Hypertherm HPRXD Series Leitfaden

Gas Console Manifold Replacement

HPRXD Systems

Field service bulletin

807570 – Revision 0 – July, 2012

Hypertherm, Inc.

Etna Road, P.O. Box 5010

Hanover, NH 03755 USA

603-643-3441 Tel (Main Office)

603-643-5352 Fax (All Departments)

[email protected] (Main Office Email)

800-643-9878 Tel (Technical Service)

[email protected] (Technical Service Email)

800-737-2978 Tel (Customer Service)

customer.service@hypertherm.com (Customer Service Email)

866-643-7711 Tel (Return Materials Authorization)

877-371-2876 Fax (Return Materials Authorization)

[email protected] (RMA email)

Hypertherm Automation

5 Technology Drive, Suite 300

West Lebanon, NH 03784 USA

603-298-7970 Tel

603-298-7977 Fax

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau

Rodenbacher Chaussee 6

D-63457 Hanau-Wolfgang, Deutschland

49 6181 58 2100 Tel

49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

82 Genting Lane

Media Centre

Annexe Block #A01-01

Singapore 349567, Republic of Singapore

65 6841 2489 Tel

65 6841 2490 Fax

65 6841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit A, 5th Floor, Careri Building

432 West Huai Hai Road

Shanghai, 200052

PR China

86-21 5258 3330/1 Tel

86-21 5258 3332 Fax

Hypertherm Europe B.V.

Vaartveld 9

4704 SE

Roosendaal, Nederland

31 165 596907 Tel

31 165 596901 Fax

31 165 596908 Tel (Marketing)

31 165 596900 Tel (Technical Service)

00 800 4973 7843 Tel (Technical Service)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building

2-1-1 Edobori, Nishi-ku

Osaka 550-0002 Japan

81 6 6225 1183 Tel

81 6 6225 1184 Fax

Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia

Guarulhos, SP - Brasil

CEP 07115-030

55 11 2409 2636 Tel

55 11 2408 0462 Fax

Hypertherm México, S.A. de C.V.

Avenida Toluca No. 444, Anexo 1,

Colonia Olivar de los Padres

Delegación Álvaro Obregón

México, D.F. C.P. 01780

52 55 5681 8109 Tel

52 55 5683 2127 Fax

Hypertherm Korea Branch

#3904 Centum Leaders Mark B/D,

1514 Woo-dong, Haeundae-gu, Busan

Korea, 612-889

82 51 747 0358 Tel

82 51 701 0358 Fax

HPRXD and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.

Other trademarks are the property of their respective holders.

Printed in USA

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electrical power before performing any maintenance.

All work requiring removal of the power supply cover must be performed by a

qualified technician.

See the Safety Section of the system’s Manual for more safety precautions.

Field Service Bulletin 807570 Revision 0 1

Gas Console manifold Replacement

Introduction

Purpose

This document describes the steps necessary to replace the gas manifold in an HPRXD manual gas console or the two

manifolds in the HPRXD auto gas console.

Tools required

Torx driver - T20

Phillips head screwdriver - number 2

228946 (Auto gas console) – Kit Contents

Part number Description Quantity

229524 Manifold subassembly: HPRXD auto gas inlet 1

229525 Manifold subassembly: HPRXD auto gas outlet 1

228947 (Manual gas console) – Kit Contents

Part number Description Quantity

229526 Manifold subassembly: HPRXD manual gas inlet 1

2Field Service Bulletin 807570 Revision 0

Gas Console manifold Replacement

Manual gas console (078532)

Remove the old manifold

1. Turn OFF all power to the system.

2. Turn off all supply gases and disconnect the supply gas hoses from the console.

3. Remove the cover from the gas console.

4. Remove the connectors from the nine solenoid valves (SV2, SV3, SV4, SV6, SV8, SV9, SV10, SV11, and SV12).

They can be very difficult to remove, but do not use pliers or other tools that can pinch or damage the wires.

