MP Systems PURGE Series User manual

(Purge Operator) R04
INSTALLATION, OPERATION, & MAINTENANCE MANUAL
MP Systems - 34 Bradley Park Road, East Granby, CT 06026 USA
Phone + 1 (877)-689-1860 - Email m[email protected]
PURGE Series

(Purge Operator) R04
MP SYSTEMS is committed to delivering
quality products and providing maximum
productivity and uptime. Our engineering
team is diligent in eliminating high
maintenance issues associated with
machine tool accessories, to allow better
performing equipment for your business.
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. These relationships
facilitate superior application experiences. Our goal is to help make you
more productive with less downtime, decreased cycle times, improved tool
life and more parts out the door.

(Purge Operator) R04
PURGE SERIES INSTALLATION, OPERATION, MAINTENANCE MANUAL
DOCUMENT PART #: B PURGE OPERATOR
Revision
Description
Date
Issued
Proofed By:
00
Original
04/25/19
B. Jalbert
01
•Purge Drive Tuning Instructions
Added
•Add 1 ¼” Hose to Install Kit
•Add Mounting Bracket to Install
Kit
9/9/19
02
•Update PLC screens to match
V6.20
•Removed Drive Tuning
Instructions
•Add info on 480/400V system
6/4/20
B. Jalbert
03
•Update dip tube info and quick
start guide details. Removed
settings for FM5/8 & Manifold.
Added filter selection guide.
6/23/21
K. Quintin
04
•Fixed info on 480VAC specs
•Updated quick start guide and
install info.
•Updated start/stop mode of
operation.
•Updated PLC settings
3/28/22
K. Quintin

(Purge Operator) R04
Table of Contents
1. Introduction....................................................................................................................... 1
1.1. Symbology ................................................................................................................. 2
2. Safety Measures................................................................................................................ 3
2.1. General Rules............................................................................................................. 4
2.2. Prevention of Mechanical Risks ............................................................................... 4
2.3. Prevention of Electrical Risks................................................................................... 4
3. Intended Uses ................................................................................................................... 5
3.1. Why the Purge Works................................................................................................ 5
3.2. Features and Benefits ............................................................................................... 6
3.3 Considerations and Explanations............................................................................. 7
4. Specifications ................................................................................................................... 9
4.1. Electrical Specifications............................................................................................ 9
4.2. Mechanical Specifications ........................................................................................ 9
4.3. Floor Layout..............................................................................................................10
5. Moving & Storage ............................................................................................................11
5.1. Delivery Checks........................................................................................................11
5.2. Transport & Carriage................................................................................................11
5.3. Storage......................................................................................................................11
6. Installation........................................................................................................................12
6.1. Install Kit Components.............................................................................................13
6.2. Recommended Tools for Installations ....................................................................13
6.3. Electrical Installation................................................................................................15
6.3.1. Selecting Voltage...............................................................................................15
6.3.2. Power Harness Installation...............................................................................16
6.3.3. Control Signal Installation (Optional)...............................................................17
6.4. Inlet Installation ........................................................................................................18
6.4.1. Inlet Suction Dip Tube.......................................................................................18
6.5. Return Installation and Hose Routing.....................................................................21
6.5.1. Return Installation .............................................................................................21
6.5.2. Hose Routing .....................................................................................................21
6.6. Filling the Tank .........................................................................................................22
6.6.1. Feed Pump Installation & Priming Procedure..................................................22
7. Operation..........................................................................................................................23
7.1. PLC Set Up and Settings..........................................................................................23
7.1.1. PLC Initial Set Up...............................................................................................23
7.1.2. PLC Settings ......................................................................................................24
7.1.3. Alarms ................................................................................................................32

(Purge Operator) R04
8. Maintenance.....................................................................................................................34
8.1. Routine Maintenance................................................................................................34
8.1.1. Filter Bag Replacement.....................................................................................35
8.1.2. Filter Bag Selection ...........................................................................................36
9. Spare Parts.......................................................................................................................38
10. Schematics and Diagrams...........................................................................................39

1
1. Introduction
This manual contains instructions for installation, operation and maintenance of
the Purge Full Flow Filtration System, as well as indicating residual risk associated with
it. This manual has been specifically compiled and produced to enable easy and safe
use by appropriate personnel.
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.
MP SYSTEMS does not accept responsibility for improper use of the equipment,
unauthorized modifications, or non-observance of the instructions contained in the
manual. This manual must be kept in a safe place and made available to personnel
qualified to use and maintain Purge Systems.

