Troubleshooting / Hypertherm Powermax errors

Hypertherm Powermax Error Codes

Every plasma fault stops the cutting table, and in OEE it is lost availability. These are the error codes of Hypertherm Powermax plasma systems (45 XP, 65, 85, 105, 125 and the SYNC models): what each code means, which models show it, the likely causes, the first checks, and how to log it so it stops coming back.

How errors show

On Powermax65, 85, 105 and 125 (non-SYNC) a fault icon and code appear in the lower-left corner of the LCD. The operator screen shows a short code such as 0-30. Press the auto/manual and current/gas buttons together for about 2 seconds to open the service screen, where F shows the full code (0-30-0 or 0-30-1) and a log of internal 1-, 2- and 3- codes.

SYNC models show the full code with an icon, and the torch LED turns yellow or red. Powermax45 XP and 45 SYNC flash the code in three parts on a 2-digit display; some faults show only by LEDs. Warnings let you keep cutting, faults stop the arc.

Safety first.
Before you open the case or work on the torch, switch the unit off and unplug it, or lock out and tag the disconnect. The bulk capacitors stay charged for minutes after switch off: Hypertherm says wait about 10 minutes. Let the power supply cool first, since parts stay hot for up to an hour. The torch fires instantly, so switch off or lock the torch before changing consumables.

Work inside the cover is for qualified technicians only. Follow lockout/tagout and your site's safe-work procedures, and check the manual for your exact model before you act.

Quick lookup

Faults stop the arc and the table, so in OEE they are availability losses; a warning lets you keep cutting, often with worse cut quality, until you act.

Type a code or a word (gas, torch, cap, temperature) to filter the list. Click a code for its causes and first checks. The operator screen shows the short form (0-30); the table uses the full code from the service screen (0-30-0).

67 codes

CodeName
0-11-0Remote controller cut mode invalid
0-11-1Remote controller current invalid
0-11-2Remote controller pressure invalid
0-12-0Low input gas pressure (warning)
0-12-1Output gas pressure low
0-12-2Output gas pressure high
0-12-3Output gas pressure unstable
0-13-0AC input unstable (line resonance)
0-14-0Cartridge installation problem
0-14-1Cartridge not recognized
0-19-9Power board hardware protection
0-20-0Low gas pressure
0-21-0Gas flow lost while cutting
0-22-0No gas input
0-30-0Torch stuck open
0-30-1Torch stuck closed
0-32-0End of consumable life
0-32-1Cartridge at end of life reinstalled
0-40-0PFC/Boost IGBT module under temperature
0-40-1PFC/Boost IGBT module over temperature
0-40-2Inverter IGBT module under temperature
0-40-3Inverter IGBT module over temperature
0-40-5Duty cycle exceeded
0-50-0Retaining cap off
0-50-1Torch-lock switch in lock (X) position
0-50-2Torch unlocked but not prepared to fire
0-50-3Reading cartridge data
0-51-0Start/trigger signal on at power up
0-52-0Torch not connected
0-60-0AC input voltage phase loss
0-60-1AC input voltage too low (under voltage)
0-60-2AC input voltage too high (over voltage)
0-61-0AC input unstable: shutdown
0-98-0Internal communication failure
0-98-1RF communication failure (cartridge to torch)
0-98-2Torch to power supply communication failure
0-99-0System hardware fault (service required)
1-00-0Digital signal processor (DSP) fault
1-10-0A/D converter fault
1-20-0I/O fault
1-30-0Flash memory fault
2-00-0A/D converter value out of range
2-01-0Auxiliary switch disconnected
2-10-0Inverter module temperature sensor open
2-10-1Inverter module temperature sensor shorted
2-11-0Pressure sensor open
2-11-1Pressure sensor shorted
2-20-0Torch ID
3-00-0DC bus voltage (VBUS) out of range
3-10-0Fan speed
3-10-1Fan fault
3-11-0PFC module temperature sensor open
3-11-1PFC module temperature sensor shorted
3-11-2PFC module temperature sensor circuit fault
3-20-0Fill valve
3-20-1Dump valve
3-20-2Valve ID
3-20-3Electronic regulator is disconnected
3-41-0Drive fault
3-42-05 or 24 VDC fault
3-42-118 VDC fault
3-43-0Inverter capacitors unbalanced
3-44-1PFC over current
3-51-1Inverter saturation fault
3-52-0Shoot through
3-60-0Power board
3-70-0Internal serial communications fault

Each code: causes and first checks

0-11-0: Remote controller cut mode invalid

Warning: act before it becomes a stop

What it means: The CNC or remote controller sent an operating mode the power supply cannot accept, so the setting is ignored.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Wrong mode number in the CNC program or serial command
  • On SYNC models, a mode that does not suit the installed cartridge (cut cartridge: mode 1 or 2, gouge cartridge: mode 3; Powermax45 SYNC: 1 cut, 2 gouge)
  • Damaged RS-485 or interface cable

First checks, in this order

  1. Check the mode value the CNC program sends
  2. Check that the installed consumables or cartridge match that mode
  3. Inspect the interface cable and its connectors
  4. Have the controller software corrected if the value is wrong

0-11-1: Remote controller current invalid

Warning: act before it becomes a stop

What it means: The controller asked for an output current outside the range the power supply (or the installed SYNC cartridge) allows.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Current value in the CNC program is too high or too low (Powermax45 XP accepts 10 to 45 A)
  • Cartridge or consumables do not match the requested amperage
  • Interface cable fault

First checks, in this order

  1. Compare the programmed amperage with the machine and consumable rating
  2. Correct the process variable in the CNC program
  3. Inspect the interface cable

0-11-2: Remote controller pressure invalid

Warning: act before it becomes a stop

What it means: The controller requested a gas pressure that is not allowed for the selected process, mode, torch and lead length.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Pressure value in the CNC program outside the allowed window
  • Torch, lead length or cartridge differs from what the program assumes
  • Interface cable fault

First checks, in this order

  1. Check the programmed gas pressure against the cut chart for that torch and lead
  2. Correct the CNC process variable
  3. Inspect the interface cable

0-12-0: Low input gas pressure (warning)

Warning: act before it becomes a stop

What it means: Older Powermax65/85 firmware warns that the incoming air pressure is low; the machine keeps running.[1][10]

Also on: Models: Powermax65, 85 (DSP firmware revision E or earlier).

