Hypertherm has a wide variety of handheld systems to meet your applications. Choose the thickness capacity that you require.

Transcription

1 Hypertherm has a wide variety of handheld systems to meet your applications. Choose the thickness capacity that you require. MANUAL SYSTEM SECTIONS: Company Technology Products Contact us Service Careers Website guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com

2 Hypertherm - POWERMAX190c Manual System Portable air plasma cutting system with built-in compressor 1/8" (3 mm) Recommended Capacity 3/16" (4.5 mm) Maximum Capacity 1/4" (6 mm) Severance Capacity Get Powermax 190c Brochure PDF MANUAL SYSTEM SECTIONS: The benefits of Hypertherm technology Integrated compressor - no air supply needed Convenience of 120 V (or 230 V international) input 1.32 kw cutting power exceeds most competitors Portable, professional package Built-in storage compartment for consumables click here for larger view Powermax190c makes these industries more productive: HVAC fabrication and installation Building contractors - metal studs Trade contractors - mechanical Auto or truck service and repair Factory and farm maintenance Art and decorative metal Other sheet metal applications Superior performance and versatility The Powermax190c plasma cutting system takes professional metal-cutting power where it has never been before. Just plug it into most household power± and you're in business. And don't worry about providing separate air, because a built-in compressor gives you all you'll need. You'll be able to cut most sheet metals almost anywhere. (1 of 7) [12/8/2004 2:56:31 PM]

3 Hypertherm - POWERMAX190c Manual System Recommended capacity: mild steel* to 1/8 inch (3 mm) at cutting speeds over 20 inches (500 mm) per minute. Maximum capacity: mild steel* to 3/16 inch (4.5 mm) at cutting speeds over 10 inches (250mm) per minute. Severance capacity: mild steel* to 1/4 inch (6 mm) at slow speed. * Non-ferrous metals typically require a 10-20% capacity reduction. ± A 20-amp circuit for 120-volt operation is recommended (10-amp for 230 V). Advanced power supply Superior power supply design delivers proven Hypertherm performance in a compact, truly portable package kw delivers superior cutting power from a 120 V (or 230 V, 1PH internationally) outlet for the sheet metal professional. Built-in air compressor provides required gas. Boosted open-circuit voltage rating can accommodate low-line conditions of -20% typical on work sites or when utilizing extension cords. Advanced electronic architecture provides constant current control for consistent quality on varying power levels. A chopper power supply provides superior energy efficiency over competitive droopers. Hypertherm's patented pilot-arc control circuit facilitates uninterrupted cutting on expanded metal or grating while minimizing torch consumable wear. Over- and under-voltage sensing circuits protect the machine from damage and permit motor-generator operation (on 2.5 kva auxiliary circuits). (2 of 7) [12/8/2004 2:56:31 PM]

4 Hypertherm - POWERMAX190c Manual System Intelligent torch design Hypertherm's new patented PAC105 torch design delivers maximum performance in a rugged, ergonomic handle. Intelligent torch features promote cut accuracy and speed, while enhancing productivity and life. Higher speed and capacity. Total cutting power is a product of output current (amps) and output voltage. The PAC105 torch is designed to generate a boosted output voltage - rated at 110 volts - producing up to 45% more total cutting power than typical competitors with the same output current. Longer consumable life. HyLife electrodes last longer than ordinary designs (300% longer, in some tests) by using the same hafnium-sizing technologies developed for Hypertherm's advanced mechanized systems. Easier operation. An optional patented nozzle shield (shown right) provides additional nozzle protection and allows superior, no-stick drag cutting and template following. No interference. A patented "blow-back" torch design provides a strong pilot arc for penetrating rust, paint and other coatings without the high-frequency interference that can damage sensitive electronics (PCs, phone systems, machine controllers, automobile microchips). Rugged operation. No breakable ceramics threaten the life of the torch. The durable, high-impact clamshell handle provides years of reliable service. Cooler operation. A standard post-flow feature provides torch cooling after the cut for longer torch life and easier consumable handling. An interrupt feature automatically stops the post-flow on re-trigger for rapid re-fire. Safe starting. Hypertherm's patented safety trigger protects against accidental starts. Ready access to consumables. A built-in parts compartment keeps consumables close at hand. (3 of 7) [12/8/2004 2:56:31 PM]

5 Hypertherm - POWERMAX190c Manual System Superior field reliability for the professional contractor or sheet metal worker The Powermax190c is designed to travel and work hard at the toughest job sites. Over 30 years of research and development dedicated exclusively to plasma cutting results in reliability that is unsurpassed. Mechanical and electrical design are validated through aggressive, accelerated life, stress, transportation and field testing. Voltage sensing circuits protect against miswiring in the field. Designed to resist damage from rain (to IP23 standard) Backed by Hypertherm's full three-year power supply and one-year torch warranty CSA/NRTL and CE safety certifications document safety compliance. Beware of systems without these important certifications. Additional options for specialized requirements Circle Cutting Guide for cutting measured circles. Leather Cable Covers for torch leads provide additional protection against damage. (4 of 7) [12/8/2004 2:56:31 PM]

6 Hypertherm - POWERMAX190c Manual System The powermax190c standard system components Power Supply with Integrated Air Compressor PAC105 Torch with Lead 20' (6.1 m) Spare Consumables Work Cable with Clamp 20' (6.15 m) Primary Power Cable 10' (3 m) Options Circle Cutting Guide Leather Torch Cable Covers Ordering information System Description 120 V 1 PH, 60 Hz, 20' (6.1 m) Torch Leads, CSA 230 V, 1 PH 50/60 Hz, 20' (6.1 m) Torch Leads, CE System Number Torch Consumable Parts (Standard) Item Number Swirl Ring Electrode Nozzle Retaining Cap Torch Consumable Parts (Shielded) Item Number Retaining Cap, Shielded Shield (5 of 7) [12/8/2004 2:56:31 PM]

7 Hypertherm - POWERMAX190c Manual System A: On/Off Switch B: Power On Indicator C: Fault Indicator Torch Cap Sensor Over-Temperature Condition Input Voltage Out of Range Specifications Input Voltages Input 1.32 kw Output Voltage Output Current Duty Cycle Maximum OCV Dimensions Weight with Torch Gas Supply IP V, 1 PH, 60 Hz, CSA 230 V, 1 PH, 50/60 Hz, CE 120 V: 20 Amps 230 V: 10 Amps 110 VDC 12 Amps 12 Amps, 40 C (104 F) on 20/10 A circuit 335 VDC 15.8" (400 mm) D; 8.5" (216 mm) W; 12" (305 mm) H 120 V: 50 lbs (25 kg) 230 V: 58 lbs (29 kg) On-board air compressor Operating data Mild Steel± Hand Torch Recommended Capacity 1/8" (3 mm) Maximum Capacity 3/16" (4.5 mm) Severance Capacity 1/4" (6 mm) ± non-ferrous metals typically require a 10% - 20% de-rating Hypertherm, Powermax, PAC, HyLife are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries. (6 of 7) [12/8/2004 2:56:31 PM]

8 Hypertherm - POWERMAX190c Manual System Company Technology Products Find us Service Careers Website guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com (7 of 7) [12/8/2004 2:56:31 PM]

9 Hypertherm - POWERMAX380 Manual System High-performance portable plasma cutting system 1/4" (6 mm) Recommended Capacity 3/8" (10 mm) Maximum Capacity 1/2" (12 mm) Severance Capacity Get Powermax380 Brochure PDF MANUAL SYSTEM SECTIONS: The leader in 115/230-volt air plasma cutting performance The Powermax380 delivers outstanding plasma cutting performance and value to the sheetmetal contractor, fabricator and service professional. This portable system applies leading Hypertherm technology for the optimal use of the compressed air and 115/230-volt power most commonly available on the job site or in the shop. Superior portability and flexibility maximize on-demand productivity. Powermax380 makes these industries more productive: HVAC fabrication/installation Steel construction Plumbing and sprinkler installation Automotive repair Commercial kitchen installation Farm maintenance Metal artwork And much more Superior versatility and performance (1 of 6) [12/8/2004 2:57:58 PM]