2
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. 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 Purge Series before service can
be done.

3
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.
These safety instructions contain all the general rules that must be
observed during commissioning, operations and all periods of attendance to
the machine.
It is essential that these instructions are supplied and always available to the
installer, competent operators, and authorized maintenance personnel.
The following basic instructions must be observed when using the Purge Series:
•Operation and maintenance must be carried out only by qualified
personnel 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 Purge Series must be
operated with all panels in place and secured.
•Dangerous voltage contained within Purge Series. Before carrying out
any operations on Purge Series, ensure that the electrical supply has
been switched off.
•Operating Purge Series with safety protection removed is strictly
forbidden.
•Before installing Purge Series ensure operating conditions are suitable for
intended use.
MP SYSTEMS disclaims all responsibility for damage to person(s) or
things resulting from non-standard assembly of the machine or from re-
use of its individual components. Unauthorized replacement or removal
of one or more parts of the machine is forbidden.

4
2.1. General Rules
The Purge 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 remains and can arise through improper use of the machine and can be
of various types:
•Risk due to escaped coolant/cutting fluid.
•Risk due to excessive noise caused by operating outside permitted limits.
•Risk of accidents caused by scraping against edged sheet metal profiles.
2.2. Prevention of Mechanical Risks
In operation, the Purge Series contains some moving parts. These parts constitute a
possible source of danger to the operator, therefore to avoid any possible danger it
is necessary to observe the following operational rules:
•Before removing any panels/guards, ensure electrical supply to the
machine has been switched off.
•Never start the Purge Series with any panel/guards removed.
•The additives present in coolant/cutting fluid may have a corrosive action
that can irritate the skin and eyes.
oAlways wear gloves & eye protection when handling
coolant/cutting fluid.
2.3. Prevention of Electrical Risks
When power to the machine is switched on, the machine is a source of danger,
especially if the basic safety rules are not followed. In order to avoid any possible
danger, it is necessary to observe the following basic operation rules:
•When making electrical connections to the Purge Series, observe state
and federal electrical codes or those otherwise in force. Observe the
technical & electrical supply conditions imposed by the power supply
companies.
•Before carrying out any work on the Purge Series, switch off the electrical
supply at the main isolator.
•Work on the Purge Series 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 machine is earthed before powering on the Purge
Series.
•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.

5
3. Intended Uses
3.1. Why the Purge Works
Without the Purge
•Coolant and chips run through the machine and go into the “dirty side” of
the machine tank.
•Coolant flows from dirty side to clean side through a screen, which
collects chips and debris.
•As the screen gets blocked, coolant can no longer flow into the clean
side, starving the pumps.
•The loss of coolant can cause poor part finish, increase tooling wear, out
of tolerance parts, and alarming out in the middle of a part cycle. In some
cases, there is no alarm for loss of flood coolant, which could allow the
problem to cause more and more damage until it is found and resolved.
•To resolve the issue properly, the machine must be shut down, the tank
drained and removed from under the machine, chips removed, and
screens cleaned. Everything then must be put back together; the tank
moved back into place, hoses reconnected, pumps plugged back in, tank
refilled with coolant, and then the machine can be turned on and run
again, repeating the cycle.
With the Purge
•Coolant comes out of the tool or nozzle, falls down with chips, (goes
through chip conveyor), and goes into a collection funnel in the “dirty side”
of the tank.
•The Purge system pulls in coolant and chips from the funnel at a rate
faster than is being provided. This creates a difference in fluid level
between the inside and the outside of the funnel, pushing chips towards
the Purge collection dip tube.
•The fluid with chips is pumped through a set of filters that are selected
based on material and cutting process, and can be easily changed to
meet the needs of different part programs in the future.
•The chips are collected in the filter bags and the coolant flows back to the
clean side of the tank.
•The volume of fluid coming in to the clean side of the tank exceeds the
volume being pumped out, again, creating a fluid height difference,
pushing all debris in the tank towards the Purge collection dip tube and
away from the pumps, while also providing the pumps with more than
enough coolant so they never pull in air.
•When the Purge filters are dirty, the Purge will alarm out but will not stop
the machine tool. The Purge can then be shut down to replace the filters
quickly and easily, which results in more coolant up time.