If the code continues, replace B2 or P14, as necessary.
7. If you cannot find or correct the problem, speak to your cutting machine supplier or regional
Hypertherm Technical Service team.
Troubleshooting for low coolant flow
Diagnostic codes 540, 541, 542
The low coolant flow diagnostic codes (540 – 542) can occur because of a low coolant level, blockages
or damage in the coolant hoses, or problems with the coolant pump.
Symptoms
Code Symptoms XPR models XPR action Code cancels with...
540 For a minimum of 40 seconds after the Plasma Start
switch is set to ON, the coolant flow rate is less than
1.9 L/min (0.5 gal/min).
541 For a minimum of 10 seconds after the coolant flow
rate gets to 1.9 L/min (0.5 gal/min), the flow rate
stays less than 3.03 L/min (0.8 gal/min).
542 XPR170 and XPR300: For a minimum of 1 second,
the coolant flow rate is less than 3.79 L/min (1 gal/
min).
XPR460: The low coolant flow rate limit is less than
2.5 L/min (0.66 gal/min) when the coolant temper-
ature is ≤0°C (≤32°F) or less than 4.9 L/min (1.3
gal/min) when the coolant temperature is ≥40°C
(104°F). For flow rates and temperatures that are
between these values, use the same scale to cal-
culate the limits. For example, a flow rate less than
3.8 L/min (1.0 gal/min) with a coolant temperature of
≥20°C (68°F) can also cause a 542 code to occur.
All models Shut down Remote on-off
Corrective action
1. Make sure that the coolant level in the coolant reservoir is sufficient.
You can see the coolant level from the coolant-level view window on the front of the cooler. You also
can see coolant levels on the CNC screen or the XPR web interface.
Diagnostics and Troubleshooting
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811530 Instruction Manual XPR460
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