CAN communication troubleshooting for choppers

Diagnostic codes 504 – 508, 514 – 516, 601, 604, 606

Do these steps if you get a diagnostic code that is related to Controller Area Network (CAN) communication issues with a chopper.

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...
504 Chopper 1 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
505 Chopper 2 cannot receive communications (at least once-per-second) from the main control PCB through the CAN. XPR300™, XPR460™ Shut down Remote on-off
506 Chopper 3 cannot receive communications (at least once-per-second) from the main control PCB through the CAN. XPR460 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
514 The main control PCB cannot receive communications (at least once-per-second) from Chopper 1 through the CAN. All models None Remote on-off
515 The main control PCB cannot receive communications (at least once-per-second) from Chopper 2 through the CAN. XPR300, XPR460 None Remote on-off
516 The main control PCB cannot receive communications (at least once-per-second) from Chopper 3 through the CAN. XPR460 None Remote on-off
601 For a minimum of 30 seconds after power is supplied to the cutting system, Chopper 1 does not identify itself to the main control PCB through the CAN. All models Shut down Remote on-off
604 The inductor thermocouples for Chopper 2 were sensed, but Chopper 2 was not sensed. XPR300, XPR460 None
  • Start process
  • Set process
  • Remote on-off
606 The main control does not receive CAN communications from Chopper 3 after power is supplied to the cutting system. XPR460 None
  • Start process
  • Set process
  • Remote on-off

Corrective action

  1. Remove the power from the cutting system.
  2. Make sure that the chopper ID cable connector is fully engaged in J8 on each chopper in the plasma power supply.
  3. Examine the CAN cable connections:
    If you see this condition...Do these steps...
    You only have diagnostic code 504.
    Examine the CAN cable connections between Chopper 1 and Chopper 2 in the plasma power supply:
    1. Make sure that all cable connections are fully tightened.
    2. If you find bent pins, make the bent pins straight.
    3. If you find bent sockets or broken pins, get a new cable.
    You have diagnostic codes 503 and 504 together (XPR300 and XPR460 only).
    Examine the CAN cable connections between Chopper 2 and Chopper 3:
    1. Make sure that all cable connections are fully tightened.
    2. If you find bent pins, make the bent pins straight.
    3. If you find bent sockets or broken pins, get a new cable.
    You have diagnostic codes 504 and 505 together (XPR460 only).
    Examine the CAN cable connection between Chopper 3 and the control PCB (PCB 1) on the plasma power supply:
    1. Make sure that all cable connections are fully tightened.
    2. If you find bent pins, make the bent pins straight.
    3. If you find bent sockets or broken pins, get a new cable.
    You have other diagnostic codes. Continue with the next step.
  4. Make sure that the green Light Emitting Diode (LED) is illuminated on Chopper 1/PCB 2, Chopper 2/PCB 3, and Chopper 3/PCB 8 for the following:
    • D22 (+18/-5 VDC)
    • D14 (+5 VDC)
    • D21 (+3.3 VDC)

    ​Each illuminated LED shows that there is power to that chopper control PCB (PCB 2, PCB 3, and PCB 8).​

  5. If at least one LED is not illuminated, do the following:
    If you see this condition...Do these steps...
    No LED is illuminated.
    1. Make sure that the J2 power connector is fully engaged.
    2. Make sure that the wiring to the J2 connector is good.
    3. Do a check for 24 VDC on J2 pin 1 and pin 3 for each chopper in the system.
    4. If the wiring is good and you continue to get the same diagnostic code, speak to your cutting machine supplier or regional Hypertherm® Technical Service team.
    Each LED is illuminated except for one or two. Replace the chopper control PCB if necessary. Speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  6. If each green LED is illuminated, examine each chopper control PCB:
    1. Make sure that the D3 LED and D4 LED are flashing one time per second.

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

    2. Make sure that Dual Inline Package (DIP) switches 1 – 4 on S2 are in the OFF position.
    3. Make sure that the CAN cable connector is fully engaged in J7.
    4. If an LED is not operating correctly, speak to your cutting machine supplier or regional Hypertherm Technical Service team.
  7. Make sure that the D33 LED and D34 LED are flickering.

    A flickering LED shows that communications on the CAN cable is functional.

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