PowerMax Model Numbers: PM-1 PM-3 PM-4 Service and Parts Manual FOR USE BY MIDMARK TRAINED TECHNICIANS ONLY SF-1920 Part No. 10559400 Rev AA1 (7/14/17)
Table Of Contents General Information Section A Section B GENERAL INFORMATION Symbols... iii Ordering Parts... iii Serial Number Location... iii Specifications... iv Model Identification / Compliance Charts... v Warranty Information... vi OPERATION & TROUBLESHOOTING Theory of Operation... A-2 COMPONENT TESTING Pump Filters... B-2 Check for Leaks... B-3 Vacuum Switch... B-4 Exhaust Mufflers... B-9 Check Valve... B-10 Low Voltage... B-12 Fuse... B-14 On/Off Switch... B-16 Section C Section D Section E ACCESS PROCEDURES Vacuum Switch Cover...C-2 Electrical Box Cover...C-3 WIRING DIAGRAMS PowerMax Models PM-1...D-2* PM-3... D-3* PM-4... D-4* EXPLODED VIEWS / PARTS LISTS PowerMax Models PM-1, PM-3, PM-4...E-2 * Indicates multiple pages due to model / serial number break(s) Rev 7/14/17
General Information Symbols DANGER Indicates an imminently hazardous situation which will result in serious or fatal injury if not avoided. This symbol is used only in the most extreme conditions. WARNING Indicates a potentially hazardous situation which could result in serious injury 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. 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, 2nd ) Refer to Section B for component testing procedures. 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 / 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 Service Department with the required information. Serial / Model Number Location Customer Service: 1-800-643-6275 Technical Service: 1-888-279-1260 AA215700 iii
General Information Weights, Dimensions, Electrical Specifications PowerMax Surgical Suction Systems AA214000 Model Users Height (IN.) Width (IN.) Depth (IN.) Weight (LBS.) HP Voltage (50/60 Hertz) Breaker Size per Pump (Amps) Tank Capacity (GAL) CFM Maximum PM-1 1 31" 32" 25" 150 3/4 208-230 @ 5.1 Amp 20 20 8 PM-3 2-3 31" 32" 25" 210 1.5 208-230 @ 9.7 Amp 20 20 16 PM-4 3-4 34" 38" 27" 290 2.25 208-230 @ 14.3 Amp 20 32 24 iv www.midmark.com 1-800-Midmark www.documark.com
General Information Model Identification / Compliance Chart Model PM-1 Description PowerMax Surgical Suction System 1 User UL 60601-1 X Complies To: CAN #601.1-M90 X Electrical Supply Requirements: VAC Amps 208 / 230 Configurable 5.1 Cycles (Hz) 50/60 PM-3 PowerMax Surgical Suction System 2 3 User X X Configurable 208 / 230 9.7 50/60 PM-4 PowerMax Surgical Suction System 3 4 User X X Configurable 208-230 13.8 50/60 v
General Information Limited Warranty Information SCOPE OF WARRANTY Midmark Corporation ( Midmark ) warrants to the original purchaser its new PowerMax 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 PERIODAPPLICABLE WARRANTY PERIOD The applicable warranty period, measured from the date of installation for the original user, shall be:the applicable warranty period, measured from the date of installation for the original user, shall be: PowerMax Surgical Suction Vacuums: Two (2) years or 1,500 usage hours (whichever comes first) 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 maintenance 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.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 maintenance 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 consequential damages or delay, including, but not limited to, damages for loss of profits or loss of use.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. NO AUTHORIZATION No person or firm is authorized to create for Midmark any other obligation or liability in connection with the products.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, EXPRESSOR IMPLIED. MIDMARK MAKES NO IMPLIED WARRANTIES OF ANY KIND INCLUDING ANY WARRANTIES OF MERCHANTABILTY OR FITNESS FOR ANY PARTICULAR PURPOSE. THIS WARRANTY IS LIMITED TO THE REPAIR OR REPLACEMENT OF DEFECTIVE PARTS.THIS WARRANTY IS MIDMARK S ONLY WARRANTY AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSOR IMPLIED. MIDMARK MAKES NO IMPLIED WARRANTIES OF ANY KIND INCLUDING ANY WARRANTIES OF MERCHANTABILTY OR FITNESS FOR ANY PARTICULAR PURPOSE. THIS WARRANTY IS LIMITED TO THE REPAIR OR REPLACEMENT OF DEFECTIVE PARTS. vi
Section A Troubleshooting Section A Troubleshooting Function / System Page Theory of Operation... A-2 A-1
