Midmark PowerVac P3, PowerVac P5, PowerVac P7, PowerVac P14, PowerVac P6 Parts Manual

PowerVac

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®

Model Numbers:

Single Vac Units

P3 P5 P7

Twin Vac Units

P6 P10 P14

Service and

Parts Manual

Earlier Version Current Version

FOR USE BY MIDMARK TRAINED TECHNICIANS ONLY

Part No. 004-0494-00 Rev. AA7 (5/13/19)

GENERAL INFORMATION

Back

Ordering Parts ......................... iii

Serial Number Location .......... iii

Specifications ........................... iv

Model Identification /

Compliance Charts: ................. v

Warranty Information............... vi

TESTING & REPAIR - continued

cont.

Section B -

General Information

ACCESS PROCEDURES

TROUBLESHOOTING

Vacuum System ....................... A-2

Electrical System Operation

Power to System .................................

Wall Switch On ................................... A-4

Section A

Bottom Float contact Closed .............. A-5

Middle Float Contact Closed ............. A-6

Top Float Contact Closed ................... A-7

Liquid Evacuation Pump

(Accessory) ..............................

A-3

A-11

TESTING & REPAIR

Belt ............................................ B-2

Check Valve .............................. B-6

Vacuum Relief Valve................. B-9

Exhaust .....................................B-12

Float .......................................... B-15

Section B

Low Voltage .............................. B-18

Door Limit Switch & Circuit Breaker (On/Off Switch)

.............................................. B-21

Contactor .................................. B-26

Fuse........................................... B-28

Table Of Contents

Relay.......................................... B-31

Transformer .............................. B-34

FOR USE BY MIDMARK TRAINED TECHNICIANS ONLY

Section C

WIRING DIAGRAMS

Section D

EXPLODED VIEWS / PARTS LISTS

Section E

Liquid Evacuation Pump

Section E

* Indicates multiple pages due to model / serial number break(s)

Fan..........................................B-37

Gauge ..................................... B-41

Motor ......................................B-43

Capacitor ................................B-44

Pump ......................................B-50

Liquid Evacuation Pump

(Accessory) ............................

Separator Tank ....................... B-58

Front Cover ............................ C-2

Top Cover ............................... C-3

Electrical Cover ...................... C-4

Back Cover (Previous Tank)... C-5

Back Cover (Large Tank) ........ C-6

PowerVac Liquid Evacuation Pump

(Accessory) ............................

PowerVac® Single Models

(P3, P5, P7) .............................

PowerVac ® Twin Models

(P6, P10, P14) .........................

(Accessory) ...........................

®

.................................................. D-2*

B-53

D-4

E-2*

E-3*

E-4*

Symbols

AA158000-1i

0

5

1

0

1

5 2

0

2

5

-

3

0

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Ordering Parts

WARNING

Indicates a potentially hazardous situation which

could result in serious injury if not avoided.

The following information is required when ordering parts:

• Serial number & model number

• Part number for desired part.

[Refer to Exploded Views / Parts Lists section]

CAUTION

Indicates a potentially hazardous situation which may result in minor or moderate injury if not avoided. It may also be used to alert against unsafe practices.

Equipment Alert

Indicates a potentially hazardous situation which

could result in equipment damage if not avoided.

In Section A, test the components in the order indicated. (ex.

1st

then,











The symbols below may be used in this manual to represent the operational status of table functions and components.

Refer to Section B for component testing procedures.

Indicates the function / component is working properly. No action required.

2nd

)







Non-warranty parts orders may be faxed to Midmark using the Fax Order Form in the back of this manual.

For warranty parts orders, call Midmark's Technical Service Department with the required information.

Hours: 8:00 am until 5:00 pm EST [Monday - Friday] Phone: 1-(800)-Midmark

Model / Serial Number Location

Tank Serial

Number

General Information

Indicates the function / component is working, but a problem exists.

Indicates the function / component is not working at all.

Base Serial

Number

Rev 9/10/18

iii

General Information

Model

P3

Model

P5

Model

P7

Model

P6

Model

P10

Model

P14

Evacuation Control

Box (Optional)

Max Users

3-5 5-7 7-10 6-10 10-14 14-20

N/A

Vac Unit

H x W x D

26" x 19.5" x 18.5" 26" x 19.5" x 18.5" 26" x 19.5" x 18.5" 26" x 39" x 18.5" 26" x 39" x 18.5" 26" x 39" x 18.5"

N/A

Separator H x W x D

32" x 22" x 22" 32" x 22" x 22" 32" x 22" x 22" 32" x 22" x 22" 32" x 22" x 22" 32" x 22" x 22"

5" x 5.5" x 6"

Actual Weight (lbs)

Vac Unit - 355 Separator - 47

Vac Units - 710 Separators - 94

2

Total HP 222444N/A

Voltage 208 / 230 208 / 230 208 / 230 208 / 230 208 / 230 208 / 230 115 VAC

Amps 11.4 11.4 11.4 22.8 22.8 22.8 3

Hertz 60 60 60 60 60 60 60

Recommended

Breaker Size (Amps)

(Min. 20 Amp ea.)

30 30 30 2 x 30 2 x 30 2 x 30

15

Inlet Connection Size

(in.)

1 1/2" 1 1/2" 1 1/2" 2" 2" 2"

N/A

Fuses

1/8 A, 250V

Type T

1/8 A, 250V

Type T

1/8 A, 250V

Type T

1/8 A, 250V

Type T

1/8 A, 250V

Type T

1/8 A, 250V

Type T

1/4A, 250V, Type T

3A, 250V, Type T

Drain Connection Size

(in.)

1 1/2" 1 1/2" 1 1/2" 1 1/2" 1 1/2" 1 1/2"

N/A

Back

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Classifications: Class 1, Type B Applied Part

iv

Rev. 9/10/18

General Information

UL 60601-1

CAN/CSA 22.2,

#601.1-M90

VAC Amps Cycles (Hz)

P3

PowerVac® Dry Vacuum

System - Single - 3 - 5 User

V x x 230 11.4 60

P5

PowerVac® Dry Vacuum

System - Single - 5 - 7 User

V x x 230 11.4 60

P7

PowerVac® Dry Vacuum

System - Single - 7 - 10 User

V x x 230 11.4 60

P6

PowerVac® Dry Vacuum

System - Twin - 6 - 10 User

V x x 230 22.8 60

P10

PowerVac® Dry Vacuum

System -Twin - 10 - 14 User

V x x 230 22.8 60

P14

PowerVac® Dry Vacuum

System - Twin - 14 - 20 User

V x x 230 22.8 60

Complies To:

Model

Description

Serial Number

Prefix

Electrical Supply Requirements:

Back

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®

Rev 9/10/18

v

General Information

Back

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LIMITED WARRANTY

SCOPE OF WARRANTY

Midmark Corporation (“Midmark”) warrants to the original purchaser its new PowerVac® products and components (except for components not warranted under “Exclusions”) manufactured by Midmark to be free from defects in material and workmanship under normal use and service. Midmark’s obligation under this warranty is limited to the repair or replacement, at Midmark’s option, of the parts or the products the defects of which are reported to Midmark within the applicable warranty period and which, upon examination by Midmark, prove to be defective.

APPLICABLE WARRANTY PERIOD

The applicable warranty period, measured from the date of installation for the original user, shall be five (5) years or 10,000 usage hours (whichever comes first) for all warranted products and components and ten (10) years or 20,000 usage hours (whichever comes first) for the pump only.

EXCLUSIONS

This warranty does not cover and Midmark shall not be liable for the following: (1) repairs and replacements because of misuse, abuse, negligence, alteration, accident, freight damage, or tampering; (2) products which are not installed, used, and properly cleaned as required in the Midmark “Installation”

manual and or PowerVac manufactured by Midmark; (5) charges by anyone for adjustments, repairs, replacement parts, installation, or other work performed upon or in connection with such products which is not expressly authorized in writing in advance by Midmark.

EXCLUSIVE REMEDY

Midmark’s only obligation under this warranty is the repair or replacement of defective parts. Midmark shall not be liable for any direct, special, indirect, incidental, exemplary, or consequential damages or delay, including, but not limited to, damages for loss of profits or loss of use.

®

Care Guide for this applicable product; (3) products considered to be of a consumable nature; (4) accessories or parts not

NO AUTHORIZATION

No person or firm is authorized to create for Midmark any other obligation or liability in connection with the products.

THIS WARRANTY IS MIDMARK’S ONLY WARRANTY AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED. MIDMARK MAKES NO IMPLIED WARRANTIES OF ANY KIND INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. THIS WARRANTY IS LIMITED TO THE REPAIR OR REPLACEMENT OF DEFECTIVE PARTS.

vi

Troubleshooting

Go To Page:

Back

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5

1 0 2

0

1

5 2

5

0

3

0

Function / System Page

Vacuum System ................................... A-2

Electrical System Operation

Power to System......................... A-3

Wall Switch On ........................... A-4

Bottom Float Contact Closes ...... A-5

Middle Float Contact Closes ....... A-6

Top Float Contact Closes ........... A-7

Liquid Evacuation Pump.......................A-11

Models:

Serial Numbers:

AA220500

Section A

Rev 2/08

A-1

Troubleshooting

Back

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Vacuum System Operation

Operatory waste (air, solids and liquids) is pulled into the separator through the inlet hose by the rotary claw pump in the vacuum base unit.

Air is separated from liquids and solids. Air then flows into the pump and out through the exhaust hose.

Refer To: Page

Low or No Suction ................................ A-9

Earlier Version Shown

Fresh air is pumped in through the Vacuum Relief Valve to the pump and out through the exhaust. (When ports are opened in the operatories the VRV closes to compensate.)

The check valve connected below the drain port allows the unit to drain liquids and solids upon removal of vacuum from the chamber when the pump / motor shuts off.

The fan(s), hour meter and vacuum pump start to run when power is supplied by the wall switch. The fan(s) and hour meter then begin to cycle with the vacuum pump / motor. The float switches control the pump motor by a 24 vac relay via motor contactor.

The upper and lower reed switch floats interact as a latching circuit with the internal relay to release upon drain below the bottom float.

Air

Liquids

Fresh Air

Intake

Fr

A-2

Vacuum System

Rev 9/10

Models:

Serial Numbers:

All

Troubleshooting

Back

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Electrical System

(Power to System Wall Switch Open All Float Switches Open)

• Power (230 VAC) is on supplying Line Voltage to the Vacuum Pump Electrical System.

• 230 V is applied to the 230 V / 24 V Transformer energizing it.

• 24 V is applied from one side of Transformer, to the Terminal Block.

• From the Terminal Block, 24 V is applied to Terminal 6 of CR1 Relay, thru CR1 normally closed contacts (6 & 2) to one side of the coil on Contactor “C”, also to J1 & J2 Plug (pin 1), and thru the Timer to one side of the Wall On / Off Light.

• 24 V is also applied thru the closed Door Limit Switch,Circuit Breaker & Timer to one side of the Wall On/Off Switch.

VACUUM PUMP ELECTRICAL SYSTEM

Common

Top Float

Middle Float

Bottom Float

AA160800i

Top Float

3

Middle Float

4

2

1

Transformer

Fuse F1

BK

RD

WH

RD

BL

Energized

GN/YL

Circuit

Breaker

YL

Light

On

On/Off

Light

Remote

Wall

Switch

On

WH

Transformer

OR

230 VAC Power On

WH

RD

WH

BL

RD

WH

RD

BL

SEPARATOR FLOAT SWITCH ASSEMBLY

Earlier Version HasThree Reed Switch Floats. The Middle Float in Current Version is Not Used and No Longer Installed

Contacts

Open

Contacts

Open

Contacts

Open

Water Level

Water Low, All Float Switches Open

BL

WH

YL

OR

Jumper

Terminal

Block

BL

Refer To: Page

Motor will not Run ................................. A-10

Motor Cutting Out ................................. A-11

NOTE:

Some units have dual fans that are wired in parallel.

FAN

Fan

Off

RD

Contacts

RD

WH

BK

OR

RD

BL

WH

BL

RD

BL

WH

1

BL

WH

To J1 or J2 Plug on

Evacuation Board

Separation Tank

Open

WH

BK

BL

RD

2

RD BK

or

to Float on

CONTACTOR

"C"

Contacts

Open

Power Removed From

Coil, Contacts Open.

BL

WH

Coil

7

6

Coil

8

Coil

5

WH

BK

3

4

3

BK

RD

BK

CR1 (Float Switch) RELAY

Contacts Open

CR1 Coil Not Energized

Contacts Remain in

Same Position

BK

GN/YL

BL

RD

4

BL

2

3

BL

1

RD

NOTE:

Circuit Breaker &

BL

Door Limit Switch

Closed

Manual reset button on earlier versions, automatic reset on current versions.

RD

HOUR

METER

HOURS

BK BK

Thermal

Reset

Meter

Stopped

Pump

Stopped

AA2480i

Models:

Serial Numbers:

All

Power to System

Rev 11/2/15

A-3

Troubleshooting

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- continued (Wall Switch On, Power to System, All Float Switches Open)

• Remote Wall Switch is turned on, the On / Off Light comes on.

• 24 V is applied to the other side of the coil of Contactor “C”, energizing the coil and closing its contacts.

• The Fan(s), Hour Meter, and Vacuum Pump run.

Electrical System

- continued (Wall Switch OFF

,

Power to System, All Float Switches Open, Timer ON)

• Remote Wall Switch is turned off, the Timer turns on and starts to measure two hours.

• The Timer will run the Vacuum for one minute every two hours while the Remote Wall Switch is turned off by completing the 24 V circuit to the Contactor "C" coil.

VACUUM PUMP ELECTRICAL SYSTEM

SEPARATOR FLOAT

SWITCH ASSEMBLY

Earlier Version Shown

Earlier Version HasThree Reed Switch Floats. The Middle Float in Current Version is Not Used and No Longer Installed

Contacts

Open

Contacts

Open

Contacts

Open

Water Level

Water Low, All Float Switches Open

Top Float

Middle Float

Bottom Float

Common

Bottom Float

AA160800i

Top Float

3

Middle Float

4

2

1

Transformer

Energized

BL

YL

WH

BK

YL

GN/YL

WH

RD

BL

Circuit

Breaker

OR

Jumper

Terminal

Block

BL

RD

WH

RD

WH

Light

On

On/Off

Light

Remote

Wall

Switch

On

WH

Transformer

OR

Fuse F1

RD

230 VAC Power On

WH

RD

WH

BL

RD

WH

RD

BL

RD

WH

BK

OR

BL

WH

1

WH

To J1 or J2 Plug on

Evacuation Board

Separation Tank

Circuit Breaker &

BL

Door Limit Switch

Contacts

Closed

WH

BK

BL

RD

2

RD BK

or

to Float on

Closed

CONTACTOR

Contacts

BL

Coil

7

Coil

8

Coil

WH

BK

3

4

3

"C"

BK

RD

BK

Closed

Coil Energized

Contacts Closed

CR1 (Float Switch) RELAY

WH

Contacts Open

6

5

CR1 Coil Not Energized

Contacts Remain in

Same Position

NOTE:

Some units have dual fans that are wired in parallel.

