the oil sleeve using tool no. 1206598, and place it on the axel before mounting 24 25 26 27 30 31 32 When mounting the wobble disc, lubricate the bearings with oil. The large roller bearings 25 and 31 are identical. Remember to place locking ring 27 on the axel. No. 26 No. 32 Inspect the bearing surfaces for wear. As long as there is only regular wear without holes or ridges, as in the pictures above, the wobble disc can be used again. Poseidon_GB01 7 Adjustment/Test F Adjustment of reed switch Place the reed switch in the plastic case with the screw loose enough so that the switch can still be moved back and forth. Place the reed switch as far forward in the direction of the water outlet as possible. Start the machine on setting 1, without a water connection. After approx. 20 seconds, the machine stops, and you can then adjust the reed switch. Slowly push the reed switch back until the machine starts. Next pull the reed switch approx. 3 mm away from the machine, and tighten the screw in the plastic casing. Finally, test the start/stop function with a water connection to the machine. This adjustment can also be made with an ohmmeter. In that case, remember to disconnect the machine from the power source. B Y - P A S S . 3 - 4 m m . Poseidon_GB01 1 Adjustment/Test F Torque Poseidon_GB01 2 Poseidon_GB01 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 A 1 0 1 2 S 1 b l L 3 L 2 X 1 0 V X 2 2 3 0 V X 3 4 0 0 V X 4 S c h ü tz 2 a 2 b r s w L 1 X 5 P ro g ra m m 1 a 1 F lo w 1 B 2 X 7 S te u e r p la tin e C o n tro l P C B B 2 B 3 S tro e m u n g s w a e c h te r T h e r m o s c h a lte r M o to r F lo w s e n s o r T h e r m a l s w itc h K 1 S c h u e tz C o n ta c to r m o to r S u c k in g 2 1 S 1 X 6 2 3 4 3 p h M o to r Wiring Diagrams P E A 1 3 p h M 1 M o to r 4 S 1 D r e h s c h a lte r R o ta ry 4 a X m a /b X 1 0 M o to rs te c k e r S a m m e lk le m m e M o to r c o n n e c to r C o n c e n tr a tio n te r m in a l s w s c h w a rz b ra u n b la u b la c k b ro w n b lu e s w itc h Q 1 K 1 2 3 5 4 6 A 1 A 2 b r b l X 1 0 X m a X m b 1 2 3 6 5 U 1 4 7 (1 4 ) 9 V 1 W 1 M 1 M 3 ~ U 2 Ä n d e ru n g D a tu m V 2 W 2 B 3 N a m e g e z . D a tu m N a m e 2 7 .0 9 .0 1 P o e s c h l B e z . 3 p h S te rn R Z e ic h n .- N r .: 7 1 1 8 6 B l. 1 v o n 1 P r o je k tb e z . g e p . G P o s e id o n 1 Poseidon_GB01 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 A 1 0 1 2 S 1 b l L 3 2 b r L 2 s w L 1 X 1 0 V X 2 2 3 0 V X 3 4 0 0 V X 4 S c h ü tz 2 a 1 X 5 P ro g ra m m 1 a P E F lo w X 7 1 1 3 1 2 S u c k in g X 6 2 3 4 5 2 4 4 B 2 6 Wiring Diagrams K 1 S 1 Q 4 a 1 4 K 1 1 3 R 1 1 2 3 4 5 6 7 8 1 a 2 a 3 a 4 a 5 a 6 a 7 a 8 a S 2 2 5 2 6 K 1 A 1 S te u e r p la tin e C o n tro l P C B B 2 B 3 S tro e m u n