Hypertherm HPR400XD HyPerformance Plasma Cutting System
Overview
The Hypertherm HPR400XD is the 400 A model in the HyPerformance Plasma family, positioned by Hypertherm as the ultimate in HyPerformance mild steel cutting with heavy-duty stainless steel and aluminium capability. It is a mechanized system for X-Y cutting tables, bevel heads and robotic cutting, delivering 80 kW at 100% duty cycle. On mild steel the datasheet lists dross-free cutting up to 38 mm (1-1/2 in), production pierce of 50 mm (2 in) and maximum cutting capacity of 80 mm (3.2 in).
Seven Star LLC supplies the Hypertherm HPR400XD to heavy plate processors, shipbuilders, structural steel fabricators and equipment manufacturers in Oman and the GCC, and provides engineering support in Muscat. Because the system includes a power supply, gas console, torch and leads, we review your cutting table, materials and gas availability before preparing a configuration and quotation.
Operating Principle
HyPerformance systems use HyDefinition technology, which Hypertherm explains as aligning and focusing the plasma arc for more powerful precision cutting of mild steel up to 80 mm. A tightly constricted arc gives a narrow kerf and a squarer edge than conventional air plasma, and the separate plasma and shield gases are chosen to suit each material. On the Hypertherm HPR400XD oxygen plasma with air or oxygen shield is used for mild steel, while stainless steel and aluminium are cut with nitrogen, F5 or H35 plasma gas and nitrogen or air shield.
For thin stainless steel the HDi technology delivers HyDefinition cut quality from 3 to 6 mm using F5 plasma and nitrogen shield. LongLife technology, as the datasheet describes it, significantly increases consumable life and keeps HyDefinition cut quality consistent over a longer period. Hypertherm also states that consumables support up to 45 degree bevel capability at the main current levels, which allows weld preparation directly on a bevel-equipped machine.
Engineering Design of the Hypertherm HPR400XD
The power supply is a heavy industrial unit measuring 118 cm high, 88 cm wide and 126 cm long, with a weight of 851 kg including the torch. It is available for three-phase inputs from 200/208 V up to 600 V at 50 or 60 Hz, drawing for example 131 A at 400 V or 110 A at 480 V. Output is 400 A at 200 VDC, with a maximum open-circuit voltage of 360 VDC and a power factor of 0.98 at 80 kW. The large footprint and weight mean the Hypertherm HPR400XD is installed as a fixed part of a cutting cell, so floor space, crane access and cable routing should be planned before delivery.
Gas is delivered through either a manual gas console at 8.3 bar (120 psi) or an automatic gas console at 8 bar (115 psi). Plasma gas options are oxygen, nitrogen, F5, H35, air and argon; shield gas options are nitrogen, oxygen, air and argon. The H35 and nitrogen mixed plasma processes require the automatic gas console, as does the maximum stainless steel pierce of 75 mm, which also needs a controlled motion process.
From a maintenance point of view, the Hypertherm HPR400XD benefits from a consumable design that Hypertherm tested for cut quality over life: the datasheet compares bevel angle results over hundreds of starts on 25 mm mild steel at 400 A against competing systems. In general workshop practice, keeping gas quality, torch alignment and consumable condition under control is what preserves that edge quality, and our team can advise on consumable stock levels for the Hypertherm HPR400XD based on your cutting hours.
Key Features
The following capabilities make the Hypertherm HPR400XD a common choice for heavy mechanized cutting.
- HyDefinition technology focuses the arc for precision mild steel cutting up to 80 mm.
- Dross-free mild steel cutting up to 38 mm reduces grinding and secondary operations.
- Stainless steel production pierce is 45 mm, with maximum pierce of 75 mm and severance of 80 mm using the automatic console.
- Aluminium production pierce is 38 mm, with maximum cutting capacity of 80 mm.
- HDi technology gives HyDefinition quality on thin stainless steel from 3 to 6 mm.
- LongLife technology maintains cut quality and extends consumable life over many starts.
- A 100% duty cycle at 80 kW and 40 °C supports continuous production.
- Consumables support bevel cutting up to 45 degrees for weld preparation.
Industrial Applications
The Hypertherm HPR400XD suits plants that cut heavy carbon steel plate in volume while also handling thick stainless and aluminium. Typical users in Oman include fabricators building process modules, pipe racks and structural steel for oil and gas and power projects in Sohar and Duqm, shipyards preparing hull and deck plate, manufacturers of tanks and pressure vessels, and heavy equipment builders that need thick-plate parts with bevelled edges. Its operating data covers mild steel from 0.5 mm at 30 A up to 80 mm at 400 A, so one system can serve both thin brackets and thick base plates.
Cut plate usually moves straight to welding, and Seven Star LLC supplies welding equipment and consumables for that stage as well, such as the Lincoln Electric Power Wave S500 for automated MIG, the ESAB Rebel EMP 285ic for fit-up and repair, and LongTeng EL8 submerged arc wire for thick-plate seams. For the latest mechanized generation and handheld units, see our plasma cutting systems category. Seven Star LLC supplies the Hypertherm HPR400XD with integration advice for your table and gas supply.
Technical Specifications
These figures are taken from the Hypertherm HPR400XD datasheet; capacities depend on gas console and process.
| Parameter | Specification |
|---|---|
| Model | Hypertherm HPR400XD |
| Mild steel capacity | Dross-free 38 mm; production pierce 50 mm; maximum cut 80 mm |
| Stainless steel capacity | Production pierce 45 mm; maximum pierce 75 mm; severance 80 mm |
| Aluminium capacity | Production pierce 38 mm; maximum cut 80 mm |
| Output current / voltage | 400 A / 200 VDC |
| Duty cycle | 100% at 40 °C at 80 kW |
| Input (3-phase) | 200/208 V to 600 V, 50/60 Hz (e.g. 131 A at 400 V, 110 A at 480 V) |
| Power factor | 0.98 at 80 kW |
| Maximum open-circuit voltage | 360 VDC |
| Dimensions | 118 cm H x 88 cm W x 126 cm L |
| Weight with torch | 851 kg |
| Plasma gas | O2, N2, F5, H35, air, Ar |
| Shield gas | N2, O2, air, Ar |
| Gas pressure | 8.3 bar manual console; 8 bar automatic console |
| Example cut speed | Mild steel 25 mm at 400 A: 2210 mm/min (O2 plasma, air shield) |
Documentation
The Hypertherm HPR400XD datasheet attached to this page includes the full operating data chart with current, thickness and approximate cutting speed for mild steel, stainless steel and aluminium. Hypertherm notes that the chart does not list every available process, so additional cut charts can be reviewed with our engineers for specific materials.
Call To Action
For a quotation on the Hypertherm HPR400XD, send Seven Star LLC your cutting table make, required materials and thicknesses, gas console preference and site supply voltage. Our Muscat engineering team will confirm the system package and recommended consumables and support your cutting operation anywhere in Oman and the GCC.
- datasheet Hypertherm HPR400XD Datasheet Download
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