Troubleshooting Theory of Operation Air is drawn from the operatories through a Surgical Operatory Recover Room Package to an ASME-certified reservoir and then into the pump inlets. Rapidly rotating vanes propel the air to the discharge of the pump, producing vacuum levels in the range of 13-20 inches of mercury ("Hg). Vacuum level is adjustable by adjusting the pump "on-off" points at the vacuum switch. A vacuum gauge provides monitoring of vacuum level. Equipment Alert PowerMax units use rotary vane vacuum pumps that require no lubrication. Service life of carbon vanes will be reduced by petroleum products. Verify all local codes. Vent To Outside Optional Exhaust Kit Troubleshooting Page Low Suction in Operatories... A-3 High Vacuum Level... A-4 Pump - Motor Overheats... A-5 Cycles with No Vacuum Being Used... A-6 Runs with No Suction at Operatory... A-7 Will Not Run... A-8 A low voltage relay allows "on-off" operation of the PowerMax from a remote unit in the operatories. Single pump unit supply a maximum flow rate of 8 cubic feet per minute (cfm); dual pump units deliver 16 cfm while triple pump units provide 24 cfm. Pump 1 Pump 2 Pump 3 Check Valve Check Valve Switch 1 Switch 2 Switch 3 Check Valve Low Voltage Control L1 L2 Incoming Power From Dedicated 20A Circuit CAUTION Motors are thermally protected and will have line voltage applied to them when the tank vacuum level is below the minimum setpoint, either could cause the system to restart without warning. Pump exhaust can cause eye or skin damage. Keep air stream airways from face and hands. Vacuum Switch Vacuum Storage Tank Vacuum Line From Operatories Electrical Box AA214100 A-2 Theory of Operation All
Vacuum System Troubleshooting Problem: Low Suction in Operatories Refer To: Page 1st Replace Pump Filters Refer to: Section B Pump Filters Pump Filters... B-2 Check for Leaks... B-3 Vacuum Switch... B-4 4th Replace Vanes Pump vanes are worn and need replaced. Replacement instructions are included with the vanes. Check Vacuum Lines Refer to: Section B Check for Leaks Repair any damaged or collapsed vacuum lines. 2nd 5th Adjust Vacuum Switch Refer to: Section B Vacuum Switch 3rd Flush Vacuum Pump Order Midmark Flushing Solvent, 77000699. Flushing instructions are included with solvent. AA217600 Replace Collection Canister Canister in operatory is full. 6th All Vacuum System A-3
Troubleshooting Vacuum System Refer To: Page Pump Filters... B-2 Vacuum Switch... B-4 Problem: High Vacuum Level 1st Replace Pump Filters Refer to: Section B Pump Filters 2nd Check Vacuum Lines Repair any damaged or collapsed vacuum lines. 3rd Adjust Vacuum Switch Refer to: Section B Vacuum Switch AA217900 A-4 Vacuum System All
Vacuum System Troubleshooting Problem: Pump / Motor Overheats (Operating Temperature Measured at Pump Exhaust is 180 or Higher) WARNING Pump Motors are thermally protected with an automatic reset and may start without warning. Replace Pump Filters Refer to: Section B Pump Filters 1st Refer To: Page Pump Filters... B-2 Exploded Views and Part Numbers... E-1 3rd Check Exhaust Mufflers and Piping Clean exhaust mufflers with a rag. Check exhaust piping for damaged or collapsed pipes. 4th Flush Vacuum Pump Order Midmark Flushing Solvent, 77000699. Flushing instructions are included with solvent. 2nd Check Vacuum Lines Repair any plugged, damaged or collapesed vacuum lines. 5th Replace Vanes Pump vanes are worn and need replaced. Replacement instructions are included with the vanes. Clean Vacuum / Motor Vents 7th 8th Listen for Noise in Motor If noises are heard from the motor, bearings are defective. Replace motor/pump. Check Equipment Room Temperature. Temperature should be -40 to 104 Fahrenheit -4 to 37 Celsius 6th AA218000 All Vacuum System A-5
Troubleshooting Vacuum System Refer To: Page Check Valve... B-8 Check for Leaks... B-3 Problem: Cycles with No Vacuum Being Used Clean or Replace Check Valve Refer to: Section B Check Valve 1st AA218100 Check for Leak in PowerMax or Piping System Refer to: Section B Check for Leaks 2nd A-6 Vacuum System All
Vacuum System Troubleshooting Problem: Runs with No Suction at Operatory 2nd Check Vacuum Lines Repair any damaged or collapsed vacuum lines. Verify Inlet Ball Valve is Opened 1st AA218200 All Vacuum System A-7
