Midmark PowerVac G Parts Manual

FOR USE BY MIDMARK TRAINED TECHNICIANS ONLY

Model Numbers:

Service and

Parts Manual

PowerVac

®

G

G3

G5

G7

004-0790-00 Rev. AA7 (1/20/20)

Single Vac Units

G6

G10

G14

Twin Vac Units

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midmark.com

ii[Revised: 11/27/17]

Table of ContentsTable of Contents

GENERAL INFORMATION

Symbols .................................................................iii

Ordering Parts & SN location .............................iii

Specications ....................................................... iv

Model Identication & Compliance Chart .......... v

Warranty ............................................................... vi

TROUBLESHOOTING

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

Electrical System Operation ........................... A-3

Troubleshooting Chart ..................................... A-4

VFD Error Codes ......................................... A-6

TESTING & ADJUSTMENTS

Door Limit Switch & On/O Switch ................ B-2

Float ................................................................... B-5

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

Motor & Pump ................................................. B-10

Master Control Panel ..................................... B-15

VFD (Variable Frequency Drive) .................. B-18

Line Filter ......................................................... B-20

Fuse & Transformer ....................................... B-22

PC Board ......................................................... B-25

Contactor ......................................................... B-28

Pressure Sensor ............................................. B-30

Fan ................................................................... B-32

Gauge .............................................................. B-34

Separator Tank ............................................... B-35

Vacuum Adjustment ................................... B-36

VRV ........................................................... B-37

General InfoSection A

Section E

Section B

Section CSection D

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

ACCESS PROCEDURES

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

Top Plate ............................................................ C-3

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

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

VFD Covers ......................................................... C-6

WIRING DIAGRAMS

PowerVac G (Electrical Box) ......................... D-2

VFD (Variable Frequency Drive) .................... D-5

Motor Connections ...................................... D-6

PC Board ........................................................... D-7

EXPLODED VIEWS

Single Models ................................................... E-2

Twin Models ...................................................... E-3

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iii[Revised: 1/20/20]

General InformationGeneral Information

WARNING

Indicates a potentially hazardous situation which

could result in serious injury if not avoided.

Equipment Alert

Indicates a potentially hazardous situation which

could result in equipment damage if not avoided.

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

Symbols

The symbols below may be used in this manual to represent

the operational status of table functions and components.

Indicates the function / component is working properly.

No action required.

Indicates the function / component is working,

but a problem exists.

Indicates the function is not working at all, or that the

component is faulty.

Ordering Parts

The following information is required when ordering parts:

 • Serialnumber&modelnumber

 • Partnumberfordesiredpart

(Refer to Section E: Exploded Views & Parts Lists)

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 to 5:00 p.m. EST (Monday thru Friday)

Phone:1-800-Midmark(1-800-643-6275)

Serial Number Location

Note

Used for special instructions or additional information.

Tank Serial

Number Label

Base Serial

Number Label

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iv[Revised: mo/dd/yr]

Model Max

Users

Base Unit

HxWxD

Separator

HxWxD

Actual Weight

(LBS.)

Total

HP

Voltage Amps Hertz Recommended

Breaker Size

(Amps)

Inlet

Connection

Size (IN.)

Fuses Drain

Connection

Size (IN.)

G3 3-5 25 x 22 x 20

Each

34 x 22 x 22

Each

Base Unit - 375

Separator - 49

3 230 20 60 30 1 1/2” 1/8 A, 250V

Type T

1 1/2”

G5 5-7 25 x 22 x 20

Each

34 x 22 x 22

Each

Base Unit - 375

Separator - 49

3 230 20 60 30 1 1/2” 1/8 A, 250V

Type T

1 1/2”

G7 7-10 25 x 22 x 20

Each

34 x 22 x 22

Each

Base Unit - 375

Separator - 49

3 230 20 60 30 1 1/2” 1/8 A, 250V

Type T

1 1/2”

G6 6 25 x 22 x 20

Each

34 x 22 x 22

Each

Base Unit - 375

Separator - 49

6 230 40 60 2 x 30 2” 1/8 A, 250V

Type T

1 1/2”

G10 10 25 x 22 x 20

Each

34 x 22 x 22

Each

Base Unit - 375

Separator - 49

6 230 40 60 2 x 30 2” 1/8 A, 250V

Type T

1 1/2”

