The performance standard for air plasma cutting and gouging

1 1⁄4" (32 mm)

Recommended capacity

1 1⁄2" (38 mm)

Maximum capacity

1 3⁄4" (44 mm)

Severance capacity

ISO 9001
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 Setting a new performance Machine torch operation
in plasma cutting technology standard for air plasma cutting Recommended pierce capacity:
When you only do one thing, you’d better do The Powermax1650 is the latest addition Up to 1⁄ 2 inch (12 mm).
it better than anyone else does. As the only to the Powermax G3 series of systems. Maximum pierce capacity:
manufacturer to focus exclusively on thermal With advanced technologies in both power Up to 3 ⁄4 inch (19 mm).
cutting technology, Hypertherm is committed supply and torch, Hypertherm G3 products
Cutting above 3 ⁄4 inch (19 mm) requires
to providing the highest quality systems in the cut faster, and more economically, than
an edge start.
world. All of our engineering resources go any hand system available anywhere today. Its
into improving the performance, reliability and Auto-voltage™ circuit provides automatic Note: The cut capacities noted above are on mild steel.
Some metals, such as aluminum and stainless steel, may
value of our systems. All of our associates adjustment to any input voltage from 200
require up to a 20% reduction in cut speed and capacity.
are 100% devoted to serving and supporting to 600 volts, 3-phase (CE 230 to 400 V
our plasma customers. A demonstrated 3-phase). A state-of-the-art, microprocessor- The power supply:
commitment to technology leadership, quality driven architecture assures optimum system the heart of the system
and support make Hypertherm the first choice reliability. Add to this Hypertherm’s advanced Advanced technology gives the
of the true cutting professional. torch technology, and easy-to-read controls Powermax1650 the power to cut
and features, and you have the most powerful, with greater quality and efficiency.
advanced, and reliable plasma cutter money
can buy. 100-amp, 16-kilowatt output provides
ample power for cutting heavy plate
Hand torch operation cleanly and quickly.
Recommended capacity: metals to Auto-voltage input sensing allows you
1 1⁄4 inch (32 mm) at cutting speeds of to run on voltages from 200 to 600 volts,
19 inches per minute (482 mm). 3-phase, with no rewiring.
Maximum capacity: metals to CNC/Robotic machine interface is
1 1⁄ 2 inch (38 mm) at cutting speeds over standard on all units, allowing for automated
10 inches per minute (250 mm/min). control and rapid mechanized installation.
Severance capacity: rough cut on metals New Boost Conditioner ™ circuit
up to 1 3⁄4 inch (44 mm) at low speed. 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 Options for specialized
and uneven surfaces. requirements
Back-lit LED’s clearly convey all the F I N E C UT
TM
C ONS U MAB L ES for
information necessary to monitor the system Hypertherm’s patented Coaxial-assist ™ superior cut quality on thin plate,
status, including an easily readable and jet design boosts cutting speed as much mild and stainless steel.
understandable air pressure gauge. as 20% over conventional designs. CI RCLE CUTTI NG G U I DE for cutting
Electrode measured circles.
The torch: intelligent design
Shield gas Plasma gas LEATH E R CABLE COV E RS for torch leads.
combines performance, durability,
comfort and safety AI R FI LTRATION KIT with a .85 micron
The Powermax1650 features Hypertherm’s filter and auto-drain filter bowl.
patented T100 safety trigger torch and H EAT SH I E LDprotects hands from
T100M mechanized torch, which produce excessive reflective heat.
outstanding cut performance, reliability and Coaxial-assist™
jet STATIONARY MOU NTI NG KIT
operator comfort. for fixed installation on
The longest consumable life in the industry, Workpiece table or floor.
and we’ll prove it. HyLife® electrodes last
longer than ordinary designs by using the Hypertherm’s ETR™ (Easy Torch Removal) Chemically cross-linked torch
same patented technologies developed for system allows for easy switching between cable jacket provides improved
advanced Hypertherm mechanized systems. hand and machine torches, while providing resistance to molten spray
Dual-threshold ™ pilot circuit significantly a radical integrated approach to strain relief and cut-through.
reduces nozzle wear by boosting pilot designed for durability. CSA/NRTL and CE
current precisely when needed. Hypertherm’s patented safety trigger certifications comply with
protects against accidental starts. Safety the highest safety standards.
Cutting arc interlocks deactivate the torch when the IP23CS compliance means
Output current (Amps)

consumable parts are removed, using a resistance to rain damage.

Boosted durable mechanical contact.
pilot arc The Powermax1650 is backed
No breakable ceramic parts. by Hypertherm’s full three-year
Pilot arc
Patented “blow-back” technology power supply warranty and
provides a pilot arc without excessive one-year torch warranty.
Start Workpiece Arc Stop
high-frequency interference. No parts excluded. Examine
sensed transfer
Consumables for gouging, extended-nozzle competitive policies closely.
cutting, pipe saddle cutting and other
Patented nozzle shield technology lets you
applications. Most consumables compatible
drag the torch on the workpiece at full
with existing G3 systems, resulting in
output, without damaging consumables, Relative cutting speed,
fewer stock parts.
and protects the nozzle from molten metal Powermax1650 vs. oxyfuel
spray and double arcing. Engineered for superior reliability 200
Postflow cooling reduces torch stress. The Powermax1650 is designed for heavy
Inches per minute

