Diagnostic codes

Use this table to identify a diagnostic code and where to find more troubleshooting information about it.

Table 1. Diagnostic code descriptions
Code Priority Description XPR models Corrective action
500 Failure GCC->Main CAN t/o All models CAN communication troubleshooting for gas connect consoles
501 Failure Mix->Main CAN t/o All models CAN communication troubleshooting for mixing modules in consoles
503 Failure TCC->Main CAN t/o All models CAN communication troubleshooting for consoles
504 Failure Ch1->Main CAN t/o All models CAN communication troubleshooting for choppers
505 Failure Ch2->Main CAN t/o XPR300™, XPR460™
506 Failure Ch3->Main CAN t/o XPR460
507 Failure Main no CAN All models
  1. CAN communication troubleshooting for choppers
  2. CAN communication troubleshooting for gas connect consoles
  3. CAN communication troubleshooting for mixing modules in consoles (if applicable)
  4. CAN communication troubleshooting for consoles
508 Error CAN Busy All models
509 Failure Cooler->Main CAN t/o XPR460
This code occurs when the cooler does not receive Controller Area Network (CAN) communications for the main control at least once per second. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm® Technical Service team.
  • XPR® action: Shut down
  • Code cancels with: Remote on-off
510 Failure Main->GCC CAN t/o All models CAN communication troubleshooting for gas connect consoles
511 Failure Main->Mix CAN t/o All models CAN communication troubleshooting for mixing modules in consoles
513 Failure Main->TCC CAN t/o All models CAN communication troubleshooting for consoles
514 Failure Main->Ch1 CAN t/o All models CAN communication troubleshooting for choppers
515 Failure Main->Ch2 CAN t/o XPR300, XPR460
516 Failure Main->Ch3 CAN t/o XPR460
519 Failure Main->Cooler CAN t/o XPR460
This code occurs when the main control does not receive CAN communications from the cooler at least once per second. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: None
  • Code cancels with: Remote on-off
520 Alert Ignite t/o (no pilot arc) All models Troubleshooting for an ignition timeout
521 Alert Pilot arc t/o (no arc transfer) All models Troubleshooting for a pilot arc timeout
522 Alert Preflow t/o All models Troubleshooting for gas flow process timeouts
523 Error Preflow purge t/o All models
524 Error Cutflow purge t/o All models
525 Error Inert gas purge t/o All models
530 Alert Low psi–Line A All models Troubleshooting for low inlet gas pressure
531 Alert Low psi–Line B All models
532 Alert Low psi–H2O All models Troubleshooting for low shield water pressure
533 Alert Low psi–F5 All models Troubleshooting for low inlet gas pressure
534 Alert Low psi–Shield All models Troubleshooting for low shield gas pressure
540 Error Low flow 1–Coolant All models Troubleshooting for low coolant flow
541 Error Low flow 2–Coolant All models
542 Failure Low flow–Coolant All models
543 Error High flow 1–Coolant All models Troubleshooting for high coolant flow
544 Failure High flow–Coolant All models
550 Alert No plasma arc All models Troubleshooting for low current
552 Alert DC below limit–Ch1 All models
553 Alert DC below limit–Ch2 XPR300, XPR460
554 Alert DC below limit–Ch3 XPR460
555 Failure DC exceeds limit–Ch1 All models Troubleshooting for high current
556 Failure DC exceeds limit–Ch2 XPR300, XPR460
557 Failure DC exceeds limit–Ch3 XPR460
560 Error Over temp–Ch1 All models Troubleshooting for over-temperature faults for choppers and coolant
561 Error Over temp–Ch2 XPR300, XPR460
562 Error Over temp–Ch3 XPR460
570 Alert Start on powerup All models Troubleshooting for start switch faults
571 Alert Start on wait-start All models
574 Info Start removed preflow All models
575 Info Start removed ignite All models
576 Info Start removed pilot All models
577 Info Start removed ramp up All models
580 Error Over temp–Ind 1 All models Troubleshooting for over-temperature faults for inductors and transformers
581 Error Over temp–Ind 2 All models
582 Error Over temp–Ind 3 XPR300, XPR460
583 Error Over temp–Ind 4 XPR300, XPR460
584 Error Over temp–Ind 5 XPR460
585 Error Over temp–Ind 6 XPR460
586 Error Over temp–Xfmr All models
587 Error Over temp–Coolant All models Troubleshooting for over-temperature faults for choppers and coolant
588 Failure Fan timeout All models Troubleshooting for a fan timeout
589 Error Over temp–Xfmr2 XPR460 Troubleshooting for over-temperature faults for inductors and transformers
600 Error No TCC found All models CAN communication troubleshooting for consoles
601 Error No Chopper 1 found All models CAN communication troubleshooting for choppers