Likely causes

  • Supply pressure set too low
  • Restricted or undersized supply hose
  • Dirty air filter element

First checks, in this order

  1. Raise the inlet gas pressure at the compressor or regulator
  2. Check the supply hose and filter
  3. Run a gas test and compare set and actual pressure

0-12-1: Output gas pressure low

Warning: act before it becomes a stop

What it means: The pressure leaving the power supply's regulator is below the set value; cutting continues but cut quality can suffer.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP and 45 SYNC (shown on a CNC only), 105 (listed as 0-12-X), 125, 65/85/105 SYNC; Powermax65/85: see note. Powermax65/85 service manual 807120: on DSP firmware J or later 0-12-1 means pressure high and 0-12-2 means low; on older firmware the reverse.

Likely causes

  • Low inlet pressure
  • Kinked or blocked air line or torch lead
  • Regulator or valve not working correctly

First checks, in this order

  1. Raise the inlet pressure (SYNC guide: hold 110 to 120 psi, 7.6 to 8.3 bar, while flowing; never above 135 psi, 9.3 bar)
  2. Straighten or clear kinked or blocked lines
  3. Run a gas test and compare set and actual pressure
  4. If still low, have the valve and pressure sensor tested (Test 10)

0-12-2: Output gas pressure high

Warning: act before it becomes a stop

What it means: The regulated output pressure is above the set value; the system keeps running.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP and 45 SYNC (shown on a CNC only), 105 (listed as 0-12-X), 125, 65/85/105 SYNC; Powermax65/85: see note. Powermax65/85 service manual 807120: meaning of 0-12-1 and 0-12-2 swaps with DSP firmware revision (J or later: 0-12-2 is low).

Likely causes

  • Inlet pressure too high
  • Regulator or valve fault

First checks, in this order

  1. Lower the inlet pressure into the allowed range
  2. Run a gas test and compare set and actual pressure
  3. Have the valve and pressure sensor tested (Test 10)

0-12-3: Output gas pressure unstable

Warning: act before it becomes a stop

What it means: The output pressure is swinging instead of holding steady; cutting continues.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP and 45 SYNC (shown on a CNC only), 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Supply pressure fluctuating, for example other tools sharing the air line
  • Partly blocked line or filter
  • Regulator or valve not working correctly

First checks, in this order

  1. Check the supply pressure while gas is flowing
  2. Check filters and hoses for restriction
  3. Run a gas test for a few minutes and watch the reading
  4. Have the valve tested (Test 10)

0-13-0: AC input unstable (line resonance)

Warning: act before it becomes a stop

What it means: The incoming power is unstable; the system keeps working, sometimes at reduced capacity. On non-SYNC units the Power LED blinks fast (3 Hz).[1][2][3][4][6]

Also on: Models: Powermax45 XP, 65, 85, 105, 125, 65/85/105 SYNC. Powermax45 SYNC: same condition shown by a flashing Power ON LED, no code.

Likely causes

  • Weak or unstable supply line
  • Running on a generator
  • Line impedance causing resonance

First checks, in this order

  1. Do a cold restart
  2. If on a generator, move to mains power (SYNC models also offer a GEN setting)
  3. If it keeps returning, have an electrician check and correct the supply

0-14-0: Cartridge installation problem

Hits OEE: Availability

What it means: A SYNC cartridge was installed but could not pass its data to the power supply; the system stops until this is cleared.[6][8][9]

Also on: Models: Powermax45 SYNC, 65/85/105 SYNC.

Likely causes

  • Cartridge not seated correctly
  • Electrical noise, for example from TIG welders nearby
  • Bad data connection

First checks, in this order

  1. Switch the torch lock to the yellow X position and back to green
  2. Do a quick restart
  3. Remove and reinstall the cartridge
  4. Reduce electrical noise near the work area

0-14-1: Cartridge not recognized

Warning: act before it becomes a stop

What it means: The cartridge cannot send its data, so you can keep cutting but must set amperage and mode by hand and no cartridge data is logged.[6][8][9]

Also on: Models: Powermax45 SYNC, 65/85/105 SYNC.

Likely causes

  • Dust or dirt in the cartridge
  • Broken green ring inside the cartridge
  • Faulty cartridge

First checks, in this order

  1. Blow light air into the cartridge to clean it and reinstall it
  2. Look inside the cartridge for a broken green ring
  3. Install a new cartridge

0-19-9: Power board hardware protection

Hits OEE: Availability

What it means: The power board saw a hardware problem or electrical noise and shut the inverter off for a few seconds. Non-SYNC manuals call it a warning (alert) because it often clears itself.[1][2][3][6][8]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC, 45 SYNC (on a CNC or cartridge reader only).

