XPR460 plasma cutting system
The Hypertherm XPR460® is part of the world’s most powerful and versatile family of mechanized plasma cutters for cutting mild steel, stainless steel, and aluminum over various thicknesses and imperfect surfaces. XPR460 pays you back with maximum versatility, productivity and precision. You can expect superior part-to-part consistency over consumable life from the first cut to the last. XPR460’s precision cutting produces parts with less dross and rework, reducing secondary operations.
System information
Benefits
Widest versatility expands capabilities
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Provides superior cutting versatility for mild steel, stainless steel, and aluminum
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Offers the widest range of cutting power for various metals and thicknesses
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Delivers high-quality, consistent cutting on imperfect metal surfaces, including paint and rust
Optimized productivity drives lower operating costs
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Maximum power optimizes productivity by delivering higher cut quality, thicker cutting capability, and faster cutting speeds
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Argon-assist technology enables piercing and edge-starting on the thickest mild steel and stainless steel
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Cuts with oxygen up to 460 Amps, delivering the best cutting outcomes on mild steel
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Exclusive Arc Response Technology™ intervenes in adverse events to preserve consumable life and prevent torch damage
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Delivers excellent part-to-part consistency over consumable life from the first cut to the last
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Provides a smooth surface, low angularity, and minimal to no dross for clean parts off the table
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XPR® embedded technology improves 45-degree bevel cut quality on thick material making the welding process more efficient
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Exclusive SureCut™ technology delivers improved outcomes by automatically embedding advanced cutting capabilities into our plasma cutting process
Specifications
| Maximum open-circuit voltage | 360 VDC |
| Maximum output current | 460 A |
| Maximum output power | 102 kW |
| Output voltage | 50–222 VDC |
| 100% duty arc voltage | 222 V |
| Duty cycle rating | 100% at 102 kW, 40° C (104° F) |
| Operational ambient temperature range | -10° C–40° C (14° F–104° F) |
| Power factor | 0.98 at 102 kW |
| Cooling | Forced air (Class F) |
| Insulation | Class H |
| EMC emissions classification (CE models only) | Class A |
| IP rating | IP21 |
| Unit dimensions |
H = 124.76 cm (49.12″) W = 87.3 cm (34.5″) |
| Lift points |
Top lift eye weight rating 680 kg (1,500 lb.) Bottom life truck slots |
Operating data
Cut chart thickness
| Mild steel |
mm | inches |
|---|---|---|
| Production pierce capacity (air shield gas) | 50 | 2 |
| Enhanced pierce capacity (argon-assist piercing)* | 64 | 2 1/2 |
| Production severance | 90 | 3 1/2 |
| Enhanced severance | 102 | 4 |
| Stainless steel |
||
| Production pierce capacity | 38 | 1 1/2 |
| Enhanced pierce capacity (argon-assist piercing)* | 64 | 2 1/2 |
| Production severance | 90 | 3 1/2 |
| Enhanced severance (argon-assist cutting)* | 130 | 5 |
| Aluminum |
||
| Production pierce capacity (N2 shield gas) | 38 | 1 1/2 |
| Enhanced pierce capacity (argon-assist piercing)* | 50 | 2 |
| Production severance | 80 | 3 |
* Argon-assist technology for thicker piercing and thickness severance cutting is available with CorePlus, VWI, OptiMix gas consoles.
This does not represent a complete list of processes or thicknesses that are available.
| Console | Cutting gases | Current (A) | Cut chart thickness (mm) | Approximate cutting speed (mm/min) | Cut chart thickness (in) | Approximate cutting speed (ipm) |