Troubleshooting Vacuum System Refer To: Page Vacuum Switch... B-4 Low Voltage... B-13 On/ Off Switch (Testing)... B-15 Fuse... B-12 1st Verify Switches in Electrical Box Are On Problem: Will Not Run 2nd Check Voltage in Breaker Note: If circuit breaker is tripped, measure voltage at the line side of the vacuum switch while the unit is running. Voltage should be in the range of 208-230. Voltage outside this range may result in failure to start and possible damage to unit. Install a buck/boost transformer as required. 3rd Check Low Voltage Refer to: Section B Low Voltage 6th Check Fuse Refer to: Section B Fuse 5th Check Vacuum Switch Refer to: Section B Vacuum Switch 4th Check On/Off Switch Refer to: Section B On/Off Switch WARNING High Voltage. When testing components with power on use care to prevent electrical shock. A-8 Vacuum System Rev. 3/10 All
Troubleshooting WARNING Pump Motors are thermally protected with an automatic reset and may start without warning. Problem Probable Cause Correction Pump filters dirty. Replace filters. Low Suction in Operatories High Vacuum Level at PowerMax Vacuum lines plugged, damaged or collapsed. Pump vanes sticking. Pump vanes worn. Vacuum switch "off" point set too low. Disposable collection canister in operatory full. Pump filters dirty. Vacuum lines plugged, damaged or collapsed. Vacuum switch "on" point set too high. Pump filters dirty. Repair lines. Clean pump with Midmark flushing solvent. Replace vanes. Adjust vacuum switch. Replace canister. Replace filters. Repair lines. Adjust vacuum switch. Replace filters. Pump overheats (Operating Temperature measured at pump Exhaust is 180 degrees Fahrenheit or Higher) Vacuum lines plugged, damaged or collapsed. Exhaust muffler dirty or exhaust piping plugged. Dirt buildup in pump chamber. Pump vanes worn. Excessive ambient temperature in equipment room. Repair lines. Remove and clean metal exhaust muffler. Disassemble, inspect and clean exhaust system as necessary. Verify outside exhaust vent is open. Clean pump with Midmark flushing solvent. Replace vanes. Check that installation site is properly vented and, if necessary, air conditioned to prevent ambient temperature from exceeding 104 degrees Fahrenheit. A-9
Troubleshooting Problem Probable Cause Correction Pump check valve's) leaking. Clean or replace check valve. PowerMax Cycles with No Vacuum Being Used Motor Overheats; Thermal Overload Shuts Down Motor (See Warning at beginning of Troubleshooting Table) PowerMax runs but there is no suction in the operatory. PowerMax will not run Leak in PowerMax or piping system. Motor overloaded due to problem with vacuum pump. Motor bearings defective. Listen for noisy bearings. Motor dirty. PowerMax inlet ball valve closed. Open or damaged vacuum piping. Tank drain valve open. Service switches in PowerMax electrical box in "Off" position. Electrical Component is not working properly. Fuse blown. Low Voltage. Check for leaks by allowing PowerMax to reach 20 Hg and shut down. Close the receiver tank inlet valve to isolate unit from piping system. Do not use any vacuum from piping system for several minutes. If the vacuum gauge continues to drop while inlet valve is closed, the leak is within the unit. If the vacuum gauge maintains the same reading, but drops after opening the inlet valve, the leak is in the piping system. See " Pump Overheats". Return unit to Midmark for repair. Clean / vacuum motor vents. Open inlet ball valve. Repair Vacuum lines. Close drain valve. Each PowerMax pump has its own on-off switch. Verify that each switch in the electrical box is in the "On" position. Check Line Voltage. Check fuse. Check Low Voltage. A-10
Section B Testing & Repair Components Page Pump Filters... B-2 Check for Leaks... B-3 Vacuum Switch... B-4 Exhaust Mufflers... B-9 Check Valve... B-10 Low Voltage... B-12 Fuse... B-14 On/Off Switch... B-16 B-1
Testing & Repair Filters Function and Location www.midmark.com: File Name Filter Replacement...10542100 Atmospheric air is drawn in through inlet filter before flowing to the vacuum/motor and exhaust air is released through the outlet filters. Filters protect the pump/motor from moisture and debris. Filters should be changed annually. Outlet Filter Inlet Filter AA217300 B-2 Filters All
Testing & Repair Checking For Leaks Check Step 1: Check for Leaks... Run PowerMax until gauge reaches 20 "Hg. Close the receiver tank inlet valve. Do not use any vacuum for several minutes. Note: If the vacuum gauge continues to drop while the inlet valve is closed, the leak is within the unit. If the vacuum gauge maintains the same reading, but drops after opening the inlet valve, leak is in the piping system. Gauge Valve in Closed Position AA205900 Caution Avoid water contact with electrical parts. Step 2: If gauge shows there is a leak, use soapy water to check for plumbing joint leaks. Soapy Water All Checking for Leaks B-3
