CAN communication troubleshooting for mixing modules in OptiMix consoles

Diagnostic codes 501, 507, 508, 511

Do these steps if you get a diagnostic code that is related to Controller Area Network (CAN) communication issues with the mixing module in an OptiMix™ gas connect console.

Multiple CAN diagnostic codes at the same time can identify a problem with the CAN cable. If there is only one code, the problem is more likely to be caused by what the code says and not by the CAN cable.

Symptoms

Code Symptoms XPR® models XPR action Code cancels with...
501 The OptiMix gas connect console cannot receive communications (at least once-per-second) from the main control Printed Circuit Board (PCB) through the CAN. All models Shut down Remote on-off
507 There is a problem with the CAN when power is supplied to the cutting system. All models None Remote on-off
508 The load on the CAN bus is more than capacity for 10 milliseconds or more. All models None Remote on-off
511 The main control PCB cannot receive communications (at least once-per-second) from the gas connect console’s mix module through the CAN. All models Ramp down Remote on-off

Corrective action

  1. Remove the power from the cutting system.
  2. Tighten loose CAN cable connections between the plasma power supply, the cooler, and the gas connect console.
  3. Tighten loose connections on the control PCB chassis in the gas connect console.
  4. Make sure that the D16 (+5 VDC) Light Emitting Diode (LED) and the D18 (+3.3 VDC) LED are illuminated on the control PCB.

    D16 and D18 show that there is power to the PCB. Refer to Gas connect console control PCB (141375) diagram.

  5. Make sure that the D30 LED and the D31 LED on the control PCB are flashing one time per second.

    A flashing LED shows that the mircoprocessor on the PCB is functional.

  6. If the D24 LED and the D25 LED on the control PCB are flickering and you have diagnostic codes 600 and 602, do the following:
    1. Make sure that the CAN cables between the plasma power supply and the cooler and between the cooler and the gas connect console are connected.
    2. Disconnect the CAN cable between the control PCB and the mixer in the OptiMix console.
    3. With the cable disconnected, do D24 and D25 stop flickering? OptionDescription
      If yes...
      • There is damage to the CAN cable. Use an ohm meter to make sure that there is continuity at each connector. Measure each pin in the same order as the CAN connectors. For example, in the image, pin 1 in connector A aligns with pin 1 in connector B. If there is no continuity, replace the cable.
        End A and End B of a Controller Area Network cable that shows the aligned pin locations at the cable ends.
      • There is a bad connection between the plasma power supply and the cooler or between the cooler and the gas connect console. Reconnect the CAN cable, or replace it if necessary.
      • There is a bad connection between the small CAN jumper cable for the gas connect console control PCB and the sheet metal panel in the gas connect console. Reconnect the CAN cable, or replace it if necessary.
      If no... Continue with the next step.
  7. If the control PCB in the gas connect console is operating correctly but you continue to see the same diagnostic code, do the following:
    1. Replace the CAN cable between the control PCB and the mixer.
    2. Disconnect the CAN cable between the gas connect console and the TorchConnect™ console.
    3. With the cable disconnected, do a check for the following:
      • Make sure that each green LED on the mixer is operating correctly.
      • Make sure that the XPR web interface or the Computer Numerical Control (CNC) screen shows that the cutting system is equipped with an OptiMix gas connect console.
  8. Examine D24 and D25 on the control PCB again:
    If you see this condition...Do these steps...
    D24 and D25 are not illuminated and are not flickering. Reconnect the CAN cables to the plasma power supply and the cooler.
    D24 is not illuminated, and D25 is flickering.
    1. Examine the control PCB in the gas connect console for shorts.
    2. Look for a shorting block across pin 1 and pin 2 of J16.
    3. If there is a shorting block, remove it and start the cutting system again.
  9. Examine the green LED on the mixer PCB in the OptiMix console:
    If you see this condition...Do these steps...
    The green LED is flashing one time per second, and the yellow LED is flickering. No action is necessary. This is the correct operation. The cutting system is ready for use.
    The green LED is flashing one time per second, and the yellow LED is not illuminated.
    1. Examine the CAN cable between the control PCB and the mixer.
    2. Look for pins that are bent or broken.
    3. Make sure that all connections are fully tightened.
    The green LED is blinking one time per second, and the red LED is illuminated and not flickering. There is a possible problem with the mixer in the OptiMix console. Speak to your cutting machine supplier or regional Hypertherm® Technical Service team.

    On the mixer PCB, look for a green LED, a yellow LED, and a red LED that are aligned in a row.

  10. If you cannot find or correct the problem, speak to your cutting machine supplier or regional Hypertherm Technical Service team.