MP Systems VR8 Installation, Operation & Maintenance Manual
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MP Systems VR8 Installation, Operation & Maintenance Manual

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INSTALLATION, OPERATION, & MAINTENANCE MANUAL
R Series
MP Systems - 34 Bradley Park Road, East Granby, CT 06026 USA - Phone + 1 (877)-689-1860 - Email mpteam@mp-
systems.net
MPSYSTEMS-M-001/06

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  • Page 1 INSTALLATION, OPERATION, & MAINTENANCE MANUAL R Series MP Systems - 34 Bradley Park Road, East Granby, CT 06026 USA - Phone + 1 (877)-689-1860 - Email mpteam@mp- systems.net MPSYSTEMS-M-001/06...
  • 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 R SERIES INSTALLATION, OPERATION, MAINTENANCE MANUAL DOCUMENT PART #: B R OPERATOR Date Proofed Revision Description Issued Original 06/05/2014 S. Devlin   Added Hydracell priming Updated all control signal 12/24/2014 S. Devlin instructions electrical drawings  Added low side visual ...

  • Page 4: Table Of Contents

    Contents Introduction ......................... 1 1.1. Symbology ........................1 Safety Measures ......................... 2 2.1. General Rules ....................... 3 2.2. Prevention of Mechanical Risks ..................3 2.3. Prevention of Electrical Risks ..................3 Intended Uses ........................4 3.1. Features & Benefits ...................... 5 Specifications ........................
  • Page 5 7.2. Testing ........................29 7.3. Start Up ........................29 7.4. Settings ........................30 7.4.1. R/R2 Series PLC Settings ..................31 7.4.2. Variable/Adaptive Series PLC Settings (VR Series) ..........33 7.4.3. Variable/Adaptive Series PLC Settings (VR2 Series) ........... 37 7.4.4. RA11 Series PLC Settings ..................41 7.5.
  • Page 6 10.2 Relief Valve Identifier ....................66 11. Hose Identification ......................67 11.1. Fitting Identification ..................... 68 RF8 Series Flow Diagram ......................71 RFC Series Flow Diagram ....................... 72 RA11 Series Flow Diagram ...................... 73 RT Series Flow Diagram ......................74 RF16 Series Flow Diagram ......................

  • 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.

  • Page 8: Safety Measures

    MP SYSTEMS.  To function correctly and for operator security, the R Series must be operated with all panels in place and secured.  Dangerous voltage contained within R Series; before carrying out any operations on R Series, ensure that the electrical supply has been switched off.

  • Page 9: General Rules

    2.1. General Rules R Series has been designed and constructed in such a way to minimize any possible cause of danger to the operator and their surroundings. However, residual risk still remains and can arise through improper use of the machine and can be of various types;...

  • Page 10: Intended Uses

    3. Intended Uses  MP SYSTEMS auxiliary coolant and chip control systems are constructed for use on milling and turning machines that have existing coolant tanks, complete machining environment enclosures, CNC controls with interlocks and low pressure pumps, typically referred to as flood pumps.

  • Page 11: Features & Benefits

     Cutting operations that suffer from chip evacuation problems can see improved speed, accuracy, surface finish and reliability when using the R Series high pressure system.  In problem holes, high pressure can allow for higher speeds and higher feed rates, with little to no pecking.

  • Page 12: Specifications

    4. Specifications MP SYSTEMS equipment ships with an identification label. The label is located by the main disconnect on the front of the machine. Information listed on Identification Label;  Pump Type  Serial Number  Build Date  Operating Voltage (208-230VAC/460VAC) ...

  • Page 13: Electrical Specifications

    4.1. Electrical Specifications FLA @ 208/230VAC MODEL FLA @ 460VAC (STANDARD VAC) RF8 / VR8 23.8-22.4 11.2 RF CE / VR CE (200/400V) 28 @ 200 14 @ 400 RFO5 24.9 11.75 RFC8 / VRC8 38.8-37.4 19.2 RA11 RAC11 RT / VRT RF16 / VR16 RFC16 VR10...

