Champion Simplex Installation and operating instructions

CQF3475 v.02 August 06, 2019
Control Panel
OPERATION & SERVICE MANUAL
Simplex Units
THIS MANUAL CONTAINS IMPORTANT SAFETY INFORMATION AND SHOULD ALWAYS
BE AVAILABLE TO THOSE PERSONNEL OPERATING THIS UNIT. READ, UNDERSTAND
AND RETAIN ALL INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT TO PREVENT
INJURY OR EQUIPMENT DAMAGE.
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 2 CQF3475 v.02
Operation & Service August 06, 2019
Safety and Operation Precautions
Champion compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving
maximum service from this machine, the owner must exercise care in its operation and maintenance. This book is
written to give the operator and maintenance department essential information for day-to-day operation,
maintenance and adjustment. Careful adherence to these instructions will result in economical operation and
minimum downtime.
Boxed text formats are used within this manual to alert users of the following conditions:
Indicates a hazard with a high level of risk, which if not avoided, WILL result in death or serious
injury.
Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or
serious injury.
Indicates a hazard with a low level of risk which, if not avoided, MAY result in a minor or moderate
injury.
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 3 CQF3475 v.02
Operation & Service August 06, 2019
Safety and Operation Precautions
Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances
cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for
safety hazards and be cautious. Some general safety precautions are given below:
Failure to observe these notices will result in injury to or death of personnel.
Keep fingers and clothing away from rotating fan, drive coupling/belting, etc.
Disconnect the compressor unit from its power source, lockout and tagout before working on the unit –
this machine is automatically controlled and may start at any time.
Do not loosen or remove the belt covers, or break any connections, etc., in the compressor air system
until the unit is shut down and the air pressure has been relieved.
Electrical shock can and may be fatal.
Perform all wiring in accordance with the National Electrical Code (NFPA-70) and any applicable local
electrical codes. Wiring and electrical service must be performed only by qualified electricians.
Open main disconnect switch, lockout and tagout and check for voltage before working on the control.
REFER TO THE COMPRESSOR OPERATION & SERVICE MANUAL FOR ADDITIONAL IMPORTANT SAFETY
INFORMATION.
Failure to observe these notices could result in damage to equipment.
Stop the unit if any repairs or adjustments on or around the compressor are required.
Do not use the air discharge from this unit for breathing unless used in accordance with NFPA99
compliant Level 1 Medical Air Supply and Filtration Systems.
An Excess Flow Valve should be on all compressed air supply hoses exceeding 1/2 inch inside diameter
(OSHA Regulation, Section 1926.302).
Do not exceed the rated maximum pressure values shown on the nameplate.
Do not operate unit if safety devices are not operating properly. Check periodically. Never bypass safety
devices.
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 4 CQF3475 v.02
Operation & Service August 06, 2019
Table of Contents
Section 1 –Revision History..........................................................................................................................5
Section 2 –General Info................................................................................................................................5
2.1 Features..............................................................................................................................................5
Section 3 –Control Panel Start Up and Operation .......................................................................................6
3.1 Apply Power.................................................................................................................................6
3.2 Motor Jog..................................................................................................................................... 7
3.3 Automatic Operation...................................................................................................................7
Section 4 –Wiring Diagrams.........................................................................................................................8
4.1 No Protection Circuit - 115V, 1 Phase .........................................................................................8
4.2 No Protection Circuit - 208V thru 230V, 1 Phase ........................................................................9
4.3 No Protection Circuit - 208V thru 575V, 3 Phase ......................................................................10
4.4 With Protection Circuit - 115V, 1 Phase ....................................................................................11
4.5 With Protection Circuit - 208V thru 230V, 1 Phase ...................................................................12
4.6 With Protection Circuit - 208V thru 575V, 3 Phase ...................................................................13
4.7 No Protection Circuit - with Hour Meter & Selector Switch - 115V, 1 Phase............................14
4.8 No Protection Circuit - with Hour Meter & Selector Switch - 208V thru 230V, 1 Phase...........15
4.9 No Protection Circuit - with Hour Meter & Selector Switch - 208V thru 575V, 3 Phase...........16
4.10 With Protection Circuit - with Hour Meter & Selector Switch - 115V, 1 Phase.........................17
4.11 With Protection Circuit - with Hour Meter & Selector Switch - 208V thru 230V, 1 Phase........18
4.12 With Protection Circuit - with Hour Meter & Selector Switch - 208V thru 575V, 3 Phase........19
4.13 3 Phase Hydrovane Simplex Control Panel................................................................................20
4.14 1 Phase Hydrovane Simplex Control Panel................................................................................21
Section 5 –Parts List ...................................................................................................................................22
5.1 No Protection Circuit - 115V......................................................................................................22
5.2 No Protection Circuit - 208V, 230V, & 460V..............................................................................24
5.3 No Protection Circuit - 208V (25-30hp) & 230V (30hp).............................................................26
5.4 No Protection Circuit - 575V......................................................................................................28
5.5 With Protection Circuit - 115V...................................................................................................30
5.6 With Protection Circuit - 208V, 230V, & 460V ..........................................................................32
5.7 With Protection Circuit - 208V (25-30hp) & 230V (30hp) .........................................................34
5.8 With Protection Circuit - 575V...................................................................................................36
Section 6 –Aftermarket..............................................................................................................................38
6.1 Voltage Conversion Kits.............................................................................................................38
6.2 Selector Switch ..........................................................................................................................39
6.3 Hour Meter................................................................................................................................40
Notes...........................................................................................................................................................41
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 5 CQF3475 v.02
Operation & Service August 06, 2019
Section 1 – Revision History
Version
Date
Notes
00
12-4-17
First Release
01
04-17-18
Second Release
02
08-06-19
Third Release
Section 2 – General Info
The Simplex Control System uses relay based devices to control the operation of the simplex
compressor unit.