G14 14 25 x 22 x 20

Each

34 x 22 x 22

Each

Base Unit - 375

Separator - 49

6 230 40 60 2 x 30 2” 1/8 A, 250V

Type T

1 1/2”

PowerVac

®

G Speci cations

Classi cations: Class 1, Type B Applied Part

Specications

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v[Revised: mo/dd/yr]

Model Identication / Compliance Chart - PowerVac

®

G

Model Description

Complies To: Electrical Ratings:

UL

60601-1

CAN / CSA

22.2,

#601.1-M90

EN

60601-1-2

(EMC)

VAC

+/- 10%

Amps Cycles (Hz)

G3 PowerVac

®

G Dry Vacuum System - Single - 3 to 5 User

• • •

230 20 60

G5 PowerVac

®

G Dry Vacuum System - Single - 5 to 7 User

• • •

230 20 60

G7 PowerVac

®

G Dry Vacuum System - Single - 7 to 10 User

• • •

230 20 60

G6 PowerVac

®

G Dry Vacuum System - Twin - 6 to 10 User

• • •

230 40 60

G10 PowerVac

®

G Dry Vacuum System - Twin - 10 to 14 User

• • •

230 40 60

G14 PowerVac

®

G Dry Vacuum System - Twin - 14 to 20 User

• • •

230 40 60

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vi[Revised: mo/dd/yr]

Warranty

MidmarkCorporation(“Midmark”)warrantstotheoriginalpurchaseritsnewPowerVac

®

G products and components (except for components not warranted under “Exclusions”) manufac-

tured 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(5)yearsor10,000usagehours(whichevercomesrst)forallwarrantedproductsand

components.Ten(10)yearsor20,000usagehours(whichevercomesrst)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

®

G Care Guide for this applicable product; (3)

products considered to be of a consumable nature; (4) accessories or parts not 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 conse-

quentialdamagesordelay,including,butnotlimitedto,damagesforlossofprotsorlossofuse.

No Authorization

Nopersonorrm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 NOT IMPLIED WARRANTIES OF ANY KIND

INCLUDING ANY WARRANTIES OF MECHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. THIS WARRANTY IS LIMITED TO THE REPAIR OR REPLACEMENT OF DEFECTIVE

PARTS.

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A-1[Revised: mo/dd/yr]

Section ASection A

Operation &

Troubleshooting

Vacuum System Operation .................A2

Electrical System Operation ..............A3

Troubleshooting ..................................A4

VFD Covers .......................................C-6

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A-2 Always verify model & serial number

Models:

Serial Numbers:

[Revised: 9/20/11]

All

all

Vacuum System Operation

Air, water, and solids from the operatory are

pulled into the separator. Air is expelled out

through the pump exhaust while water and

solids fall to the bottom of the tank. The

vacuum in the separator keeps the check

valve to the drain closed and the tank

graduallylls.

Therisinguidleveleventuallyclosesthetop

oatswitch,whichturnsthepumpo.Since

vacuum is no longer being maintained, the

check valve opens allowing water and solids

to drain from the separator. The upper and

lowerreedswitchoatsinteractasalatching

circuit with the internal relay to release upon

drainbelowthebottomoat.

Note:Ifthepowerisshuto,theunitwilldrain

automatically due to a loss of vacuum

regardless of the water level in the tank.

When the tank drains enough to open the

bottomoatswitch,thepumpstartsrunning

again. This restores vacuum and closes the

checkvalve.Note:ifthepoweristurnedo,

tank will drain completely.

When no instruments (suction tips) are being

used(HVEsshutofor5secondsormore)

the system goes into sleep mode to save

energy. Sleep mode pressure is set to 6”Hg.

Vacuum pressure will ramp down from its

normal operating pressure to sleep mode

pressure when the unit goes to sleep. The

sleep mode pressure is maintained at 6”Hg

until the variable frequency drive (VFD)

senses an increase in vacuum pressure is

required when an instrument (suction tip) has

been opened. The VFD will then speed up

the motor to increase vacuum pressure to the

normal operating pressure.

AA2267

Pump Operating

(Sleep Mode)

Check Valve

(Closed)

Check Valve

(Closed)

Check Valve

(Open)

From

Operatory

Pump Operating

Exhaust

Drain

Pump

Stopped

Water and Solids

Air (Atmospheric

Pressure)

Vacuum

Note

Earlier production units

had three reed switch

floats. The middle float

was not used and is

not installed in current

production units.

