Number 1: Counting down the top five Powermax fault codes: 0-30

By Hypertherm
Posted on 03/22/2019 in SPARK the blog, Plasma cutting

We’ve been counting down the most common Powermax fault codes for the past month.

And now, without further ado, we present the Number 1, most frequent code we get calls about. Are you ready?

Drumroll please…0-30 is the most common fault code seen on the Powermax65, Powermax85, Powermax105, and Powermax125. It can mean that there are issues related to your consumables or there could be external factors impacting system operation. To clear this code, start by checking the following first:

  1. Did you change your consumables while the power supply was on? If yes, restart.
  2. Do you have the right consumables installed? If no, change the consumables.
  3. Is the swirl ring deformed or damaged? If yes, replace.
  4. Is the electrode surface damaged or pitted? If yes, replace.
  5. Is your air wet or oily? Fix the compressor and/or replace filters.
  6. Is your torch damaged? Test with a spare torch known to work and replace torch, if needed.

If you've checked all of the above and the code still hasn't cleared, it’s time to switch into service mode. We’ve explained how to do this in the Number 2 post, but for those of you who need a reminder, here it is. Look at the front of your system and press the two buttons below the LCD display at the exact same time until you see the screen change. Then look for the letter ‘F’ on the left on the display, fifth-row down from the top. You’ll notice that the fault codes are longer. You’ll either see a 0-30-0 (torch stuck open) or 0-30-1 (torch stuck closed).

Powermax Buttons.jpg

Fault code 0-30-0 means the electrode and the nozzle not making electrical contact. Reasons may include:

  • Wrong consumables
  • Gas valve is open or leaking
  • Physical damage to the torch and/or consumables
  • A deformed swirl ring is stopping electrode movement
  • An over tightened retaining cap has damaged the swirl ring

Fault code 0-30-1 means the nozzle and electrode are stuck together and cannot create an arc. Possible causes may include:

  • Low gas pressure
    • Gas restrictions
    • Gas leaks caused by a damaged torch lead or regulator
    • Hose diameter impacting flow rate
  • External filters may be constricting the gas flow, verify all flow rates for components feeding the power supply
  • Gas restrictions
  • A deformed or damaged swirl ring is stopping electrode movement
  • Regulator needs to be replaced

To troubleshoot, place the unit in gas test mode and refer to the manual for Test 6. Ensure that only the dump valve light is on during the gas test.

More resources

Hypertherm Cutting Institute offers a short course on troubleshooting and resolving a 0-30 fault code.

Hypertherm’s North American Technical Service Team can help. If you’re in the United States or Canada, call (800) 643-9878, or email the team.

If you need a new or replacement part, we recommend reaching out to one of our authorized distributors or service centers. For a list of locations near you, visit Where to buy at



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