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Powermax105 SYNC plasma cutter

The Powermax105 SYNC^® is a next-generation, professional-grade air plasma cutter that dramatically simplifies system operation for gouging and recommended cutting up to 32 mm (1-1/4″). Features automated system process set-up via advanced RFID-enabled SmartSYNC^® torches, and a revolutionary single-piece cartridge consumable that provides trackable utilization data. The Powermax105 SYNC maximizes productivity through reductions in downtime, optimized cut quality performance, and streamlined consumable inventory management.

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Where to buy

System information

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

Unsupported applications

Marking

For scoring, indicating part identification, hole or weld locations

Try Powermax45 XP

Precision gouging

For spot and tack weld removal at very low output current (<25 A)

Try Powermax45 XP

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 capacity

Capacity	Thickness	Cut speed
Recommended	32 mm (1-1/4″)	500 mm/min (20 ipm)
	38 mm (1-1/2″)	250 mm/min (10 ipm)
Severance (hand cutting)	50 mm (2″)	125 mm/min (5 ipm)
Pierce*	22 mm (7/8″)

*Pierce rating for handheld cutting, or mechanized cutting with programmable torch height control.

Maximum removal gouging

Capacity	Metal removal rate	Gouge profile
Typical gouge	8,6 kg (19.1 lbs.) per hour	6,6 mm D x 6,0 mm W (0.26″ D x 0.24″ W)

General specifications

Input voltages	CSA 200–600 V, 3-PH, 50/60 Hz CE/CCC 200–600 V, 3-PH, 50/60 Hz 380–400 V, 3-PH, 50/60 Hz
Kilowatt output	16.8 kW
Input current	CSA 200/208/240/480/600 V, 3-PH 58/56/49/25/22 A @ 16.8 kW CE/CCC 230/400 V, 3-PH 50/29 A @ 16.8 kW 380/400 V, 3-PH 30/28 A @ 16.8 kW
Output current	30–105 A
Rated output voltage	160 VDC
Duty cycle @ 104° F	CSA 70% @ 105 A, 240 V, 3-PH 80% @ 105 A, 480–600 V, 3-PH 100% @ 94 A, 480–600 V, 3-PH 100% @ 88 A, 240 V, 3-PH CE/CCC 80% @ 105 A, 400 V, 3-PH 100% @ 94 A, 400 V, 3-PH 100% @ 88 A, 230 V, 3-PH
Open circuit voltage (OCV)	CSA – 300 VDC CE/CCC – 288 VDC
Dimensions with handles	592 mm D; 274 mm W; 508 mm H (23.3″ D; 10.8″ W; 20.0″ H)
Weight w/7,6 m (25′) torch	CSA 45.3 kg (95 lbs.) CE/CCC 230–400 V, 42.7 kg (94 lbs.) 400 V, 39.4 kg (87 lbs.)
Gas supply	Clean, dry, oil-free air or nitrogen
Optimum inlet gas pressure	7.6–8.3 bar (110–120 psi)
Minimum inlet gas pressure	5.5 bar (80 psi)
Recommended inlet gas flow rate	Cutting: 260 I/min @ 5.9 bar (550 scfh, 9.2 scfm @ 90 psi) Gouging: 260 I/min @ 4.8 bar (550 scfh, 9.2 scfm @ 70 psi)
Input power cable length	3 m (10′)
Power supply type	Inverter–IGBT
Engine drive requirement	30 kW for full 105 A output
Electrical efficiency	91%
Certifications	CSA – for use in the Americas and Asia, except China CE – for use in Europe, Australia & New Zealand - RCM, Serbia, UK - UKCA, Ukraine, and other countries where accepted. CCC – for use in China
Warranty	Power supplies have a 3-year warranty and torches a 1-year warranty

Buying information

Visit our where to buy page to find a potential partner, or contact Hypertherm directly if you need further assistance.

Standard configurations

CE/CCC	75° hand torch		75° and 15° hand torch	180° full-length machine torch					180° full-length machine torch and 75° hand torch
Torch lead length	7,6 m (25′)	15,2 m (50′)	7,6 m (25′)	7,6 m (25′)		10,7 m (35′)	15,2 m (50′)		10,7 m/7,6 m (35′/25′)
Powermax105 SYNC power supplies			Without remote pendant	With remote pendant	Without remote pendant	Without remote pendant	With remote pendant	Without remote pendant	With remote pendant
Standard power supply 400 V	059690	059691	059692
Standard power supply 230-400 V	059679	059680
Power supply with CPC port and voltage divider 400 V				059694	059693		059695	059681
Power supply with CPC port and voltage divider 230-400 V					059682			059683
Power supply with CPC port, voltage divider and serial port 400 V					059697	059765		059698
Power supply with CPC port, voltage divider and serial port 230-400 V					059712	059764