10 Hypertherm - POWERMAX380 Manual System The Powermax380 delivers superior cut speed and quality on mild steel, galvanized, stainless and aluminum. With its easy-switching, dual-voltage (115/230 V) versatility, the Powermax380 combines the convenience of 115-volt operation wherever you go, with the added capacity supported by 230-volt input. At any setting, enjoy cut speeds two to ten times faster than with conventional mechanical (nibblers, snips and cutting wheels) or oxyfuel cutting processes, with excellent precision and edge quality. Recommended Capacity: metals* to 1/4 inch (6 mm) at cutting speeds over 20 inches (500 mm) per minute. Maximum Capacity: metals* to 3/8 inch (10 mm) at cutting speeds over 10 inches (250 mm) per minute. Severance Capacity: rough cut on metals* up to 1/2 inch (12 mm) at low speed. * The cut capacities noted above are on mild steel. Some metals, such as aluminum and stainless steel, may require up to a 20% reduction in cut speed and capacity. Leading power supply technology Superior power supply design delivers Hypertherm's leading performance and versatility in a portable package. 27-amp, 2.43-kW output for enhanced speed and capacity. 115/230-volt dual-voltage system adapts quickly and easily to the power available. A boost circuit compensates for low-line conditions typical on work sites with long extension cords and shared circuits, while maintaining uncompromised performance. Advanced, digitally controlled design allows constant current control with infinite adjustment for the most consistent cut quality. Hypertherm's patented pilot-arc control circuit facilitates uninterrupted cutting on expanded metal or grating, while minimizing torch consumable wear. (2 of 6) [12/8/2004 2:57:58 PM]

11 Hypertherm - POWERMAX380 Manual System The smartest torch design Hypertherm's patented PAC110T torch design delivers maximum performance and durability. The torch's intelligent features promote cut accuracy and speed, while enhancing productivity and life. Patented "blow-back" design generates a strong pilot arc for piercing metals through rust, paint and other coatings, without the electrical high frequency that can damage or interfere with sensitive electronics (PC's, phone systems, machine controllers, automobile microchips). No breakable ceramic torch parts; no special care required. Hypertherm's patented safety trigger protects against accidental starts. Durable clamshell handle design survives inevitable drops and field abuse. Post-flow cooling feature provides torch cooling after the cut for longer torch life and easier consumable handling. An interrupt feature automatically stops the post-flow for rapid re-firing. Safety interlocks deactivate the torch when consumables are removed. A built-in parts compartment keeps consumables close at hand. Engineered for superior field reliability The Powermax380 is designed to travel and work hard at the toughest job sites. With over 30 years dedicated exclusively to research and development of plasma cutting technology, Hypertherm's reliability is unsurpassed. Electro-mechanical design is validated through aggressive, accelerated life, stress, transportation and field-testing. Voltage sensing circuits protect against improper supply voltage. Designed to resist water damage (to IP23C standard). Backed by Hypertherm's full three-year power supply and one-year torch warranty. CSA/NRTL and CE safety certifications document safety compliance. Beware of systems without these important certifications. A built-in parts compartment for on-site convenience Switching between 115 and 230-volt operation is quick and easy, for superior job-site versatility. (3 of 6) [12/8/2004 2:57:58 PM]

12 Hypertherm - POWERMAX380 Manual System Additional options for specialized requirements Circle Cutting Guide for cutting measured circles Leather Cable Covers for torch leads, providing additional protection against damage Powermax380 system components Standard Power Supply PAC110T Torch 20' (6.1 m) Spare Consumables and Air Fitting Work Cable and Clamp 20' (6.1 m) Options Circle Cutting Guide Leather Torch Lead Covers Ordering information System Part Numbers with 20' (6 m) torch 115/230 V,1 PH, 60 Hz, CSA /230 V,1 PH, 50 Hz, CE (4 of 6) [12/8/2004 2:57:58 PM]

13 Hypertherm - POWERMAX380 Manual System Operating data Recommended Capacity Maximum Capacity Severance Capacity 1/4" (6 mm) 3/8" (10 mm) 1/2" (12 mm) Material Thickness Current Approximate Travel Speed* (inches) (mm) (amps) (ipm) (mm/min) Mild Steel 18 GA 10 GA 3/16 1/4 3/ Aluminum 18 GA 10 GA 3/16 1/4 3/ Stainless Steel 18 GA 10 GA 3/16 1/4 3/ *Travel speeds are approximately 80% of maximum. A: Power On Indicator B: Insufficient Air Pressure Warning C: Torch Cap Sensor Warning D: On/Off Switch E: Over-Temperature Warning F: Cutting Current Output Control A G: Air Pressure Gauge H: Air Pressure Adjust Control Knob I: Gas Test/Set Position (5 of 6) [12/8/2004 2:57:58 PM]

14 Hypertherm - POWERMAX380 Manual System Specifications Input Voltages Input 2.43 kw Output Voltage Output Current Duty Cycle Maximum OCV Dimensions Weight with Torch Gas Supply Flow Rate Flow Pressure 115/230 V, 1 PH, 60 Hz, CSA 115/230 V, 1 PH, 50 Hz, CE Certified 115/230 V, 1 PH: 28/14 Amp (where indicated) 92 VDC Adjustable, Amps 27 Amps, 40 C (104 F) 288 VDC 16" (406 mm) D; 8.5" (216 mm) W; 12" (305 mm) H 55 lbs (25 kg) Clean, dry, oil-free air 270 scfh; 4.5 cfm (129 l/min) 60 psi (4.1 bar) Company Technology Products Find us Service Careers Website Guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com (6 of 6) [12/8/2004 2:57:58 PM]

15 Hypertherm - POWERMAX600 Manual System High-performance portable plasma cutting system 1/2" (12 mm) Recommended Capacity 5/8" (16 mm) Maximum Capacity 7/8" (22 mm) Severance Capacity Get Powermax600 Brochure PDF MANUAL SYSTEM SECTIONS: The benefits of Hypertherm technology Superior speed and capacity Longer parts life Lower operating cost Higher-quality cuts Safety Reliability Ease of use -in a robust, portable cutting system. Powermax600 makes these industries more productive Manufacturing and fabrication Equipment maintenance and repair Construction and demolition Auto or truck modification and repair General welding service and repair Metal scrapping and salvage And many more Superior performance by hand or machine The Powermax600 raises performance and reliability standards for air plasma cutting systems. All you need is input power and low-cost compressed air to cut through mild steel, stainless steel, aluminum and most other metals with new power and productivity. (1 of 8) [12/8/2004 2:58:13 PM]

16 Hypertherm - POWERMAX600 Manual System Recommended Capacity: steel up to 1/2 inch (12 mm) at cutting speeds over 24 inches (600 mm) per minute. Maximum Capacity: steel up to 5/8 inch (16 mm) thick at cutting speeds over 10 inches (250 mm) per minute. Severance Capacity: rough cuts on steel up to 7/8 inch (22 mm) thick. Non-ferrous metals generally require a 10%-20% speed and thickness reduction. Machine Torch Operation Up to 1/8 inch (3 mm) thick at 100% duty cycle. Up to 1/4 inch (6 mm) at 50% duty cycle. The Power Supply: The Heart of the Machine Advanced technology in the power supply enables the Powermax600 to cut with greater quality and efficiency. 40-amp, 5.6 kilowatt output cuts through steel up to 5/8 inch (16 mm) thick. Advanced digitally-controlled inverter design improves cut quality by delivering constant output regardless of variations in line voltages or torch-to-work distances. High duty cycle permits industrial cutting. Output current adjustable to 40 amps enables high-quality cutting over a wide range of thicknesses. An active electronic pilot-arc controller helps maintain uninterrupted operation when cutting expanded metal or grating. An architecture that tolerates power fluctuation and surges permits unrestricted operation on motor generators providing 8 kva auxiliary power (see instructions). The Torch: Intelligent Design for Easier Cutting and Lower Operating Cost (2 of 8) [12/8/2004 2:58:13 PM]