Likely causes

  • Electrical noise
  • Input power dropped out
  • Repeated real hardware fault, often inverter saturation (3-51-1) or a bad auxiliary switch (2-01-0)

First checks, in this order

  1. Wait a few seconds and try cutting again
  2. If it shows at power up, wait 1 minute to see whether 0-99 (non-SYNC) or a 2- or 3- code appears
  3. Open the service screen or fault log to read the hardware code
  4. If 0-99 follows after 1 minute, have the auxiliary power switch tested (Test 12)

0-20-0: Low gas pressure

Warning: act before it becomes a stop

What it means: Gas pressure is below the minimum for the selected process, mode, torch and lead length. SYNC manuals say the system keeps running; the fault LED still lights.[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC. Powermax45 XP and 45 SYNC: shown by the Gas Pressure and System Fault LEDs, no code.

Likely causes

  • Inlet pressure too low (non-SYNC manuals give 85 to 135 psi, 5.9 to 9.3 bar)
  • Dirty air filter element
  • Supply hose too small or restricted
  • Leaks at fittings

First checks, in this order

  1. Check all supply connections for leaks
  2. Check the inlet pressure while flowing
  3. Replace a dirty filter element and clean the bowl
  4. Use at least 3/8 in (10 mm) ID hose, 1/2 in (13 mm) for runs of 15 to 30 m
  5. Run a gas test and compare set and actual pressure

0-21-0: Gas flow lost while cutting

Hits OEE: Availability

What it means: The DSP saw a sudden jump in nozzle to electrode voltage, which usually means air was lost, and shut the inverter off. The Powermax125 calls it excessive arc voltage change.[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Kinked or blocked supply line or torch lead
  • Leak in the torch lead
  • Worn consumables or cartridge
  • Torch height control interfering (mechanized cutting)
  • Regulator not passing air

First checks, in this order

  1. Check inlet pressure and look for kinks or blockages
  2. Inspect the torch lead for leaks, kinks or twists
  3. Replace the consumables or cartridge
  4. On a CNC, lock out torch height control and retest
  5. In gas test mode confirm air flows through the regulator

0-22-0: No gas input

Hits OEE: Availability

What it means: The power supply senses no air at its inlet and will not fire.[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC. Powermax45 XP and 45 SYNC: Gas Pressure LED blinks, no code.

Likely causes

  • Air supply disconnected or turned off
  • Blocked gas line
  • Faulty pressure switch or sensor

First checks, in this order

  1. Connect or turn on the air supply
  2. Check the line for blockages and loose fittings
  3. Restart the power supply
  4. If air is present, have the pressure sensor tested (Test 10)

0-30-0: Torch stuck open

Hits OEE: Availability

What it means: After a start signal the nozzle and electrode are not touching, so the pilot arc cannot start. The operator screen shows 0-30 (Torch consumables stuck in the 65/85 operator manual).[1][2][3][6][10][11]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC. Powermax45 XP and 45 SYNC: Torch Cap LED blinks slowly, no code.

Likely causes

  • Wrong consumables, or consumables loosened or changed with power on
  • Wet or oily air
  • Damaged or pitted electrode contact face
  • Deformed swirl ring
  • Debris inside a SYNC cartridge (more common near end of life)
  • Damaged torch

First checks, in this order

  1. Turn the power off, refit or replace the consumables, then turn it on to clear
  2. Check the air for water or oil
  3. Inspect the electrode and swirl ring and replace damaged parts
  4. SYNC: shake loose debris from the cartridge or fit a new one
  5. Try a torch you know is good
  6. Service: run Test 6

0-30-1: Torch stuck closed

Hits OEE: Availability

What it means: After a start signal the nozzle and electrode will not separate, so no arc forms.[1][2][3][6][11]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC. Powermax45 XP and 45 SYNC: Torch Cap LED blinks rapidly, no code.

Likely causes

  • Low gas pressure from restrictions, leaks or a small hose
  • Damaged or deformed swirl ring
  • Regulator not working correctly

First checks, in this order

  1. Check inlet pressure, hoses and filters
  2. Replace the consumables including the swirl ring
  3. Non-SYNC: in the service screen set G to 1 (gas test); only the dump valve light should be on
  4. Replace the regulator if the gas test fails
  5. Try a known good torch

0-32-0: End of consumable life

Hits OEE: Availability

What it means: The system detected that the electrode and nozzle (or the SYNC cartridge) are worn out and stops until they are replaced.[2][3][6]

Also on: Models: Powermax105, 125, 65/85/105 SYNC.

Likely causes

  • Worn electrode and nozzle
  • Cartridge at end of life (SYNC)
  • Electrical noise near the machine (Powermax125 manual)

First checks, in this order

  1. Replace the electrode and nozzle, or install a new SYNC cartridge
  2. Check the other consumables for wear
  3. Powermax125: if parts are new, try another circuit or location

0-32-1: Cartridge at end of life reinstalled

Warning: act before it becomes a stop

What it means: A SYNC cartridge that already triggered 0-32-0 was fitted again; you can cut, but Hypertherm strongly advises a new cartridge.[6][7]

Also on: Models: Powermax65/85/105 SYNC.

Likely causes

  • Worn cartridge put back in the torch

First checks, in this order

  1. Install a new cartridge

0-40-0: PFC/Boost IGBT module under temperature

Hits OEE: Availability

What it means: The boost (PFC) IGBT is too cold to run safely.[1][2][6]

Also on: Models: Powermax65, 85, 105, 65/85/105 SYNC (SYNC: CSA models and 105 SYNC 230 to 400 V CE only). Powermax45 XP and 45 SYNC: temperature faults show on the Temperature LED, no code.

Likely causes

  • Unit stored or used in very cold conditions
  • Faulty temperature sensor or circuit

First checks, in this order

  1. Move the unit somewhere warmer if near minus 30 C (minus 22 F)
  2. Have the temperature sensors checked (Test 4)

0-40-1: PFC/Boost IGBT module over temperature

Hits OEE: Availability

What it means: The boost (PFC) IGBT is too hot and the system stops until it cools.[1][2][6]

Also on: Models: Powermax65, 85, 105, 65/85/105 SYNC (SYNC: CSA models and 105 SYNC 230 to 400 V CE only). Powermax45 XP and 45 SYNC: Temperature LED, no code.