FAN

Fan

On

BK

GN/YL

BL

RD

4

BL

2

3

BL

1

RD

BK BK

RD

HOUR

METER

HOURS

Thermal

Reset

Meter

Running

NOTE:

Manual reset button on earlier versions, automatic reset on current versions.

Pump

Running

AA2478i

Wall Switch On

A-4

Rev 11/2/15

Models:

Serial Numbers:

All

Troubleshooting

Back

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- continued (Water Rises, Bottom Float Switch Closes, Middle and Top Switches Remain Open.)

• Contactor “C” contacts remain closed.

• The Fan(s), Hour Meter, and Vacuum Pump continue to run.

SEPARATOR FLOAT SWITCH ASSEMBLY

Earlier Version Shown

Earlier Version HasThree Reed Switch Floats. The Middle Float in Current Version is Not Used and No Longer Installed

Contacts

Open

Contacts

Open

Contacts

Closed

Water Level

Bottom Float Switch Closed, Middle and Top Remain Open.

Top Float

Middle Float

Bottom Float

Common

Bottom Float

Top Float

AA160801i

3

Middle Float

Light

On

On/Off

Light

Remote

Wall

Switch

On

4

2

1

WH

RD

WH

BL

RD

WH

OR

230 VAC Power On

WH

RD

BL

Transformer

Fuse F1

BK

RD

GN/YL

WH

RD

BL

Breaker

NOTE:

Some units have dual fans that are wired in parallel.

VACUUM PUMP ELECTRICAL SYSTEM

Transformer

Energized

BL

YL

Circuit

WH

Terminal

Block

BL

OR

Jumper

WH

RD

Contacts

WH

BK

OR

RD

BL

WH

BL

RD

BL

WH

1

WH

To J1 or J2 Plug on

Evacuation Board

Separation Tank

Circuit Breaker &

BL

Door Limit Switch

Closed

Coil

BK

BL

RD

2

3

2

3

RD BK

or

to Float on

Closed

CONTACTOR

"C"

Contacts

Closed

Contacts Closed

BL

WH

7

6

Coil

8

Coil

5

WH

BK

4

Coil Energized

CR1 Coil Not Energized

FAN

Fan

On

BK

RD

BK

CR1 (Float Switch) RELAY

Contacts Open

Contacts Remain in

Same Position

RD

4

2

3

NOTE:

Manual reset button on earlier versions, automatic reset on current versions.

HOUR

METER

BK

BK BK

RD

BK

GN/YL

BL

RD

BL

1

RD

HOURS

Thermal

Reset

Meter

Running

Pump

Running

AA2478i

Models:

Serial Numbers:

All

Bottom Float

Switch Closed

Rev 11/2/15

A-5

Troubleshooting

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- continued (Water Reaches Middle Float, Middle and Bottom Float Switches are Closed, Top Switch Remains Open.)

• Contactor “C” contacts remain closed.

• The Fans, Hour Meter, and Vacuum Pump continue to run.

Top Float

Middle Float

Bottom Float

Common

AA160802i

Bottom Float

Top Float

4

3

Middle Float

1

2

Light

On

On/Off

Light

Remote

Wall

Switch

On

WH

RD

BL

RD

SEPARATOR FLOAT SWITCH ASSEMBLY

Earlier Version Shown

Earlier Version HasThree Reed Switch Floats. The Middle Float in Current Version is Not Used and No Longer Installed

Contacts

Open

Contacts

Closed

Water Level

Contacts

Closed

Middle and Bottom Float Switches are Closed, Top Remains Open.

NOTE:

Some units have dual fans that are wired in parallel.

Fan

On

FAN

HOUR

METER

BK

BK BK

RD

BK

GN/YL

BL

RD

4

BL

2

3

BL

1

RD

HOURS

Thermal

Reset

Meter

Running

Pump

Running

AA2478i

VACUUM PUMP ELECTRICAL SYSTEM

RD

WH

Transformer

Fuse F1

BK

RD

WH

RD

BL

Energized

YL

GN/YL

Circuit

Breaker

BL

WH

YL

OR

Jumper

Terminal

Block

BL

WH

Transformer

OR

230 VAC Power On

WH

BL

RD

WH

RD

BL

BK

OR

RD

BL

WH

BL

RD

BL

WH

1

WH

To J1 or J2 Plug on

Evacuation Board

Separation Tank

Circuit Breaker &

BL

Door Limit Switch

Contacts

Closed

WH

BK

BL

RD

2

RD BK

or

to Float on

Closed

CONTACTOR

Contacts

BL

Coil

7

Coil

8

Coil

WH

BK

3

4

3

"C"

BK

Closed

Coil Energized

Contacts Closed

CR1 (Float Switch) RELAY

WH

Contacts Open

6

5

CR1 Coil Not Energized

Contacts Remain in

Same Position

BK

RD

BK

NOTE:

Manual reset button on earlier versions, automatic reset on current versions.

A-6

Switch Closed

Middle Float

Rev 11/2/15

Models:

Serial Numbers:

All

Electrical System

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• The Top Float Switch sends 24v to the coil of CR1 Float Switch Relay changing the contacts position.

• Power is removed from the coil of Contactor “C”, opening its contacts.

• The Fan(s), Hour Meter, and Vacuum Pump stop running.

• CR1 Float Switch Relay remains energized through its own normally closed tips (6&4) and the bottom float swich (pin 3) of J1& J2

• The Collection tank starts to Drain, Pump remains off until Bottom Float Switch opens interupting 24v to the CR1 Float Switch Relay coil.

• CR1 Float Switch Relay returns to its nornal state energizing Contactor "C", the Vacuum Pump, Fan(s) Motors,

and Hour Meter restart .

SEPARATOR FLOAT

SWITCH ASSEMBLY

Earlier Version Shown

Earlier Version HasThree Reed Switch Floats. The Middle Float in Current Version is Not Used and No Longer Installed

Contacts

Closed

Water Level

Contacts

Closed

Contacts

Closed

All Float Switches are Closed.

Top Float

Middle Float

Bottom Float

AA160803i

Common

Bottom Float

Top Float

3

Middle Float

4

1

2

Light

On

On/Off

Light

Remote

Wall

Switch

On

VACUUM PUMP ELECTRICAL SYSTEM

RD

Contacts

RD

Open

WH

Transformer

Fuse F1

BK

RD

WH

RD

BL

GN/YL

Circuit

Breaker

Energized

BL

YL

WH

Terminal

Block

BL

OR

Jumper

WH

Transformer

OR

230 VAC Power On

WH

RD

WH

BL

RD

WH

RD

BL

BK

OR

RD

BL

WH

RD

BL

WH

1

BL

WH

To J1 or J2 Plug on

Evacuation Board

Separation Tank

Circuit Breaker &

BL

Door Limit Switch

WH

Closed

NOTE:

Some units have dual fans that are wired in parallel.

CONTACTOR

Contacts

Open

BL

Coil

BK

7

Coil

8

Coil

BL

WH

RD

BK

2

3

4

2

3

RD BK

or

to Float on

Fan

"C"

BK

RD

BK

Power Removed From

Coil, Contacts Open.

CR1 (Float Switch) RELAY

WH

Contacts Open

6

5

CR1 Coil

Energizes

Contacts Change

Positions

Troubleshooting

FAN

RD

HOUR

METER

HOURS

BK BK

Thermal

Reset

Meter Stops

Off

BK

GN/YL

BL

RD

4

BL

2

3

BL

1

RD

NOTE:

Manual reset button on earlier versions, automatic reset on current versions.

Pump Stops

AA2479i

Models:

Serial Numbers:

All

Top Float

Switch Closed

Rev 11/2/15

A-7

Troubleshooting

Back

Go To Table Of Contents

Vacuum System

Problem: Operatory has low or no suction.

Earlier Version Shown

Will the motor start?

If motor runs go to 2nd check. If not Refer to Section A - Motor will not run.

Check Belt Tension.

Refer to: Section B - Belt. (Earlier Version ONLY)

2nd







1st







Refer To: Page

Motor will not Run ................................. A-9

Belt ............................................... B-2

Check Valve ......................................... B-6

Vacuum Relief Valve ............................ B-9

Exhaust ............................................... B-12

Check Vacuum Relief Valve.

Refer to: Section B - Vacuum Relief Valve.

5th







A-8

with Motor Running

Check Hoses and Bulkhead Fittings.

Check for leaks, kinks and loose connections in the hoses, bulkhead fittings and separator lid gasket.

Check Exhaust.

Remove exhaust line to see if suction increases. Unclog or replace exhaust line if suction increased when checking.

Refer to: Section B - Exhaust

Low or No Suction

Rev 9/10/18

Models:

Serial Numbers:

3rd

All







6th







Earlier Version Shown

Check Drain Line for Suction.

Refer to: Section B - Check Valve.

4th







Troubleshooting

Back

Go To Table Of Contents

Vacuum System

Problem: Motor will not run.

Check Float.

Refer to: Section B - Float

6th







Is Pump locked up?

Refer to: Section B - Pump

Reset Thermal Overload.

Refer to: Section B - Motor

2nd







Refer To: Page

Door Limit Switch................................B-20

Float...................................................B-15

Pump .................................................B-49

Low Voltage .......................................... B-18

Motor ..................................................B-42

Contactor .............................................. B-25

Fuse .................................................. B-27

1st







Check Door Limit Switch.

Refer to: Section B - Door Limit Switch

Check Fuse.

Refer to: Section B - Fuse

Check Relay.

Refer to: Section B - Relay

Relay ................................................ B-30

3rd



5th

7th











Earlier Version Shown

Models:

Serial Numbers:

All

Check Low Voltage.

Refer to: Section B - Low Voltage

4th







Check Motor.

Refer to: Section B - Motor

Earlier Version Shown

Check Contactor.

Refer to: Section B - Contactor

9th







Motor Not Running

8th







Rev 9/10/18

A-9

Troubleshooting

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Vacuum System

Problem: Motor cutting out or running at a reduced speed.

RER

1st





4th







Check Equipment Room Temperature.

Temperature should be - 40° to 104° Fahrenheit

- 4 to 37 Celsius

Check Exhaust line and valve.

Refer to: Section B - Exhaust

Refer To: Page

Contactor .............................................. B-25

Pump ....................................................B-44

Exhaust ............................................... B-12

Motor ..................................................B-42

Check Contactor Voltage.

Refer to: Section B - Contactor

2nd







A-10

Motor Cutting Out

Rev 9/10/18

Models:

Serial Numbers:

All

Earlier Version Shown

Check Motor.

Refer to: Section B - Motor

Is Pump locked up?

Refer to: Section B - Pump

5th







3rd







AA158503i

HIGH VOLTAGE

LOW

VOLTAGE

K4

C1

115 VAC

J4

F3 FUSE

F2 FUSE

F1 FUSE

115 VAC

Supply

Neutral

(Blue)

Line

(Black)

J7

J6

BK

GN

RD

WH

POWER

ON

LIGHT

BL

WH

BK

BL

YL

BK

BR

GN/YL

WH

BK

BL

YL

GN/YL

Grd

J5

PLUG

4

1

2

3

4

3

2

1

K1

RELAY

VACUUM PUMP #1

Top Float Swt.

Bottom Float Swt.

RELAY

Contacts

Open

LED

OFF

RELAY

K2

K3

RELAY

Neutral

(Wht)

Line (Blk)

EVAC. PUMP

J8

J9

1

4

2

3

Middle

Float Swt.

Common

Top

Float Swt.

Bottom

Float Swt.

To

Separator

Float Assy.

1

4

2

3

BK

GN

RD

WH

Com.

Bottom

Middle

Top

WH

BK

RD

WH

BK

RD

J2

PLUG

2

3

1

4

2

3

BK

RD

WH

To Motor Control

(CR1 Relay)

System #2

(Same As

Above J1)

1

4

2

3

Coil (7)

N/O (4)

1

4

2

3

BK

RD

WH

To Motor Control

(CR1 Relay)

System #1

N/O

Com. (6)

WH

RD

BK

J3

Plug

1

2

J1

PLUG

2

3

1

Light

On

115 VAC

Power On

Transformer

Energized

24 VAC

On

115 VAC

Power On

Contacts

Closed

VACUUM PUMP #2

Contacts

Closed

FLOATS

Contacts

Closed

EVAC. PUMP

LED

ON

Evac.

Pump

Swt.

LED

ON

115 VAC

Power On

LIQUID

EVACUATION

PUMP

Pump

On

115 VAC

Power On

Electrical System for Accessory - Liquid Evacuation Pump

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The Liquid Evacuation Pump is an optional accessory for the PowerVac®.

• 115 VAC is applied to the 115V / 24V Transformer energizing it.

• 24 VAC is applied from one side of the Transformer to the J3 plug.

• When the water level reaches the

• When the water level reaches the Power is supplied to J8 and J9 terminals, energizing the Liquid Evacuation Pump.

NOTE:

The Liquid Evacuation Pump will continue to run until the water level drops below the contacts.

If the

Top

float closes, K1 relay contacts close, and its LED is on, a problem is occurring with the system. Check for a restriction in the lines, pump not functioning, or PC board problem.

Liquid Evacuation Pump Electrical System shown when the Bottom & Middle Float Switches are Closed and Pump is running.

Bottom

float switch, opening K3 & K4 relay

Bottom Middle

float switch, K3 relay contact closes.

float switch, K2 & K4 relay contact close.

(Liquid Evac Pump is Optional)

Optional Liquid Evac Pump Must use a Three Float Assembly

Troubleshooting

Refer To: Page

Evacuation Pump Will Not Run............. A-12

Pump Runs But Will Not Pump ............. A-13

Pump tripping Thermal Overload .......... A-14

Serial Numbers:

Models:

All

Liquid Evac Pump

Electrical

Rev 9/10/18

A-11

Troubleshooting

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Evacuation Pump System

Problem: Evacuation Pump will not run.

