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MP Systems R Series Installation, Operation & Maintenance Manual

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INSTALLATION, OPERATION, & MAINTENANCE MANUAL
R Series Models
MP Systems - 34 Bradley Park Road, East Granby, CT 06026 USA
Phone + 1 (877)-689-1860 / Email mpteam@mp-systems.net
Rev. 8.1

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  • Page 1 INSTALLATION, OPERATION, & MAINTENANCE MANUAL R Series Models MP Systems - 34 Bradley Park Road, East Granby, CT 06026 USA Phone + 1 (877)-689-1860 / Email mpteam@mp-systems.net Rev. 8.1...

  • Page 2: Table Of Contents

    Table Of Contents Intro ................................1-7 Index........................................3 Risk Prevention ....................................4 Features and Benefits ..................................5 Getting Familiar w/ Machine Tool Components ..........................6 Unboxing ......................................7 Theory Of Operation ............................Theory of Operation (Mill Specific) ..............................8 Theory of Operation (Lathe Specific) ..............................9 Mechanical Theory Of Operation ..............................

  • Page 3: Index

    Latching M-Code - A latching M-Code turns on/off and stays on until another latching code from the same modal group turns it on/off. Machine Tool - Lathe, Mill, or other CNC based tooling. MP Systems units are designed for tools that utilize coolant / cutting oil and a conveyor chip removal system.

  • Page 4: Risk Prevention

    Failure to install alarms to the proper circuit can result in serious risk. Before carrying out any work on the R Series, switch off the electrical supply at the main isolator.

  • Page 5: Features And Benefits

    Cutting operations - Operations that suffer from chip evacuation problems can see improved speed, accuracy, surface finish, and reliability when using an R series high pressure system. Problem holes - Higher pressures allows for higher speeds and higher feed rates, and little to no pecking. This allows for 5-20% faster drilling than a standard low pressure unit.

  • Page 6: Getting Familiar W/ Machine Tool Components

    Getting Familiar w/ Machine Tool Components and High Pressure Integration Before installation, an understanding for how the existing machine tool functions and how the MP Systems pump will integrate into it must be established. Locating R-Series Specifications MACHINE TOOLING Most programmable CNC machine tools on the market are made up of very similar overall core components, however every tool will vary in function and form.

  • Page 7: Unboxing

    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 considered necessary and/or useful, without compromising the essential characteristics.

  • Page 8: Theory Of Operation (Mill Specific)

    The alarm will be wired in series with the TSC overload protector to ensure that the MP Systems alarm is at an adequate level to stop the machine tool and is chained into the tool’s OEM alarm circuit.

  • Page 9: Theory Of Operation (Lathe Specific)

    7. Wire number 8 will take the place of the wire removed from the overload, If the turret flood pump contactor has unused terminals present, wire 9 will be used to carry 24V to the MP Systems harness. If tying the MP Systems pump into series with the alarm.
  • Page 10 When the machine tool operator provides signal to the high pressure pump via the assigned M-Code for “Coolant ON” the feed pump will begin to transfer coolant up from the machine tool’s tank through the inlet tube to the MP Systems tank. As coolant enters the tank it is filtered through two 5 micron filter bags to catch most particulate.
  • Page 11 Transformer Layout MP Systems recommends the use of the ‘Normally Closed’ alarm circuit when wiring into machine tool electrical cabinet. When wiring control signals, be sure to take into account any accessories that were purchased with the R-Series. Dual Pressure (DP), RC Chiller (RC), Variable Pressure, Mist Collector (MC), Washdown, etc.
  • Page 12 Pre-Installation Before installation, confirm any options that have been purchased and ensure that all components are both present and undamaged. Use this page to make note of key details for the most efficient troubleshooting throughout the life of the machine. Recommended Tools for Installation To Be Filled Out By End User: •...
  • Page 13 Utilize the Space below to draw out connections for future reference. Rev. 8.1...