|---|---|---|---|---|---|---|
| Mild steel | ||||||
| Core™, CorePlus™, VWI™, and OptiMix™ |
O2 plasma O2 shield |
30 | 0.5 | 5348 | 0.018" | 215 |
| 3 | 1153 | 0.135" | 40 | |||
| 5 | 726 | 3/16" | 30 | |||
|
O2 plasma Air shield |
50 | 3 | 3820 | 0.105" | 155 | |
| 5 | 2322 | 3/16" | 95 | |||
| 8 | 1369 | 5/16" | 55 | |||
|
O2 plasma Air shield |
80 | 3 | 5582 | 0.105" | 225 | |
| 6 | 3048 | 1/4" | 110 | |||
| 12 | 1405 | 1/2" | 55 | |||
|
O2 plasma Air shield |
130 | 3 | 6502 | 0.135" | 240 | |
| 10 | 2680 | 3/8" | 110 | |||
| 38 | 256 | 1 1/2" | 10 | |||
|
O2 plasma Air shield |
170 | 6 | 5080 | 1/4" | 200 | |
| 12 | 3061 | 1/2" | 115 | |||
| 25 | 1175 | 1" | 45 | |||
| 60 | 152 | 2 3/8" | 6 | |||
|
O2 plasma Air shield |
220 | 10 | 3715 | 3/8" | 150 | |
| 18 | 2369 | 5/8" | 110 | |||
| 60 | 158 | 2 1/2" | 6 | |||
|
O2 plasma Air shield |
300 | 12 | 3940 | 1/2" | 155 | |
| 25 | 1950 | 1" | 75 | |||
| N2 shield | 300 | 50 | 560 | 2" | 21 | |
| 80 | 165 | 3" | 7 | |||
|
O2 plasma Air shield |
460 | 12 | 4826 | 1/2" | 190 | |
| 38 | 1372 | 1 1/2" | 54 | |||
| 60 | 559 | 2 1/2" | 22 | |||
| 102 | 130* | 4" | 5* | |||
| Stainless steel | ||||||
| Core, CorePlus, VWI, and OptiMix |
N2 plasma N2 shield |
40 | 0.8 | 6100 | 0.036" | 240 |
| 3 | 2683 | 0.105" | 120 | |||
| 6 | 918 | 1/4" | 32 | |||
| VWI and OptiMix |
F5 plasma N2 shield |
80 | 3 | 4248 | 0.135 | 140 |
| 6 | 1916 | 1/4" | 70 | |||
| 12 | 864 | 1/2" | 34 | |||
| OptiMix |
H2-Ar-N2 plasma N2 shield |
170 | 10 | 1975 | 3/8" | 80 |
| 12 | 1735 | 1/2" | 65 | |||
| 38 | 256 | 1-1/2" | 10 | |||
| 300 | 12 | 2038 | 1/2" | 80 | ||
| 25 | 1040 | 1" | 40 | |||
| 50 | 387 | 2" | 17 | |||
| 75 | 162 | 3" | 6 | |||
| VWI and OptiMix |
N2 plasma H2O shield |
300 | 12 | 2159 | 1/2" | 85 |
| 25 | 1302 | 1" | 50 | |||
| 50 | 434 | 2" | 15 | |||
| OptiMix |
H2-Ar-N2 plasma N2 shield |
460 | 18 | 2337 | 5/8" | 92 |
| 38 | 966 | 1 1/2" | 38 | |||
| 60 | 534 | 2 1/2" | 21 | |||
| 127 | 77* | 5" | 3* | |||
| Aluminum | ||||||
| Core, CorePlus, VWI, and OptiMix |
Air plasma Air shield |
40 | 1.5 | 4799 | 0.036 | 240 |
| 3 | 2596 | 1/8" | 85 | |||
| 6 | 911 | 1/4" | 32 | |||
| VWI and OptiMix |
N2 plasma H2O shield |
80 | 3 | 3820 | 1/8" | 140 |
| 6 | 2203 | 1/4" | 80 | |||
| 10 | 956 | 1/2" | 28 | |||
|
N2 plasma H2O shield |
130 | 6 | 2413 | 1/4" | 95 | |
| 10 | 1702 | 3/8" | 70 | |||
| 20 | 870 | 3/4" | 35 | |||
|
N2 Plasma H2O shield |
300 | 12 | 2286 | 1/2" | 90 | |
| 25 | 1302 | 1" | 50 | |||
| 50 | 524 | 2" | 20 | |||
| OptiMix |
H2-Ar-N2 plasma N2 shield |
300 | 12 | 3810 | 1/2" | 150 |
| 25 | 2056 | 1" | 80 | |||
| 50 | 391 | 2" | 15 | |||
|
H2-Ar-N2 plasma N2 plasma |
460 | 18 | 2337 | 5/8" | 92 | |
| 38 | 1372 | 1 1/2" | 38 | |||
| 60 | 559 | 2 1/2" | 21 | |||
| 80 | 762 | 3" | 30 | |||
*Argon-assisted cutting
Buying information
Visit our where to buy page to find a potential partner, or contact Hypertherm directly if you need further assistance.
Resources
Manuals and documents
.XPR Cut charts (Revision 7)
Last updated
01/22/2025
PDF (17.62MB)
Training
XPR torch
| Part number Standard |
Part number Standard Bevel/Robotic |
Part number Bevel/Robotic |
Description |
| 428383 | 428825 | 428831* | Lead: 6.6′ |
| 428384 | 428826 | 428832* | Lead: 8.2′ |
| 428385 | 428827 | 428833* | Lead: 9.8′ |
|
428386 |
428828 | 428834* | Lead: 11.5′ |
| 428824 | 428829 | 428335* | Lead: 13.1′ |
| 428387 | 428830 | 428836* | Lead: 4.8′ |
| 428978** | 428979** | Lead: 20′** | |
| 428916 | Lead: Thru arm robotic 11.5′ | ||
| 428918 | Lead: Thru arm robotic 14.8′ | ||
| 420500 | Torch mounting sleeve: Standard | ||
| 420501 | Torch mounting sleeve: Short | ||
| 420502 | Torch mounting sleeve: Extended | ||
| 420788 | Rotational torch mounting sleeve: Short | ||
| 420789 | Rotational torch mounting sleeve: Medium | ||
| 420790 | Rotational torch mounting sleeve: Extended | ||
| 420220 | Quick-disconnect torch receptacle | ||
| 420221 | Quick-disconnect XPR torch | ||
| 420368 | Water tube |
* Bevel/Robotic leads sets 428831-428836 include an extended 1.2 m (48″) strain relief.
