Intelliguard II User Manual
Contents
1. components is malfunctioning or is disconnected 5 After the system is fully installed and powered up check to ensure there are no flashing lights on the capacity indicator or brain box If there are flashing lights contact Tulsa Winch service dep t for guidance Sel 0119 docx Rev0O CAPACITY INDICATOR REALTIME DISPLAY The Capacity Indicator displays the measured torque value using five LED s as follows Table 1 Capacity Indicator Realtime LED Display Torque Load of rated Capacity Indicator LED Display capacity 0 lt Torque lt 70 0 Snore ore Power Status Torque see above 71 lt Torque lt 80 60000 81 lt Torque lt 90 91 lt Torque lt 100 Oe Tore sA eee 111 lt Torque lt 125 The Capacity Indicator displays its status using the Power LED which is a dual color type The Power LED will appear as a static color red green orange for normal operation or will flash when an error occurs in downloading via the USB connection Table 2 Capacity Indicator Status Display Power On T OOS oe System Initialization Power Status Torque see above Power On Qooaona No Torque Recorded Power On Torque Records Available Power On System Error On USB Flashing Sel 0119 docx RevO The Capacity Indicator also displays system errors that might occur When a system error occurs the LED s on the Capacity Indicator will start flashing see chart below and t2. errors recorded Sel 0119 docx RevO 15 ERROR HANDLING AND TROUBLESHOOTING Some errors are transient and may be the result of the installation process i e Loss of Communications while others indicate a system hardware problem that demands factory servicing Table 6 Errors and Their Disposition Make sure that the cables are securely connected Connect USB CAN adapter and run the DataloggerGU program Using DataloggerGU select the Technician mode and enter PIN 9707 Select the Administrator mode as well and enter PIN 1234 Click on Clear Errors button to clear the error states Click on Clear Flash to clear the Datalogger memory Turn off the power supply and retest If the error persists please call Tulsa Winch Inc Connect USB CAN adapter and run the DataloggerGU program Using DataloggerGU select the Technician mode and enter PIN 9707 Select the Administrator mode as well and enter PIN 1234 Click on Display Time to show the current Datalogger time If the displayed time is correct click on Clear Errors to clear the error state and then click on Erase Flash to clear the memory If the displayed time is not correct click on Set Clock to update the Datalogger to the current time on the PC After setting the time click on Display Time to verify that the time was correctly saved Turn off the power supply and retest If the error persists please ca
3. 0 00 10 S Downloaded from Datalogger Other 01 03 09 06 10 00 9S Serial Number changed special 01 13 09 12 02 29 168 S Error Realtime Clock hattery is low events that 01 03 09 06 11 00 1S Power On ha N appear in 01 03 09 08 32 01 51T the fixed 01 03 09 09 42 09 7S Clutch Engaged location 01 03 09 09 04 31 81 T record area 01 03 09 09 05 32 82 T 01 03 09 09 06 33 83 T 01 03 09 09 10 37 87 T Beginning of new records 01 03 09 09 16 43 93 T 01 03 09 09 17 44 94 T 01 03 09 09 18 45 95 T 01 03 09 09 24 51 101 T e 01 03 09 09 25 52 102 T Torque above minimum 01 03 09 09 35 02 112 T start of winch usage 01 03 09 09 40 07 117 T 01 03 09 09 41 08 118 T 01 03 09 09 43 10 120 T 01 03 09 09 44 11 121 T 01 04 09 09 48 15 125 T 01 04 09 09 57 24 116 T 01 04 09 09 59 26 114 T 01 04 09 10 03 30 110 T 01 04 09 10 04 31 109 T 01 04 09 10 05 32 108 T 01 04 09 10 11 38 102 T 01 04 09 10 15 42 98 T 01 04 09 10 16 43 97 T 01 04 09 10 22 49 91 T 01 04 09 10 23 50 90 T 01 04 09 10 27 54 86 T Torque above minimum 01 04 09 10 28 55 85 T start of winch usage 01 04 09 10 29 56 84 T 01 04 09 11 02 29 OT 01 09 09 12 02 29 172 S Error Bargraph disconnected 02 07 09 16 44 00 2 S Power Off 02 07 09 16 44 07 1S Power On 02 07 09 16 44 07 8S Clutch Disengaged Torque near full rated capacity and exceeding rated capacity A system
4. RUFNEK with INtelliguard User Manual Intelliguard II Cush WINCH gt This manual MUST be kept with the winch at all times New winch operators MUST read and understand the contents fully INTRODUCTION The torque induced within the winch drive train is measured by a torque sensing unit and relayed to the capacity indicator amp the data logger as a percentage of allowed torque The data logger will only record torque instances that are greater than 80 of the rated torque capacity of the winch System events such as power on power off clutch disengage and clutch engage are also recorded For more information contact us by mail at 11135 S James Jenks OK 74037 Call 918 298 8300 or fax us at 918 298 8367 You may also go to our Web site at www team twg com TABLE OF CONTENTS INTELLIGUARD II KIT 3 INSTALLATION STEPS 4 CAPACITY INDICATOR REALTIME DISPLAY 6 DOWNLOADING FROM THE DATALOGGER 8 CAPACITY INDICATOR FILE NAMING 10 EVENT RECORDS 11 RAW DATA LOG FILE 13 SUMMARY REPORT FILE 14 ERROR HANDLING AND TROUBLESHOOTING 15 TULSA WINCH LIMITED WARRANTY 16 INTELLIGUARD II KIT Capacity Indicator Data Logger Power supply connects to vehicle ignition system 12v Connects to clutch position indicator Winch Connects to torque sensor Winch i g Sel 0119 docx RevO INSTALLATION STEPS 1 Ensure you have the data logger wiring harness and capacity indicator th