  • Page 14: Symbols And Terminal Markings- Nema / Iec

    Symbols and Terminal Markings— NEMA / IEC All contactors within the machine tool cabinet have markings to indicate exactly what they are. Per DIN standards, the terminals of auxiliary contacts on contactors and control devices are marked with a two digit number. •...

  • Page 15: M-Codes

    M-Codes M-code is the machine control language for modern CNC machine tools. While various platforms do share some commonalities in programming, an M-Code’s function is ultimately determined by the manufacturer of the machine tool. The machine tool electrical booklet should always be referred to determine M-Code functions. A machine tool may have hundreds of different M-Codes.
  • Page 16 M-Code Contact Functionality Breakdown Latching - Used for standing actions such as “Coolant on” A Latching M-Code will change state once called upon, and will remain in said state until otherwise acted upon. When the machine tool operator enters the M-Code for “Coolant ON” the wire is supplied power, and will remain powered until the “Coolant OFF”...

  • Page 17: Wiring Pinout Explanation

    Finish Com Wire 17 Finish Out Green Wire System Ground The MP Systems harness should never see mixed voltages. 24V power must be drawn from one source. Installation will use either: • Wire 9 (MP 24VDC) • Wire 5 (0V Common) paired with a machine tool 24VDC source *Variable Pressure Units, please see pg.43 for details on pressure/port functionality*...
  • Page 18 Locating R-series Pump to Machine Tool 24v Power Source: Before installing the high pressure pump, determine all signal wire Locating and Testing The Flood Pump Contactor Overload: locations and test alarms. All signal wire connections must be able to be located and understood before continuing work or The overload for each flood pump typically will be mounted just installation.
  • Page 19 Typical Flood Pump Contactor Schematic Contactor physical shape Contactor ID Wire Installed may vary, but the terminal identifications should always remain the same. Each Contactor located in the Machine Tool’s cabinet should be labeled. After locating the contactor(s) being used for installation, denote them above Typical M-Code Relay Schematic Denote any M-Codes...

  • Page 20: Lathe Applications

    When not in use, simply zip-tie this in place near the cable. Installation Notes: Wire signals required for desired pump function (R Series electrical diagrams are located in electrical cabinet) All MP Systems high pressure pumps utilize 24VDC signals for control.
  • Page 21 Models with multiple pumps or features will require the installation be repeated for each output in the system. Every output powered by the MP Systems high pressure coolant system should be tied into the machine tools hard alarm circuit to ensure the unit operates in series with the machine tool.
  • Page 22 Generic Mill Application Alarm / Signal Wiring Typical Mill installations require both one port and one alarm signal. Models with multiple pumps or additional features will require the installation For mill installations, you will need to locate the Through be repeated for each output in the system. Every pump powered by the MP Spindle Coolant contactor in the machine tool cabinet.
  • Page 23 R Series Control Signal Explanation (Fixed Pressure) Rev. 8.1...
  • Page 24 VR Series Control Signal Explanation Rev. 8.1...

  • Page 25: Power Harness Installation

    If an opening is not available, create a hole and use the supplied cord grip to secure the power harness in place. Connect the machine tool three phase power wires to the line side of the circuit breaker and then connect MP Systems power Machine Tool Mounted wires to the load side.

  • Page 26: Low Pressure Installation

    Low Pressure Installation The low pressure system consists of two dip tubes, an inlet and return hose, weld clamps, and hardware. The dip tubes should be mounted on the clean side of the tank, but should be as far away from the flood pump(s) as possible to avoid turbulence issues.

  • Page 27: Low Pressure Hose Routing

    If you have any questions regarding installation methods or require a unique method of routing due to spatial concerns, please reach out to the MP Systems team before routing to confirm the installation method does not present any issues. Return Inlet Hose clamps should not be overtightened.
  • Page 28 A check valve must only be introduced after discussing your application with MP Systems, as if clean coolant is not maintained, the check valve may become clogged. It is imperative that inlet’s dip tube is placed in the clean side of the tank to avoid chip related issues.

