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MP Systems V Series, Installation Operation & Maintenance

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INSTALLATION, OPERATION, & MAINTENANCE MANUAL 

V Series 

MP Systems - 34 Bradley Park Road, East Granby, CT 06026 USA - Phone + 1 (877)-689-1860 - Email mpteam@mp-

systems.net 

Summary of Contents for V Series

Page 1: ...INSTALLATION OPERATION MAINTENANCE MANUAL V Series MP Systems 34 Bradley Park Road East Granby CT 06026 USA Phone 1 877 689 1860 Email mpteam mp systems net ...

Page 2: ...sales team and manufacturing personnel MP SYSTEMS high pressure coolant systems accessories are low maintenance and longer lasting MP SYSTEMS prides itself on building and supporting a dependable product Our team works closely with CNC machine tool manufactures distributors and customers to provide excellent customer service These relationships facilitate superior application experiences Our goal ...

Page 3: ...Proofed By 00 Original 06 05 2014 S Devlin 01 Updated all control signal electrical drawings Updated KVA Added Aeration explanation 12 24 2014 S Devlin 02 Filter bag replacement images Formatting Updated mpteam mp systems net 05 19 2015 S Devlin 03 Added introduction and Symbology Updated safety measures Formatting ...

Page 4: ...age 12 6 3 Moving with a Fork Truck 12 6 4 Storage 13 7 Installation 14 7 1 Installation Kit Components 14 7 2 Recommended Tools for Installation 14 7 3 Electrical Installation 15 7 3 1 Power Signal Installation 15 7 3 2 3 Phase Power Cable Installation 15 7 3 3 Control Signal Cable Installation 16 7 4 Low Pressure Hose Installation 20 7 5 High Pressure Installation 21 7 5 1 Generic 4 Port Install...

Page 5: ...intenance 28 9 1 Filter Bag Replacement 29 9 2 Basic Pump Maintenance 30 10 Options Accessories 31 10 1 Options 31 11 Spare Parts 32 11 1 Relief Valve Identifier 33 Appendix A Hoses Fittings 34 Appendix B Pipe Sizing 36 Appendix C Power Harness 37 ...

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Page 7: ...th authors rights MP SYSTEMS does not accept responsibility for any inaccuracies contained in this manual whether due to errors in printing or transcription It furthermore reserves the right to carry out such modifications to its products as it considers necessary and or useful without compromising their essential characteristics MP SYSTEMS does not accept responsibility for improper use of the eq...

Page 8: ... dangerous voltage Failure to heed this warning carries a risk of injury or death WARNING Indicates a possible danger situation Failure to heed this warning carries a risk of injury INFORMATION Indicates important information or advice on the use of the machine FLAMMABLE Indicates possible flammable material LOCK OUT TAG OUT Lock Out Tag Out R Series before service can be done ...

Page 9: ...sonnel following the instructions contained in this manual Always keep a copy of this manual near the machine Carry out routine maintenance operations with great care have worn or damaged parts replaced by qualified personnel and use original parts or those recommended by MP SYSTEMS To function correctly and for operator security the MP unit must be operated with all panels in place and secured Da...

Page 10: ...g against edged sheet metal profiles 2 2 Prevention of Mechanical Risks In operation MP System s products contain some moving parts These parts constitute a possible source of danger to the operator therefore in order to avoid any possible danger it is necessary to observe the following operational rules Before removing any panels guards ensure electricity supply to the machine has been switched o...

Page 11: ...anies Before carrying out any work on the unit switch off the electrical supply at the main isolator Work on the unit must only be carried out by authorized personnel Always replace worn out or defective components Before working on electrical equipment always read the manual that contains the machines circuit diagram Always make sure there is no electric power to the equipment Check to ensure the...

Page 12: ...the machine tool and its coolant much cleaner The V 2 Series has CNC controlled outlet ports that are to be turned on as needed so the high pressure is used only on the tool in the cut This allows maximum pressure to be used when needed but limits detrimental effects of high pressure coolant The V 2 Series is intended for use with coolants with viscosities between 90 and 140 SUS 100 F It can work ...

