MP Systems R Series Instruction manual

MPSYSTEMS-M-001/06
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
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.

MPSYSTEMS-M-001/06
R SERIES INSTALLATION, OPERATION, MAINTENANCE MANUAL
DOCUMENT PART #: B R OPERATOR
Revision Description Date
Issued Proofed By:
00 Original 06/05/2014 S. Devlin
01 Updated all control signal
electrical drawings

Added Hydracell priming
instructions 12/24/2014 S. Devlin
02
Added low side visual
Super/Severe duty
schematics
RF20 mechanical/electrical
specifications
R Control schematic
R Signal schematic
Filter bag replacement diagram
Updated PLC settings for all R
Series
Recalculated kVA/FLA ratings
04/10/2015 S. Devlin
03
RV finish signal PLC
settings
Schematic corrections
Removed MP1200
installation
Added ‘how-to’ wire MP1200 in
line with flood pump
Added RC PLC settings 06/22/2015 S. Devlin
04
Removed pump specific
schematics
Updated format/style
Delivery check
Storage instructions
Control signal explanation
Added general rules
Added safety measure
Update electrical/mechanical
specifications
Transportation procedure
MP 1200 installation procedure
RC installation procedure
11/10/2016 S. Devlin
05
AC (Auto Cross) information
updated.
Updated Flow Diagrams
Electrical Specifications
Voltage Selection
VR Installation Options
Obsolete RC/CS 30
Added PLC Settings
MP1200 Installation Options
Mechanical Specifications
R/VR Control Schematics
Spare Parts List
05/7/2018 S. Devlin
06
Added fitting explanation for
generic kit
Added Ambient
Temperature Chart
Updated spare parts list
Updated FLA
Added VR10 info
Added relief valve ID page
Update RC and VR/VR2 PLC
Settings
Add CB kits for RFC/VRC
Updated mechanical Specs
Instructions for programming
variable pressure
Reformatted
Updated Logo
5/28/20 B. Backhaus
J. Bastiaanse

MPSYSTEMS-M-001/06
Contents
1. Introduction.........................................................................................................................1
1.1. Symbology....................................................................................................................1
2. Safety Measures.................................................................................................................2
2.1. General Rules...............................................................................................................3
2.2. Prevention of Mechanical Risks....................................................................................3
2.3. Prevention of Electrical Risks .......................................................................................3
3. Intended Uses.....................................................................................................................4
3.1. Features & Benefits ......................................................................................................5
4. Specifications......................................................................................................................6
4.1. Electrical Specifications................................................................................................7
4.2. Mechanical Specifications.............................................................................................8
4.2.1. Floor Layout...........................................................................................................9
4.3. Options & Accessories.........................................................................................11
5. Moving & Storage.............................................................................................................12
5.1. Delivery Checks..........................................................................................................12
5.2. Transport & Carriage ..................................................................................................12
5.3. Moving with a Fork Truck............................................................................................13
5.4. Storage.......................................................................................................................13
6. Installation.........................................................................................................................14
6.1. Installation Kit Components........................................................................................14
6.2. Recommended Tools for Installation...........................................................................14
6.3. Electrical Installation...................................................................................................15
6.3.1. Selecting Voltage .................................................................................................16
6.3.2. Power Harness Installation...................................................................................17
6.3.3. Control Signal Harness Installation ......................................................................18
6.4. Low Pressure Installation............................................................................................22
6.4.1. Low Pressure Hose Routing.................................................................................23
6.5. High Pressure Installation...........................................................................................24
6.5.1. Generic Mill Installation........................................................................................24
6.5.2. Generic Lathe Installation.....................................................................................25
6.5.3. 8JIC to 6JIS Fitting Explanation...........................................................................27
7. Operation..........................................................................................................................28
7.1. Filling & Priming..........................................................................................................28

MPSYSTEMS-M-001/06
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. Alarms.........................................................................................................................43
7.6. Slow Fill Alarm ............................................................................................................44
8. Maintenance .....................................................................................................................45
8.1. Routine Maintenance..................................................................................................45
8.1.1. Filter Bag Replacement........................................................................................46
9. Options & Accessories......................................................................................................47
9.1. Auto Cross..................................................................................................................47
9.2. Dual Pressure .............................................................................................................47
9.3. Dual Simultaneous Pressure.......................................................................................47
9.4. Variable Pressure........................................................................................................48
9.4.1. How to Program Variable Pressure ......................................................................48
9.5. MP 1200 Mist Collector (MC)......................................................................................49
9.5.1. Control Signal Options (MC).................................................................................49
9.5.2. Plumbing Instructions (MC) ..................................................................................50
9.5.3. Understanding Gauge & Speed Control (MC) ......................................................51
9.6. RC Mountable Chiller (RC) .........................................................................................52
9.6.1. Chiller Ambient Temperature Chart......................................................................53
9.6.2. Mounting Instructions (RC)...................................................................................54
9.6.3. Plumbing Instructions (RC)...................................................................................55
9.6.4. Electrical Installation.............................................................................................56
9.6.5. Priming & Start-Up................................................................................................57
9.6.6. Settings (RC)........................................................................................................58
9.6.6.1. Settings (RC).....................................................................................................60
9.6.7. Alarms ‘RC’...........................................................................................................61
9.6.8. Maintenance (RC) ................................................................................................62
10. Spare Parts.......................................................................................................................64
10.1 Solenoid Identifier..........................................................................................................65

MPSYSTEMS-M-001/06
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......................................................................................................75

1 MPSYSTEMS-M-001/06
1. Introduction
This manual contains instructions for installation, operation and maintenance of R Series
auxiliary coolant and chip control systems as well as indicating residual risk associated with them.
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 to the same non-observance of the instructions contained in
the manual. The manual must be kept in a safe place and made available to personnel
qualified to use and maintain R Series auxiliary coolant and chip control systems.
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 R Series before service can be done.

2 MPSYSTEMS-M-001/06
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 R 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 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.
Operating R Series with safety protection removed is strictly forbidden.
Before installing R 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.

3 MPSYSTEMS-M-001/06
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;
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, R Series contains 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 off.
Never start R 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 R Series, observe state and federal electrical codes
or those otherwise in force. Observe the technical supply conditions imposed by the power
supply companies.
Before carrying out any work on the R Series, switch off the electrical supply at the main
isolator.
Work on the R 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 R 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.

4 MPSYSTEMS-M-001/06
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.
MP SYSTEMS auxiliary coolant and chip control systems are intended to work alongside the
standard low pressure pump. The high pressures generated can dramatically improve tool life
and reduce cycle time, but should only be used where process improvements warrant its use.
MP SYSTEMS auxiliary coolant and chip control systems includes 2 large capacity filters. The
filters primarily protect the high pressure pump and the cutting tools present in the machine
tool. The presence of the 2 large capacity filters keeps the machine tool and its coolant much
cleaner.
MP SYSTEMS auxiliary coolant and chip control systems are intended for use with water
based coolants or oils with viscosities between 90 and 140 SUS @ 100° Fahrenheit.