Likely causes

  • Duty cycle exceeded
  • Fan not running
  • Blocked airflow or cover fitted the wrong way round

First checks, in this order

  1. Leave the power on so the fan can cool the unit
  2. Check the fan runs (Test 11)
  3. Clear space around the unit
  4. Make sure the cover louvers face the fan
  5. Work within the rated duty cycle

0-40-2: Inverter IGBT module under temperature

Hits OEE: Availability

What it means: The inverter IGBT is too cold to run.[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC. Powermax45 XP and 45 SYNC: Temperature LED, no code.

Likely causes

  • Very cold location
  • Faulty inverter temperature sensor

First checks, in this order

  1. Move the unit to a warmer place if near minus 30 C (minus 22 F)
  2. Have the inverter temperature sensor checked (Test 4)

0-40-3: Inverter IGBT module over temperature

Hits OEE: Availability

What it means: The inverter IGBT is too hot and cutting stops until it cools (Powermax125 trips above about 76 to 81 C depending on model).[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC. Powermax45 XP and 45 SYNC: Temperature LED, no code.

Likely causes

  • Duty cycle exceeded
  • Fan not running or dirty
  • Poor airflow, component barrier missing or cover reversed

First checks, in this order

  1. Keep the unit powered on so the fan cools it
  2. Confirm the fan runs (Test 11)
  3. Clear airflow around the unit and check the cover and barrier
  4. Reduce arc on time to stay within duty cycle

0-40-5: Duty cycle exceeded

Hits OEE: Availability

What it means: The Powermax45 SYNC reached its duty cycle limit and must cool for at least 3.5 minutes.[8][9]

Also on: Models: Powermax45 SYNC.

Likely causes

  • Long continuous arc on time at high amperage
  • Poor airflow
  • Fan not working

First checks, in this order

  1. Let the unit cool
  2. Clear space around the unit
  3. Check the fan runs
  4. Lower the amperage or shorten continuous cuts

0-50-0: Retaining cap off

Hits OEE: Availability

What it means: The cap sensor says the consumables are missing or loose. On SYNC models it also shows if the cartridge is off, the torch was unplugged at power on, or the torch was locked during a restart.[1][2][3][6][10]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC. Powermax45 XP and 45 SYNC: Torch Cap LED on, no code.

Likely causes

  • Consumables or retaining cap missing, loose or wrong
  • Cartridge not installed correctly (SYNC)
  • Torch disconnected when the unit was switched on
  • Cap sensor switch or torch plunger damaged

First checks, in this order

  1. Turn the power off and fit the correct consumables and cap
  2. SYNC: set the torch lock to green, refit the cartridge, then quick restart
  3. Check the plunger in the torch head springs back freely
  4. Service: with the cap fitted, torch connector pins 5 and 7 should show continuity (Test 8)
  5. Try a known good torch, then do a cold restart

0-50-1: Torch-lock switch in lock (X) position

Hits OEE: Availability

What it means: The SmartSYNC torch lock switch is set to the yellow X, so the torch will not fire.[6][8]

Also on: Models: Powermax45 SYNC, 65/85/105 SYNC (not the mini machine torch).

Likely causes

  • Torch left locked after a consumable change

First checks, in this order

  1. Move the switch to the green ready to fire position
  2. Hand torch: pull the trigger once for the warning air puffs, then again to cut

0-50-2: Torch unlocked but not prepared to fire

Hits OEE: Availability

What it means: A normal step: the lock switch is on green but the hand torch still needs one trigger pull before it will make an arc.[6][8]

Also on: Models: Powermax45 SYNC, 65/85/105 SYNC (not the mini machine torch).

Likely causes

  • Torch was just unlocked or restarted

First checks, in this order

  1. Hand torch: pull the trigger once to get the warning puffs, then fire again
  2. Machine torch: it clears in about 1 second; if not, send a STOP from the CNC

0-50-3: Reading cartridge data

Hits OEE: Availability

What it means: A normal status: the system is reading the SYNC cartridge and will not cut until it finishes.[6][8]

Also on: Models: Powermax45 SYNC, 65/85/105 SYNC.

Likely causes

  • Cartridge just installed
  • Electrical noise slowing the data read (up to about 6 seconds)

First checks, in this order

  1. Wait for the code to clear by itself
  2. Hand torch: expect 0-50-2 next, then pull the trigger once
  3. If a different code appears, troubleshoot that code

0-51-0: Start/trigger signal on at power up

Hits OEE: Availability

What it means: The power supply was getting a start signal at the moment it was switched on (a stuck start), so it disables itself.[1][2][3][4][6]

Also on: Models: Powermax45 XP, 65, 85, 105, 125, 65/85/105 SYNC. Powermax45 SYNC: fault LEDs flash alternately, no code.

Likely causes

  • Trigger held while switching on
  • CNC sending a start signal at power up
  • Shorted trigger switch or torch wiring

First checks, in this order

  1. Release the trigger or remove the CNC start signal
  2. Do a quick restart
  3. Service: pins 6 and 7 of the torch connector should read very low resistance when the trigger is pulled
  4. Try a known good torch

0-52-0: Torch not connected

Hits OEE: Availability

What it means: No torch is detected in the FastConnect receptacle.[1][2][3][6][8]

Also on: Models: Powermax45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Torch lead unplugged or not fully seated
  • Torch unplugged while the unit was on
  • Damaged receptacle pins

First checks, in this order

  1. Push the torch lead fully into the FastConnect receptacle
  2. Cycle the power switch
  3. Service: run a continuity check on the receptacle

0-60-0: AC input voltage phase loss

Hits OEE: Availability

What it means: One phase of the 3-phase supply is missing; the system stops and needs a cold restart once fixed.[1][2][3][4][6]

Also on: Models: Powermax45 XP (3-phase), 65, 85, 105, 125, 65/85/105 SYNC (SYNC: CE models and 105 SYNC CSA only). Powermax45 SYNC: shown by a flashing LED, no code.

