MP Systems PURGE Series Installation, Operation & Maintenance Manual
MP Systems PURGE Series is a full-flow filtration system designed to capture and remove chips and debris from your machine tool's coolant system. This prevents clogging and ensures a constant supply of clean coolant, improving part quality, tool life and machine uptime. The system features a high-quality, 3HP pump, adjustable flow rate, a debris collection unit with replaceable filters and a control box with programmable settings. It is designed for ease of installation and maintenance, and can be easily integrated into your existing machine tool setup.
PDF
Download
Document
Advertisement
Advertisement
INSTALLATION, OPERATION, & MAINTENANCE MANUAL PURGE SERIES MP Systems - 34 Bradley Park Road, East Granby, CT 06026 USA Phone + 1 (877)-689-1860 - Email [email protected] MPSYSTEMS-M-011/02 (Purge Operator) 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-011/02 (Purge Operator) PURGE SERIES INSTALLATION, OPERATION, MAINTENANCE MANUAL DOCUMENT PART #: B PURGE SERIES Date Description Issued Revision 00 Original • 01 • • • 02 • • 04/25/19 Purge Drive Tuning Instructions Added Add 1 ¼” Hose to Install Kit Add Mounting Bracket to Install Kit Update PLC screens to match V5.20 Removed Drive Tuning Instructions Add info on 480/400V system Proofed By: B. Jalbert 9/9/19 6/4/20 B. Jalbert MPSYSTEMS-M-011/02 (Purge Operator) Table of Contents 1. Introduction ......................................................................................................................... 1 1.1. 2. 3. Safety Measures ................................................................................................................. 3 2.1. General Rules .............................................................................................................. 4 2.2. Prevention of Mechanical Risks ................................................................................... 4 2.3. Prevention of Electrical Risks ....................................................................................... 4 Intended Uses ..................................................................................................................... 5 3.1. 5. 6. Why the Purge Works .................................................................................................. 5 3.1.1. Without the Purge ................................................................................................. 5 3.1.2. With the Purge ...................................................................................................... 5 3.2. 4. Symbology ................................................................................................................... 2 Features and Benefits .................................................................................................. 6 3.2.1. Flow ...................................................................................................................... 6 3.2.2. Debris Collection Device ....................................................................................... 6 3.2.3. Collection Pump.................................................................................................... 6 3.2.4. Debris Collection Unit ........................................................................................... 6 3.2.5. Control Box ........................................................................................................... 6 3.2.6. Clean Section of Tank........................................................................................... 6 Specifications ...................................................................................................................... 7 4.1. Electrical Specifications ............................................................................................... 7 4.2. Mechanical Specifications ............................................................................................ 7 4.3. Floor Layout ................................................................................................................. 7 Moving & Storage ............................................................................................................... 8 5.1. Delivery Checks ........................................................................................................... 8 5.2. Transport & Carriage ................................................................................................... 8 5.3. Storage ........................................................................................................................ 8 Installation........................................................................................................................... 9 6.1. Install Kit Components ................................................................................................. 