Testing & Repair Vacuum Switch Function and Location The vacuum switch regulates the vacuum level. A vacuum gauge monitors the vacuum levels. Vacuum switch is factory set at 13 "Hg. Refer To: Page Adjustment (Check SN on Page)...B-5 & B-6 Testing (Check SN on Page)...B-7 & B-8 Wire Diagrams... D-1 Exploded Views... E-1 AA215400 B-4 Vacuum Switch All
Testing & Repair Vacuum Switch Adjustment *Note - This procedure is only for units with Serial Numbers listed below. Refer to following pages for other Serial Number listings. Check Vacuum Setpoints... Close ball valve and drain valve. Turn PowerMax on. Observe Gauge, unit should shut off at 20 Hg. Open drain valve, unit should turn on at 13 Hg. Perform adjustment if necessary Refer To: Page Location and Function... B-4 Testing... B-7 Electrical Box Cover... C-2 Wiring Diagrams... D-1 Exploded Views... E-1 www.midmark.com: File Name Vacuum Switch Replacement...10399700 Caution When testing components with power on use care to prevent electrical shock. Vacuum Range Switch Adjuster Low Setpoint for Low Limit AA206400 Vacuum Range.. Adjust vacuum range if system didn t shut off at 20 Hg. Clockwise will decrease reading. Counter Clockwise will increase reading. Adjustments Low Setpoint.. Adjust Low Limit if system didn t turn on at 13 Hg. Clockwise will decrease reading. Counter Clockwise will increase reading. PM-1 0701PM10001 thru 0810PM10022 PM-3 PM-4 0701PM30001 thru 0902PM30083 0701PM40001 thru 0811PM40016 Vacuum Switch Rev 3/09 B-5
Testing & Repair Vacuum Switch Adjustment *Note - This procedure is only for units with Serial Numbers listed below. Check Vacuum Setpoints... Close ball valve and drain valve. Turn PowerMax on. Observe Gauge, unit should shut off at 20 Hg. Open drain valve, unit should turn on at 13 Hg. Perform adjustment if necessary Refer To: Page Location and Function... B-4 Testing... B-8 Electrical Box Cover... C-2 Wiring Diagrams... D-1 Exploded Views... E-1 www.midmark.com: File Name Vacuum Switch Replacement...10399700 WARNING High Voltage. When testing components with power on use care to prevent electrical shock. Vacuum Range Switch Adjuster Low Setpoint for Low Limit AA206401 Vacuum Range.. Adjust vacuum range if system didn t shut off at 20 Hg. Clockwise will decrease reading. Counter Clockwise will increase reading. Adjustments Low Setpoint.. Adjust Low Limit if system didn t turn on at 13 Hg. Clockwise will decrease reading. Counter Clockwise will increase reading. B-6 Vacuum Switch PM-1 0810PM10023 thru Present PM-3 0902PM30084 thru Present PM-4 0811PM40017 thru Present All V785000 thru Present Rev 10/09
Testing & Repair Vacuum Switch Testing - *Note - This procedure is only for units with Serial Numbers listed below. Refer to following pages for other Serial Number listings. Step 1: Perform Adjustment. Refer to Section B Vacuum Switch Adjustment. Step 2: Turn power off. Refer To: Page Function and Location... B-4 Adjustment... B-5 Vacuum Switch Cover... C-2 Wire Diagrams... D-1 Exploded Views... E-1 Step 3: Remove vacuum switch cover and verify there are no black/burnt melted wires. If there are replace pressure switch. Refer to Section C Vacuum Switch Cover Step 4: Turn power on. Step 5: Set meter to V. Caution When testing components with power on use care to prevent electrical shock. Meter Reading No Vacuum on Gauge Less than 24 Volts on Reading Status Required Action Replace Vacuum Switch. AA214900 Step 6: Place meter probes on both yellow wires. 24 Volt Reading Vacuum Switch - OK PM-1 0701PM10001 thru 0810PM10023 PM-3 0701PM30001 thru 0902PM30084 PM-4 0701PM40001 thru 0811PM40016 Vacuum Switch Rev 3/09 B-7
Testing & Repair Vacuum Switch Testing *Note - This procedure is only for units with Serial Numbers listed below. Step 1: Perform Adjustment. Refer to Section B Vacuum Switch Adjustment. Step 2: Turn power off. Refer To: Page Function and Location... B-4 Adjustment... B-6 Vacuum Switch Cover... C-2 Wire Diagrams... D-1 Exploded Views... E-1 Step 3: Remove vacuum switch cover and verify there are no black/burnt melted wires. If there are replace pressure switch. Refer to Section C Vacuum Switch Cover Step 4: Turn power on. Step 5: Set meter to V. WARNING High Voltage. When testing components with power on use care to prevent electrical shock. L2 T2 T1 L1 L2 T2 T1 L1 Meter Reading Status Required Action AA214901 Voltage Not Equal T1 & T2 Voltage = L1 & L2 Voltage Replace Vacuum Switch. Vacuum Switch - OK Step 6: Bleed tank vacuum level down to less than 13"Hg. Vacuum swicht will make an audible click. Check line voltage across L1 and L2. Check line voltage across T1 and T2. These voltages should be the same. B-8 Vacuum Switch PM-1 0810PM10023 thru Present PM-3 0902PM30084 thru Present PM-4 0811PM40017 thru Present All V785000 thru Present Rev 10/09
