Rock Compressors. Service and Parts Manual. Twin R22 Triple R42 FOR USE BY MIDMARK TRAINED TECHNICIANS ONLY. Model Numbers: R42 Shown

Transcription

1 Rock Compressors Model Numbers: Twin R22 Triple R42 Service and Parts Manual R42 Shown FOR USE BY MIDMARK TRAINED TECHNICIANS ONLY SF-1862 Part No Rev. C ( /2013)

2 Table Of Contents General Information Section A GENERAL INFORMATION Symbols... iii Ordering Parts... iii Model / Serial Number Location... iii Weights, Dimensions, Electrical Specifications... iv Warranty Information... v OPERATION & TROUBLESHOOTING Compression Cycle...A-2 Purge Cycle... A-4 Section B Section C Section E Section Section E D FOR USE BY MIDMARK TRAINED TECHNICIANS ONLY * Indicates multiple pages due to a serial number break for the parts illustration COMPONENT TESTING & REPLACEMENT Pressure Switch... B-2 On/Off Switch... B-7 Capacitor... B-10 Compressor Heads... B-13 Low Voltage - MCP... B-17 Intake Filter... B-19 Checking for Leaks... B-21 Coalescing Filter... B-22 Solenoid... B-24 Desiccant Tank... B-27 Fuse Replacement... B-29 Fan Replacement... B-31 Check Valve... B-36 ACCESS PROCEDURES Quiet Cover... C-2 WIRING DIAGRAMS R22... D-2 R42... D-3 (Motor & Pressure Switch) R42... D-4 (On & Off Switch) EXPLODED VIEWS / PARTS LISTS R22... E-2 R42... E-3

3 General Information Symbols Caution Indicates a potentially hazardous situation which could result in injury if not avoided. Equipment Alert Indicates a potentially hazardous situation which could result in equipment damage if not avoided. Note Amplifies a procedure, practice, or condition. Indicates that the component the check mark appears beside should be tested before replacing it. In Section A, test the components in the order indicated. (ex. 1st then, 2nd ) Refer to Section B for component testing procedures. These symbols are used throughout 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 / component is not working at all. Ordering Parts General Information The following information is required when ordering parts: Serial number & model number Part number for desired part. [Refer to Exploded Views / Parts Lists section] 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 Serial / Model Number iii

4 General Information Weights, Dimensions, Electrical Specifications Built-In Low Voltage Contactor Condensate Drain Canister (Provided) Fresh Air Intake Kit (Provided) 5 High Pressure Flexible Air Hose Terminated in 3/8 MNPT (Provided) Leveling Feet AA143400i 32 in. (81.3 cm) 32 in. (81.3 cm) Model Users No. Breaker 80PSI db-a Volts HP Total Amps Tank Size Width Depth Height Weight Heads (Gal.) (In.) (In.) (In.) (lbs.) R R iv

5 General Information Warranty All Apollo products are thoroughly inspected and tested in accordance with rigid specifications and standards. Our products are guaranteed against any defective material and workmanship from the date of shipment; provided, that the installation, operation, and maintenance is done in accordance with Apollo procedures as outlined in our Installation and Maintenance Guides. No other warranties or guarantees, expressed or implied are made. Midmark s obligation under the warranty is to provide parts to the dealer for repairs or, at its option, to provide the replacement product (excluding labor and shipping charges). All special, incidental and/or consequential damages are excluded. We will not issue credit for product without first attempting to correct the problem in the field. Written notice of breach of warranty must be given to Midmark within the warranty period. The warranty does not cover damage resulting from improper installation or maintenance, accident or misuse. The warranty does not cover damage resulting from the use of cleaning, disinfecting or sterilizing chemicals and processes. The warranty does not cover vacuum failures due to hard water deposits. Failure to follow instructions provided in Midmark s Installation and Maintenance Guides will void the warranty. * All warranty repairs must be repaired by authorized dealers and/or service dealers only - no exceptions. * Labor charges are NOT included. * Warranty period starts from the installation date. * Shipping damage or damage caused by equipment handlers and installers is not covered. Warranty Periods from Date of Install RevolutionTM Scroll Oil-Less Air Compressor 3 Years UltraVac Vacuum 3 Years Classic BronzeTM Vacuum 2 Years Gold Series Vacuum 2 Years Dry Vacuum (DryVacTM) 2 Years The Rock Oil-less Air Compressors 2 Years Oil-less Air Compressors 2 Years Lubricated Air Compressors 2 Years Replacement Parts and Accessories 90 Days** ** Replacement parts and repairs are covered under the remaining warranty of the unit they are replacing, or 90 days from the date of shipment, which ever is the longest. Customer Service/Technical Support Department hours are from 8:00 AM through 5:00 PM EST. Midmark Customer Service/Technical Support is available for order entry and technical support by phone MIDMARK or (937) or FAX (877) , Monday through Friday. We are closed on major holidays. Additional product documentation and specifications are available at your request or at our website at v

6 General Information vi

7 Section A Operation & Troubleshooting Operation & Troubleshooting Function / System Compression Cycle... A-2 Purge Cycle... A-4 A-1

8 Operation & Troubleshooting Intake Air PreCooler EQUIPMENT ALERT Room temperature should be between 40 and 100 F (4 C to 38 C). Lack of proper ventilation is the main reason for compressors failures. Whenever possible, use exhaust fan to bring cool air from dental office to the equipment room, or run fresh air intake lines to the outside so the compressor can breathe in fresh, outside air. Exhaust the stale, hot air out through the roof or side wall. Intake Filter Compressor (Running) White Red Purge Tank (Pressurizing) Atmospheric Air Pressurized Air Troubleshooting Compressor will not Start... A-6 Motor runs Intermittently or "Chugs"... A-7 Compressor Heads run but will not Pressurize to 100 PSI... A-8 Cycles with no Air in use... A-9 Moisture Indicator is Pink... A-10 Element Indicator is Red... A-11 High Pressure... A-12 Excessive Noise... A-13 Overheating... A-14 Compressor runs to Frequently... A-15 Coalescing Filter Dessicant Tank Check Valve (Open) Storage Air Moisture Indicator Pressure Relief Valve (Closed) (Opens at 125 PSI) Compression Cycle Atmospheric air is drawn in through intake filters to the compressor head(s) where air is compressed and exhausted. Bottom Port (Closed) Normally Open Solenoid Valve (Closed) Pressure Switch (Contacts Closed) Compressor Head Unloader Valve (Closed) Manual Needle Purge Valve (Closed) Ball Valve (Open) 100 PSI Supply Air to Operatory Air travels through the pre-cooler where it is cooled 10 to 15 F (-12.2 to -9.4 Celsius) within ambient room temperature. Cool air enters the coalescent filter, which removes % of all particulate matter. As the clean air travels through the desiccant tank it is dried to -25 F (-31.7 Celsius) dew point. Condensate Drain Can Assembly Storage Tank (Pressurizing) The clean dry air flows into the main storage tank through a check valve. Some air is directed to the purge tank. As both tanks fill, the pressure switch opens at preset pressure and stops the compressor. AA150401i A-2 Compression Cycle Rev 7/23/08 All