  • Page 29: High Pressure Installation

    Systems unit can be easily shortened to length in the field. If during setup it is determined a different length High pressure hose is ideal, reach out to MP Systems to order a custom length hose. Once assembled, tighten each connection...

  • Page 30: Hose Fitting Identification

    Most Japanese made machine tools utilize JIS style fittings, while high pressure should be able to withstand a minimum of MP Systems machines are made in the USA and utilize JIC fittings. 1,000 PSI / 7 MPa. This is where the requirement for adapter fittings comes in.

  • Page 31: High Pressure Installation (Lathe Specific)

    Machine Tool Hose The MP systems hose will be connected to the side of the tee. The check valve will ensure that high pressure does not work its way backwards to the OE flood pump(s).
  • Page 32 For further information on fitting identification, please see page 29. Attach one end of the MP Systems hose to the now disconnected end on the machine tool. After the adapter fittings are in place and the hose has been...

  • Page 33: Operation

    Operation Filling & Priming Testing A few steps must be taken before the MP Systems auxiliary coolant Review your work to ensure all connections are secure and no and chip control system can be put into operation. hoses are rubbing. Rubbing hoses can lead to a burst line over the course of time, resulting in down-time of the system.
  • Page 34 Verify that the alarm on both the unit and machine tool has gone off. Do not attempt to use any filter aside from the MP Systems issued filters. Should you wish to explore a different Micron rated filter, Close the wye valves atop the machine once again.

  • Page 35: Variable Pressure Start Up

    Close the wye valves atop the machine once again. Return to the MP Systems PLC and press and hold the enter Do not attempt to use any filter aside from the MP Systems issued button until the tank fills back up. Once the tank is full, reset filters.

  • Page 36: Plc Settings

    When modifying PLC settings, the incorrect input could result in malfunction of the PLC. Before making any modifications to the PLC settings, please contact MP Systems so we can ensure your changes you wish to implement do not negatively effect another function of the PLC.
  • Page 37 PLC Settings Variable / Adaptive Servies PLC Settings (VR Series) Fixed Pressure RF Series PLC Settings Continued... MAIN SCREEN GPM X.X - High Pressure System 1 RD P PULSE LATCH Status RD P PULSE / LATCH HP X FP X Sets the reduced pressure input as - High Pressure System 2 0=PLS 1=LAT _...
  • Page 38 PLC Settings BINARY PRESSURE Variable / Adaptive Series PLC Settings (VR Series) BINARY PRESSURE Enables variable pressure to be  Password: 0515 [ ] – User Menu ON = 1 OFF = 0 <<0>> controlled by binary input signal (two inputs, four pressures). SET TIME Default = 0 SET TIME...
  • Page 39 PLC Settings  VRT PLC Settings Password: 6478 [ ] – User Menu HIGH SPEED RUN TIMER MAIN SCREEN HP10HP20FP0 L*** MC HS RUN 20 Sets duration of mist collector high mode after high pressure system is 0 P2 shut down. Default = (20 sec) ALARM HISTORY ALARM TYPE...
  • Page 40 RT PLC Settings PLC Settings MAIN SCREEN LVL XXXX  Password: 3434 [ ] – User Menu LVL – Current tank level FILL HP1 – High pressure ON/OFF pump 1 RESERVOIR SKIM SETUP SKIM ON = 1 OFF= 0 Enable/disable tank skim function HP2 –...
  • Page 41 PLC Settings - Modification Log After making any changes to the default PLC settings of the unit, please note the changes in the log below so that any and all custom settings are recorded. In the event of the PLC battery dying, custom data will be lost unless otherwise recorded. Ex: I7 Assignment 09/25/2023 Ex: Set to 0 for use w/ Binary Control...

  • Page 42: Alarms

    Alarms The MP Systems unit is programmed with several available alarms. These alarms are in place to protect both the operator and the equipment in use. The unit provides normally open (NO) and normally closed (NC) alarm contacts to indicate internal faults with the high-pressure system.