9 6.2. Recommended Tools for Installations .......................................................................... 9 6.3. Electrical Installation ...................................................................................................10 6.3.1. Selecting Voltage .................................................................................................11 6.3.2. Power Harness Installation ..................................................................................11 6.3.3. Control Signal Installation (Optional) ....................................................................12 6.4. Inlet Installation ...........................................................................................................12 6.4.1. Suction Dip Tube Placement................................................................................12 6.4.2. Feed Pump Installation ........................................................................................12 MPSYSTEMS-M-011/02 (Purge Operator) 6.5. 6.5.1. Return Installation ................................................................................................14 6.5.2. Hose Routing .......................................................................................................14 6.6. 7. Return Installation and Hose Routing ..........................................................................14 Filling the Tank ...........................................................................................................14 Operation ...........................................................................................................................15 7.1. 8. PLC Set Up and Settings ............................................................................................15 7.1.1. PLC Initial Set Up ................................................................................................15 7.1.2. PLC Settings ........................................................................................................16 7.1.3. Alarms .................................................................................................................22 Maintenance ......................................................................................................................24 8.1. Routine Maintenance ..................................................................................................24 8.1.1. Filter Bag Replacement .......................................................................................25 9. Spare Parts ........................................................................................................................26 10. Schematics and Diagrams ..............................................................................................27 MPSYSTEMS-M-011/02 (Purge Operator) 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. 1 MPSYSTEMS-M-011/02 (Purge Operator) 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. 2 MPSYSTEMS-M-011/02 (Purge Operator) 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 reuse of its individual components. Unauthorized replacement or removal of one or more parts of the machine is forbidden. 3 MPSYSTEMS-M-011/02 (Purge Operator) 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 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, the Purge 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 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. o Always 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. 4 MPSYSTEMS-M-011/02 (Purge Operator) 3. Intended Uses 3.1. Why the Purge Works 3.1.1. 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. 3.1.2. With the Purge • • • • • • 5 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 quickly and easily replace the filters, which results in more coolant up time. MPSYSTEMS-M-011/02 (Purge Operator) 3.2. Features and Benefits 3.2.1. Flow • • Constant adjustable flow rate captures machine tool outflow. Excess flow reverses flow direction in tank which prevents chips from building up on the screens. 3.2.2. Debris Collection Device • Directs and contains incoming debris for pickup by the collection pump • Type of collection device may be more complex based on application o For more information, please call MP SYSTEMS. 