Resolving a 0-51 fault code on your Powermax system

How to fix a start signal at power up fault 

This short video will help you identify the symptoms of a 0-51 fault code for the Powermax® product line and explains where to locate the fault code on the machine and some possible solutions to this fault. A 0-51 fault code indicates that the Powermax power supply is receiving a start signal when the system is being powered on. It is sometimes referred to as a “stuck start” fault and can occur if the power supply is turned on while the torch trigger is pressed. The system is disabled if you attempt to power it on while pressing the torch trigger.

You will learn how to troubleshoot the problem, what the most common solutions to this fault condition are, and when you need to talk to an expert for additional assistance.

Symptoms of a start signal at power up error

Typical symptoms of a 0-51 fault include the torch not firing combined with the Powermax machine displaying the correct fault code or fault icon for a start signal at power up fault (0-51 or 0-51-0).  

Finding the fault code

Each Powermax system displays the 0-51 fault code differently. Locate the operator manual that came with your system or access a digital copy online at Hypertherm.com. Use the maintenance and troubleshooting section of the operator manual to determine which fault code your system is indicating. If you suspect a 0-51 fault code, use the fault table to verify that the machine is indicating the 0-51 fault code.  

  • For the Powermax30 XP, the gas pressure and temperature LEDs blink when the system is powered on.

  • For the Powermax30 Air, the internal compressor LED and the temperature LED blink alternately when the machine is powered on.

  • For the Powermax45 XP, an alternating blinking torch fault and temperature LED on the front of the machine indicate a start signal is being given at power up. In addition to the alternating LEDs, the fault condition blinks on the two-digit display in the format 0-51-0.

  • For higher amperage machines such as the Powermax65, 85, 105, and 125, when you power the machine on the 0-51 fault will appear on the display screen along with the fault icon.

Troubleshooting your 0-51 fault code 

 

Machine Torch Configuration

For systems being used with a machine torch configuration, turn off the power supply, disconnect all cables on the rear of the power supply except the air hose and power cord, then restart the power supply.

 

Hand Torch Configuration

For systems being used in a hand torch configuration, first make sure you are not pressing the torch trigger while turning the power supply on. To test this possibility, begin by turning the power supply off. Release the torch trigger and do not press it again until the machine is successfully powered on. Cycle the power to the machine while making sure not to press the torch trigger. If this was the cause of the fault code, turning the machine on without pressing the trigger will clear the fault from the screen and the machine will power up properly.

If the 0-51 start signal fault still appears upon power up, then the trigger switch, torch lead, or power supply may be damaged.

For the Powermax30 XP and Powermax30 Air systems, contact your local authorized repair center for assistance.

For all other Powermax systems, you will need a multimeter to perform a continuity check to determine if the torch lead assembly or power supply is damaged. If you don’t have a multimeter, or aren’t familiar with how to use one, contact your local authorized repair center so they can continue the troubleshooting process for you.

  • First, you need to determine if the issue is within the torch lead assembly or the power supply. To confirm which part is damaged, a continuity test on the torch connector is needed.

    • Press the red button on the connector and pull the connector out of the receptacle.

    • If there is a torch disable switch, make sure it is in the green “ready to fire” position.

    • Using the multimeter, check for continuity between pins 6 and 7 at the quick disconnect of the torch lead.

  • If high resistance, or OL, is measured when the trigger switch is not depressed, the problem lies within the power supply and the power supply needs to be taken to an authorized repair center for further testing.

  • If there is continuity, or low resistance (less than 1 ohm when not depressing the trigger switch), either the trigger switch or the torch lead assembly is damaged.

    • To determine which part needs to be replaced, remove the left side of the torch handle or shell.

    • For both Duramax and Duramax Lock torches, leave the multimeter connected to pins 6 and 7 of the quick disconnect and unplug the start switch connector.

    • If continuity is still measured at approximately 1 ohm or less with the start switch disconnected, then the torch lead is defective, and you need to replace it.

    • If a high resistance or OL is measured, then the start switch is defective, and it needs to be replaced.

The ability to identify fault codes and troubleshoot solutions helps you minimize downtime when you experience a cutting disruption. Whether you need to hold the torch differently when powering it up to avoid pressing the trigger, or you have reached the point when you need to replace your power supply, understanding how to quickly resolve fault codes saves time and money, ensuring you get the most from your Powermax system.   

Your operator manual explains all Powermax fault codes and shares steps you can take to resolve them, so we recommend keeping a copy nearby while using your Powermax system.

 

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