Powermax45 SYNC plasma cutter
For metal workers who want the most versatile system available to gouge, cut, and mark, Powermax45 SYNC delivers the best return on investment with a patented single-piece cartridge, up to 5x longer consumable life, and greater cutting power than higher-amperage competitors.
System information
Applications
Drag cutting
For dragging the torch directly across the work piece
Fine feature cutting
For narrow kerf width with minimal dross and heat affected zone
Max control gouging
For precise metal removal, shallower gouge profiles and light metal washing
Max removal gouging
For aggressive metal removal, deep gouge profiles, and extreme metal washing
Mechanized cutting
For portable automation and table cutting
Marking
For scoring, indicating part identification, hole or weld locations
Unsupported applications
Precision gouging
For spot and tack weld removal at very low output current (<25 A)
Extended reach cutting
For improved visibility and accessibility when cutting in confined spaces
Extended reach gouging
For improved visibility and accessibility when gouging in confined spaces
Flush cutting
For cutting closer to base materials using a 45 degree
Benefits
Simplify operations and boost productivity
- Simplified system operation minimizes the time and costs spent on training and troubleshooting.
- Reductions to downtime during consumable change-outs and elimination of costs associated with premature disposal of consumable parts.
- Cartridge usage data provides valuable insights for improving cutting operations and consumable inventory management.
Easy to use
- Cartridges are easy to identify by process with clear laser marking and color coding to eliminate part mix-ups.
- RFID-enabled SmartSYNC torches and cartridges automatically set the correct amperage and operating mode, eliminating setup errors.
- End-of-life consumable detection eliminates the uncertainty of knowing when to change the cartridge.
- Less operator fatigue when using hand torches with our new flexible lead. The lead has the same robustness of our previous lead jacket material and will also be used on robotic torches.
Maximize performance
- Tackle a wide range of jobs with easily interchangeable torch styles and application specific cartridges for various types of cutting and gouging.
- Optimized cartridge consumable design provides up to twice the life for handheld cutting and improved quality over life in mechanized setups compared to standard consumables.
- Time-saving hand torch controls allow the operator to adjust the amperage on the fly, change cartridges and applications without returning to the power supply.
Industry-leading reliability
- SmartSYNC torches are engineered for rugged, industrial environments.
- SpringStart™ technology ensures consistent starting and a more reliable torch.
- Industry-leading reliability reduces production downtime.
Specifications
Cut and gouge capacities
| Capacity | Thickness | Cut speed |
|---|---|---|
| Recommended | 16 mm (5/8″) | 500 mm/min (20 ipm) |
| Severance (hand cutting) | 29 mm (1-1/8″) | 125 mm/min (5 ipm) |
| Pierce* | 12 mm (1/2″) |
*Pierce rating for handheld use or with automatic torch height control.
| Gouge capacity | Metal removal rate | Groove profile |
|---|---|---|
| Typical gouge | 3.4 kg (7.5 lbs.) per hour | 3,2 mm D x 6,8 mm W (0.12″ D x 0.26″ W) |
General specifications
Specifications - CSA |
|
|---|---|
|
Input voltages (± 10%) |
200–240 V, 1-PH, 50/60 Hz 480 V, 3-PH, 50/60 Hz |
|
Input current @ 6.9 kW |
200–240 V, 1-PH 39/32 A 480 V, 3-PH 10 A |
|
Output current |
9–45 A |
|
Rated output voltage |
155 VDC |
|
Duty cycle @ 40° C (104° F) |
50% @ 45 A, 200–240 V, 1-PH 60% @ 41 A, 200–240 V, 1-PH 100% @ 32 A, 200–240 V, 1-PH 50% @ 45 A, 480 V, 3-PH 60% @ 41 A, 480 V, 3-PH 100% @ 32 A, 480 V, 3-PH |
|
Open circuit voltage (OCV) |
275 VDC 200–240 V 375 VDC 480 V |
|
Weight with 6.1 m (20′) torch |
14 kg (31 lbs.) |
CSA – for use in the Americas and Asia, except China
Specifications - CE/CCC |
|
|---|---|
|
Input voltages (± 10%) |
230 V, 1-PH, 50/60 Hz 400 V, 3-PH, 50/60 Hz |
|
Input current @ 6.9 kW |
230 V, 1-PH, 33 A 400 V, 3-PH, 10 A |
|
Output current |
9–45 A |
|
Rated output voltage |
155 VDC |
|
Duty cycle @ 40° C (104° F) |
50% @ 45 A, 230 V, 1-PH 60% @ 41 A, 230 V, 1-PH 100% @ 32 A, 230 V, 1-PH 50% @ 45 A, 400 V, 3-PH 60% @ 41 A, 400 V, 3-PH 100% @ 32 A, 400 V, 3-PH
|
|
Open circuit voltage (OCV) |
275 VDC 200-240 V 265 VDC 400 V |
|
Weight with 6.1 m (20′) torch |
15 kg (33 lbs.) |
CE – for use in Europe, Australia & New Zealand - RCM, Serbia, UK – UKCA, Ukraine, and other countries where accepted. CCC – for use in China.