g s w a e c h te r T h e r m o s c h a lte r M o to r F lo w s e n s o r T h e r m a l s w itc h K 1 S c h u e tz C o n ta c to r M 1 M o to r R 1 W id e r s ta n d R e s is to r S 1 S 2 D r e h s c h a lte r S te r n - D r e ie c k - S c h a lte r R o ta ry s w itc h S ta r - tr ia n g le X m a /b X 1 0 M o to rs te c k e r S a m m e lk le m m e M o to r c o n n e c to r C o n c e n tr a tio n te r m in a l s w s c h w a rz b ra u n b la u b la c k b ro w n b lu e m o to r A 1 3 p h M o to r 3 p h A 2 X m a X m b 1 2 3 6 5 4 7 9 s w itc h (1 4 ) U 1 V 1 W 1 M 1 M b r 3 ~ U 2 Ä n d e ru n g D a tu m V 2 N a m e g e z . b l B 3 D a tu m N a m e 1 6 .1 1 .0 1 P o e s c h l S 2 Z e ic h n u n g S 2 D r a w in g S c h a lte r s te llu n g s w itc h S te rn p o s itio n s ta r B e z . R P r o je k tb e z . 3 p h u m s c h a ltb a r P o s e id o n Z e ic h n .- N r .: 7 1 1 9 9 B l. v o n 1 1 G g e p . W 2 2 Poseidon_GB01 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 0 1 A 1 2 S 1 N X 1 0 V X 5 P ro g ra m m P H 2 3 0 V X 3 4 0 0 V X 4 S c h ü tz P E F lo w X 7 1 B 2 K 1 2 S te u e r p la tin e C o n tro l P C B B 2 B 3 S tro e m u n g s w a e c h te r T h e r m o s c h a lte r M o to r F lo w s e n s o r T h e r m a l s w itc h C 1 B e tr ie b s k o n d e n s a to r o p e r a tin g 3 5 A 1 4 6 A 2 Q S u c k in g X 6 K 1 S c h u e tz C o n ta c to r 2 1 S 1 2 3 M 1 M o to r S 1 D r e h s c h a lte r R o ta ry X m a /b X 1 0 X 1 1 /1 2 M o to rs te c k e r S a m m e lk le m m e R e ih e n k le m m e M o to r c o n n e c to r C o n c e n tr a tio n te r m in a l T e r m in a l S tr ip 1 p h M o to r m o to r c a p a c ito r Wiring Diagrams X 2 1 a 1 1 A 1 2 a 2 1 p h 4 4 4 a s w itc h X 1 1 C 1 X 1 0 X 1 2 X m a X m b 1 5 3 6 4 7 2 9 (1 4 ) U 1 Z 1 M 1 M 1 ~ U 2 Ä n d e ru n g Z 2 D a tu m B 3 N a m e g e z . D a tu m N a m e 2 8 .0 1 .0 2 P o e s c h l Z e ic h n .- N r .: B e z . 1 p h R S ta n d a rd 7 1 2 0 5 B l. 1 v o n 1 P r o je k tb e z . P o s e id o n G g e p . 3 Spare Parts Proposal H 1 0 7 0 0 6 3 1 8 0 2 5 2 9 6 1 0 0 6 6 6 9 9 9 8 6 3 0 1 1 6 6 2 6 0 2 2 7 4 9 7 = 1 1 1 9 5 7 1 9 8 = 1 1 1 9 8 2 0 9 9 = 1 1 1 9 5 7 0 9 9 9 8 6 1 0 0 6 1 0 9 7 9 9 6 3 0 1 3 3 5 5 1 9 1 9 1 1 1 0 7 1 2 0 7 0 0 0 0 8 0 0 6 3 9 0 7 0 0 6 3 9 7 9 9 9 7 9 9 Poseidon_GB01 1 Spare Parts Proposal H 1 0 1 1 1 9 4 1 0 3 0 0 1 1 7 9 3 6 0 1 2 6 2 0 5 8 1 8 1 1 6 4 4 1 5 9 2 0 0 6 1 6 1 0 1 0 4 2 3 0 0 1 7 1 6 6 1 0 1 0 6 1 1 6 0 2 9 4 5 6 1 0 0 9 4 1 1 1 1 8 5 1 2 1 0 1 1 1 9 4 1 1 Poseidon_GB01 2 Spare Parts Proposal H 9 9 6 1 0 0 6 1 1 3 2 0 0 6 2 3 0 7 5 0 1 6 1 6 1 0 1 7 4 9 9 9 9 9 9 8 3 2 0 0 6 5 6 1 8 0 2 5 1 1 3 2 0 0 6 1 5 3 2 0 0 6 1 5 9 8 = 1 1 1 9 8 2 0 9 9 = 1 1 1 9 5 7 0 1 0 7 1 2 0 7 0 4 3 2 0 0 6 6 4 Poseidon_GB01 3