Electrical Operation...............A3

Troubleshooting.....................A4

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A-3[Revised: 11/2/15]

Electrical System Operation

When Main input power supply (230V) is on, it is

supplying line voltage to the vacuum pump electrical

system.

The Main input power supply (230V) is supplied to

the contactor, thermostat, fans, transformer, variable

frequencydrive(VFD),andthelinelter.Whenthe

On/Oswitchormastercontrolswitchareintheiro

state or the front panel is removed from the unit, the

contactor will remain open and the input power will be

connected to the input side of the contactor, thermo-

stat, fans, and the transformer only.

When the contactor is energized, it closes and con-

nectsthemaininputpowersupplytothelinelter.

Main input power supply is then applied to the VFD

through RL1 and SR2 (single phase).

Thetransformer’soutputsends24voltsACtothePC

board. 24 volts AC power is used to control the door

limitswitch,hourmeter,andoats.Theelectronicson

thePCboardconvert24VACto24VDCforthepres-

sure sensor though the means of a connector.

When instruments (suction tips) are in use, the vacu-

um pump is running and claws are turning to build up

vacuum pressure. The pressure sensor is constantly

measuring the amount of vacuum pressure. When

the pressure level drops below the vacuum set point

(12”Hg – factory setting), the pressure measure-

ment initiates the VFD to speed up the motor. When

pressure is above set point the VFD slows the motor

down.

Whenthevacuumisshutofromtheremoteswitch

the timer starts and will turn on the vacuum for one

minute every two hours. (Standard on new units,

older units can be upgraded)

Vacuum Operation.................A2

Troubleshooting.....................A4

Note

On twin units a parallel cable (4-pin Master / 6-pin Slave) connects the two base units on the side of the electrical box. The plumbing is connected using a tee assembly.

The parallel connection is controlled between variable frequency drives in a twin configuration. Twin units run the same as a single unit. Keypad, hour meter and fans are

located on the outside of the base unit. Pressure sensor and float are located on the separator tank.

AA2486i

VFD

Box

Parallel

Connection

Fans

Themostat

230 VAC

Line Voltage

Line Filter

Contactor

Pressure

Sensor

Transformer

YL

3

2

1

ON

CTS

Note

Timer Bd. Std. after SN: V1648735 units prior to this can be updated

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A-4

Troubleshooting Chart

Problem Display/Symptom Cause Check Action

Motor not running

Or Breaker keeps

tripping.

NOTE:

When working on

twin unit unplug

parallel harness

NA

No power. Checkon/oswitchonfrontofthebase. Verifyon/oswitchisintheonpostion.

Check disconnect box/ circuit breaker (Main). Verify disconnect box/circuit breaker (Main) is in the on

postion.

Low Voltage Harness

disconnected/loose.

Checkdoorlimitswitch,on/oswitchand

master control panel harness.

Secure/Replace harness connections.

Faulty Switch

Check LED light “D4”, if “ON” only check “Low Volt-

age”. If LED light is not on, preform checks on Door

Limitswitch,On/Oswitch,andmastercontrolpanel.

Refer to: Section B “PCBoard” to check LED light,

“Door Limit Switch”, “On/OSwitch”and “Master

ControlPanel”.

Replace Switch

Separator tank not drain-

ing.

"PossibleClogintank.Removelidtoseeiftankis

full.

Remove clog.

Check valve is stuck closed. Refer to section B check

valve.

Repair/ Replace check valve

Turnpoweroandunplugoatharnessfrombase

unit. Turn unit back on, if the unit runs check Section

B: Float

Replace Float Assembly

Wire harness between

VFDandPCboardloose

or broken.

Check for loose or broken wire harness between

VFDandPCboard.

EnsuregreycableispluggedintoVFDandPC

board.

Secure/Replace harness connections.

Pumpislockedup.

Feel for pump pulley drag or sticking. Refer to sec-

tion B pump.

Contact Midmark Technical Service.

1-800-643-6275

PCboard

Malfunctioning.

Turnmainpowersupplyon.(Keepunitturnedo.)

UnplugwireharnessfromJ6onPCboard.

Testresistance.SetmetertoΏ.MeterReading>1

ΏRefertoSectionBPCBoard

ReplaceMainPCBoard

Check Daughter Card. Refer to Section B Daughter

Card

ReplaceMainPCBoard

Contactor not working

properly.

