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iGUARD Troubleshooting
Communications
- Anything to do with programming, saving a profile, and/or using the iGCON software tool
- Won't drive ANY PVA analog gages
- Won't drive SOME PVA analog gages
- Won't drive the remote I/O board
- Won't communicate over the modem
- Drops modem communications
- Problems with being a MODbus slave
1. Anything to do with programming, saving a profile, and/or using the iGCON software tool - The iGUARD was specifically designed to be easy to update in the field. All that is required is a copy of the iGCON software tool, and the connector from the PC to the iGUARD. iGCON is available for free on the internet or from FW Murphy. See the detailed instructions in the IOM for the iGCON tool.
a. If you have any version prior to 1.22 of iGCON, make sure and print the configuration file out before you update to a newer version of the tool. There were some previous version compatibility problems and the only reliable way around them is to
i. Update the operating software on both the user interface board and the I/O board,
ii. Force a factory default
iii. Cycle power to the iGUARD.
iv. Using the printout, hand enter all the data back to the iGUARD or back into the iGCON tool (and re-send)
b. If you have any version of the iGUARD programmed with software prior to 1.20, please contact Technical Services (918 317-4100) as there is one operating quirk that may or may not affect you - depending on your application - and you should be aware of. See the iGCON software IOM for more details
c. If you connect to the iGUARD but the unit does not return the stored user profile, you have either a version mismatch, or the iGUARD is in a factory default profile setting.
2. Won't drive ANY PVA analog gages - there is NO gage movement of any gage in the system
a. Are the gages powered up? - Try cycling gage power. If there is power the backlights will come on, and the indicators will move from the under-stop position to the zero value position, waiting for data.
b. Are the gages plugged in? - The Deutsch® connectors on the back of the gages are usually somewhat stiff and tight. Make sure that the plug is fully inserted and the mechanical latch is made.
c. Is the connector plugged into the iGUARD? The Molex Minifit® connectors are usually easy to plug and unplug, but make sure that the plug is fully seated and the latch is completely engaged.
d. Are the connections intact between the iGUARD and the gages? - Check the wiring for cuts, scrapes, and crushing damage between the iGUARD and the gages. It may take an ohmmeter to verify that the wiring is intact (Properly terminated, the wiring should read approximately 60 ohms)
e. Check for a terminating resistor - There should be a 120 ohm resistor on each end of the RS-485 bus.
f. Check the orientation of the data lines - Make sure that the polarity of the data lines is correct
3. Won't drive SOME PVA analog gages - Some gages respond properly, but one or more do not.
a. Are the non-responding gages powered up? - Try cycling gage power. If there is power the backlights will come on, and the indicators will move from the under-stop position to the zero value position, waiting for data.
b. Are the non-responding gages plugged in? - The Deutsch® connectors on the back of the gages are usually somewhat stiff and tight. Make sure that the plug is fully inserted and the mechanical latch is made.
c. Are the connections intact between the iGUARD and the gages? And from gage to gage- Check the wiring for cuts, scrapes, and crushing damage between the iGUARD and the gages, as well as between the gages. It may take an ohmmeter to verify that the wiring is intact (Properly terminated, the wiring should read approximately 60 ohms)
d. Check for a terminating resistor - There should be a 120 ohm resistor on each end of the RS-485 bus. Without a terminating resistor, gage operation may be erratic.
e. Check the orientation of the data lines between the gages that are working and the one(s) that are not - Make sure that the polarity of the data lines is correct
f. Make sure that the gage is supported for the application - Particularly with a mechanically fueled engine (non-ECU) there is data that is not available (% load, fuel consumption etc) so a gage for these parameters will not display anything.
4. Won't drive the remote input/output (RI/O) board - There are four LED's to help with the communications troubleshooting.
a. LED 1 (the top one) is a power indicator.
b. LED 2 indicates the system is communicating RS485 or RS-232
c. LED 3 indicates that there is data by flashing rapidly
d. LED 4 indicates that there is a COMM failure when it is on
e. Is the RI/O board powered up? - There are four LED's. The top one should be blinking slowly if there is power.
f. Is the connector plugged into the iGUARD? The Molex Minifit® connectors are usually easy to plug and unplug, but make sure that the plug is fully seated and the latch is completely engaged.
g. Are the connections intact between the iGUARD and the RI/O board? - Check the wiring for cuts, scrapes, and crushing damage between the iGUARD and the RI/O board. It may take an ohmmeter to verify that the wiring is intact (Properly terminated, the wiring should read approximately 60 ohms)
h. Check for a terminating resistor - There should be a 120 ohm resistor on each end of the RS-485 bus.
i. Check the orientation of the data lines - Make sure that the polarity of the data lines is correct
5. Won't communicate over the modem
a. Verify the physical connections at the iGUARD
i. Is there a dial tone at the phone jack?
ii. Is the iGUARD powered?
iii. Is the modem powered?
iv. Is there a connection between the modem and the phone jack?
v. Is there a connection between the iGUARD and the modem?
vi. Is the power to the modem routed through a relay on the iGUARD that is programmed for modem control?
b. Verify the physical connections at the PC end
i. Is there a dial tone at the phone jack?
ii. Is the receiving computer powered on?
iii. Is the receiving modem powered on?
iv. Is there a connection between the phone jack and the modem?
v. Is there a connection between the modem and the computer?
c. Verify the software settings in the iGUARD
i. In the communications settings the modem connection must be enabled.
ii. Verify that a relay has been programmed for "Modem Control"
iii. Verify the initialization string sent from the iGUARD to the modem is correct (Check the modem documentation!!!)
d. Verify the software settings in the iGCON program (See the iGCOM IOM for more details on how to do this)
a. If possible, use a standard phone to call out from the remote site to the PC Have someone there answer the phone. Listen for static, buzzing, loud crackling etc. If these noises are present then typically one (or both) of the modems are disconnecting because they are not getting enough signal through to verify a 'good connection'.
b. Check the cabling for intermittent shorts/opens in the wiring by wiggling/tugging. This is typically a case where the connections work fine while the set is not running, but start acting strange while running. Usually the vibration is moving the cable connectors enough to cause problems.
c. Tighten down any mounting/installation screws for gender changers, extension cables etc.
d. Verify the modem initialization strings from the iGUARD AND the PC are correct for your application.
e. Try a different modem.
7. Problems with being a MODbus slave
a. Verify the physical connections
i. Power to the iGUARD and/or PC/PLC?
ii. RS-485 connection polarity correct?
iii. Terminating resistors in place?
b. Verify that the Baud rates on the iGUARD and the PC/PLC match
c. Verify that the data & number of stop bits match too
d. Verify that the data register addresses that are being polled are correct
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