3.2.3. Collection Pump • High quality cast pump with a 3 HP inverter duty motor. • Computer controlled pump delivers a constant flow – even as filters in the DCU begin to clog • Rugged 3.2.4. Debris Collection Unit • Compact size (20”x25”) vs. Filtration Area (QTY. 4 9”X9” Filter Locations) • Versatile: Accepts a vast array of filtering elements • Customer can continue to run machine tool while changing purge filters • Hour timer can be implemented to develop replacement schedule per application 3.2.5. Control Box • 3 Phase 208V (Optional 480V) twist lock connection with pigtail • Can be tied into machine tool power • HMI communication which tracks and reports usage • Optional strobe light for alarm indication • Standard terminal strip for full machine tool communication 3.2.6. Clean Section of Tank • Provides constant flow of clean coolant to prevent starvation of flood and high pressure pumps, protects tools and present tank equipment, and creates a positive flow outward through tank filters and screens 6 MPSYSTEMS-M-011/02 (Purge Operator) 4. Specifications MP SYSTEMS equipment ships with an identification label. The label is located on the control box on the front of the machine. *Information listed on Identification Label: • • • • • 4.1. MODEL Purge Pump Type Serial Number Build Date Operating Voltage (208-230VAC) (Optional 480V) FLA (Full Load Amps). Largest Load, for determining power service requirements. Electrical Specifications FLA @ 208/230VAC FLA @ 480VAC (Standard VAC) (USEABLE @400V +/- 5%) CONTROL SIGNALS ALARM CIRCUIT 9* 6* Fused 24VDC NC/NO COMPONENT FLA @ 208/230VAC (Standard VAC) / ACCESSORY Feed Pump 9* 4.2. FLA @ 480VAC (USEABLE @400V +/- 5%) HP RPM 6* 3 3600 Mechanical Specifications MODEL LENGTH WIDTH HEIGHT CAPACITY (in) (in) (in) (gal) Purge 32 25 36 30 4.3. 7 FLOW RATE 30-60GPM Floor Layout MPSYSTEMS-M-011/02 (Purge Operator) 5. Moving & Storage 5.1. Delivery Checks When taking delivery of a machine, ensure that the machine has been transported in the correct position. Carefully check the physical condition of the box for any signs of external damage. If there is evidence of damage, remove the packaging to ensure there is no damage to the contents of the skid. In case of damage, DO NOT accept the goods and immediately inform MP SYSTEMS. If you are unsure if there is damage to the contents and accept delivery, you must write “Damaged” on the delivery receipt. In the event of irregularities during transit, the freight company will bear the full responsibility for any damage suffered. 5.2. Transport & Carriage The machine must be transported in a vertical position, as shipped. The tank MUST BE EMPTY before moving. The Purge Series has been constructed to be moved by fork truck. 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 Section 4.2. Mechanical Specifications for unit weight. Only trained and licensed Fork Truck operators may transport this machine. MP SYSTEMS is not responsible for any damage caused by unauthorized use. WARNING: Do not transport machine with fluid in tank. 5.3. Storage The Purge Series must be stored in a cool and dry environment, avoiding all extreme conditions including 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 the coolant manufacturer 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 Purge Series before storage can lead to bacterial growth, which will contaminate any coolant it comes into contact with. Contaminated coolants effectiveness is also greatly reduced. 8 MPSYSTEMS-M-011/02 (Purge Operator) 6. Installation All MP SYSTEMS Purge Series are shipped on wooden pallets designed for the safe transport of the Purge Series Full Flow Filtration System. A large MP SYSTEMS box protects the Purge from any unnecessary damage during transportation. If there is visible damage from transportation, refer to Section 5.1 Delivery Checks. 6.1. Install Kit Components COMPONENT QUANTITY/LENGTH Return Dip Tube Inlet Dip Tube Power Harness Circuit Breaker 1 ¼”” Hose 2 ½” Hose Hose Clamps T-Bolt Hose Clamp for Return Dip Tube Mounting Brackets Return Hose Clamp Operation Manual 5MC Steel Ring Filter Bags 1 1 1 1 25’ 10’ 5 1 2 1 1 4 6.2. Recommended Tools for Installations • • • • • • • • Phillips (Cross) Head Screwdriver Flat Blade Screwdriver Electric Drill 7/8” UniBit (Step Drill) 1 ¼” Conduit Punch or equivalent size hole saw 12” Pipe Wrench (Minimum) Metric Hex Keys Teflon Pipe Tape / Liquid Pipe Sealant When installing MP Systems products, the correct location of the dip tubes is important to a successful install. The best way to do this is to use a preexisting hole in the tank can be used to pass the various pipes through the tank top. This is not only quick and easy, but also gives you a perfect window to be able to see what is going on in your tank for troubleshooting. Sometimes, this is simply not an option and a hole must be drilled in the tank. If you find yourself in a pinch, most hardware stores like Home Depot or Lowes will have the required hole saws available, you will want to find a bi-metallic hole saw like a Milwaukee or Lenox depending on which store you go to. These tend to be the best option in a hurry, however they will wear out, so if you have a lot of holes to drill, it may be wise to purchase more than one. If you know ahead of time that you will need them, then they can be ordered from McMaster, or MP Systems stocks and can ship a kit with all the necessary components. 