Prolonging system life and performance

By Hypertherm
Posted on 06/10/2014 in SPARK the blog, Plasma cutting

You likely know the saying: "An ounce of prevention is worth a pound of cure." That saying proves true for a lot of things in life including your cutting system. Fortunately, a small investment of your time is often all it takes to keep your system in good shape. The key though is to do it regularly! Your routine should contain two components: (1) routine cleaning and inspection, and (2) replacement of common wear items. Your owner's manual will walk you through the recommended steps for your particular system, but here's an example of the preventive maintenance program for our HyPerformance HPR or HPRXD systems.


  1. Verify inlet pressure of gases
  2. Inspect all air filters
  3. Check coolant levels and condition
  4. Inspect torch for leaks (o-rings and water tubes)


  1. Inspect hoses and leads for cracks
  2. Inspect gas fittings for leaks
  3. Verify coolant flow


  1. Clean inside of power supply
  2. Check with main contactor
  3. Conduct a more thorough coolant flow test
  4. Inspect pilot arc relay
  5. Inspect gas line connections
  6. Inspect ground and table-to-work piece connections

In addition to the daily, weekly, and monthly tasks outlined above, you also need to focus on common wear items. Because plasma systems are precision machines with moving parts like torches, main contactors, relays, and such, these parts are going to wear out. The frequency of part replacement will vary depending on system usage, but typically you’ll want to replace items after a set number of months or arc hours. Recommendations (again for our HyPerformance HPR or HPRXD systems)  are as follows:

Every 6 months (or 500 arc hours)

  1. Torch o-rings and bullet plugs
  2.  Air filter
  3. Coolant filter

Every 12 months (or 1,000 arc hours)

  1. Torch main body
  2. Pilot arc relay
  3. Main contactor

Every 2 years (or 2,000 arc hours)

  1. Torch receptacle
  2. Coolant pump
  3. Torch leads

Every 3 years (or 3,000 arc hours)

  1. Check valves
  2. Cooling fans
  3. Coolant pump motor
  4. Gas and pilot arc leads

You can learn more about our Preventive Maintanance programs for HyPerformance HPR and HPRXD systems at