The Powermax45 SYNC is a high-return plasma cutting solution offering simplified operation, extended consumable life, and flexible cutting, gouging, and marking capabilities. Its SmartSYNC technology and cartridge-based consumables maximize productivity while reducing training time, setup errors, and operating costs.
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
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
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
| 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) |
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 |
The Powermax45 SYNC is a versatile, professional plasma cutting system designed for metalworkers who require a single solution for cutting, gouging, and marking across a wide range of applications. Featuring Hypertherm’s patented single-piece cartridge consumable system, the Powermax45 SYNC simplifies operation, reduces downtime, and delivers up to five times longer consumable life compared to traditional multi-part consumables.
Equipped with RFID-enabled SmartSYNC™ torches, the system automatically sets the correct amperage and operating mode, eliminating setup errors and improving consistency. Suitable for both handheld and mechanized cutting, the Powermax45 SYNC provides excellent cut quality, reliable starts, and strong performance in demanding industrial environments.
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 torches | Machine torches | 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′) | ||||
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.
Hypertherm cartridges | |
| Process | Cartridge |
| 45 A | 428927 |
| FineCut® hand cutting | 428928 |
Hypertherm cartridges | |
| Process | Cartridge |
| 45 A | 428925 |
| FineCut® mechanized cutting | 428926 |
| Ohmic ring kit | 428895 (contains 3 #420580 ohmic rings) |
Mechanized cartridges can be used on hand torches if a stand-off is desired.
Hypertherm cartridges | |
Process | Cartridge |
Max removal gouging 45–85 A | 428932 |
Max control gouging 45–85 A | 428933 |
Powermax45 SYNC
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