Check PC Board

Refer to: Section B - Liquid Evacuation Pump

Check Float Assembly

Refer to: Section B - Float Assembly

3rd







5th







Check Low Voltage to PC Board

Refer to: Section B - Liquid Evacuation Pump

Refer To: Page

Liquid Evacuation Pump

2nd







Check Supply Voltage to PC Board

Refer to: Section B - Liquid Evacuation Pump

Check Thermal Motor Protector

Refer to: Section B - Liquid Evacuation Pump

Check Supply Voltage ...............B-53-B-56

Check Low Voltage....................B-53-B56

Check Float Assembly....................... B-15

Check Thermal Motor Protector...B-53-B-56

Check PC Board........................B-53-B-56

Check Pump Motor....................B-53-B-56

1st







4th







Earlier Version Shown

A-12

Evacuation Pump

Will Not Run

Rev 9/10/18

Models:

Serial Numbers:

All

Earlier Version Shown

Check Pump Motor

Refer to: Section B - Liquid Evacuation Pump

6th







Troubleshooting

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Evacuation Pump System

Problem: Evacuation Pump runs but does not

remove liquid from Separator.

Check Supply Voltage to Pump

Supply voltage is low. Refer to: Section B - Liquid Evacuation Pump

2nd

Check for Obstructions in Outlet of Separator / Lines.

Refer to: Section B - Liquid Evacuation Pump

Check Pump Location

Pump should be positioned as close as possible below the separator.







Refer To: Page

Liquid Evacuation Pump..............B-53-B-56

4th







5th







Check Discharge Line from Pump

Do not run a discharge head of greater then 35 ft. (15 Psi).

Models:

Serial Numbers:

All

6th







Earlier Version Shown

Check Suction Line Into Pump

Check for leaks. Avoid "looping" suction pipe as it could trap air. Suction line should not be more than 6 ft. in length.

Check Evac. Pump Impeller for Obstructions or Damage.

Refer to: Section B - Liquid Evacuation Pump

Evacuation Pump Runs

but Will Not Pump

Rev 9/10/18

1st

3rd







A-13







Troubleshooting

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Evacuation Pump System

Problem: Evacuation Pump Motor keeps tripping

on Thermal Overload.

2nd





Check for Obstructions in Discharge Line from Pump

Refer to: Section B - Liquid Evacuation Pump



Check Ambient Temperature at Motor

Temperature should not exceed 104° F (40° C) around pump.

Check Supply Voltage to Pump

Supply voltage is low. Refer to: Section B - Liquid Evacuation Pump

6th







Check Pump Location

Pump should be positioned as close as possible below the separator. Suction line should not be more than 6 ft. in length.

Refer To: Page

Liquid Evacuation Pump ....................... B-52

1st







5th







Check Discharge Line from Pump

Do not run a discharge head of greater then 35 ft. (15 Psi).

Evacuation Pump Keeps

Tripping on Thermal

A-14

Protector

3rd







Rev 9/10/18

Models:

Serial Numbers:

Earlier Version Shown

All

Motor Thermal Protector Weak

Replace motor pump.

Check Evac. Pump Impeller for Obstructions or Damage.

Refer to: Section B - Liquid Evacuation Pump

7th

4th











Testing & Repair

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Testing & Repair

Components: Page

Belt ....................................................B-2

Check Valve ......................................... B-6

Vacuum Relief Valve ............................ B-9

Exhaust ............................................... B-12

Float ..................................................... B-16

Low Voltage .......................................... B-18

Door Limit Switch &

Circuit Breaker (On/Off Switch) ........... B-21

Contactor ............................................. B-26

Fuse ..................................................... B-28

Relay .................................................... B-31

Transformer ......................................... B-34

Fan ....................................................... B-37

Gauge ................................................... B-41

Motor .................................................... B-43

Pump .................................................... B-50

Liquid Evacuation Pump (Accessory) .. B-53

Separator Tank (Rinse)....................... B-58

Models:

Serial Numbers:

Section B

B-1

Testing & Repair

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Belt

Location & Function

The Belt runs on a motor pulley system operating the pump. Belt should never have nicks, cracks or any visible damage, this will affect performance.

Earlier versions of the PowerVac® the belt will need adjusting from time to time. Newer versions of the PowerVac® have an auto tensioner.

WARNING

Motors installed after 12/08 are thermally protected

with automatic reset. Unit may start without warning.

Motor Pulley

Refer to: Page

Belt Adjustment (Tension) .................... B-3

Belt Replacement (Earlier Version) ........ B-4

Belt Replacement (New Version) ........... B-5

B-2

Belt

Serial Numbers:

Rev 9/10/18

Models:

Belt

Pump Pulley

Earlier Version Shown

AA162300i

All

Testing & Repair

10

15

20

25

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Belt

Checking and Adjusting Belt Tension (Earlier Versions Only)

(Small End O-ring)

Large End

O-ring

12"

50

150

100

Check belt tension using belt tension checker...

A. Remove front cover. Refer to: Section C Front Cover. B. Position o-ring on large end of tension checker to 12” (use "Inches of Span Length" increments on checker). C. Slide o-ring on small shaft to 0 pounds. D. Align straight edge with belt. E. Apply force on the plunger until o-ring on large shaft is even with straight edge. F. Remove the tension checker and read the defection force the small o-ring was moved to.

Verify deflection reading is 7 lbs.

7 pounds

WARNING

Motors installed after 12/08 are thermally protected with automatic reset. Unit may start without warning.

15

10

25

20

30

I

f adjustment is needed... A. Loosen Motor Mount Bolt. B. Move adjustment nut clockwise to tighten belt. C. Move adjustment nut counter clockwise to loosen belt D. Use belt tension checker to recheck deflection reading. E. Tighten motor mount bolt. F. Replace front cover.

Refer to: Page

Belt Location and Function .................... B-2

Belt Replacement (Earlier Version) ........ B-4

Belt Replacement (New Version) ........... B-5

Front Cover ........................................... C-2

Motor Mount Bolt

ON

OFF

HOURS

AA168200i

Models:

Serial Numbers:

P3

0611P3P0000 to 0801P3P0611

V245092 to V317654

Straight Edge

If no adjustment is needed...

A. Tighten motor mount bolt. B. Replace front cover.

0611P5P0000 to 0801P5P0240

V245092 to V317641

P5

0611P7P0000 to 0712P7P0104

V245092 to V317634

P7

Adjustment Nut

Belt

Rev 9/10/18

B-3

Testing & Repair

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Belt

Replacement (Earlier Versions Only)

Caution

The On/Off switch controls only the secondary circuit power. The main power source must be turned off to remove all power in the control box.

WARNING

Motors installed after 12/08 are thermally protected

with automatic reset. Unit may start without warning.

Removal

Step 1: Disconnect power at on/off switch

and main power supply box.

Refer to: Page

Belt Location and Function .................... B-2

Belt Adjustment (Earlier Version) .......... B-3

Belt Replacement (New Version) ........... B-5

Front Cover ........................................... C-2

Removal

Step 2: Remove front cover.

Refer to: Section C - Front Cover

Motor Mount Bolt

Removal

Step 3: Loosen motor mount bolt

and adjustment bolt.

Removal

Step 4: Remove belt.

Installation

Step 5: Replace belt.

Installation

Step 6: Tighten adjustment bolt

and motor mount bolt.

Installation

Step 7: Set belt tension.

ON

OFF

HOURS

Refer to: Section B - Belt Adjustment

Installation

Step 8: Replace front cover.

B-4

Belt

Serial Numbers:

Rev 9/10/18

Models:

Adjustment Bolt

0611P3P0000 to 0801P3P0611

V245092 to V317654

P3

AA162700i

Installation

Step 9: Connect power.

0611P5P0000 to 0801P5P0240

V245092 to V317641

P5

0611P7P0000 to 0712P7P0104

V245092 to V317634

P7

Belt

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Replacement

with automatic reset. Unit may start without warning.

Step 1: Disconnect power at on/off switch

(Newer Versions Only)

Step 2: Remove front cover.

Refer to: Section C Front Cover

Step 3: Slightly push tension arm up toward the

pulley and remove belt with other hand.

WARNING

Motors installed after 12/08 are thermally protected

and main power supply box.

Testing & Repair

Refer to: Page

Belt Location and Function .................... B-2

Belt Adjustment (Earlier Version) .......... B-3

Belt Replacement (Earlier Version) ........ B-4

Front Cover ........................................... C-2

Models:

Serial Numbers:

P3

0802P3P0612 thru

Present

Tension Arm

Step 4: Slightly push tension arm up toward the

pulley and install new belt with other hand.

P5

0801P5P0241 thru

Present

P7

0712P7P0105 thru

Present

AA221600

All

V785000 thru

Present

Step 5: Replace front cover.

Belt

Rev 9/10/18

B-5

Testing & Repair

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Check Valve

Location and Function

The Check Valve located in the drain allows the separator to drain upon removal of vacuum pressure. When the pump is not running, the valve opens, allowing liquids to drain. If the pump is running the valve closes to keep air in the drain from back flushing into the system.

Each vacuum pump in a multiple pump installation requires a check valve to be installed into the intake line.

This prevents loss of suction pressure when one pump in the system is turned off. If no check valve is present, flow will be allowed through he "off" pump, creating a loss suction of the rest of the system.

Vacuum Pressure keeps Valve

Closed when Pump is Running

Refer to: Page

Check Valve Test ................................. B-7

Check Valve Replacement .................... B-8

Earlier Version Shown

Located at bottom

drain on all units

B-6

When Pump Stops Valve Opens

for Liquids and Solids to Drain

Check Valve

Serial Numbers:

Rev 9/10/18

Multiple Units have two additional check

valves, located in the Tee Assembly

Note: When installing check valve in horizontal position,

Models:

confirm the hinge for the flapper is on top of the valve.

All

Testing & Repair

AA163000i

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Check Valve

Testing

Equipment Room

Operatory

On / Off Switch

AA152901i

Step 2: Turn vacuum off and

ensure that water drains from separator.

Refer to: Page

Check Valve Location and Function ...... B-6

Check Valve Replacement .................... B-8

Step 3: Turn power off.

Step 4: Allow unit to drain completely.

Step 1: Vacuum 1-2 gallons of fresh

water into system through operatory lines.

Note: If water does not drain out, remove lid and see if valve is clogged.

Serial Numbers:

(If so flush and clean tank, if not replace valve.) If water drains out, continue with next test on step 3.

Models:

All

Earlier Version Shown

Step 6: Turn power on and place hand over end of drain hose.

Note: If you feel suction check valve is stuck, replace check valve.

If no suction is felt then check valve is good.

Step 5: Pull drain hose

Check Valve

out of drain.

Rev 9/10/18

B-7

Testing & Repair

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Check Valve

Replacement

Removal

Step 1: Turn power off.

All Units

Removal

Step 3: Unscrew check valve.

Check Valve

Drain Hose

Verify criteria of valve so the correct position is "up".

Installation

Step 5: Install drain hose to check valve.

Refer to: Page

Check Valve Location and Function ...... B-6

Check Valve Test ................................. B-7

Installation

Step 4: Install check valve.

Twin Units

Removal

Step 1: Turn power off.

Removal

Step 2: Remove drain hose

from check valve.

Removal

Step 3: Unscrew check valve.

Earlier Version Shown

Installation

Step 6: Turn power on and place hand over end of check valve.

Note: Verify you do NOT feel any suction.

B-8

AA162900i

Check Valve

Serial Numbers:

Rev 9/10/18

Removal

Step 2: Remove drain hose from check valve.

Models:

All

Twin Unit Tee Assembly Check Valves

Installation

Step 4: Install check valve.

Installation

Step 5: Install drain hose to check valve.

Testing & Repair

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Vacuum Relief Valve

Location and Function

The Vacuum Relief Valve regulates the vacuum pressure in the PowerVac .

The Vacuum Relief Valve has a 1" NPT male fitting on one side and 1" NPT female fitting on the other side.

The valve is adjustable up to 18"Hg. Recommended range for the system vacuum is from 10" to 18"Hg. The valve is preset at the factory for 12" Hg.

The Vacuum Relief Valve is located on top of the separator tank in the "T" Fitting on Single Models and in the center of the mounted "T" assembly on the Twin Models.

®

Twin Unit Location

Refer to: Page

VRV Adjustment ................................... B-10

VRV Replacement ................................ B-11

Single Unit Location

Models:

Serial Numbers:

All

Earlier Version Shown

Vacuum Relief Valve

Rev 9/10/18

B-9

Testing & Repair

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Vacuum Relief Valve

Adjustment

Step 1: Turn power off.

Single Unit Location

0

2

5

2

0

3

-

Step 2: Remove the filter and valve by unscrewing from tee-fitting.

Filter

Valve

5

1

0 1

5

0

Step 3: Adjust the center mounted screw inside the valve.

Twin Unit Location

Refer to: Page

VRV Location and Function................... B-9

VRV Replacement ................................ B-11

Note: Use 1/4 inch nutdriver and phillips screwdriver.

Each full clockwise turn increases the vacuum level by approximately 2 inch Hg.

Vacuum Relief Valve

B-10

AA163100i

Earlier Version Shown

Rev 9/10/18

Models:

Serial Numbers:

Step 4: Install filter and valve.

Note: Recommended Range is 10” Hg - 18 Hg.

Vacuum is preset at 12” Hg. If reading is low check for leaks or open operatory lines.

All

Testing & Repair

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Vacuum Relief Valve

Replacement

Removal

Step 1: Turn power off.

Single Unit Location

Refer to: Page

VRV Location and Function................... B-9

VRV Adjustment ................................... B-10

Filter

Twin Unit Location

Valve

5

1

0

2

0

1

5

2

5

0 3

0

Removal

Step 2: Unscrew valve from tee-fitting.

Unscrew valve from filter.

Models:

Serial Numbers:

All

Installation

Step 3: Screw filter onto valve.

AA163200i

Earlier Version Shown

Screw valve assembly into tee-fitting.

Installation

Step 4: Turn power on.

Installation

Step 5: Perform Adjustment.

Refer to: Section B - VRV Adjustment

Vacuum Relief Valve

Rev 9/10/18

B-11

Testing & Repair

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Exhaust Valve

Location and Function

The exhaust check valve provides protection for the pump. It prevents moisture from entering the pump from the exhaust line.

Refer to: Page

Exhaust Valve Check ........................... B-13

Exhaust Valve Replacement ................. B-14

B-12

Exhaust Valve

Rev 2/08

Models:

Serial Numbers:

Earlier Version Shown

All

Testing & Repair

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Exhaust Valve

Check

Step 1: Turn power off.

Barbed Fitting

Exhaust Valve

Refer to: Page

Exhaust Valve Location and Function ... B-12

Exhaust Valve Replacement ................. B-14

Step 2: Remove exhaust hose from barbed fitting.

Remove barbed fitting.

Step 3: Remove exhaust valve from nipple.

Step 4: Shake valve and listen for movement of flap.

