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Hypertherm Powermax85 SYNC

Name: Hypertherm Powermax85 SYNC
Brand: SWP Ltd
SKU: HYP-087196
Price: 4200.00 GBP
Availability: InStock

£4,200.00

Shipping calculated at checkout.

The Hypertherm Powermax85 SYNC is a professional 85 A air plasma system for heavy-duty cutting and gouging in demanding workshop environments.

Key Features

Hypertherm Powermax85 SYNC air plasma
Recommended cutting up to 25 mm
Single-piece SYNC cartridge system
RFID SmartSYNC torch communication
Handheld, mechanised and robotic use
Engineered for rugged industrial workshops

Everything we sell is supported by our factory trained engineers at our premesis in Manchester or nationwide through our mobile service engineers.

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Supply

380-400v

Warranty

6 years

Free Delivery

UK mainland delivery

Service

In-house engineers

Support

0161 223 1843

Expert Advice

Paul Jones says

This is a high-output air plasma cutter for cutting and gouging steel up to about 25 mm in a workshop setting. In a bodyshop or fabrication bay, I’d typically see a Powermax85 SYNC used for chassis work, bracketry, jig fabrication and general plate cutting where oxy-fuel would be slower or too crude.

In day-to-day use, the key is matching the SmartSYNC torch cartridge to the job – standard mechanised/stand-off for general cutting, fine feature cartridges for detail work, and gouging cartridges when you’re removing welds or repairing previous work. Air supply quality matters: clean, dry air (or nitrogen where specified) makes a big difference to cut edge, consumable life and reliability.

A common issue I see is operators running worn cartridges too long or using the wrong type, which gives poor edge quality and excessive dross, then they blame the machine rather than the setup. The SYNC end-of-life indication helps, but habits still matter.

Set up correctly, with suitable cartridges and a decent air supply, this system is a reliable, efficient plasma solution for professional workshop use.

Paul Jones, Technical Director

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Technical Datasheet

Download the official manufacturer datasheet for Hypertherm Powermax85 SYNC including specifications, compatibility information and technical details.

Download Hypertherm Powermax85 SYNC Datasheet

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Our team of welding experts at BWS is ready to assist you every step of the way. Whether you have questions about specific products, need guidance on selecting the right equipment, or seek welding-related advice, our knowledgeable staff is here to help.

We also have some of the most experienced engineers in the industry who are able to offer full technical support on top of what the manufacturers offer.

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Technical Features

Next‑generation professional 85 A air plasma system for hand, mechanised and robotic cutting and gouging with a recommended cut capacity of 25 mm and severance up to 38 mm, suitable for heavy bodyshop and fabrication work.
Automated process setup via RFID‑enabled SmartSYNC torches that communicate with the power source and cartridge to automatically set amperage and operating mode, reducing setup errors and operator training time.
Patented single‑piece, colour‑coded cartridge consumables for different processes (drag cutting, mechanised cutting, gouging, FineCut, FlushCut, HyAccess) that simplify consumable selection, minimise parts mix‑up and streamline inventory.
Cartridge end‑of‑life detection and built‑in usage data tracking, allowing operators or workshop managers to monitor consumable performance and change cartridges at the right time to maintain cut quality.
On‑torch controls for adjusting amperage on the fly and changing cartridges or process without returning to the power supply, speeding up job changeovers at the bench or on the jig.
Supports a wide range of cutting and gouging applications including drag cutting, mechanised/standoff cutting, fine feature cutting, max removal gouging, max control gouging, extended‑reach cutting and flush cutting, giving one system for most workshop plasma tasks.
High torch output of 12.2 kW at 85 A with efficiently designed consumables that deliver fast cutting speeds and cleaner edges, reducing secondary grinding and dressing.
Multiple torch configurations available – 75° and 15° hand torches, long hand torches, 180° mechanised machine torches and robotic torches – to suit handheld use, CNC tables, track burners and robot cells.
Compatible with CPC port, voltage divider and optional serial communication on certain power supply variants, enabling reliable integration with CNC and robotic systems for remote start, arc OK, height control and process parameter control.
Auto‑Voltage capability on appropriate models to accept 200–600 V single‑ or three‑phase input without manual linking, useful for mixed‑supply workshops and mobile plant with generators.
Robust inverter‑type IGBT power supply with high electrical efficiency (~92%) designed for continuous industrial duty cycles, supporting sustained cutting and gouging in busy bodyshops and fabrication shops.
Engine‑drive friendly, with specified generator size around 20 kW / 25 kVA for full 85 A output, suitable for mobile repair units and on‑site structural work.
Designed for demanding environments, with power supplies and SmartSYNC torches engineered for rugged industrial use and tested to operate reliably under workshop conditions.
Time‑saving consumable and process identification via laser‑marked, colour‑coded cartridges that make it easy for operators to pick the correct setup for the job, even across multiple bays.
Supports mechanised pierce up to 20 mm with correct torch height control, making it suitable for CNC plate work and bracket production where pierce quality matters.
Compact footprint with integrated handles and relatively low unit weight, making it practical to relocate around the workshop or between bays when required.
Full range of genuine Hypertherm cartridges and accessory kits (ohmic ring kits, HyAccess and FlushCut options) available to tailor the system for fine detail work, access into tight areas, and aggressive gouging for weld removal or crack chasing.
Designed to reduce downtime and troubleshooting through simplified consumables, automated setup and clear status feedback, supporting higher arc‑on time in professional repair and fabrication environments.
Backed by long‑term manufacturer warranty on power supply and torch, with genuine parts support, making it well‑suited to workshops that prioritise reliability, serviceability and support from engineering‑led suppliers like BWS.

