50276.PMX1250 Hypertherm Powermax1250 Plasma Cutter
User Manual: Hypertherm-Powermax1250-Plasma-Cutter Igor's of metalworking and electrical manuals
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The performance standard for air plasma cutting
ISO 9001
SERIES
G3 ™
7⁄8"
(22 mm)
11⁄8"
(29 mm)
11⁄2"
(38 mm)
Maximum capacity
Severance capacity
Recommended capacity
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.
A new generation of plasma cutting technology
SERIES
G3 ™
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.
Machine torch operation
Up to 5⁄8inch (16 mm) maximum.
Up to 3⁄8inch (10 mm) recommended.
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
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.
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 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
7⁄8inch (22 mm) at cutting speeds over
20 inches (500 mm) per minute.
Maximum capacity: metals to 11⁄8inch
(29 mm) at cutting speeds over 10 inches
(250 mm) per minute.
Severance capacity: rough cut on metals
up to 11⁄2inches (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.
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.
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.
Pilot arc
Boosted
pilot arc
Cutting arc
StopStart Workpiece
sensed
Arc
transfer
Output current (Amps)
Options for specialized
requirements
FINECUTTM CONSUMABLES for
superior cut quality on thin plate,
mild and stainless steel.
CIRCLE CUTTING GUIDE
LEATHER CABLE COVERS for
torch leads.
AIR FILTRAT ION KIT with
a 0.85 micron filter and
auto-drain filter bowl.
WHEEL KIT for easy
mobility.
HEAT SHIELD protects
hands from excessive
reflective heat.
Plasma gas
Electrode
Shield gas
Workpiece
Coaxial-assist™
jet
Superior productivity
through technology
Calculated cost per foot of cut on
3⁄4" (19 mm) mild steel
$0.38
$0.62
$0.92
$1.06
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 70 – 80 amp
cutting range.
Powermax1250
Competitor A
Competitor B
Competitor C
Input voltages 200 – 600 V, 1- or 3-PH, 50/60 Hz, CSA
230 – 400 V, 3-PH, 50/60 Hz, CE
Input current @ 12.0 kW 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
Output voltage 150 VDC
Duty cycle @ 40˚ C 60% @ 80 A, 230 – 600 V, 3-PH
(104˚ F) 60% @ 80 A, 480 V, 1-PH
50% @ 80 A, 240 V, 1-PH
50% @ 80 A, 200 – 208 V, 3-PH
40% @ 80 A, 200 – 208 V, 1-PH
Maximum OCV 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
Powermax1250
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
Specifications
A
D
C
H
G
J
K
I
E
B
Maximum
Material Thickness Current travel speed*
(inches) (mm) (amps) (ipm) (mm/min.)
Mild steel 22 GA. 0.8 25 500 12700
10 GA. 3.6 40 151 3835
1
⁄
4
640 741880
3
⁄
8
10 80 94 2388
1
⁄
2
12 80 60 1524
3
⁄
4
19 80 31 787
12580 16406
Aluminum
1
⁄
32
0.8 25 610 15494
1
⁄
16
1.5 25 268 6807
1
⁄
4
3.2 40 76 1930
3
⁄
8
10 80 121 3073
1
⁄
2
12 80 75 1905
3
⁄
4
19 80 37 940
Stainless 22 GA. 0.8 25 496 12598
steel 10 GA. 3.6 40 107 2718
1
⁄
4
640 471194
3
⁄
8
10 80 83 2108
1
⁄
2
12 80 50 1270
3
⁄
4
19 80 24 610
12580 14356
*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 your operator manual for more details.
S IP23CS
(where indicated)
High-performance portable plasma cutting system
A: Cutting-current output
control, 25 – 80 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
Operating data
Hand torch Machine torch
Recommended capacity
7
⁄
8
" (
22 mm)
3
⁄
8
" (
10 mm)
Maximum capacity 1
1
⁄
8
" (
29 mm)
5
⁄
8
" (
16 mm)
Severance capacity 1
1
⁄
2
" (
38 mm) –
SERIES
G3 ™
F
Hypertherm, Powermax, G3 Series, HyLife, Boost Conditioner, Dual-threshold, Auto-voltage, Coaxial-assist, ETR (Easy Torch Removal) and FineCut are trademarks of Hypertherm, Inc. and may be
registered in the United States and/or other countries.
© Copyright 2/04 Hypertherm, Inc. Revision 5
860110
Hypertherm, Inc. USA 603-643-3441 Tel 603-643-5352 Fax manual.info@hypertherm.com
Hypertherm Automation, LLC USA 603-298-7970 Tel 603-298-7977 Fax info@hyperthermautomation.com
Hypertherm Plasmatechnik, GmbH Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax
HTDeutschland.info@hypertherm.com
Hypertherm (S) Pte Ltd Singapore 65 6 841 2489 Tel 6 65 841 2490 Fax HTSingapore.info@hypertherm.com
Hypertherm UK, Ltd England 44 1928 579 074 Tel 44 1928 579 604 Fax HTUK.info@hypertherm.com
France 00 800 3324 9737 Tél 00 800 4973 7329 Fax HTFrance.info@hypertherm.com
Hypertherm S.r.l. Italia 39 02 725 46 312 Tel 39 02 725 46 400 Fax HTItalia.info@hypertherm.com
Hypertherm Europe B.V. Nederland 31 165 59 69 08 Tel 31 165 59 69 01 Fax
HTEurope.info@hypertherm.com
Japan 81 05 5975 7387 Tel 81 05 5975 7376 Fax HTJapan.info@hypertherm.com
Hypertherm Brasil Ltda. 55 21 2278 6162 Tel 55 21 2578 0947 Fax HTBrasil.info@hypertherm.com
www.hypertherm.com
Ordering information
Systems part numbers
With 25' With 50' With 75'
(7.5 m) torch (15 m) torch (23 m) torch
200 – 600 V, 1/3-PH, CSA
Manual system 087008 087009 087049
Mechanized system 087012 087013 087051
230 – 400 V, 3-PH, CE
Manual system 087020 087021 087050
Mechanized system 087022 087023 087052