9 Operation & Troubleshooting Compression Cycle Electrical Schematic Supply Line Voltage is always present on one side of the Contactor contacts. Line Voltage is also being supplied to the 240 / 24 VAC transformer energizing it. The Transformer supplies 24 VAC thru the fuse to the On/Off switch on the wall and to one side of the 24 VAC Contactor Coil. When the On/Off switch is turned to the on position the Contactor Coil is energized closing the contacts. With the contacts closed, line voltage is supplied to the Fan Motor energizing it. At the same time, line voltage is supplied to one side on the Vac Unit On/Off switch. Line VAC 24 VAC Transformer ENERGIZED 24 VAC Fuse On Unit Wall On / Off Switch ON Fan Motor RUNNING LINE VAC Solenoid Valve (Normally Open when not energized) ENERGIZED (CLOSED) When the Vac Unit On/Off switch is turned on, line voltage is supplied to one side of the Pressure Switch. If the Pressure Switch is at 80 PSI (+ / - 5 PSI) or below it's contacts are closed. Line voltage is then supplied to the Compressor energizing it. Supply Line Voltage 24 VAC Contactor w/ 24 VAC Coil CLOSED LINE VAC Unit On / Off Switch ON LINE VAC Pressure Switch LINE VAC CLOSED (Below Pressure Setting) LINE VAC Compressor RUNNING AA150700i It is also supplied to the normally open Solenoid Valve, closing the valve, preventing the compressed air from being discharged to the Condensate Drain Can Assembly. The system will continue to run until the pressure inside the system reaches 100 PSI ( + / - 5 PSI) Note: The compression and purge cycles will continue as the pressure inside the system fluctuates below the 80 PSI and up the 100 PSI pressure settings. All Compression Cycle A-3

10 Operation & Troubleshooting Purge Cycle The pressure switch will open, shutting off electrical current to compressor head(s) and the solenoid/purge valve. A mechanical valve on the pressure switch opens up to unload the compressor heads. At the same time the unloader solenoid opens, starting the purge cycle. Intake Air Intake Filter Troubleshooting Motor runs Intermittently or "Chugs"... A-7 Moisture Indicator is Pink... A-10 Element Indicator is Red... A-11 High Pressure... A-12 Excessive Noise... A-13 Overheating... A-14 Compressor runs to Frequently... A-15 Purge Tank (Releasing Pressure) Air from the purge tank flows back through the gauge cluster in through the metered orifice. The clean dry air drives out the moisture from the desiccant beads and into the condensate drain canister.. PreCooler Coalescing Filter Compressor (Not Running) Dessicant Tank Purge Air Check Valve (Closed) Storage Air White Red Atmospheric & Purge Tank Pressure Pressurized Air Moisture Indicator Pressure Relief Valve (Closed) (Opens at 125 PSI) Note: Bottom Port (Open) Ball Valve (Open) Manual Needle Purge Valve (Closed) Under normal operation conditions, a small amount of moisture with some oil may be under the unloader exhaust muffler. This is not a malfunction. It is evidence of what the filter on the Desiccant Drying System captured the moisture, and did not permit it to enter the operatory air supply. Condensate Drain Can Assembly Normally Open Solenoid Valve (Open) Pressure Switch (Contacts Open) Compressor Head Unloader Valve (Open) 100 PSI Supply Air to Operatory Storage Tank (Pressure At Pressure Switch Setting) AA150501i A-4 Purge Cycle All

11 Operation & Troubleshooting Purge Cycle Electrical Schematic Pressure inside the system reaches 100 PSI (+ / - 5 PSI) causing the Pressure Switch Contacts to open. Power is removed from the Compressor stopping it. At the same time, power is removed from the Normally Open Solenoid Valve, Opening the valve, allowing pressure to be released from the top of the compressor head to the Condensate Drain Can Assembly. It also allows the Purge Tank to release its pressure thru the Desiccant Tank to the Condensate Drain Can Assembly. The Fan Motor continues to run as voltage is present as long as the Wall On / Off Switch is On, providing power to the contactor Coil closing its contacts. Line VAC Supply Line Voltage 24 VAC Transformer ENERGIZED 24 VAC Fuse On Unit 24 VAC Contactor w/ 24 VAC Coil CLOSED LINE VAC Wall On / Off Switch ON Fan Motor RUNNING Unit On / Off Switch ON LINE VAC Pressure Switch NO VAC OPEN (At or Above Pressure Setting) NO VAC NO VAC Solenoid Valve (Normally Open when not energized) NOT ENERGIZED (OPEN) Compressor OFF AA150800i Note: The compression and purge cycles will continue as the pressure inside the system fluctuates below the 80 PSI and up the 100 PSI pressure settings. All Purge Cycle A-5