Page 13: ... easily recognized through the lack of re cutting of chips Heavy cuts can be made far more reliably with high pressure coolant Tools that smoke or burn will see tool life greatly improved This allows for much heavier cuts with tools that can be pushed much harder greatly improving cycle times Jobs already being run with flood coolant will see dramatic increase in productivity with high pressure co...

Page 14: ...dentification Label Pump Type Serial Number Build Date Operating Voltage 208 230VAC 460VAC FLA Full load Amps Largest load for determining power service requirements The operating voltage may be changed in the field if necessary Changing the operating voltage can only be done by specialized personnel Not available on all systems All specifications are subject to change ...

Page 15: ...ain 7 5 1750 21 20 10 5 Feed Pump 1 0 3450 3 5 3 4 1 7 Heat Exchanger 0 33 3425 1 1 0 55 Control Power Isolated Control Signals Alarm Circuit 150VA Transformer 24vdc NC 110VAC Secondary NO Primary Fused Optional 4 port variants Model 208 230 VAC 460 VAC kVA V 2 SO2 25 12 10 V 2 SO8 25 12 10 V 2 SW2 25 12 10 V 2 SW8 25 12 10 V 2 HO2 26 13 10 5 V 2 HO8 26 13 10 5 V 2 HW2 26 13 10 5 V 2 HW8 26 13 10 ...

Page 16: ...imensions Rating HB BAG ORING 2 5MC 7 x 32 4 4 ft 7 x 32 5 Micron Environments Temperature range 41º 104º F Relative humidity 20 95 noncondensing Voltage range 85 115 The V 2 Series should be placed on the floor to avoid damaging vibrations The V 2 Series should be moved on its own castors or by lifting from underneath All covers should be on during operation ...

Page 17: ...11 5 Floor Layout ...

Page 18: ...ase of unit The machine must be moved in such a way as to avoid the risk of damage Do not attempt to lift the machine with equipment that is inadequate or unsuitable especially with equipment that is too small for overall weight of machine Refer to the Mechanical Specifications section for unit weight Before moving machine take care to ensure that all removable panels are firmly attached to the un...

Page 19: ...lease refer to coolant manufacture for correct flushing agent Removing all coolant from the system will ensure coolant does not become contaminated while in the system Contaminated coolant may lead to malfunctions Not properly draining flushing the unit before storage can lead to jammed solenoids diaphragms that become stuck and bacterial growth Bacterial growth will contaminate any coolant it com...

Page 20: ...l Signal Harness 1 Spare 5 Micron Filter Bag 1 Operation Installation Manual 1 Inlet Dip Tube 1 Return Dip Tube 1 1 1 4 Diameter Inlet Hose 15 1 1 4 Diameter Return Hose 15 2 Hose Clamp 2 Hose Clamp 2 Weld Clamp Mounting Dip Tubes 1 Self Taping Hex Screws Mounting Weld Clamps 2 7 2 Recommended Tools for Installation Philips Cross Head Screwdriver Flat Blade Screwdriver Electric Drill 7 8 UniBit St...

Page 21: ...on Verify on the service tag of machine that the 3 phase power is adequate for the FLA of V 2 Series V 2 Series FLA is located on identification label and in the Electrical Specifications Section of this manual Confirm correct voltage from supply power with voltage on V 2 Series identification label If available power is too great a circuit breaker will need to be installed Normally shipped with V...

Page 22: ...UMMY PLUG 19 Pin Only 2 Wire signals needed to perform desired pump function All MP signals are 24vdc Relays may need to be installed for 110VAC signals Signals and M codes may vary between machines Confirm with machine tool electrical drawing before wiring Some external M codes may require latching functions MP Alarm contains both NC and NO connections through 1 common NC alarms are typically wir...