9 MPSYSTEMS-M-011/02 (Purge Operator) HIGH PRESSURE X PURGE X X X X X X CDR X X X X X PIPE SIZE 1 1/4" 1 1/2" 2" 2 1/2" ALL ALL HOLE SAW 1 3/4" 2" 2 1/2" 3" ARBOR PIN 3/16 X 2 McMaster 3789A29 3789A33 3789A39 3789A45 3789A61 97395A618 MP Systems AK HOLE SAW KIT AK HOLE SAW KIT AK HOLE SAW KIT AK HOLE SAW KIT AK HOLE SAW KIT AK HOLE SAW KIT Cutting a hole in sheet metal seems like a common task, however doing it right will not only be safer, but can also improve tool life, cut speed, and cut quality (clean vs. jagged edges). 1. Start by measuring twice. Use the green pipe clamp for the dip tube you are installing to help layout where the hole needs to be drilled, as well as where the fasteners will need to go for the clamp. Use a center punch to locate the holes and prevent drill drift. 2. Use the appropriate size drill to make a pilot hole in the center of the cut. *NOTE* Only the drill should be used at this point, do not use the drill bit while attached to the hole saw. When the drill breaks through, you can damage the hole saw by “punching” the sheet metal and breaking or bending the teeth. 3. Install the blank pin in the arbor, then thread on the hole saw. (In a pinch, an old drill bit installed backwards can work as a guide too) Be sure to set your drill to low speed and change from drilling to torque mode. 4. Apply cutting fluid and begin cutting, feathering the trigger to maintain a moderate speed. 5. Be sure to continuously add cutting fluid to keep the hole saw cool and lubricate the cut. 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. LOCK OUT/TAG OUT any and all power disconnect switches before performing any work on equipment. 10 MPSYSTEMS-M-011/02 (Purge Operator) Be sure to observe local and federal electrical codes in effect. Observe the technical supply conditions imposed by the power supply company. 6.3.1. Selecting Voltage Many large industrial facilities run on 480v 3phase @ 60Hz electricity. Most machine tools in the 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. (Optionally, 480V units can be purchased, voltage cannot be changed in the field) Utilizing machine tool voltage makes lockout/tag-out far easier and allows it to comply with most local regulations. Power can either be pulled from a separate drop, or from the machine tool using the provided circuit breaker in the installation kit if the machine tool breaker allows. 6.3.2. Power Harness Installation 1. Mount supplied power harness with hardware provided in the installation kit and route the cable: • If ¾” conduit plug is not available, knock out hole and use supplied cord grip. 2. Wire power cable in parallel with machine tool power: • Be sure to leave enough cable to properly ground the unit. 3. Locate proper grounding point. Attach using supplied ring terminals. 3 phase power installation should only be performed by qualified personnel. 11 MPSYSTEMS-M-011/02 (Purge Operator) 6.3.3. Control Signal Installation (Optional) Using machine tool control signals is not recommended by MP SYSTEMS. If required for your application, please contact MP SYSTEMS for more information. 6.4. Inlet Installation 6.4.1. Suction Dip Tube Placement One of the biggest factors of a successful Purge install is where you place the suction dip tube in the tank. There is only one suction tube and it can only be placed in one location. MP SYSTEMS recommends placing the suction point either immediately adjacent to the chips’ point of entry as depicted in Example A, or in the path of high velocity coolant, as depicted in Example B. • • • The maximum chip size the Purge can handle is ¼”. If larger chips are present, an optional screen or basket can be added to separate the larger chips out. In less than ideal cases where some of the debris may be missed, the Purge will still provide an excess of clean coolant directly to the clean side of the machine tool tank. This will provide the machine tool with more coolant up-time, however you may have to clean out the tank periodically. Also, because of the Purge’s high flow, it will eventually capture debris that is in suspension, even with a poorly placed dip tube. The illustrations on the next page show various conveyor/tank conditions and how the Purge might be installed. 6.4.2. Feed Pump Installation 1. After locating your collection point, the feed pump must be put on the floor, as close as 2. 3. 4. 5. possible to the collection point, prior to connecting the dip tube. Connect your dip tube to the inlet of the feed pump using the shortest hose possible. • Use supplied hose clamps to secure hose during installation. To prime, add coolant into the outlet of the feed pump until the coolant trickles out of the inlet. Attach the hose between the feed pump outlet and the Purge inlet. • Use supplied hose clamps to secure hose during installation. Run the yellow cable attached to the feed pump to the bottom of the purge electrical panel and plug it into the matching connector. Refer to the Floor Layout in Section 4.3 for a visual example. Do not place hoses on top of unit or stand vertically. 