Robotic plasma cutter Powermax65 SYNC®

automatedfor metalhigh-precision

Overview
The Powermax65 SYNC® is a next-generation professional grade air plasma cutter that simplifies system operation for gouging and cutting (recommended up to 20 mm / 3/4"). Features include automated system process set-up via RFID-enabled SmartSYNC® torches and a single-piece cartridge consumable that provides trackable utilization data. The system is designed to maximize productivity by reducing downtime, optimizing cut quality, and streamlining consumable inventory management.

Applications

• Drag cutting — for dragging the torch directly across the work piece
• Extended reach cutting — improved visibility and accessibility when cutting in confined spaces
• Extended reach gouging — improved visibility and accessibility when gouging in confined spaces
• Fine feature cutting — narrow kerf width with minimal dross and heat affected zone
• Flush cutting — for cutting closer to base materials using a 45° approach
• Max control gouging — precise metal removal, shallower gouge profiles, light metal washing
• Max removal gouging — aggressive metal removal, deep gouge profiles, extreme metal washing
• Mechanized cutting — for portable automation and table cutting

Benefits

• Easy to use
  • Cartridges are easy to identify by process with clear laser marking and color coding to reduce part mix-ups
  • RFID-enabled SmartSYNC torches and cartridges automatically set correct amperage and operating mode to eliminate setup errors
  • End-of-life consumable detection removes uncertainty about when to change the cartridge
  • Flexible torch lead reduces operator fatigue for handheld use
• Minimize operation costs
  • Simplified operation reduces time and cost for training and troubleshooting
  • Reduced downtime during consumable change-outs and reduced costs from premature disposal of parts
  • Cartridge usage data supports improved cutting operations and consumable inventory management
• Maximize performance
  • Easily interchangeable torch styles and application-specific cartridges for various cutting and gouging tasks
  • Optimized cartridge design provides up to twice the life for handheld cutting and improved quality in mechanized setups
  • Hand torch controls enable amperage adjustment, cartridge and application changes 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
  • Overall design reduces production downtime

Torches and consumables
SmartSYNC torches feature RFID capability that, when coupled with a Hypertherm cartridge, communicates with the Powermax SYNC system to automatically set amperage and process. Available in handheld, mechanized and robotic configurations.

Hypertherm cartridges (selected examples and part numbers)

• Drag cutting / FineCut (hand torches): 65 A — 428931; 45 A — 428927; FineCut hand cutting — 428928
• Mechanized and FineCut (machine torches): 65 A — 428930; 45 A — 428925; FineCut mechanized cutting — 428926; Ohmic ring kit — 428895 (contains 3 #420580 ohmic rings)
• Max removal / Max control gouging: Max removal gouging 45–85 A — 428932; Max control gouging 45–85 A — 428933
• FlushCut options: FlushCut 65 A — 428952
• HyAccess cartridges (examples): Drag cutting 65 A — 428984; Gouging 65 A — 428987; Mechanized cutting 65 A — 528079

Cut and gouge capacities (from cut charts)
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 (selected)
Specifications - CSA (for the Americas and Asia, except China):
Input voltages (±10%): 200–480 V, 1-PH, 50/60 Hz; 200–600 V, 3-PH, 50/60 Hz
Input current @ 9 kW: 200/208/240/480 V, 1-PH 52/50/44/22 A; 200/208/240/480/600 V, 3-PH 32/31/27/13/13 A
Output current: 20–65 A
Rated output voltage: 139 VDC
Duty cycle @ 40° C (104° F): 50% @ 65 A, 230–600 V, 1/3-PH; 40% @ 65 A, 200–208 V, 1/3-PH; 100% @ 46 A, 230–600 V, 1/3-PH
Open circuit voltage (OCV): 295 VDC
Weight with 7.6 m (25') torch: 27.8 kg (61.7 lbs.)

Specifications - CE/CCC (for Europe, Australia & NZ, China where applicable):
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 (also listed 270 VDC in CE/CCC table)
Weight with 7.6 m (25') torch: 24.1 kg (52.7 lbs.)

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 l/min @ 5.9 bar (450 scfh, 7.5 scfm @ 85 psi); Gouging: 210 l/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

Notes
- Single-piece Hypertherm cartridges are optimized by process and amperage; dimensions differ from traditional consumables and should be considered when using templates and guides.
- Mechanized cartridges can be used on hand torches if a stand-off is desired.

Caractéristiques / spécifications techniques

• Model: Powermax65 SYNC®
• Brand: Hypertherm
• Recommended cut: up to 20 mm (3/4") at 500 mm/min (20 ipm)
• Maximum severance (hand): 32 mm (1-1/4")
• Pierce rating (handheld or with THC): 16 mm (5/8")
• Gouge metal removal rate: ~4.0 kg/hr; groove profile ~2.9 mm D x 6.4 mm W
• Input voltages (CSA): 200–480 V 1-PH; 200–600 V 3-PH
• Output current range: 20–65 A
• Rated output voltage: 139 VDC
• Duty cycle examples: 50% @ 65 A (230–600 V); 100% @ 46 A (230–600 V)
• Open circuit voltage: 295 VDC
• Weight (with 7.6 m torch): 27.8 kg (CSA) / 24.1 kg (CE/CCC)
• Dimensions (with handles): 483 mm D x 233 mm W x 430 mm H
• Gas: clean, dry, oil-free air or nitrogen; recommended inlet flow ~210 l/min @ ~5–5.9 bar for cutting/gouging
• Electrical efficiency: 91.2%
• Recyclability: 100%
• Warranty: power supply 6 years; torch 1 year
• Consumable platform: single-piece Hypertherm cartridges (multiple process-specific cartridges available, including FineCut, FlushCut, HyAccess, Max removal/control and mechanized variants)