17 Hypertherm - POWERMAX600 Manual System Longer Consumable Life. HyLife electrodes last longer than ordinary designs (113% longer, in some tests) by using the same patented hafnium-sizing technologies developed for advanced Hypertherm mechanized systems. Dual-threshold pilot circuit significantly reduces nozzle wear by boosting pilot current precisely when needed for a strong arc transfer - and not before. click here for larger view Patented nozzle shield technology protects the nozzle from molten metal spray and the double-arcing that destroys consumables. Post-flow cooling reduces torch stress. Higher Speed. A patent-pending coaxial-assist jet design boosts cutting speed as much as 20% over conventional designs by stabilizing and shaping the cutting arc. Easier Operation. Torch shielding lets you drag the torch on the workpiece at full output without damaging consumables. Competitive stand-off devices can't match it for convenience and control. No Interference. Patented "blow-back" torch design provides a pilot arc without the excessive high-frequency interference that can damage sensitive electronics. Safe Starting. Hypertherm's patented PAC123T safety trigger torch protects against accidental starts. Rugged Operation. No breakable ceramics threaten the life of the torch. The durable, high-impact clamshell handle provides years of reliable service. Ready Access to Consumables. Built-in parts compartment keeps consumables close at hand. Easy Torch Change. A quick-disconnect feature helps keep service downtime to a minimum. (Not available on CE models.) Versatile Applications. Hypertherm offers consumables for gouging, extended nozzle cutting, pipe saddle cutting, and other applications. (3 of 8) [12/8/2004 2:58:13 PM]

18 Hypertherm - POWERMAX600 Manual System Engineered for Superior Reliability The Powermax600 anticipates heavy use under the harshest conditions. Mechanical and electrical design are validated through aggressive, accelerated life, stress, transportation, and field testing. Voltage input protection guards against damage from mis-wiring in the field. Wide voltage operating range of ±15% minimizes performance deterioration, shut-down, or potential damage due to fluctuating power line conditions. IP23 compliance means resistance to rain damage. The internally mounted air regulator is protected from impact damage. The Powermax600 is backed by Hypertherm's full three-year power supply warranty and one-year torch warranty. Unlike some competitive warranties, the Hypertherm warranty backs the entire system and torch. CE certifications comply with the highest safety standards. Options for Specialized Requirements Machine Torch for high-quality cutting on mechanized tables or other fixtures. Wheel Kit for maximum mobility without an unwieldy cart. Extra-Long Torch Leads and Work Cables (50'/15 m) for additional reach. Circle Cutting Guide for cutting measured circles. Leather Cable Covers for torch leads to provide additional protection against damage. (4 of 8) [12/8/2004 2:58:13 PM]

19 Hypertherm - POWERMAX600 Manual System Powermax600 Standard System Components Power Supply PAC123T Torch Quick-disconnect Torch (not on CE models) Spare Consumables Work Cable with Clamp 15 feet (4.5 m) Primary Power Cable Options FineCut Consumables for superior cut quality on thin plate, mild and stainless steel Machine Torch and Remote Start Switch Wheel Kit Extended Work Cable 50 feet (15 m) Circle Cutting Guide Leather Torch Cable Covers (5 of 8) [12/8/2004 2:58:13 PM]

20 Hypertherm - POWERMAX600 Manual System Ordering Information System Part Numbers. 15' (4.5 m) torch 25' (7.5 m) torch 50' (15 m) torch 208/240 V, 1 PH, 50/60 Hz, CSA. Hand System Machine System V, 3 PH, 50/60 Hz, CSA. Hand System Machine System V, 3 PH, 50/60 Hz, CE. Hand System Machine System V, 3 PH, 50/60 Hz, CE. Hand System Machine System Specifications Input Voltages.. Input 5.6 kw Output Voltage Output Current Duty Cycle Maximum OCV Dimensions Weight with Torch Gas Supply Flow Rate Flow Pressure 208/240 V, 1 PH, 50/60 Hz, CSA 480 V, 3 PH, 50/60 Hz, CSA 400 V, 3 PH, 50/60 Hz, CE Certified 230 V, 3 PH, 50/60 Hz, CE Certified 208/240 V, 1 PH: 46/40 Amps 230/400/480 V, 3 PH: 17/9.7/12 Amps 140 VDC Adjustable, Amps 5.6 kw, 40 C (104 F) 300 VDC 20" (510 mm) D; 9.5" (240 mm) W; 17" (430 mm) H 47 lbs (21 kg) Clean, dry, oil-free air or nitrogen 360 scfh; 6 cfm (170 l/min) 72 psi (5.0 bar) (6 of 8) [12/8/2004 2:58:13 PM]

21 Hypertherm - POWERMAX600 Manual System A: Power On Indicator B: Pressure Gauge C: Low Air Pressure Warning D: Over-Temperature Warning E: Ready Indicator - Operating Conditions Met F: Cutting Current Output Control 20 to 40 amps G: Low Line Voltage Warning H: Gas Test/Set Position I: Torch Cap Sensor Warning J: Pilot Arc Controller Switch (not on CE models) Operating Data Mild Steel± Hand Torch Machine Torch Recommended Capacity 1/2" (10 mm) 1/8" (3 100% duty cycle Maximum Capacity 5/8" (16 mm) 1/4" (6 50% duty cycle Severance Capacity 7/8" (22 mm) - ± Non-ferrous metals typically require a 10% - 20% rating reduction. Material Thickness Current Approximate Travel Speed* (inches) (mm) (amps) (ipm) (mm/min) Mild Steel 26 GA. 16 GA. 1/8 1/4 3/8 5/ ,635 12,700 5,970 1, Aluminum GA. 1/8 1/4 3/8 5/ ,080 13,590 5,335 1, (7 of 8) [12/8/2004 2:58:13 PM]

22 Hypertherm - POWERMAX600 Manual System Stainless Steel 26 GA. 16 GA. 1/8 1/4 3/8 5/ ,370 12,700 5,080 1, * Maximum travel speeds are the results of Hypertherm's laboratory testing. For optimum cut performance, actual cutting speeds may vary based on different cutting applications. Refer to the operator's manual for more detail. Hypertherm, Powermax, PAC, HyLife, Dual-threshold and Coaxial-assist are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries. Company Technology Products Find us Service Careers Website guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com (8 of 8) [12/8/2004 2:58:13 PM]

23 Hypertherm - POWERMAX1000 G3 Series Manual System Get Powermax1000 Brochure PDF MANUAL SYSTEM SECTIONS: The performance standard for air plasma cutting 3/4" (19 mm) Recommended capacity 1" (25 mm) Maximum capacity 1 1/4" (32 mm) Severance capacity The third generation of plasma cutting has a second great product The benefits of Hypertherm technology Superior speed and cutting capacity Longer parts life Lower operating cost Higher-quality cuts Safety Realiability Ease of use in a robust, portable cutting system. Hypertherm the world leader in plasma cutting technology When you only do one thing, you'd better do it better than anyone else. As the only major manufacturer to focus exclusively on plasma cutting technology, Hypertherm is committed to providing the highest quality systems in the world: improving the performance, reliability and value of our systems, and serving and supporting Hypertherm users. This commitment to technology leadership, quality and support makes Hypertherm the first choice of the true cutting professional. Superior performance by hand or machine The Powermax1000 is the latest addition to the Powermax G3 Series. With advanced technologies in both power supply and torch, Hypertherm G3 products cut faster and more economically than any system available today. The Powermax1000's Auto-voltage circuit provides automatic adjustment to any input voltage from 200 to 600 volts, 1- or 3-phase (CE 230 to 400 V 3-phase only). A state-of-the-art, (1 of 8) [12/8/2004 2:58:28 PM]

24 Hypertherm - POWERMAX1000 G3 Series Manual System microprocessor-based architecture assures optimum system reliability. Add to this Hypertherm's advanced torch technology and easy-to-read controls, and you have the most advanced plasma cutter money can buy. Recommended capacity: metals to 3/4 inch (19 mm) at cutting speeds over 20 inches (500 mm) per minute. Maximum capacity: metals to 1 inch (25 mm) at cutting speeds over 10 inches (250 mm) per minute. Severance capacity: rough cut on metals up to 1 1/4 inches (32 mm) at low speed. The cut capacities above are on mild steel. Some metals, such as aluminum and stainless steel, may require up to 20% reduction in cut speed and capacity. Machine torch operation Up to 1/2 inch (12 mm) at 50% duty cycle. Up to 3/8 inch (10 mm) at 100% duty cycle. The power supply: the heart of the machine Advanced, intelligent technology gives the Powermax1000 the power to cut with greater speed, quality and efficiency. 60-amp, 8.4-kilowatt output provides ample power for clean, quick cutting. Auto-voltage runs on voltages from 200 to 600 volts, 1- or 3-phase, (CE 230 to 400 V 3-phase only) without the need for manual rewiring. New Boost Conditioner circuit compensates for input voltage variation. Advanced, digitally-controlled inverter design delivers continuously adjustable, constant current output, from 20 to 60 amps, permitting high-quality cuts over a wide range of metal thicknesses. An active electronic pilot arc controller for cutting expanded metal or grating. (2 of 8) [12/8/2004 2:58:28 PM]