12 Operation & Troubleshooting Compression Cycle Refer To: Pressure Switch... B-2 ON/OFF Switch... B-7 Capacitor... B-10 Compressor Heads... B-13 Low Voltage Contactor... B-17 3rd Check Capacitor Refer to: Section B Capacitor Problem: Compressor will not Start 1st Check Low Voltage Contactor Refer to: Section B Low Voltage Contactor 5th Motor/Compressor Frozen Turn off electrical power. Verify compressor fan will rotate by hand. If not Replace compressor head(s). Refer to: Section B Compressor Heads 4th Thermal Overload Cut Allow compressor to cool, then restart. 2nd Check voltage at Breaker Was proper voltage is measured at the breaker and not at motor terminals? If yes, check the in the following order : Check for broken or loose wires. If there is Pressure, Perform Pressure Switch Adjustment. (Refer to: B Pressure Switch) Check voltage at On/Off Switch. (R42 Model ONLY) (Refer to: B On/Off Switch) A-6 Compression Cycle All

13 Compression Cycle & Purge Cycle- continued Operation & Troubleshooting Problem: Motor runs Intermittently or "Chugs" Refer To: Line Voltage... B-35 Perform Line Voltage Test Refer to: Section B Line Voltage 1st 2nd Purge System Manually purge compressor. AA orfice 3rd Check for Blockage in Air Line Remove discharge hose from head and test run. If unit runs correctly check for obstruction in air line to storage tank. Obstruction will be at an orifice or other restriction. All Compression & Purge Cycle A-7

14 Operation & Troubleshooting Compression Cycle - continued Refer To: Solenoid (Exhaust Valve)... B-24 Pressure Switch... B-2 Intake Filter... B-19 Checking for Leaks... B-21 Compressor Heads... B-13 Check for Blockage in Air Line Inspect all air lines for restrictions. 6th Problem: Compressor Heads run but will not Pressurize to 100 PSI 9th Check for Worn Piston Cup Refer to: Section B Compressor Heads 5th Check for Air Leaks Refer to: Section B Checking for Leaks. Check Coalescing Filter 7th If indicator is red, change filter. Refer to: Section B Coalescing Filter 8th Check Solenoid Refer to: Section B Solenoid Clean or Replace Intake Filter Refer to: Section B Intake Filter. 4th Check Exhaust Valve Refer to: Section B Solenoid. 2nd Verify Shut-Off valve is Closed. 1st Clean or Replace Pressure Switch Unloader Valve Refer to: Section B Pressure Switch. 3rd AA A-8 Compression Cycle All

15 Compression Cycle - continued Operation & Troubleshooting Problem: Compressor cycles with no air being used Refer To: Checking for Leaks... B-21 3rd Check for Air Leaks Refer to: Section B Checking for Leaks. 1st Check Manual Purge Valve Should be in "OFF" position (Horizontal) AA Check for Leak in Office Air System Close the storage tank shut off. Pump up storage tank to 100 PSI. If pressure is maintained at 100 PSI for minutes, leak is not in compressor. 2nd All Compression Cycle A-9

16 Operation & Troubleshooting Refer To: Desiccant Tank... B-27 Solenoid... B-24 Compressor runs to frequently... A-15 Compression Cycle & Purge Cycle- continued Problem: Moisture Indicator is Pink Is Compressor running too frequently? Refer to: Section A Compressor runs to Frequently. 3rd Perform Unloading System Function Test Refer to: Section B - Solenoid 1st Check Desiccant Drying Chamber Refer to: Section B Desiccant Tank 2nd Purge Air Lines 5th Preform a Manual Purge. Note: Under normal operation conditions, a small amount of moisture with some oil may be under the unloader exhaust muffler. This is not a malfunction. It is evidence that the filter on the Desiccant Drying System captured the moisture, and did not permit it to enter the operatory air supply. AA Check for Condensation in Air Lines Is there moisture in operatory air? 4th A-10 Compression & Purge Cycle All

17 Compression Cycle & Purge Cycle- continued Problem: Element Indicator is Red Operation & Troubleshooting Refer To: Intake Filter... B-19 Coalescing Filter... B-22 Verify Float is Working Check for clogs. 2nd 1st Change Intake Filter Refer to: Section B Intake Filter 3rd Change Coalescing Filter Refer to: Section B Coalescing Filter AA All Compression & Purge Cycle A-11

18 Operation & Troubleshooting Refer To: Check Valves... B-36 Compression Cycle & Purge Cycle- continued Problem: High Pressure 1st Check Exhaust Remove hoses one at a time between Heads and Pressure Relief Valve. Verify exhaust air flow is not obstructed. Clean or Replace Check Valve 2nd Refer to: Section B Check Valve 3rd Check Pressure Switch Settings Check contacts and operating range, psi. AA A-12 Compression & Purge Cycle Rev 6/06 All

19 Operation & Troubleshooting Compression Cycle & Purge Cycle- continued Problem: Excessive Noise Refer To: Compressor Heads... B-13 Checking for Leaks... B-21 Intake Filters... B-19 1st Check for Worn Piston Cup Refer to: Section B Compressor Heads 2nd Check for Leaky Hose Refer to: Section B Checking for Leaks 3rd Replace Intake Filters Refer to: Section B Intake Filters. AA All Compression & Purge Cycle A-13

20 Operation & Troubleshooting Refer To: Intake Filter... B-19 Solenoid (Exhaust Valve)... B-24 Pressure Switch... B-2 Line Voltage... B-35 Fans... B-31 Compression Cycle & Purge Cycle- continued Problem: Overheating 4th Check Exhaust Remove hoses one at a time between Heads and Pressure Relief Valve. Verify exhaust air flow is not obstructed. 1st Clean Intake Filters Refer to: Section B Intake Filter 2nd Clean or Replace Exhaust Valve Refer to: Section B Solenoid. Check fan operation Refer to: Section B Fans 6th Clean or Replace Pressure Switch Unloader Valve Refer to: Section B Pressure Switch. 3rd AA Perform Line Voltage Test Refer to: Section B Line Voltage 5th A-14 Compression & Purge Cycle All

21 Operation & Troubleshooting Compression Cycle & Purge Cycle- continued Problem: Compressor runs too Frequently Refer To: Solenoid... B-24 Pressure Switch... B-2 Coalescing Filter... B-23 1st Check for Air Leaks Refer to: Section B Checking for Leaks Change Element Indicator 2nd Refer to: Section B Coalescing Filter Check Solenoid Refer to: Section B Solenoid 3rd 4th Check Pressure Switch Refer to: Section B Pressure Switch AA Note: More than the 35% duty cycle the Rock Compressors are rated for would be "Running to Frequently". All Compression & Purge Cycle A-15

