Plasma cutting system XPR460®

for aluminumfor stainless steelfor steel

Product overview
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 delivers maximum versatility, productivity, and precision with superior part-to-part consistency over consumable life, reduced dross and rework, and improved cutting outcomes across a wide range of materials.

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 for best outcomes on mild steel
  • Exclusive Arc Response Technology™ intervenes in adverse events to preserve consumable life and prevent torch damage
  • Extended Pilot Arc (EPA) eliminates manual edge‑finding, streamlining setup and minimizing downtime
  • Web interface accessible via Wi‑Fi and Ethernet LAN in the power supply for system monitoring and service
  • Built-in IIoT via Ethernet LAN and MTConnect® enables remote data access for smarter monitoring
  • Manual Set‑Mode supports straightforward applications (gouging, off‑table beveling) and retains last setup for faster repeatable workflows
• Precision cutting reduces secondary operations
  • Excellent part‑to‑part consistency over consumable life from first cut to last
  • Smooth surfaces, low angularity, and minimal to no dross for clean parts off the table
  • XPR® embedded technology improves 45° bevel cut quality on thick material
  • SureCut™ technology embeds advanced cutting capabilities into the plasma process for improved outcomes

Key specifications (electrical / mechanical)
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 x L x W): 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 lift truck slots

Operating data — cut chart summary
Mild steel
Production pierce capacity (air shield gas): 50 mm (2 in)
Enhanced pierce capacity (argon‑assist): 64 mm (2 1/2 in)
Production severance: 90 mm (3 1/2 in)
Enhanced severance: 102 mm (4 in)

Stainless steel
Production pierce capacity: 38 mm (1 1/2 in)
Enhanced pierce capacity (argon‑assist): 64 mm (2 1/2 in)
Production severance: 90 mm (3 1/2 in)
Enhanced severance (argon‑assist): 130 mm (5 in)

Aluminum
Production pierce capacity (N2 shield gas): 38 mm (1 1/2 in)
Enhanced pierce capacity (argon‑assist): 50 mm (2 in)
Production severance: 80 mm (3 in)

Consumables, torches and starter kits
The XPR torch family and consumable stackups cover a wide amperage range (30 A up to 460 A) and multiple shield/gas processes for mild steel, stainless and non‑ferrous materials. Torch lead and mounting sleeve options, bevel/robotic lead sets, water tube and quick-disconnect options are available. Starter kits available for mild steel consumables (part numbers listed on product page).

Caractéristiques / spécifications techniques

• Product family: Hypertherm XPR mechanized plasma systems
• Model: XPR460®
• Maximum output current: 460 A
• Maximum output power: 102 kW
• Output voltage range: 50–222 VDC (100% duty arc voltage 222 V)
• Max open-circuit voltage: 360 VDC
• Duty cycle: 100% at 102 kW, 40° C (104° F)
• Operational ambient temperature: -10° C–40° C (14° F–104° F)
• Power factor: 0.98 at 102 kW
• Cooling method: Forced air (Class F)
• Insulation class: H
• EMC (CE models): Class A
• Ingress protection: IP21
• Dimensions (H x L x W): 124.8 cm x 123.8 cm x 90.5 cm (49.12″ x 48.75″ x 35.64″)
• Lift rating: Top lift eye 680 kg (1,500 lb.)
• Key technologies: Arc Response Technology™, Extended Pilot Arc (EPA), SureCut™ technology, XPR embedded technology, Argon‑assist piercing, IIoT support (Ethernet LAN, MTConnect®), web interface (Wi‑Fi/Ethernet)
• Cutting performance examples: Mild steel production severance 90 mm; enhanced severance 102 mm. Stainless enhanced severance up to 130 mm with argon‑assist. Aluminum production severance 80 mm.
• Torch and consumable options: Multiple torch lead lengths, bevel/robotic leads, shield caps, nozzles, swirl rings, electrodes and water tubes covering amperages from 30 A to 460 A.