Maintenance and Repair

Basic troubleshooting
The following table provides an overview of the most common problems that can arise when using the Powermax
system and explains how to solve them.

Note:  Fault icons and corresponding fault codes appear in the LCD display. Refer to page 8-6 Fault codes
and solutions.

If a fault occurs while using a generator, turn OFF the power supply, wait 30 to 45 seconds, and turn ON
the power supply.

If you are unable to fix the problem by following this basic troubleshooting guide, or if you need further assistance:
1. Call your Hypertherm distributor or authorized Hypertherm repair facility.
2. Call the nearest Hypertherm office listed in the front of this manual.

Problem Solutions

The ON/OFF power switch is set to • Verify that the power cord is plugged into the receptacle.
ON (I), but the power ON LED is not
illuminated. • Verify that the power is ON at the main power panel or at the
line‑disconnect switch box.
• Verify that the line voltage is not too low (more than 15% below the
rated voltage).
• Verify that the circuit breaker has not been tripped.

The arc does not transfer to the • Clean the area where the work clamp contacts the workpiece to ensure
workpiece. a good metal-to-metal connection.
• Inspect the work clamp for damage and repair as necessary.
• The pierce-height distance may be too large. Move the torch closer to
the workpiece and fire the torch again.

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 Maintenance and Repair

Problem Solutions

The arc blows out, but re-ignites when • Inspect the consumable parts and replace them if they are worn or
the torch trigger is pressed again. damaged. See page 8-3 Inspect the consumables.
• Replace the air filter element if it is contaminated. See page 8-10
Replace the air filter element and air filter bowl.
• Make sure the gas pressure is at the proper level.
The arc sputters and hisses. • The air filter element is contaminated. Replace the element. See page
8-10 Replace the air filter element and air filter bowl.
• Inspect the gas line for moisture. If necessary, install or repair the gas
filtration to the power supply. See the Power Supply Setup section.
The cut quality is poor. • Verify that the torch is being used correctly. See the Basic System
Operations, Hand Cutting, or Mechanized Cutting section.
• Inspect the consumables for wear and replace as necessary. See 8-3
Inspect the consumables.
• Check the air pressure and air quality.
• Verify that the cutting mode switch is in the proper position for the
cutting operation.
• Verify that the correct consumables are installed.

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Maintenance and Repair

Fault codes and solutions

A label with descriptions for these common fault codes can be found inside the front cover of this manual. Peel off the
label and place it on the rear of the power supply for reference.

Note: If a fault occurs while using a generator, turning the power switch quickly to OFF and then to ON
again (sometimes called a “quick reset” or “quick restart”) may not clear the fault. Instead, turn OFF the power
supply and wait 30 to 45 seconds before turning ON again.

Fault Description Power Fault Fault Solutions

code LED LED icon
0-12 Low input gas pressure On Off • Adjust the gas inlet pressure as needed.
or unstable gas pressure:
Warning (the system
continues to operate)
0-13 AC input unstable: Warning Blinks Off • Correct the power source.
(the system continues to (3 Hz)
operate)
0-19 Power board hardware On On The inverter shuts down and does not fire
protection. One or more again for several seconds. If the fault is
power board hardware faults caused by electrical noise, the fault clears
(or noise) detected. in a few seconds and the machine operates
normally.
A true 0-19 fault may display for up to 60
seconds before fault code 0-99 displays
on the operator screen. A qualified service
technician must service the system. Contact
your distributor or authorized repair facility.
0-20 Low gas pressure On On • Check the input gas supply.
• Adjust the gas pressure to the acceptable
range using Manual mode. See the Basic
System Operations section. Perform a
quick restart.
0-21 Gas flow lost while cutting On On • Restore the gas inlet pressure and restart
the power supply.
• Check the torch lead for leaks or kinking.
• Change consumables.
0-22 No gas input On On • Connect the gas source and restart the
power supply.

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 Maintenance and Repair

Fault Description Power Fault Fault Solutions

code LED LED icon
0-30 Torch consumables stuck On On • If the consumables became loose or were
removed while the power supply is ON, turn
This indicates either a OFF the power supply, correct the problem and
“torch stuck open” or then turn ON the power supply to clear this
a “torch stuck closed” fault.
situation.
• Change consumables.
• If the consumables appear to be installed
correctly, the torch may be damaged. Contact
your Hypertherm distributor or authorized repair
facility.
0-32 End of consumable life On On • Replace the electrode and nozzle.
• Check the remaining consumables for wear and
replace as needed.
0-40 Over/under temperature On On • Leave the power supply on to allow the fan to
cool the power supply.
• If the internal temperature of the power supply
approaches ‑30° C (-22° F), move the power
supply to a warmer location.

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Maintenance and Repair

Fault Description Power Fault Fault Solutions

code LED LED icon
0-50 Retaining cap off On On • Turn OFF the power supply. Verify that the
consumables are installed and restart the power
supply.
• If the consumables appear to be installed
correctly, the torch may be damaged. Contact
your Hypertherm distributor or authorized repair
facility.
0-51 Start/trigger signal on at On On • If the power supply is turned on while the torch
power up trigger is pressed, the system is disabled.
Release the trigger and recycle the power
This situation indicates switch.
that the power supply is
receiving a start signal. It
is sometimes referred to
as a “stuck start.”
0-52 Torch not connected On On • Plug a torch lead into the FastConnect
receptacle on the front of the power supply and
recycle the power switch.

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 Maintenance and Repair

Fault Description Power Fault Fault Solutions

code LED LED icon
0-60 AC input voltage error On On • Phase loss: Check all input phases and fuses.
• Over voltage: Check the line, decrease the
voltage.
• Under voltage: Check the line, increase the
voltage.
0-61 AC input unstable: On On • The incoming line current is unstable. Power
Shutdown down and correct the line problem before
continuing.
0-98 Internal communication On On • Power down, wait 20 seconds, power up.
failure
• A qualified service technician must open the
power supply case and check the ribbon cable
between the control board and the DSP board.
0-99 System hardware fault — On On • A qualified service technician must service the
service required system. Contact your distributor or authorized
repair facility.
Indicates a major fault
with the system.

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