Testing & Repair Exhaust Mufflers Location and Function Refer To: Page Exploded Views... E-1 The exhaust mufflers provide lower sound (dba) levels for the Midmark PowerMax Vacuum System. Exhaust mufflers can be cleaned using a rag. AA217400 All Exhaust Mufflers B-9
Testing & Repair Check Valve Location and Function Refer To: Page Clean... B-11 A check valve is installed into each 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 the "off" pump, creating a loss suction of the rest of the system. AA217500 B-10 Check Valve All
Testing & Repair Check Valve Clean Refer To: Page Function and Location... B-10 Exploded Views... E-1 Step 1: Disconnect power. Step 2: Remove air line tubing from check valve. Disassemble check valve from manifold. AA215000 Step 3: Blow valve out with air to clean. Replace valve if it is sticking. All Check Valve B-11
Testing & Repair Low Voltage - Control Circuit Testing Step 1: Remove electrical box cover. Check for broken or loose wiring. Refer to: Section C Electrical Box Cover *Note - This procedure is only for units with Serial Numbers listed below. Refer to following pages for other Serial Number listings. Relay Refer To: Page Fuse...B-15 Wiring Diagrams... D-1 Exploded Views... E-1 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. Step 4: Insert screwdriver into relay to start manually. Note: If system starts, replace contactor relay. 230 VAC Primary Relay Transformer RED LOW VOLTAGE WHITE CONTROL BLUE WHT BLU YLW 230 VAC Secondary Caution When testing components with power on use care to prevent electrical shock. 1/2 A FUSE BLU 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 contactor connections. Note: Verify reading is 24 volts. Meter Reading High Voltage = < Line Voltage Low Voltage = < 24 Volts High Voltage = Line Voltage Low Voltage = 24 Volts Status Required Action Replace Contactor Relay Replace Transformer Contactor Relay - OK Transformer - OK AA158701i Step 6: Bypass the remote switch to verify it is not defective. Disconnect the Red, White and Blue wires from the remote switch. Connect the Blue and Red wires together. If the relay and fans work, then replace remote switch or wiring. B-12 Low Voltage Rev 3/09 PM-1 0701PM10001 thru 0810PM10022 PM-3 0701PM30001 thru 0902PM30084 PM-4 0701PM40001 thru 0811PM40017
*Note - This procedure is only for units with Serial Numbers listed below. Low Voltage - Control Circuit Testing Step 1: Remove electrical box cover. Check for broken or loose wiring. Refer to: Section C Electrical Box Cover Testing & Repair Refer To: Page Fuse...B-15 Wiring Diagrams... D-1 Exploded Views... E-1 Step 2: Check high voltage on contactor relay. Set meter to V. Place meter probes on indicated wires. Note: Verify reading is 230 volts. Relay Step 4: Insert screwdriver into relay to start manually. Note: If system starts, replace contactor relay. BLU 230 VAC Relay Transformer 24 VAC YEL LOW VOLTAGE CONTROL RED BLUE WHT RED WARNING High Voltage. When testing components with power on use care to prevent electrical shock. Step 5: Check fuse. Refer To: Section B Fuse Step 3: Check Low Voltage from transformer to low voltage wires. Place meter probes on blue and red wire contactor connections. Note: Verify reading is 24 volts. Meter Reading Status Required Action High Voltage = < Line Voltage Low Voltage = < 24 Volts High Voltage = Line Voltage Low Voltage = 24 Volts Replace Contactor Relay Replace Transformer Contactor Relay - OK Transformer - OK AA158702i Step 6: Bypass the remote switch to verify it is not defective. Disconnect the Red, White and Blue wires from the remote switch. Connect the Blue and Red wires together. If the relay and fans work, then replace remote switch or wiring. PM-1 0810PM10023 thru Present PM-3 0902PM30084 thru Present PM-4 0811PM40017 thru Present All V785000 thru Present Low Voltage Rev 10/09 B-13
Testing & Repair Fuse Function and Location The fuse protects the low voltage control system against overload failure, mainly short circuits. It is located in the electrical box and accessed on top of the electrical box. Refer to: Page Testing... B-15 AA215100 B-14 Fuse All
