XPR460

XPR460®: part of the world’s most powerful and versatile family of mechanized plasma cutters.

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

Provides superior cutting versatility for mild steel, stainless steel, and aluminum
Offers the widest range of cutting power for various metals and thicknesses
Delivers high-quality, consistent cutting on imperfect metal surfaces, including paint and rust
XPR automated gouging minimizes or eliminates grinding compared to carbon arc gouging, producing weld-ready parts faster with cleaner gouge profiles

Optimized productivity drives lower operating costs

Maximum power optimizes productivity by delivering higher cut quality, thicker cutting capability, and faster cutting speeds
Argon-assist technology enables piercing and edge-starting on the thickest mild steel and stainless steel
Cuts with oxygen up to 460 Amps, delivering the best cutting outcomes on mild steel
Exclusive Arc Response Technology™ intervenes in adverse events to preserve consumable life and prevent torch damage
The web interface tool can be accessed via Wi-Fi and Ethernet LAN in the power supply for system monitoring and service
Built-in IIoT (Industrial Internet of Things) via Ethernet LAN and MTConnect^® enables remote data access for smarter monitoring from anywhere in the world
Manual Set-Mode is ideal for straightforward applications like gouging and off-table beveling; it retains your last setup for faster, repeatable workflows and simplifies set up and operations without the need for CNC/PLC integration

Precision cutting reduces secondary operations

Delivers excellent part-to-part consistency over consumable life from the first cut to the last
Provides a smooth surface, low angularity, and minimal to no dross for clean parts off the table
XPR^® embedded technology improves 45-degree bevel cut quality on thick material making the welding process more efficient
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 = 124.8 cm (49.12″) L = 123.8 cm (48.75″) W = 90.5 cm (35.64″)
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™	O₂plasma O₂shield	30	0.5	5348	0.018″	215
			3	1153	0.135″	40
			5	726	3/16″	30
	O₂plasma Air shield	50	3	3820	0.105″	155
			5	2322	3/16″	95
			8	1369	5/16″	55
	O₂plasma Air shield	80	3	5582	0.105″	225
			6	3048	1/4″	110
			12	1405	1/2″	55
	O₂plasma Air shield	130	3	6502	0.135″	240
			10	2680	3/8″	110
			38	256	1 1/2″	10
	O₂plasma Air shield	170	6	5080	1/4″	200
			12	3061	1/2″	115
			25	1175	1″	45
			60	152	2 3/8″	6
	O₂plasma Air shield	220	10	3715	3/8″	150
			18	2369	5/8″	110
			60	158	2 1/2″	6
	O₂plasma Air shield	300	12	3940	1/2″	155
	O₂plasma Air shield	300	25	1950	1″	75
	N₂shield	300	50	560	2″	21
	N₂shield	300	80	165	3″	7
	O₂plasma 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 N₂shield	40	0.8	6100	0.036″	240
			3	2683	0.105″	120
			6	918	1/4″	32
VWI and OptiMix	F5 plasma N₂shield	80	3	4248	0.135″	140
			6	1916	1/4″	70
			12	864	1/2″	34
OptiMix	H₂-Ar-N₂ plasma N₂shield	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
	N₂ plasma H₂O shield	460	16	2896	5/8″	115
			38	1172	1-1/2″	46
			60	564	2-1/2″	20
OptiMix	H₂-Ar-N₂ plasma N₂shield	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
	N₂Plasma H₂O shield	300	12	2286	1/2″	90
			25	1302	1″	50
			50	524	2″	20
OptiMix	H₂-Ar-N₂ plasma N₂shield	300	25	2056	1″	80
	H₂-Ar-N₂ plasma N₂shield	300	50	391	2″	15
	H₂-Ar-N₂ plasma N₂plasma	460	18	2337	5/8″	92
			38	1372	1 1/2″	38
			60	559	2 1/2″	21
			80	762	3″	30
VWI and OptiMix	N₂ plasma H₂O shield	460	16	3536	5/8″	140
			38	1605	1-1/2″	63
			50	1175	2″	45

*Argon-assisted cutting

Torches and 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.

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.

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
40 A	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

Gouging Consumables

Mild Steel

Amperage	Process	Shield cap	Shield	Nozzle retaining cap	Nozzle*	Swirl ring	Electrode	Water tube
170A	O₂/Air	420200	10086659	420365	10087904 (.140) Bore	420242	10086653	420368
300A	O₂/Air	420200	10086659	420365	10086655 (.180) Bore	420242	10086653	420368
460A	O₂/Air	420200	10086659	420365	10086657 (.195) Bore	420242	10086653	420368

XPR170 starter kits

Part number	Description
10083904	XPR460 Mild steel consumables starter kit
10083905	XPR460 Mild steel consumables starter kit (torch included)

XPR460

XPR460

XPR460®: part of the world’s most powerful and versatile family of mechanized plasma cutters.

System information

Torches and consumables

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