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Qualifications and Requirements
Coolant requirements
Add the correct type and amount of coolant before you operate the plasma cutting system.

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Specifications
Qualifications and Requirements
- Document requirements
- Operator qualifications
  A person is considered qualified to operate the cutting system if he or she is trained and knowledgeable about cutting system equipment construction, operation, and work methods, and about how to recognize and avoid hazards that can be present with certain cutting system equipment or work methods.
- Qualifications of service personnel
  It can be hazardous to do service and maintenance on industrial cutting systems and equipment.
- System electrical requirements
- Process-gas requirements for all gas connect consoles
  You must supply the process gases for your cutting system.
- Shield-water requirements (VWI and OptiMix)
  If you use water as a shield fluid, use the following water pressure requirements, flow requirements, and water-purity guidelines.
- Torque specifications for gas or water plumbing and hose connections
  For the best results, use the recommended torque specifications for plumbing and hose fittings.
- Coolant requirements
  Add the correct type and amount of coolant before you operate the plasma cutting system.
  - Coolant requirements for operation between -10°C – 40°C (14°F – 104°F)
    Use the Hypertherm® premixed coolant for the usual operating temperature range for plasma cutting systems. Adjust the coolant mix to operate the system at temperatures that are colder than -10°C (14°F).
  - Coolant requirements for operation in temperatures above 40°C (104°F)
    Use the correct treated water mixture as coolant when you operate the cutting system at temperatures that stay higher than 40°C (104°F).
  - Flow requirements for coolant
    The correct coolant flow rate is necessary for cutting system operation. If the flow rate is too low or too high, the system will stop automatically to prevent damage.
  - Purity requirements for coolant water
    Always use water that meets the specifications in the following table when using a custom coolant mix.
- Requirements to put system components in position
- Torch mounting bracket requirements
  Make sure to use a torch mounting bracket that obeys the requirements for XPR® torches.
- Torch lifter requirements
  Use a torch lifter that has the correct weight capacity for XPR® torches.
- CNC requirements for plasma cutting systems
  There are specific Computer Numerical Control (CNC) features that are necessary for integration with plasma cutting systems.
- Recommended grounding and shielding
  It is important to use grounding and shielding best practices when you set up a plasma cutting system. This can minimize problems related to Electromagnetic Interference (EMI), or electrical noise.
Installation
Connect for Communication
Coolant Installation
Operation
Maintenance
Diagnostics and Troubleshooting
Parts List
Wiring Diagrams

Coolant requirements

Add the correct type and amount of coolant before you operate the plasma cutting system.

The cutting system ships without coolant in the reservoir. Before you operate the cutting system, you must fill it with coolant.

The coolant capacity for the plasma cutting system is between 22.7 liters – 45.4 liters (6 U.S. gallons – 12 U.S. gallons). The coolant reservoir can contain a maximum of 15.1 liters (4 U.S. gallons). But when the plasma cutting system is fully installed, it can contain between 22.7 liters – 45.4 liters (6 U.S. gallons – 12 U.S. gallons).

Lead length has an effect on the total coolant volume needed. A cutting system with long leads needs more coolant than a cutting system with short leads.

Before you fill the coolant reservoir, choose the best coolant for your operating conditions. The ambient temperature range where your cutting system operates affects the coolant that you choose.

Notice

LOW COOLANT LEVELS CAN DAMAGE THE CUTTING SYSTEM AND COOLANT PUMP

There is a risk of serious damage to the cutting system and to the coolant pump if you operate the cutting system with no coolant or with low coolant. If your coolant pump is damaged, pump replacement can be necessary.

Never operate the cutting system if you get a low coolant level notice.

Notice

AUTOMOTIVE ANTIFREEZE CAN CAUSE DAMAGE TO THE TORCH COOLANT SYSTEM

Antifreeze contains chemicals that can cause damage to the torch coolant system.

Never use automotive antifreeze as an alternative to Hypertherm coolant.

Make sure to read and follow the warning and cautions below. Refer to the Safety Data Sheets (SDS) for safety data and information about how to handle and store coolant, propylene glycol, and benzotriazole. You can find the SDS online. Technical documentation is available at www.hypertherm.com/docs.

Warning

COOLANT CAN BE IRRITATING TO SKIN AND EYES AND HARMFUL OR FATAL IF SWALLOWED

Propylene glycol and benzotriazole are irritating to skin and eyes, and harmful or fatal if swallowed.

When you come into contact, flush skin or eyes with water. If swallowed, seek immediate medical attention.