  • Page 14: Mechanical Specifications

    Control Power Control Signals Alarm Circuit 150VAC Transformer 24VDC 110VAC Secondary Primary Fused 4.2. Mechanical Specifications LENGTH WIDTH HEIGHT CAPACITY WEIGHT MODEL (in) (in) (in) (gal) (lbs) RA11 VR16 1250 RF16 VR20 1315 VRT40 2000 RT40 Accessories RC36 MP1200 *Approximate values. All mechanical specifications are subject to change. FLOW RATE VARIABLE MODEL...

  • Page 15: Floor Layout

    4.2.1. Floor Layout R / VR SERIES 15” – 24” 36” 28” MPSYSTEMS-M-001/06...
  • Page 16 RF16 / RT / VR16 / VRT SERIES 15” – 24” 42” 38” MPSYSTEMS-M-001/06...

  • Page 17: Options & Accessories

    Simultaneous Pressure Port 1 1000psi - Port 2 500psi Can be mounted on top of R Series or mount directly to machine tool. MP1200 Mist Collector Removes mist from machine tool cabinet. Removes heat from oil using ambient air temperature.

  • Page 18: Moving & Storage

    The machine must be transported in a vertical position (casters/wheels down). Machine tank MUST BE EMPTY before moving. R Series has been constructed so, as to be moved by fork truck or rolled around on casters on base of unit.

  • Page 19: Moving With A Fork Truck

    Ensure the tank is completely empty of coolant when moving. 5.4. Storage The R Series must be stored in a cool and dry environment, avoiding all extreme conditions. Avoid freezing conditions. All coolant must be drained from machine before being stored. If...

  • Page 20: Installation

    6. Installation All MP SYSTEMS, R Series are shipped on wooden pallets designed for the safe transport of the R Series auxiliary coolant and chip control system. A large MP SYSTEMS container protects the R Series from any unnecessary damage during transportation.

  • Page 21: Electrical Installation

    6.3. Electrical Installation Before connecting electrical power, pay close attention to the electrical data on machine plate. Ensure that the voltage of the power supply is compatible with that specified on plate. All installation work must be carried out by qualified personnel. Always consult machine tool wiring diagram before connecting power.

  • Page 22: Selecting Voltage

    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. Utilizing machine tool voltage makes lockout/tag-out far easier and allows it to comply with, most, local regulations.

  • Page 23: Power Harness Installation

    1. Mount supplied power harness with hardware provided in installation kit and route cable:  Make sure R Series power cable is able to reach mounted power harness.  If 3/4” conduit plug is not available, knock out hole and use supplied cord grip.

  • Page 24: Control Signal Harness Installation

    1. Mount supplied control signal harness with hardware provided in installation kit and route cable;  Make sure R Series signal cable is able to reach mounted control signal harness.  If 1/2” conduit plug is not available, knock out hole and use supplied cord grip.
  • Page 25 6.3.3.1. R/RA11 Series Control Signal Explanation MPSYSTEMS-M-001/06...
  • Page 26 6.3.3.1.1. Variable/Adaptive Series Control Signal Explanation (VR) MPSYSTEMS-M-001/06...
  • Page 27 6.3.3.2. Generic Mill Applications  Typical Mill installations require 1 port and 1 alarm signal.  Locate TSP (Through Spindle) contactor in machine tool cabinet. o Refer to machine tool electrical drawings booklet.  Remove 3 phase power from bottom of low pressure TSP contactor. ...

  • Page 28: Low Pressure Installation

    6.4. Low Pressure Installation 1. Mount supplied weld clamps on clean side of machine tool coolant tank, after the screens, typically near the low pressure pumps already installed in tank;  Use open area of tank. If no opening available, use 1 1/4" conduit punch or equivalent size hole saw.

