Do a container test to measure coolant flow

The container test helps to find problems with coolant flow.

  1. Get an empty container that has a minimum capacity of 3.79 liters (1 U.S. gallon) and includes volume measurements, if possible.
  2. Remove the power from the cutting system.
  3. Remove the correct coolant-return hose (red band) from the correct coolant-return fitting.
    • For the XPR170® and XPR300®, the correct coolant-return hose (red band) is connected to the coolant-return fitting (red) on the rear of the plasma power supply.
      Figure 1. XPR170 and XPR300 coolant-return hose
    • For the XPR460®, the correct coolant-return hose (red band) is connected to the coolant-return fitting (large red) on the rear of the cooler.
      Figure 2. XPR460 coolant-return hose
      This image shows the coolant-return hose (red band) and coolant-return fitting (large red) at the rear of the cooler.
  4. Use the container to collect coolant leaks if necessary.
  5. Remove the coolant from the container before you start the test.
  6. Put the end of the coolant-return hose in the container.
  7. Supply power to the cutting system.
  8. Send a process to the cutting system.
  9. When you hear the coolant pump start, let the coolant flow in the container for 30 seconds.
  10. After 30 seconds, look at the quantity of coolant in the container.

    Make sure that the container has a minimum of 1.89 liters (0.5 U.S. gallon) of coolant.

  11. If the flow rate is outside of the correct range, an internal obstruction or leak can be the cause.

    Problems with the torch or consumable parts can be a source of flow restrictions. Make sure the consumable parts are in good condition and that you are using the correct consumable parts for the process.

  12. If you find obstructions, remove them.
  13. If you find parts that have damage, replace them.
  14. If coolant flow stays slow, and it has been more than six months since the last coolant replacement, replace the coolant.

    Refer to Coolant replacement and its significance.

    Hypertherm recommends coolant replacement every six months. Replace the coolant if you find copper pieces or if the coolant is clear and not the original pink color.

  15. If coolant flow stays slow after replacement, make sure that the bypass-operation is correct and that these components are in good condition:
    • Consumable parts and torch
    • Console-to-console leads
    • Coolant check valve
    • Coolant bypass valve
    • Valve seals
    • Coolant solenoid
    • Coolant-pump motor
  16. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team.