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23 Component Section BTesting & Repair Component Testing & Repair Components / Procedure Pressure Switch... B-2 On/Off Switch... B-7 Capacitor... B-10 Compressor Heads... B-13 Low Voltage - Master Control Panel... B-17 Intake Filter... B-19 Checking for Leaks... B-21 Coalescing Filter... B-22 Solenoid... B-24 Desiccant Tank... B-27 Fuse Replacement... B-29 Fan Replacement... B-31 Line Voltage... B-35 Check Valve... B-36 B-1

24 Component Testing & Repair Pressure Switch Location and Function During the Compression Cycle... When the storage tank is filled to the preset pressure the pressure switch will open and stop the compressor. Pressure Switch Testing... B-3 Adjustment... B-4 Replacement... B-5 Wiring Diagrams... D-1 Exploded Views / Part Numbers... E-2 During the Purge Cycle... The pressure switch shuts off current to the compressor head(s) and the solenoid / purge valve. A mechanical valve on the pressure switch opens up to unload the compressor headlines. At the same time the unloader solenoid opens, starting the purge cycle. Cut-In / Cut-Out time Cut-In / Cut-Out is the minimum and maximum discharge pressures at which the compressor will switch from unload to load operation (cut-in) or from load to unload (cut-out). The pressure switch controls Cut-In / Cut-Out times. AA AA NOTE: Pressure Switches on models up to 2HP have a Preset Cut-In adjuster. Models 2HP and over have Manual adjuster for Cut-In setting. Both Models have Manual Cut-Out Adjusters. B-2 Pressure Switch All

25 Component Testing & Repair Pressure Switch Testing NOTE: Step 1: Perform Adjustment. Refer to Section B Pressure Switch Adjustment. If Adjustment can not be made, then perform voltage test to the On/Off Switch before checking voltage on the Pressure Switch. You will need the readings from the On/Off Switch check to verify the test on the Pressure Switch. Refer to: Section B On/Off Switch Test Pressure Switch Function / Location... B-2 Adjustment... B-4 Replacement... B-5 On/Off Switch Test... B-8 Wiring Diagrams... D-1 Exploded Views / Part Numbers... E-2 Step 2: Turn power off. GRN W/YLW STRIPE Step 3: Remove cover and verify there are no black/burnt melted wires. If there are replace pressure switch. WHT GRY GRY BLK Step 6: Place meter probes on black wire and white wire. Step 4: Turn power on. Step 5: Set meter to V. WHT GRN W/YLW STRIPE GRY GRY BLK Step 7: Place meter probes on both inner gray wires. Note: Verify pressure is less than "cut in". Refer to:sectin B: Adjustment. Meter Reading No Pressure on Gauges. Not same Volt Readings as on/off switch. Less than 230 Volts on inner wire check. Status Required Action Replace Pressure Switch. NOTE: If pressure is above cut-in and voltage is read during testing when the contacts are supposed to be open, then contacts are melted and pressure switch needs replacement. Same Voltage as on/off Switch. 230 Volt Readings on inner wires. Pressure Switch - OK AA153600i All Pressure Switch B-3

26 Component Testing & Repair Pressure Switch Adjustment Pressure Switch Function / Location... B-2 Testing... B-3 Replacement... B-5 Wiring Diagrams... D-1 Exploded Views / Part Numbers... E-2 Cut-In Adjustment Step 1: Run compressor until pressure reaches 100 lbs. Note: Compressor should shut off close to 100 lbs. Cut-Out Adjustment - Models over 2HP Step 1: Run compressor until pressure reaches 100 lbs. Note: Compressor should shut off close to 100 lbs. If not perform a Cut-In adjustment Cut-In Adjuster Cut-Out Adjuster Step 2: If compressor didn't shut down at 100 lbs, turn nut on adjuster to reset gauge. Clockwise will increase reading. Counter Clockwise will decrease reading. AA Step 2: Compressor should start back up after a 20 lb drop on the gauge. If needed, turn nut to adjust. Clockwise will increase reading. Counter Clockwise will decrease reading. NOTE: Pressure Switches on models up to 2 HP have a Preset Cut-In adjuster. Models 2HP and over have Manual adjuster for Cut-In setting. Both Models have Manual Cut-Out Adjusters. B-4 Pressure Switch All

27 Component Testing & Repair Pressure Switch Replacement of Unloader Valve Twin Rock Valve installed in Opposite Direction Removal Caution Line voltage is present at the power inlet Step 1: Disconnect power to compressor. Remove cover. Pressure Switch Function / Location... B-2 Testing... B-3 Adjustment... B-4 Wiring Diagrams... D-1 Exploded Views / Part Numbers... E-2 Installation Step 3: Install cover. Unloader Valve Removal Step 3: Remove valve from pressure switch. AA153700i Installation Step 1: Install new unloader valve in pressure switch. Removal Step 2: Remove air line from pressure switch. Installation Step 2: Reconnect air line to unloader valve. All Pressure Switch B-5

28 Component Testing & Repair Pressure Switch Replacement of Pressure Switch Removal Caution Line voltage is present at the power inlet Step 1: Disconnect power to compressor. Remove cover. AA155800i Pressure Switch Function / Location... B-2 Testing... B-3 Adjustment... B-4 Replacement... B-5 Wiring Diagrams... D-1 Exploded Views / Part Numbers... E-2 Removal Step 4: Unscrew pressure switch from storage tank fitting. Installation Step 1: Screw new pressure switch into storage tank. Removal Step 3: Disconnect wires. Remove conduits from pressure switch box. Installation Step 2: Install conduits. Connect wiring. Refer to: Sec D Wiring Diagrams Installation Step 4: Install cover. AA154100i Removal Step 2: Remove air line from pressure switch. Installation Step 3: Install air line. B-6 Pressure Switch All

29 Component Testing & Repair On / Off Switch Function / Location The on/off switch sends power to the compressor heads. On / Off Switch Testing... B-8 Replacement... B-9 Wiring Diagrams... D-1 Exploded Views / Part Numbers... E-9 R22 - Twin Rock R42 - Triple Rock All On / Off Switch B-7

