MP Systems V Series Owner's manual

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

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.

V2 SERIES INSTALLATION, OPERATION, MAINTENANCE MANUAL
DOCUMENT PART #: B V-2 OPERATOR
Revision
Description
Date Issued
Proofed By:
00
Original
06/05/2014
S. Devlin
01
▪Updated all control signal
electrical drawings
▪Updated KVA
▪Added Aeration explanation
12/24/2014
S. Devlin
02
▪Filter bag replacement
images
▪Formatting
▪Updated mpteam@mp-
systems.net
05/19/2015
S. Devlin
03
▪
▪Added introduction and
Symbology
▪Updated safety measures
▪Formatting

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..........................................................................................................................................5
3. Intended Uses .................................................................................................................................................................6
3.1. Features & Benefits.................................................................................................................................................7
4. Specifications ..................................................................................................................................................................8
4.1. Electrical Specifications...........................................................................................................................................9
4.2. Mechanical Specifications.....................................................................................................................................10
5. Floor Layout ..................................................................................................................................................................11
6. Moving & Storage .........................................................................................................................................................12
6.1. Delivery Checks.....................................................................................................................................................12
6.2. Transport & Carriage.............................................................................................................................................12
6.3. Moving with a Fork Truck......................................................................................................................................12
6.4. Storage..................................................................................................................................................................13
7. Installation ....................................................................................................................................................................14
7.1. Installation Kit Components..................................................................................................................................14
7.2. Recommended Tools for Installation....................................................................................................................14
7.3. Electrical Installation.............................................................................................................................................15
7.3.1. Power / Signal Installation ............................................................................................................................15
7.3.2. 3 Phase Power Cable Installation..................................................................................................................15
7.3.3. Control Signal Cable Installation...................................................................................................................16
7.4. Low Pressure Hose Installation.............................................................................................................................20
7.5. High Pressure Installation .....................................................................................................................................21
7.5.1. Generic 4 Port Installation ............................................................................................................................21
7.5.2. Generic 8 Port Remote Manifold Installation ...............................................................................................22
8. Operation......................................................................................................................................................................24
8.1. Filling & Priming....................................................................................................................................................24
8.2. Testing...................................................................................................................................................................25
8.3. Start Up .................................................................................................................................................................25
8.3.1. Initial Pressure Setting ..................................................................................................................................26

8.4. Alarms ...................................................................................................................................................................27
8.4.1. Alarm Descriptions........................................................................................................................................27
9. Maintenance.................................................................................................................................................................28
9.1. Filter Bag Replacement.........................................................................................................................................29
9.2. Basic Pump Maintenance......................................................................................................................................30
10. Options & Accessories...................................................................................................................................................31
10.1. Options..............................................................................................................................................................31
11. Spare Parts ....................................................................................................................................................................32
11.1. Relief Valve Identifier........................................................................................................................................33
Appendix A: Hoses & Fittings................................................................................................................................................34
Appendix B: Pipe Sizing.........................................................................................................................................................36
Appendix C: Power Harness..................................................................................................................................................37

1
1. Introduction
This manual contains instructions for installation, operation, and maintenance of MP
System’s auxiliary coolant and chip control systems, as well as indicating the 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.

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 R 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 any MP System product;
▪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 MP unit must be operated with all
panels in place and secured.
▪Dangerous voltage contained within this unit; before carrying out any operations, ensure
that the electrical supply has been switched off.
▪Operating this unit with safety protection removed is strictly forbidden.
▪Before installing this unit, 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
MP System’s products have 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, MP System’s products contain 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 the unit 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.

5
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 MP System’s products, 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 unit, switch off the electrical supply at the main
isolator.
▪Work on the unit 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 unit.
▪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.

6
3. Intended Uses
▪The V-2 Series was constructed for use on sliding headstock and like machines that have
existing low pressure pumps (flood), tanks, complete machining environment enclosures and
CNC controls with interlocks.
▪The V-2 Series is intended as an auxiliary coolant and chip control system working alongside
the standard low pressure pump. The high pressures developed, 1000-2000 PSI depending on
model, can dramatically improve many machining processes (cycle time), but should only be
used where process improvements warrant its use.
▪The V-2 Series includes a large capacity filter, which is there primarily to protect the high
pressure pump system and cutting tools. However, its presence in the system tends to keep the
machine tool and its coolant much cleaner.
▪The V-2 Series has CNC controlled outlet ports that are to be turned on as needed, so the high
pressure is used only on the tool in the cut. This allows maximum pressure to be used when
needed, but limits detrimental effects of high pressure coolant.
▪The V-2 Series is intended for use with coolants with viscosities between 90 and 140 SUS @
100 F. It can work outside this range, but the results are not consistent.
▪The V-2 Series is intended for use with coolants blended for high pressure service, uncontrolled
properties of some coolants will cause air entrainment, this will airlock the flood pump, reducing
its pumping ability. This in turn will cause changing lock line point of impact, short filter life, and
high pressure pump starving. Special flood pumps, auxiliary tanks, and air separators can
reduce these symptoms, but the problem is best solved with help from the oil blender.