  • Page 29: Low Pressure Hose Routing

    6.4.1. Low Pressure Hose Routing For best results be sure 1 1/4" low pressure hoses are lying flat on the floor. This will ensure coolant from unit will not drain back to machine tool coolant tank. Hoses not lying on the floor may lead to air becoming entrained in coolant and can also lead to supply pump losing prime.

  • Page 30: High Pressure Installation

    Coolant distributors present in machine tool MUST be able to withstand the pressure created by unit. If coolant distributors are inadequate, they will need to be modified. If unsure contact MP SYSTEMS (877-689-1860). 6.5.1. Generic Mill Installation 1. Disconnect hose from machine tool through spindle pump;...

  • Page 31: Generic Lathe Installation

    6.5.2. Generic Lathe Installation 1. Disconnect hose leading to turret, from low pressure pump, as well as the fitting the hose was connected to; 2. Install supplied check valve in place of removed fitting;  Arrow pointing towards turret, away from low pressure pump. 3.
  • Page 32 6.5.2.1. Generic Lathe Installation Cont. Check Valve Turret Low Pressure Pump Install after branching low pressure hoses. MPSYSTEMS-M-001/06...

  • Page 33: 8Jic To 6Jis Fitting Explanation

    6.5.3. 8JIC to 6JIS Fitting Explanation MPSYSTEMS-M-001/06...

  • Page 34: Operation

    7. Operation A few steps must be taken before MP SYSTEMS auxiliary coolant and chip control system can be put into operation. 7.1. Filling & Priming 1. Fill machine tool coolant tank with coolant/cutting fluid; 2. Fill tank of R Series with coolant/cutting fluid;...

  • Page 35: Testing

    7.2. Testing  Ensure all connections are secure and no hoses are rubbing.  Supply pump properly primed.  Prime valve has been closed.  Ensure motor rotation for all motors present in unit rotate clockwise.  Activate M-Codes and ensure corresponding port on unit activates. ...

  • Page 36: Settings

    7.4. Settings Caution: Modifying PLC settings may result in malfunction. Please contact MP SYSTEMS before modifying PLC settings. Parameters can be modified through PLC. Fill options, ON/OFF delay, skimmer options, etc. Only ‘standard’ PLC settings listed. PLC SETTINGS SUBJECT TO CHANGE...

  • Page 37: R/R2 Series Plc Settings

    7.4.1. R/R2 Series PLC Settings MAIN SCREEN HP – High pressure ON/OFF LVL – Current tank level FILL – Indicates supply pump fill. ALARM HISTORY ALARM TYPE Using the down arrow (▼), from PLC main screen control pad, will DATE: 00/00/2015 TIME: 24hr display 10 most recent alarms.
  • Page 38 7.4.1.1. R/R2 Series PLC Settings [  ] 3434 SKIM ON/OFF – Activate/Deactivate skim function. 1=ON 0=OFF LATCH ON/OFF – Latching or Pulsing alarm signal. 1=ON 0=OFF RD P PULSE/LATCH – Operate Reduced Pressure (RD) option with Pulsing/Latching M-Codes. 0=Pulsing 1=Latching. 6478 [ ...

  • Page 39: Variable/Adaptive Series Plc Settings (Vr Series)

    7.4.2. Variable/Adaptive Series PLC Settings (VR Series) MAIN SCREEN - High Pressure System 1 Status - High Pressure System 2 Status - Feed Pump Status - Reservoir/MP Tank Level (0-1000) - Port 1 Pressure (PSI) - Port 2 Pressure (PSI) INFO SCREEN ⓘ...
  • Page 40 0515 [  ] – User Menu SET TIME - Sets system time. 24hr Clock Format (for scheduling and logging events) DATE – DD/MM/YY Sets system date (for scheduling and logging events) ON/OFF DELAY – Sets time that must elapse before high pressure system 1 starts when on signal is received.
  • Page 41 7.4.2.1. Variable/Adaptive Series PLC Settings (VR Series) 3434 [  ] – Setup Menu RESERVOIR SKIM SETUP - Enable/disable tank skim function and displays time duration between tank skim events when enabled. Default = (0) ALARM LATCH – Sets alarm output as a latching signal (which keeps its state constant when triggered) or pulsing signal (which changes state for 5 seconds before reverting).
  • Page 42 6478 [  ] – Mist Collector Menu HIGH SPEED RUN TIMER - Sets duration of mist collector high-mode after high pressure system is shut down. Default = (20 sec) RUN SIGNAL TYPE - Sets run signal as latching input or pulsing input. Default = (0) RUN MODE - Allows mist collector to auto run whenever a high...