Likely causes

  • Blown fuse or tripped breaker on one phase
  • Loose supply connection
  • Generator problem

First checks, in this order

  1. Have an electrician check every phase and fuse at the panel and at the machine
  2. If on a generator, test on mains power
  3. Do a cold restart after the fix

0-60-1: AC input voltage too low (under voltage)

Hits OEE: Availability

What it means: Line voltage is below the allowed range (roughly more than 10 to 15 percent under rating, by model).[1][2][3][4][6]

Also on: Models: Powermax45 XP, 65, 85, 105, 125, 65/85/105 SYNC (not 65/85 SYNC CSA). Powermax45 SYNC: shown by a flashing LED, no code.

Likely causes

  • Undersized supply or long extension cable
  • Supply sagging under load
  • Small generator

First checks, in this order

  1. Have an electrician measure the voltage at the machine and raise it
  2. Test on mains power if using a generator
  3. Do a cold restart

0-60-2: AC input voltage too high (over voltage)

Hits OEE: Availability

What it means: Line voltage is above the allowed range (about 10 percent over rating, up to 20 percent on 3-phase 45 XP).[1][2][3][4][6]

Also on: Models: Powermax45 XP, 65, 85, 105, 125, 65/85/105 SYNC (not 65/85 SYNC CSA). Powermax45 SYNC: shown by a flashing LED, no code.

Likely causes

  • Supply set too high or wrong tap
  • Generator overshooting

First checks, in this order

  1. Have an electrician measure and lower the supply voltage
  2. Test on mains power if using a generator
  3. Do a cold restart

0-61-0: AC input unstable: shutdown

Hits OEE: Availability

What it means: Incoming current is so unstable that the system shuts down.[1][2][3][4][6]

Also on: Models: Powermax45 XP, 65, 85, 105, 125, 65/85/105 SYNC (not 65/85 SYNC CSA).

Likely causes

  • Line resonance on the supply
  • Phase converter in use
  • Generator power

First checks, in this order

  1. Power down and have the line problem corrected
  2. Try a different AC source
  3. Do not run the unit from a phase converter
  4. Do a cold restart after the fix

0-98-0: Internal communication failure

Warning: act before it becomes a stop

What it means: The control (LCD) board and the DSP board are not talking. SYNC manuals say it can still cut but the front panel controls stop working; non-SYNC tables show the fault LED on.[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Loose or damaged ribbon cable between the control board and DSP board
  • Board fault

First checks, in this order

  1. Do a cold restart
  2. Service: check the ribbon cable is fully seated on both boards
  3. Replace the ribbon cable if the fault returns

0-98-1: RF communication failure (cartridge to torch)

Warning: act before it becomes a stop

What it means: The SYNC cartridge and torch cannot talk by radio; you can keep cutting but must set amperage and mode by hand.[6][8][9]

Also on: Models: Powermax45 SYNC, 65/85/105 SYNC.

Likely causes

  • Cartridge not fitted correctly
  • Broken green ring inside the cartridge
  • Damaged RF part or loose wires on the torch PCB

First checks, in this order

  1. Refit the cartridge
  2. Check the green ring inside the cartridge
  3. Install a new cartridge
  4. Service: check the torch PCB wiring (Test 14)

0-98-2: Torch to power supply communication failure

Warning: act before it becomes a stop

What it means: The SmartSYNC torch is not sending data to the power supply; cutting can continue with manual settings. The torch LED flashes yellow slowly.[6][8][9]

Also on: Models: Powermax45 SYNC, 65/85/105 SYNC.

Likely causes

  • Torch PCB fault
  • Damaged torch lead
  • Quick-disconnect receptacle problem
  • Communication circuit on the power supply PCB

First checks, in this order

  1. Reseat the torch lead in the receptacle
  2. Inspect the lead and connector pins
  3. Service: run Test 14 to find the faulty part

0-99-0: System hardware fault (service required)

Hits OEE: Availability

What it means: A major hardware fault was found; the operator screen shows 0-99 and the real cause is a 1-, 2- or 3- code in the fault log.[1][2][3][10]

Also on: Models: Powermax65, 85, 105, 125 (non-SYNC).

Likely causes

  • Repeated 0-19-9 events
  • Any internal 1-nn-n, 2-nn-n or 3-nn-n fault

First checks, in this order

  1. Open the service screen (press the auto/manual and current/gas buttons together for about 2 seconds)
  2. Read the live code in the F field and the fault log
  3. Have a qualified technician repair the unit

1-00-0: Digital signal processor (DSP) fault

Hits OEE: Availability

What it means: An internal processor self check failed; it is often not a hardware failure.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Internal processor check error
  • Failed DSP board or power board

First checks, in this order

  1. Do a cold restart
  2. If it returns, have a technician replace the DSP or power board (Powermax45 XP: power board)

1-10-0: A/D converter fault

Hits OEE: Availability

What it means: The analog to digital converter self check failed.[1][2][3][4]

Also on: Models: Powermax45 XP, 65, 85, 105, 125.