30 Component Testing & Repair On / Off Switch Testing NOTE: Verify system is not pressurized. (System pressure below 80 PSI.) Step 3: Place meter probes on rear terminals on relay. Reading = 230 volts. On / Off Switch Function / Location... B-7 Replacement... B-9 Wiring Diagrams... D-1 Exploded Views / Part Numbers... E-9 Step 1: Remove electrical cover and on/off switch cover. Relay Step 2: Set meter to V. Step 5: Place meter probes on two gray wires on right side of terminal block. Reading should show no voltage. To Motor To Motor Step 8: Place meter probes on top right and top left side. Reading = 230 volts. Top Step 4: Turn switch off. Step 7: Turn switch on. Step 9: Place meter probes on bottom right and bottom left side. Reading = 230 volts. Bottom Meter Reading Status Required Action AA154600i Relay, Switch readings < 230 volts. If Voltage is present on Terminal Test. Replace On / Off Switch. Caution Do not allow wires to touch together. Relay, Switch readings = 230 volts. If Voltage is not present on Terminal Test. On / Off Switch - OK Step 6: Pull switch out of housing. B-8 On / Off Switch R42

31 Component Testing & Repair On / Off Switch Replacement Removal Caution Line voltage is present at the power inlet Step 1: Disconnect power to compressor. AA155800i On / Off Switch Function / Location... B-7 Testing... B-8 Wiring Diagrams... D-1 Exploded Views / Part Numbers... E-9 Twin Model Triple Model Removal Twin Model - R22 Step 2: Remove electrical box cover. Disconnect wires and remove switch. Removal Triple Model - R42 Step 2: Remove switch cover. Replace switch. Refer to: Section D for wire diagram Installation Twin Model - R22 Step 1: Connect wires and install switch. Install electrical box cover. Installation Triple Model - R42 Step 1: Connect wires and install switch. Install switch cover. AA154300i Installation Step 3: Reconnect power to compressor. All On / Off Switch B-9

32 Component Testing & Repair Capacitor Function / Location The capacitor s function is to store electricity, or electrical energy. The capacitor also functions as a filter, passing alternating current (AC), and blocking direct current (DC). Capacitor Testing... B-11 Replacement... B-12 Wiring Diagrams... D-1 Exploded Views / Part Numbers... E-5 B-10 Capacitor All

33 Component Testing & Repair Capacitor Testing Step 2: Disconnect wire connections on capacitor. Capacitor Function / Location... B-10 Replacement... B-12 Wiring Diagrams... D-1 Exploded Views / Part Numbers... E-5 Step 3: Discharge capacitors by touching two screwdrivers to two contacts on capacitor and each other. Electrical Box Cover Step 1: Remove electrical box cover. Step 5: Place meter probes on capacitor connectors. Meter Reading Status Required Action "O" or "Open" Reading Replace Capacitor Start Low and Increases Capacitor - OK Step 4: Set meter to Ω. All Capacitor B-11

34 Component Testing & Repair Capacitor Replacement Removal Caution Line voltage is present at the power inlet Step 1: Disconnect power to compressor. AA155800i Capacitor Function / Location... B-10 Testing... B-11 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Removal Step 2: Remove quiet cover if applicable. Refer to: Section C Quiet Cover Removal Step 3: Remove electrical box cover. Disconnect wires Remove mounting screws from capacitor and replace. Installation Step 2: Install Quiet Cover if applicable. Refer to: Section C Quiet Cover. Capacitors Installation Step 1: Install capacitor mounting screws. Connect wires. Install electrical box cover. Electrical Box Cover B-12 Capacitor All

35 Component Testing & Repair Compressor Heads Function and Location Atmospheric air is drawn in through intake filters to the compressor head(s) where air is compressed and exhausted to the resorvoir (tank). Heat is generated from the compression process. Compressor Heads Rebuild - Removal... B-14 Rebuild - Installation...B-15 Replacement... B-16 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 All Compressor Heads B-13

36 Component Testing & Repair Compressor Heads Rebuild - Removal Removal Caution Line voltage is present at the power inlet Vent air lines to the compressor to release pressure. Step 1: Disconnect power to compressor. Removal Step 2: Remove head bolts and head. Note: Mark orientation of ports so head covers are reassembled correctly. Exhaust Side Compressor Heads Function / Location... B-13 Rebuild - Installation...B-15 Replacement... B-16 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Removal Step 4: Remove cross tubes. Intake Side Removal Step 3: Clean and inspect valves and valve plates. If discolored or worn, replace. Verify "X" notch on corner is facing up. Torque in. lbs. Removal Step 5: Remove the retainer plate, piston cup and cylinder. Discard piston cup and o-rings on cylinder and cross tube. NOTE: Verify proper orientation of the ports, incorrect placement of the head on the valve plate will result in misalignment of the valve ports and valve damage. Damaged valves must be replaced before pump can operate. AA154900i Removal Step 6: Clean all parts with water based solvent cleaner. B-14 Compressor Heads All

37 Compressor Heads Rebuild - Installation Installation Step 9: Reconnect power supply to pump and check compressor for leaks. Refer To: Section B Checking for Leaks. Installation Step 8: Install head over valve plates and torque to in. lbs. Component Testing & Repair Compressor Heads Function / Location... B-13 Rebuild - Removal... B-14 Replacement... B-16 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Installation Step 7: Install o-ring on top of valve plate. Installation Step 4: Install valves. Installation Step 6: Install new cylinder o-rings in the bottom of the valve plates. Position valve plates over cylinders. Installation Step 5: Install new o-rings on cross tubes and reinstall tubes into valve plate. Installation Step 3: Install cylinders at an angle over cups to avoid damage. Installation Step 1: Place new piston cup on rod. Installation Step 2: Apply medium thread locking compound to retainer screws and install retainer plate. AA154800i All Compressor Heads B-15