602 Error No GCC found All models CAN communication troubleshooting for gas connect consoles
604 Alert No Chopper 2 found XPR300, XPR460 CAN communication troubleshooting for choppers
605 Error No cooler found XPR460
This code occurs after power is supplied and the main control does not receive CAN communications for the cooler. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: None
  • Code cancels with: Remote on-off
606 Alert No Chopper 3 found XPR460 CAN communication troubleshooting for choppers
610 Failure Ch1 Torch Protect ChA All models Troubleshooting for consumable part failure or no chopper current
611 Failure Ch1 Torch Protect ChB All models
612 Failure Ch2 Torch Protect ChA XPR300, XPR460
613 Failure Ch2 Torch Protect ChB XPR300, XPR460
614 Failure Ch3 Torch Protect ChA XPR460
615 Failure Ch3 Torch Protect ChB XPR460
620 Alert Arc stretch detected All models Troubleshooting for a ramp-down error
621 Failure Over voltage–DC bus All models Troubleshooting for high DC bus voltage
622 Failure Under voltage–DC bus All models Troubleshooting for low DC bus voltage
623 Error Ch1 DC at idle All models Troubleshooting for idle choppers with current
624 Error Ch2 DC at idle XPR300, XPR460
625 Error Ch3 DC at idle XPR460
626 Alert No DC output–Ch1 All models Troubleshooting for consumable part failure or no chopper current
627 Alert No DC output–Ch2 XPR300, XPR460
628 Alert No DC output–Ch3 XPR460
631 Failure DC at wait-start All models Troubleshooting for current sensor faults
640 Info No error All models
No operator action is necessary.
  • XPR action: None
  • Code cancels with: Is not applicable.
642 Info System powered All models
No operator action is necessary.
  • XPR action: None
  • Code cancels with: Start or set process; remote on-off
643 Info No process loaded All models
Select a process to stop the Initial Checks (2) state of operation and start the Gas Purge/Pump On state (3). There is no limit for how long the system waits for input. Refer to Sequence of operation.
  • XPR action: None
  • Code cancels with: Start or set process; remote on-off
645 Info System is off All models
No operator action is necessary. Plasma cutting system operation continues when the remote on-off switch is set to the ON position. Refer to Sequence of operation.
  • XPR action: None
  • Code cancels with: Start or set process; remote on-off
646 Info System turned off All models
No operator action is necessary. Plasma cutting system operation continues when the remote on-off switch is set to the ON position. Refer to Sequence of operation.
  • XPR action: Shut down
  • Code cancels with: Start or set process; remote on-off
647 Info Process selected All models
No operator action is necessary.
  • XPR action: None
  • Code cancels with: Start or set process; remote on-off
651 Alert HF timeout XPR460
This code occurs when the high frequency output is on for more than 350 ms. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: None
  • Code cancels with: Set process; remote on-off
652 Error Block def over limit XPR460
This code occurs during the ramp-up or ramp-down state if the process block time definition is more than one second. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: Shut down
  • Code cancels with: Remote on-off
653 Error Block time over limit XPR460
This code occurs during the ramp-up or ramp-down state if the process block timer is more than one second. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: Shut down
  • Code cancels with: Remote on-off
654 Alert Ch1 ArcOn Timeout All models Troubleshooting for arc timeouts during the Ignite state
655 Alert Current (DC) preflow All models Troubleshooting for current in chopper during preflow
656 Error Default case XPR460
This code occurs when a default case is run unintentionally. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: Shut down
  • Code cancels with: Remote on-off
657 Error Bad block type XPR460
This code occurs when the block type is incorrect. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: Shut down
  • Code cancels with: Remote on-off
658 Alert Block def under limit XPR460
This code occurs when the process block duration is less than the minimum. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: End of cycle
  • Code cancels with: Start or set process; remote on-off
659 Alert State dur under limit XPR460
This code occurs when the state duration is less than the minimum. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: End of cycle
  • Code cancels with: Start or set process; remote on-off
660 Error Thermistor Fault–Ind 1 All models
Use a digital multimeter to measure the resistance from the thermistor. Refer to Measure resistance from thermistors.