Likely causes

  • Internal processor check error
  • Failed DSP or power board

First checks, in this order

  1. Do a cold restart
  2. If it returns, have the DSP or power board replaced

1-20-0: I/O fault

Hits OEE: Availability

What it means: An input/output self check on the control electronics failed.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Internal processor check error
  • Failed DSP or power board

First checks, in this order

  1. Do a cold restart
  2. If it returns, have the DSP or power board replaced

1-30-0: Flash memory fault

Hits OEE: Availability

What it means: The DSP board's flash memory check failed.[6]

Also on: Models: Powermax65/85/105 SYNC.

Likely causes

  • Internal processor check error
  • Failed DSP or power board

First checks, in this order

  1. Do a cold restart
  2. If it returns, have the DSP or power board replaced

2-00-0: A/D converter value out of range

Hits OEE: Availability

What it means: An analog reading inside the unit is outside its expected range.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • DSP board fault
  • Power board fault

First checks, in this order

  1. Do a cold restart
  2. If it returns, have the DSP or power board replaced

2-01-0: Auxiliary switch disconnected

Hits OEE: Availability

What it means: The auxiliary contact on the main power switch is not reporting to the power board.[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Auxiliary switch cable unplugged or damaged
  • Faulty power switch auxiliary contact

First checks, in this order

  1. Check the auxiliary cable at the power switch and power board
  2. Service: Test 12, pins 4 and 5 should read low ohms with the switch ON and high with it OFF

2-10-0: Inverter module temperature sensor open

Hits OEE: Availability

What it means: The inverter heatsink temperature sensor reads as an open circuit.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Broken sensor wire or loose connector
  • Failed thermistor
  • Power board fault (Powermax45 models)

First checks, in this order

  1. Powermax45 models: do a cold restart first
  2. Check the sensor wiring
  3. Measure the thermistor: about 10 kilohms at room temperature (Test 4)
  4. Replace the heatsink temperature sensor assembly, or on Powermax45 models the power board

2-10-1: Inverter module temperature sensor shorted

Hits OEE: Availability

What it means: The inverter heatsink temperature sensor reads as a short circuit.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Pinched or shorted sensor wire
  • Failed thermistor
  • Power board fault (Powermax45 models)

First checks, in this order

  1. Powermax45 models: do a cold restart first
  2. Check the sensor wiring
  3. Measure the thermistor (Test 4)
  4. Replace the sensor assembly or power board as directed

2-11-0: Pressure sensor open

Hits OEE: Availability

What it means: The gas pressure sensor reads as an open circuit.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Unplugged or broken sensor wiring
  • Failed pressure sensor

First checks, in this order

  1. Check the sensor wiring and connector
  2. Run the pressure sensor test (Test 10; Powermax45 XP: Test 6)
  3. Replace the pressure sensor or valve assembly

2-11-1: Pressure sensor shorted

Hits OEE: Availability

What it means: The gas pressure sensor reads as a short circuit.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Shorted sensor wiring
  • Failed pressure sensor

First checks, in this order

  1. Check the sensor wiring
  2. Run the pressure sensor test
  3. Replace the pressure sensor or valve assembly

2-20-0: Torch ID

Hits OEE: Availability

What it means: The DSP cannot identify the torch plugged into the receptacle.[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Torch lead not fully seated
  • Wrong or damaged pins in the FastConnect receptacle
  • Damaged torch lead

First checks, in this order

  1. Reseat the torch lead and do a quick restart
  2. Service: check the receptacle pin-out and continuity against the wiring diagram

3-00-0: DC bus voltage (VBUS) out of range

Hits OEE: Availability

What it means: The internal DC bus voltage is outside its normal window.[1][2][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 65/85/105 SYNC.

Likely causes

  • PFC boost circuit or PFC IGBT fault (models with PFC)
  • Power board fault
  • Flyback supply problem

First checks, in this order

  1. Have a technician test the PFC IGBT
  2. Measure the bus voltage at the power board test points (Test 2, Powermax45 XP Test 3)
  3. Check the flyback circuit (Test 5) and replace the faulty board

3-10-0: Fan speed

Hits OEE: Availability

What it means: The cooling fan is turning slower than the minimum speed.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Dirt or debris on the fan
  • Worn fan

First checks, in this order

  1. Clean the fan assembly
  2. Run the fan test (Test 11; Powermax45 XP: Test 10)
  3. Replace the fan if it stays slow

3-10-1: Fan fault

Hits OEE: Availability

What it means: The fan is not working correctly.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Pinched or damaged fan wires
  • Loose fan connector on the power board
  • Failed fan

First checks, in this order

  1. Check the fan wiring and connector
  2. Run the fan test
  3. Replace the fan assembly

3-11-0: PFC module temperature sensor open

Hits OEE: Availability

What it means: The PFC IGBT temperature sensor reads as an open circuit.[1][2][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 65/85/105 SYNC (SYNC: CSA and 105 SYNC CE/CCC 230 to 400 V).

Likely causes

  • Wiring fault
  • Failed sensor inside the PFC module
  • Power board fault (Powermax45 models)

First checks, in this order

  1. Powermax45 models: do a cold restart first
  2. Check the associated wiring
  3. Run the temperature sensor test (Test 4)
  4. Replace the PFC IGBT module, or on Powermax45 models the power board

3-11-1: PFC module temperature sensor shorted

Hits OEE: Availability

What it means: The PFC IGBT temperature sensor reads as a short circuit.[1][2][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 65/85/105 SYNC (SYNC: CSA and 105 SYNC CE/CCC 230 to 400 V).