25 Hypertherm - POWERMAX1000 G3 Series Manual System New gouging setting allows for improved arc transfer, easier operation and faster metal removal. CNC/robotic machine interface is standard on all units, allowing automated control and rapid change over to mechanized operation. The torch: intelligent design combines performance, durability, comfort and safety The Powermax1000 features Hypertherm's T60 safety trigger torch and T60M mechanized torch. A revolutionary design delivers outstanding cut performance, reliability and operator comfort. The longest consumable life in the industry, and we'll prove it. Patented HyLife electrodes last longer than ordinary designs. Patented Dual-threshold pilot circuit significantly reduces nozzle wear by boosting pilot current precisely when needed. Patented nozzle shield lets you drag the torch on the workpiece at full output, without damaging consumables, and protects the nozzle from molten metal spray and double arcing. Postflow cooling to reduce torch stress. Hypertherm's patented Coaxial-assist jet design boosts cutting speed as much as 20% over conventional designs. Hypertherm's revolutionary new ETR (Easy Torch Removal) system allows for easy switching between manual and mechanized torches. It also features a radically new integrated approach to strain relief and durability. Hypertherm's patented safety trigger protects against accidental starts. Interlocks deactivate the torch when the consumable parts are removed, using a durable mechanical contact. No breakable ceramic parts. Patented "blow-back" technology provides a pilot arc without excessive high-frequency interference. Consumables for gouging, extended-nozzle cutting, pipe saddle cutting and other applications. click here for larger view (3 of 8) [12/8/2004 2:58:28 PM]

26 Hypertherm - POWERMAX1000 G3 Series Manual System Engineered for superior reliability The Powermax1000 is designed for heavy use under the harshest conditions. Mechanical and electrical designs are validated through aggressive, accelerated testing. New fan-on-demand feature minimizes dust ingestion. Chemically cross-linked torch cable jacket provides improved resistance to molten spray and cut-through. CSA/NRTL and CE certifications comply with the highest safety standards. IP23CS compliance for resistance to water damage. The Powermax1000 is backed by a full, three-year power supply warranty and a one-year torch warranty. No parts excluded. Examine competitive policies closely. Options for specialized requirements FineCut Consumables for superior cut quality on thin plate, mild and stainless steel Circle cutting guide Leather cable covers for torch leads. Air filtration kit with a.85 micron filter and auto-drain filter bowl. Wheel kit for easy mobility. Heat shield protects hands from excessive reflective heat. (4 of 8) [12/8/2004 2:58:28 PM]

27 Hypertherm - POWERMAX1000 G3 Series Manual System Operating cost calculations are based on consumable price, tested consumable life, tested cutting speed, estimated labor and power costs. Competitive units are in the amp cutting range. Powermax1000 G3 series standard system components Power supply T60 or T60M torch Spare consumables Work cable with clamp 15 feet (4.5 m) Primary power cable Options Circle cutting guide Wheel kit Leather cable covers Air filtration kit Extended work cable Hand heat shield Ordering Information With 25' (7.5 m) torch Systems part numbers With 50' (15 m) torch With 75' (23 m) torch V, 1/3-PH, CSA Hand system Machine system V, 3-PH, CE Hand system Machine system (5 of 8) [12/8/2004 2:58:28 PM]

28 Hypertherm - POWERMAX1000 G3 Series Manual System Operating data Recommended capacity Maximum capacity Severance capacity. Hand torch Machine torch 3/4" (19 mm) 3/8" (10 100% duty cycle 1" (25 mm) 1/2" (12 50% duty cycle 1 1/4" (32 mm) - Maximum Material Thickness Current travel speed* (inches) (mm) (amps) (ipm) (mm/min) Mild steel 26 GA 10 GA 1/4 3/8 1/2 5/8 3/4 Aluminum 1/32 1/8 1/4 3/8 1/2 5/8 Stainless steel 26 GA 14 GA 1/4 3/8 1/2 5/8 3/ *Maximum travel speeds are the results of Hypertherm's laboratory testing. For optimum cut performance, actual cutting speeds may vary based on different cutting applications. Refer to the operator's manual for more details A: Cutting-current output control, amps B: Gas test/set position C: Air pressure range, gouging mode D: Air pressure adjust control knob E: Cutting mode selector switch F: Pilot arc control mode G: Normal cutting mode H: Gouging mode I: Power on indicator J: Air pressure range, cutting mode (6 of 8) [12/8/2004 2:58:28 PM]

29 Hypertherm - POWERMAX1000 G3 Series Manual System Specifications Input voltages Input 8.4 kw Output voltage Duty 40 C (104 F) Maximum OCV (where indicated) V, 1/3-PH, Hz, CSA V, 3-PH, Hz, CE 200/208/230/240/480 V, 1-PH: 50/48/44/42/22 A 200/208/230/240/400/480/600 V, 3-PH: 30/29/26/24/15/12/11 A 140 VDC 60 A, V, 3-PH 60 A, V, 1-PH 60 A, V, 3-PH 60 A, V, 3-PH 300 VDC Dimensions 23.1" (586 mm) D; 10.7" (271 mm) W; 19.6" (498 mm) H Weight with torch 83 lbs (37 kg) Gas supply Clean, dry, oil-free air or nitrogen Flow rate 400 scfh; 6.7 cfm (189 l/min) at 90 psi (6.2 bar) Flow pressure 70 psi (4.8 bar) flowing, 25' leads 75 psi (5.1 bar) flowing, 50' leads Hypertherm, Powermax, G3 Series, HyLife, Boost Conditioner, Dual-threshold, Auto-voltage, Coaxial-assist and ETR (Easy Torch Removal) are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries Company Technology Products Find us Service Careers Website guide Home (7 of 8) [12/8/2004 2:58:28 PM]

30 Hypertherm - POWERMAX1000 G3 Series Manual System Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com (8 of 8) [12/8/2004 2:58:28 PM]

31 Hypertherm - POWERMAX1250 G3 Series Manual System Get Powermax1250 Brochure PDF MANUAL SYSTEM SECTIONS: The performance standard for air plasma cutting 7/8" (22 mm) Recommended capacity 1 1/8" (29 mm) Maximum capacity 1 1/2" (38 mm) Severance capacity A new generation of plasma cutting technology The benefits of Hypertherm technology Superior speed and cutting capacity Longer parts life Lower operating cost Higher-quality cuts Safety Realiability Ease of use in a robust, portable cutting system. Hypertherm - the world leader in plasma cutting technology When you only do one thing, you'd better do it better than anyone else. As the only major manufacturer to focus exclusively on plasma cutting technology, Hypertherm is committed to providing the highest quality systems in the world: improving the performance, reliability and value of our systems, and serving and supporting Hypertherm users. This commitment to technology leadership, quality and support makes Hypertherm the first choice of the true cutting professional. Superior performance by hand or machine The Powermax1250 is the first of the Powermax G3 Series. With new technologies in both power supply and torch, it cuts faster and more economically than any system available today. In fact, it cuts 80% faster on 1-inch (25 mm) mild steel than any competitor tested. Its Auto-voltage circuit provides automatic adjustment to any input voltage (1 of 8) [12/8/2004 2:58:35 PM]

32 Hypertherm - POWERMAX1250 G3 Series Manual System from 200 to 600 volts, 1- or 3-phase. A state-of-the-art, microprocessor-based architecture assures optimum system reliability. Add to this Hypertherm's advanced torch technology and easy-to-read controls, and you have the most advanced plasma cutter money can buy. Recommended capacity: metals to 7/8 inch (22 mm) at cutting speeds over 20 inches (500 mm) per minute. Maximum capacity: metals to 1 1/8 inch (29 mm) at cutting speeds over 10 inches (250 mm) per minute. Severance capacity: rough cut on metals up to 1 1/2 inches (38 mm) at low speed. The cut capacities above are on mild steel. Some metals, such as aluminum and stainless steel, may require up to 20% reduction in cut speed and capacity. Machine torch operation Up to 5/8 inch (16 mm) at 50% duty cycle. Up to 3/8 inch (10 mm) at 100% duty cycle. The power supply: the heart of the machine Advanced, intelligent technology gives the Powermax1250 the power to cut with greater speed, quality and efficiency. 80-amp, 12-kilowatt output provides ample power for clean, quick cutting. Auto-voltage runs on voltages from 200 to 600 volts, 1- or 3-phase, without the need for manual rewiring. New Boost Conditioner circuit compensates for input voltage variation. Advanced, digitally-controlled inverter design delivers continuously adjustable, constant current output, from 25 to 80 amps, permitting high-quality cuts over a wide range of metal thicknesses. An active electronic pilot arc controller for cutting expanded metal or grating. New gouging setting allows for improved (2 of 8) [12/8/2004 2:58:35 PM]

