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MP Systems Cyclonic Debris Removal Series Installation Operation & Maintenance

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INSTALLATION, OPERATION, & MAINTENANCE MANUAL
Cyclonic Debris Removal Series
Pump Serial Number: ________________
Date: 7/28/2022
Revision: 06
MP Systems - 34 Bradley Park Road, East Granby, CT 06026 USA - Phone + 1 (877)-689-1860 - Email mpteam@mp-systems.net

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  • Page 1 INSTALLATION, OPERATION, & MAINTENANCE MANUAL Cyclonic Debris Removal Series Pump Serial Number: ________________ Date: 7/28/2022 Revision: 06 MP Systems - 34 Bradley Park Road, East Granby, CT 06026 USA - Phone + 1 (877)-689-1860 - Email mpteam@mp-systems.net...
  • Page 2 Thanks to our quality components, dedicated engineers, 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.
  • Page 3 CDR SERIES INSTALLATION, OPERATION, MAINTENANCE MANUAL DOCUMENT PART #: B CDR OPERATOR Revision Description Date Issued Author Original 8/25/2020 K. Quintin • Updated for production model. K. Quintin 1/25/2021 • Added quick start guide components, K. Quintin 4/26/2021 • updated with more information. •...

  • Page 5: Table Of Contents

    Table of Contents Introduction ........................3 1.1. Symbology ......................4 Safety Measures ......................5 2.1. General Rules ......................6 2.2. Prevention of Mechanical Risks ................6 2.3. Prevention of Electrical Risks ................. 6 Intended Uses ......................7 3.1. Features & Benefits ....................8 3.2.
  • Page 6 7.2 Set Mode of Operation ..................... 33 PLC & Alarm Displays ..................34 PLC Settings ......................35 Maintenance ......................39 Spare Parts ........................ 40 10. Warranty Information ....................41...

  • Page 7: Introduction

    All associated rights, in particular the rights of reproduction, publication, and translation, are retained by the producer in accordance with 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.

  • Page 8: Symbology

    1.1. Symbology Symbology contained in this manual. DANGER: Indicates possible danger. Failure to heed this warning carries a risk of accident or injury. DANGEROUS VOLTAGE: Indicates dangerous voltage. Failure to heed this warning carries a risk of injury or death. WARNING: Indicates a possible danger situation.

  • Page 9: Safety Measures

    2. Safety Measures MP SYSTEMS disclaims all responsibility for non-observance of the instructions and advice contained in this manual. It furthermore disclaims all responsibility for damage caused by improper or inappropriate use of the machine or by modifications made without authorization.

  • Page 10: General Rules

    • Check all electrical connections and connecting cables are well insulated and replace any cables that are evidently worn or damaged. • Be sure to use power cables supplied by MP SYSTEMS or that have been approved by MP SYSTEMS.

  • Page 11: Intended Uses

    3. Intended Uses The CDR is a proven effective solution for high volume, multiple shift machining applications with a filtering conveyor. It provides constant, full flow coolant filtration to catch and prevent fines from accumulating in the machine’s coolant tank, where they contaminate the entire coolant system and machining environment.

  • Page 12: Features & Benefits

    Features & Benefits 3.1. CDR Features: ▪ 80 GPM (gallons per minute) constant flow rate ▪ Filtration down to 3um (depending on density) ▪ Full flow filtration system to circulate coolant in tank. ▪ Quick and convenient cleanout ▪ Easy Installation with complete parts kit ▪...

  • Page 13: Considerations And Explanations

    Considerations and Explanations 3.2. • The CDR is not intended to be a replacement for filtering conveyors and is not to be used after a standard hinge belt conveyor. • The CDR is intended to be used after the following filtering conveyor styles. Drum, disc, filter box, and in certain applications, magnetic conveyors.
  • Page 14 o The high fluid velocities create high centrifugal forces that “pull” the denser particles towards the walls of the cyclone cone. The velocity and forces increase as the cone narrows towards the bottom. The heavier concentrated debris is discharged through the bottom apex. The lighter fluid exits the top of the cyclone via the vortex finder and returns to the machine coolant tank.
  • Page 15 machine tank. This number can then be compared to the number of gallons that are removed by the filter daily. • Severe Duty models use an additional filter vessel containing a perforated screen basket that can be manually emptied, cleaned, and re-used. The purpose of this vessel is to capture particles larger than 1/16”...

