Powermax65 SYNC

Smarter control. More productive plasma cutting.

The Powermax65 SYNC is a high-performance plasma cutting solution that maximizes productivity through simplified operation, extended consumable life, and SmartSYNC automation. It supports cutting, gouging, and marking applications while reducing downtime, training requirements, and consumable inventory complexity.

Applications

Drag cutting
For dragging the torch directly across the work piece

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

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)

Flush cutting
For cutting closer to base materials using a 45 degree

Benefits

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.

Minimize operation costs

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.

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

Cut capacity	Thickness	Cut speed
Recommended	20 mm (3/4″)	500 mm/min (20 ipm)
	25 mm (1″)	250 mm/min (10 ipm)
Severance (hand cutting)	32 mm (1-1/4″)	125 mm/min (5 ipm)
Pierce*	16 mm (5/8″)

Pierce rating for handheld use or with automatic torch height control.

Gouge capacity	Metal removal rate	Groove profile
Typical gouge	4,0 kg (8.8 lbs.) per hour	2,9 mm D x 6,4 mm W (0.11″ D x 0.25″ W)

General specifications

Specifications – CE/CCC
Input voltages (± 10%)	380–400 V, 3-PH, 50/60 Hz
Input current @ 9 kW	380/400 V, 15.5/15 A
Output current	20–65 A
Rated output voltage	139 VDC
Duty cycle @ 40° C (104° F)	50% @ 65 A, 380–400 V, 3-PH 100% @ 46 A, 380–400 V, 3-PH
Open circuit voltage (OCV)	295 VDC 270 VDC
Weight with 7.6 m (25′) torch	24.1 kg (52.7 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	483 mm D; 233 mm W; 430 mm H (19″ D; 9.2″ W; 17″ H)
Gas supply	Clean, dry, oil-free air or nitrogen
Recommended inlet gas flow rate	Cutting: 210 I/min @ 5.9 bar (450 scfh, 7.5 scfm @ 85 psi) Gouging: 210 I/min @ 4.8 bar (450 scfh, 7.5 scfm @ 70 psi)
Electrical efficiency	91.2%
Recyclability	100%
Warranty	Power supply: 6-year Torch: 1-year

more about the
Powermax65 SYNC

The Powermax65 SYNC® is a next-generation, professional-grade air plasma cutting system engineered to simplify cutting and gouging operations while delivering high productivity and consistent performance. Designed for recommended cutting up to 20 mm (3/4″), it features Hypertherm’s advanced RFID-enabled SmartSYNC® torches and a revolutionary single-piece cartridge consumable.

The system automatically sets the correct amperage and operating mode, reducing setup time and eliminating operator error. With trackable consumable usage data, optimized cut quality, and reduced downtime during consumable change-outs, the Powermax65 SYNC is ideal for both handheld and mechanized cutting in demanding industrial environments.

Torches and consumables

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 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′)

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

Hypertherm cartridges
Process	Cartridge
65 A	428931
45 A	428927
FineCut^® hand cutting	428928

These cartridges have different dimensions as compared to traditional consumables which need to be factored when using cutting templates and guides. Drag cartridge:

Mechanized and FineCut for machine torches

Hypertherm cartridges
Process	Cartridge
65 A	428930
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.