12 MPSYSTEMS-M-011/02 (Purge Operator) A Conveyor ✓ Perfect! This is the best case for the Purge. All of the flow from the conveyor is directed immediately into the dip tube. Tank B Conveyor ✓ In this case, the exit is very wide, however all of the flow is getting directed down a known path. This smaller channel, whether it be part of the conveyor or part of the tank geometry, increases the velocity of the fluid and directs it right into the Purge dip tube. O This is a less than ideal situation. With a long exit, or multiple exits along the same side, some of the coolant at the far ends can be missed by the dip tube. The purge will still work and will collect the majority of the debris, but you won’t have the same level of collection. Tank C Conveyor Tank D Conveyor Tank 13 X When a conveyor has exits on both sides, or when the conveyor has more than one exit and they are far apart, the Purge cannot collect everything. In this case, the Purge would only collect half of the debris missed by the conveyor. MPSYSTEMS-M-011/02 (Purge Operator) 6.5. Return Installation and Hose Routing 6.5.1. Return Installation The bottom of the return pipe is cut at a 45° angle. Be sure to point the dip tube into the tank and not into a wall. Tank tops usually have multiple cutouts in the clean section of the tank for various pumps and accessories. One of these holes can be utilized for the Purge return, but try to use one farthest from the screen. ✓ DIP TUBE X X O ✓ X O ✓ CLEAN DIRTY TANK TANK SCREEN 6.5.2. Hose Routing The Purge uses a gravity based return. Because of this, the hose must be as short as possible and have a continuous downward slope as depicted in Example A below. If the hose goes under the tank level or over the top of the Purge, as depicted in Example B and C, it can block the flow of coolant, causing an alarm. • • Use supplied T-Bolt Hose Clamp to connect hose to Purge outlet. Use normal supplied hose clamp to secure hose to dip tube. ✓ Purge X A Tank 6.6. B C Filling the Tank 1. Fill machine tool coolant tank with coolant/cutting fluid. 2. To access the Purge tank for filling, unscrew four of the wingnuts and remove one of the filter tops. 3. Fill Purge tank with 30 Gallons of coolant/cutting fluid. 14 X • Be sure to use the same coolant being used in machine tool tank. 4. Replace filter top and hand tighten wingnuts. MPSYSTEMS-M-011/02 (Purge Operator) 7. Operation 7.1. PLC Set Up and Settings 7.1.1. PLC Initial Set Up After connecting all hoses and power, the Purge can be turned on and the PLC set up. 1. If there is a screen in the tank that separates the clean and dirty side, be sure to clean the screen if installing on a machine tool that has already been run. Obstructions between the clean and dirty side can prevent proper operation. 2. Go into the settings on the PLC and confirm the amp settings match your motor name plate. • These are the default settings for min and max amps. These are average values that will allow the unit to get started. Changing these values to match your motor will allow the Purge to run at its best. MIN AMP MAX AMP LOW VOLT 3.0 8.0 HIGH VOLT 2.0 4.0 • The motor plate will list “AMPS” or “FLA” depending on manufacturer. This is the MAX AMP value. • The MIN AMP should be set to the current the motor pulls when it is sucking air. This can be found by running the motor for a few seconds before hooking up the hoses, or if it has already been installed, by raising the dip tube out of the tank to make the pump suck air briefly. 3. Turn on all of the coolant pumps in the tank • You should see the coolant flowing into the clean section from the dirty section through the screen. The coolant on the clean side of the screen will be lower than the dirty side. 4. From the main screen, start the Purge and wait 30 seconds. • The first time you turn on the Purge, there will be air in the hose which might alarm out the machine. This is OK. • If it alarms, clear the alarm and restart from the main screen until coolant flows. • If you get more than 5 consecutive alarms, check for loose connections or blocked inlet. • If the problem persists, contact MP SYSTEMS. 5. Check to make sure the coolant is flowing through the screen in the reverse direction. The coolant in the clean side should now be level with or higher than the dirty side. • If the coolant is not flowing in reverse, hit “STOP” on the PLC Screen, go to “SETTINGS”, and increase the FLOW value. • Once the FLOW Value has been entered, go back to the main screen and select “START”. • Continue to increase the flow value until reverse flow is achieved. 