Page 23: ... Port 7 13 PORT 8 Turns on Port 8 14 N A N A 15 N A N A 16 NO ALARM OUT Closes on MP Fault GRN PE Ground Wire V 2 19 Pin 1 4 Port Function 1 PORT 1 Turns on Port 1 2 PORT 2 Turns on Port 2 3 PORT 3 Turns on Port 3 4 PORT 4 Turns on Port 4 5 0v 0v Common 6 Dump Valve On Opens Dump Valve 7 ALARM COM 24v 24 Vdc 8 NC ALARM OUT Opens on MP Fault 9 24 Vdc 24 Vdc from MP Pump 10 NO ALARM OUT Closes on MP...

Page 24: ... 5 0v 0v Common 6 Dump Valve On Opens Dump Valve 7 ALARM COM 24v 24 Vdc 8 NC ALARM OUT Opens on MP Fault 9 24 Vdc 24 Vdc from MP Pump 10 PORT 5 Turns on Port 5 11 PORT 6 Turns on Port6 12 PORT 7 Turns on Port 7 13 PORT 8 Turns on Port 8 14 N A N A 15 N A N A 16 NO ALARM Closes on MP Fault 17 N A N A 18 N A N A 19 N A N A GRN PE Ground ...

Page 25: ... Applications Typical lathe configurations consist of wiring in series with the existing low pressure contactor along with an external M Code This allows for both low and high pressure pumps to be utilized Wiring through low pressure contactor before external M Codes ensures the MP V Series Pump will shut down whenever machine is in hard alarm Typical lathe applications use wire 9 to supply 24vdc ...

Page 26: ...always touching bottom of the tank to ensure proper suction of coolant 2 Run the Inlet and Return hose to their respected connections The V 2 Series return and inlet are clearly marked so there is no confusion of where to place them Connect the inlet hose with the 2 2 hose clamps supplied in V 2 Series Instillation Kit Inlet Return hoses should be no longer than 15 Hoses must be placed on floor ne...

Page 27: ...e routing inside machining cabinet 7 5 1 Generic 4 Port Installation Depending on the options installed on machine tool holes may need to be drilled and JIC Bulkheads will need to be installed Locate suitable location for 4 holes to be drilled Use caution to make sure there is clearance for hoses to be routed on the inside of the machine tool cabinet Install 4 JIC Bulkheads included in installatio...

Page 28: ...3 Drill 4 pilot holes in each corner of 3 x11 rectangle Holes must be large enough for small jigsaw blade or sawzall blade to fit through 4 Cut out rectangle starting in one of the four pilot holes 5 Using supplied mounting bracket lineup center hole with hole in machine cabinet and mark the 6 screw holes on perimeter of mounting bracket 6 Tap 6 holes for M6 7 Using a high performance RTV Silicone...

Page 29: ...23 ...

Page 30: ...ur coolant into filter vessel you can see coolant start to trickle out of feed pump inlet Keep this valve open until coolant comes out of the feed pump inlet and starts to fill up the hose on the inlet side of the feed pump This may take a few minutes After the hose is about full of coolant close the T handle ball valve and reseal the filter lid The feed pump has now been primed with coolant and i...

Page 31: ...inside V 2 Series will designate dump solenoid 7 Trip the overload inside the V 2 Series electrical panel to ensure machine reports error and stops running 8 3 Start Up Coolant from the machine tool is pumped into the top of filter vessel The coolant is pumped by a self priming pump inside the V Series high pressure system through a set of valves Coolant flows through a 5 micron nominal size 2 pol...

Page 32: ...ode 4 Slowly turn regulator clock wise to achieve desired PSI This will dead head the pump to maximum output so as to not let the pump ever go over rated PSI setting 5 Once desired pressure is acquired shut down high pressure system 6 Reattach supplied high pressure lines 7 High Pressure system is ready to run On lathe applications when high pressure is tee d into machine tools low pressure pump s...

Page 33: ...ool in to feed hold MP Systems recommends using Normally Closed alarm circuits This will allow machine tool to go into alarm if the V 2 Series ever becomes disconnected from machine tool 8 4 1 Alarm Descriptions Alarm Display Symptom s Cause Red Light 1 Clogged Filter s 2 Prime Issue 3 Machine Coolant Tank Screen Clogged 4 Clogged Hose s 5 Sucking in Air 6 Improper Feed Pump Rotation Pressure is b...