Check Contactor. Refer to: Section B Contactor Replace Contactor.

[Revised: 2/25/19]

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A-5

Troubleshooting Chart

Problem Display/Symptom Cause Check Action

Motor not running

Or Breaker keeps

tripping.

-Continued-

NOTE:

When working on

twin unit unplug

parallel harness

VFD not working properly. Check if there is an error code displayed. Refer to:

Section A VFD Error Code Chart

Follow required actions in testing.

LightsnotworkingonPCboardcheckFuse.

Refer to: Section B Fuse and Transformer.

Replace Fuse

Lights not working on VFD, check Line Filter. Refer

to: Section B Line Filter

Secure/Replace harness connections.

Lights not working on VFD, check Contactor. Refer

to: Section B Contactor

Replace Contactor

LightsnotworkingonPCboardchecktransformer

Refer to: Section B Fuse and Transformer.

Replace Transformer

Lights not working on VFD. Check Ohms at J6

terminal. Greater than 5 ohm. Refer to Section

BPCBoard(main power on, unit power on, J 6

Unplugged)

ReplacePCBoard

Lights not working on VFD. Disconnect drive harness

at J6 Location to check for 24V DC. If Voltage is not

present Ohm out drive harness. Refer to section B

VFD Variable Frequency Test.

Replace Drive Harness

Lights not working on VFD. Check for line Voltage

(208-230V) at incoming terminal strip on VFD. If

Line voltage is present. Refer to section D Variable

Frequency Drive

Replace VFD

Motor bad.

Preformallmotorchecks.Referto:Section B Motor

&Pump

Replace Motor

Operatory has low

or no suction.

NA

Motor not running. See“Problem”,motornotrunningor

breaker keeps tripping

See “Action” , motor not running or

breaker keeps tripping.

Leaking or loose

connection.

Checkhosesandbulkheadttings. Secure/Replace hoses or bulkhead connections.

Check Separator lid gasket. Replace Separator Lid Gasket

Check drain line check valve. Refer to: Section B

Check Valve

Replace Check Valve.

Pumppulleynotspinning

freely.

Moisture in the pump. Ptrapnotinstalledproperly. Drain,releasepump,installmissing“P”trapper

instructions.

Ptrapdrainsystemclogged. Drain,releasepump,removeclogfrom“P”trapdrain.

Incorrect line cleaners. Customer should be using non sudsing line cleaners. Release pump, refer customer to user’s manual.

Incorrect line cleaning

process.

How customer is cleaning lines. Release pump, refer customer to user’s manual.

Suds from ultrasonic cleaner

getting into pump.

Suctionlineclosetoultrasonic,Inquirewithsta. Release pump, advise customer not to use product to

drain ultrasonic cleaner.

[Revised: 2/25/19]

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A-6

Troubleshooting Chart

Problem Display/Symptom Cause Check Action

Operatory has low

or no suction.

-Continued-

Pumppulleynotspinning

freely.

-Continued-

Timer Kit not installed properly. Installation of kit. Release pump, correct or install timer kit.

Timer kit faulty Check dip switch location on timer board dip switches

are to be in down position or timer is malfunctioning

Release pump, repair replace timer kit.

No power to timer kit. Ifpowerisbeingturnedotovacuumsystem.Vacuum

system must be powered for timer to function correctly.

Release pump, continual power needed for timer

kit.

NA

Exhaust Hose Clogged Remove exhaust hose to see if suction increases. if

suction increased check for clog.

Unclog or replace

exhaust line

Pressuresensornot

working properly.

Check pressure sensor. Referto:SectionBPressure

Sensor

Replace pressure sensor.

Motor cutting out

or running at a

reduced speed.

N/A

Ambient temperature too high. Check Equipment Room Temperature should be 40° to

104 ° degrees Fahrenheit or

4 - 37 Celsius.

Refer to installation manual site requirements

Contactor not working properly.

Check Contactor. Refer to: Section B Contactor Replace Contactor

Pumpislockedup.

Referto:SectionBPump Contact Midmark Technical Service. 1-800-643-

6275

Exhaust Hose Clogged Remove exhaust hose to see if suction increases. if

suction increased check for clog.

