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Prepare to troubleshoot internal components
Troubleshooting for common problems
Troubleshooting for fault codes
- Fault icons and fault codes
  The Powermax45 SYNC® power supply shows faults using a combination of fault icons and fault code numbers. Some faults are shown by the icons only, others are shown by the icons and a fault code number.
- Operational faults
  An operational fault code can be for a notification or for a condition that stops the cutting process. Hypertherm® recommends that you do the steps for all faults that occur. Troubleshooting all faults helps you to get optimal cut quality and consumable life.
- Internal component faults (1-nn-n, 2-nn-n, 3-nn-n)
  Fault codes in the 1-nn-n, 2-nn-n, and 3-nn-n formats identify possible damage to components inside the plasma power supply.
- Troubleshooting procedures for fault LEDs and 0-nn-n fault codes
  - Troubleshooting for AC input power that is not stable
    The Power ON Light Emitting Diode (LED) can flash to identify when the Alternating Current (AC) input power is not stable and a system shutdown is necessary.
  - Troubleshooting for low gas pressure faults
    When the Gas Pressure fault Light Emitting Diode (LED) and the System Fault LED both illuminate while the system is ON, the gas pressure is less than the minimum pressure for the selected process, operating mode, torch, lead length, and Hypertherm® cartridge type.
  - Troubleshooting for missing gas input faults
    The Gas Pressure fault Light Emitting Diode (LED) flashes quickly when there is no gas supply input to the plasma power supply.
  - Troubleshooting for TSO and TSC faults
    A flashing Torch Cap fault Light Emitting Diode (LED) identifies either a Torch Stuck Open (TSO) or a Torch Stuck Closed (TSC) condition.
  - Troubleshooting for temperature-related faults
    When the Temperature fault Light Emitting Diode (LED) and the System Fault LED both illuminate while the system is ON, the internal temperature of the plasma power supply is too hot or too cold. Hypertherm® recommends that you operate the system only in external temperatures between -10°C – 40°C (14°F – 104°F).
  - Troubleshooting for when the Hypertherm cartridge or torch is not ready to cut
    The Torch Cap fault Light Emitting Diode (LED) illuminates when the torch or Hypertherm® cartridge is not ready to cut or is not able to cut.
  - Troubleshooting for start signal faults
    The Temperature fault Light Emitting Diode (LED) and the System Fault LED flash alternately when the system receives a Start signal from the torch at the same time that the power switch is set to ON (I). This fault can prevent the torch from firing a plasma arc.
  - Troubleshooting for input voltage faults
    A flashing Power ON Light Emitting Diode (LED) can identify a problem with the input voltage.
  - Troubleshooting for remote controller faults (0-11-n)
    A 0-11-n fault code identifies a problem with the remote controller. There can also be a problem with the software interface to the system. The system cannot interpret the operating mode, output current, or gas pressure information coming from the controller.
  - Troubleshooting for incorrect output gas pressure conditions (0-12-n)
    An 0-12-n fault code identifies a condition where the output gas pressure is too low, too high, or not stable. The 0-12-n fault codes show only on a Computer Numerical Control (CNC) through an RS-485 serial interface. They do not show on the plasma power supply 2-digit display.
  - Troubleshooting for Hypertherm cartridge installation faults (0-14-n)
    An 0-14-n fault identifies a condition where the Hypertherm® cartridge is not recognized or is not operating correctly.
  - Troubleshooting for PCB hardware protection faults (0-19-9)
    A 0-19-9 fault code usually occurs when the input power stops or when power Printed Circuit Board (PCB) hardware protection occurs for components in the plasma power supply.
  - Troubleshooting for duty cycle faults (0-40-5)
    A 0-40-5 fault code indicates that the plasma power supply has exceeded its rated duty cycle.
  - Troubleshooting for torch-lock switch faults (0-50-n)
    A 0-50-n fault code is usually an indication that the torch-lock switch is set to the yellow lock (X) position or that the system is reading data from the Hypertherm® cartridge.
  - Troubleshooting for torch connection faults (0-52-0)
    The system usually shows a 0-52-0 fault code as an indication that the torch is not connected to the plasma power supply.
  - Troubleshooting for an RF communication fault (0-98-1)
    An 0-98-1 fault code identifies a Radio Frequency (RF) communication failure between the Hypertherm® cartridge and the torch.
  - Troubleshooting for a plasma power supply or torch communication fault (0-98-2)
    An 0-98-2 fault code identifies a communication failure between the torch and the plasma power supply.
- Troubleshooting procedures for 1-nn-n, 2-nn-n, and 3-nn-n fault codes
Service parts
Service procedures for the cover, panels, and connectors
Service procedures for the gas supply
Service procedures for the PCBs and related components
Change system settings
How the plasma power supply operates
System diagrams

Troubleshooting for duty cycle faults (0-40-5)

A 0-40-5 fault code indicates that the plasma power supply has exceeded its rated duty cycle.

Fault codes and fault LEDs


Fault code	Fault LEDs	Torch LED	Description	Stops the system from operating?
0-40-5	ON	Yellow	The plasma power supply has reached its duty cycle limit and must cool down for at least 3.5 minutes.	Yes

Corrective action for 0-40-5 faults

Wait for the plasma power supply to cool down.
Make sure that there is sufficient air flow around the plasma power supply.
Make sure that the fan is operating correctly.
If possible, decrease the output current (A), or decrease the period of continuous "arc on" time when you cut.

These steps can help to keep the system in its duty cycle limits.