Note: If you are able to hear the valve flap moving, it

Models:

Serial Numbers:

is good. If valve is stuck and not moving, remove valve and clean. If valve will not work, replace the exhaust valve. Refer to: Section B Replacement

All

Nipple

Earlier Version Shown

AA163400i

Exhaust Valve

Rev 9/10/18

B-13

Testing & Repair

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Exhaust Valve

Replacement

Removal

Step 1: Turn power off.

Barbed Fitting

Exhaust Valve

Refer to: Page

Exhaust Valve Location and Function .. B-12

Removal

Step 2: Remove exhaust hose from barbed fitting.

Remove barbed fitting.

Installation

Step 5: Screw barbed fitting into exhaust valve.

Connect exhaust hose to barbed fitting.

Removal

Step 3: Remove exhaust valve from nipple.

Installation

Step 4: Screw new exhaust valve onto nipple.

B-14

Exhaust Valve

Rev 9/10/18

Nipple

Models:

Serial Numbers:

Earlier Version Shown

All

Installation

Step 6: Turn power on.

AA163400i

Testing & Repair

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Float Assembly

Location and Function

The Float Assembly contains three Float (Reed) Switches mounted on a bracket at different intervals.

The Reed Switch has contacts that remain open until the liquid in the separator rises, causing the float to rise until the magnet contacts the Reed Switch.

When the magnet contacts the Reed Switch, the open contacts inside the reed close.

When the top float switch closes, the fan, hour meter and vacuum pump stop running until the bottom float opens and the cycle starts again.

The upper and lower floats interact as a latching circuit with the internal relay to release upon drain below the bottom float. The magnet in the float is to activate the reed switch within the stem.

If the PowerVac installed, it begins running when the middle float switch closes, avoiding the vacuum pump shut-off that would occur if the liquid level closed the top switch.

®

has a Liquid Evacuation Pump (Accessory)

Refer to: Page

Check Float .......................................... B-16

Replace Float ........................................ B-17

Reed Switch

Contacts are open

until

magnet closes it.

Magnet

Float

Earlier Versions had Three Reed Switch Floats. The Middle Float was for the Liquid Evac Pump Option. If You Have a Liquid Evac Pump Connected to the PowerVac you Must Replace Float With a Three Reed Switch Float Assembly. If There is No Evac Pump Connected to the PowerVac, You can Replace the Float With a Two Reed Switch Float Assembly.

Models:

Serial Numbers:

All

Current Version Shown

AA2293

Float Assembly

Earlier Version

Shown

Rev 9/11

B-15

Testing & Repair

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Float Assembly

Earlier Versions had Three Reed Switch Floats. The Middle Float was for the Liquid Evac Pump Option. If You Have a Liquid Evac Pump Connected to the PowerVac you Must Replace Float With a Three Reed Switch Float Assembly. If There is No Evac Pump Connected to the PowerVac, You can Replace the Float With a Two Reed Switch Float Assembly.

Check

To check float switches...

Note: If pump is not running, unplug float from base unit. If pump doesn't start running, test relay (Section B) if pump starts running, continue with float checks...

A) Turn power off and plug float into base unit. B) Remove gasket on separator lid. C) Lift lid/float assembly out of tank and lay across top of tank. D) Turn power on. E) Move floats to down position. F) Raise bottom float to reed swtich, then raise top float to reed swtich. Motor should stop

after top switch is raised.

G) Move top float down first, then lay bottom float down.

Motor should not start until bottom float is down.

Note: Floats should move freely, if float does not work properly, replace the float assembly.

Refer to: Page

Float Location and Function .................. B-15

Replace Float ........................................ B-17

Rinse Separator Tank .......................... B-58

Relay Test ........................................... B-32

B-16

Note:

If no water in separator, but still runs when

unplugged from vacuum base unit, float maybe stuck.

Float Assembly

Rev 9/10/18

Models:

Serial Numbers:

All

Current Version Shown

AA2336

Float Assembly

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Replacement

Removal

Step 1: Turn power off.

Unplug float cord.

Earlier Versions had Three Reed Switch Floats. The Middle Float was for the Liquid Evac Pump Option. If You Have a Liquid Evac Pump Connected to the PowerVac you Must Replace Float With a Three Reed Switch Float Assembly. If There is No Evac Pump Connected to the PowerVac, You can Replace the Float With a Two Reed Switch Float Assembly.

Float Cord Fitting

Removal

Step 3: Lift separator lid.

Hold onto float underneath lid. Loosen float cord fitting on top of separator. Float will come down into your hand.

Testing & Repair

Refer to: Page

Float Location and Function .................. B-15

5

1

0

2

0

1 5 2

5

0 3

0

Installation

Step 4: Insert new float assembly up through separator lid.

Check Float .......................................... B-16

Tighten float cord fitting on top of separator.

Installation

Step 6: Plug in float cord to vacuum base unit.

Turn power on.

Models:

Serial Numbers:

All

Earlier Version

Shown

Removal

Step 2: Pull gasket down off separator lid.

Installation

Step 5: Set lid on separator.

Install gasket.

AA163700i

Float Assembly

Rev 9/10/18

B-17

Testing & Repair

Back

Go To Table Of Contents

Master Control Panel and Low Voltage

Location and Function

Wiring for Remote ON/OFF Switch, Master Control Panel

Low voltage (24VAC) wiring provides power for a remote ON/ OFF switch and indicator light (optional).

Refer to: Page

Master Control Panel Test ................... B-19

Low Voltage Test ................................. B-20

B-18

AA163400i

Low Voltage

Earlier Version Shown

Models:

Serial Numbers:

Rev 12/10

All

Testing & Repair

Back

Go To Table Of Contents

Master Control Panel

Test

Step 1: Disconnect power at on/off switch

and main power supply box.

Caution

When testing components with power on use care to prevent electrical shock.

Step 2: Bypass the remote switch to verify it is not defective.

Disconnect the Red and Blue wires from the remote switch. Connect the Blue and Red wires together.

Refer to: Page

Location and Function .......................... B-18

Low Voltage Test ................................. B-20

Models:

Serial Numbers:

Step 3: Connect power to the PowerVac

Turn the On/Off switch On.

Note: If the fan, hour meter and pump start running

then replace the remote switch.

®

All

Earlier Version Shown

Low Voltage

Rev 9/10/18

B-19

Testing & Repair

Transformer

Contactor

Back

Go To Table Of Contents

Low Voltage

Test

Step 1: Turn power off.

Step 2: Remove electrical cover.

Refer to: Section C Access Procedures

Caution

When testing components with power on use care to prevent electrical shock.

Refer to: Page

Location and Function .......................... B-18

Master Control Panel Testing .............. B-19

Access Procedrues .............................. C-1

Step 3: Set meter to V.

~

Step 4: Turn power on.

Step 5: Place probes on red low voltage wire on contactor

and yellow wire coming from transformer.

Note:

5

1 0 2

0

1 5 2

5

0

3

-

0

Verify voltage is 24 VAC.

B-20

Low Voltage

Rev 9/10/18

AA2335

Models:

Serial Numbers:

All

Testing & Repair

Back

Go To Table Of Contents

Door Limit Switch & PowerVac® Circuit Breaker (ON/OFF Switch)

Location & Function

With facility power (230 VAC) supplied to the system....

The transformer continuously supplies 24 VAC to the normally-open door limit switch.

With the front access cover in place...

The plastic bumper on the top right side of the access cover, trips the door limit switch causing it to close.

When the limit switch is closed, 24 VAC flows thru the switch to the PowerVac® circuit breaker circuit breaker switch ON, current is supplied to the remote wall switch

Note: If the facility does not have a remote wall switch,

(if applicable)

the PowerVac switch for the system.

.

®

circuit breaker serves as the ON/OFF

(ON / OFF Switch)

. With the

Refer to: Page

Door Limit Switch Testing .................... B-22

Circuit Breaker (On/Off) Testing .......... B-23

Door Limit Switch Replacement ........... B-24

Circuit Breaker Replacement (On/Off) B-25

When the front access cover is removed...

The door limit switch opens and stops current flow to the PowerVac® circuit breaker. This is a safety feature that prevents the system from operating with the cover removed.

Models:

Serial Numbers:

All

Earlier Version Shown

Door Limit Switch

On/Off Switch

Rev 2/08

B-21

Testing & Repair

Back

Go To Table Of Contents

Door Limit Switch

Step 1: Turn power off.

Testing

During this step, the motor belt and pulley may spin with front cover off. Stay clear and keep everything out of the vacuum base!

Step 3: Turn power on and depress activation button with a screwdriver.

Note: If motor starts up, quickly take pressure off switch.

Plastic bumper may be obstructed or damaged. Check plastic bumper on door for damage. If it is damaged, switch it with plastic bumper on opposite side of door until a replacement can be ordered. If motor doesn't start, continue with step 4.

Caution

Step 2: Remove front cover.

Refer to: Section C Front Cover.

Refer to: Page

Door Limit / Circuit Breaker Function .. B-21

Circuit Breaker (On/Off) Testing .......... B-23

Door Limit Switch Replacement ........... B-24

Circuit Breaker Replacement (On/Off) B-25

Section C Front Cover ......................... C-2

Caution

When testing components with power on use care to

Mounting Screw

prevent electrical shock.

Step 5: Remove mounting screw for door limit switch.

Disconnect electrical leads.

Step 4: Turn power off.

C O M

NO

N C

AA164100i

With switch 'untripped'...

OL

less than 5

ΩΩ

Ω

ΩΩ

Door Limit Switch &

B-22

ON

OFF

HOURS

AA164000i

gnidaeRreteMsutatSnoitcAderiuqeR

Limit switch - OK

Circuit Breaker

Rev 9/10/18

Replace switch

Models:

Serial Numbers:

Activation

Button

Caution

Door limit switch is a safety device. If switch is not working, do not bypass.

Warranty will be void if switch is bypassed. If both tests fail, it must be replaced!

All

Limit Switch Test

Step 6: Test continuity. Set meter to

Place meter probes on

Note: Check switch 'tripped' and 'untripped'.

Step 7: Install front cover.

With switch 'tripped'...

gnidaeRreteMsutatSnoitcAderiuqeR

OL

less than 5

ΩΩ

Ω

ΩΩ

Ω.Ω.

Ω.

Ω.Ω.

COM and NO

Replace switch

Limit switch - OK

terminals.

Testing & Repair

Back

Go To Table Of Contents

Circuit Breaker (ON/OFF Switch)

Testing

Step 1: Turn power off.

Step 2: Remove front cover.

Refer to: Section C Front Cover.

Caution

When testing components with power on use care to prevent electrical shock.

Circuit Breaker Test

Step 3: Test continuity. Set meter to

Disconnect leads from switch terminals. Place meter probes on

Note: Check switch 'tripped' and 'untripped'.

COM and NO

Ω.Ω.

Ω.

Ω.Ω.

Refer to: Page

Door Limit / Circuit Breaker Function .... B-19

Door Limit Switch Testing ..................... B-20

Door Limit Switch Replacement ............ B-22

Circuit Breaker Replacement (On/Off) .. B-23

Front Cover .......................................... C-2

terminals.

OL

less than 5

Models:

Serial Numbers:

gnidaeRreteMsutatSnoitcAderiuqeR

Circuit Breaker is Good

ΩΩ

Ω

ΩΩ

Replace Circuit Breaker

All

AA165501i

Step 4: Connect switch leads.

With switch 'tripped'...

gnidaeRreteMsutatSnoitcAderiuqeR

OL

less than 5

ΩΩ

Ω

ΩΩ

Door Limit Switch &

Circuit Breaker

Install front cover.

Replace Circuit Breaker

Circuit Breaker is Good

Rev 9/10/18

B-23

Testing & Repair

Back

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Door Limit Switch

Replacement

Removal

Step 1: Disconnect power at on/off switch

and main power supply box.

Removal

Step 2: Remove front cover.

Refer to: Section C Front Cover

Caution

The On/Off switch controls only the secondary circuit power. The main power source must be turned off to remove all power in the control box. Vacuum system must not have power when front cover is off base unit.

Plunger

Mounting Screw

WARNING

Motors installed after 12/08 are thermally protected with automatic reset. Unit may start without warning.

Refer to: Page

Door Limit / Circuit Breaker Function .. B-21

Door Limit / Circuit Breaker Testing .... B-22

Circuit Breaker (On/Off) Testing .......... B-23

Circuit Breaker Replacement (On/Off) B-25

Front Cover .......................................... C-2

Removal

Step 3: Disconnect wires from limit switch.

Mounting Screw

Installation

Step 6: Connect wiring to limit switch.

Door Limit Switch &

B-24

Circuit Breaker

ON

OFF

HOURS

Rev 9/10/18

AA165700i

Models:

Serial Numbers:

Removal

Step 4: Remove mounting screw and pull out limit switch and bracket.

Remove switch from bracket.

Installation

Step 5: Align limit switch with hole in side panel and

plunger away from mounting screws. Install mounting screw as shown.

Installation

Step 7: Install front cover.

Installation

Step 8: Turn power source on.

All

Rev 1/09

Testing & Repair

Back

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Circuit Breaker (ON/OFF Switch)

Replacement

Removal

Step 1: Disconnect power at on/off switch

and main power supply box.

Removal

Step 2: Remove front cover.

Refer to: Section C Front Cover

Refer to: Page

Door Limit / Circuit Breaker Function .... B-19

Door Limit Switch Test .......................... B-20

Circuit Breaker (On/Off) Testing ........... B-21

Door Limit Switch Replacement ............ B-22

Front Cover .......................................... C-2

Removal

Step 4: Push in on both side of breaker and push forward to pull out of panel.

Installation

Step 5: Push in on both sides of breaker.

Push breaker into panel and release sides to snap it in to place.

Removal

Step 3: Disconnect wires from back of breaker.

Models:

Serial Numbers:

All

Installation

Step 6: Install front cover and restore power.

AA165600i

Door Limit Switch &

Circuit Breaker

Rev 9/10/18

B-25

Testing & Repair

Back

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Contactor

Location and Function

When the PowerVac® is turned on either by the remote wall switch or vacuum unit on/off switch, the Contactor is energized. It sends current to the fan, hour meter and pump, turning them on.

Earlier Version

Refer to: Page

Contactor Testing ................................. B-27

Current Version

B-26

Contactor

Earlier Version Shown

Models:

Serial Numbers:

Rev 3/14/19

All

Contactor

Back

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Test

Step 1: Turn power off.

Caution

When testing components with power on use care to prevent electrical shock.

Testing & Repair

Refer to: Page

Contactor Location and Function ......... B-26

Electrical Cover .................................... C-4

Step 3: Turn power on.