|
Dimensions with handles |
442 mm D; 173 mm W; 357 mm H (17.4″ D; 6.8″ W; 14.1″ H) |
|---|---|
|
Gas supply |
Cutting: air (clean, dry, and oil-free), nitrogen, F5 Gouging: air (clean, dry, and oil-free), nitrogen, F5 Marking: air (clean, dry, and oil-free) |
|
Recommended gas inlet flow rate/pressure |
188 I/min @ 5.9 bar (400 scfh 6.7 scfm @ 90 psi) |
|
Input power cable length |
3 m (10′) |
|
Power supply type |
Inverter – IGBT |
|
Engine drive requirement |
12.5 kVA (10 kW) for full 45 A output |
|
Electrical efficiency |
90% |
|
Recyclability |
100% |
|
Warranty |
Power supply: 6-year, Torch: 1-year |
Buying information
ORDERING INFORMATION - CSA (For use in the Americas and Asia, except China)
Below are the standard system configurations, which include a power supply, torch or torches, work cable, 1-2 cartridges, and product information.
|
75° hand torch |
75° and 15° |
|
180° full-length |
180° full-length machine torch |
||||
|---|---|---|---|---|---|---|---|---|
|
Torch lead length |
6,1 m |
15,2 m |
6,1 m (20′) and |
|
7,6 m |
15,2 m |
7,6 m (25') and |
|
|
X = With remote pendant |
|
|
|
|
X |
X |
||
|
Powermax65 SYNC power supplies |
Handheld |
Mechanized | ||||||
|
200-240 V CSA standard power supply |
088560 |
088561 |
088564 |
|
|
|
|
|
|
200-240 V CSA power supply with CPC port and voltage divider |
088562 |
088563 |
|
|
088580 |
088582 |
088581 |
088583 |
|
200-240 V CSA power supply with CPC port, voltage divider, and serial port |
|
|
|
|
088584 |
088588 |
|
|
CUSTOM CONFIGURATIONS - CSA
Select power supply, torch, work cable, cartridge, and other components.
|
Power supply option |
Standard |
With CPC port and voltage divider |
With CPC port, voltage divider and serial port |
|---|---|---|---|
| Powermax45 SYNC 230 V CSA |
088570 |
088571 |
088572 |
| Powermax45 SYNC 480 V CSA |
088573 |
|
|
ORDERING INFORMATION - CE/CCC
(CE - For use in Europe, Australia & New Zealand - RCM, Serbia, UK - UKCA, Ukraine, and other countries where accepted. CCC - for use in China.)
Below are the standard system configurations, which include a power supply, torch or torches, work cable, 1-2 cartridges, and product information.
|
75° hand torch |
75° and 15° |
|
180° full-length |
180° full-length machine torch |
||||
|---|---|---|---|---|---|---|---|---|
|
Torch lead length |
6,1 m |
15,2 m |
6,1 m (20′) |
|
7,6 m |
15,2 m |
7,6 m (25') |
|
|
X = With remote pendant |
|
|
|
|
X |
|
X |
|
|
Powermax45 SYNC power supplies |
Handheld |
Mechanized | ||||||
|
400 V CE/CCC standard power supply |
088565 |
088566 |
|
|
|
|
|
|
|
400 V CE/CCC power supply with CPC port and voltage divider |
088567 |
|
|
088585 |
|
088586 |
||
|
230 V CE/CCC standard power supply |
088568 |
|
|
|
|
|
||
|
230 V CE/CCC power supply with CPC port and voltage divider |
088569 |
|
|
|
088587 |
|
|
|
CUSTOM CONFIGURATIONS - CE/CCC
Select power supply, torch, work cable, cartridge, and other components.
|
Power supply option |
Standard |
With CPC port and voltage divider |
With CPC port, voltage divider and serial port |
|---|---|---|---|
| Powermax45 SYNC 400 V CE/CCC |
088574 |
088575 |
088576 |
| Powermax45 SYNC 230 V CE/CCC |
088577 |
088578 |
088579 |
~ AVAILABLE FOR ALL SYSTEMS ~
Torch options
View the Torches and Consumables section below for torch and cartridge options.