  • Page 43: Variable/Adaptive Series Plc Settings (Vr2 Series)

    7.4.3. Variable/Adaptive Series PLC Settings (VR2 Series) MAIN SCREEN - High Pressure System 1 Status - High Pressure System 2 Status - Feed Pump Status - Reservoir/MP Tank Level (0-1000) - Port 1 Pressure (PSI) - Port 2 Pressure (PSI) INFO SCREEN ⓘ...
  • Page 44 0515 [  ] – User Menu SET TIME - Sets system time. 24hr Clock Format (for scheduling and logging events) DATE – DD/MM/YY Sets system date (for scheduling and logging events) ON/OFF DELAY – Sets time that must elapse before high pressure system 1 starts when on signal is received.
  • Page 45 FILTER LIFE ALARM LEVEL - Sets the minimum level at which a warning alarm will be triggered when filter monitoring is enabled. Default = (20%) DEFAULT RESET – Reset PLC settings to factory defaults. Code = 1234 7.4.3.1. Variable/Adaptive Series PLC Settings (VR2 Series) 3434 [ ...
  • Page 46 Default = 0 6478 [  ] – Mist Collector Menu HIGH SPEED RUN TIMER - Sets duration of mist collector high-mode after high pressure system is shut down. Default = (20 sec) RUN SIGNAL TYPE - Sets run signal as latching input or pulsing input. Default = (0) RUN MODE - Allows mist collector to auto run whenever a high...

  • Page 47: Ra11 Series Plc Settings

    7.4.4. RA11 Series PLC Settings MAIN SCREEN FLO – Current GPM, 3, 8, 11 LVL – Current tank level FILL – Indicates supply pump fill. M – Displayed when pump is in manual mode ALARM HISTORY ALARM TYPE Using the down arrow (▼), from PLC main screen control pad, DATE: 00/00/2015 TIME: 24hr will display 10 most recent alarms.
  • Page 48 7.4.4.1. RA11 Series PLC Settings [  ] 3434 SKIM ON/OFF – Activate/Deactivate skim function. 1=ON 0=OFF LATCH ON/OFF – Latching or Pulsing alarm signal. 1=ON 0=OFF RDP PUL/LAT – Operate Reduced Pressure (RD) option with Pulsing/Latching M-Codes. 0=Pulsing 1=Latching. MM FLOW SETTING –...

  • Page 49: Alarms

    C.B. TRIP RESET Motor overload tripped ENTER TO CLEAR  Electric motor over load set to low.  Electrical short in system causing overload to trip.  Call MP Systems 877- Drive Alarm Fault on VFD present in unit 689-1860 MPSYSTEMS-M-001/06...

  • Page 50: Slow Fill Alarm

    In the event of a Persistent ‘Slow Fill’ alarm (Displayed on PLC) please follow the steps below. The following steps will assist in determining the root cause of the issue. If the problem continues please contact MP SYSTEMS @ (877)-689-1860.  Check inlet pressure gauge;...

  • Page 51: Maintenance

    8. Maintenance Before carrying out any operation on unit or accessing internal components, ensure that the power supply has been switched to the ‘OFF’ position. Before working on the unit, carefully read the safety instructions set out in Section 2. Safety Measures It is good practice to carry out periodic checks on machine, in order to ensure it is working properly.