33 Hypertherm - POWERMAX1250 G3 Series Manual System arc transfer, easier operation and faster metal removal. CNC/robotic machine interface is standard on all units, allowing automated control and rapid change over to mechanized operation. The torch: intelligent design combines performance, durability, comfort and safety The Powermax1250 features Hypertherm's T80 safety trigger torch (patent pending) and T80M mechanized torch. A revolutionary design delivers outstanding cut performance, reliability and operator comfort. The longest consumable life in the industry, and we'll prove it. Patented HyLife electrodes last longer than ordinary designs (up to 10 times longer in some tests). Patented Dual-threshold pilot circuit significantly reduces nozzle wear by boosting pilot current precisely when needed. Patented nozzle shield lets you drag the torch on the workpiece at full output, without damaging consumables, and protects the nozzle from molten metal spray and double arcing. Postflow cooling to reduce torch stress. Hypertherm's patented Coaxial-assist jet design boosts cutting speed as much as 20% over conventional designs. Hypertherm's revolutionary new ETR (Easy Torch Removal) system allows for easy switching between manual and mechanized torches. It also features a radically new integrated approach to strain relief and durability. Hypertherm's patented safety trigger protects against accidental starts, with interlocks to deactivate the torch when the consumable parts are removed, using a durable mechanical contact. No breakable ceramic parts. Patented "blow-back" technology provides a pilot arc without excessive high-frequency interference. Consumables for gouging, extended-nozzle cutting, pipe saddle cutting and other applications. click here for larger view (3 of 8) [12/8/2004 2:58:35 PM]

34 Hypertherm - POWERMAX1250 G3 Series Manual System Engineered for superior reliability The Powermax1250 is designed for heavy use under the harshest conditions. Mechanical and electrical designs are validated through aggressive, accelerated testing. Auto-voltage accepts any voltage from 200 to 600 volts, without damage to the system from incorrect wiring or faulty linking. The Boost Conditioner eliminates performance deterioration, shut-down or potential damage due to fluctuating powerline conditions. New fan-on-demand feature minimizes dust ingestion. Chemically cross-linked torch cable jacket provides improved resistance to molten spray and cut-through. CSA/NRTL and CE certifications comply with the highest safety standards. IP23CS compliance for resistance to water damage. The Powermax1250 is backed by a full, three-year power supply warranty and a one-year torch warranty. No parts excluded. Examine competitive policies closely. Options for specialized requirements (4 of 8) [12/8/2004 2:58:35 PM]

35 Hypertherm - POWERMAX1250 G3 Series Manual System FineCut Consumables for superior cut quality on thin plate, mild and stainless steel Circle cutting guide Leather cable covers for torch leads. Air filtration kit with a 0.5 micron filter and auto-drain filter bowl. Wheel kit for easy mobility. Heat shield protects hands from excessive reflective heat. Operating cost calculations are based on consumable price, tested consumable life, tested cutting speed, estimated labor and power costs and an assumption of 50% duty cycle operation. Competitive units are in the amp cutting range. Powermax 1250 G3 series standard system components Power supply T80 or T80M torch Spare consumables Work cable with clamp 15 feet (4.5 m) Primary power cable Options Circle cutting guide Wheel kit Leather cable covers Air filtration kit Extended work cable Hand heat shield, gouging (5 of 8) [12/8/2004 2:58:35 PM]

36 Hypertherm - POWERMAX1250 G3 Series Manual System Ordering Information With 25' (7.5 m) torch Systems part numbers With 50' (15 m) torch With 75' (23 m) torch V, 1/3-PH, CSA Manual system Mechanized system V, 3-PH, CE Manual system Mechanized system Operating data Recommended capacity Maximum capacity Severance capacity. Hand torch Machine torch 7/8" (22 mm) 3/8" (10 100% duty cycle 1 1/8" (29 mm) 5/8" (16 50% duty cycle 1 1/2" (38 mm) - Maximum Material Thickness Current travel speed* (inches) (mm) (amps) (ipm) (mm/min) Mild steel 22 GA 10 GA 1/4 3/8 1/2 3/4 1 Aluminum 1/32 1/16 1/4 3/8 1/2 3/4 Stainless steel 22 GA 10 GA 1/4 3/8 1/2 3/ *Maximum travel speeds are the results of Hypertherm's laboratory testing. For optimum cut quality, speeds should be reduced between 35 50%, depending upon the material. Refer to your operators manual for more detail (6 of 8) [12/8/2004 2:58:35 PM]

37 Hypertherm - POWERMAX1250 G3 Series Manual System A: Cutting-current output control, amps B: Gas test position C: Back-lit fault indicators D: Air pressure range, gouging mode E: Air pressure adjustment knob F: Cutting mode selector switch G: Pilot arc control mode H: Normal cutting mode I: Gouging mode J: Power on indicator K: Air pressure range, cutting mode Specifications Input voltages Input 12.0 kw Output voltage Duty 40 C (104 F) Maximum OCV (where indicated) V, 1- or 3-PH, 50/60 Hz, CSA V, 3-PH, 50/60 Hz, CE 200/208/230/240/480 V, 1-PH: 70/70/60/58/31 A 200/208/230/240/400/480/600 V, 3-PH: 41/40/37/34/21/17/17 A 150 VDC 80 A, V, 3-PH 80 A, 480 V, 1-PH 80 A, 240 V, 1-PH 80 A, V, 3-PH 80 A, V, 1-PH 300 VDC Dimensions 23.1" (586 mm) D; 10.65" (271 mm) W; 19.6" (498 mm) H Weight with torch 96.6 lbs (44 kg) Gas supply Clean, dry, oil-free air or nitrogen Flow rate 400 scfh; 6.7 cfm (189 l/min) at 90 psi (6.2 bar) Flow pressure 70 psi (4.8 bar) flowing, 25' leads 75 psi (5.1 bar) flowing, 50' leads Hypertherm, Powermax, G3 Series, HyLife, Boost Conditioner, Dual-threshold, Auto-voltage, Coaxial-assist and ETR (Easy Torch Removal) are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries (7 of 8) [12/8/2004 2:58:35 PM]

38 Hypertherm - POWERMAX1250 G3 Series Manual System Company Technology Products Find us Service Careers Website Guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com (8 of 8) [12/8/2004 2:58:35 PM]

39 Hypertherm - POWERMAX1650 Manual System Get Powermax1650 Brochure PDF The performance standard for air plasma cutting and gouging MANUAL SYSTEM SECTIONS: 1-1/4" (32 mm) Recommended capacity 1-1/2" (38 mm) Maximum capacity 1-3/4" (44 mm) Severance capacity Delivering superior power and performance in a proven technology! The benefits of Hypertherm technology Superior speed and cutting capacity Longer parts life Lower operating cost Higher-quality cuts Safety Reliability Ease of use in a robust, portable cutting system. Hypertherm the world leader in plasma cutting technology When you only do one thing, you'd better do it better than anyone else does. As the only manufacturer to focus exclusively on plasma cutting technology, Hypertherm is committed to providing the highest quality systems in the world. All of our engineering resources go into improving the performance, reliability and value of our systems. All of our associates are 100% devoted to serving and supporting our plasma customers. A demonstrated commitment to technology leadership, quality and support make Hypertherm the first choice of the true cutting professional. Setting a new performance standard for air plasma cutting (1 of 9) [12/8/2004 2:58:41 PM]