Cable options
|
|
Work cables |
Control cables |
||||
|---|---|---|---|---|---|---|
|
Cable length |
Hand clamp |
Remote pendant |
CNC, spade connector, divided voltage |
CNC, spade connector, no divided voltage |
RS-485 Serial comm, unterminated |
RS-485 Serial comm, D-sub |
|
7.6 m (25') |
223595 |
128650 |
228350 |
023206 |
223236 |
223239 |
|
15.2 m (50') |
223596 |
128651 |
228351 |
023279 |
223237 |
223240 |
|
22.8 m (75') |
223127 |
128652 |
|
|
|
|
Resources
Manuals and documents
1_Powermax45 SYNC Product Brochure A4 EURO English
Last updated
10/07/2025
SmartSYNC torches
SmartSYNC torches feature RFID capability that when coupled with a Hypertherm cartridge will communicate with a Powermax SYNC system to automatically set the amperage and process on the power supply. Available in handheld, mechanized and robotic torch configurations.
|
|
Hand |
Machine |
Robotic/Mini |
|||
|---|---|---|---|---|---|---|
|
|
75° |
15° |
180° |
180° |
90° |
45° |
|
4.5 m (15′)​ |
|
|
|
059733 |
|
|
|
7.6 m (25') |
059726 |
059723 |
059719 |
059734 |
059731 |
059729 |
|
10.7 m (35') |
|
|
059720 |
|
|
|
|
15.2 m (50') |
059727 |
059724 |
059721 |
059735 |
059732 |
059730 |
|
22.8 m (75') |
059728 |
059725 |
059722 |
|
059767 |
059766 |
|
|
Long torches |
|||
|---|---|---|---|---|
|
|
0.6 m (2′), 45° |
0.6 m (2′), 90° |
1.2 m (4′), 45° |
1.2 m (4′), 90° |
|
4.5 m (15′)​ |
|
|
|
|
|
7.6 m (25') |
|
528114 |
|
|
|
10.7 m (35') |
|
|
|
|
|
15.2 m (50') |
528116 |
528117 |
528118 |
528119 |
|
22.8 m (75') |
||||
Hypertherm cartridges
The Hypertherm cartridge consumable platform is a revolutionary change to standard air plasma consumables. Each single-piece cartridge is optimized by process and amperage to ensure performance while dramatically simplifying the parts needed to cut or gouge with plasma.
Hypertherm cartridges for Powermax systems are manufactured to uphold our high standards for quality and reliability. As part of the manufacturing process, we test-fire each cartridge to ensure proper assembly and function. As a result, there may be burn marks on the tip of the cartridge. This is normal and not a sign of damage.
Drag cutting and FineCut for hand torches
Mechanized and FineCut for machine torches
Related products
Powermax65 SYNC plasma cutter
Professional-grade 20 mm (3/4″) plasma cutter provides automated process set-up and a revolutionary cartridge consumable platform for ease of use and optimized performance. Featuring a wide variety of torches and application capabilities for handheld and mechanized cutting and gouging.
Read more
Powermax85 SYNC plasma cutter
Professional-grade 25 mm (1″) plasma cutter provides automated process set-up and a revolutionary cartridge consumable platform for ease of use and optimized performance. Featuring a wide variety of torches and application capabilities for handheld and mechanized cutting and gouging.
Read more
Powermax105 SYNC plasma cutter
Professional-grade 32 mm (1-1/4″) plasma cutter provides automated process set-up and a revolutionary cartridge consumable platform for ease of use and optimized performance.
Read more
Robotic torch clamp kit
The robotic torch clamp kit is designed to simplify integration of Powermax® robotic torches on robots. The clamp fits perfectly with the torch dimensions and securely holds the torch during cutting applications.
Read more
Hypertherm cartridge reader
The Hypertherm cartridge reader provides a simple process for reviewing data stored in Hypertherm cartridges. Data analysis helps customers understand cartridge utilization and identify operator training opportunities.
Read more
Cartridge ohmic ring: #428895
The ohmic contact ring clips onto the mechanized cartridge, and connects it via electrical wire to torch height controls (THCs) that support the use of ohmic contact to find the surface of the workpiece before each cut.
Read more
SmartSYNC torches
With simple, twist-on consumable installation, and convenient power and amperage adjustment controls on handheld models, SmartSYNC® torches for Hypertherm’s Powermax45/65/85/105 SYNC® plasma systems, and Powermax45® XP with adapter, allow the operator to change consumables and applications without returning to the power supply.
Read more