Service Manual Poseidon
Contents
1. 2 3 4 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A1 RS MG ee s1 i i 13 bl 1 o X1 OV i 2 2a e L2 br o X2 230V XS 4 E i 1 Programm 1 i LI T sw o X3 400V H 1 tE a H Flow Sucking i PE m o X4 Sch tz X7 X6 H 1 1 2 1234 1 1 815 le sara gs 4 4 21416 B2 S1 Q 4a 1 2 3 4 5 8 8 R1 Al Steuerplatine Control PCB ta 2a 3a 4a 5a 6a 7a 8a B2 Stroemungswaechter Flow sensor B3 Thermoschalter Motor Thermal switch motor K1 Schuetz Contactor K1la ees M1 Motor 3ph Motor 3ph A2 R1 Widerstand Resistor Xma Xmb S1 Drehschalter Rotary switch 11213 6 4 7 9 S2 Stern Dreieck Schalter Star triangle switch 14 Xma b Motorstecker Motor connector X10 Sammelklemme Concentration terminal sw schwarz black br braun brown bl blau blue vivam B3 S2 Zeichnung Schalterstellung Stern S2 Drawing switch position star Anderung Datum Name Datum Name Md 3ph umschaltbar Zeichn Nr T1199 BL gez 16 11 01 Poeschl ALTO gep Projektbez Poseidon m ony 5 e Q D Q 9 3 0 1099 uopiesog 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 LI LJ N 1 X1 OV A1 Steuerplat2. Remove locking ring 27 The wobble disc is easily removed with wheel dresser no 1205715 and special legno 1206150 1206168 Remember to remove parallel key 17 before removing D bearing cover Check bearing surfaces for wear Ifin doubt replace set 28 completely Poseidon GBO1 6 Auto Service Repair 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 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 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 GBO1 7 Auto Adjustment Test 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
3. 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 BY PASS Poseidon GBO1 Auto Adjustment Test Torque Poseidon GB01 1099 uopiesog 2 3 4 6 7 8 9 10 11 12 14 15 16 17 18 19 20 A1 Peer 81 13 6x1 ov i i L2 br X2 230V X5 A1 Steuerplatine Control PCB i 1 Programm EN L1 sw gt i O X3 400V B2 Stroemungswaechter Flow sensor 1L 1a B3 Thermoschalter Motor Thermal switch motor BEES 1 0 X4 Sch tz Flow Sucking 1 1 K1 Schuetz Contactor RE E sea M1 Motor 3ph Motor 3ph 4 S1 Drehschalter Rotary switch 4a Xma b Motorstecker Motor connector 413 X10 Sammelklemme Concentration terminal Al K1 E sw schwarz black 214 br braun brown bl blau blue X10 Xma Xmb 1 3 6 5 4 7 9 14 U1 V1 w1 IN M1 M 3 a u2 v2 wa B3 nderung Datum Name Datum Name Bez Zeichn Nr 3ph Stern BI gez 27 09 01 Poeschl 9 71186 Projektbez gep Poseidon von ony 5 e Q D Q 9 3 0 1099 uopiesog
4. 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 GBO1 O ring Auto Service Repair Cylinder block 1 Oil filling Plate Torque 37 Nm S NS 7 N u A MN t Oil sleeve up ring NNE RS SAS SS A Oll draining Always replace secondary sleeves when replacing pressure sleeves Check for free passage in the thrust collar s drainage holes Drainthe oil by looseningthe plug atthe bottom ofthe cylinder block Loosenthe 8 nuts evenly in consideration ofthe 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 GBO1 4 Auto Service Repair 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 t
5. Poseidon 7 Total Cleaning Confidence Service Manual TsJ 6 03 02 Index Poseidon TechnicalData Trouble shooting Service Repair AdjustmentTest WiringDiagrams SparePartsProposal Speciallnformation Auto Technical Data Poseidon 1200 Nominal values Voltage mac 200 240 400 415 440 440 6 10 _ Frequency Hz 15 50 50 50 60 Motor coupling CUT O o Numberofphases Peel Do 3 3 3 3 Power consumption JA CC 2 High voltage kv 24in2sec S Leakage current ma 075 Absorption power MI Axelpower AN Revolutions Mil Control voltage VAC 200 240 400 Signal voltage microprocessor__ vac 5 1 IP classification Y dl 45 E Es EE Eis OO COO qu Emm 3 EN 1 EE E 440 Bypass time auto start stop Sec 20 1 Bypass time manua Min 5 Water volume high pressure Vmin Opening pressure pump outlet Bar Bypass pressure Bar 1 JM Suction capacity Bar 17 Suctionheightprimed Im 1 18 Max water inlet temperature E ES 05 EN o c ENS 8 5 no Oo T Es E ES Em Es Es 7 EN 4 En pa a Em a EE oil volume JLitre Oil type Pump oil 100 A ES MA E _ T o Zen Es S