15 MPSYSTEMS-M-011/02 (Purge Operator) 7.1.2. PLC Settings Caution: Modifying PLC settings may result in malfunction. Please contact MP SYSTEMS before modifying PLC settings. Parameters can be modified through PLC. Standard PLC settings listed as well as additional options. MAIN DISPLAY START/STOP – Press to start and stop the PURGING – Indicates that the system is Purge unit manually. The colored window to Purging (See BAG LIFE EXT. page 19) the right will change between green and red TOTAL RUN TIME – Displays the amount to indicate whether the Purge is on or off of time the Purge has been run in its lifetime respectively. CURRENT PSI – Displays the current PSI SETTINGS – Press to go into the Settings CURRENT – Displays the motor current display (See page 16) FILTER LIFE – Displays estimated filter life ALARM HISTORY – Press to go into the FREQUENCY – Displays current motor frequency alarm history display CHANGE FILTERS – Indicates that the filters will need to be changed soon. PURGE HOURS V. MACHINE TOOL HOURS – Displays the number of hours the Purge and the Machine Tool (if connected) ran over the course of the week as compared to the previous week. The colored window to the right will change between green and red to indicate whether the Purge ran more than the machine or the machine ran more than the Purge respectively. 16 MPSYSTEMS-M-011/02 (Purge Operator) SETTINGS RESTORE DEFAULTS – Restores settings back to factory settings MORE SETTINGS – Press to go into the More Settings display (See page 18) AUTOMATIC START/STOP – Press to go into the Automatic Start/Stop display(See Page 19) STROBE ON – Turns the light on/off for alarms. USE COOLANT ON – (Optional) If using the optional signal interface, will run at a second, higher speed when coolant is on. USE MACHINE READY – (Optional) If using the optional signal interface, will turn on the Purge when the machine tool is in a “Safe to Run” state. EMAIL\ TEXT OPTIONS – (Optional) Contact MP SYSTEMS for more information. FLOW – Used to set requested flow rate. MAX 80 GPM COOLANT ON – Used to set second flow rate for when coolant is on. MAX 80 GPM MAX FREQ/MIN PSI/MAX PSI/MIN AMP – Used to set values for Max Frequency cut off, Min Pressure, Max Pressure, and Minimum Current. Contact MP SYSTEMS before changing. IMPELLER DIAMETER – Used to set impeller diameter: 4.84 = FM8 4.47 = FM5 MANIFOLD DIAMETER – Used to set manifold inlet hose size: 2” IN or 1.25” IN SOFTWARE VERSION – Displays current software version. Make note of Software Version when contacting MP SYSTEMS for support. 17 MPSYSTEMS-M-011/02 (Purge Operator) MAX FLOW OPTION On larger machine tools that require higher flow rates, and have little or no restrictions between the “Clean” and “Dirty” sides of the tank, the Max Flow option can be used. *IF YOU ARE NOT SURE IF MAX FLOW IS RIGHT FOR YOU, CONTACT MP SYSTEMS.* *FLOW RATES CAN EXCEED 100GPM. IMPROPER USE CAN CAUSE TANK OVER FLOW* Instead of maintaining a specific flow rate, the Purge will slowly increase the flow rate over time until it reaches the limit of the system. It will then slow down a small amount, and then begin ramping up to the limit again. It will stop this loop when the pressure reaches the max setting. TO ENABLE – Set both the FLOW and COOLANT ON settings to 88 GPM. Once both are set, the MAX FLOW settings will show on the screen. START – Starting frequency. Recommend starting at 30Hz. If TANK OVER FLOW alarm occurs during startup, lower this setting. INC – How often the ADD value is added to the output frequency. ADD – What is added to the output frequency. SUB – What is subtracted from the output frequency, when the float switch is triggered. START INC ADD SUB 18 EXAMPLE 30 0:01 0.1 5 Hz Min:Sec Hz Hz MPSYSTEMS-M-011/02 (Purge Operator) MORE SETTINGS ALARM OUT – (Optional) Used to select alarm output behavior. Either NC or NO. SLOW START – When the Purge starts, it will run a slow start procedure to slowly fill the return hose, this prevents air bubbles getting trapped and causing the tank to overflow. Contact MP SYSTEMS before changing these settings. LOW/HIGH PRESSURE, MAX FREQUENCY, SENSOR ERROR – Contact MP SYSTEMS before changing these settings. ZERO – This will zero out the pressure sensor, only when the pump is off. Contact MP SYSTEMS if you suspect your pressure sensor is having issues. 19 MPSYSTEMS-M-011/02 (Purge Operator) AUTO START/STOP UPDATE RTC SETTING – Used to update Real Time Clock if it is incorrect START TIME – Used to set time when the Purge will turn itself on. Set to 00:00 to disable (24H) STOP TIME – Used to set time when the Purge will turn itself off. Set to 00:00 to disable (24H) DAYS OF THE WEEK – Used to set which days of the week to follow the on off schedule. BAG LIFE EXT. – While the Purge is running, the Purge will run for the ON time and then shut off for the OFF time, then turn itself back on and repeat. When the Purge is running, debris tends to be pressed against the walls and is not allowed to fall to the bottom until the pump stops. This can cause the Purge to alarm out when the bags are not entirely full. The bag life extension feature will cycle the bags, allowing the debris to fall over time, and get more use out of each filter. 