38 Component Testing & Repair Compressor Heads Replacement Removal Installation Caution Line voltage is present at the power inlet Vent air lines to the compressor to release pressure. Step 1: Disconnect power to compressor. Equipment Alert Do not over torque Inlet/Outlet fittings. Head will crack and leak. Compressor Heads Function / Location... B-13 Rebuild - Removal... B-14 Rebuild - Installation...B-15 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Removal Step 2: Disconnect the wiring, tubing and mounting nuts from heads. Note: On Model R22 Loose platform bolts and raise platform slightly for more room to work. Step 1: Install new heads on platform. Connect the following to heads... Wiring - Refer to: Section D Wire Diagrams Tubing Mounting Nuts under platform Removal Step 3: Remove heads from platform. AA155000i Installation Step 2: Reconnect power supply to pump and check compressor for leaks. Refer To: Section B Checking for Leaks. B-16 Compressor Heads All

39 Component Testing & Repair Low Voltage - Master Control Panel Function and Location The Master Control Panel will allow the user to control the dental equipment from the office area. Supplies power to the fans and relay switch. Low Voltage Control Testing... B-18 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 *Note: Relay Switch is always live unless Low Voltage is turned off. AA156700i Equipment Room Operatory All Low Voltage Contactor B-17

40 Component Testing & Repair Low Voltage - Master Control Panel Testing Step 1: Remove electrical box cover. Check for broken or loose wiring. Step 2: Check high voltage on contactor relay. Set meter to V. Place meter probes on front, black and white wires. Note: Verify reading is 230 volts. Relay Low Voltage Control Function and Location... B-17 Fuse... B-29 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Step 4: Insert screwdriver into relay to start manually. Note: if system starts, replace contactor relay. 230 VAC Primary Relay Transformer 230 VAC Secondary RED LOW VOLTAGE WHITE CONTROL BLUE BLU WHT BLU YLW Caution When testing components with power on use care to prevent electrical shock. 1/2 A FUSE Step 5: Check fuse. Visually check to see if blown. Refer To: Section B Fuse Step 3: Check Low Voltage from transformer to low voltage wires. Place meter probes on Yellow and Red wire connections at Relay. Note: Verify reading is 24 volts. Meter Reading Status Required Action High Voltage = < 230 Volts Low Voltage = < 24 Volts High Voltage = 230 Volts Low Voltage = 24 Volts Replace Relay Replace Transformer Relay - OK Transformer - OK AA158701i Step 6: Bypass the remote switch to verify it is not defective. Disconnect Red, White and Blue wires from switch. Connect the blue and red wires together. If the relay and fans work, then replace remote switch or wiring. B-18 Low Voltage Contactor Rev 5/07 All

41 Component Testing & Repair Intake Filters Function and Location Atmospheric air is drawn in through intake filters before flowing to the compressor heads. Intake filters protect the heads from dust and debris and should be changed annually. Intake Filters Clean and Replacement... B-20 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 All Intake Filter B-19

42 Component Testing & Repair Intake Filter Clean and Replacement Cleaning Filter Step 1: Unclamp filter from hose. Remove barbed fitting on motor tray. Pop off one side of filter housing. Intake Filters Function and Location... B-19 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Removal Step 1: Remove filter from hose and barbed fitting on motor tray. Cleaning Filter Step 2: Remove filter and clean with a nonflammable solvent. Wipe out housing and allow filter and housing to dry. Do Not Remove Cap Installation Step 1: Install filter onto barbed fitting. Cleaning Filter Step 3: Install filter back into housing. Assemble housing. Connect hose and install onto barbed fitting. AA156800i Installation Step 2: Clamp hose onto filter housing. B-20 Intake Filter All

43 Component Testing & Repair Checking for Leaks Checking for Leaks Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Check Step 1: Verify shut-off valve is closed. Check Step 2: Turn power on. Note: Compressor should run quietly and storage tank will begin to pressurize. Check Step 3: Use soapy water to check for compressor plumbing joint leaks. AA Soapy Water All Checking for Leaks B-21

44 Component Testing & Repair Coalescing Filter Function and Location The Coalescing Filter removes water, oil and other contaminates from compressed air. Coalesced liquids gravitate into the sump bowl where they are discharged through the drain. Coalescing Filter Replacement... B-23 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 AA B-22 Coalescing Filter All

45 Coalescing Filter Replacement Removal Step 1: Disconnect power to compressor. Drain storage tank of all air and liquid. Removal - Element Indicator Only Step 2: Remove mounting screws. Remove Element Indicator by cutting ties. Installation - Element Indicator Only Step 1: Install new indicator and mounting screws. Element Component Testing & Repair Coalescing Filter Function and Location... B-22 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Removal - Entire Assembly Only Step 2: Disconnect coalescing housing from tube fitting on bottom. Disconnect top of coalescing houseing at fittings. AA155800i Removal - O-ring and Filter Only Step 2: Push on black release button on front of filter housing, turn slightly and pull off lower half of coalescing assembly. Filter O-ring Removal - Entire Assembly Only Step 3: Remove fittings and tube from bottom of housing. Installation - Entire Assembly Only Step 1: Install fittings and tube onto bottom of housing. Removal - O-ring and Filter Only Step 3: Remove filter and o-ring. Release Button Installation - Entire Assembly Only Step 2: Connect power to compressor and check for leaks. Refer to: Section B Checking for Leaks Installation - O-ring and Filter Only Step 1: Install new filter and o-ring. Old Style Fittings (Threaded) Old Fittings can be Replaced by New Style Fittings (Compression) Installation - O-ring and Filter Only Step 2: Connect housing back to coalescing assembly and lock into place. All other Apollo Models New Style Fitting R22 Model New Style Fitting Soapy Water AA157300i All Coalescing Filter Rev 3/07 B-23

46 Component Testing & Repair Solenoid Function and Location During the compression cycle... The normally open Solenoid Valve, closes, preventing the compressed air from being discharged to the Condensate Drain Can Assembly. Solenoid Testing... B-25 Replacement... B-26 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 During the purge cycle... Power is removed from the Normally Open Solenoid Valve, Opening the valve, allowing pressure to be released from the top of the compressor head to the Condensate Drain Can Assembly. It also allows the Purge Tank to release its pressure thru the Desiccant Tank to the Condensate Drain Can Assembly, regenerating the desiccant drying system. B-24 Solenoid All