Specification

Input Voltage

400 V, 3-PH, 50–60 Hz

Output Current

25–85 A

Rated Output Voltage

143 VDC

Duty Cycle

60% @ 85 A, 380–400 V, 3-PH; 100% @ 66 A, 380–400 V, 3-PH

Open Circuit Voltage

270 VDC

Weight

23.5 kg

Dimensions

483 mm D x 233 mm W x 430 mm H

Gas Supply

Cutting: air (clean, dry and oil-free), nitrogen

Recommended Gas Flow

Cutting: 210 l

min @ 5.9 bar; Gouging

210 l

Input Power Cable Length

3 m

Power Supply Type

Inverter - IGBT

Engine Drive Requirement

20 kW or 25 kVA

Electrical Efficiency

91.9%

Recyclability

100%

Warranty

Power supply: 6-year, torch: 1-year

Recommended Cut Capacity

25 mm

Maximum Cut Capacity

32 mm

Severance Capacity

38 mm

Pierce Capacity

20 mm

Torch Output

12.2 kW

Weight with 7.6 m Torch

23.5 kg

FAQs

What cutting capacity does the Hypertherm Powermax85 SYNC offer for workshop use?

It is rated for a recommended cut capacity of 25 mm mild steel with severance up to 38 mm and a mechanized/handheld pierce capacity of 20 mm. In practice that comfortably covers most fabrication, chassis work, bracket manufacture and heavier bodyshop repairs where you’re cutting up to 1 inch plate or sections.

What power supply and duty cycle does the Powermax85 SYNC require in a UK workshop?

The CE/CCC version runs on 380–400 V three‑phase, 50–60 Hz and delivers 25–85 A output at 12.2 kW with a 60% duty cycle at 85 A and 100% at 66 A. That means it suits a standard three‑phase industrial supply and will run continuous production cutting at around 66 A without thermal trips, provided the workshop has a suitable 20 kW / 25 kVA supply or generator.

How do the SYNC cartridges and SmartSYNC torches affect consumables and setup?

The system uses SmartSYNC torches with RFID‑coded single‑piece cartridges instead of a traditional consumable stack. Cartridges are colour‑coded by process (drag cutting, mechanized, FineCut, FlushCut, gouging, HyAccess) and the torch automatically sets amperage and mode, reducing setup errors and training time. End‑of‑life detection and up to 5x longer consumable life compared to typical competitors help lower consumable spend and downtime in busy shops.

What gas, air quality and compressor setup are needed for reliable operation?

It runs on clean, dry, oil‑free air or nitrogen with a recommended flow of about 210 l/min at around 5.9 bar for cutting and slightly lower pressure for gouging. In a professional workshop you’ll need a properly sized compressor and dryer, plus good filtration, to maintain that flow and pressure consistently; poor air quality will shorten cartridge life and degrade cut quality, so correct airline treatment is important for long‑term reliability.