Fuse Check WARNING For continued protection against risk of fire, replace the fuse with a 1/3 amp 250V Slo-Blo type only. Step 1: Turn power off. Testing & Repair Refer to: Page Function and Location... B-14 Electrical Box Cover... C-3 Exploded Views... E-1 Step 2: Remove electrical box cover. Refer to: Section C Electrical box cover Step 4: Remove fuse from electrical box. Push in and turn cap counter clockwise. Step 3: Remove terminal leads. Test continuity. Set meter to Ω. Place meter probes on both fuse terminals. Note: Refer to table below. AA191600 Step 5: Visually check to see if fuse is burnt or broken. Note: If fuse is burnt or broken replace with a 1/3 amp 250V Slo-Blo fuse. AA202500 Meter Reading Status Required Action OL - off line Continuity checks ok Visually looks ok Replace Fuse 1/3 amp 250V Slo-Blo fuse Fuse is Good Step 6: Reinstall into electrical box. Push in and turn cap clockwise until it locks in place. All Fuse B-15
Testing & Repair On/Off Switches Function and Location The On/Off switch send power to the compressor heads. Each compressor head has an On/Off switch which are located in the electrical box. Refer to: Page Testing... B-17 Wire Diagrams... D-1 AA217700 B-16 On/Off Switch All
On/Off Switch Testing Step 1: Remove electrical box cover. Refer to: Section C Electrical Box Step 2: Set meter to V. Testing & Repair Refer to: Page Function and Location... B-16 Electrical Box Cover... C-3 Wire Diagrams... D-1 Caution When testing components with power on use care to prevent electrical shock. Step 4: Place meter probes on top right and top left side. Step 3: Turn switch on. NOTE: If all connections on top but one are reading correct voltage when there is multiple switches, check jumper wire connections. Step 5: Place meter probes on bottom right and bottom left side. Meter Reading Status Required Action Step 6: Turn switch off. 230 Volt < 230 Volts 115 Volt < 115 Volts 230 Volt 230 Volts 115 Volt 115 Volts Replace On/Off Switch On/Off Switch - OK AA191300 All On/Off Switch B-17
Section C Section C Access Procedures Removing & Installing Page Vacuum Switch Cover...C-2 Electrical Box Cover...C-3 C-1
Access Procedures Vacuum Switch Cover Removal/Installation Removal Step 1: Disconnect power. Refer To: Page Exploded Views / Part Numbers... E-1 Removal Step 2: Loosen cap nut. Pull cover off. Installation Step 1: Place cover on vacuum switch. Secure cap nut. AA215900 C-2 Vacuum Switch Cover All
Access Procedures Electrical Box Cover Removal/Installation Refer To: Page Exploded Views / Part Numbers... E-1 Removal Step 1: Disconnect power. Removal Step 2: Loosen screws. Pull cover off. Installation Step 1: Secure cover on front of electrical box. Tighten four screws through front cover. AA215800 All Electrical Box Cover Rev 3/08 C-3
Section D Wiring Diagrams Model Page PowerMax Suction System PM-1... D-2 PM-3... D-3 PM-4... D-4 D-1
Wiring Diagrams PowerMax PM-1 (Single- 208-230 VAC) MOTOR 208-230 VAC 6 3 4 1 BLK HOURS HOUR METER BLK BLK RED GRN/YEL BLU BRN WHT FUSE 3/4 AMP WHT RED ORN SWITCH BLK BLU BLK RED CONTACTOR ORN BLK (Not Used) WHT RED BLU WHT TRANSFORMER TERMINAL BLOCK RED BLK GRN/YEL BLU YEL DEDICATED SUPPLY 208-230 VAC YEL YEL AA214200 L2 T2 T1 L1 VACUUM SWITCH D-2 Wiring Diagrams Rev 3/09 PM-1 0708PM10001 thru 0810PM10022
PowerMax PM-1 (Single 208-230 VAC) Wiring Diagrams PM-1 0904PM10023 thru Present ALL V785000 thru Present Wiring Diagrams Rev 10/09 D-3
Wiring Diagrams PowerMax PM-3 (Twin- 208-230 VAC) LEFT MOTOR 208-230 VAC 6 3 4 1 RIGHT MOTOR 208-230 VAC 6 3 4 1 BLK HOURS HOUR METER BLK BLK RED GRN/YEL BRN WHT BLK RED BRN WHT FUSE 3/4 AMP GRN/YEL BLU WHT RED ORN SWITCH SWITCH BLK BLU BLK RED BLK RED CONTACTOR ORN BLK (Not Used) WHT RED BLU WHT TRANSFORMER TERMINAL BLOCK RED BLK GRN/YEL BLU YEL DEDICATED SUPPLY 208-230 VAC YEL YEL AA214300 L2 T2 T1 L1 VACUUM SWITCH D-4 Wiring PM-3Diagrams All Rev 3/09 PM-3 0708PM30001 thru 0902PM30083
PowerMax PM-3 (Twin 208-230 VAC) Wiring Diagrams PM-3 0902PM30084 thru Present ALL V785000 thru Present Wiring Diagrams Rev 10/09 D-5
Wiring Diagrams PowerMax PM-4 (Triple- 208-230 VAC) LEFT MOTOR 208-230 VAC 6 3 4 1 RIGHT MOTOR 208-230 VAC 6 3 4 1 RIGHT MOTOR 208-230 VAC 6 3 4 1 BLK HOURS HOUR METER BLK BLK BRN WHT RED GRN/YEL BLK RED BRN WHT FUSE 3/4 AMP GRN/YEL BLK RED GRN/YEL BLU WHT RED ORN SWITCH SWITCH BLK BLU BLK RED BLK RED CONTACTOR ORN BLK (Not Used) WHT RED BLU WHT TRANSFORMER TERMINAL BLOCK RED BLK GRN/YEL BLU YEL DEDICATED SUPPLY 208-230 VAC YEL YEL BRN WHT SWITCH L2 T2 T1 L1 VACUUM SWITCH AA214400 D-6 Wiring Diagrams Rev 3/09 PM-4 0708PM40001 thru 0811PM40016