  • XPR action: Shut down
  • Code cancels with: Remote on-off
661 Error Thermistor Fault–Ind 2 All models
662 Error Thermistor Fault–Ind 3 XPR300, XPR460
663 Error Thermistor Fault–Ind 4 XPR300, XPR460
664 Error Thermistor Fault–Ind 5 XPR460
665 Error Thermistor Fault–Ind 6 XPR460
666 Error Thermistor Fault–Xfmr All models
667 Error Thermistor Fault–Ch1 All models
Use a digital multimeter to measure the resistance from the thermistor. Refer to Measure resistance from thermistors.
  • XPR action: Ramp down
  • Code cancels with: Remote on-off
668 Error Thermistor Fault–Ch2 XPR300, XPR460
669 Error Thermistor Fault–Ch3 XPR460
670 Error Thermistor Fault–Coolant All models
Use a digital multimeter to measure the resistance from the thermistor. Refer to Measure resistance from thermistors.
  • XPR action: Shut down
  • Code cancels with: Remote on-off
671 Error No Thermistor–Ind 1 All models
672 Error No Thermistor–Ind 2 All models
673 Error No Thermistor–Ind 3 XPR300, XPR460
674 Error No Thermistor–Ind 4 XPR300, XPR460
675 Error No Thermistor–Ind 5 XPR460
676 Error No Thermistor–Ind 6 XPR460
677 Error No Thermistor–Xfmr All models
678 Error No Thermistor–Ch1 All models Make sure that the two wires for J9 are fully engaged. Use a digital multimeter to measure the resistance from the thermistor. Refer to Measure resistance from thermistors.
  • XPR action: Ramp down
  • Code cancels with: Remote on-off
679 Error No Thermistor–Ch2 XPR300, XPR460
680 Error No Thermistor–Ch3 XPR460
681 Error No Thermistor–Coolant All models
Use a digital multimeter to measure the resistance from the thermistor. Refer to Measure resistance from thermistors.
  • XPR action: Shut down
  • Code cancels with: Remote on-off
682 Error No Thermistor–Xfmr2 XPR460
683 Error Thermistor Fault–Xfmr2 XPR460
691 Error Node reset All models Troubleshooting for a console reset message
695 Alert Low inlet H2-Mix (OptiMix™ only) All models Troubleshooting for low inlet pressure for hydrogen, argon, or nitrogen
696 Alert Low inlet Ar-Mix (OptiMix only) All models
697 Alert Low inlet N2-Mix (OptiMix only) All models
699 Error Mix Fault (OptiMix only) All models
No operator action is necessary.
  • XPR action: Ramp down
  • Code cancels with: Set process; remote on-off
700 Alert Gas Inlet F5–GCC (VWI™ or OptiMix only) All models Troubleshooting for low inlet pressure for hydrogen, argon, or nitrogen
701 Alert Low Inlet H2O–GCC (VWI or OptiMix only) All models
702 Alert Shield Gas Inlet N2–TCC All models
703 Alert Shield Gas Inlet O2–TCC All models Troubleshooting for shield gas inlet pressure in the console
704 Alert Shield Gas Inlet Air–TCC All models
705 Alert Shield Gas Inlet Ar–TCC All models
706 Error No sensor P1–TCC All models Troubleshooting for pressure transducer faults
707 Error No sensor P2–TCC All models
708 Error No sensor P3–TCC All models
709 Error No sensor P4–TCC All models
710 Error No sensor P5–TCC All models
711 Error No sensor P14–TCC All models
712 Error No sensor P6–GCC (VWI or OptiMix only) All models
713 Error No sensor P7–GCC (VWI or OptiMix only) All models
714 Error No sensor P8–GCC (VWI or OptiMix only) All models
715 Error No sensor P9–GCC All models
716 Alert Process Invalid All models Troubleshooting for invalid processes
717 Alert Low voltage–mix (OptiMix only) All models
Confirm the output voltage of the 24 VDC power source in the gas connect console. Make sure that the output voltage is 24 VDC.
