WinCATT Operation & Troubleshooting

1) DUMP VALVE
a) Attempt to manually fire the dump valve using WinCATT
i) If it fires, then WinCATT software is functioning properly
(1) Check to see if laptop is on battery power
(a) If so, there is a power problem
(i) Check to see that the fans are running
(ii) Check for the three indicator LEDs inside the case
(iii) Check external and internal power connections
(iv) Check 24V 1A fuse, replace w/ spare if necessary
(This is the system power)
(b) If not on battery power
(i) Check cable and solenoid
1. Remove coil; insert screwdriver; energize using
WinCATT
2. Screwdriver should stick (magnetically) to solenoid
(ii) Check cartridge by swapping with another one
ii) If WinCATT dumps without command from you
(1) Check the PCMCIA…
(a) Cable
(b) Card

2) LOAD CELL
a) Return to Windows (Exit the WinCATT software if necessary)
i) Click the Measurements and Automation Icon
ii) Maximize (OR double click) the Devices and Interfaces menu on
the left hand side
iii) Look for the DAQ card and highlight device #1
iv) Click “Test Panel”
v) Test Channel #2
(1) The Average Voltage reading should be between .2V and .4V
(2) Anything above .1 means there is a signal from the load cell
b) Check 1/16A fuse inside Junction Box
i) Hard to see, replace with 1/16A or 1/8A fuse (Time Delay fuse not
acceptable at this time)
c) Shunt Cal. Relay
i) Jump terminals 7 and 11
(1) Average Voltage should then be between 5.5V and 5.8V

*NOTE: DO NOT ATTEMPT TO DIAGNOSE AN AMPLIFIER*

 ADDITIONAL NOTES ON LOAD CELLS:

3) HYDRAULIC
a) WinCATTs with hydraulic load cells have two mutually exclusive
features
i) A junction box with a transducer (no amplifier) AND
ii) Four, 2mm mini jumpers inside the WinCATT enclosure
(1) The jumpers should be at #s 8, 9, 13, and 14 as read on the
printed circuit board

OVERHEAD VIEW

13 8

14

4) ELECTRONIC
a) WinCATTs with electronic load cells have one mutually exclusive
feature
i) A junction box with an amplifier (no transducer)
ii) If there are jumpers at the specified locations used with hydraulic
load cells, they should be removed (hold on to them for use in
Hydraulic WinCATTs
5) SOFTWARE ERRORS
a) Data Buffer Overflow (Will cause premature dumping)
i) Navigate to C:/Wincatt2000/Wincatt.ini
(1) Increase buffer size from 450 to 4500
(2) Save and Exit file
(3) Restart WinCATT
ii) From within WinCATT software; Edit Preferences
(1) Change minimum torque trigger to between 250 & 500 Password: farr001
b) Error 7 & Error 43
i) WinCATT.ini file is corrupted
(1) Most likely caused by a space or period at the end of the Job#
(a) Restart WinCATT
(i) Hit Stop (Not Continue)
(ii) Manually exit WinCATT
(iii) Start a new job
(iv) Go to Utility Menu
(v) Click “Make Default”
(b) If (a) does not work: Reinstall WinCATT
(i) Navigate to and run C:/Build55/Setup.exe
NOTE (ii) Change your preferences, they’ll have been reset

c) Security Key
i) The USB Hardlock key is missing or broken
(1) If the key is there, check for red LED
(a) Check to see if it is loose
(2) If the key is missing, it must be located
(a) Contact Bing if customer cannot find the key
d) Error 10401 @ Digital Group Config.
i) Check for DAQ card
ii) Check Connection at DAQ card
iii) Go to Measurements and Automation
(1) Devices & Interfaces
(a) Click View <> Refresh until the card is recognized

e) NAN in Torque or Turns output box

i) Unplug CT cable from J-Box
ii) Shut down the PC
iii) Restart PC
iv) Go to WinCATT test / config.
v) Plug in the CT cable
vi) Zero the Torque and Turns
vii) Repeat entire process if necessary
 MAXIMUM TURNS
REACHED

If your graph closely resembles this one, you can remedy it by:
A.) Setting maximum turns to a higher number
OR
B.) Clicking the reset button if a great deal of time lapses
before you begin registering torque
 DUMP AT REFERENCE TORQUE
SETTING IS SELECTED

Yellow line represents Reference Torque

If your graph closely resembles this one, you can remedy it by:
A.) Setting the “Dump at reference torque” option to “OFF”

NOTE: Assure this setting wasn’t deliberately in the “ON” position

 DATA BUFFER OVERFLOW

FOLLOWED BY THE “DATA BUFFER OVERFLOW” ERROR

If your graph closely resembles this one, you can remedy it by:
A.) Refer to Section 5: Software Errors
 MINIMUM TURNS NOT
REACHED

If your graph closely resembles this one, you can remedy it by:
A.) Setting minimum turns to a lower number
a. Zero (0) is accepted by WinCATT
Master Shunt Calibration is done immediately after a successful calibration
to create a set point that future field shunt calibrations reference to check for
drift in the load cell