XPR460 plasma cutting system
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How-to videos (1)
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Operator and instruction manuals (7)
.XPR460 Plasma Instruction Manual (Revision 0) ADDENDUM
Last updated
07/08/2026
Part number: 811530_R0_ADD1
Showing 6 of 7 documents
Application notes (2)
CNC Communication Protocol for XPR cutting systems with the 141545 main control PCB (Revision 2)
Last updated
03/16/2026
Part number: 10085793
XPR™ True Hole Conversion on an EDGE Connect CNC (Revision 1)
Last updated
05/03/2019
Part number: 810350
Showing 2 of 2 documents
Specifications
For full specifications, reference the manual.
| 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 |
Consumables
Please contact an authorized Hypertherm distributor to place your consumables order.
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 |
XPR 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 |
*Reference "XPR Gouging Charts for Nozzle"
Stainless Steel
| Amperage | Process | Shield cap | Shield | Nozzle retaining cap |
Nozzle* | Swirl ring | Electrode | Water tube |
|---|---|---|---|---|---|---|---|---|
| 170A | H2-Ar/N2 | 420200 | 10086659 | 420365 | 10087907 (.165) Bore |
420242 | 10086650 | 420368 |
| N2/N2 | 420200 | 10086659 | 420365 | 10087907 (.165) Bore |
420242 | 10086650 | 420368 | |
| 300A |
H2-Ar/N2 | 420200 | 10086659 | 420365 | 10087909 (.210) Bore |
420242 | 10086650 | 420368 |
| N2/N2 | 420200 | 10086659 | 420365 | 10086655 (.180) Bore |
420242 | 10086650 | 420368 | |
| 460A |
H2-Ar/N2 | 420200 | 10086659 | 420365 | 10087911 (.250) Bore |
420242 | 10086650 | 420368 |
| N2/N2 | 420200 | 10086659 | 420365 | 10087909 (.210) Bore |
420242 | 10086650 | 420368 |
*Reference "XPR Gouging Charts for Nozzle"
XPR460 starter kits
| Part number | Description |
|---|---|
| 10083904 | XPR460 Mild steel consumables starter kit |
| 10083905 | XPR460 Mild steel consumables starter kit (torch included) |
Preventive maintenance
.XPR Preventive Maintenance Program Instruction Manual (Revision 3)
Last updated
07/07/2025
Part number: 809490
Field service bulletins (3)
XPR Control PCB Replacement Steps Field Service Bulletin (Revision 1)
Last updated
08/07/2026
Part number: 10088336
XPR PCB Firmware Updates with the Control-PCB Kit 10084334 Field Service Bulletin (Revision 2)
Last updated
03/16/2026
Part number: 10084813
Showing 3 of 3 documents
Technical support
| Resource center |
| Support by product |
| System support |
| Software updates and support |
| Report counterfeit consumables |
| Documents library |
| Training |
| FAQs |
| For educators |
| Tradeshows and events |
| Additional resources |
Useful links
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Recycling information for Hypertherm customers and recyclers
Learn about Hypertherm's committment - Elimination, recycling, and reduction of waste is the foundation of a good approach to end-of-life equipment management. Determine the most sustainable path for your system.