- 210 2824050-1
The Powermax85 SYNC is a high-capacity plasma cutting solution that combines SmartSYNC automation, extended cutting thickness, and cartridge-based consumables to reduce downtime, simplify operation, and maximize performance across cutting and gouging 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
Flush cutting
For cutting closer to base materials using a 45 degree
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
Precision gouging
For spot and tack weld removal at very low output current (<25 A)
Marking
For scoring, indicating part identification, hole or weld locations
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
| Cut capacity | Thickness | Cut speed |
|---|---|---|
| Recommended | 25 mm (1″) | 500 mm/min (20 ipm) |
| 32 mm (1-1/4″) | 250 mm/min (10 ipm) | |
| Severance (hand cutting) | 38 mm (1-1/2″) | 125 mm/min (5 ipm) |
| Pierce* | 20 mm (3/4″) |
*Pierce rating for handheld use or with automatic torch height control
| Gouge capacity | Metal removal rate | Groove profile |
|---|---|---|
| Typical gouge | 8,2 kg (18.2 lbs.) per hour | 3,5 mm D x 6,6 mm W (0.14″ D x 0.26″ W) |
Specifications – CE/CCC | |
|---|---|
Input voltages (± 10%) | 400 V, 3-PH, 50/60 Hz |
Input current @ 12.2 kW | 380/400 V, 3-PH, 20.5/19.5 A |
Output current | 25–85 A |
Rated output voltage | 143 VDC |
Duty cycle @ 40° C (104° F) | 60% @ 85 A, 380–400 V, 3-PH 100% @ 66 A, 380–400 V, 3-PH |
Open circuit voltage (OCV) | 270 VDC |
Weight with 7,6 m (25′) torch | 23.5 kg (52 lbs.) |
Dimensions with handles | 483 mm D; 233 mm W; 430 mm H (19″ D; 9.2″ W; 17″ H) |
|---|---|
Gas supply | Cutting: air (clean, dry, oil-free air), nitrogen |
Recommended inlet gas flow rate/pressure | 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) |
Input power cable length | 3 m (10′) |
Power supply type | Inverter–IGBT |
Engine drive requirement | 20 kW or 25 kVa for full 85 A output |
Electrical efficiency | 91.9% |
Recyclability | 100% |
Warranty | Power supply: 6-year, Torch: 1-year |
The Powermax85 SYNC® is a next-generation, professional-grade air plasma cutting system designed to simplify cutting and gouging operations while delivering high power and productivity. Engineered for recommended cutting up to 25 mm (1″), it incorporates advanced RFID-enabled SmartSYNC® torches and a revolutionary single-piece cartridge consumable with trackable utilization data.
Automatic system process set-up eliminates manual adjustments, reduces setup errors, and minimizes downtime. The Powermax85 SYNC supports a broad range of applications—including handheld and mechanized cutting, extended reach cutting and gouging, and flush cutting—making it a highly flexible solution for demanding industrial environments where productivity, cut quality, and consumable management are critical.
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′) |
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| 059733 |
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7,6 m (25′) | 059726 | 059723 | 059719 | 059734 | 059731 | 059729 |
10,7 m (35′) |
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| 059720 |
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15,2 m (50′) | 059727 | 059724 | 059721 | 059735 | 059732 | 059730 |
22,8 m (75′) | 059728 | 059725 | 059722 |
| 059767 | 059766 |
30 m (100′) | 059770 |
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| 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′) |
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7,6 m (25′) |
| 528114 |
| |
10,7 m (35′) |
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15,2 m (50′) | 528116 | 528117 | 528118 | 528119 |
22,8 m (75′) |
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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 |
85 A | 428935 |
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:
Hypertherm cartridges | |
Process | Cartridge |
85 A | 428934 |
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.
Hypertherm cartridges | |
Process | Cartridge |
Max removal gouging 45–85 A | 428932 |
Max control gouging 45–85 A | 428933 |
Hypertherm cartridges | |
Process | FlushCut™ |
| 85 A | 428953 |
| 65 A | 428952 |
Hypertherm cartridges | |
Process | HyAccess™ |
| Drag cutting 65 A | 428984 |
| Gouging 65 A | 428987 |
| Mechanized cutting 65 A | 528079 |
Powermax85 SYNC
