ProXR + PR55-22 NexGen ESP32 communication failure after previously working setup

Hardware
1

I have a ProXR controller with a Dual Interface Fusion / PR55-22 NexGen ESP32 module, and I am trying to determine whether I am dealing with a configuration issue, firmware mismatch, or a hardware/interface failure.

This exact hardware configuration previously worked in our setup, but it is no longer functioning correctly. Since the failure began, I have also tried replacing the ESP/NexGen module, and the replacement behaved the same way, so the issue does not appear to be isolated to a single ESP module.

The NexGen itself appears to be alive. The ESP32 USB bootloader works, firmware backup and restore work, Wi-Fi configuration works and the module joins the network, and the HTTP interface is reachable. At times, /relayCount has returned correctly. However, actual board control is failing. The endpoint /relayON?relay=1 returns failed to execute command, raw /sendCommand calls time out with no response, and NCD Base Station reports communications error: device did not respond as expected. Diagnostics fail, and the ESP sometimes reaches a solid green connection state, but Base Station then hangs while loading.

I have tried the original slot and alternate slot, reseating the module, matching baud rates, power cycling, firmware backup and restore, testing over both USB and Wi-Fi, and swapping in a replacement NexGen/ESP module. One additional observation is that when the board baud rate is set to 115200, /relayCount responds, but command execution still fails. At other baud settings, even /relayCount times out. That makes it seem like there may be at least partial communication at 115200, but not a healthy command/response path.

At this point, it appears I may be dealing with a communication failure between the NexGen module and the ProXR board, or a failure somewhere on the ProXR side of the interface. Can you advise on:

  1. the exact slot, jumper, and routing configuration the Fusion/NexGen module should use with a ProXR board
  2. the correct firmware or firmware variant for this setup
  3. whether this behavior is consistent with a board-to-board communication fault or hardware failure
  4. whether there are specific components you would recommend replacing or returning for service, given that the same symptoms persisted after swapping the ESP/NexGen module

PXL_20260320_181001974
PXL_20260320_1810019741920×2557 578 KB

2

Hi,

There are quite a few variables with Fusion because there are so many options.

What is the voltage and amperage of your power supply?

Do the Busy ready lights come on while powered?

If you open a socket to the board using a simple TCP socket or serial terminal, does anything come out of the socket/serial?

Can you try setting the controller for USB or TCP communications and these steps:

  1. Power Down the Controller
  2. Set the Configuration/Run Jumper to Configuration
  3. Power Up the Controller
  4. Try connecting to the board using Base Station again with the baud rate of 115200 and 57600 between the WiFi Module and the board.
3

Thanks for your response Jacob. The controller is powered by the same 12 V, 1.5 A supply that was used when this setup previously worked. The Ready LED is solid while powered, and the Busy LED flickers slightly during connection attempts.

I also tested the USB serial connection directly on COM3 outside of Base Station. The port opens successfully, but at both 115200 and 57600 there is no readable serial output and reads time out.

I then repeated the test in configuration mode using the RUN/PGM jumper, with the jumper set to PGM. I tested with the module-to-board baud set to 115200 and then 57600. Neither baud rate changed the behavior. Base Station still failed to connect, and configuration mode did not produce any different result from normal operation.

Does this pattern point more strongly to a communication fault on the ProXR side, board-to-board interface failure, or another board-level hardware issue? If so, are there specific components you recommend replacing or returning for service?

4

This point to a fault on the proxr side as it should be responding to commands.

Can you confirm that when you’re attempting to connect to the board using the USB you’re setting the Serial Port’s settings to the desired values? These settings are covered on this guide: NexGen WiFi Module User Guide - NCD.io under the section “Serial”. e.g. Set the USB Baud Rate to 115200 and the Board Baud Rate to 115200 or 57600.

You could also try disconnecting power from the lower level boards (the boards with relays), and disconnecting them from the top layer board (FLL) and see if that allows comms through.

If you’ve done the above and are still having issues I would have to recommend an RMA for us to evaluate and repair the board as necessary: Log In ‹ NCD.io — WordPress. I would recommend shipping everything back for the RMA minus the Pluggable connectors so you don’t have to rewire the loads.

5

Thanks, I tried the additional steps you suggested, including confirming the baud settings and isolating the lower relay board, and the behavior did not change. The board still does not respond properly, so at this point I am going to move forward with an RMA. Thank you for the help.