PowerMax PM-4 (Triple 208-230 VAC) Wiring Diagrams PM-4 0811PM40017 thru Present ALL V785000 thru Present Wiring Diagrams Rev 10/09 D-7
Section E Exploded Views & Parts Lists Model: Page PM-1, PM-3, PM-4... E-2 Midmark Corporation 2006 SF-1920 E-1
PowerMax PM-1 PM-3 PM-4 Installation Kit...E-3 Label Locations...E-8 Pump / Motor...E-7 Electrical Box...E-6* Tank and Main Components...E-4 Pneumatic Tubes and Hoses...E-5* AA216100 E-2 Midmark Corporation 2007 SF-1915 * Indicates multiple pages due to a model / serial number break for the parts illustration
1 62976701 2 040-0312-00 3 MRP70967 AA216200 Item Description Qty. 20199900 Kit (includes items 1-4) 1 Vac Hose Assembly (1/2"x1/2", 72"L)... 1 2 Bolt (5/16-18" x 1/2"")... 4 3 Rubber Foot... 4 Always Specify Model & Serial Number PM-1 0708PM10001 thru Present PM-3 0708PM30001 thru Present PM-4 0708PM40001 thru Present All V785000 thru Present Installation Kit Rev 10/09 E-3
AA215900 Refer To: Page Electrical Box Assembly...E-7 1 040-0375-00 BBT20107 14 2 a) 64934600 b) 64997500 77002017 13 3 a) 64997100 b) 64997200 64997700 11 BBT20107 12 64997900 10 77009108 9 62947800 62903216 8 7 6 4 10378600 5 62903310 62906105 AA216300 Item Description Qty. 1 Hex Flange Screw (3/8"-16 x 3/4")... 1 2 a) 20 Gal Saddle (PM-1 & PM-3 Models)... 1 b) 32 Gal Saddle (PM-4 Model)... 1 3 a) 20 Gal Tank (PM-1 & PM-3 Models)... 1 b) 32 Gal Tank (PM-4 Model)... 1 4 Ball Valve (1/2" NPT)... 1 5 Nipple, Close, Steel (1/2" NPT)... 1 6 Elbow 90 degree (1/2" NPT)... 1 7 Nipple, L, (1/2" NPT x 3" LG)... 1 8 Gauge (0-30 IN HG / 0-76 CM HG)... 1 9 Phillips Screw (#6-32)... 1 10 Control Box Cover... 1 11 Control Box... 1 (Also refer to: Electrical Box Assembly) 12 Tee (5/16"-18 x 1-1/4")... 1 13 Nipple, Close (1/2" NPT)... 1 14 Flange Head (1/4"-20)... 3 Always Specify Model & Serial Number E-4 Tank and Main Components Rev 8/11 PM-1 0708PM10001 thru Present PM-3 0708PM30001 thru Present PM-4 0708PM40001 thru Present All V785000 thru Present
Note: New style 24 vac Vacuum Switch replaces the old style switch for this serial break only. 1 10600600 New Style 24vac Refer To: Page Check Valve Assembly...B-8 Vacuum Switch...B-4 Old Style Vacuum Switch 2 a) 30166902 b) 30172402 Note: Configuration Shown is for a PM-3. PM-1 & PM-4 May Have Different Quantities of Items, Refer to Item List. 4 5 3 a) 20169204 b) 20169205 c) 20169206 77002017 62986800 77006066 10 9 11 8 5 4 10378700 6 62933902 a) 64997100 b) 64997200 7 3 AA216400-1 PVV50525 Item Description Qty. 1 Vacuum Switch... 1 2 Manifold Block a) Models PM-1 and PM-3 (20 Gal)... 1 b) Model PM-4 (32 Gal)... 1 3 Hoses a) PM-1, PM-3, PM-4 (24"Length)... 2 b) PM-3 & PM-4 Only (32" Length)... 1 c) PM-4 Only (44" Length) Not Shown... 1 4 90 degree Elbow (1/2" FTF x 3/8" NPT) PM-1... 1 PM-3... 2 PM-4... 3 5 Check Valve (1/2" NPT)... PM-1... 1 PM-3... 2 PM-4... 3 6 Tank a) PM-1 & PM-3 (20 Gal)... 1 b) PM-4 (32 Gal)... 1 7 Petcock Assembly... 1 8 Ball Valve. Ref Tank and Main Components 9 Pipe Plug (1/2" NPT)... 1 10 Bulkhead Anchor (1/2")... 1 11 Nipple, Close (1/2" NPT)... PM-1... 2 PM-3... 3 PM-4... 4 Always Specify Model & Serial Number PM-1 0708PM10001 thru 0904PM10022 PM-3 0708PM30001 thru 0902PM30083 PM-4 0708PM40001 thru 0811PM40016 Pneumatic Tubes and Hoses Rev 7/14/17 E-5
Note: Configuration Shown is for a PM-3. PM-1 & PM-4 May Have Different Quantities of Items, Refer to Item List. 1 2 30126601 62900512 Test Refer To: Page Check Valve Assembly...B-8 Vacuum Switch...B-4 3 a) 30166902 b) 30172402 5 6 4 a) 20169204 b) 20169205 c) 20169206 77002017 62986800 77006066 11 10 12 9 6 5 10378700 7 62933902 a) 64997100 b) 64997200 8 4 AA216400 PVV50525 Item Description Qty. 1 Vacuum Switch... 1 2 Nipple, Hex (1/4" NPT x 1/4" NPT)... 1 3 Manifold Block a) Models PM-1 and PM-3 (20 Gal)... 1 b) Model PM-4 (32 Gal)... 1 4 Hoses a) PM-1, PM-3, PM-4 (24"Length)... 2 b) PM-3 & PM-4 Only (32" Length)... 1 c) PM-4 Only (44" Length) Not Shown... 1 5 90 degree Elbow (1/2" FTF x 3/8" NPT) PM-1... 1 PM-3... 2 PM-4... 3 6 Check Valve (1/2" NPT)... PM-1... 1 PM-3... 2 PM-4... 3 7 Tank a) PM-1 & PM-3 (20 Gal)... 1 b) PM-4 (32 Gal)... 1 8 Petcock Assembly... 1 9 Ball Valve. Ref Tank and Main Components 10 Pipe Plug (1/2" NPT)... 1 11 Bulkhead Anchor (1/2")... 1 12 Nipple, Close (1/2" NPT)... PM-1... 2 PM-3... 3 PM-4... 4 Always Specify Model & Serial Number E-5.1 Pneumatic Tubes and Hoses Rev 10/29/15 PM-1 0904PM10023 thru V1706473 PM-3 0902PM30084 thru V1706473 PM-4 0811PM40017 thru V1706473 All V785000 thru V1706473