Likely causes

  • Wiring fault
  • Failed sensor inside the PFC module
  • Power board fault (Powermax45 models)

First checks, in this order

  1. Powermax45 models: do a cold restart first
  2. Check the associated wiring
  3. Run Test 4
  4. Replace the PFC IGBT module or power board

3-11-2: PFC module temperature sensor circuit fault

Hits OEE: Availability

What it means: The temperature measuring circuit for the PFC module on the power board is not working.[1][2][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 65/85/105 SYNC (SYNC: CSA and CE/CCC 230 to 400 V).

Likely causes

  • Power board temperature circuit fault

First checks, in this order

  1. Run Test 4
  2. If Test 4 passes, replace the power board

3-20-0: Fill valve

Hits OEE: Availability

What it means: The fill valve of the electronic regulator is not connected.[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Loose or damaged regulator wiring
  • Failed electronic regulator or solenoid valve assembly

First checks, in this order

  1. Check the regulator wiring
  2. Run Test 9
  3. Replace the electronic regulator or solenoid valve assembly

3-20-1: Dump valve

Hits OEE: Availability

What it means: The dump valve of the electronic regulator is not connected.[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Loose or damaged regulator wiring
  • Failed electronic regulator or solenoid valve assembly

First checks, in this order

  1. Check the regulator wiring
  2. Run Test 9
  3. Replace the electronic regulator or solenoid valve assembly

3-20-2: Valve ID

Hits OEE: Availability

What it means: The DSP does not recognize the electronic regulator fitted.[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Jumper on the power board in the wrong position
  • Harness fault between regulator and power board

First checks, in this order

  1. Check the jumper at J4 or J6 on the power board against the wiring diagram
  2. Check the regulator harness to the power board

3-20-3: Electronic regulator is disconnected

Hits OEE: Availability

What it means: The electronic regulator is not drawing current (not powered).[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Loose regulator connector on the power board (7-pin on non-SYNC, 10-pin on SYNC)
  • Failed regulator

First checks, in this order

  1. Inspect the regulator connector and wiring at J4 or J6
  2. Replace the electronic regulator or solenoid valve assembly

3-41-0: Drive fault

Hits OEE: Availability

What it means: A device on the power board, such as the start/transfer, machine motion or inrush relay, did not respond when told to switch.[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Relay or driver circuit fault on the power board

First checks, in this order

  1. Do a cold restart
  2. If it returns, have a technician check the power board relays and drive circuit

3-42-0: 5 or 24 VDC fault

Hits OEE: Availability

What it means: The 5 V or 24 V supply from the flyback circuit is out of range.[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Flyback circuit fault on the power board

First checks, in this order

  1. Run the flyback circuit test (Test 5)
  2. Replace the faulty board

3-42-1: 18 VDC fault

Hits OEE: Availability

What it means: The 18 V driver supply from the flyback circuit is out of range (Powermax125: driver voltage fault).[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Power board fault
  • Inverter IGBT fault

First checks, in this order

  1. Replace the power board
  2. Check the inverter IGBT and replace it if faulty

3-43-0: Inverter capacitors unbalanced

Hits OEE: Availability

What it means: The voltage on one or both inverter bulk capacitors is more than 25 percent away from nominal.[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Failed bulk capacitor
  • Inverter IGBT fault
  • DC bus problem

First checks, in this order

  1. Measure the bus and capacitor voltages (Test 2)
  2. Test the inverter IGBT
  3. Replace the bulk capacitors

3-44-1: PFC over current

Hits OEE: Availability

What it means: Current in the PFC (boost) IGBT is too high.[1][2][6]

Also on: Models: Powermax65, 85, 105, 65/85/105 SYNC (SYNC: CSA and 105 SYNC 230 to 400 V CE only).

Likely causes

  • Failed PFC IGBT
  • Power board fault

First checks, in this order

  1. Test the PFC IGBT with an IGBT tester
  2. Replace the PFC IGBT if faulty
  3. Replace the power board if needed

3-51-1: Inverter saturation fault

Hits OEE: Availability

What it means: The inverter is in over current because its upper and lower IGBTs are switching in phase instead of opposite each other.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Failed inverter IGBT
  • Failed output diodes
  • Power board fault

First checks, in this order

  1. Test both inverter IGBTs
  2. Test the output diodes (Test 3)
  3. Replace the IGBT module, then the power board if needed

3-52-0: Shoot through

Hits OEE: Availability

What it means: A short circuit caused a high current spike through the inverter IGBT.[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Failed inverter IGBT
  • Power board fault

First checks, in this order

  1. Test both inverter IGBTs
  2. Test the output diodes (Test 3)
  3. Replace the IGBT module or power board

3-60-0: Power board

Hits OEE: Availability

What it means: The DSP does not recognize the power board (Powermax45 SYNC: power PCB fault).[1][2][3][4][6][8]

Also on: Models: Powermax45 XP, 45 SYNC, 65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Wrong power board fitted for this unit
  • Power board fault

First checks, in this order

  1. Confirm the power board part number matches the power supply model
  2. Replace the power board if wrong or faulty

3-70-0: Internal serial communications fault

Hits OEE: Availability

What it means: The DSP board and the power board are not communicating.[1][2][3][6]

Also on: Models: Powermax65, 85, 105, 125, 65/85/105 SYNC.

Likely causes

  • Loose or damaged cable between the DSP and power boards
  • Failed DSP or power board

First checks, in this order

  1. Check the cable and connectors between the two boards
  2. Replace the DSP or power board if needed

Log it, or the same alarm comes back

A plasma fault stops the arc and the table waits until it is cleared, so in OEE terms it is a breakdown. Log the code, the machine and the minutes lost, every time, even when new consumables clear it in a minute.