  • Page 52: Filter Bag Replacement

    8.1.1. Filter Bag Replacement 1. Switch power to ‘OFF’ position; 2. Close valve to filter vessel that will be changed; 3. Let system pressure equalize for up to 30 seconds; 4. Remove 4 wing nuts on filter cover;  Lift away filter cover. 5.

  • Page 53: Options & Accessories

    9. Options & Accessories 9.1. Auto Cross Auto Cross (AC) system automatically switches between the two filter vessels present in unit. Once a filter bag becomes depleted, the AC system senses the lack of flow and will switch to the clean filter. PLC will display depleted filter #.

  • Page 54: Variable Pressure

    The pump will increase or decrease speed to MP SYSTEMS standard installation is simple maintain set pressure. This ensures the and straight forward. User only needs to pump only works as hard as needed, greatly install 2 wires onto stock coolant contactor, reducing unnecessary heat input &...

  • Page 55: Mp 1200 Mist Collector (Mc)

    Once high pressure becomes de-activated MP 1200 will run at full speed for 20 seconds, to clear remaining mist/vapor from machine tool cabinet. Standard Control MP 1200 settings can be modified through R Series PLC, please refer to Section 7.4: Settings.  Latching M-Codes...

  • Page 56: Plumbing Instructions (Mc)

     Ensure 1/2” black push lock hose from drain of MP1200, bottom of unit, connects to the 1/2" hose barb on top of return of the R Series. Refer to B MP1200 INSTALL manual supplied with MP 1200 mist collector;...

  • Page 57: Understanding Gauge & Speed Control (Mc)

    9.5.3. Understanding Gauge & Speed Control (MC) 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 58: Rc Mountable Chiller (Rc)

    9.6. 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.

  • Page 59: Chiller Ambient Temperature Chart

    9.6.1. Chiller Ambient Temperature Chart Ambient Temperature Chart Ambient temperature is not to exceed 95°F or go below 70°F. Loss in in capacity results when ambient temps are outside the operating range. If set point temperature is greater than 2° below ambient temperature a loss of capacity is possible.

  • Page 60: Mounting Instructions (Rc)

     Use the (3) mounting points shown, to align RC unit in the correct position; o A person(s) should be present to assist in alignment.  Use supplied 1/4‒20 x 3/4" bolts to fasten RC unit to R Series;  RC unit mounted. MPSYSTEMS-M-001/06...

  • Page 61: Plumbing Instructions (Rc)

    Once the RC chiller unit has been mounted and securely fastened, the following steps will need to be taken to ensure the RC unit functions correctly:  Connect 1” RC unit inlet hose to circulation pump located in R Series;  Connect 1/2" hose from RC unit return to R Series tank;...

  • Page 62: Electrical Installation

    9.6.4. Electrical Installation 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.

  • Page 63: Priming & Start-Up

    9.6.5. Priming & Start-Up Fill Here  R Series vertical reservoir must be filled before RC unit can be primed;  Ensure outlet hose for circulation pump has been firmly fastened; Open  Open 1” ball valve leading from R...

  • Page 64: Settings (Rc)

    9.6.6. Settings (RC) MAIN SCREEN - Control Mode (Setpoint/Ambient Tracking) ~ F- Ambient/Setpoint Temperature ~ F- On/Off ~ F- Inlet Temperature - Compressor Status - Circulation Pump Status - Operating Mode [HI, LO, HT, SL] INFO SCREEN ⓘ (Information) Button on PLC control pad will display current PLC version.
  • Page 65 0515 [  ] – User Menu SET TIME - Sets system time. 24hr Clock Format (for scheduling and logging events) DATE – DD/MM/YY Sets system date (for scheduling and logging events) TRACKING TEMPERATURE ABOVE AMBIENT – Provides an offset (above ambient) when chiller is set to tracking mode.