20 MPSYSTEMS-M-011/02 (Purge Operator) ALARM HISTORY ALARM # – Shows the current alarm number, 0-50. Press and enter a number to jump to an alarm. ALARM ID – Brief description of alarm FREQ – Motor frequency at time of alarm PSI – Pressure at time of alarm CURRENT – Motor current at time of alarm Time – Time of alarm. If incorrect, RTC can be updated in the AUTO START/STOP display (See Page 19) Date – Date of alarm. Again, if incorrect, update the RTC. Run time – Amount of time the purge has run in total when the alarm occurred. *PLC Settings are subject to change. 21 MPSYSTEMS-M-011/02 (Purge Operator) 7.1.3. Alarms The machine uses one alarm output but MP SYSTEMS does not recommend using it. If a fault occurs, the strobe light will go off and the alarm will be displayed on the screen. EXAMPLE OF THE ALARM DISPLAY: Alarm Description Most Common Solution Clear Alarm Button 22 MPSYSTEMS-M-011/02 (Purge Operator) POSSIBLE ALARMS AND SOLUTIONS: ALARM DESCRIPTION SYMPTOM(S) MOST COMMON SOLUTION(S) Dirty Filter Alarm High Frequency • Dirty Filters Change all Filters, then press “Clear Alarm” Dirty Filter Alarm High Pressure • Dirty Filters Change all Filters, then press “Clear Alarm” • • Loose Connection Motor Tapped Incorrectly Drive Alarm Cycle Power If alarm persists, contact MP SYSTEMS Prime Feed Pump Low Flow Alarm • • Check Tank Fluid Level Clogged Inlet Sucking Air Check Inlet for Blockages Then press “Clear Alarm” • Pressure Sensor Alarm • • Tank Over Flow Alarm • 23 Pressure Sensor Unplugged Damaged Pressure Sensor Restricted Return Hose Thick Fluid Connect or Replace Sensor, then press “Clear Alarm” Check Return Hose, then press “Clear Alarm” If alarm persists, contact MP SYSTEMS MPSYSTEMS-M-011/02 (Purge Operator) 8. Maintenance Before carrying out any maintenance on the unit or accessing any 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 the machine, in order to ensure it is working properly. Maintenance operations are essential for keeping the unit at its highest efficiency. Routine maintenance does not require special technical knowledge, however, it should be carried out by trained personnel. 8.1. Routine Maintenance ROUTINE MAINTENANCE Group/Component Machine Structure Operation Maintenance Interval Visually check condition of structure (areas of corrosion and/or dents). Monthly HOSES – Visual check for leaks in hydraulic circuit. Weekly FILTERS – Replace as needed. Hydraulic Circuit Electrical Components 24 Daily/Weekly/Monthly FLUID – Check quality and cleanliness of fluid in tank. Monthly PRESSURE – Check pressure when machine is in use. Pressure must be within range listed on machine. Monthly Check current usage and seating of electrical components. Yearly MPSYSTEMS-M-011/02 (Purge Operator) 8.1.1. Filter Bag Replacement 1. Press the “STOP” button on the PLC screen, and switch power to the ‘OFF’ position. 2. Access the filter bags in the Purge tank by unscrewing the wingnuts on each filter top. 3. Remove all four dirty filter bags by slowly lifting each one, using the handles on the bag. 4. Install four all new filter bags. 5. Replace filter tops and secure wingnuts. • Tighten all wingnuts by hand. 6. Switch power to ‘ON’ position, and press the “START” button on the PLC screen. 7. Continue normal operation. Filters may not evenly fill – This is OK. If there is a significant difference in chip volume, check hoses for blockages or call MP SYSTEMS for more information. 25 MPSYSTEMS-M-011/02 (Purge Operator) 9. Spare Parts SPARE PARTS PART NAME Filter Bags PART # 208/230V 480V HB BAG PURGE ST RING #2 5MC 7X32 Filter Vessel O-Ring Fuses M ORING ED 1A FUSE ED 1/2A FUSE Gauge H GAUGE 30PSI BK ¼ Inlet Hose Clamp(s) HC 2” HOSE CLAMP T-Bolt Hose Clamp for Return HC 3” TS HOSE CLAMP Circuit Breaker ED CB 20A ED CB 10A For parts not listed, please contact MP SYSTEMS at 877-689-1860 MP SYSTSEMS recommends stocking (8) spare filter bags. 26 MPSYSTEMS-M-011/02 (Purge Operator) 10. Schematics and Diagrams POWER SCHEMATIC 208/230V 27 MPSYSTEMS-M-011/02 (Purge Operator) POWER SCHEMATIC 480V 28 MPSYSTEMS-M-011/02 (Purge Operator) CONTROL SCHEMATIC 29 MPSYSTEMS-M-011/02 (Purge Operator) FLOW DIAGRAM 30 MPSYSTEMS-M-011/02 (Purge Operator) ">

Public link updated
The public link to your chat has been updated.
Advertisement
Key features
- Full-flow filtration
- Debris collection
- Adjustable flow
- Replaceable filters
- 3HP pump
- Easy installation and maintenance
Frequently asked questions
The maximum chip size the PURGE can handle is ¼”.
Install the suction dip tube either immediately adjacent to the chips’ point of entry, or in the path of high velocity coolant.
When the PURGE filters are dirty, the system will alarm out but will not stop the machine tool. You can then shut down the PURGE and quickly replace the filters.