  • Page 43: Options And Accessories

    Port 1 & Port 2 can run at set pressure simultaneously. Dual Simultaneous Port 1 1000psi Pressure Port 2 500psi Can be mounted on top of R Series or mount directly to MP1200 machine tool. Mist Collector Removes mist from machine tool cabinet.
  • Page 44 The pump will increase or decrease speed to maintain set MP SYSTEMS standard installation is simple and straight pressure. This ensures the pump only works as hard as needed, forward. User only needs to install 2 wires onto stock greatly reducing unnecessary heat input &...
  • Page 45 Variable Pressure Control (Models w/ Multiple Pumps using Binary Control) The diagram below highlights a stripped down example of a VRT unit switching between pumps and pressures throughout a cycle. It is important to note that the PLC will always default to the pump that has been most recently called on. The chart above highlights several ports and pressures being used over the course of time.
  • Page 46 MP 1200 Mist Collector (MC) The MP 1200 Mist Collector is used to remove unwanted mist and vapors created during the manufacturing process when spraying fluid at high velocity in the machine tool cabinet. The MP 1200 aids in keeping unwanted mist/vapor from entering the work environment around the machine tool.
  • Page 47 Any wiring used for the mist collector must utilize the same common as the pump is wired into. Mixed voltages will result in fluctuations and will hinder operation. Dual-Pump R Series Models The use of a Mist Collector will result in some changes to the PLC functionality. With an MC in place, the default settings will not allow for pressure 1 to be called upon, the operator will only be able to select between Pressure 2, 3 and 4.
  • Page 48 MP 1200 will run at full speed for 20 seconds, to clear remaining mist/vapor from machine Standard Control tool cabinet. MP 1200 settings can be modified through R Series PLC, please refer to the PLC settings section. Latching M-Codes MP wire #12 (ON/OFF)
  • Page 49 • Inherent 2 speed control • • Field retrofittable on R series pumps from 2014-Current model year: Stand Mounted If access to the top of the machine is limited, or space require- ments eliminate machine mounting options, MP offers a floor stand mount that can be placed in the vicinity of the machine and plumbed for mist collection.
  • Page 50 MP 1200 Mist Collector (MC) - Gauge and Speed Control Pressure Gauge The MP 1200 gauge measures pressure in Inch Water Column (Inch W.C.). The units are by convention and due to the historical measurement of certain pressure differentials. It is used for measuring small pressure differences across an orifice.
  • Page 51 RC Mountable Chiller (RC) RC mountable chillers are built specifically for the harsh environment of the CNC machining industry. The intended purpose of the RC unit is to maintain ambient fluid temperatures of 70°F‒90°F. Maintaining these temperatures greatly increases the user’s ability to hold the tight tolerances that many customers demand. The RC unit utilizes an open-loop system, pulling fluid to and from the machine tool tank.
  • Page 52 RC Mountable Chiller (RC) - Ambient Temperature Chart Ambient Temperature Chart Ambient temperature is not to exceed 95°F or go below 70°F. Loss in capacity results when ambient temps are outside of the operating range. If set point temperature is greater than 2° below ambient temperature, a loss of capacity is possible. Pump Model RF8/VR8 RT/VRT/RF16/VR16...
  • Page 53 Use the (3) mounting points shown to align RC unit in the correct position. Ensure help is near by to assist with the person(s) alignment Use supplied 1/4-20 x 3/4” bolts to fasten RC unit to R Series Rev. 8.1...
  • Page 54 RC Mountable Chiller (RC) - Plumbing Instructions Rev. 8.1...
  • Page 55 Use the (3) mounting points shown to align RC unit in the correct position. Ensure help is near by to assist with the person(s) alignment Use supplied 1/4-20 x 3/4” bolts to fasten RC unit to R Series Rev. 8.1...
  • Page 56 RC Mountable Chiller (RC) - Plumbing Instructions Route the 1” inlet hose from the RC unit though the unit in a manor that ensures the hose will not be in contact with other components inside of the unit. The 1” hose should be secured to the ____________ Connect the tee assembly on the side of the RC unit to the bulkhead fitting coming from the top sheet metal of the...
  • Page 57 Once RC unit has been mounted and all plumbing has been completed, the electrical connections will need to be made. MP SYSTEMS has designed the RC mountable chiller to be plug and play, this allows for a simpler installation. Power/control harnesses will need to be connected to ensure RC unit can properly communicate with the R Series.
  • Page 58 RC Mountable Chiller (RC) - Priming and Start Up Instructions Always ensure that vents are pointed in a clear unobstructed direction Rev. 8.1...
  • Page 59 RC Mountable Chiller (RC) - PLC Settings STATIC TEMPERATURE S T A T I C S E T P O I N T MAIN SCREEN Set static/constant temperature. ###>### - Control Mode < < ~2~F > > Default = 72°F (Setpoint/Ambient Tracking) I >...
  • Page 60 Less than 5GPM Heat exchanger clogged. • output to interface with through heat exchanger Circulation pump rotation reversed Less than 5GPM R Series. If a fault through heat exchanger • occurs, a signal is sent OVERLOAD Electric motor short cycle. •...
  • Page 61 Abrasive Duty Upgrade (AD) MP Systems has worked extensively with companies that routinely machine very abrasive materials to develop high pressure coolant systems which can withstand the challenges of cast iron, cast aluminum and steels coated with mill scale .
  • Page 62 Washdown Push button Schematic (WD) Rev. 8.1...
  • Page 63 Oil Skimmer (OS) The Oil Skimmer effectively removes waste oil from the high pressure coolant reservoir. Key Benefits include: Extends coolant life and can reduce coolant disposal costs. Removing floating surface oils Extends cutting tool life and creates a cleaner shop environment by reducing smoke and odors.
  • Page 64 Auto Cross Auto Cross (AC) system automatically switches between the two filter vessels present in unit. The AC system allows for less down time and makes scheduling filter bag changes far easier. It is recommended that there always be a clean filter present in system, this allows for un-interrupted operation.

