Hypertherm HPRXD Series Guide

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)
[e-mail] (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
©2012 Hypertherm, Inc. All rights reserved.
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.
P1
P3P4
P2
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.

Field Service Bulletin 807570 Revision 0 9
Gas Console manifold Replacement
Remove the old lower manifold
1. Disconnect the red and black gas hoses from the manifold.
Red hoses
Black hoses
2. Disconnect the short yellow hose from the non-manifold side, leaving it connected to the manifold.
Yellow hose (short)

10 Field Service Bulletin 807570 Revision 0
Gas Console manifold Replacement
3. Remove the phillips head screw that secures the manifold to the bottom of the enclosure and slide the manifold out
far enough to access the screw that secures valve SV3.
Phillips head screw
4. Loosen the phillips head screw that secures the connector to valve SV10 and remove the connector. Discard the old
manifold.
Phillips head screw
Install the new lower manifold
NOTE: refer to the pictures shown during the removal process when installing the new manifold
1. Place the manifold about half way into the enclosure. Route the yellow hose between valve 4 and valve 5, and the red
hose between valve SV2 and SV8.
2. Attach the connectors to valves SV1, SV2, SV8, and SV9
3. Attach the connector to valve SV3.
4. Connect the hoses to the manifold in the following order; the shorter yellow hose, the red hose, and the shorter black
hose.
5. Reconnect the supply gas hoses and turn on the supply gases.
6. Run the gas leak tests for the system. See your HPRXD instruction manual for details.