5. at was calibrated from the factory for the winch you are installing 2 Recognize the length of the cable to connect to the winch from the data logger and mount the data logger in the cab accordingly 3 Mount the capacity indicator inside the cab located as to be visible by the operator when operating the winch Keep in mind the length of the cable when locating the capacity indicator 4 Route and connect the torque sensor wire from the data logger to the winch being sure not to coil the wire 5 Connect the two ringed terminals to the clutch position indicator on the winch 6 Connect the power leads red black to a power source such that the intelliguard system is powered when the PTO is energized or the ignition switch is in the on position Note the time at which the Intelliguard unit is powered on and off is logged and reported on the data log file and the summary report Sel 0119 docx RevO CAUTION 1 Ensure that the data logger wiring harness amp Capacity indicator are kept with winch The parts are calibrated from the factory for a particular winch and cannot be mixed without re calibration 2 Donot use magnets on or around winches with Intelliguard 3 Before any welding is done disconnect the data logger capacity indicator and torque sensor 4 When installing Intelliguard the power supply must be the last thing to connect Otherwise the system will invoke an error code indicating one of the
6. dump of all the records contained in the Datalogger memory The second file generated is the Summary Report file which contains a summary of important torque event ranges error events and statistics regarding operation of the winch system After a successful download to the memory stick the Capacity Indicator returns to normal operation and indicates readiness with the Power Status LED lit green At this time the Operator may inadvertently insert the memory stick again even though the Capacity Indicator is not indicating the presence of records of interest This is allowed because the Capacity Indicator employs a file naming scheme to avoid losing important data The file names are constructed as follows lt Serial Number gt SUMnnn txt OR lt Serial Number gt LOGnnn txt Where 1234567890123456 is the serial number of the Winch Intelliguard that was established during manufacture or by approved maintenance personnel at a later date SUM indicates the Summary Report file LOG indicates the Raw Data Log file nnn is a number beginning at 001 ranging through 999 txt is the file extension indicating that it is a conventional text file Sel 0119 docx RevO 11 EVENT RECORDS Event records are presented in the Raw Data Log file in the following format MM DD YY hh mm ss nnn t Where MM DD YY is the event date month day and year hh mm ss is the e
7. error occurred Sel 0119 docx Rev0O 14 SUMMARY REPORT FILE An example of the summary report file is shown below Accumulated Winch Usage determined by Datalogger ince Last Download 874 6 for torque events gt 5 RUFNEK Intelliguard Summary Report 02 07 09 Accumulated Winch Hours 874 6 Fours Winch Serial Number 009987643 Company Time period that system Vehicle was powered since last i download Winch Measurements Date Range Total Time Hours Time period that winch was E a a a a in use at torque gt minimum Power On Events 01 03 09 02 07 09 414 9 Winch Usage gt 5 01 03 09 01 20 09 412 5 Ti isd thats Torque Events gt 80 01 03 09 01 04 09 25 5 ee ees eee ee exceeded 80 of rated Breakdown of winch usaae canacitv Capacity Range Time Hours of Torque Events of Total Winch Usage Below 80 387 0 93 8 93 3 80 89 0 3 0 1 0 1 90 99 0 3 0 1 0 1 100 109 0 3 0 1 0 1 110 119 0 3 0 1 0 1 120 125 24 2 5 9 5 8 Totals 412 5 100 0 Total hours within each torque range as a percentage of total winch usage gt 5 of rated capacity For Clutch Engagement Disengagement See Detail Repo Total hours within each torque range as a percentage of total torque events gt 80 of rated Error Codes 01 09 09 172 Bargraph Heartbeat timed out capacity Up to 13 errors will be listed here more means there were more than 13 system PGM G640300 XX REV 3 11