6. d o D OOD D gt DIIIT IT 9 l 18 Ja lo E SE 12 lola Z sie fa I ke 3 o zo S s IS 13 lo E o O l D eo 2 z D lt I lt Z Z IE gt 31 1 H t 3 UJ o Z lt lt O O DIO D ID x x T gBI o o 17 gt o o Io D 3 O e m c D UJ JU us FT FPE A pressure Oil volume hie os Oil type Pumpoitoo Al O mm Poseidon GB01 3 Auto Construction Frame The frame is built of 25mm steel pipes One nozzle can be stored on each side of the machine 2 250mm wheels and 1 100mm 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 unitis 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 pumpis a4 cylinder axial piston pum
7. e pump outlet Bar 2o 7 Bypass pressure fl 12 Suction capacity fel Jowl O Suction height primed dm Jsi Max water inlet temperature Je 1Ll amp l Max water inlet pressure Bar 10 Reactionforce max N coustic pressure level gal 754 An Oil volume Lire 5 fos lAphasnri o EEE Poseidon GBO1 2 Auto Technical Data Poseidon 720 Voltage vc 010 IFrequeney 2 J sj J J Motor coupling J Number of phases fee Pt 114114 Power consumption_______la_ _____ _ J J 141 1 15 24in2scc MS 0 75 A H eakage current in ground circuit O gt 3 Axel power i30 1420 1470 ontrol voltage 230 10 ignal voltage microprocessor VAC I os 1 rios IP classification dd 46 Bypass time auto start stop sec 20 J Bypass time manual Min 5 J water volume high pressure min 115 Water volume low pressure min 125 Machine s pressure gauge Ba t5 85 ump pressure high pressure A al Ju ressure h p pump outlet pening pressure pump outlet pass pressure uction capacit uction height prime
8. he sleeves with soapy water Insert new oil sleeves using piercer no 1220429 Gently tap or press in Inspect the piston for wear on the contact surface and in the area for oil sleeves Examine the ceramic for cracks and wipe Contact surface Stainless steel Ceramic clean any deposits Oil sleeve Low pressure High pressure Poseidon GBO1 5 Auto Service Repair 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 N stator rotor
9. his 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 VOLT 0 VOLT BY PASS Poseidon GBO1 5 Auto Function C PC Board The circuit board has the following functions 1 Tostartthe electric motor when starting the machine 2 Tostopthe electric motor when operation of the machine is finished 3 Torecord 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 O 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 o
10. ine Control PCB 2 2a i i X5 1 B2 Stroemungswaechter Flow sensor l i Programm d B3 Thermoschalter Motor Thermal switch motor Bii M Lo X2 230V i 1L 1a H H C1 Betriebskondensator operating capacitor 1 o X3 400V i E Ep a ug a a K1 Schuetz Contactor 1 Flow Sucking Ene M1 Motor 1ph Motor 1ph l X7 1 H otor 1pl otor 1pl 1 TTZ T 23 1 i Amm S1 Drehschalter Rotary switch 2 S1 Xma b Motorstecker Motor connector X10 Sammelklemme Concentration terminal KA A1 4a i X11 12 Reihenklemme Terminal Strip 2 A2 X101 12 Xma Xmb m 4 5 3 614 2 719 114 uij Z M M iS 1 v za B3 Anderung Datum Name Datum Name Bez Zeichn Nr Bl F 1ph Standard 71205 gez 28 01 02 Poeschl LTO Projektbez gep Poseidon von ony 5 e Q D Q y 3 T Spare Parts Proposal Auto Spare Parts Proposal Auto Lf A N gt BCE TT A Auto Spare Parts Proposal 3200656 1802511 Y q 200615 Y X 107120704 3200615 98 1119820 99 1119570 Poseidon GB01
