Troubleshooting for water miscible coolants
When using water-miscible coolants, there are a number of things to consider. Even with apparently ideal application methods, problems can occur from time to time. To help you make the best possible use of your water-miscible coolants, we have prepared a chart with possible problems, causes and actions to be taken which can be used as a guide if difficulties arise.
| Problem | Possible Reasons | Possible Action |
| Foam Formation | 1) Low coolant level in the tank 2) Pump draws air 3) Too high concentration 4) Water too soft 5) Contamination with cleaner | 1) Top up coolant 2) Seal pump 3) Refill with a lower coolant concentration 4) Harden up with calcium acetate 5) Add defoamer |
| Instability of the Emulsion | 1) Mixing incorrectly 2) Contamination with fungi/bacteria 3) Temperature too high/low 4) Water too hard | 1) First water, then concentrate (Oil In Last) 2) Use biocide 3) Working temperature +18°C to +35°C (65°F to 95°F) 4) Use deionized water |
| Smoke Formation | 1) Too high concentration 2) Instability of the emulsion 3) Too high foreign oil content | 1) Refill with a lower coolant concentration 2) First water, then concentrate (Oil In Last) 3) Vacuum the foreign oil from the top of the tank |
| Fungal or Bacterial Contamination | 1) Contaminated water 2) Environment polluted 3) pH value too low 4) Too low concentration 5) Foreign oil content too high 6) Cross-contamination | 1) Use tap water or water treatment 2) Clean gratings 3) Increase sump concentration / use biocide 4) Top up with highly concentrated emulsion 5) Vacuum the foreign oil from the top of the tank 6) Disinfect bypass devices |
| Corrosion | 1) pH value too low 2) Too low concentration 3) Water too hard | 1) Increase concentration/ use biocide 2) Top up with highly concentrated emulsion 3) Use deionized water |
| Reduced Sump Life | 1) Pressure, volume 2) Too low concentration 3) Foreign oil content too high 4) Nozzles – Feeding 5) Abrasive wear | 1) Open valves, remove blockage 2) Top up with highly concentrated emulsion 3) Vacuum the foreign oil from the top of the tank 4) Check alignment 5) Check filter |
| Deposits | 1) Water too hard 2) Foreign oil content too high 3) Too high concentration 4) Biological contamination | 1) Use deionized water 2) Vacuum the foreign oil from the top of the tank 3) Fill with less concentrated fluid 4) Use biocide |
| Respiratory Problems / Skin Irritation | 1) pH value too high 2) Too high concentration 3) High metal abrasion 4) Dirty cleaning cloth 5) Biological contamination 6) Allergy | 1) Cleaner contaminated 2) Top up with less concentrated fluid 3) Check filters 4) Use disposable cloth 5) Use biocide 6) Allergy testing by family doctor |
Instability of the concentrate in drum | 1) Expiration date exceeded 2) Rain contamination 3) Temperature 4) Reaction with container | 1) Check storage duration in SDS 2) Correct storage (horizontal) 3) Storage temperature +5°C to +40°C (41°F to 104°F) 4) Use container without zinc or paint |