Step 2: Remove electrical cover.

Refer to Section C: Electrical Cover.

Step 5: Check voltage across contactor.

• Set meter to V.

• Place meter probes on top red wire and bottom black wire.

Note: Verify reading is 24 volts.

AA163900

Step 4: Check high voltage on contactor.

• Set meter to V.

• Place meter probes on front, left side red and black wires.

Note: Verify reading is line volts.

Step 6: Insert screwdriver to start manually.

Note: if system starts, replace contactor.

Step 7: Install electrical cover.

Note:

Line Voltage shoud be 208 - 230 VAC with circuit loaded

(equipment running)

gnidaeRreteMsutatSnoitcAderiuqeR

Models:

Serial Numbers:

All

Line Volts

(Left side check)

24 Volts

(Top and Bottom check)

)

Contactor OK

Contactor

Rev 9/10/18

B-27

Testing & Repair

Back

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Fuse

Location and Function

The fuse limits the electrical current from the transformer to the contactor. It interrupts the electrical currents in the case of an overload. Only replace fuse with 1/8 amp, 250 volt, Slo Blo, fuse.

Refer to: Page

Fuse Testing ........................................ B-29

Fuse Replacement ............................... B-30

B-28

Fuse

Earlier Version Shown

Models:

Serial Numbers:

All

Testing & Repair

AA164301i

Back

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Fuse

Testing

Step 1: Turn power off.

Step 2: Remove electrical cover.

Refer to Section C: Electrical Cover.

Refer to: Page

Fuse Location and Function ................. B-28

Fuse Replacement ............................... B-30

Electrical cover ..................................... C-4

Step 3: Remove terminal leads.

Test continuity. Set meter to Place meter probes on both fuse terminals.

Ω.Ω.

Ω.

Ω.Ω.

OL - off line

Burnt or Broken

Continuity checks ok

Visually looks ok

Models:

Serial Numbers:

gnidaeRreteMsutatSnoitcAderiuqeR

All

Replace Fuse

Fuse is Good

Step 4: Visually check fuse to see if it is burnt or broken.

Step 5: Install electrical cover.

Fuse

Rev 9/10/18

B-29

Testing & Repair

Back

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Fuse

Replacement

Removal

Step 1: Turn power off.

Removal

Step 3: Pull fuse out.

Refer to: Page

Fuse Location and Function ................. B-28

Fuse Testing ........................................ B-29

Electrical cover ..................................... C-4

Removal

Step 2: Remove electrical cover.

Refer to: Section C - Electrical Cover

B-30

Fuse

Serial Numbers:

Rev 9/10/18

Models:

AA164400i

Installation

Step 4: Insert new fuse and perform continuity test.

Refer to: Section B Fuse Test

Installation

Step 5: Install electrical cover.

All

Testing & Repair

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Relay

Location and Function

Power is disconnected from the Contactor when the relay is energized by the top float switch closing (water level reaching top float switch). The PowerVac® electrical system can be checked by pressing the test button on the side. If the unit shuts down, the rest of the electrical system is functioning properly.

Earlier Version

Refer to: Page

Relay Testing ....................................... B-32

Relay Replacement .............................. B-33

Current Version

Models:

Serial Numbers:

Earlier Version Shown

All

Relay

B-31

Rev 3/14/19

Testing & Repair

Back

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Relay

Note:

If the motor is not shutting off when the top collection tank float is actuated, check relay by pressing the Test Button. If the motor is not running, By-Pass Relay to check operation.

Test

Relay Test Button. (Motor not off with top float actuated)

Step 1: Turn power off. Step 2: Remove electrical cover.

Cover.

Refer to Section C: Electrical

Step 3: Verify all wire connections are secure to relay. Step 4: Turn power on. Step 5: Push in test button on side of relay, if unit shuts down, relay

is bad.

Note:

I

f the unit does not shut down when top float is activated, but shuts off properly when the relay test button is pressed, the coil in the relay is likely defective (barring any other wiring issues). The light on the relay is only an indicator that there is power to the coil.

Caution

When testing components with power on use care to prevent electrical shock.

24V from

transformer

By-Pass Relay Test

Step 1: Turn power off. Step 2: Disconnect blue wire from Relay(2) and connect

Step 3: Turn power on.

Refer to: Page

Relay Location and Function ................. B-30

Relay Replacement ............................... B-32

Electrical cover ..................................... C-4

Disconnect

WH

BK

BL

Coil

CR1 (Float Switch) RELAY

7

Coil

8

WH

Coil

Contacts Open

6

5

Contacts Closed

Reconnect Wire

4

3

2

1

RD

AA168500-1i

BL

wire to left side of Relay(6) which has a direct feed from the transformer.

Wire

B-32

Relay

AA164500i

Serial Numbers:

Rev 9/10/18

Test Button

Models:

All

Test Results

Unit Starts when Relay

Is By-Passed

With the Top Collection Tank Float

Actuated, Unit Only Shuts OFF When

Relay Test Button is Depressed

Status Required Action

Replace Relay

Testing & Repair

Back

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Relay

Replacement

Removal

Step 1: Disconnect power at on/off switch

and main power supply box.

Removal

Step 2: Remove electrical cover.

Refer to Section C: Electrical Cover.

Earlier Version

Refer to: Page

Relay Location and Function ................. B-30

Relay Testing ........................................ B-31

Electrical cover ..................................... C-4

Current Version

Removal

Step 3: Unplug relay from base.

Models:

Serial Numbers:

All

Installation

Step 4: Plug in new relay. Restore power.

Push in test button to verify unit shuts down after turning power on.

Installation

Step 5: Install electrical cover.

Relay

Rev 3/14/19

B-33

Testing & Repair

Back

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Transformer

Location and Function

The Transformer steps the 230 VAC supply down to 24 VAC. This is the voltage at the relay and terminal block.

Refer to: Page

Transformer Testing............................. B-35

Transformer Replacement ................... B-36

B-34

Earlier Version Shown

Transformer

Models:

Serial Numbers:

All

Testing & Repair

Back

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Transformer

Testing

Step 1: Turn power off.

Step 2: Remove electrical cover.

Refer to Section C: Electrical Cover.

Step 4: Feel transformer to verify it is not hot.

If it is hot, allow it to cool off.

Note: Transformer has a internal non-resetting overload fuse. If transformer is hot to touch, allow to cool before testing. If it's hot check ambient operating temp and input / output voltage. Verify abient room temperature doesn't exceed 104° Fahrenheit (37 Celsius).

Step 5: Turn power on.

Caution

When testing components with power on use care to prevent electrical shock.

Refer to: Page

Transformer Location and Function ..... B-34

Transformer Replacement ................... B-36

Electrical cover ..................................... C-4

Step 3: Verify all wire connections are secure to

transformer, relay and terminal block.

AA164900i

Step 6: Check low voltage on transformer connections.

• Set meter to V.

• Place meter probe on yellow wire connection from transformer to terminal block.

• Place meter probe on blue wire connection from transformer to relay.

Note: Verify reading is 24 volts (-2 / +4).

Exceeds

24 Volts -2 / +4

Within

24 Volts -2 / +4

Models:

Serial Numbers:

gnidaeRreteMsutatSnoitcAderiuqeR

All

Replace Transformer

Transformer is Good

Step 7: Install electrical cover.

Transformer

Rev 9/10/18

B-35

Testing & Repair

Back

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Transformer

Replacement

Removal

Step 1: Disconnect power at on/off switch

and main power supply box.

Removal

Step 2: Remove electrical cover.

Refer to Section C: Electrical Cover.

Removal

Step 3: Disconnect all transformer wiring.

Refer to: Page

Transformer Location and Function ....... B-33

Transformer Testing............................. B-35

Electrical cover ..................................... C-4

Installation

Step 6: Connected wiring.

Removal

Step 4: Unscrew transformer from electrical box.

B-36

Transformer

Rev 9/10/18

Models:

Serial Numbers:

Installation

Step 5: Screw new transformer into electrical box.

All

AA165000i

Installation

Step 7: Install electrical cover.

Resotre power.

Testing & Repair

Back

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Fans

Location and Function

Depending on the version of PowerVac® you have, single or dual fans are used to cool the base unit by circulating air whenever the pump is running. The ON/OFF function of the fans are controlled by the CR1 relay.

With the CR1 Relay OPEN (light OFF), 230 VAC is supplied to the fan(s) thru Contactor "C". When voltage is applied to the fan(s), the fan(s) is energized.+

With the CR1 Relay CLOSED (light ON) there is no current flow to the Contactor "C" or to the fan(s). The fan(s) do not run.

Fans in the earlier version of PowerVac® models are located on a mounting bracket above the pump. Dual fans on newer versions are located on the back cover and are wired in parallel with the same electrical box connections as the single fan unit.

Refer to: Page

Fan Testing .......................................... B-38

Fan Replacement (Earlier Version) ..... B-39

Fan Replacement (New Version) ......... B-40

Models:

Serial Numbers:

All

Earlier Version

New Version

Fan

Rev 2/08

B-37

Testing & Repair

Meter Reading Required Action

230 Volts Replace Fan

<230 Volts Replace Harness

Back

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Fan

Step 3: Set meter to V.

Testing (if fan is not running)

Step 1: Disconnect power at on/off

switch and main power supply box.

Step 2: Newer Versions - Remove back cover.

Refer to Section C: Back Cover.

Step 4: Unplug harness from fan. Turn power on at base unit and supply power box.

Note: Verify pump is running. If pump is not running, Check for 230 volts where fan(s) connect to contactor.

Caution

When testing components with power on use care to prevent electrical shock.

Refer to: Page

Fan Location and Function ................... B-37

Fan Replacement (Earlier Version) ..... B-39

Fan Replacement (New Version) ......... B-40

Electrical Cover ................................... C-4

Back Cover ........................................... C-5

Step 5: Verify fan harness connection to contactor is tight and not loose.

Check voltage in fan harness.

Note: Verify reading is 230 volts.

Fan

B-38

Rev 9/10/18

Models:

Serial Numbers:

Fan Plug Connection

AA164700i

All

Testing & Repair

Back

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Fan

Replacement (Earlier Versions Only)

Removal

Step 1: Disconnect power at on/off switch

and main power supply box.

Removal

Step 3: Disconnect plug wires from fan.

Fan Mounting Bracket

Refer to: Page

Fan Location and Function ................... B-37

Fan Testing .......................................... B-38

Fan Replacement (New Version) ........... B-39

Electrical cover ..................................... C-4

Exhaust Valve Assembly

Removal

Step 2: • Remove drain hose.

• Unscrew exhaust valve assembly.

Installation

Step 6: • Screw fan guard through front of mounting bracket and into new fan.

• Screw mounting bracket into vac base unit.

Removal

Step 4: Unscrew fan mounting bracket from vac base unit.

Removal

Step 5: • Unscrew fan guard from mounting bracket.

Models:

Serial Numbers:

• Remove fan from back of mounting bracket.

0611P3P0000 to 0801P3P0611

V245092 to V784999

P3

0611P5P0000 to 0801P5P0240

V245092 to V784999

P5

Installation

Step 7: • Connect plug wires to fan.

P7

0611P7P0000 to 0712P7P0104

V245092 to V784999

• Install exhaust valve assembly.

AA164800i

Fan

Rev 9/10/18

B-39

Testing & Repair

Back

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Fans

Step 1: Disconnect power at on/off switch

Replacement

Removal

Step 2: Remove back cover.

Refer to: Section C Back Cover

Removal

and main power supply box.

Refer to: Page

Fan Location and Function ................... B-37

Fan Testing .......................................... B-38

Fan Replacement (Earlier Version) ..... B-39

Back Cover ........................................... C-5

Removal

Step 4: Unscrew fan units from inside of cover.

Installation

Step 5: Screw fan units onto inside

of cover.

Removal

Step 3: Unscrew fan guards from

outside of cover.

Installation

Step 6: Screw fan guards onto

B-40

outside of cover.

P3

0802P3P0612 to Present

Fan

Rev 9/10/18

Models:

Serial Numbers:

P5

0801P5P0241 to Present

AA220400

P7

0712P7P0105 to Present

Installation

Step 7: Replace back cover.

Restore power.

All

V785000 thru

Present

Testing & Repair

Back

Go To Table Of Contents

Gauge

Location and Function

The Vacuum Gauge has a 1/4" NPT fitting and a range from 0 to -30 In./Hg. graduated in increments of 0.5 In./Hg. Recommended range for the system vacuum is 10"Hg to 18"Hg. The system is preset at the factory for 12"Hg.

Refer to: Page

Gauge Replacement ............................. B-42

Models:

Serial Numbers:

All

Earlier Version Shown

Gauge

Rev 9/10

B-41

Testing & Repair

Back

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Gauge

Replacement

Removal

Step 1: Turn power off.

Removal

Step 2: Unscrew gauge from fitting.

Refer to: Page

Gauge Location and Function ............... B-41

Installation

Step 3: Apply teflon tape to threads on new gauge.

Installation

Step 4: Screw new gauge into fitting.

B-42

Gauge

Serial Numbers:

Rev 9/10/18

AA165400i

Earlier Version Shown

Models:

All

Testing & Repair

Back

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Motor

Location & Function

The electric motor is located on an adjustable motor mount and is easily accessible. A thermal overload switch is located on the side of the motor (Red Button). The belt driven motor is a 2 HP single phase, 208-230 volt motor.

Earlier Version Shown

Refer to: Page

Motor Checks...................................... B-44

Belt ....................................................... B-2

Front Cover ........................................... C-2

Earlier Versions

Motor Replacement (Removal) ........... B-45

Motor Replacement (Installation) ......... B-46

Motor Mount Adjustment ...................... B-47

Newer Versions

Motor Replacement (Removal) ........... B-48

Motor Replacement (Installation) ......... B-49

Earlier Version Shown

Models:

Serial Numbers:

WARNING

Motors installed after 12/08 are thermally protected

with automatic reset. Unit may start without warning.

All

Motor

Rev 9/10/18

B-43

Testing & Repair

Back

Go To Table Of Contents

Caution

Motor

Check

Step 1: Turn off power at

on/off switch and power supply box.

Wire Connections

Step 3: Remove electrical cover off motor.

Verify all wires are connected.

The On/Off switch controls only the secondary circuit power. The main power source must be turned off to remove all power in the control box. Capacitors must be discharged before touching to remove.

Step 2: Remove front cover.

Remove belt and verify motor pulley spins freely. If it doesn't, replace motor, bearing is out in motor. If it does, continue checks.

Refer to: Section C - Front Cover

Capacitor

Step 5: Replace Capacitor.

• Access start and run capacitor by removing top cover and capacitor covers off motor.