11. le wire high pressure hose Tornado nozzle 34 quick coupling nipple Poseidon GBO1 2 Auto 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 onthe 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 GBO1 1 Auto Function C Bypass Val
12. p 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 34 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 areed 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 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 ALTO 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 Doub
13. peration 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 Identification of machine and software type 2 Read out of number of starts 3 Read out in hours minutes of operating time under flow 4 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 GBO1 6 Ato Trouble shooting Operating Requirements To ensure error free operation the following requirements must be met 1 2 Machine and equipment must be free of air and without leaks Water temperature must not exceed 85 C when inlet pressure on water supply 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 Water quality must be free of impurities gt 50 u Water supply must be sufficient at all times Ambient temperature must not exceed 40 C Supply voltage must not vary by more than 6 of the given value Poseidon GB02 1 Auto Service Repair Safety
14. s E 415 440 EE p EEE ESSES E BEE snp o d TT diol S O ee o Y Ll a m St aa et ez EE Es E ERES ES ES Poseidon GB01 1 Auto Technical Data Poseidon 1280 rimary data Unit Nominal values Tolerances oltage vac Cd 200 240 400 415 440 440 6 10 reguenc Hz o 50 50 50 50 60 Motor coupling 11 12141 Number of phases 5 Pe I 313 3 3 Power consumption da J Jel 15 High voltage _____________ kv__ 24in2sec Leakage current__________ Ima 0 75 Resistance in groundcircuit_ Ohm 02 J Absorptionpower__________ kxw_ ______ les Axelpower kW Jes Revolutions Milo 40 Jj t420 1470 Control voltage___________Jvac _______ 200 240 400 415 440 440 10 Signal voltage microprocessor__ vac 5 o P classification 45 PM Bypass time auto start stop_____ Sec 2 O Bypass time manual Min 5 J Water volume high pressure mn ieh O Water volume low pressure mn Jos Machine s pressure gauge Bar 9 85 Pump pressure high pressure Br Im Pressure h p pump outlet Bar N Im Opening pressur
15. 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 10mm special wrench no 1206754 6mm Allen wrench Suction side Max 250 bar Poseidon GB01 1 Auto Service Repair Valve cylinder head 1 Removal and mounting is done manually Lubricate the large O ring with grease Lubrication duct Pressure valve seat NI o E A o LI LIA 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 outthe pressure valve using a 2 mm piercer Check valve seats Mount again with fingers Poseidon GBO1 e 2 Valve cylinder head 2 Lock back up ai ee E Rubber sleeve secondary AE TA Thrust collar Back up ring Textile sleeve Expansion back up ring Suction valve Pressure valve When mounting textile sleeves use tool
16. ve Function The bypass valve has 4 functions 1 Protectthe machine against excess pressure 2 Relieve the pressure in bypass 3 Fastconversion to high pressure 4 Ensure 0 pressure when the machine is stopped Operation The water from the pump is led into cnamber A ofthe 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 i a i i E Dr i M EU P TET TR A ZA NA LE E Im PITT ELL PESA E FER ree a a FF K mr re Poseidon GBO1 2 Auto Function POSEIDON SPRAY Poseidon GBO1 3 Auto Function POSEIDON BY PASS Poseidon GBO1 4 Auto Function C Flow Control Flow control consists of 1 Casing 2 Piston w magnet 3 Spring 4 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 t
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