# Hypertherm XPR300

Configuration-dependent XPR300 plasma capabilities, gas-console choices, cutting-capacity boundaries, and use of the correct process charts.

Reviewed: 2026-11-01

Tags: machines, hypertherm, plasma-cutting

Hypertherm lists **45 mm** mild-steel piercing with standard oxygen and **50 mm** with supported argon assist. Mild-steel **severance is 80 mm**. For an interior start, use the pierce category for the installed process. Manual 809480 revision 9 rates duty at **100% at 66.5 kW and 40 °C**. [XPR300 operating data](https://www.hypertherm.com/hypertherm/xpr/xpr300/), [809480 revision 9](https://xnet.hypertherm.com/Xnet/library/download/?file=HYP176529)

The **25 mm mild-steel** row in chart 809830 revision 9 is **300 A oxygen plasma/air shield, above water**, for **Core, CorePlus, VWI and OptiMix**. It lists category **1**, process **1201**, **1,950 mm/min**, **155 V**, **3.30 mm** cut height and **4.4 mm** kerf compensation. Verify the complete process against the electronic chart and inspect representative features for the required quality. [809830, p. 51](https://xnet.hypertherm.com/Xnet/library/download/?file=HYP184133)

## Identify the installed configuration

| Gas-connect console | Published capability distinction |
| --- | --- |
| Core | Primarily mild-steel work; nitrogen-based stainless/aluminum capability and nitrogen marking |
| CorePlus | Adds argon capability, including marking and argon-assisted thicker piercing |
| VWI | Adds water-injection shielding and F5 capability for suitable nonferrous processes |
| OptiMix | Adds controlled mixing of hydrogen, nitrogen, and argon for suitable stainless/aluminum processes |

The 300 A constant-current supply is one component. Verify the gas-connect and TorchConnect consoles, torch, consumables, utilities and CNC integration for the selected chart. [Hypertherm XPR console comparison](https://www.hypertherm.com/solutions/about-our-products/xpr-plasma-cutting-systems/)

CorePlus also has a firmware dependency: manual revision 9 specifies XPR firmware revision U or later. Identify the power-supply variant and installed controls rather than assuming all units share an electrical connection or upgrade path. The same manual rates duty cycle at **100% at 66.5 kW and 40 °C**; shield-water operation has a different lower ambient-temperature limit from operation without shield water. Use the installation-specific requirements instead of extrapolating from an abbreviated sales specification. [809480 revision 9, components and specifications](https://xnet.hypertherm.com/Xnet/library/download/?file=HYP176529)

## Separate piercing, productive cutting, and severance

Hypertherm’s product page publishes the following **capacity categories**:

| Material/process condition | Pierce capacity | Severance capacity |
| --- | --- | --- |
| Mild steel, standard oxygen piercing | 45 mm | Mild steel: 80 mm |
| Mild steel, argon-assisted piercing | 50 mm | Same published material severance category; consult process chart |
| Stainless steel | 38 mm | 75 mm |
| Aluminum | 38 mm | 50 mm |

Apply each operating-data value to its material and starting method. Verify feature and edge requirements separately. [XPR300 operating data](https://www.hypertherm.com/hypertherm/xpr/xpr300/)

**Process Core Thickness (PCT)** balances productivity and quality. Category 4 generally needs an edge start except supported argon-assist cases; category 5 is severance, with slow speed, rougher edges, and significant dross. Separating plate does not establish production suitability. [XPR cut charts 809830, revision 9, pages 16–23](https://xnet.hypertherm.com/Xnet/library/download/?file=HYP184133)

## Read a complete chart row

A bounded metric example from **809830 revision 9, page 51** is mild steel, **300 A**, **oxygen plasma/air shield**, **above water**, supported by Core/CorePlus/VWI/OptiMix. For **25 mm**, it lists category **1**, process ID **1201**, cut speed **1,950 mm/min**, arc voltage **155 V**, cut height **3.30 mm**, and kerf compensation **4.4 mm**. These are chart settings for that process, not standalone programming instructions or guaranteed dimensional accuracy. [809830, mild-steel 300 A chart](https://xnet.hypertherm.com/Xnet/library/download/?file=HYP184133)

The manual, internally dated **May 2026**, treats printed charts as references and directs users to CNC/XPR electronic charts for reliable selection. Preserve the complete process; do not mix rows. [809830 revision 9, chart-use guidance](https://xnet.hypertherm.com/Xnet/library/download/?file=HYP184133)

Check table motion, height control, support, extraction, lead-ins and the actual material and feature geometry. Validate holes and bevels separately from straight cuts. [XPR system and console selection context](https://www.hypertherm.com/solutions/about-our-products/xpr-plasma-cutting-systems/)

## Torch and consumables are part of the process

The product page lists standard and bevel/robotic lead arrangements and mounting sleeves. It specifically limits its 6 m torch lead to console-gas assemblies of 7.5 m or less. A physically connectable lead is not proof of unrestricted configuration compatibility. Record part numbers when identifying an existing machine. [XPR300 torch configurations](https://www.hypertherm.com/hypertherm/xpr/xpr300/)

The **short torch with integrated lead** has a separate manual, **810640 revision 0**, internally dated **August 2020**. It is intended for bevel cutting pipes and beams and states compatibility with XPR consumables/processes, but requires installation changes, including a distinct coolant-hose arrangement. It is therefore not merely a shorter mounting sleeve or an instruction to substitute hardware without following its manual. [XPR short-torch manual](https://www.hypertherm.com/Download?fileId=HYP246662&zip=False)

Use the matching consumables and the manufacturer’s installation procedure. The two-page **810550 revision 4** instruction carries a **05/2025** footer and identifies the electrode torque tool and O-ring lubrication procedure. Do not infer serviceability from appearance alone or apply a generic torch-assembly method to this stack. [XPR consumable installation and removal](https://www.hypertherm.com/Download?fileId=HYP233329&zip=False)

## Utilities, maintenance, and documentation

Gas availability means more than having a cylinder of the named gas. Hypertherm’s **810530 revision 1**, internally dated **July 2019**, discusses OptiMix inlet quality, pressure **during flow**, and delivery requirements; it warns that unsuitable gas quality or supply conditions can reduce quality, speed, thickness capability, and consumable life. Use current requirements for the installed configuration and their amendments. Supply pressure, process flow, and shield-water requirements are different quantities. [OptiMix process-gas guide](https://www.hypertherm.com/Download?fileId=HYP210730&zip=False)

The preventive-maintenance manual **809490 revision 3**, dated **May 2025**, covers gas pressures/regulators, coolant, torch and consumables, leaks, and connections. It also identifies use conditions that affect replacement schedules. Keep service records and resolve deteriorating cut quality through the specified checks rather than assuming one universal consumable lifetime. Qualified personnel should follow the manuals’ isolation and safety procedures for service. [XPR preventive-maintenance program](https://www.hypertherm.com/Download?fileId=HYP177745&zip=False)

For this reference, **809480 revision 9 is dated November 2025** internally; Hypertherm also lists its revision-9 addendum and current supporting documents. Website update dates can differ from document issue dates. Keep the installed serial/configuration, firmware, current manuals/addenda, and selected process together when assessing a capability claim. [XPR300 support and documentation](https://www.hypertherm.com/resources/resources-by-product/?ProductCode=XPR300)

## Related reference

[Machine configuration references](../index.md)