40 Hypertherm - POWERMAX1650 Manual System The Powermax1650 is the latest addition to the Powermax G3 series of systems. With advanced technologies in both power supply and torch, Hypertherm G3 products cut faster, and more economically, than any system available anywhere today. Its Auto-voltage circuit provides automatic adjustment to any input voltage from 200 to 600 volts, 3-phase (CE 230 to 400 V 3-phase only). A state-ofthe-art, microprocessor-driven architecture assures optimum system reliability. Add to this Hypertherm's advanced torch technology, and easy-to-read controls and features, and you have the most powerful, advanced, and reliable plasma cutter money can buy. Hand torch operation Recommended capacity: metals to 1-1/4 inch (32 mm) at cutting speeds of 19 inches per minute (482 mm). Maximum capacity: metals to 1-1/2 inch (38 mm) at cutting speeds over 10 inches per minute (250 mm/min). Severance capacity: rough cut on metals up to 1-3/4 inch (44 mm) at low speed. Machine torch operation Recommended pierce capacity: Up to 1/2 inch (12 mm). Maximum pierce capacity: Up to 3/4 inch (19 mm). Cutting above 3/4 inch (19 mm) requires an edge start. Note: The cut capacities noted above are on mild steel. Some metals, such as aluminum and stainless steel, may require up to a 20% reduction in cut speed and capacity. The power supply: the heart of the system Advanced technology gives the Powermax1650 the power to cut with greater quality and efficiency. (2 of 9) [12/8/2004 2:58:41 PM]

41 Hypertherm - POWERMAX1650 Manual System 100-amp, 16-kilowatt output provides ample power for cutting heavy plate cleanly and quickly. Auto-voltage input sensing allows you to run on voltages from 200 to 600 volts, 3-phase, with no rewiring. CNC/Robotic machine interface is standard on all units, allowing for automated control and rapid mechanized installation. New Boost Conditioner circuit compensates for input voltage variation. Advanced digitally-controlled inverter design delivers continuously adjustable constant current output, from 30 to 100 amps, producing high-quality cuts over a wide range of metal thicknesses. An active, electronic pilot-arc controller for cutting expanded metal or grating preserves consumable life. A new gouging setting allows for longer arc lengths and easier operation, plus a metal removal rate in excess of 22 pounds per hour (10 kg). Wheels are standard on the Powermax1650 and provide improved mobility over rough and uneven surfaces. Back-lit LED's clearly convey all the information necessary to monitor the system status, including an easily readable and understandable air pressure gauge. The torch: intelligent design combines performance, durability, comfort and safety The Powermax1650 features Hypertherm's patented T100 safety trigger torch and T100M mechanized torch, which produce outstanding cut performance, reliability and operator comfort. (3 of 9) [12/8/2004 2:58:41 PM]

42 Hypertherm - POWERMAX1650 Manual System The longest consumable life in the industry, and we'll prove it. HyLife electrodes last longer than ordinary designs by using the same patented technologies developed for advanced Hypertherm mechanized systems. Dual-threshold pilot circuit significantly reduces nozzle wear by boosting pilot current precisely when needed. Patented nozzle shield technology lets you drag the torch on the workpiece at full output, without damaging consumables, and protects the nozzle from molten metal spray and double arcing. Postflow cooling reduces torch stress. Hypertherm's patented Coaxial-assist jet design boosts cutting speed as much as 20% over conventional designs. Hypertherm's ETR (Easy Torch Removal) system allows for easy switching between hand and machine torches, while providing a radical integrated approach to strain relief designed for durability. Hypertherm's patented safety trigger protects against accidental starts. Safety interlocks deactivate the torch when the consumable parts are removed, using a durable mechanical contact. No breakable ceramic parts. Patented "blow-back" technology provides a pilot arc without excessive high-frequency interference. Consumables for gouging, extendednozzle cutting, pipe saddle cutting and other applications. Most consumables compatible with existing G3 systems, resulting in fewer SKU's. Click for larger image Engineered for superior reliability The Powermax1650 is designed for heavy use and very harsh conditions. (4 of 9) [12/8/2004 2:58:41 PM]

43 Hypertherm - POWERMAX1650 Manual System Mechanical and electrical designs are validated through aggressive, accelerated testing. Fan-on-demand feature minimizes dust ingestion. Chemically cross-linked torch cable jacket provides improved resistance to molten spray and cut-through. CSA/NRTL and CE certifications comply with the highest safety standards. IP23CS compliance means resistance to rain damage. The Powermax1650 is backed by Hypertherm's full three-year power supply warranty and one-year torch warranty. No parts excluded. Examine competitive policies closely. Options for specialized requirements FineCut Consumables for superior cut quality on thin plate, mild and stainless steel Circle cutting guide for cutting measured circles Leather cable covers for torch leads. Air filtration kit with a.85 micron filter and auto-drain filter bowl. Heat shield protects hands from excessive reflective heat. Stationary Mounting Kit for fixed installation on table or floor (5 of 9) [12/8/2004 2:58:41 PM]

44 Hypertherm - POWERMAX1650 Manual System Powermax1650 G3 Series standard system components Power supply T100 or T100M torch Spare consumables Work cable with clamp 15 feet (4.5 m) Options Circle cutting guide Leather cable covers Air filtration kit Extended work cable Hand heat shield Stationary mounting kit Ordering information (6 of 9) [12/8/2004 2:58:41 PM]

45 Hypertherm - POWERMAX1650 Manual System With 25' (7.5 m) torch Systems part numbers With 50' (15 m) torch With 75' (23 m) torch V, 3-PH, CSA Hand system Machine system V, 3-PH, CE Hand system Machine system Specifications Input voltages Input 16.0 kw Output voltage Duty 40 C ( amps Output for 100% 40 C ( amps Maximum OCV (where indicated) V, 3-PH, 50/60 Hz, CSA V, 3-PH, 50/60 Hz, CE 200/208/230/240/400/480/600 V, 3-PH: 54/53/47/46/27/22/21 A 160 VDC V V V V V V 300 VDC Dimensions 26.4" (671 mm) D; 16.8" (427 mm) W; 25.8" (655 mm) H Weight with torch 128 lbs (58 kg) Gas supply Clean, dry, oil-free air or nitrogen Flow rate 550 scfh; 9.2 cfm (260 l/min) at 90 psi (6.2 bar) Flow pressure 75 psi (5.1 bar) flowing, 25' leads 80 psi (5.4 bar) flowing, 50' leads Standard machine interface signals Plasma start Transfer (start machine motion) 24VDC (100ma maximum) Arc voltage (torch control) - signal not available on rear panel connector For more information refer to your operator's manual. (7 of 9) [12/8/2004 2:58:41 PM]

46 Hypertherm - POWERMAX1650 Manual System A: Cutting-current output control, amps B: Gas test/set position C: Air pressure range, gouging mode D: Air pressure adjustment knob E: Cutting mode selector switch F: Pilot arc control mode G: Normal cutting mode H: Gouging mode I: Power on indicator J: Air pressure range, cutting mode Operating data Hand torch Machine torch Recommended capacity 1-1/4" (32 mm) 1/2" (12 mm) Maximum capacity 1-1/2" (38 mm) 3/4" (19 mm) Severance capacity 1-3/4" (44 mm) - Maximum Material Thickness Current travel speed* (inches) (mm) (amps) (ipm) (mm/min) Mild steel 26 GA 10 GA 1/4 1/2 3/ /4 Aluminum 1/32 1/8 1/4 1/2 3/4 1 Stainless steel 26 GA 14 GA 1/4 1/2 3/ / *Maximum travel speeds are the results of Hypertherm's laboratory testing. For optimum cut performance, actaul cutting speeds may vary based on different cutting applications. Refer to your operators manual for more detail. (8 of 9) [12/8/2004 2:58:41 PM]

47 Hypertherm - POWERMAX1650 Manual System Company Technology Products Find us Service Careers Website guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com (9 of 9) [12/8/2004 2:58:41 PM]