• Discharge capacitors by touching two screwdrivers to two contacts on a capacitor and to each other.

Refer to: Section C Top Cover

Refer to: Page

Motor Location and Function ................ B-42

Belt ....................................................... B-2

Front Cover ........................................... C-2

Top Cover ............................................. C-3

Earlier Versions

Motor Replacement (Removal) ............. B-44

Motor Replacement (Installation) ........... B-45

Motor Mount Adjustment ....................... B-46

Newer Versions

Motor Replacement (Removal) ............. B-47

Motor Replacement (Installation) ........... B-48

Discharge Capacitor

Run Capacitor

Reset Thermal Overload - Earlier Version Only

Step 4: • Allow motor to cool.

• Press thermal overload button.

• Install front cover.

• Connect Power.

Note: Manual reset button on earlier versions only, current versions have automatic reset.

"O" or "Open" Reading

Start Low and

Increases

B-44

AA166000i

gnidaeRreteMsutatSnoitcAderiuqeR

Earlier Version Shown

Thermal Overload Button

Replace Capacitor

Motor

Serial Numbers:

Rev 9/10/18

Electrical Cover

Capacitor - OK

Models:

Step 6: Set meter to highest

WARNING

Motors installed after 12/08 are thermally protected with automatic reset. Unit may start without warning.

All

Start

Capacitor

Ω Ω

Ω reading

Ω Ω

..

.

..

Step 7: Place meter

probes on capacitor connectors.

Motor (Removal)

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Go To Table Of Contents

Replacement (Earlier Versions Only)

Removal

Step 1: Disconnect power at on/off switch

and main power supply box

Removal

Step 2: Remove front cover.

Refer to: Section C - Front Cover

Sheave

Caution

The On/Off switch controls only the secondary circuit power. The main power source must be turned off to remove all power in the control box.

Removal

Step 5: Measure end of shaft to

face of top pulley. Write dimension down.

Removal

Step 6: • Unscrew removal bolts

from hub through holes.

• Screw bolts into threaded removal holes alternately to pull sheave off tapered hub.

Testing & Repair

Refer to: Page

Motor Location and Function ................ B-42

Motor Checks ....................................... B-43

Motor Replacement (Installation) ........... B-45

Belt ............................................... B-2

Front Cover .......................................... C-2

Measure

Removal

Step 3: Loosen motor mount bolt

and adjustment bolt.

Removal

Step 4: Remove belt.

Models:

Serial Numbers:

0611P3P0000 to 0801P3P0611

V245092 thru V784999

P3

Removal Bolt Holes

ON

OFF

HOURS

Adjustment Bolt

0611P5P0000 to 0801P5P0240

V245092 thru V784999

Removal Bolts

Removal

Step 8: Remove motor nuts and washers.

P5

Remove motor.

0611P7P0000 to 0712P7P0104

V245092 thru V784999

P7

AA165800i

Removal

Step 7: Disconnect

Motor Wire

Connections

Motor

motor wires from vac unit.

Rev 9/10/18

B-45

Testing & Repair

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Motor (Install)

Replacement (Earlier Versions Only) (Continued)

Installation

Step 9: Install new motor, nuts

and washers onto motor mount.

Installation

Equipment Alert

For proper pulley alignment and function dimension measured should equal

what you measured with the old pulley.

Installation

Step 11: Align key stock and install pulley and belt.

Measure end of shaft to face to sheave.

Refer to: Page

Motor Location and Function ................ B-42

Motor Checks ....................................... B-43

Motor Replacement (Removal) .............. B-44

Belt ............................................... B-2

Front Cover .......................................... C-2

Installation

Step 10: Connect motor wires

from vac unit to motor.

Motor Wire

Connections

AA165800i

Installation

Step 14: Replace front cover.

Pulley

Motor

Mount Bolt

Bolts

B-46

Motor

Rev 9/10/18

Installation

Step 12: Tighten adjustment bolt

Installation

Step 13: Check belt tension.

Refer to: Section B - Belt Adjustment

Models:

Serial Numbers:

and motor mount bolt.

0611P3P0000 to 0801P3P0611

V245092 thru V784999

P3

ON

OFF

HOURS

Adjustment Bolt

0611P5P0000 to 0801P5P0240

V245092 thru V784999

P5

AA165900i

Installation

Step 15: Restore power.

P7

0611P7P0000 to 0712P7P0104

V245092 thru V784999

Testing & Repair

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Motor

Adjustment (Earlier Versions Only)

Step 1: Disconnect power

at on/off switch and main power supply box.

Step 2: Remove front cover.

Refer to: Section C - Front Cover

Step 3: Loosen motor mount bolt.

Motor

Mount Bolt

Refer to: Page

Front Cover .......................................... C-2

Belt ............................................... B-2

B-3

Step 5: Check belt tension.

Refer to: Section B - Belt

Step 6: Tighten motor mount bolt.

ON

OFF

HOURS

AA168200i

Models:

Serial Numbers:

Step 4: Move adjustment nut clockwise to tighten belt

or counter clockwise to loosen belt.

0611P3P0000 to 0801P3P0611

V245092 to V784999

P3

0611P5P0000 to 0801P5P0240

V245092 to V784999

P5

Adjustment Nut

P7

0611P7P0000 to 0712P7P0104

V245092 to V784999

Step 7: Replace front cover.

Restore power.

Motor

Rev 9/10/18

B-47

Testing & Repair

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Motor

Replacement (New Versions Only)

Removal

Step 1: Disconnect power at on/off

switch and main power supply box.

Removal

Step 2: Remove front cover.

Refer to: Section C - Front Cover

Removal

Step 4: Slightly push tension arm up toward the

pulley and remove belt with other hand.

Removal

Step 3: Measure end of shaft to

face of top pulley. Write dimension down.

Measure

AA221200

Refer to: Page

Motor Location and Function ................ B-42

Motor Checks ....................................... B-43

Motor Replacement (Removal) .............. B-48

Belt ............................................... B-2

Front Cover .......................................... C-2

Removal

Step 5: Remove pulley from motor.

• Unscrew removal bolts from hub through holes.

• Screw bolts into threaded removal holes alternately to pull sheave off tapered hub.

Removal

Step 6: Disconnect

motor wires from vac unit.

B-48

Motor

Serial Numbers:

Rev 9/10/18

Models:

Removal Bolts

Removal Bolt Holes

Removal

Step 7: Remove motor from motor mount.

P3

0802P3P0612 to Present

0801P5P0241 to Present

P5

A221800

P7

0712P7P0105 to Present

Motor Wire

Connections

V785000 thru

Present

All

Testing & Repair

Back

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Motor (Install)

Replacement (New Versions Only) (Continued)

Installation

Step 8: Install new motor, nuts

and washers onto motor mount.

Equipment Alert

For proper pulley alignment and function dimension measured should equal

what you measured with the old pulley

Installation

Step 10: Align key stock and install pulley and belt.

Measure end of shaft to face to pulley.

Motor Wire

Connections

Refer to: Page

Motor Location and Function ................ B-42

Motor Checks ....................................... B-43

Motor Replacement (Removal) .............. B-47

Belt ............................................... B-2

Front Cover .......................................... C-2

Installation

Step 9: Connect motor wires

from vac unit to motor.

Installation

Step 11: Slightly push tension arm up toward the

Models:

Serial Numbers:

pulley and install belt with other hand.

P3

0802P3P0612 to Present

0801P5P0241 to Present

P5

Installation

Step 12: Replace front cover.

Refer to: Section C - Front Cover

P7

0712P7P0105 to Present

All

V785000 thru

Present

Removal Bolts

Removal Bolt Holes

A221900

Installation

Step 13: Connect power.

Motor

Rev 9/10/18

B-49

Testing & Repair

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Pump

Location & Function

The "dry" vacuum pump requires no lubricant in the pumping chamber. The pump is a dual rotary claw type, belt driven by a 2 HP single phase, 208-230 volt motor.

Refer to: Page

Pump Checks ....................................... B-51

Pump - Change Gear Lube .................. B-52

Earlier Version Shown

B-50

Earlier Version Shown

Pump

Rev 8/08

Models:

Serial Numbers:

All

Step 1: Disconnect power at on/off switch

Back

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and main power supply box.

Pump

Check

To Drain Pump

Step 4: Check for water in pump.

Note: Water may flood out, set funnel under bolt hole to move water from pump into a bucket or tray.

Step 2: Check pulley to see if locked up.

• Use belt to check pulley.

• Try to work pulley loose, turn with hand.

Note:

If pulley does not move, continue with Steps 3, 4 and 5.

Drain

Plug

• Remove drain bolt off pump & barb fitting at the bottom of the exhuast p-trap to release any water inside.

• When pump & p-trap are done draining replace drain bolt and barb fitting.

Testing & Repair

Refer to: Page

Pump, Location and Function ............... B-50

Pump, Change Gear Lube .................... B-52

Front Cover ........................................... C-2

Step 3: Check gear lubricant level.

Add if below 1/3 full. Use only Midmark gear lube P/N 064-0028-01. Remove inlet hose to add gear lube.

Note:

If you have added gear lube two times or more during the past year, call Dealer

for service. If gear lube is not light yellow /clear opaque color, it will need to be changed. Refer to: Section B - Pump, Change Gear Lube.

Add Gear Lube Here

Add

Max

After Draining Pump You Must...

Step 5: • Remove inlet hose either at pump or at separator.

Models:

Serial Numbers:

• Pour 2 ounces (1/4 cup) of conditioning fluid (002-1910-02) into pump and let soak. or WD-40 if unavailable

• Try to work pulley loose as fluid migrates through pump.

• If pump will not free up order Timer/Conditioning Fluid Kit (002-1910-01) and Socket kit (002-1911-00)

• If pumps rotates freely restore power and start vacuum. Order Timer/Conditioning Fluid Kit (002-1910-01) if needed.

All

Inlet

AA166101

Pump

5

1 0 2

0

1 5 2

5

0 3

0

Rev 9/10/18

B-51

Testing & Repair

AA2398i

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Pump

Change Gear Lube

The PowerVac® gear lube should be changed every 10 years. It will take approximately 2/3 of a quart of Midmark PN 064-0028 which can be ordered in a quart or a liter.

Step 2: Remove front cover.

Step 1: Run PowerVac for 5-10 minutes.

Disconnect main power supply to the PowerVac.

Step 3: Remove venting valve plug.

Step 4: Siphon gear lube out from venting valve hole.

Note: If you do not have a siphon hose, you may access the drain plug located below the site gauge. Place a oil absorbant mat under drain hole and funnel the gear lube out the side access hole in housing into a drain tray.

Note: Refer to Section C Front Cover

Drain Plug

Refer to: Page

Pump Location and Function .............. B-50

Pump - Check ...................................... B-51

Front Cover .......................................... C-2

Venting Valve Plug

Site Gauge

Access Hole

Step 5: Fill in new gear lube until the level

Note: Dispose of gear lube in compliance with applicable regulations.

B-52

is slightly above the middle of the site gauge. Verify seal ring on vent valve is undamged. Replace vent valve plug and or drain plug. Clean any gear lube that leaked on inside or outside housing.

Pump

Models:

Serial Numbers:

Rev 9/10/18

All

Step 6: Replace front cover.

Connect main power supply. Run pump for 5 minutes and recheck the gear lube on the site gauge.

Liquid Evacuation Pump (Accessory)

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Function

The PowerVac® Liquid Evacuation Pump Accessory provides additional security for an extremely busy practice. Easily installed as OEM or as a later accessory, the Liquid Evacuation Pump ensures that the PowerVac® operates without interruption by automatically draining the separation tank periodically throughout the day.

Earlier Versions had Three Reed Switch Floats. The Middle Float was for the Liquid Evac Pump Option. If You Have a Liquid Evac Pump Connected to the PowerVac you Must Replace Float With a Three Reed Switch Float Assembly. If There is No Evac Pump Connected to the PowerVac, You can Replace the Float With a Two Reed Switch Float Assembly.

Testing & Repair

Refer to: Page

Evacuation Pump Tests .......B-53 thru B-57

5 1

0

2

0

1 5 2

5

0

3

0

Earlier Version Shown

Models:

Serial Numbers:

All

AA165300i

Liquid Evacuation Pump

Rev 9/11

B-53

Testing & Repair

AA165103i

NEUTRAL

(WHT)

EVAC PUMP

LINE

(BLK)

F1

F2

F3

J4

J9

J6

EVAC

PUMP

K4

BOTTOM

FLOAT

TOP

FLOAT

K2

D1

D4

NEUTRAL

(BLU)

SUPPLY

LINE

(BRN)

J2

J8

J5

J1

D3

K3

J3

F3 (3 Amp Slo Blo)

F2 (3 Amp Slo Blo)

F1(1/4 Amp Slo Blo)

To CR1 Relay

System 1

To CR1 Relay

System 2

Float Relay

Evacuation Pump Relay

4

3

2

1

Transformer

115

VAC

24

VAC

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Liquid Evacuation Pump (Accessory)

Testing (Power On, Float Switches Open, No LED's On)

Refer to: Page

Evacuation Pump Tests .......B-53 thru B-57

Note:

All Electrical leads are not shown

for the purpose of clarity.

Step 4: 24 VAC should be present at J3 plug

connector 1 (yellow wire) and 2 (blue wire) from Transformer.

Note: If 24 VAC is not present replace Transformer.

Liquid Evacuation Pump

B-54

Rev 9/10/18

Models:

Serial Numbers:

Caution

When testing components with power on use care to prevent electrical shock.

Step 1: With power on, 115 VAC

is present at J6 & J7.

Note: If 115 VAC is not present check

main supply power.

Step 2: 115 VAC should be present at plug

connector 4 (Blk wire) and 3 (white wire) to Transformer.

Note: If 115 VAC is not present check fuse F1

All

and F3 and replace if necessary. If F1 & F3 fuses are good replace PC Board.

Step 3: 115 VAC should be present at plug

connector 1 (Blk wire) and 2 (white wire) to Power On Light. Light should be on.

Note: If 115 VAC is not present check fuse F1

and F3 and replace if necessary. If 115 VAC is present but light is not on, replace light. If F1 & F3 fuses and light are good replace PC Board.

AA165101i

D3

NEUTRAL

(WHT)

EVAC PUMP

LINE

(BLK)

F1

F2

F3

J4

J9

J6

EVAC

PUMP

K4

K3

BOTTOM

FLOAT

TOP

FLOAT

K2

D1

D4

NEUTRAL

(BLU)

SUPPLY

LINE

(BRN)

J2

J8

J5

J1

F2 (3 Amp Slo Blo)

F1(1/4 Amp Slo Blo)

F3 (3 Amp Slo Blo)

J3

4

3

2

1

To CR1 Relay

System 1

To CR1 Relay

System 2

Float Relay

Evacuation Pump Relay

Transformer

115

VAC

24

VAC

Liquid Evacuation Pump (Accessory)

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Testing (Power On, Bottom & Middle Float Switches Closed,

K4 Evac. Pump Relay coil energized)

Note: All Electrical leads are not shown

for the purpose of clarity.