** The 6 m (20′) lead is compatible only with console gas assemblies that are 7.5 m (24.6′) or less.
XPR consumables
Nozzles and electrodes are available in various quantities. Please contact an authorized Hypertherm distributor to place your consumables order. Your consumables may not look exactly like the pictures.
Mild steel
| Amperage | Process | Shield cap | Shield | Nozzle retaining cap | Nozzle | Swirl ring | Electrode | Water tube |
|---|---|---|---|---|---|---|---|---|
| 30 A | O2/O2 | 420200 | 420228 | 420365 | 420225 | 420407 | 420222 | 420368 |
| 50 A | O2/Air | 420200 | 420237 | 420365 | 420234 | 420233 | 420231 | 420368 |
| 80 A | O2/Air | 420200 | 420246 | 420365 | 420243 | 420242 | 420240 | 420368 |
| 130 A | O2/Air | 420200 | 420255 | 420365 | 420252 | 420242 | 420249 | 420368 |
| 170 A | O2/Air | 420200 | 420513 | 420365 | 420261 | 420260 | 420258 | 420368 |
| 220 A | O2/Air | 420200 | 420273 | 420365 | 420270 | 420406 | 420276 | 420368 |
| 300 A | O2/Air | 420200 | 420491 | 420365 | 420279 | 420406 | 420276 | 420368 |
| 460 A | O2/Air | 420200 | 520002 | 420365 | 520001 | 420819 | 420834 | 420368 |
Non-ferrous
| Amperage | Process | Shield cap | Shield | Nozzle retaining cap | Nozzle | Swirl ring | Electrode | Water tube |
|---|---|---|---|---|---|---|---|---|
| 40 A | N2/N2 | 420200 | 420291 | 420365 | 420288 | 420314 | 420303 | 420368 |
| Air/Air | 420200 | 420291 | 420365 | 420288 | 420314 | 420294 | 420368 | |
| 60 A | N2/N2 | 420200 | 420309 | 420365 | 420297 | 420323 | 420303 | 420368 |
| F5/N2 | 420200 | 420309 | 420365 | 420297 | 420323 | 420303 | 420368 | |
| N2/H2O | 420200 | 420300 | 420365 | 420296 | 420323 | 420303 | 420368 | |
| Air/Air | 420200 | 420309 | 420365 | 420297 | 420323 | 420294 | 420368 | |
| 80 A | N2/N2 | 420200 | 420309 | 420365 | 420306 | 420323 | 420303 | 420368 |
| F5/N2 | 420200 | 420309 | 420365 | 420306 | 420323 | 420303 | 420368 | |
| N2/H2O | 420200 | 420300 | 420365 | 420290 | 420323 | 420303 | 420368 | |
| Air/Air | 420200 | 420309 | 420365 | 420306 | 420323 | 420294 | 420368 | |
| 130 A | N2/N2 | 420200 |
420318 |
420365 |
420315 |
420314 | 420356 | 420368 |
| H2-Ar-N2/N2 | 420200 | 420318 | 420365 | 420315 | 420323 | 420356 | 420368 | |
| N2/H2O | 420200 | 420469 | 420365 | 420315 | 420314 | 420356 | 420368 | |
| 170 A | N2/N2 | 420200 | 420327 | 420365 | 420324 | 420314 |
420356 |
420368 |
| H2-Ar-N2/N2 | 420200 | 420327 | 420365 | 420324 | 420323 | 420356 | 420368 | |
| N2/H2O | 420200 | 420472 | 420365 | 420324 | 420314 | 420356 | 420368 | |
| Air/Air | 420200 | 420513 | 420365 | 420524 | 420260 | 420258 | 420368 | |
| 300 A | N2/N2 | 420200 | 420362 | 420365 | 420359 | 420323 | 420356 | 420368 |
| H2-Ar-N2/N2 | 420200 | 420362 | 420365 | 420359 | 420358 | 420356 | 420368 | |
| N2/H2O | 420200 | 420475 | 420365 | 420359 | 420323 | 420356 | 420368 | |
| 460 A | H2-Ar-N2/N2 | 420200 | 420998 | 420365 | 420996 | 420358 | 420997 | 420368 |
XPR460 starter kits
| Part number | Description |
|---|---|
| 10083904 | XPR460 Mild steel consumables starter kit |
| 10083905 | XPR460 Mild steel consumables starter kit (torch included) |
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