2.1 Features
NEMA 1 Enclosure (NEMA 4 optional)
120VAC Relay Controlled
Selector Switch
Optional Test-Off-Auto switch on reciprocating compressors
Standard Hand-Off-Auto-compressor selector switch (Hydrovane only).
Optional Compressor Hour Meter
Optional circuitry for the following safety controls:
Low oil level
Low oil pressure
Auto Restart in case of power failure
High temperature shut down
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 6 CQF3475 v.02
Operation & Service August 06, 2019
Section 3 – Control Panel Start Up and Operation
This start-up guide assumes the compressor package has been properly connected to an electrical
supply conforming to all National and Local electrical codes.
3.1 Apply Power
When energizing the control panel for the first time:
1. Ensure the selector switch is in the OFF position (if equipped).
2. Apply power to the control panel.
3. Press the START/RESET button (if equipped).
See Figure 3-1 below for the layout of the selector switch and push buttons on the Simplex Control
Panel.
ELAPSED TIME
HOUR METER
SELECTOR
SWITCH
START/RESET
BUTTON
OVERLOAD
RESET BUTTON
Figure 3-1: Simplex Control Panel Layout
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Simplex Control Panel 7 CQF3475 v.02
Operation & Service August 06, 2019
3.2 Motor Jog
Prior to automatic operation of the unit, each motor in the system MUST be jogged to ensure proper
compressor rotation direction.
IMPORTANT: Extended rotation in the incorrect direction can cause catastrophic damage to the
compressor.
If equipped with selector switch, jog motor using the TEST position. Verify correct rotation
direction.
If equipped with HOA (Hydrovane only), jog motor using the HAND position. Verify correct
rotation direction.
If not equipped with selector switch, jog motor using main disconnect.
3.3 Automatic Operation
Automatic starting of the compressor can cause injury or death
After the proper pump rotation has been verified:
If equipped with selector switch, place in the AUTO position to start the automatic sequencing
of the compressor.
If not equipped with selector switch, main disconnect can be closed and automatic sequencing
will be provided by the pressure switch.
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 8 CQF3475 v.02
Operation & Service August 06, 2019
Section 4 – Wiring Diagrams
4.1 No Protection Circuit - 115V, 1 Phase
347CAS546-01
Ref. Drawing
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 9 CQF3475 v.02
Operation & Service August 06, 2019
Section 4 – Wiring Diagrams (cont.)
4.2 No Protection Circuit - 208V thru 230V, 1 Phase
344CAS546-01
Ref. Drawing
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 10 CQF3475 v.02
Operation & Service August 06, 2019
Section 4 – Wiring Diagrams (cont.)
4.3 No Protection Circuit - 208V thru 575V, 3 Phase
343CAS546-01
Ref. Drawing
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 11 CQF3475 v.02
Operation & Service August 06, 2019
Section 4 – Wiring Diagrams (cont.)
4.4 With Protection Circuit - 115V, 1 Phase
348CAS546-02
Ref. Drawing
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 12 CQF3475 v.02
Operation & Service August 06, 2019
Section 4 – Wiring Diagrams (cont.)
4.5 With Protection Circuit - 208V thru 230V, 1 Phase
346CAS546-02
Ref. Drawing
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 13 CQF3475 v.02
Operation & Service August 06, 2019
Section 4 – Wiring Diagrams (cont.)
4.6 With Protection Circuit - 208V thru 575V, 3 Phase
345CAS546-02
Ref. Drawing
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 14 CQF3475 v.02
Operation & Service August 06, 2019
Section 4 – Wiring Diagrams (cont.)
4.7 No Protection Circuit - with Hour Meter & Selector Switch -
115V, 1 Phase
347CAS546-L2-00
Ref. Drawing
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 15 CQF3475 v.02
Operation & Service August 06, 2019
Section 4 – Wiring Diagrams (cont.)
4.8 No Protection Circuit - with Hour Meter & Selector Switch -
208V thru 230V, 1 Phase
344CAS546-L2-00
Ref. Drawing
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 16 CQF3475 v.02
Operation & Service August 06, 2019
Section 4 – Wiring Diagrams (cont.)
4.9 No Protection Circuit - with Hour Meter & Selector Switch -
208V thru 575V, 3 Phase
343CAS546-L2-00
Ref. Drawing
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 17 CQF3475 v.02
Operation & Service August 06, 2019
Section 4 – Wiring Diagrams (cont.)
4.10 With Protection Circuit - with Hour Meter & Selector Switch -
115V, 1 Phase
348CAS546-L2-00
Ref. Drawing
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 18 CQF3475 v.02
Operation & Service August 06, 2019
Section 4 – Wiring Diagrams (cont.)
4.11 With Protection Circuit - with Hour Meter & Selector Switch -
208V thru 230V, 1 Phase
346CAS546-L2-00
Ref. Drawing
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
1-888-229-9999

Simplex Control Panel 19 CQF3475 v.02
Operation & Service August 06, 2019
Section 4 – Wiring Diagrams (cont.)
4.12 With Protection Circuit - with Hour Meter & Selector Switch -
208V thru 575V, 3 Phase
345CAS546-L2-00
Ref. Drawing
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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Simplex Control Panel 20 CQF3475 v.02
Operation & Service August 06, 2019
Section 4 – Wiring Diagrams (cont.)
4.13 Hydrovane Simplex Control Panel, 3 Phase
301HHS546-00
Ref. Drawing
MCGUIRE AIR COMPRESSORS INC
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MCGUIRE AIR COMPRESSORS INC
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