Caution

When testing components with power on use care to prevent electrical shock.

Testing & Repair

Refer to: Page

Evacuation Pump Tests .......B-53 thru B-57

Note: • LED's D3 & D4 will cycle On & Off as

trols open and close with the level of the fluid.

• When D4 is On, the contacts in the Evac. Relay (K4) close and power will be present at J8 & J9 to run the Evac. Pump.

Models:

Serial Numbers:

the Bottom & Middle Float Con-

All

Power

Light

On

Step 1: When D3 & D4 LED's are On 115 VAC

should be present at J8 & J9.

Note: If 115 VAC is not present check Fuse F2.

If F2 Fuse is good replace PC Board.

Liquid Evacuation Pump

B-55

Rev 9/10/18

Testing & Repair

AA165100i

D3

NEUTRAL

(WHT)

EVAC PUMP

LINE

(BLK)

F1

F2

F3

J4

J9

J6

EVAC

PUMP

K4

K3

BOTTOM

FLOAT

TOP

FLOAT

K2

D1

D4

NEUTRAL

(BLU)

SUPPLY

LINE

(BRN)

J2

J8

J5

J1

F2 (3 Amp Slo Blo)

F

1(1/4 A

m

p S

lo B

lo)

F3 (3 Amp Slo Blo)

J3

4

3

2

1

To CR1 Relay

System 1

To CR1 Relay

System 2

Float Relay

Evacuation Pump Relay

Transformer

115

VAC

24

VAC

Back

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Liquid Evacuation Pump (Accessory)

Testing (Power on, All [ D1, D3, D4 ] LED's on.

Bottom, Middle, and Top float switches closed. K4 Evac. Pump Relay coil energized.)

Note: • When all three LED's (D1, D3, D4)

are on, it indicates the Separator Tank is full of liquid.

• D4 indicates the Evacuation Pump Relay coil (K4) is energized, closing its contacts and supplying 115 VAC to terminals J8 & J9 to the Evac. Pump.

• The Vacuum Pump shuts off when the contacts (K1) in the Top Float (D1) are closed.

Note:

All Electrical leads are not shown

for the purpose of clarity.

Caution

When testing components with power on use care to prevent electrical shock.

Refer to: Page

Evacuation Pump Tests .......B-53 thru B-57

Liquid Evacuation Pump

B-56

Rev 9/10/18

Models:

Serial Numbers:

All

Power

Light

On

Step 2: 115 VAC should be present at J8 & J9.

Note: If 115 VAC is not present check Fuse F2.

If F2 Fuse is good replace PC Board. If 115 VAC is present check Evacuation Pump.

WH

BK

GN/YL

AA165200i

Cover Plate

Liquid Evacuation Pump (Accessory)

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Testing Liquid Evacuation Pump Assembly

Note:

that will open, removing power to the motor should it overheat. Ambient temperature around the pump should not exceed 104°F (40°C).

The motor has a thermal protection

Testing & Repair

Refer to: Page

Evacuation Pump Tests .......B-53 thru B-57

Caution

When testing components with power on use care to prevent electrical shock.

Note:

an obstruction in the outlet side of the system. Assure nothing is obstructing the flow of the discharge from the tank and Evac. Pump during operation.

Step 1: If pump motor is running but not

Note:

A full Separator Tank may be due to

pumping fluid.

Turn power off to Evac. Pump. Check for restrictions / obstruction in the lines connected to the pump and remove obstacles. Remove cover plate (four screws) and check impeller for obstructions or wear. Replace if necessary.

Step 2: If pump motor is

not

running but has 115 VAC supplied to it (PC Board, J8 & J9) check thermal protector.

Note: Turn power Off and wait 15 minutes to allow

motor to cool and thermal protector to reset. Disconnect Black & White motor leads from terminals J8 & J9 on the Evac. Pump PC Board.

Set VOM to Ohms

Place meter probes on the White and Black motor leads and check continuity.

Note: Refer to Section E for the Impeller / Gasket Kit.

gnidaeRreteMsutatSnoitcAderiuqeR

Ω.Ω.

Ω.

Ω.Ω.

Models:

Serial Numbers:

All

OL

Continuity checks OK (20 to 30 ohms, cold reading)

Winding or Thermal Protector (TP) Stays

Open. Replace Motor Pump

Thermal protector is closed. Winding is within ohms range. Motor is ok.

Liquid Evacuation Pump

Rev 9/10/18

B-57

Testing & Repair

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Separator Tank

Rinsing Separator Tank Assembly

Step 2: Remove pressure gauge from

separator lid and temporarily replace with garden hose adapter.

Note: Garden hose adapter was supplied

as a loose part when this unit was purchased.

Step 4: Run water through garden

Pressure

Gauge

Separator

Lid

hose for approximately five (5) minutes.

Earlier Version Tank Shown

5

1

0

2

0

1 5 2

5

0

3

0

Refer to: Page

Float Assembly Check ........B-15 thru B-17

Garden

Hose

Adapter

Step 3: Attach garden hose (not

shown) to garden hose adapter.

Step 5: Turn water off, disconnect hose,

remove garden hose adpter and replace with pressure gauge.

B-58

Separator Tank

Rev 9/10/18

Models:

Serial Numbers:

Step 1: Turn On / Off switch to

"Off" position.

On / Off

Switch

AA2256i

All

Access Procedures

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Access Procedures

5

1

0

2

0 1

5

2

5

0

3

0

Removing & Installing: Page

Front Cover .......................................... C-2

Top Cover............................................. C-3

Electrical Cover ..................................... C-4

Back Cover (Previous Tank) ............... C-5

Back Cover with Large Tank ................ C-6

Models:

Serial Numbers:

Section C

C-1

Access Procedures

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Removal / Installation

Caution

Power must be disconnected when removing front cover. The On/Off switch controls only the secondary circuit power. The main power source must be turned off to remove all power in the control box.

Step 1: Unfasten front cover by turning each

fastener 1/4 turn, counter clockwise.

Removal

Step 2: Lift front cover straight up to free plastic

cones from holes in side panels.

Installation

Step 3: Align plastic cones to holes in side panels.

Plastic Cones

Refer To: Page

Exploded Views / Part Numbers:

Soft Touch .........................................

Seamless ..........................................

E-5

E-6

C-2

Installation

Step 4: Turn fasteners 1/4 turn colckwise to secure

Front Cover

front cover.

Serial Numbers:

Rev 9/10/18

Models:

Fasteners

All

Access Procedures

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Top Cover

Removal / Installation

Removal

Step 1: Disconnect power.

Installation

Step 10: Connect power.

Removal

Step 5: Unbolt and remove top cover.

Caution

The On/Off switch controls only the secondary circuit power. The main power source must be turned off to remove all power in the control box.

Earlier Version Shown

5 1

0

2

0

1

5

2

5

0

3

0

Removing & Installing: Page

Front Cover .......................................... C-2

Removal

Step 3: Unbolt and remove separator from

vacuum base unit if applicable.

Installation

Step 8: Install separator on top of vacuum

base unit if applicable.

Installation

Step 6: Install top cover.

Models:

Serial Numbers:

Removal

Step 2: Unplug float cord.

Installation

Step 9: Plug in float cord .

All

Float Cord

Removal

Step 4: Remove front cover.

Refer to: Section C - Front Cover

Installation

AA166900i

Step 7: Install front cover.

Top Cover

Rev 9/10/18

C-3

Access Procedures

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Removal / Installation

Removal

Step 1: Disconnect power.

Installation

Step 6: Connect power.

Caution

The On/Off switch controls only the secondary circuit power. The main power source must be turned off to remove all power in the control box.

Caution

When testing components with power on use care to prevent electrical shock.

Removal

Step 2: Remove two screws from electrical panel.

Electrical Cover

C-4

Rev 9/10/18

Models:

Serial Numbers:

Installation

Step 5: Install two screws.

Removal

Step 3: Remove electrical panel.

Installation

Step 4: Install electrical panel.

AA166800i

All

Back Cover

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Note

If there are hex head mounting bolts in rear cover, it has been installed using a retrofit kit. Unscrew all four bolts to remove rear cover.

Plastic Cones

Access Procedures

Removal

Step 2: Lift back cover straight up to free plastic

cones from holes in side panels.

Installation

Step 5: Align plastic cones to holes in side panels.

Removal

Step 3: Unplug both fans.

Installation

Step 4: Plug in both fans.

Models:

Serial Numbers:

P3

0802P3P0612 to Present

P5

0801P5P0241 to Present

P7

0712P7P0105 to Present

Fasteners

Installation

Step 6: Turn fasteners 1/4 turn colckwise to secure

All

V785000 thru Present

Caution

Power must be disconnected when removing back cover. The On/Off switch controls only the secondary circuit power. The main power source must be turned off to remove all power in

the control box.

Step 1: Disconnect power supply.

Unfasten back cover by turning each

fastener 1/4 turn, counter clockwise.

back cover.

Back Cover

Rev 9//10/18

C-5

Access Procedures

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Step 1: Loosen front two bolts.

Remove rear bolts.

Removal

Step 2: Remove rear bolt.

Tilt

5

1

0

2

0

1

5 2

5

0

3

-

0

Separator Tank Removal

C-6

Removal

Step 3: Tilt tank forward and pull back cover up and off.

Models:

Serial Numbers:

Rev 9/10/18

V975825

All

Installation

Step 4: Reverse steps 1 thru 3 to install.

Wiring Diagrams

Back

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Model Page All

Electrical Box .......

Electrical System

Accessory

Liquid Evacuation Pump ........................

* Indicates multiple pages due to model / serial number break(s)

..............................D-2*

..................................D-3*

D-4

Section D

D-1

Wiring Diagrams

Back

Go To Table Of Contents

Refer To: Page

Electrical Parts/Hardware ...................... E-11

Wire

Harness From: To: Part Number

A

B

C

D

E

Power

Supply

Float Plug Electrical Box

Hour Meter

Cable

Fuse Contactor

Electrical

Box

Electrical Box

Motor

015-1896-00

029-3792-00

015-2028-00

015-2032-00

Jumper Wire

015-2027-00

BL

WH

B

BL

G

RD

H

I

L

BK

OR

Fuse

D

BL

Transformer

YL

OR

A

J

RD

BK

WH

GD

WH

Contactor

Relay

LT BL

GD

BK

RD

K

E

F

G

H

I

J

K

Fan Contactor

Low Voltage

Connection

Low Voltage

Connection

Low Voltage

Connection

Terminal

Block

Contactor Relay

D-2

Contactor

Terminal

Block

Relay

Wiring Diagrams

015-2052-00

015-2033-00

015-2024-00

015-2026-00

015-2031-00

Jumper Wire

015-2030-00

Jumper Wire

Rev 11/24/14

Models:

Serial Numbers:

BK

P3

0611P3P0000 to 0801P3P0611

V245092 to V784999

C

P5

0611P5P0000 to 0801P5P0240

V245092 to V784999

F

AA167000i

BKBK

P7

0611P7P0000 to 0712P7P0104

V245092 to V784999

Refer To: Page

Back

Go To Table Of Contents

Electrical Parts/Hardware ...................... E-11

BL

Wiring Diagrams

G

H

I

Wire

Harness From: To: Part Number

A

B

C

D

E

F

G

H

I

J

K

Power

Supply

Float Plug Electrical Box

Hour Meter

Cable

Fuse Contactor

Electrical

Box

Fan Contactor

Low Voltage

Connection

Low Voltage

Connection

Low Voltage

Connection

Terminal

Block

Contactor Relay

Electrical Box

Motor

Contactor

Terminal

Block

Relay

015-1896-00

029-3792-00

015-2028-00

015-2032-00

Jumper Wire

015-2027-00

10571800

015-2033-00

015-2024-00

015-2026-00

015-2031-00

Jumper Wire

015-2030-00

Jumper Wire

BL

RD

WH

BK

OR

BL

Transformer

YL

WH

BK

WH

Contactor

LT BL

BK

RD

K

Relay

OR

RD

Fuse

GD

RD

B

D

J

A

E

C

BK

F

AA167001i

BK

Models:

Serial Numbers:

0802P3P0612 to PresentP50801P5P0241 to Present

P3

0712P7P0105 to Present

P7

V785000 thru Present

All

Wiring Diagrams

Rev 11/24/14

D-2.1

Wiring Diagrams

Back

Go To Table Of Contents

Power Supply

On/Off

Light

WH

RD

BL

RD

Remote

Wall

Switch

RD

WH

OR

WH

BL

RD

Transformer

Fuse F1

BK

RD

GN/YL

BL

YL

Circuit

Breaker

BL

WH

YL

OR

Jumper

Terminal

Block

BL

WH

FAN

HOUR

METER

RD

Contacts

RD

WH

BK

OR

RD

BL

WH

RD

BL

RD

WH

1

WH

To J1 or J2 Plug on

Evacuation Board

Separation Tank

RD

BL

Open

WH

Coil

BK

Coil

BL

RD

2

3

2

3

RD BK

or

to Float on

CONTACTOR

"C"

Contacts

Open

BL

WH

7

6

8

Coil

5

WH

BK

4

BK

RD

BK

CR1 (Float Switch) RELAY

Contacts Open

Contacts Closed

BK

RD

BK

GN/YL

BL

RD

4

BL

2

3

1

RD

NOTE:

Manual reset button on earlier versions, automatic reset on current versions.

HOURS

BK BK

Thermal

Reset

62980400 Rev A

Wiring Diagrams

D-3

Rev 10/09

Models:

Serial Numbers:

0611P3P0000 to 0801P3P0611

P3

V245092 to V784999

0611P5P0000 to 0801P5P0240

P5

V245092 to V784999

0611P7P0000 to 0712P7P0104

P7

V245092 to V784999

Wiring Diagrams

Back

Go To Table Of Contents

Light

Remote

Wall

Switch

WH

OR

To 230 VAC

Power Supply

WH

RD

BL

RD

Transformer

Fuse F1

BK

RD

GN/YL

BL

Breaker

YL

Circuit

BL

WH

YL

OR

Jumper

Terminal

Block

BL

WH

FAN

RD

Contacts

RD

WH

BK

OR

RD

BL

WH

RD

BL

RD

WH

1

WH

To J1 or J2 Plug on

Evacuation Board

Separation Tank

RD

BL

Open

WH

Coil

BK

BL

RD

2

3

2

3

RD BK

or

to Float on

CONTACTOR

Contacts

Open

BL

7

6

Coil

8

Coil

5

WH

BK

4

"C"

BK

RD

BK

WH

CR1 (Float Switch) RELAY

Contacts Open

Contacts Closed

FAN

HOUR

METER

BK

RD

BK

GN/YL

BL

RD

4

BL

2

3

1

RD

HOURS

BK BK

Thermal

Reset

NOTE:

Manual reset button on earlier versions, automatic reset on current versions.