  • Page 16: Specifications

    4. Specifications *All specifications are subject to change. All MP Systems equipment ships with identification label. The label is located by main disconnect on front of the system. The label contains • Pump Type • Serial Number • Build Date •...

  • Page 17: Mechanical Specifications

    4.2 Mechanical Specifications Model CDR80 CDR80 SD Flow Rate 80 GPM 80 GPM 48” Length 50” 24” Width 34” 48” (Standard), 66” (Tall) 48” (Standard), 66” (Tall) Height 500 lbs Weight 650lbs Capacity 15 gal (settling tank) 15 gal (settling tank) 5 gal (filter tank) Filter Volume Dimensions...

  • Page 18: Floor Layout

    Floor Layout Standard CDR Dimensions...
  • Page 19 “Severe Duty” Models Only – Extra Capacity Pre-Filter Dimensions...

  • Page 20: Moving & Storage

    Refer to Section 4.2. Mechanical Specifications for unit weight. Only trained and licensed Fork Truck operators may transport this machine. MP SYSTEMS is not responsible for any damage caused by unauthorized use.

  • Page 21: Installation

    6. Installation All MP SYSTEMS CDR Series are shipped on wooden pallets designed for the safe transport of the CDR Series Full Flow Filtration System. A large MP SYSTEMS box protects the CDR from any unnecessary damage during transportation. If there is visible damage from transportation, refer to Section 5.1 Delivery Checks.
  • Page 22 Understand tank layout to determine suction, return, and overflow locations. • Remove power completely from the chip conveyor and machine. i. Ensure chip conveyor CAN NOT turn on or injury may occur. • Remove any access panels on top of the tank that will allow for a good view or feel of the tank layout.

  • Page 23: Install Kit Components

    6.1 Install Kit Components PART DESCRIPTION MP PART NUMBER CDR OPERATOR MANUAL B CDR OPERATOR 2” INLET DIP TUBE (Single Kit) AM DIP TUBE LL 2” X 16” 1 ¼” MAGNET INLET DIP TUBES (Double Kit) AM MLLDT 1 ¼” 1 ½”...

  • Page 24: Recommended Tools For Installation

    • Knockout or Hole saws (optional) o 1.75”, 2.00”, 2.50” When installing MP Systems products, the correct location of the dip tubes is important to a successful install. The best way to do this is to use a preexisting hole in the tank can be used to pass the various pipes through the tank top.
  • Page 25 If you know ahead of time that you will need them, then they can be ordered from McMaster, or MP Systems stocks and can ship a kit with all the necessary components. HIGH PRESSURE PURGE PIPE SIZE HOLE SAW McMaster...

  • Page 26: Electrical Installation

    United States require a step down transformer as the machine tools, typically, run on 200 +/- 10% VAC. 208-230v is the standard voltage for MP Systems units. (Optionally, 480V units can be purchased, voltage cannot be changed in the field) Utilizing machine tool voltage makes lockout/tag-out far easier and allows it to comply with most local regulations.

  • Page 27: Power Harness Installation

    6.3.2 Power Harness Installation CDR kit contains power cable, circuit breaker, twist lock plug, and all necessary connectors. 1. Route supplied power harness and hardware into machine electrical panel. • Be sure to leave enough cable leading outside the machine for twist lock plug to reach CDR electrical panel.

  • Page 28: Control Signal Installation (Optional-Not Required)

    6.3.3 Control Signal Installation (Optional-Not Required) Using machine tool control signals is not recommended by MP SYSTEMS. If required for your application, please contact MP SYSTEMS for more information. • The CDR can be automatically turned on and off by connecting to a machine signal.

  • Page 29: Plumbing Installation

    6.4 Plumbing Installation Overview: There are three dip tubes and hoses that will need to be installed. 1 ½” Return 1 ¼” Overflow Dual 1 ¼” Inlets -or- 2” Single Inlet 6.4.1 Dip Tubes Installation Some pipe fittings are sent loose, and extra fittings are included to allow for optimal configurations.
  • Page 30 o The CDR is shipped with no pump inlet fitting(s) installed. They can be found in the kit. o For Dual Inlet configurations, install the assembled 2” NPT X 1 ¼” Barbs fittings into the front of the pump using appropriate pipe sealant and ensure it is fully tightened.
  • Page 31 o For single 2” inlet, assemble the supplied dip tube pipe components and green clamp to fasten to tank top. --------------------------------→ ▪ Ensure that the bottom of plate touches the bottom of tank. • Install 1 ½” Return Dip Tube o Install on opposite side of tank from the Inlet(s) to create counterflow back to inlet and circulate the tank.