Note: Configuration Shown is for a PM-3. PM-1 & PM-4 May Have Different Quantities of Items, Refer to Item List. 1 2 30126601 62900512 Test Refer To: Page Check Valve Assembly...B-8 Vacuum Switch...B-4 3 a) 30166902 b) 30172402 5 6 4 a) 20169204 b) 20169205 c) 20169206 77002017 62986800 014-0344-00 11 10 12 9 6 5 10378700 7 62933902 a) 64997100 b) 64997200 8 4 AA216400 PVV50525 Item Description Qty. 1 Vacuum Switch... 1 2 Nipple, Hex (1/4" NPT x 1/4" NPT)... 1 3 Manifold Block a) Models PM-1 and PM-3 (20 Gal)... 1 b) Model PM-4 (32 Gal)... 1 4 Hoses a) PM-1, PM-3, PM-4 (24"Length)... 2 b) PM-3 & PM-4 Only (32" Length)... 1 c) PM-4 Only (44" Length) Not Shown... 1 5 90 degree Elbow (1/2" FTF x 3/8" NPT) PM-1... 1 PM-3... 2 PM-4... 3 6 Check Valve (1/2" NPT)... PM-1... 1 PM-3... 2 PM-4... 3 7 Tank a) PM-1 & PM-3 (20 Gal)... 1 b) PM-4 (32 Gal)... 1 8 Petcock Assembly... 1 9 Ball Valve. Ref Tank and Main Components 10 Pipe Plug (1/2" NPT)... 1 11 Bulkhead Anchor (1/2")... 1 12 Nipple, Close (1/2" NPT)... PM-1... 2 PM-3... 3 PM-4... 4 Always Specify Model & Serial Number PM-1 & PM-3 V1706474 thru Present PM-4 V1706474 thru Present Pneumatic Tubes and Hoses E-5.2 Rev 10/29/15
Note: Configuration Shown is for a PM-1. PM-3 & PM-4 May Have Different Quantities of Items, Refer to Item List. 2 1 65927500 77001402 Test 3 20235600 Refer To: Page Low Voltage (Contactor)...B-12 On / Off Switch...B-17 Fuse...B-15 1 4 015-0002-06 5 64997700 62964303 13 Test 015-2029-00 12 Test BNT20210 11 77001130 10 015-1986-00 8 9 6 8 AA213100 77001090 7 62970704 62503801 6 Item Description Qty. 1 Fuse Holder... 1 2 Fuse (3/4 AMP, 250 Volt)... 1 3 Hour Meter... 1 4 Strain Relief Bushing... 1 5 Control Box a) PM-1 & PM-3... 1 b) PM-4... 1 6 Rubber Grommet... 1 7 Terminal Block... 1 8 Screw (#8 x 3/8")... 4 9 Transformer... 1 10 Switch - Motor PM-1... 1 PM-3... 2 PM-4... 3 11 Keps, Lock Nut (#10-32)... 2 12 Contactor... 1 13 Rail... 1 Always Specify Model & Serial Number PM-1 0708PM10001 thru 0810PM10022 PM-3 0708PM30001 thru 0902PM30083 PM-4 0708PM40001 thru 0811PM40016 Electrical Box Rev 9/09 E-6
Note: Configuration Shown is for a PM-1. PM-3 & PM-4 May Have Different Quantities of Items, Refer to Item List. 2 1 65927500 77001402 Test 3 20235600 Refer To: Page Solenoid Low Voltage...B-14 (Contactor) B-12 On / Off Switch...B-17 Fuse... B-15 1 4 015-0002-06 5 64997700 62964303 13 Test 015-2029-00 12 Test BNT20210 77001130 11 10 015-1986-00 8 9 6 8 7 62503801 AA213100 77001090 62970705 6 Item Description Qty. 1 Fuse Holder... 1 2 Fuse (1/3 AMP, 250 Volt)... 1 3 Hour Meter... 1 4 Strain Relief Bushing... 1 5 Control Box a) PM-1 & PM-3... 1 b) PM-4... 1 6 Rubber Grommet... 1 7 Terminal Block... 1 8 Screw (#8 x 3/8")... 4 9 Transformer... 1 10 Switch - Motor PM-1... 1 PM-3... 2 PM-4... 3 11 Keps, Lock Nut (#10-32)... 2 12 Contactor... 1 13 Rail... 1 Always Specify Model & Serial Number E-6.1 Electrical Box Rev 10/09 PM-1 0810PM10023 thru Present PM-3 0902PM30084 thru Present PM-4 0811PM40017 thru Present
61894900 10 1 20169300 77007063 9 2 77009194 3 62600207 77000796 6 4 62600117 77000788 8 5 77007029 Item Description Qty. 7 77000789 AA216500 1 Replacement Vacuum Pump... 1 2 Hex Nut (5/16"-18)... 4 3 Lock Washer (5/16")... 4 4 Flat Washer (5/16")... 4 5 Isolator, Vibration Mount... 4 6 Replacement Filters, Inlet and Exhaust... 2 7 O-Ring... 2 8 Knob... 2 9 Replacement Exhaust Silencer... 1 10 Capacitor... 1 Items 11 & 12 are Not Shown 11 Flushing Solvent (77000699)... 1 12 Vane Rebuild Kit (77000540)... 1 Always Specify Model & Serial Number PM-1 0708PM10001 thru Present PM-3 0708PM30001 thru Present PM-4 0708PM40001 thru Present All V785000 thru Present Pump / Motor Rev 10/09 Rev 9/10 E-7
65973200 9 MPM60658 8 65963400 7 6 62970502 63947500 5 65969700 4 63947100 3 2 62985500 AA216600 1 63947700 Item Description Qty. 1 PowerMax Serial Number Label... 1 2 Warning Label... 1 3 Midmark Logo Label... 1 4 Ground Label... 1 5 PowerMax Logo Label... 1 6 Electrical Hookup Label... 1 7 Fuse Replacement Label (3/4 AMP)... 1 8 Label, 24V Light... 1 9 PowerMax Exhaust Warning Label... 1 Always Specify Model & Serial Number E-8 Label Locations Rev 10/09 PM-1 0708PM10001 thru Present PM-3 0708PM30001 thru Present PM-4 0708PM40001 thru Present All V785000 thru Present
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