  • Page 66: Settings (Rc)

    9.6.6.1. Settings (RC) 3434 [  ] – Setup Menu CHILLER SLEEP MODE – Determines if chiller will hibernate when inlet temperature is equal to target temperature for a specified time. Chiller will restart automatically if inlet temperature is no longer equal to or below target temperature, or on startup of high pressure pump.

  • Page 67: Alarms 'Rc

    9.6.7. Alarms ‘RC’ RC unit uses one alarm output to interface with R Series. If a fault occurs, a signal is sent to the alarm circuit on R Series, which, typically, will put machine tool into a feed hold. The units PLC will display fault type.

  • Page 68: Maintenance (Rc)

    9.6.8. Maintenance (RC) Before carrying out any operation on the unit, ensure that the power supply has been switched to the ‘OFF’ position. Before working on the unit, carefully read the safety instructions set out in Section 2. Safety Measures It is good practice to carry out periodic checks on machine, in order to ensure it is working properly.
  • Page 69 9.6.8.1. Media Filter  Shut down R Series before any maintenance is performed. Media filter w/brackets  Loosen brackets (top/bottom).  Slide media filter out.  Clean with mild detergent or soapy RC Unit water.  Media filter can be dried using compressed air, if needed.

  • Page 70: Spare Parts

    HEPA Post Filter (New Install) MCF HEPA W/BRKT 24X24X11.5 Other 6” Poly Wire Hose HH 6” POLYWIRE 6” Mounting Collar (Flange) HC 6” COLLAR Please contact MP SYSTEMS for spare parts not listed, (877) 689-1860 MP SYSTEMS recommends stocking (10) spare filter bags. MPSYSTEMS-M-001/06...

  • Page 71: Solenoid Identifier

    10.1 Solenoid Identifier Hydroven Style Parker Style Solenoid Valve: Solenoid Valve: HV 8 NC SOL H HV 8 NC SOL Coil: HV 120V Coil: HV 04 19W COIL H 110 SOL COIL *NOTE: If problem with Hydroven style coil is suspected, replace both coil AND rectifier plug...

  • Page 72: Relief Valve Identifier

    10.2 Relief Valve Identifier MPSYSTEMS-M-001/06...

  • Page 73: Hose Identification

    Hose Identification Following information used to determine hose rating, hose size, fitting size, and fitting style. Identifying High Pressure Hose & Fittings High pressure hoses are typically labeled with size and rating of the hose (MPA/PSI/BAR). This appendix will assist in, interrupting the hose labels. MINIMUM HOSE RATING 1015 2030...

  • Page 74: Fitting Identification

    11.1. Fitting Identification Typically hose fittings will be marked with pressure rating. Caution: Be sure that fittings are also rated for correct MPA. 10 MPA ID (Inner Dimension) MPSYSTEMS-M-001/06...
  • Page 75 Determining Hose Fittings JIC Fitting Identification Male Thread OD Female thread ID Fitting Size Inch No. Thread Per Nominal Size (Outer (Inner (mm) Inch Dimension) Dimension) -4 (6) 1/4" 11.0 mm 9.9 mm -6 (9) 3/8” 14.1 mm 12.9 mm -8 (12) 1/2"...
  • Page 76 JIS & JIC Fittings Example -6 (3/8”) -6 (3/8”) -8 (1/2”) -8 (1/2”) MPSYSTEMS-M-001/06...

  • Page 77: Rf8 Series Flow Diagram

    RF8 Series Flow Diagram MPSYSTEMS-M-001/06...

  • Page 78: Rfc Series Flow Diagram

    RFC Series Flow Diagram MPSYSTEMS-M-001/06...

  • Page 79: Ra11 Series Flow Diagram

    RA11 Series Flow Diagram MPSYSTEMS-M-001/06...

  • Page 80: Rt Series Flow Diagram

    RT Series Flow Diagram MPSYSTEMS-M-001/06...

  • Page 81: Rf16 Series Flow Diagram

    RF16 Series Flow Diagram MPSYSTEMS-M-001/06...

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