CSA	75° hand torch		75° and 15° hand torch	180° full-length machine torch					180° full-length machine torch and 75° hand torch
Torch lead length	7,6 m (25′)	15,2 m (50′)	7,6 m (25′)	7,6 m (25′)		10,7 m (35′)	15,2 m (50′)		10,7 m/7,6 m (35′/25′)
Powermax105 SYNC power supplies			Without remote pendant	With remote pendant	Without remote pendant	Without remote pendant	With remote pendant	Without remote pendant	With remote pendant
Standard power supply	059625	059626	059634
Power supply with CPC port and voltage divider	059627	059628		059636	059637		059639	059638	059687
Power supply with CPC port, voltage divider and serial port					059684	059762*		059763*

* Ring terminated worklead

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
Powermax105 SYNC 380-400 V CE/CCC	059708	059709	059710
Powermax105 SYNC 230-400 V CE	059701	059702	059703
Powermax105 SYNC 200-600 V CSA	059704	059705	059706

Torch options

View the Torches and consumables section below for torch and cartridge options.

Cable options

Control cables
Cable length	Remote pendant	CNC, spade connector, divided voltage	CNC, spade connector, no divided voltage	CNC, D-sub connector, divided voltage	RS-485 Serial comm, unterminated	RS-485 Serial comm, D-sub
7,6 m (25′)	128650	228350	023206	223048	223236	223239
15,2 m (50′)	128651	228351	023279	123896	223237	223240
22,8 m (75′)	128652

Work cables
Cable length	Hand clamp	C-style clamp	Ring terminal
7,6 m (25′)	223254	223287	223284
15,2 m (50′)	223255	223288	223285
22.8 m (75′)	223256	223289	223286

Resources

Manuals and documents

View all

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
105 A	428937
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:

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
105 A	428936
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.

Max removal and max control gouging

Hypertherm cartridges
Process	Cartridge
Max removal gouging 105 A	428938
Max removal gouging 45–85 A	428932
Max control gouging 105 A	428939
Max control gouging 45–85 A	428933

FlushCut options

Hypertherm cartridges
Process	FlushCut™
105 A	428954
85 A	428953
65 A	428952

HyAccess options

Hypertherm cartridges
Process	HyAccess™
Drag cutting 65 A	428984
Gouging 65 A	428987
Mechanized cutting 65 A	528079

How customers are using our solutions

Our operation became much faster and cheaper after we acquired the Powermax SYNC, as in addition to being able to work with a single cartridge for many hours, we can also get information about the cuts we have made to further optimize our processes.”

Aço e Ferro

Scrapyard

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Powermax

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Powermax85 SYNC plasma cutter

Powermax

Professional-grade 25 mm (1″) plasma cutter provides automated process set-up and a revolutionary cartridge consumable platform for ease of use and optimized performance. Featuring a wide variety of torches and application capabilities for handheld and mechanized cutting and gouging.

Robotic torch clamp kit

Accessories

The robotic torch clamp kit is designed to simplify integration of Powermax^® robotic torches on robots. The clamp fits perfectly with the torch dimensions and securely holds the torch during cutting applications.

Powermax EtherCAT Interface for EDGE Connect

Accessories

The Powermax^® EtherCAT^® Interface is an all-in-one adapter that allows a digital connection between the Powermax equipment and the EDGE^® Connect CNC. This allows faster equipment setup, an intuitive operator interface, and access to real-time diagnostics information.

Hypertherm cartridge reader

Accessories

The Hypertherm cartridge reader provides a simple process for reviewing data stored in Hypertherm cartridges. Data analysis helps customers understand cartridge utilization and identify operator training opportunities.

ProNest 2025

ProNest

ProNest^® CAD/CAM part nesting software for advanced mechanized cutting is designed to supercharge your cutting operation, helping you achieve greater automation, efficiency, and profitability.

ProNest 2025 LT

ProNest

ProNest^® LT is a material nesting software designed for light industrial, mechanized plasma, waterjet, and oxyfuel cutting in production environments.

Design2Fab 6

Design2Fab

Design2Fab^® sheet metal layout software is Hypertherm’s HVAC program for the design and layout of specialty fittings for ductwork and other mechanical applications.

SmartSYNC torches

Powermax

With simple, twist-on consumable installation, and convenient power and amperage adjustment controls on handheld models, SmartSYNC^® torches for Hypertherm’s new Powermax65/85/105 SYNC^® plasma systems allow the operator to change consumables and applications without returning to the power supply.

How can we help you?

Request a quote

Contact sales

Product support

Powermax105 SYNC plasma cutter

System information

Applications

Drag cutting

Mechanized cutting

Unsupported applications

Benefits

Specifications

Cut capacity

Maximum removal gouging

General specifications

Buying information

Standard configurations

Custom configurations

Power supply options

Torch options

Cable options

Resources

Manuals and documents

Torches and consumables

SmartSYNC torches

Hypertherm Cartridges

Drag cutting and FineCut for hand torches

Mechanized and FineCut for machine torches

Max removal and max control gouging

FlushCut options

HyAccess options

How customers are using our solutions

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Accessories

Software

Torches

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