Unclog or replace exhaust line

Motor not running. See“Problem”,motornotrunningor

breaker keeps tripping.

See “Action” , motor not running or

breaker keeps tripping.

Motor running at

top speed all the

time.

NA

Pressuresensornot

working properly.

Check pressure sensor. Referto:SectionBPressure

Sensor

ReplacePressuresensor

Plumbinglinesleaking. Checkoceplumbingsystemforleaks. Repair/ReplacePlumbingLines

VRV Malfunctioning Check VRV. Refer to: Section B VRV Adjust/Replace VRV

Oil Leak

Leaking Oil

OilReservoirisoverlled. Check site glass.RefertosectionBPump Drain Oil

Pumpisoverheating Check ambient temperature in the room. Temperature

should be 40° to 104° F or 4° to 40° C

Contactacertiedspecialisttoadjusttempera-

ture.

Check Clearance around unit. Allow 12inch on the front

and right side and allow 6 inches on the left side and

back

Adjustbaseunittoclearancespecications.

Check if fans are working. Refer to section B Fans Replace fans

Minor Oil leak Minimal oil leakage may occur with no harm to the vacu-

um.Refertotheoilsiteglasslllevelrequirements.

Monitoroillevelsandllasneeded.

Replace absorbent pad if required.

[Revised: 2/25/19]

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A-7

VFD (Variable Frequency Drive)

Error Codes

Problem Display/Symptom Cause Check Action

VFD Error Code

oL1 Motor Overload Pumpislockedup. Referto:SectionBPump Contact Midmark Technical Service.

1-800-643-6275

oL2 Drive Overload Pumpislockedup.

Referto:SectionBPump Contact Midmark Technical Service.

1-800-643-6275

oL3 Over torque

Detection 1

Pumpislockedup.

Referto:SectionBPump Contact Midmark Technical Service.

1-800-643-6275

oL4 Over torque

Detection 2

Pumpislockedup.

Referto:SectionBPump Contact Midmark Technical Service.

1-800-643-6275

FbHExcessivePressure

(Feedback Sensor)

Pressuresensorfailure.

Referto:SectionBPressureSensor Replace pressure sensor.

FbL Feedback Loss

(Feedback Sensor)

PlumbingSystemisnot

Complete

Check unit/units are hooked up in the operatory

j-box.

Secure Connections at J-Box

Check HVE, saliva ejector tips are closed Close Tips

Check clean outs are closed Close Clean Outs

Checkhosesandbulkheadttings. Secure/Replace hoses or bulkhead

connections.

Check Separator lid gasket. Replace Separator Lid Gasket

Check drain line check valve. Refer to: Section B

Check Valve

Replace Check Valve.

Harness not properly con-

nected to base unit or

pressure sensor on tank.

Referto:SectionBPressureSensor Replace pressure sensor.

There is a broken wire in

one of the harnesses.

CheckPCBoardPressureSensorHarnessat

J13.

Repair/ReplacePCboardpressureharness.

The 24V power supply on

thecontrolPCBdaughter

card has failed.

Check Daughter Card. Refer to Section B

Daughter Card

ReplaceMainPCBoard

Pressuresensorfailure.

Referto:SectionBPressureSensor Replace pressure sensor.

GF (Ground Fault) One of the wires in the

motor harness is creating a

short circuit.

Refer to Section D: Motor Connections Replace motor harness

The motor insulation is

damaged.

Refer to Section D: Motor Connections Replace Motor

[Revised: 11/2/16]

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A-8

VFD (Variable Frequency Drive)

Error Codes

Problem Display/Symptom Cause Check Action

VFD Error Code

-Continued-

LF OutputPhaseLoss VFD has loose connec-

tions.

Checkred(V/T2),blue(W/T3)&black(U/T1)wire

connections on the VFD and the motor. Refer to

Section D VFD

Secure/Replace motor harness

Damaged Motor

Refer to Section D: Motor Connections Replace Motor

Bad drive transistor Contact Midmark Technical Service Replace VFD

LF2 Output Current

Imbalance

VFD has loose

connections.

Checkred(V/T2),blue(W/T3)&black(U/T1)wire

connections on the VFD and the motor. Refer to

Section D VFD

Secure/Replace motor harness

Damaged Motor

Refer to Section D: Motor Connections Replace Motor

Bad drive transistor Contact Midmark Technical Service.