7
3.1. Features & Benefits
▪High pressure coolant when properly applied can save considerable time per cycle,
dramatically improve tool life, and remove many of the requirements for operator
intervention.
▪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. This allows for 5-20% faster drilling.
▪Coolant fed reamers & boring tools, either through tool or close nozzle, can greatly
improve finish, tool life and accuracy.
▪In severe milling applications, the improvements will be easily recognized through the
lack of re-cutting of chips.
▪Heavy cuts can be made far more reliably with high pressure coolant. Tools that smoke
or burn will see tool life greatly improved. This allows for much ‘heavier’ cuts with tools
that can be pushed much harder, greatly improving cycle times.
▪Jobs already being run with ‘flood’ coolant will see dramatic increase in productivity with
high pressure coolant.
▪Often, time consuming programing methods such as rough/finish cuts, interrupted feed,
non-optimum tool and feed speeds can be eliminated with the use of high pressure
coolant. High pressure coolant gives the ability to break and/or control the chips that
typically cause slow speeds.
▪Rings of material left on drills and boring bars can be blown off with high pressure
coolant.
▪Coolant through sub spindle can stop miss chucking and reduce parts being marked by
chips left in the collet.

8
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)
▪FLA (Full load Amps). Largest load, for determining power service requirements.
The operating voltage may be changed in the field if necessary. Changing the
operating voltage can only be done by specialized personnel. Not available on all
systems.
*All specifications are subject to change.

9
4.1. Electrical Specifications
All power for motor and hydraulics is derived from the high pressure pump input source.
Main Power: 3 Phase @ 60Hz
Motor
HP
RPM
208-230 VAC FLA
460 VAC FLA
High Pressure Main
7.5
1750
21-20
10.5
Feed Pump
1.0
3450
3.5-3.4
1.7
Heat Exchanger
0.33
3425
1.1
0.55
Control Power - Isolated
Control Signals
Alarm Circuit
150VA Transformer
24vdc
NC
110VAC Secondary
NO
Primary Fused
*Optional 4 port variants
Model
208-230 VAC
460 VAC
kVA
V-2 SO2
25
12
10
V-2 SO8
25
12
10
V-2 SW2
25
12
10
V-2 SW8
25
12
10
V-2 HO2
26
13
10.5
V-2 HO8
26
13
10.5
V-2 HW2
26
13
10.5
V-2 HW8
26
13
10.5

10
4.2. Mechanical Specifications
Model
V-2 Series
Length
43 ½”
Width
24”
Height
36”
Capacity
5 GAL
Weight*
580 lbs
V-2 –1000 PSI @ 8 GPM
V-2 –2000 PSI @ 5 GPM
Filter
Area
Dimensions
Rating
HB BAG ORING #2 5MC
7 x 32
4.4 ft²
7” x 32”
5 Micron
Environments:
Temperature range: 41º-104º F
Relative humidity: 20-95 % noncondensing
Voltage range: 85-115 %
The V-2 Series should be placed on the floor to avoid damaging vibrations.
The V-2 Series should be moved on its own castors or by lifting from underneath.
All covers should be on during operation.

11
5. Floor Layout

12
6. Moving & Storage
6.1. Delivery Checks
When taking delivery of machine, carefully check the
physical condition of the packaging. Having removed
the packaging, check that the machine has not
suffered any knocks or damage. Check that the
machine has been transported in the correct position.
In case of damage, do not accept the goods and
immediately inform MP SYSTEMS.
DO NOT accept the machine in the event of irregularities during transit. The hauler will bear
the full responsibility for any damage suffered.
6.2. Transport & Carriage
The machine must be transported in a vertical position (casters/wheels down). Machine tank
MUST BE EMPTY before moving. MP System’s products have been constructed so, as to be
moved by fork truck or rolled around on casters on base of unit.
The machine must be moved in such a way as to avoid the risk of damage.
Do not attempt to lift the machine with equipment that is inadequate or unsuitable, especially
with equipment that is too small for overall weight of machine. Refer to the Mechanical
Specifications section for unit weight.
Before moving machine, take care to ensure that all removable panels are firmly attached to
the unit to prevent them from falling.
WARNING: Do not transport machine with fluid in tank.
6.3. Moving with a Fork Truck
To move the machine with a fork truck, the two blades must be
inserted under the long side of the machine. The base is
designed for transportation by fork truck. Insert blades
symmetrically with respect to the center of gravity of the
machine, and push them in through the whole depth of the
machine. Lifting than can be carried out. Carry out the moving
operation at a very slow speed.
Ensure the tank is completely empty of coolant when moving.

13
6.4. Storage
MP System’s products 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 utilizing water based
coolants, the system must be flushed before storage,
please refer to coolant manufacture for correct flushing
agent. Removing all coolant from the system will ensure
coolant does not become contaminated while in the system.
Contaminated coolant may lead to malfunctions.
Not properly draining/flushing the unit before storage can lead to jammed
solenoids, diaphragms that become stuck and bacterial growth. Bacterial growth
will contaminate any coolant it comes in contact with. Contaminated coolants
effectiveness is also greatly reduced.

14
7. Installation
All MP System’s products are shipped on wooden pallets designed for the safe transport of the
auxiliary coolant and chip control system. A large MP SYSTEMS container protects the unit
from any unnecessary damage during transportation.
7.1. Installation Kit Components
COMPONENT
QUANTITY/LENGTH
Power Harness
1
Control Signal Harness
1
Spare 5 Micron Filter Bag
1
Operation & Installation Manual
1
Inlet Dip Tube
1
Return Dip Tube
1
1 1/4" Diameter Inlet Hose
15’
1 1/4" Diameter Return Hose
15’
2” Hose Clamp
2
½” Hose Clamp
2
Weld Clamp (Mounting Dip Tubes)
1
Self-Taping Hex Screws (Mounting Weld Clamps)
2
7.2. Recommended Tools for Installation
▪Philips (Cross) Head Screwdriver
▪Flat Blade Screwdriver
▪Electric Drill
▪7/8” UniBit (Step Drill)
▪1 1/4" Conduit Punch or equivalent size hole saw
▪12” Pipe Wrench (Minimum)
▪Metric Hex Keys
▪Teflon Pipe Tape / Liquid Pipe Sealant