Hypertherm Powermax 45 Sync

Powermax 45 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.


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


BENEFITS

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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.

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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.

Standard configurations

Below are the standard system configurations, which include a power supply, torch and work cable.

CSA

75° hand torch

75° and 15° hand torch

180° full-length machine torch

180° full-length machine torch
and 75° hand torch

 

6.1 m (20′)

15.2 m (50′)

6.1 m (20′) and 7.6 m (25')

7.6 m (25′)

15.2 m (50')

7.6 m (25') and

6.1 m (20')

Powermax45 SYNC power supplies

 

 

Without remote pendant

Without remote pendant

With remote pendant

Without remote pendant

With
remote pendant

Standard power supply

088560

088561

088564

 

 

 

 

Power supply with CPC port and voltage divider

088562

088563

 

088580

088582

088581

088583

Power supply with CPC port, voltage divider and serial port

 

 

 

088584

 

 

 


Custom configurations

Select power supply, torch, work cable, cartridges, and other components

Power supply options

 

Standard power supply

Power supply with CPC port and voltage divider

Power supply with CPC port, voltage divider and serial port

Powermax45 SYNC 230V CSA
 

088570

088571

088572

Powermax45 SYNC 480V CSA

088573

 

 

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

 

 

 

 

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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.

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Industry-leading reliability

  • SmartSYNC torches are engineered for rugged, industrial environments.
  • SpringStartâ„¢ technology ensures consistent starting and a more reliable torch.
  • Industry-leading reliability reduces production downtime.


SPECIFICATIONS

Cut capacity

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.

Maximum removal gouging

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

Input voltages

CSA

200–440 V, 1-PH, 50/60 Hz

480 V, 3-PH, 50/60 Hz

480 V, 3-PH, 10 A @ 6.9kW

 

CE

230 V, 1-PH, 50/60 Hz

400 V, 3-PH, 50/60 Hz

Kilowatt output

6.9 kW

Input current

CSA

200-240 V, 1-PH 39/32 A @ 6.5 kW

 

CE

230 V, 1-PH, 33 A

400 V, 3-PH, 10 A

Output current

9–45 A

Rated output voltage

155 VDC

Duty cycle @ 104° F

CSA

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

 

CE

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)

CSA

275 VDC 200-240 V

275 VDC 480 V

 

CE

265 VDC 400 V

Dimensions with handles

442 mm D; 173 mm W; 357 mm H (17.4″ D; 6.8″ W; 14.1″ H)

Weight w/6.1 m (20′) torch

CSA

14 kg (31 lbs.)

 

CE

15 kg (33 lbs.)

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 @ 85 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%

Certifications

CSA - certified for use in the Americas and Asia, except China

CE - for use in Europe, Australia, New Zealand, Belarus, Kazakhstan, Serbia,
Ukraine, and other countries where accepted.
Also RCM, Ukraine, and Serbian. UKCA – Great Britain

Warranty

Power supplies have a 3-year warranty and torches a 1-year warranty


Mechanized and FineCut for machine 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

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:

DragCut cartridge with dimensions to factor when using cutting templates and guides

FineCut cartridge:

FineCut cartridge with dimensions to factor when using cutting templates and guides


Mechanized and FineCut for machine torches

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.


Max removal and max control gouging

Hypertherm cartridges

Process

Cartridge

Max removal gouging 45–85 A

428932

Max control gouging 45–85 A

428933