47 Component Testing & Repair Solenoid Testing Step 1: Check high voltage on pressure switch. Set meter to V Step 3: Verify no air is coming out of bottom of coalescing filter. Solenoid Function and Location... E-24 Replacement... E-26 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 GRN W/YLW STRIPE BLK GRY GRY WHT Step 2: Place meter probes on both inner gray wires. Meter Reading Status Required Action Less than 230 Volts on inner wire check. Air is coming out of coalescing filter. Doesn't work after cleaning. 230 Volt Readings on inner wires. NO air coming out of coalescing filter. Works after Cleaning. Replace Pressure Switch or ON/OFF Switch Pressure Switch - OK IN AA158900i Step 4: Clean solenoid. Loosen nut on top of solenoid and lift top off. Wipe stem off with a clean rag. Reassemble. All Solenoid B-25

48 Component Testing & Repair Solenoid Replacement Removal Step 1: Disconnect power to compressor. Drain storage tank of all air and liquid. Installation Step 1: Install new solenoid assembly to fittings. Connect tubing to coalescing filter. Solenoid Function and Location... B-24 Testing... B-25 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 AA155800i Model R22 Installation Step 2: Reconnect wiring and conduit to pressure switch. Refer To: Section D Wire Diagrams Installation Step 4: Connect power. Perform Pressure Switch adjustment to verify system is working correctly. Refer To: Section B Pressure Switch Removal Step 3: Disconnect tubing from solenoid assembly. Unscrew solenoid assembly from fittings. Model R42 Removal Step 2: Remove pressure switch cover. Disconnect wiring and conduit from pressure switch. Refer To: Section D wire Diagrams Installation Step 3: Install pressure switch cover. AA159000i B-26 Solenoid All

49 Component Testing & Repair Desiccant Tank Function and Location Moisture vapor drying takes place as the air is directed through the silica and alumina gel (desiccant material) from bottom to top in the drying chamber of the desiccant tank. Desiccant Tank Replacement... E-28 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 When the desiccant becomes so saturated with water and oil that the manual purge cycle fails to regenerate it, the desiccant tank will need to be replaced. The drying chamber is internally coated with an anticorrosive material. A stainless steel wire mesh screen supports the air drying media, consisting of an activated alumina buffer bed and silica gel (desiccant material). Twin Model R22 Triple Model R42 All Desiccant Tank B-27

50 Component Testing & Repair Desiccant Tank Replacement Removal Step 1: Disconnect power to compressor. Open storage tank drain valve to release all air pressure, and then close valve. Installation Step 4: Connect power to the compressor. AA155800i Removal Step 3: Remove mounting bolts. Installation Step 2: Install tank to saddle with mounting bolts. Desiccant Tank Location and Function... E-27 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Installation Step 5: Test pump-up and purge operations. Check for and seal all leaks. Triple Model R42 Twin Model R22 Removal Step 2: Loosen compression nuts and separate copper tubing from end of the desiccant tank. Installation Step 3: Install copper tubing to desiccant tank. Removal Step 4: Unscrew tank from solenoid assembly. Installation Step 1: Screw tank into solenoid assembly. AA159200i B-28 Desiccant Tank All

51 Component Testing & Repair Fuse Function and Location The fuse protests the low voltage control system against overload failure, mainly short circuits. Only the Triple Model R42 has a fuse. It is located on the front panel. Fuse Replacement... E-30 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Note: The Twin Model R22, uses a low voltage circuit breaker switch instead. R42 Fuse B-29

52 Component Testing & Repair Fuse Replacement Removal Step 1: Unscrew fuse holder out of front panel. Remove fuse from holder. Fuse Function and Location... E-29 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Installation Step 1: Insert fuse into fuse holder and screw into front panel. Fuse NOTE: Fuse needs replaced if it is burnt or broken. AA159500i B-30 Fuse R42

53 Component Testing & Repair Fan Function and Location Fans cool down the heads and also cause air to flow over the after cooler which helps cool the system air after compression. Fan Testing... E-32 Replacement (R22-Twin)... E-33 Replacement (R42-Triple)...E-34 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Twin Model R22 (Two fans are located underneath Heads) Triple Model R42 All Fan B-31

54 Component Testing & Repair Fan Testing Step 2: Set meter to V. Fan Function and Location... E-31 Replacement (R22-Twin)... E-33 Replacement (R42-Triple)... E-34 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Step 1: Disconnect wires from fan. TO 3 FANS BLK BLK BLK WHT WHT WHT WHT BLK Step 3: Place meter probes on fan wires. Reading = 230 volts. Meter Reading Status Required Action Step 4: Place meter probes on rear terminals on relay. Reading = 230 volts. Relay One Fan < 230 Volts Replace Fan All Fans < 230 Volts 230 Volts Replace Relay Fan and Relay OK AA159900i B-32 Fan All

55 Component Testing & Repair Fan Replacement Removal Pre-Cooler Fan Step 1: Remove electrical box cover. Disconnect wires between fan and relay. Installation Pre-Cooler Fan Step 1: Install screws into fan guard. Connect fan wires. Fan Function and Location... E-31 Testing... E-32 Replacement (R42-Triple)... E-34 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Removal Pre-Cooler Fan Step 2: Remove screws from pre-cooler fan and replace fan. Installation Pre-Cooler Fan Step 2: Install electrical box cover. Installation Fans under Platform Step 3: Install screws into fan guard on top and bottom of platform. Removal Fans under Platform Step 3: Remove intake filters. Remove tubing from platform. Unbolt motors. AA160200i Removal Fans under Platform Step 4: Move motor up to remove screws out of fan guard on platform. Remove screws from fan guard underneath platform. Replace fan from underneath. Installation Fans under Platform Step 4: Bolt Motors into platform. Install tubing from platform to motors. Install intake filters to tubing. Reconnect wires between fan and relay. R22 Fan B-33

56 Component Testing & Repair Fan Replacement Removal Step 1: Disconnect fan wires. Fan Function and Location... E-31 Testing... E-32 Replacement (R22-Twin)...E-33 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Removal Step 3: Remove screws from front of fan and remove fan. Removal Step 2: Remove screws from behind platform. Installation Step 2: Connect wires between fan and relay. Installation Step 1: Install screws into front and back of fan guard. AA160300i B-34 Fan R42