  • Page 65: Replacement Component Identification And Service

    See solenoid identifier before ordering / replacing filters. Solenoid Coils See solenoid identifier MP SYSTEMS recommends stocking (10) spare filter bags. MP 1200 (MC) Please Contact MP Systems @ +1 (877) 689-1860 for spare parts not listed Stage 1: Baffle (Washable)

  • Page 66: Filter Bag Replacement

    Should you wish to explore a different Micron rated • Reinstall the filter cover, securing it back down with the four wing filter, please reach out to MP Systems and discuss nuts. your application with our engineering team. •...

  • Page 67: Solenoid Identifier

    Solenoid Identifier: 1. Parker Solenoid and Coil - HV 8 NC SOL / HV 04 19W 110 - Solenoid fits either Hydac or Hydroven Block 2. Hydac Solenoid and Coil - HV 8 NC SOL HC / HV 120V COIL HC 3.

  • Page 68: Relief Valve Identifier

    Systems directly for information regarding considerations that need to be made for a suitable replacement. If the unit already has a differing valve from what is depicted above, please reach out to MP Systems if replacement is needed. Rev. 8.1...
  • Page 69 RF8 Series Flow Diagram RFC Series Flow Diagram Rev. 8.1...
  • Page 70 RT Series Flow Diagram RF16 Series Flow Diagram Rev. 8.1...

  • Page 71: Floor Layouts

    Floor Layouts R / VR SERIES RF16 / RT / VR16 / VRT SERIES Rev. 8.1...
  • Page 72 R-Series High Pressure Pump Specifications Electrical Mechanical FLOW RATE OUTPUT VARIABLE MODEL PRESSURE PRESSURE MOTOR 1 MOTOR 2 Rev. 8.1...

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