Dover TWG Tulsa Winch Intelliguard II User manual

User Manual
Intelliguard II
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 & 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 [phone]
or fax us at [phone]. 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

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INTELLIGUARD II KIT
Data Logger
Capacity
Indicator
Power supply connects
to vehicle ignition
system
(12v)
Connects to
clutch position
indicator
(Winch)
Connects to
torque sensor
(Winch)

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INSTALLATION STEPS
1. Ensure you have the data logger, wiring harness and
capacity indicator that 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.

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1. Ensure that the data logger, wiring harness, &
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. Do not 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
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.

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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)
Capacity Indicator LED Display
0 ≤ Torque ≤ 70%
Power/Status % Torque (see above)
71% < Torque ≤ 80%
81% < Torque ≤ 90%
91% < Torque ≤ 100%
101% < Torque ≤ 110%
111% < Torque ≤ 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
Status
LED Display
Power On
System Initialization
Power/Status % Torque (see above)
Power On
No Torque
Recorded
Power On
Torque
Records Available
Power On
System Error
On USB
(Flashing)
Power Off

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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 the 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
Value
Error
Flashing LED Display
167
Real Time Clock Stopped
Power/Status Error Code
168
Real Time Clock Battery
Low
169
Invalid Real Time Clock
Value
170
Internal Datalogger
Memory Error
172
Loss of Communications
Between Capacity
Indicator and Datalogger
173
Capacity Indicator not
Responsive to Datalogger
Commands
Capacity Indicator

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DOWNLOADING FROM THE DATALOGGER
When a torque record in the range of interest occurs
(>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 color
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.

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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.

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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 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:
“<Serial Number>SUMnnn.txt”
OR
“<Serial Number>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