57 Component Testing & Repair Line Voltage Testing Components to check for line voltage include the High Voltage Breaker, Low Voltage Contactor, Relay, On/Off Switch and the Pressure Switch. Step 1: Check high voltage in Breaker. Set meter to V Line Voltage Pressure Switch (Testing)... B-3 On/Off Switch (Testing)... B-8 Low Voltage Contactor (Testing)... B-18 Wiring Diagrams... D-1 Exploded Views (R22 - Twin)... E-2 Exploded Views (R42 - Triple)... E-3 Step 2: Check voltage in Low Voltage Contactor and Relay. Refer to: Section B Low Voltage Contactor Meter Reading Status Required Action < 230 Volts in Breaker Replace Breaker < 24 Volts - Low Voltage Contactor Replace Low Voltage Contactor < 230 Volts - Relay Replace Relay < 230 Volts - On/Off Switch Replace On/Off Switch < 230 Pressure Switch Replace Pressure Switch AA160400i < 230 Volts Terminal Block Replace Terminal Block 230 Volts = Breaker Breaker 24 Volts = Low Voltage Contactor Low Voltage Contactor Step 3: Check voltage in On/Off Switch and high voltage terminal connections. Refer to: Section B On/Off Switch 230 Volts = Relay Relay 230 Volts = On/Off Switch On/Off Switch 230 = Pressure Switch Pressure Switch Step 4: Check voltage in Pressure Switch. Refer to: Section B Pressure Switch 230 = Volts Terminal Block Terminal Block All Low Voltage Contactor B-35

58 Component Testing & Repair Check Valve Replacement Removal Step 1: Disconnect power to compressor. NOTE: Installation Step 12: Connect power to compressor. Use teflon tape and thread adhesive on fitting threads when reinstalling. Removal Step 4: Remove tube from Desiccant tank to elbow. Remove elbow from block fitting. Removal R42 Models Only Step 2: Remove shroud. Installation R42 Models Only Step 11: Install shroud. Removal Step 5: Unscrew gauge from block fitting. Installation Step 8: Install gauge. Block R22 Model Removal Step 6: Unscrew block. Unscrew check valve. R42 Model Installation Step 9: Install elbow into block. Install tube from elbow to Desiccant tanks. Check Valve Installation Step 7: Install new check valve. Install block. Removal Step 3: Remove tube from side of cluster block to below moisture gage. Installation Step 10: Install tube from side of cluster block to below moisture gage. AA171100i B-36 Check Valve Rev 7/06 ALL

59 Section C Access Procedures Access Procedures Removing & Installing: Quiet Cover... C-2 Midmark Corporation 2005 SF-1864 C-1

60 Access Procedures Quiet Cover Removal / Installation Refer To: Exploded Views / Part Numbers: R22 - Twin... E-2 R42- Triple...E-3 Removal Step 1: Turn both quiet cover fastener counter-clock wise. Lift quiet cover off of compressor. Fastener AA160500i Installation Step 1: Place quiet cover on top of compressor. Turn both quiet cover fastener clockwise. C-2 Quiet Cover Midmark Corporation 2005 SF-1864 All

61 Section D Wiring Diagrams Wiring Diagrams Model R22... D-2 R42 (Motor & Pressure Switch).. D-4 R42 (On/Off Switch)... D-5 D-1

62 Wiring Diagrams LEFT MOTOR WHT BLK GRN W/YLW BRN BRN/WHT BRN BRN/WHT RIGHT MOTOR BLK WHT GRN W/YLW Refer To: Operation & Troubleshooting... A-1 Component Testing / Repair... B-1 Access Procedures... C-1 Wiring Diagrams... D-1 Exploded Views / Part Numbers... E-1 WHT WHT BLK BLK YLW BLK L1 115 BLK or 230 ORG WHT 230 VAC PRIMARY 24 VAC SECONDARY BLU GRN W/YLW GRY GRY WHT T1 T2 L2 115V or 230V WHT BLK GRN W/YLW RED WHT BLK WHT BLK WHT BLK BLK WHT GRN W/YLW GRY GRY FAN ON A/C WHT BLK WHT (L) FAN BLK WHT WHT BLK (R) FAN GRY GRY ON/OFF - 1/2 AMP CIRCUIT BREAKER SWITCH BLU RED WHT LOW VOLTAGE MPM60622 D-2 Motor & Pressure Switch Rev 2/22/06 R22

63 Wiring Diagrams TO LEFT MOTOR # 1 BRN BRN WHT BLK GRN W/YLW STRIPE TO 3 FANS BLK BLK BLK WHT WHT WHT TO TERMINAL BLOCK 230 VAC Primary Transformer WHT Relay VAC Secondary BLK YLW BLU BLK TO LT MTR BLK TO MID MTR WHT TO LT MTR WHT TO MID MTR WHT BLK BRN BRN TO WHT TERMINAL BLOCK GRY GRY BLK GRN W/YLW STRIPE TO MIDDLE MOTOR # 2 BRN BRN TO WHT RIGHT BLK MOTOR GRN W/YLW STRIPE # 3 PRESSURE SWITCH GRN W/YLW STRIPE BLK GRY GRY GRY WHT ON/OFF SWITCH L1 T1 T2 L2 Refer To: Operation & Troubleshooting... A-1 Component Testing / Repair... B-1 Access Procedures... C-1 Wiring Diagrams... D-1 Exploded Views / Part Numbers... E-1 WHT ORG WHT RED BLU 230V BLK BLK GRN W/YLW STRIPE RED BLUE WHITE LOW VOLTAGE CONTROL 1/2 A FUSE MPM60623 R42 Motor & Pressure Switch Rev 2/22/06 D-3

64 Wiring Diagrams GRN BLK WHT BLK LOAD WHT GRN WHT BLK A D Refer To: Operation & Troubleshooting... A-1 Component Testing / Repair... B-1 Access Procedures... C-1 Wiring Diagrams... D-1 Exploded Views / Part Numbers... E-1 BLK WHT B C LINE E Item Description Part Number A B Switch Box, DBL, W/GND STUD Elec. Wiring to Switch F C Press Switch Wiring D Ground Label E Nut KEPS 10/32 BNT20210 F Switch ON/Off DPST ECS10417 AA145100i D-4 On / Off Switch R42