150
Powermax1650
use and very harsh conditions. Oxyfuel
100
Mechanical and electrical designs
50
are validated through aggressive,
accelerated testing. 0
.25" .5" .75" 1.00" 1.25" 1.5"
Fan-on-demand feature minimizes (6 mm) (12 mm) (19 mm) (25 mm) (32 mm) (38 mm)

dust ingestion. Thickness

 E
High-performance portable plasma cutting system
Powermax1650 Options
G3 Series standard Circle cutting guide – 027668 A: Cutting-current output
control, 30 – 100 amps
F
system components Leather cable covers – 024548
Power supply B: Gas test/set position A G
Air filtration kit – 128647 B
T100 or T100M torch C: Air pressure range, H
Extended work cable – 123655
Spare consumables gouging mode I
Hand heat shield – 128658
Work cable with clamp D: Air pressure
Stationary mounting kit – adjustment knob
15 feet (4.5 m) C
128788
E: Cutting mode selector switch J
Ordering information F: Pilot arc control mode
Systems part numbers
G: Normal cutting mode
With 25' With 50' With 75'
(7.5 m) torch (15 m) torch (23 m) torch H: Gouging mode D
200 – 600 V, 3-PH, CSA
Hand system 059275 059276 059301
I: Power on indicator
Machine system 059279 059280 059303 J: Air pressure range,
230 – 400 V, 3-PH, CE
Hand system 059288 059289 059302
cutting mode
Machine system 059290 059291 059304
Operating data
S IP23CS
Recommended capacity
Hand torch
1 1⁄4" (32 mm)
Machine torch
1
⁄ 2" (12 mm)
Specifications (where indicated)
Maximum capacity 11⁄2" (38 mm) 3
⁄4" (19 mm)
Input voltages 200 – 600 V, 3-PH, 50 – 60 Hz, CSA Severance capacity 1 3⁄4" (44 mm) –
230 – 400 V, 3-PH, 50 – 60 Hz, CE
Input current 200/208/230/240/400/480/600 V, 3-PH:
Maximum
@ 16 kW output 53/51/46/44/27/22/21 A Material Thickness Current travel speed*
Output voltage 160 VDC (inches) (mm) (amps) (ipm) (mm/min.)
Duty cycle @ 40˚ C 60% @ 200 – 208 V Mild steel 26 GA. 0.5 30 638 16205
(104˚ F) @ 100 amps 70% @ 230 – 240 V 10 GA. 3.4 40 151 3835
80% @ 400 – 600 V 1
⁄4 6.4 60 132 3353
1
Output for 100% duty 80 A @ 200 – 208 V ⁄2 12.7 100 88 2235
3
cycle @ 40˚ C (104˚ F) 85 A @ 230 – 240 V ⁄4 19.0 100 47 1194
90 A @ 400 – 600 V 1 25.4 100 28 711
Maximum OCV 300 VDC 1 1⁄4 31.8 100 19 482
1
Dimensions 26.4" (671 mm) D; 16.8" (427 mm) W; Aluminum ⁄32 0.8 30 610 15494
1
25.8" (655 mm) H ⁄8 3.2 40 204 5182
1
Weight with torch 128 lbs (58 kg) ⁄4 6.4 60 145 3683
1
Gas supply Clean, dry, oil-free air or nitrogen
⁄2 12.7 100 108 2743
3
⁄4 19.0 100 57 1448
Flow rate 550 scfh; 9.2 cfm (260 l/min) at 90 psi (6.2 bar) 1 25.4 100 33 838
Flow pressure 75 psi (5.1 bar) flowing, 25' leads Stainless 26 GA. 0.5 30 631 16027
80 psi (5.4 bar) flowing, 50' leads
steel 14 GA. 1.9 40 221 5613
1
⁄4 6.4 60 110 2794
Standard machine interface signals 1
⁄2 12.7 100 79 2007
3
Plasma start ⁄4 19.0 100 39 991
Transfer (start machine motion) 1 25.4 100 23 584
11⁄4 31.8 100 14 356
24 VDC (100 ma maximum)
* Maximum travel speeds are the results of Hypertherm’s laboratory testing.
Arc voltage (torch height control) – signal not available on rear panel connector For optimum cut performance, actual cutting speeds may vary based on
For more information, refer to your operator’s manual. different cutting applications. Refer to the operator’s manual for more details.

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.

Hypertherm, Inc. USA 603-643-3441 Tel 603-643-5352 Fax [email protected]

Hypertherm Automation, LLC USA 603-298-7970 Tel 603-298-7977 Fax [email protected]
Hypertherm Plasmatechnik, GmbH Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax
[email protected]
Hypertherm (S) Pte Ltd. Singapore 65 6 841 2489 Tel 65 6 841 2490 Fax
www.hypertherm.com [email protected]
Hypertherm (Shanghai) Consulting Co., Ltd. P.R. China 86 21 5835 5362 /3 Tel 86 21 5835 5220 Fax
[email protected]
Hypertherm Branch of Hypertherm UK, LLC England 00 800 3324 9737 Tel 00 800 4973 7329 Fax
[email protected]
France 00 800 3324 9737 Tél 00 800 4973 7329 Fax [email protected]
Hypertherm S.r.l. Italia 39 02 725 46 312 Tel 39 02 725 46 400 Fax [email protected]
Hypertherm Europe B.V. Nederland 31 165 596907 Tel 31 165 596901 Fax
[email protected]
Japan 81 0 559 75 7387 Tel 81 0 559 75 7376 Fax [email protected]
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