62980400 Rev B

Models:

Serial Numbers:

0802P3P0612 to V1648734

P3

0801P5P0241 to V1648734

P5

0712P7P0105 to V1648734

P7

V785000 thru V1648734

All

Wiring Diagrams

Rev 11/2/15

D-3.1

Wiring Diagrams

WH

Transformer

OR

Fuse F1

BK

RD

GN/YL

FAN

RD

Contacts

RD

Open

WH

BK

OR

RD

BL

WH

BL

RD

BL

RD

WH

1

YL

WH

YL

OR

Jumper

Terminal

Block

WH

BK

BL

2

RD

3

CONTACTOR

Contacts

Open

BL

Coil

7

6

Coil

8

Coil

5

WH

BK

4

"C"

BK

RD

BK

WH

CR1 (Float Switch) RELAY

Contacts Open

Contacts Closed

FAN

HOUR

METER

BK

RD

BK

GN/YL

BL

RD

4

BL

2

3

1

RD

HOURS

BK BK

Thermal

Reset

Remote

Switch

D-3.2

On/Off

Light

WH

RD

BL

Wall

WH

RD

BL

RD

Wiring Diagrams

To 230 VAC

Power Supply

WH

RD

BL

Rev 11/2/15

BL

Circuit

Breaker

Models:

Serial Numbers:

WH

1

WH

To J1 or J2 Plug on

Evacuation Board

Separation Tank

RD

2

3

RD BK

or

to Float on

4

NOTE:

BL

Manual reset button on earlier versions, automatic reset on current versions.

AA2481i

V1648735 to Present

P3

V1648735 to Present

P5

V1648735 to Present

P7

V1648735 thru Present

All

Wiring Diagrams

Back

Go To Table Of Contents

Refer To: Page

Liquid Evacuation Pump Repair Kit ....... E-14

LIQUID EVACUATION PUMP

ELECTRICAL SYSTEM

To Motor Control

(CR1 Relay)

System #1

Coil (7)

N/O (4)

N/O

Com. (6)

To Motor Control

(CR1 Relay)

(Same As

Above J1)

BK

4

RD

3

2

WH

1

Com.

Bottom

Middle

Top

System #2

BK

RD

GN

WH

4

RD

3

2

WH

1

To

Separator

Float Assy.

4

3

2

1

BK

4

RD

3

2

WH

1

BK

4

3

2

1

Common

Bottom

Float Swt.

Middle

Float Swt.

Top

Float Swt.

BK

RD

GN

WH

BK

RD

WH

BK

J1

PLUG

J5

PLUG

J2

PLUG

J3

Plug

K1

3 2 1

VACUUM PUMP #1

4

3 2 1

K2

3 2 1

VACUUM PUMP #2

K3

Earlier Versions had Three Reed Switch Floats. The Middle Float was for the Liquid Evac Pump Option. If You Have a Liquid Evac Pump Connected to the PowerVac you Must Replace Float With a Three Reed Switch Float Assembly. If There is No Evac Pump Connected to the PowerVac, You can Replace the Float With a Two Reed Switch Float Assembly.

HIGH VOLTAGE

RELAY

K4

EVAC. PUMP

WH

BK

Transformer

Energized

F3 FUSE

F2 FUSE

115 VAC

Power On

F1 FUSE

Contacts

C1

Open

115 VAC

Supply

Neutral

(Blue)

J7

EVAC. PUMP

BL

Neutral

(Wht)

Line (Blk)

J6

Line

(Black)

115 VAC

J4

115 VAC

J8 J9

BR

4

3

2

1

115

VAC

BL

2

RELAY

FLOATS

RELAY

YL

1

Contacts

Open

Contacts

Open

24 VAC

On

Contacts

Open

BL

YL

LOW

VOLTAGE

Top Float Swt.

OFF

LED

Bottom Float Swt.

OFF

LED

Evac.

Pump

Swt.

OFF

LED

BK

WH

BK

WH

GN/YL

Grd

GN/YL

POWER

ON

LIGHT

EVACUATION

115 VAC SUPPLY

LIQUID

PUMP

D-4

Wiring Diagrams

Models:

Serial Numbers:

061-0939-00 Rev. B

Accessory for All

Models

Exploded Views &

Back

Go To Table Of Contents

Parts Lists

Model Page P3, P5, P7

P6, P10, P14

Accessory (All Models)

Liquid Evacuation Pump .................... E-4

(Single Units) ....................

(Twin Units) ...................

E-2

E-3

Section E

E-1

PowerVac

Back

Go To Table Of Contents

®

P5 P7

Vacuum Base Unit ...... E-9*

Loose parts ................. E-10*

Shipping Bolt Assy ..... E-17

5

1 0 2

0

1

5

2

5

0 3

-

0

Separator Assembly ... E-5*

Loose parts ................. E-6*

Fan Assembly ............. E-13*

Fuses .............. E-15

Drain Assembly .......... E-8*

E-2

Front Panel Controls .. E-12*

* Indicates multiple pages due to model / serial number break(s)

Electrical Box .............. E-12*

AA166500i

Labels ..........................E-16*

0

5

1

0

1

5

2

0

2

5

-

3

0

AA161100i

0

5

1

0

1

5

2

0

2

5

-

3

0

PowerVac

Back

Go To Table Of Contents

P6 P10 P14

Vacuum Base Unit ...... E-9*

Loose parts ................. E-10*

Shipping Bolt Assy ..... E-17

Twin Tee Assembly ..... E-7

Separator Assembly ... E-5*

Loose parts ................. E-6*

Fuses .............. E-15

Fan Assembly ............. E-13*

Motor Mount................ E-10

Front Panel Controls .. E-12*

Labels ..........................E-16*

* Indicates multiple pages due to model / serial number break(s)

Drain Assembly .......... E-8*

Electrical Box .............. E-12*

E-3

Liquid Evacuation Pump

Back

Go To Table Of Contents

Electrical ..................... E-14*

Pump ........................... E-15*

E-4

AA167100i

Earlier Version Shown

Always Specify Model & Serial Number

Models:

Serial Numbers:

014-0501-00

Back

Go To Table Of Contents

014-0515-00

029-3859-00

15

14

16

17

2

014-0540-00

a) 029-3811-00

1

b) 77007079

014-0550-00

Refer To: Page

Drain Assembly ........................... E-8

Vacuum Relief Valve ................... B-9

014-0512-00

NLA

029-3862-00

015-2067-00

NLA

13

8

7

12

9

11

10

3

4

029-3860-00

5

053-1616-00

6

029-3839-00

Earlier Versions had Three Reed Switch Floats. The Middle Float was for the Liquid Evac Pump Option. If You Have a Liquid Evac Pump Connected to the PowerVac you Must Replace Float With a Three Reed Switch Float Assembly. If There is No Evac Pump Connected to the PowerVac, You can Replace the Float With a Two Reed Switch Float Assembly. See Next Page for Two Float Assembly PN

Note

Single models require one separator assembly. Twin models require two separator assemblies. NLA = No Longer Available

Item Description Qty.

1 Vacuum Relief Valve

(Twin Unit location is on Tee Assembly)

a) Valve with Filter ....................................... 1

b) Filter Only ............................................... 1

2 Gauge Vac 2" x 1/4" NPT ............................ 1

AA157600i

3 NLA - (

4 Wash Down Fitting ....................................... 1

5 Gasket .......................................................... 1

6 Refer to: Drain Assembly ......................... Ref

7 NLA -1/4" 20 x 1/2" Pan Head Phillips 'TT' . 6

8 NLA -Legs .................................................... 3

9 NLA - (

10 Float Assembly ............................................ 1

11 Bulkhead Assembly w/45 ............................. 1

12 Bracket ......................................................... 1

13 Pipe Nipple 1-1/2" NPT ................................ 1

14 Elbow 90, 1-1/2" NPT .................................. 1

15 Bulkhead Fitting 1-1/2" ................................. 1

16 Tee Fitting .................................................... 1

17 Cap

Always Specify Model & Serial Number

Replace with 029-5144-00

(Twin Units Only) ..................................

) .......... Ref

1

Models:

Serial Numbers:

V245092 to V975824

0611P3P0000 thru Present

P3

V245092 to V975824

0611P5P0000 thru Present

P5

V245092 to V975824

P7

0611P7P0000 thru Present

Separator

Rev. 12/11

E-5

014-0515-00

Back

Go To Table Of Contents

029-3859-00

014-0540-00

a) 029-3811-00

b) 77007079

014-0501-00

18

13

17

16

15

014-0550-00

7

10

14

053-2159-00

2

Refer To: Page

Drain Assembly ........................... E-8

Vacuum Relief Valve ................... B-9

9

030-1905-00-312

3

030-1918-00-312

4

Earlier Versions had Three Reed Switch Floats. The Middle Float was for the Liquid Evac Pump Option. If You Have a Liquid Evac Pump Connected to the PowerVac you Must Replace Float With a Three Reed Switch Float Assembly. If There is No Evac Pump Connected to the PowerVac, You can Replace the Float With a Two Reed Switch Float Assembly. See Next Previous Page for Three Float Assembly PN

050-7981-00-312

050-7984-00

12

11

13

014-0512-00

7

10

9

029-3862-00

9

002-1448-00

7

9

029-3860-00

029-5144-00

1

029-3839-00

6

040-0250-188

5

Note

AA2259

Single models require one separator assembly. Twin models require two separator assemblies.

Item Description Qty.

1 Separator Assembly

2 • Gasket ........................................................ 1

3 • Tank ........................................................... 1

4 • Legs ........................................................... 3

5 • 1/4" 20 x 1/2" 'TT' ...................................... 6

6 • Refer to: Drain Assembly ...................... Ref

7 • Float Assembly .......................................... 1

8 • Bulkhead Assembly w/45 .......................... 1

9 • Wash Down Fitting ..................................... 1

10 • Pipe Nipple 1-1/2" NPT .............................. 1

11 • Bracket ....................................................... 1

12 • Separator Lid ............................................. 1

13 • Bulkhead Fitting 1-1/2" .............................. 1

14 • Gauge Vac 2" x 1/4" NPT .......................... 1

15 • Elbow 90, 1-1/2" NPT ................................ 1

16 • Tee Fitting .................................................. 1

17 • Cap 18 • Vacuum Relief Valve

a) Valve Assembly with Filter ....................... 1

(Twin Units Only) ...............................

(Twin Unit location is on Tee Assembly)

b) Filter Only ................................................. 1

Always Specify Model & Serial Number

(includes items 2-17) .

1

E-5.1

Separator

Rev. 10/1/

Models:

Serial Numbers:

P3

V975825 to V1465490

P5

V975825 to V1465490

P7

V975825 to V1465490

014-0515-00

Back

Go To Table Of Contents

029-3859-00

014-0540-00

a) 029-3811-00

b) 77007079

014-0501-00

18

13

17

16

15

014-0550-00

7

10

14

053-2159-00

2

Refer To: Page

Drain Assembly ........................... E-8

Vacuum Relief Valve ................... B-9

9

030-1905-00-312

3

030-1918-00-312

4

Earlier Versions had Three Reed Switch Floats. The Middle Float was for the Liquid Evac Pump Option. If You Have a Liquid Evac Pump Connected to the PowerVac you Must Replace Float With a Three Reed Switch Float Assembly. If There is No Evac Pump Connected to the PowerVac, You can Replace the Float With a Two Reed Switch Float Assembly. See Next Previous Page for Three Float Assembly PN

050-7981-00-312

050-7984-00

12

11

13

7

014-0512-00

Beginning Serial Number Label on Separator Tanks

10

9

029-3862-00

9

7

002-1448-00

9

029-3860-00

029-5144-00

1

029-3839-00

6

5

040-0250-188

Note

AA2259

Single models require one separator assembly. Twin models require two separator assemblies.

Item Description Qty.

1 Separator Assembly

2 • Gasket ........................................................ 1

3 • Tank ........................................................... 1

4 • Legs ........................................................... 3

5 • 1/4" 20 x 1/2" 'TT' ...................................... 6

6 • Refer to: Drain Assembly ...................... Ref

7 • Float Assembly .......................................... 1

8 • Bulkhead Assembly w/45 .......................... 1

9 • Wash Down Fitting ..................................... 1

10 • Pipe Nipple 1-1/2" NPT .............................. 1

11 • Bracket ....................................................... 1

12 • Separator Lid ............................................. 1

13 • Bulkhead Fitting 1-1/2" .............................. 1

14 • Gauge Vac 2" x 1/4" NPT .......................... 1

15 • Elbow 90, 1-1/2" NPT ................................ 1

16 • Tee Fitting .................................................. 1

17 • Cap 18 • Vacuum Relief Valve

a) Valve Assembly with Filter ....................... 1

(Twin Units Only) ...............................

(Twin Unit location is on Tee Assembly)

b) Filter Only ................................................. 1

Always Specify Model & Serial Number

(includes items 2-17) .

1

Models:

Serial Numbers:

P3

V1465491 to present

P5

V1465491 to present

P7

V1465491 to present

Separator

Rev. 10/1/13

E-5.2

014-0535-00

Back

Go To Table Of Contents

014-0530-00

029-3773-01

6

PVC50975

2

5

014-0492-00

3

014-0494-01

4

3

029-3846-00

Item Description Qty.

(includes items 1 thru 8)

AA161300i

1 Bushing 2" MPT x 1 1/2" FPT 2 Adapter 1 1/2"

Hose Assembly

3 Swivel Connector ......................................... 2

4 Intake Hose 1 1/2" x 6' ................................. 1

5 Drain Hose 1" x 6' ........................................ 1

6 Garden Hose Adapter .................................. 1

7 Pipe Nipple

Always Specify Model & Serial Number

(PVC) ...................................

(includes items 3 & 4)

(Threaded, Plastic) ...................

(Exhaust) .....

1 1

1

Separator Loose Parts

E-6

Rev 4/1/16

Models:

Serial Numbers:

All

Up to Production Date 5/3/2006

This page is intentionally blank

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E-6.1

Midmark PowerVac P3, PowerVac P5, PowerVac P7, PowerVac P14, PowerVac P6 Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual