2. If the coolant reservoir is not full, fill it with coolant.
3. If the coolant reservoir level is sufficient, but the code continues:
a. Make sure that the coolant pump is ON and the gauge is spinning.
b. Make sure that the bypass is working.
c. Examine the coolant hoses for restrictions or blockages.
d. Make sure that the consumables are correct for the operator-selected process.
e. Examine the coolant filter, and replace the filter if necessary.
Refer to Table 30 on page 248.
f. Clean the coolant pump screen, or replace the screen if you find damage.
4. If coolant filter or coolant pump screen replacement is not necessary, do a coolant flow test to identify
the source of a coolant leak or obstruction.
5. Send a process command to start the coolant pump.
The coolant pump starts automatically when it receives a process command.
6. If the coolant flow test value is equal to or greater than the permitted limit, but the XPR web interface
shows a lower value, examine the cooler control PCB (PCB 2 in the cooler) for +24 VDC on J4 pin 3
and pin 5.
If you get this condition... Do these steps...
There is no voltage on J4 pin 3 and pin
5.
1. Examine the wire harness that connects to J4.
2. Look for a short.
3. If no short is found, replace the cooler control PCB.
The voltage on J4 pin 3 and pin 5 is
+24 VDC.
1. Examine the flow sensor output (in frequency) at the cooler control PCB.
2. Measure the frequency on J4 pin 4 (pulse) and pin 5 (ground).
3. If the value is different by more than 0.8 L/min (0.2 gal/min), or if there are no
pulses (0 Hz), replace the flow sensor.
Minimum flow rate limits
Liters per minute (L/min) U.S. gallons per minute (gal/min)
Frequency (Hz)
1.89 L/min 0.5 gal/min 15 Hz
3.78 L/min 1.0 gal/min 33 Hz
5.67 L/min 1.5 gal/min 51 Hz
7. If you cannot find or correct the problem, speak to your cutting machine supplier or regional
Hypertherm Technical Service team.
Diagnostics and Troubleshooting
8
327811530Instruction ManualXPR460
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