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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 procedures for 1-nn-n, 2-nn-n, and 3-nn-n fault codes
  - Troubleshooting for DSP and I/O faults (1-nn-n)
    1-nn-n fault codes identify possible damage to components inside the plasma power supply.
  - Troubleshooting for an analog-to-digital converter fault (2-00-0)
    A 2-00-0 system fault indicates that the analog-to-digital converter value is out of range.
  - Troubleshooting for inverter module temperature sensor faults (2-10-n)
    2-10-n faults could indicate that there is a problem with the power Printed Circuit Board (PCB).
  - Troubleshooting for solenoid valve pressure sensor faults (2-11-n)
    A 2-11-0 or 2-11-1 fault code identifies a possible problem with the gas pressure sensor in the solenoid valve.
  - Troubleshooting for VBUS faults (3-00-0)
    A 3-00-0 fault indicates that the Direct Current (DC) bus voltage (VBUS) is out of range.
  - Troubleshooting for fan faults (3-10-n)
    A 3-10-0 or 3-10-1 fault code identifies a problem with the system's internal fan.
  - Troubleshooting for PFC module temperature sensor faults (3-11-n)
    A 3-11-n fault code indicates a problem with the Power Factor Correction (PFC) temperature sensor circuit.
  - Troubleshooting for inverter IGBT faults (3-51-1, 3-52-0)
    3-51-1 or 3-52-0 fault codes indicate that there is a phase or short circuit problem with the inverter module.
  - Troubleshooting for a power PCB fault (3-60-0)
    A 3-60-0 fault code indicates that the system does not recognize the power Printed Circuit Board (PCB).
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 DSP and I/O faults (1-nn-n)

1-nn-n fault codes identify possible damage to components inside the plasma power supply.

Fault codes and fault LEDs


Fault code	Fault LEDs	Torch LED	Description	Stops the system from operating?
1-00-0	ON ON	Red	A DSP PCB fault occurred.	Yes
1-20-0	ON ON	Red	An input/output (I/O) fault occurred.	Yes

Corrective action for 1-00-0 and 1-20-0 faults

Do a cold restart.

In some conditions, a restart can remove the fault condition.
Replace the power Printed Circuit Board (PCB).

If restarting the plasma power supply does not remove the fault condition, it is possible that the power PCB must be replaced.