1-800-643-6275

Replace VFD

oC Overcurrent One of the wires in the

motor harness is creating a

short circuit.

Refer to Section D: Motor Connections Replace motor harness

The motor overheated

repeatedly causing

insulation to be damaged

Refer to Section D: Motor Connections Replace motor

Pumplockedup

RefertoSectionB:Pump Contact Midmark Technical Service.

1-800-643-6275

Uu1 or Uu Undervoltage The power has been

momentarily interrupted.

Checkifunitwaspoweredo. Turn unit back on.

Incoming voltage is low. Check incoming voltage. (208-230) Contactacertiedelectrician.

Faulty Switch

CheckOn/Oswitch.Referto:SectionBOn/O

Switch

ReplaceON/Oswitch.

Check Door Limit switch. Refer to: Section B

Door Limit Switch

Replace Door Limit Switch

Check Master control panel. Refer to: Section B:

MasterControlPanel

ReplaceMasterControlPanel

Output connections from

the contactor are loose.

Check wire connections on contactor. Secure Connections.

Input power connections to

the VFD are loose

Check wire connections on VFD Secure Connections.

The internal VFD circuitry

has worn out.

Refer to section B VFD Variable Frequency Test. Replace VFD

[Revised: 11/2/16]

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A-9

VFD (Variable Frequency Drive)

Error Codes

Problem Display/Symptom Cause Check Action

VFD Error Code

-Continued-

ou Overvoltage Incoming voltage high Check incoming voltage. Contactacertiedelectrician.

Powersurge.

Check incoming voltage. Refer to Section B

Contactor

Cycle power to unit.

Ground fault in the VFD

circuit causing the

capacitors to overcharge.

Performcontinuitycheckon

motor harness for shorts. Refer to section D: Mo-

tor Connections

Replace Motor Harness

Performcontinuitycheck

on the motor windings for shorts. Refer to section

D: Motor Connections

Replace Motor

oH or oH1 Heatsink

Overheat

Ambient temperature is too

high.

Check room temperature. Refer to Installation

Manual-Specications

Allow room to cool or add ventilation fan to

room.

Pumplockedup

RefertosectionBPump Contact Midmark Technical Service.

1-800-643-6275

VFD Cooling Fan has

malfunction.

Check VFD Fan. Replace VFD.

SC Communication Error Front display board not

communicating.

Remove Ethernet cable from back of front display.

Re power. If no error code on main drive

controller.

Replace front display board.

Main drive controller not

communicating

Remove Ethernet cable from back of front display.

Re power. If error code remains on main drive

controller.

Replace VFD

[Revised: 11/2/16]

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B-1[Revised: mo/dd/yr]

Section BSection B

Testing &

Adjustments

Door Limit Switch & On/O Switch ...................... B-2

Float .................................................................... B-5

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

Motor & Pump .....................................................B10

Master Control Panel ........................................ B-15

Low Voltage ....................................................... B-17

VFD (Variable Frequency Drive) ....................... B-19

Line Filter .......................................................... B-20

Fuse & Transformer ........................................... B-22

PC Board ........................................................... B-25

Contactor ........................................................... B-28

Pressure Sensor ............................................... B-30

Fan .................................................................... B-32

Gauge ............................................................... B-34

Separator Tank .................................................. B-35

Vacuum Adjustment .......................................... B-36

VRV .................................................................. B-37

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B-2 Always verify model & serial number

Models:

Serial Numbers:

[Revised: mo/dd/yr]

Door Limit Switch & On/O Switch

(Circuit Breaker)

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owsthrutheswitchtothe

PowerVacGcircuitbreaker(On/O)switch.Withthecircuitbreaker

switch ON, current is supplied to the remote wall switch (if appli-

cable).

When the front access cover is removed...

ThedoorlimitswitchopensandstopscurrentowtothePowerVac

circuit breaker. This is a safety feature that prevents the system from

operating with the cover removed.

All

all

Door Limit Switch

Note

If the facility does not have a remote wall switch, the PowerVac

G circuit breaker serves as the On/Off switch for the system.

On/O Switch

(Circuit Breaker )

Door Limit Switch Test .......................B-3

On/O Switch Test ............................. B-4

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B-3 Always verify model & serial number

Models:

Serial Numbers:

[Revised: 2/17/11]

All

all

With switch “untripped”...

