Remove old coolant from the system

Remove all of the old coolant from the system before you add new coolant.

Remove the power from the cutting system.

  1. Remove the right external panel from the plasma power supply (this is the panel on the right when you look at the front of the unit).
    Note:

    M6 (10 mm hex) screws hold the panel in position.

  2. To remove old coolant from the coolant reservoir:
    1. Connect a tube with a 3/8-inch inner diameter to the outlet of the valve on the bottom of the reservoir.
    2. Put the other end of the tube into an empty container that holds the approximate total coolant volume for your cutting system.
    3. Open the valve that is located on the bottom of the reservoir.
    4. Remove the cap from the reservoir inlet to let the coolant flow out of the reservoir.
  3. To remove the old coolant from the heat exchanger:
    1. Keep one end of the tube with the 3/8-inch inner diameter connected to the valve on the bottom of the reservoir and the other end of the tube in the container.
    2. Remove the coolant return hose from the rear of the plasma power supply.
      coolant hose identification and air gun
      1 Coolant supply (green)
      2 Coolant supply hose (green)
      3 Coolant return (red)
      4 Coolant return hose (red)
    3. Attach compressed air (no more than 6.89 bar/100 psi) to the coolant return hose fitting on the rear of the plasma power supply at the location where the return coolant hose (red band) was connected before.
    4. For no longer than 30 seconds, use the compressed air to blow all of the coolant back into to the reservoir and filter housing.
      Note:

      The coolant is necessary to lubricate surfaces that must turn freely. If air flows through the cutting system for longer than 30 seconds, it can remove the coolant that is necessary for lubrication.

    5. Close the valve at the bottom of the reservoir and remove the tube with the 3/8-inch inner diameter from the outlet.
      Note:

      Do not keep the tube with the 3/8-inch diameter in the of the plasma power supply.

    6. Keep the coolant return hose (red band) disconnected from the rear of the plasma power supply.
    7. Put a container under the pump plug.
    8. Remove the plug and coolant-pump screen and set them to the side.
      Pump plug location
    9. Remove the coolant supply hose (green band) from the rear of the plasma power supply.
    10. Attach compressed air (no more than 3.45 bar/50 psi) to the coolant supply hose fitting on the rear of the plasma power supply where the coolant supply hose (green band) was connected before.
    11. For no more than 30 seconds, use the compressed air to blow all of the coolant into the container.
    12. Keep the coolant supply hose (green band) disconnected.
      Note:

      The coolant is necessary to surfaces that turn freely. If air flows through the cutting system for longer than 30 seconds, it can remove the coolant necessary for lubrication.

  4. Clean and replace the coolant-pump screen if necessary:
    1. Clean the coolant-pump screen.
    2. Rinse the screen with water if you find debris.
    3. Examine the coolant-pump screen.
    4. If you find damage on the coolant-pump screen, replace it (127559).
    5. Install the coolant-pump screen.
    6. Wipe the O-ring on the plug.
    7. Make sure that the O-ring is free of debris, cracks, and dents.
    8. Install the plug on the coolant pump housing.
  5. To remove the old coolant from the filter housing and replace the coolant filter:
    filter location for the coolant
    1. Remove the filter housing from the inner part of the plasma power supply.
    2. Discard all of the coolant from the inner part of the filter housing.
    3. Remove and discard the coolant filter.
    4. Examine the filter housing for debris.
    5. Rinse the filter housing to remove debris, if found.
    6. Install a new coolant filter (027005).
    7. Install the filter housing.
  6. To remove the old coolant from hoses and leads:
    Note:

    Cutting system hoses and leads can hold a large volume of coolant.

    Make sure to remove all of the old coolant from the hoses and leads. If you do not, the new coolant will mix with the old coolant. This will cause faster deterioration of the new coolant.

    1. Put the disconnected end of the coolant return hose into an empty container.
      Note:

      Use a container that holds the approximate total coolant volume for your cutting system.

    2. Attach compressed air (no more than 6.89 bar/100 psi) to the disconnected end of the coolant supply hose (green band).
    3. For approximately 3 minutes, inject compressed air into the coolant supply hose fitting to force coolant to flow out of the coolant return hose (red band) into an empty container.
    4. After 3 minutes, look for coolant that flows out of the coolant return hose (red band).
    5. Do the previous step again until coolant flow from the coolant return hose (red band) stops.
    6. When the coolant flow from the coolant return hose (red band) stops, connect the two hoses to the rear of the plasma power supply.