  • Page 32: Hoses And Clamps Installation

    Overflow port on settling tank MUST BE higher than overflow dip tube in machine tank. • 80GPM to 60GPM conversion. (Optional – Contact MP Systems) 1. For smaller tanks, 80GPM may be too high of a flow rate and cause spillover.
  • Page 33 • Severe Duty “SD” models only: • For Severe Duty models, there is an additional filter vessel that will need to be installed between the CDR pump outlet, and the CDR inlet manifold. Longer hoses are provided in the installation kit. The purpose of this vessel is to capture all particles larger than 1/16”...

  • Page 34: Pump Priming Procedure

    6.4.3 Pump Priming Procedure Before turning the system on and checking motor rotation, the pump must first be primed. Failure to do this will result in damage to the pump’s mechanical seal. • Ensure inlet hose(s) are attached to the inlet of pump and the clamps are tightened securely.

  • Page 35: Operation

    7. Operation 7.1 Start Up Checklist After priming the CDR there are a few things to inspect before running the machine. MP Systems recommends running the system with the manual start (#9) and stop (#0) buttons when first turning the system on. 1.
  • Page 36 re-filters the fluid to maintain cleanliness. By creating a depression of fluid height near the inlet dip tube, and an excess of coolant height near the return dip tube, it will create a counterflow back towards the inlet dip tube. 7.

  • Page 37: Set Mode Of Operation

    7.2 Set Mode of Operation A. Manual Operation using On/Off Buttons on PLC. (Factory Default) • The pump can be manually turned on/off by pressing the #9 (ON) and #0 (OFF) buttons. B. Auto Start When Powered On (Optional) • The pump can be set to automatically turn on when the unit is powered up. •...

  • Page 38: Plc & Alarm Displays

    PLC & Alarm Displays MAIN SCREEN PRESS “9” TO TURN ON PRESS “0” TO TURN OFF = SLEEP MODE ON/OFF = RUNNING STATUS ON/OFF #### = AUTO ENABLE/DISABLED = RUN MODE = INLET PRESSURE Run Mode: MNL = MANUAL MODE ON/OFF SCH = SCHEDULED RUN MODE SIG = MACHINE SIGNAL RUN MODE...

  • Page 39: Plc Settings

    PLC Settings Caution: Modifying PLC settings may result in malfunction. Please contact MP SYSTEMS before modifying PLC settings. MAIN DISPLAY BUTTONS “i” • Press button to access program version screen. • Press to access alarm history. • Press to access run time hour counters. Hours/Days/Months USER SETTINGS MENU From the main PLC HMI screen, press buttons 1 &...
  • Page 40 EXTERNAL SIGNAL – (Only functions when external interface signal with machine tool is connected). When turned on, this feature will allow the system to run automatically whenever an external 24vdc signal is received from the machine tool. To enable, change the setting from 0 to 1 and press enter. The main screen will now display “AUTO”...
  • Page 41 PRESSURE ALARM DELAY – This is the amount of time in seconds that the system pressure can be below the low-pressure alarm set point before the system alarms out. This setting should not be changed unless discussed with MP Systems. To change setting, enter new time in seconds and press enter.
  • Page 42 ALARM SOUND – There is an optional buzzer sound that can be set to alert the operator whenever the system is in alarm. To enable, change the setting from 0 to 1 and press enter. OFF DELAY TIME – (Only applicable if using external signal harness to run CDR). When using an external signal to run the system, there is an off delay that will continue to run the pump for a set amount of time after the external signal is removed.

  • Page 43: Maintenance

    8. Maintenance General maintenance for CDR Series consists of scraping debris from settling tank, periodically cleaning Y strainer before inlet of spin filters, and in some cases cleaning out the discharge apex of spin filters. The settling tank should only be scraped when a reasonable amount of debris has built up to the point where large quantities can be removed at a time.

  • Page 44: Spare Parts

    Depending on the abrasive nature of the particles going through the filters, they may wear down over time and need to be replaced. The filters are assembled from modular parts that can be replaced as needed. Contact MP Systems for more information and to purchase replacement components.

  • Page 45: Warranty Information

    CDR Series equipment comes standard with a 2 year parts warranty. Warranty is void if proper installation, specification, and operational procedures are not followed. Contact MP Systems directly for warranty claims. MP Systems 34 Bradley Park Road East Granby, CT 06026 Phone 877-689-1860 •...

This manual is also suitable for:

Cdr80Cdr80 sd

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