Two of the nine SV connectors

5. Disconnect the four hoses (blue, red, green, and black) on the open (right side) side of the enclosure.

Blue Red Green Black

Note: The hose connections use

push-to-connect fittings.

To disconnect a hose, push

the connector-collar toward

the fitting, and pull the hose

away from the fitting.

To make a connection, push

the hose into the appropriate

connector until it stops, about

12 mm (0.472 in).

Connector-collar

Field Service Bulletin 807570 Revision 0 3

Gas Console manifold Replacement

6. Disconnect the valve power connector J3.3 and the communication cable connector.

7. The two hoses (yellow and green) that attach to the control board from the manifold should be disconnected at the

manifold.

Green hose

Control board

Yellow hose

4Field Service Bulletin 807570 Revision 0

Gas Console manifold Replacement

8. Remove the phillips head screw that secures the manifold to the base of the enclosure.

9. Carefully pull the manifold out the side of the enclosure to access valves SV1, SV5, and SV7. Remove the connectors

by loosening the phillips head screw and pulling off the connector.

Phillips head screws (3)

SV5SV7 SV1

Field Service Bulletin 807570 Revision 0 5

Gas Console manifold Replacement

10. Remove the yellow hose loop from the old manifold and install it onto the new manifold. The old manifold can be

discarded.

Yellow hose

Install the new manifold

NOTES:

• Always make sure the number on the valve matches the number on the connector

• Refer to the pictures shown during the removal process when installing the new manifold

1. Attach the connectors to valves SV1, SV5, and SV7 and tighten the phillips head screw to 0.7 Nm (6 in-lbs).

2. Attach the connectors to valves SV2, SV3, SV4, SV6, SV8, SV9, SV10, SV11, and SV12.

3. Attach the yellow hose and then the green hose to the front of the manifold.

4. Slide the manifold back into place and secure it to the base of the enclosure with the phillips head screw that was

removed previously.

5. Reconnect the communication cable and the valve power connector.

6. Reconnect the hoses (red, green, black, and blue). Make sure the hoses are fully seated into the valve connection.

There is a mark on the hoses that indicates when the hose is fully inserted, but it may not still be visible in the field.

The tubing is fully seated when the mark is no longer visible.

7. Reconnect the supply gas hoses and turn on the supply gases.

8. Run the gas leak tests for the system. See your HPRXD instruction manual for details.

6Field Service Bulletin 807570 Revision 0

Gas Console manifold Replacement

Auto gas console (078533)

Remove the old upper manifold

1. Turn OFF all power to the system.

2. Turn off all supply gases and disconnect the supply gas hoses from the console.

3. Remove the cover from the gas console.

4. Disconnect the gas hoses (7)

Black

Yellow

Red

White

Black

Green

Blue

Field Service Bulletin 807570 Revision 0 7

Gas Console manifold Replacement

5. Disconnect the wire harness from the pressure transducers P1, P2, P3, and P4 by turning the connector ring a 1/4

turn counter-clockwise.

P3P4

6. Remove the connectors (4) from the valves.

8Field Service Bulletin 807570 Revision 0

Gas Console manifold Replacement

7. Remove the 2 phillips head screws that secure the manifold to the rear panel and pull the manifold out of the

enclosure.

Phillips head screws (2)

8. Loosen the phillips head screw that secures the connector to valve SV10 and remove the connector.

Phillips head screw

Install the new upper manifold

NOTE: refer to the pictures shown during the removal process when installing the new manifold

1. Attach the connector to the valve marked SV10 first.

2. Mount the manifold onto the rear wall of the enclosure. The mounting screws should be tightened to

3.3 Nm (29 in-lbs).

NOTE: Make sure the yellow, black, and red wires are not trapped under the manifold when it is installed

3. Reconnect the gas hoses (7).

4. Attach the black 1/4 inch hose (the short one) to the manifold.

5. Install the connectors to the solenoid valves, SV11, SV12, SV13, and SV14.

NOTE: Make sure the yellow, black, and red wires are not trapped under the manifold when it is installed.

6. Attach the connectors to the pressure transducers, P1, P2, P3, and P4.

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