  • XPR action: Ramp down
  • Code cancels with: Set process; remote on-off
718 Alert High voltage–mix All models
719 Alert Mix pwm 100% All models Troubleshooting for duty cycle limit on proportional valve supply voltage
720 Alert Mix P21>Pin All models Troubleshooting for pressure out is greater than pressure in
721 Error Mix checksum All models Troubleshooting for gas mixture faults
722 Error Mix flow cal All models
723 Error Mix pressure cal All models
724 Error Mix I2C1 All models Troubleshooting for gas mixture communication errors
725 Error Mix I2C2 All models
726 Error Mix system clock All models Troubleshooting for gas mixture faults
727 Error Bad Temp Reading–Ch1 XPR460
These codes occur when consecutive temperature samples are different by more than 2°. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: Ramp down
  • Code cancels with: Start or set process; remote on-off
728 Error Bad Temp Reading–Ch2 XPR460
729 Error Bad Temp Reading–Ch3 XPR460
730 Alert Solenoid error V1 All models Troubleshooting for solenoid valve V1 in the console
733 Alert Solenoid error V4 All models Troubleshooting for solenoid valves V4 – V12 in the console
734 Alert Solenoid error V5 All models
735 Alert Solenoid error V6 All models
736 Alert Solenoid error V7 All models
737 Alert Solenoid error V8 All models
738 Alert Solenoid error V9 All models
739 Alert Solenoid error V10 All models
740 Alert Solenoid error V11 All models
741 Alert Solenoid error V12 All models
742 Alert Mix I2C1 Alert All models Troubleshooting for gas mixture communication errors
743 Alert Mix I2C2 Alert All models
744 Alert Low Speed–MagFan 1 All models Troubleshooting for low fan speeds – MAGFAN
745 Alert Low Speed–MagFan 2 All models
746 Alert Low Speed–MagFan 3 XPR460
747 Alert Low Speed–CabFan 1 XPR460 Troubleshooting for low fan speeds – CAB FAN 1
748 Alert Low Speed–HxFan 1 All models Troubleshooting for low fan speeds – HXFAN
749 Alert Low Speed–HxFan 2 XPR300, XPR460
750 Alert Low Speed–CtrlFan 1 XPR170™, XPR300 This system does not use this code.
751 Alert Low Speed–CtrlFan 2 XPR170, XPR300 This system does not use this code.
752 Error Phase Fault–Ch1 All models Troubleshooting for phase errors in choppers
753 Error Phase Fault–Ch2 XPR300, XPR460
754 Error Phase Fault–Ch3 XPR460
755 Alert Low level–Coolant All models
Fill the coolant reservoir with coolant. Refer to Fill the cutting system with coolant.
  • XPR action: None
  • Code cancels with: Set process; remote on-off
756 Info Leak test results All models Do a gas leak test
757 Error DC work exceeds limit All models
Make sure that you have the most recent XPR firmware. You can log into the Xnet at www.hypertherm.com to download it. If the code continues, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: End of cycle
  • Code cancels with: Remote on-off
758 Alert Main 24V dip All models
Make sure that you have the most recent XPR firmware. You can log into the Xnet at www.hypertherm.com to download it. If the code continues, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: None
  • Code cancels with: Set process; remote on-off
759 Alert GCC 24V bus low All models
Make sure that you have the most recent XPR firmware. You can log into the Xnet at www.hypertherm.com to download it. If the code continues, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: Ramp down