Page 34: ...and fluid components inside the machine tool such as added nozzles Filter bag service intervals will vary widely depending upon application Filter bag must be changed when the pump goes into alarm As the filter bag becomes plugged the feed pump will run more often Smaller the fines the more often the filter bag will need to be replaced Filter Bag must be changed when Red Dirty Filter Button is ill...

Page 35: ... pressure system 2 Let pressure equalize for 30 seconds 3 Loosen 3 galvanized eye bolts on filter cover Lift away filter top 4 Slowly lift filter bag by handles on bag seal coolant should drop as bag is lifted 5 Install new bag 6 Replace filter top and secure 3 galvanized eye bolts ...

Page 36: ...Pump Crank Case Maintenance HydraCell Only Hydracell crank case uses high quality 10w 30 motor oil MP Systems recommends Synthetic motor oil Change after first 100 hours After initial change change every 2000 hours of pump operation ...

Page 37: ...ill greatly benefit from this option Remote 8 Port Valve Block MP Systems standard configuration for V 2 Series high pressure system The remote valve block is mounted on machine tool with 8 ports facing inside the cabinet This allows for only one house running form the V 2 Series to the machine tool Another benefit of the remote valve block is the reduced pressure on ports 3 4 Remote 12 Port MP Sy...

Page 38: ...r ED CA7 30 00 120 Heat Exchanger and Supply Pump Motor Contactor ED CA8 9 10 120 7 5HP Motor Overload 200 208 230VAC 460VAC ED KTA7 25H 25A ED KTA7 25H 16 1HP Feed Supply Pump Overload 200 208 230VAC 460VAC ED KTA7 25S 4A ED KTA7 25S 2 5 ED KTA7 25S 6 3A Please call MP SYSTEMS at 877 689 1860 with any other part request that may not be listed on the above table ...

Page 39: ...33 11 1 Relief Valve Identifier ...

Page 40: ...se call MP Systems 877 689 1860 Minimum Rating MPA PSI 7 1015 PSI 14 2030 PSI Tokai High Pressure Hoses The picture above is labeled EXC105 12 105 12 represent pressure rating and hose size respectively 105 10 5 MPA 1522 PSI 12 12 MM 1 2 The picture above is labeled PA1004 10 and 04 represent pressure rating and hose size respectively 10 10 MPA 1450 PSI 04 1 4 ID 105 10 5 MPA 1522 PSI 12 12mm 1 2 ...

Page 41: ...g Some high pressure hoses may be properly rated but the fittings may not be properly rated Use caution and make sure to check both MPA ratings to ensure proper high pressure hose rating To determine the size of the fitting the ID Inner Dimension of the fitting must be measured 10 MPA 1450 PSI ID Inner Dimension ...

Page 42: ... 0 119 3 8 0 675 0 091 0 126 1 2 0 840 0 109 0 147 3 4 1 050 0 113 0 154 1 1 315 0 133 0 179 1 1 660 0 140 0 191 1 1 900 0 145 0 200 2 2 375 0 154 0 218 2 2 875 0 203 0 276 3 3 500 0 216 0 300 The following table contains approximate dimensions of female pipe fittings Pipe Trade Size ID Inner Dimension Inches 1 8 330 1 4 450 3 8 590 1 2 725 3 4 920 1 1 170 1 1 4 1 510 1 1 2 1 750 2 2 230 2 1 2 2 6...

Page 43: ... If supplied V Series Power cable harness are not adequate for local electrical code please contact MP Systems 877 689 1860 Power Feed to MP Systems If local electrical code requires a circuit breaker to feed power to MP Systems V Series high pressure system MP Systems offers them separately V Series Model Part Number V Series 200 208 230V AK CB40 KIT V Series 480V AK CB20 KIT ...

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Page 47: ...cification and operational procedures are not followed Use only filter bags purchased directly from MP Systems to maintain warranty of flow related parts Contact MP Systems directly for warranty claims MP Systems 34 Bradley Park Road East Granby CT 06026 Phone 877 689 1860 Fax 860 653 2877 Email info mp systems net ...

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