48 Hypertherm - MAX200 Manual System MANUAL SYSTEM SECTIONS: High Capacity, Dual-Gas Plasma Cutting System For Cutting Gauge To 2 Inch (50 mm) Metals 1" (25 mm) Recommended Maximum Mechanized Production Capacity 2" (50 mm) Maximum Cutting Capacity High Capacity...Low Cost Operation...Dual Gas Capabilities: The MAX200 is the Answer to your Heavy Duty Metal Cutting Needs The MAX200 continues Hypertherm's tradition of combining advanced technology and superior quality to deliver operating advantages that are unmatched in the industry. The MAX200 Advantage 200 amp, 30 kw power output delivers heavyduty cutting capacity up to 2 inches (50 mm) thick on most metals; typical cutting speeds greatly exceed oxyfuel or other methods. 100% duty cycle at full power keeps you cutting - all day long. Adjustable power output from 40 to 200 amps lets the operator precisely match power to cutting requirements. A state-of-the-art transistorized power supply maintains constant output current regardless of variations in input voltages or torch-to-work distances, ensuring clean, square cuts throughout the cutting range. MAX200's dual gas system - plasma and shield - allows you to run on Air/Air, O2/Air, N2/Air, N2/CO2, Ar-H2-N2 or other combinations for optimal results on all metals and in all conditions. The MAX200's patented shielded torch frontend practically eliminates the possibility of double arcing, greatly enhancing piercing Get MAX200 hardcopy brochure Hypertherm is ISO 9001 registered (1 of 4) [12/8/2004 2:58:49 PM]

49 Hypertherm - MAX200 Manual System capabilities and extending consumable parts life. The water-cooled torch provides maximum cooling, another factor behind MAX200's long consumable parts life; the cooling system is built into the power supply for exceptional convenience. The MAX200 can be used on cutting machines or for hand-held applications. A machine motion delay control comes built into every system. Optional Torch Height Control (THC) and inductive Initial Height Sensing (IHS) are available for machine use. New consumables, an optional extended torch and heat shield, optimize the MAX200 for gouging applications. A full set of easy-to-read indicator and diagnostic lights monitor the status of external door panels, transformer temperature, coolant level, plasma and shield gas pressure, coolant temperature, and coolant flow, greatly simplifying troubleshooting. Extended leads up to 150' (45 m) are available for both handheld and mechanized systems for added flexibility. The MAX200 is available in all common voltages, including 240/480 V, 3Ø, 60 Hz and 220/380/415 V, 3Ø, 50/60 Hz configurations. Safety interlocks are built in, ensuring maximum operator safety. MAX200 comes equipped with casters for easy wheeling, and there is a lifting eye located at the balance point for use with cranes. A full two-year warranty on the power supply and one-year coverage on the torch backs up Hypertherm's quality commitment. MAX200 System Components (2 of 4) [12/8/2004 2:58:49 PM]

50 Hypertherm - MAX200 Manual System Power Supply Torch Assembly 25'/50' (7.5 m/15 m) Torch Leads Consumable Parts Kit 25' (7.5 m) Work Cable with Clamp Torch Coolant Specifications Model Number: MAX200 Input Voltage: 240/480 V 3Ø, 60 Hz 220/380/415 V, 3Ø, 50/60 Hz Input 30 kw Output: 90/45 A, 240/480 V 98/57/52 A, 220/380/415 V Output Voltage: 150 V DC Output Current: 40 to 200 A Duty Cycle: 100% Maximum OCV: 280 V DC Dimensions: 41" (1040 mm) Depth 28" (710 mm) Width 43" (1090 mm) Height Weight: 780 lbs. (350 kg) Gas Supply: Plasma Gas: Air, N2, O2, Ar-H2 Plasma Flow (Air): 66 scfh (31 1/min) Plasma Pressure: 120 psig (8.3 bar) Shield Gas: Air, N2, CO2 Shield Gas Flow (Air): 280 scfh (132 l/min) Shield Gas Pressure: 90 psig (6.2 bar) *Note: Other Voltages available Operating Data MATERIAL THICKNESS CURRENT APPROXIMATE TRAVEL SPEED (inches) (mm) (amps) (ipm) (mm/min) MILD STEEL 1/4 3/8 1/2 3/ /4 1 1/ (3 of 4) [12/8/2004 2:58:49 PM]

51 Hypertherm - MAX200 Manual System ALUMINUM 3/16 1/4 3/8 1/2 3/ /4 1 1/2 STAINLESS 3/16 1/4 3/8 1/2 3/ /4 1 1/ Hypertherm and MAX are trademarks of Hypertherm, Inc., and may be registered in the United States and/or other countries. Company Technology Products Find us Service Careers Website guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com (4 of 4) [12/8/2004 2:58:49 PM]

52 Hypertherm - Manual System Accessories MANUAL SYSTEM SECTIONS: Protecting your investment, increasing your productivity Hypertherm accessories are designed to help you get the most out of your plasma cutting system. Our wide range of useful accessories help make a good thing better by enhancing productivity, improving convenience, increasing system reliability and life, and making your cutting jobs easier. Hypertherm accessories are designed and manufactured with the same skill and care that have made our plasma cutting systems the first choice of cutting professionals for over 30 years. Just one more reason why Hypertherm is the leader in plasma cutting technology. Get Manual Accessories Brochure PDF Air filtration kit Additional protection for your investment, this ready-to-install kit comes with a.85 micron filter to protect against contaminated air, as well as an auto-drain moisture separator. Attaches to the power supply through existing mounting holes. An indicator in the filter housing turns red when airflow is reduced, providing a visible prompting to change the filter. Hand gouging heat shield This shield provides additional protection for the operator in gouging operations. Comes complete with hardware, just install on the torch handle for a heat barrier between your hand and the arc. Narrow for high mobility, arc control and visibility, but also lightweight for operator comfort. (1 of 3) [12/8/2004 2:58:54 PM]

53 Hypertherm - Manual System Accessories Wheel kit Adds increased mobility for applications where the machine must be moved to various locations in the same shop or work-site. Comes as one complete, pre-assembled kit, attaches to the base of the power supply. Uses two axle-mounted wheels and two casters for improved travel over rough and uneven surfaces. Circle cutting guide This guide is designed to utilize hand torches for performing high-quality straight cuts, circle cuts up to 22 inches (56 cm) in diameter, circle cuts down to 4 inches (10 cm) in diameter, and bevel cuts all in one complete, professional package. Facilitates consistent and accurate measured circles in work pieces. Ideal for end-users cutting repetitive holes. Uses an adjustable point pivot, stabilizing wheels and a torch head bushing. Comes standard with magnetic base and suction cups. Extended torch leads/work leads To increase flexibility, the Powermax line is available with optional 50 foot torch leads and 50 foot work leads. Adding to the reach of the machine, these options are ideal for working on large projects, helping reduce the time required to move the machine. (2 of 3) [12/8/2004 2:58:54 PM]

54 Hypertherm - Manual System Accessories Leather torch sheathing Available in 25 foot sections, this option provides additional protection for torch leads against burn-through and abrasion. Velcro closure helps prevent bunching and is easily removed. Company Technology Products Find us Service Careers Website Guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com (3 of 3) [12/8/2004 2:58:54 PM]

55 Hypertherm - FineCut Consumables Get FineCut Brochure PDF MANUAL SYSTEM SECTIONS: FineCut Consumables FineCut consumables are an innovative addition to Hypertherm s industry-leading line of plasma cutting torches. They deliver significant increases in cut quality by providing a narrower kerf with virtually no heat-affected zone and by dramatically reducing dross. Hand-torch and machine-torch operators who choose FineCut consumables consistently achieve superior metal finishing and increased productivity. Customer Testimonial "I'm elated with the new nozzles. The difference is as clear as night vs. day. The new nozzles provide a cleaner, smoother cut that makes my life much easier. My customers immediately noticed and like the improved products." Cole Wagley, Prairie Outfitters Core benefits of FineCut technology Better overall finish on both mild and stainless steel resulting from a decreased heat-affected zone Finer cut quality than standard nozzles made possible by narrower kerf width and improved cut angularity Elimination of some secondary operations because of virtually dross-free cutting FineCut consumables benefit many common applications HVAC Sign fabrication and installation Metal sculpting and ornamental work Commercial kitchen installation Beverage fountain installation Cart and shelf fabrication Tank and container fabrication Door and elevator fabrication and installation (1 of 4) [2/3/2005 9:05:33 AM]