Meter Reading Required Action

OL Limit switch - OK

less than 5 ohms Replace limit switch

With switch “tripped”...

Meter Reading Required Action

OL Replace limit switch

less than 5 ohms Limit switch - OK

Door Limit Switch

Test

Door Limit Switch Function ................ B-2

On./O Switch Testing .......................B-4

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

Caution

When testing components with power on

use care to prevent electrical shock.

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.

Caution

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 damaged, switch it with plastic

bumper on opposite side of door until a

replacement can be ordered. If motor doesn’t

start, continue to step 4.

Step 4: Turn power off.

Step 5: Remove mounting screw for door limit switch.

Disconnect electrical leads.

Step 6: Testcontinuity.SetmetertoΏ.

 PlacemeterprobesonCOMandNOterminals.

Note: Check switch “tripped” and “untripped”.

Step 7: Install front cover.

COM

NC

NO

AA2290

Activation Button

Mounting Screw

Step 1: Turn power off at on/off switch and

main power supply box.

Remove electrical cover.

Turn power on at on/off switch and

main power supply box.

Check to see if D4 LED light is on.

If light is on, door limit switch is ok.

If light is off, continue with step 2.

Note: Refer to Section C Electrical Cover

Step 2: Turn power off.

Remove front cover.

Note: Refer to Section C: Front Cover.

Note

When working on Twin units,

unplug parallel harness.

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B-4 Always verify model & serial number

Models:

Serial Numbers:

[Revised: 2/17/11]

AA165501i

On/O Switch (Circuit Breaker)

Test

All

all

Step 2: Remove front cover.

Note: Refer to Section C: Front Cover.

Step 3: Testcontinuity.SetmetertoΏ.

Disconnect leads from switch terminals.

 PlacemeterprobesonCOMandNOterminals.

Note: Check switch “tripped” and “untripped”.

Caution

When testing components with power on

use care to prevent electrical shock.

Door Limit Switch Function ................ B-2

Door Limit Switch Testing ..................B-3

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

Step 4: Connect switch leads and install front cover.

With switch “untripped”...

Meter Reading Required Action

OL Switch - OK

less than 5 ohms Replace Switch

With switch “tripped”...

Meter Reading Required Action

OL Replace Switch

less than 5 ohms Switch - OK

Step 1: Turn power off at on/off switch and

main power supply box.

Remove electrical cover.

Turn power on.

Check to see if D4 LED light is on.

If light is on, on/off switch is ok.

If light is off, continue with step 2.

Note: Refer to Section C Electrical Cover

Note

When working on Twin units,

unplug parallel harness.

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B-5 Always verify model & serial number

Models:

Serial Numbers:

[Revised: 11/2/16]

All

all

Float Assembly

Location & Function

Onearlierproductionunitstheoatassembly

containedthreeoat(reed)switchesmountedon

abracketatdierentintervals.Currentunitsonly

havetwooatswitches.

The reed switch has contacts that remain open

until the liquid in the separator rises, causing the

oattoriseuntilthemagnetcontactsthereed

switch.

When the magnet contacts the reed switch, the

open contacts inside the reed closes.

Whenthetopoatswitchcloses,thevacuum

pumpstoprunninguntilthebottomoatopens

and the cycle starts again.

Theupperandloweroatsinteractasalatching

circuit with the internal relay to release upon drain

belowthebottomoat.Themagnetintheoatis

to activate the reed switch within the stem.

Check Float .......................................B-6

Reed Switch

Contacts are

Open Until

Magnet Closes

Float

Magnet

Float

Note

Earlier production units

had three reed switch

floats. The middle float

was not used and is

not installed in current

production units.

Check

Result

Required

Action

Float connection

removed from

base

Pump starts

running

Troubleshoot

oats

Pump still

not running

Troubleshoot

Pump

To check if float switches are preventing pump from running...

A) Turn power off at on/off switch.

B) Remove float wire connection from rear of base by un-threading connector and removing.

C) Turn power back on at on/off switch.

D) If pump runs the tank is either full (not draining) or there is a issue with the floats proceed

to next page.

E) If the pump doesn’t run proceed with troubleshooting the pump base.

Equipment Alert

Running pump with float wire connection removed from base other than to briefly troubleshoot

can cause damage to the pump.

Float Wire

Connection

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Midmark PowerVac G Parts Manual

Midmark PowerVac G Parts Manual

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