  • Reason code: the code plus the machine, for example 0-30-0 torch stuck open, table 2, so a consumable problem that repeats on one table shows up as a pattern.
  • Loss bucket: a stop that needs a reset, a part or a technician is an availability loss (breakdown). Stops shorter than your micro-stop threshold go to performance (minor stops). The six big losses page shows where each one belongs.
  • What to count: how often each code fires per week and the minutes it costs. Two numbers a week turn "that alarm comes up sometimes" into a ranked list. The MTBF and MTTR calculator and the downtime cost calculator do the math. The MTTR guide shows the formula step by step.

The free OEE tracker logs each stop with its reason and turns the week into a downtime Pareto, so the code that costs the most rises to the top.

A code tells you what the power supply detected, not what happened at the table in the seconds before. Fabrico's camera-based OEE software syncs camera video with machine data, so you can replay the moment the table stopped next to the code.

Frequently asked questions

What does Hypertherm error code 0-30 mean?

0-30 means the torch consumables are stuck. In the service screen it splits into 0-30-0 (torch stuck open: nozzle and electrode not touching after a start) and 0-30-1 (torch stuck closed: they will not separate). Hypertherm calls it the most common code on the Powermax65, 85, 105 and 125. Start by switching off, refitting or replacing the consumables, checking for wet or oily air and low gas pressure, then try a known good torch.

What does 0-50 mean on a Powermax?

0-50-0 is retaining cap off: the cap sensor thinks the consumables are missing or loose. Switch off, fit the correct consumables and cap, and switch on again. On SYNC models it also appears if the cartridge is not seated, the torch was unplugged at power on, or the torch was locked during a restart; 0-50-1, 0-50-2 and 0-50-3 are torch lock and cartridge reading steps that clear once the torch is unlocked and ready.

How do I reset a fault on a Powermax?

Fix the cause first. Many warnings clear by themselves. For the rest, do a quick restart (switch off, then straight back on) or a cold restart: switch off and wait about 20 seconds on the 65/85/105, 30 seconds on the 125 and 45 XP, or about 1 minute on SYNC models, then switch on. On a generator, use a cold restart instead of a quick one. If a 1-, 2- or 3- code or 0-99 comes back after a cold restart, the unit needs a qualified technician.

What do the fault LEDs mean on a Powermax45 XP?

The green Power ON LED shows the unit has power. Four yellow LEDs flag temperature, torch cap, gas pressure and a general system fault. A steady Torch Cap LED means consumables or the torch lock need attention; a slow blink means torch stuck open and a fast blink means torch stuck closed. A blinking Gas Pressure LED means no air is connected. When a numeric code applies, it blinks on the 2-digit display in three parts.

What is the difference between a warning and a fault on a Powermax?

A warning (shown as a Notice icon on SYNC models) means the system keeps running but cut quality or performance may suffer, for example 0-12 output gas pressure codes. A fault stops cutting until you clear the cause, for example 0-30 or 0-50. An error icon means parts inside the power supply need repair; that is where the internal 1-, 2- and 3- codes and 0-99 (service required) point.

Sources

Codes and meanings follow the manufacturer documentation below. Wording is ours, simplified for the shop floor; the manual for your exact model and software version wins if it differs.

  1. Service Manual: Powermax65/85, part 807120, Revision 4 (March 2022), Hypertherm document library hypertherm.com (file served from xnet.hypertherm.com)
  2. Powermax105 Service Manual, part 807580, Revision 4 (library date 2026-07-28), hypertherm.com (served from xnet.hypertherm.com)
  3. Powermax125 Service Manual, part 808070, Revision 3.1 (library date 2026-01-09), hypertherm.com (served from xnet.hypertherm.com)
  4. Powermax45 XP Service Manual, part 809230, Revision 2 (library date 2018-05-08), hypertherm.com (served from xnet.hypertherm.com)
  5. Powermax45 XP Operator Manual, part 809240, Revision 4 (library date 2021-01-04), hypertherm.com (served from xnet.hypertherm.com)
  6. Powermax65/85/105 SYNC Troubleshooting Guide, part 810430, Revision 0 (library date 2022-02-11), hypertherm.com (served from xnet.hypertherm.com)
  7. Operator Manual for Powermax65/85/105 SYNC, part 810470, Revision 4.1 (library date 2026-07-14), hypertherm.com (served from xnet.hypertherm.com)
  8. Powermax45 SYNC Service Manual, part 811480, Revision 2.1 (library date 2026-07-08), hypertherm.com (served from xnet.hypertherm.com)
  9. Operator Manual for Powermax45 SYNC, part 811470, Revision 3 (library date 2025-12-29), hypertherm.com (served from xnet.hypertherm.com)
  10. Powermax65/85 Operator Manual, part 806650, Revision 4 (library date 2018-06-29), hypertherm.com (served from xnet.hypertherm.com)
  11. Number 1: Counting down the top five Powermax fault codes: 0-30, Hypertherm blog (22 March 2019), hypertherm.com
  12. Powermax45 Operator Manual, part 805780 (library date 2013-03-28), hypertherm.com (served from xnet.hypertherm.com)

See the moment the table stopped

Fabrico, a light MES with computer vision, syncs camera footage with machine and timeline data, so you can replay the exact moment the cutting table stopped and review the cause next to the plasma error. Cameras also catch short stops and a line that is switched on but not producing, the losses nobody writes down. Machines connect through a PLC, a Fabrico IoT device or an AI camera.

Book a Fabrico demo
The lookup stays free.

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Related tools: full troubleshooting directory · OEE calculator · downtime cost · MTBF / MTTR · glossary

OEE essentials: OEE calculator · What is OEE · How to improve OEE · Six big losses · Availability · TEEP · Cost of downtime · OEE benchmark · Free OEE tracker · Free OEE software · How to track downtime · How to implement OEE · Light MES vs full MES