56 Hypertherm - FineCut Consumables If you are looking for even better cut quality on thinplate metals using your Hypertherm plasma systems... order a starter kit today and begin experiencing the FineCut difference! Ordering information FineCut starter kit for: Description Part Number Powermax Powermax600 CE Powermax1000/1250/ Powermax1000/1250/1650 CE Kits include: 5 nozzles, 2 swirl rings, 5 electrodes, 5 o-rings, 1 deflector and 1 tube of silicone lubricant Operating data Material Mild steel Stainless steel Thickness Torch standoff Current Approximate travel speed Arc voltage GA mm in. mm amps ipm mm/min volts Powermax350/380, MAX20 Item Number Part Number Description Retaining cap Nozzle, PAC110 FineCut Electrode, extended Swirl ring (2 of 4) [2/3/2005 9:05:33 AM]

57 Hypertherm - FineCut Consumables Powermax600/800/900, MAX40cs/42/43 Item Number Part Number Deflector Deflector - CE, FineCut 3* Shield, ohmic, FineCut Retaining cap 5* Retaining cap, ohmic Description Nozzle, PAC123 FineCut Electrode, extended Swirl ring, hand, FineCut Swirl ring, machine * Not for use on the Powermax600 Powermax1000/1250/ Item Number Part Number Deflector Description Deflector, CE, FineCut Shield, ohmic, FineCut Retaining cap Retaining cap, ohmic Nozzle, T60/T80/T100, FineCut Electrode Swirl ring, hand, FineCut Swirl ring, machine (3 of 4) [2/3/2005 9:05:33 AM]

58 Hypertherm - FineCut Consumables Company Technology Products Contact us Service Careers Website guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com (4 of 4) [2/3/2005 9:05:33 AM]

59 Hypertherm - Customer testimonial Powermax1650 Delivers Continuous Improvement and Productivity Gains Metal Services Incorporated, a sister company of Smithco Engineering Inc, in Tulsa Oklahoma, and Amercool Manufacturing, Inc. in Whitehouse, Texas, recently purchased 2 Powermax1650s for their cutting tables. Metal Services does the steel fabrication work for Smithco Engineering and Amercool. Since Smithcos' founding in 1952, Smithco has been known as a premier manufacturer and full service provider of air-cooled heat exchangers to the refining, gas processing, gas transmission, petrochemical, utilities and other heavy industries. Amercool is a 15 year old company that supplies air-cooled heat exchangers to the power generation and gas compression markets. But in today s aggressive business climate, standing on reputation is not enough. Their technologies and procedures underscore their commitment to excellence, product quality, engineering, service, and customer satisfaction. Full-service engineering, fabrication, and inspection of air-cooled heat exchangers are Smithco s exclusive activities. The company replaced MAX100 power supplies on their cutting table with Powermax1650s and in the words of Metal Services management, The results have been amazing. Some of the key areas of improvement were a 12 percent increase in sheet metal assembly efficiency with no other changes to their process. This improvement has been attributed to parts that are more consistently dimensionally correct and cut complete and clean. With the Powermax1650s, part square has checked within 1/32 of an inch total on over 200 parts that have been measured. According to the management team The most compelling positive result from this retrofit has been a reduction in overtime by approximately 30 percent. This has now added additional capacity to the production facility allowing Metal Services to expand our business capabilities and generate additional revenue opportunities. In addition, this installation provided dramatic air quality improvement in the shop due to reduced smoke, creating a more positive environment and increasing productivity. The improvements in performance and productivity prompted Metal Services (1 of 2) [2/3/2005 9:05:34 AM]

60 Hypertherm - Customer testimonial to purchase a Powermax600 as well. This unit is used to cut skeletons as well as complete other maintenance tasks originally cut by oxy-fuel. Once again, Hypertherm delivers extensive production improvement and lower labor costs. Management has already decided to make future purchases of Hypertherm plasma cutting systems with the goal of continuing to increase productivity and to reduce costs. Company Technology Products Find us Service Careers Website guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com (2 of 2) [2/3/2005 9:05:34 AM]

61 Hypertherm Company Hypertherm: synonymous with metal cutting leadership Since 1968, Hypertherm has had a single goal. Cut the cost of cutting metal. The company s one and only focus is plasma cutting technology. Its single-minded mission provide customers throughout the world with the best plasma cutting equipment and service available in the industry. That s why Hypertherm holds more plasma cutting patents globally and has more customers worldwide than any other brand. Hypertherm plasma cutting equipment is used to manufacture products that facilitate the production of heavy equipment for farming, construction and highway repairs. Aid in the manufacture of the world's most prestigious motor cars. Enable naval vessels and commercial ships to safely sail the oceans of the globe. Keep international airlines flying. Allow the smallest welding operations to be competitive. Help noted artists create imaginative sculptures. Company Technology Products Find us Service Careers Website guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com [2/3/2005 9:05:35 AM]

62 Hypertherm Technology Plasma means productivity The plasma arc cutting process is today's choice for cutting metal most efficiently. Hypertherm has played a vital role in the metalworking industry for over 30 years. The company contributed many pioneering advances during that time and has become the industry standard for cut quality and weldability. From the beginning, Hypertherm established itself as the innovator in plasma cutting technology. In fact, Hypertherm was the first plasma cutting equipment company to earn ISO 9001 registration in the USA. We share this plasma expertise gained over three decades through seminars and educational workshops. In this section, you will have access to information provided in these forums-- including the evolution of plasma's use in the metalworking industry and Hypertherm's patented LongLife and HyDefinition technologies. Company Technology Products Find us Service Careers Website Guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com [2/3/2005 9:05:36 AM]

63 Products Overview A demonstrated commitment to technology leadership, quality and support make Hypertherm cutting systems the first choice of true cutting professionals around the world. Whether you are involved in light fabrication, plant maintenance or high-volume plate cutting, Hypertherm has the system for you. No one is more committed to providing you with a cutting solution that will drive costs out of your operation. Consumables are a critical part of a Hypertherm system and feature a host of performance-enhancing patented technologies. Only by using genuine Hypertherm consumables can you be sure to get all the performance you paid for. Manual systems Mechanized systems Consumables Laser s Company Technology Products Find us Service Careers Website guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com [2/3/2005 9:05:37 AM]

64 Company Locator Hypertherm worldwide locator This geographic guide to Hypertherm sales and service partners allows you to find U.S. and Canadian distributors, OEMs, repair centers, as well as Hypertherm subsidiaries and sales offices throughout the world. Simply click on the type of Hypertherm affiliate you seek. In each case, you will be guided through a series of clickable maps- country, state-so you can discern the Hypertherm sales, service and marketing partner that is most convenient to you. International distributors, OEMs and repair centers will be added to our site in the near future. North American distributors Worldwide OEMs North American repair centers Hypertherm worldwide subsidiaries and sales offices Company Technology Products Contact us Service Careers Website guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com [2/3/2005 9:05:37 AM]

65 Hypertherm Services Comprehensive product support and customer services Hypertherm is dedicated to the consistent delivery of support and services that will exceed customer expectations of added value and problem solving. We provide all the tools, documents and knowledge necessary to maximize product performance and customer productivity. Hypertherm also continuously measures critical processes and monitors customer satisfaction to continuously improve the quality and level of services. In addition, we strongly urge our outsourcing partners to adopt a commitment to excellence, attentiveness to customer needs and continuous improvement. Company Technology Products Find us Service Careers Website guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com [2/3/2005 9:05:38 AM]

66 Hypertherm Careers Hypertherm, Inc., A career at Hypertherm Hypertherm s strength is fueled by individual energy. The unique accomplishments of outstanding men and women within our worldwide organization contribute to a shared corporate dynamism. Skill is the first requirement for the career-oriented applicant at Hypertherm. Expertise gained through education and training in specific disciplines is crucial. But just as important as skill, is an expressed comfort level with Hypertherm s corporate culture and values, with the needs and expectations of our customers and with our business goals. Hypertherm s mission statement includes "providing for the development and well-being of our associates." That means that Hypertherm is open to helping you map a career path that will assure your personal and professional growth as well as enabling you to continue your educational development. Company Technology Products Contact us Service Careers Website guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com [2/3/2005 9:05:39 AM]

67 Hypertherm Site Guide This Hypertherm site guide has been designed to provide you with quick access to the information you are looking for. Simply click on the topic category that interests you to open a particular section of our web site. Hypertherm is continually trying to improve our web site to meet customer expectations. Please info@hypertherm.com with your comments and/or suggestions. Company Technology Products Find us Service Careers Website guide Home Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH USA Tel Tel (Toll Free in the USA and Canada) Fax info@hypertherm.com [2/3/2005 9:05:40 AM]

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