8. he Datalogger will log the errors that it can detect with a corresponding error event value Table 3 Capacity Indicator Error Display and Error Event Values Error Event Error Flashing LED Display Value 167 Real Time Clock Stopped o AO00 Power Status Error Code 168 Real Time Clock Battery q qooe6 ee fo eee 169 Invalid Real Time Clock Value 170 Internal Datalogger Memoyeron OO Between Capacity Indicator and Datalogger 173 Capacity Indicator not Responsive to Datalogger Commands Capacity Indicator Sel 0119 docx Rev0O DOWNLOADING FROM THE DATALOGGER When a torque record in the range of interest occurs gt 80 rated capacity and is available for download the Power Status LED on the Capacity Indicator will change color to indicate that records are available for downloading To download the data the user must insert a standard USB memory stick in the connector on the side of the Capacity Indicator and wait for the Capacity Indicator to generate the Raw Data Log and Summary Report files on the memory stick Progress through the process of downloading will occur as follows 1 Power Status LED will change from green to orange amber indicating that records of interest are available for download 2 Operator removes dust cap to expose the USB connector 3 Operator inserts standard USB memory stick FAT16 or FAT32 format into the mating connector 4 Power Status LED will flash rapidly with red c
9. ll Tulsa Winch Inc ee H ee re 172 Make sure that the cables are securely connected Connect USB CAN adapter and run the DataloggerGU program Using DataloggerGU select the Technician mode and enter PIN 9707 i Select the Administrator mode as well and enter PIN 1234 l Click on Clear Errors button to clear the error states l Click on Clear Flash to clear the Datalogger memory Turn off the power supply and retest If the error persists please call Tulsa Winch Inc O S O 173 Make sure that the cables are securely connected Connect USB CAN adapter and run the DataloggerGUI program Using DataloggerGUI select the Technician mode and enter PIN 9707 Select the Administrator mode as well and enter PIN 1234 Click on Clear Errors button to clear the error states Click on Clear Flash to clear the Datalogger memory Turn off the power supply and retest If the error persists please call Tulsa Winch Inc If the error persists please call Tulsa Winch Inc Sel 0119 docx RevO 16 TULSA WINCH LIMITED WARRANTY Effective 1 1 2005 Supersedes All Prior Warranties Seller warrants that each article sold under this order shall at the time of shipment i conform to applicable specifications and ii be free from defects in material and workmanship during normal and ordinary use and service the Warranty Buyer s exclusive remedy and Seller s sole obligation under this Warra
10. nty shall be at Seller s option to repair or replace any article or part thereof which has proven to be defective or to refund the purchase price of such article or part thereof This Warranty shall expire one 1 year from the date the article is first shipped by Seller Notice of claimed breach of this Warranty must be given by Buyer to Seller within the applicable period Such notice shall include an explanation of the claimed warranty defect and proof of date of purchase of the article or part thereof for which warranty coverage is sought No allowances shall be made by Seller for any transportation labor charges parts in and out costs adjustments or repairs or any other work unless such items are authorized in writing and in advance by Seller Nor shall Seller have any obligation to repair or replace items which by their nature are expendable If an article is claimed to be defective in material or workmanship or not to conform to the applicable specifications Seller will either examine the article at Buyer s site or issue shipping instructions for return to Seller This Warranty shall not extend to any articles or parts thereof which have been installed used or serviced otherwise than in conformity with Seller s applicable specifications manuals bulletins or instructions or which shall have been subjected to improper installation operation or usage misapplication neglect overloading or employment for other than normal and o
11. of Seller s negligence in manufacture installation or otherwise with regard to the articles covered by this Warranty and at the expiration of the Warranty period as above stated all such liabilities shall terminate Tulsa Winch Inc P O Box 1130 Jenks OK 74037 TULSA WINCH Voice 918 298 8300 A Fax 918 298 8367 Web www tulsawinch com Email sales tulsawinch com Sel 0119 docx Rev0O