  • Code cancels with: Set process; remote on-off
763 Alert Coolant solenoid fault XPR170, XPR300 This system does not use this code.
764 Alert Main contactor fault All models Troubleshooting for a main contactor fault
765 Alert Inrush contactor fault XPR300, XPR460 Troubleshooting for an inrush contactor fault
766 Alert Pump enable fault All models Troubleshooting for a pump-enable fault or remote-relay fault
767 Alert Remote relay fault All models
768 Alert Gas Inlet – O2 Line A All models Troubleshooting for gas inlet pressure faults
769 Alert Gas Inlet – Argon Line B All models
770 Alert Gas Inlet – N2 Line B All models
771 Alert Gas Inlet – Air Line A All models Troubleshooting for gas inlet pressure faults
772 Alert High inlet line A All models
Decrease the air or O2 inlet pressure.
  • XPR action: Ramp down
  • Code cancels with: Set process; remote on-off
773 Info System reverted to VWI XPR460
This code occurs when the system changes from an OptiMix system to a VWI system as a result of an error condition. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: None
  • Code cancels with: Start or set process; remote on-off
774 Alert P5 >= P2 All models
Increase the air inlet pressure.
  • XPR action: Ramp down
  • Code cancels with: Set process; remote on-off
775 Alert Node update All models
Refer to the XPR Firmware Updates Field Service Bulletin (809820).
  • XPR action: None
  • Code cancels with: Start or set process; remote on-off
776 Alert Wifi reset All models
The wireless module was reset. Decrease the number of wireless connections to the plasma cutting system.
  • XPR action: None
  • Code cancels with: Start or set process; remote on-off
777 Alert Pilot relay fault All models Troubleshooting for a pilot relay fault
778 Alert Hv relay fault XPR170, XPR300 This system does not use this code.
779 Error Ch1 15V bus All models Troubleshooting for high or low chopper voltage
780 Error Ch2 15V bus XPR300, XPR460
781 Error Ch3 15V bus XPR460
782 Alert Low psi–P2 All models
Increase the air inlet pressure.
  • XPR action: None
  • Code cancels with: Set process; remote on-off
784 Error Main 24V high All models Troubleshooting for high voltage on the 24 V power supply
785 Alert Cooler Fan1 Tach XPR460
These codes occur when feedback for a fan tachometer is less than the minimum. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: None
  • Code cancels with: Start or set process; remote on-off
786 Alert Cooler Fan2 Tach XPR460
787 Alert Cooler Fan3 Tach XPR460
788 Alert Cooler Fan4 Tach XPR460
789 Alert Fieldbus fault All models
This code occurs when there is an error during communication with the fieldbus (field bus) module. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: None
  • Code cancels with: Start or set process; remote on-off
790 Error Eco mode timeout XPR460
This code occurs when the system cannot find choppers after it gets out of eco mode. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: None
  • Code cancels with: Remote on-off
791 Error No Thermistor–Con Xfmr All models
Use a digital multimeter to measure the resistance from the thermistor. Refer to Measure resistance from thermistors.
  • XPR action: Shut down
  • Code cancels with: Remote on-off
792 Error Thermistor Fault–Con Xfmr All models
Use a digital multimeter to measure the resistance from the thermistor. Refer to Measure resistance from thermistors.
  • XPR action: Shut down
  • Code cancels with: Remote on-off
793 Error Over temp–Con Xfmr All models Troubleshooting for over-temperature faults for inductors and transformers
794 Alert No MAC found All models
This code occurs when the main control cannot use a Media Access Control (MAC) address from the EEPROM. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: None
  • Code cancels with: Start or set process; remote on-off
795 Alert Cooler 24V XPR460
This code occurs when the 24 VDC bus is less than 20 V. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: None
  • Code cancels with: Start or set process; remote on-off
797 Error Firmware Version Mismatch XPR460
Make sure that you have the most recent XPR firmware. You can log into the Xnet at www.hypertherm.com to download it. If you continue to get this code, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  • XPR action: None
  • Code cancels with: Remote on-off
Note:

Refer to Sequence of operation for descriptions of cutting system operations.