12. olor while recording the Raw Data Log file on the memory stick 5 Power Status LED will pause for approximately 1 second 6 Power Status LED will flash rapidly again with red color while recording the Summary Report file on the memory stick 7 Power Status LED will change to green to indicate successful completion of the recording process OR Power Status LED will begin flashing red color at a slow rate on off at 1 second rate to indicate that an error occurred during the process 8 Operator removes the memory stick from the Capacity Indicator mating connector Sel 0119 docx RevO Upon completion of the file recording process if an error occurred the Power Status LED will continue to slowly flash until the ignition power is cycled off and back on to reset the Capacity Indicator If the Operator attempts to download again after such a system error the process will begin again and if successful the Power Status LED will change to green per the steps described above Should the recording of files on the memory stick fail for any reason hardware problem or memory stick is full the Power Status LED may immediately begin to slowly flash red while the memory stick is first inserted in the Capacity Indicator Sel 0119 docx Rev0O 10 CAPACITY INDICATOR FILE NAMING The Capacity Indicator generates two files on the memory stick during the download process The first file is the Raw Data Log file which contains a
13. rdinary use and service This Warranty shall not apply to any articles or parts thereof furnished by Seller to Buyer s specifications and or furnished by Buyer or acquired from others at Buyer s request SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND OTHER THAN THE WARRANTY EXPRESSLY SET FORTH ABOVE SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE The remedies for this Warranty shall be only those expressly set forth above to the exclusion of any and all other remedies of whatsoever kind The limited remedies set forth above shall be deemed exclusive even though they may fail their essential purpose No agreement varying or extending the foregoing Warranty remedies exclusions or limitations shall be effective unless in a writing signed by an executive officer of Seller and Buyer This Warranty is non transferable Under no circumstances shall Seller be liable i for any damage or loss to any property other than the warranted article or part thereof or ii for any special indirect incidental or consequential damage or loss even though such expenses damages or losses may be foreseeable The foregoing limitations on Seller s liability in the event of breach of warranty shall also be the absolute limit of Seller s liability in the event
14. um another record will be made to indicate the end of the winch usage for that session Whenever torque is measured above the 80 of rated capacity level a record is made These records are made consecutively every second or so as long as the measured torque remains above the 80 level until measured torque drops below that level Depending on the calibration of the Datalogger s torque sensor circuit the maximum measurable torque is limited to the performance of the Torque Sensor itself The Datalogger cannot differentiate high torque values above 125 of rated capacity All torque measurements in excess of 125 will be recorded at the 125 value Table 5 Torque Event Values and Descriptions 0 5 First Torque Measured Below Minimum Usage Level lt 5 First Torque Measured Above Minimum Usage Level gt 5 80 125 Torque Measured in Near Rated Capacity Range 126 255 Undefined not applicable Sel 0119 docx RevO 13 RAW DATA LOG FILE An example of the Raw Data Log file is shown below RUFNEK Intelliguard Detail Report 02 07 09 SERIAL NUMBER 009987643 01 02 09 06 10 29 OS Memory Cleared 01 02 09 06 10 00 0S Memory Cleared Up to five Memory Clear 01 02 09 06 10 00 OS Memory Cleared events will be shown 01 02 09 06 10 29 OS Memory Cleared These are never erased 01 02 09 06 10 00 OS Memory Cleared 01 02 09 06 10 00 11 S Accumulated Hours lt ________ 01 02 09 06 1
15. vent time hour minute and seconds nnn is the event or torque value in the maximum range of 0 255 t is the event type either S for System Event or T for Torque Event System Events are those recorded events that indicate a change in system status or the change of an input i e clutch switch or a system error that has occurred since the last download The system events are recorded with the S flag at the end of the record and are defined in the chart below Table 4 System Event Values and Descriptions 0O Memory Cleared by Administrator __ pT PowerUp gt 2 PowerDown _____ Se E 5 Administrator Logging on 6 Administrator Logged off sd Clutch Engaged 8 Clutch Disengaged Cid G Serial Number Entered 169 Invalid Clock Value Communications Lost Between Datalogger and Capacity Indicator 173 Bargraph not responsive to Datalogger Commands 174 255 undefined not applicable Sel 0119 docx RevO 12 Torque Events are those recorded torque values that either indicate operation of the winch above below the minimum torque level gt 5 or near full rated capacity gt 80 The beginning of winch usage is defined to be an increase in measured torque above the minimum level gt 5 But only the increase above the minimum for the first time will be recorded in any one winch usage session When measured torque subsequently drops below the minim
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