When to Replace Cables
This page helps you identify when to replace power, Ethernet, or I/O cables in your OV80i system to avoid downtime and inconsistent performance.
Most inspection issues are caused by cable damage or loose connectors — check cables before changing system settings or retraining.
Common Signs You Need to Replace a Cable
| Symptom | Possible Cause |
|---|---|
| Camera randomly disconnects or reboots | Loose or damaged power/Ethernet connector |
| Trigger fails intermittently | Cut or pinched digital I/O wire |
| Pass/fail outputs stop working | Output cable has broken conductor |
| Camera doesn't appear on the network | Damaged or low-quality Ethernet cable |
| Inspection shows random failures | Power or data interruptions during capture |
| Visible cable damage | Split insulation, bent pins, or exposed conductors |
Recommended Replacement Timeline
| Cable Type | Check Every | Replace If... |
|---|---|---|
| Power (M12) | Monthly | Heat damage, loose fit, discoloration |
| Ethernet (RJ45) | Monthly | No snap, click, or frequent disconnections |
| Digital I/O (bare leads or M12) | Quarterly | Pinched wires, tensioned cable ends, missing shield |
Best Practices for Cable Health
- ✅ Use strain relief or cable ties to reduce stress on connectors
- ✅ Keep slack in cables near moving parts
- ✅ Route away from high EMI sources (e.g., motors, welders)
- ✅ Use Overview-supplied or industrial-grade shielded cables
- ❌ Never force or twist connectors — especially M12
- ❌ Don't mix third-party cables with unknown electrical tolerances
Quick Cable Tests (Before Replacing)
- Swap with known-good spare to isolate issue
- Check camera LEDs — solid red or blinking red may indicate power issues
- Use ping or browser access to test Ethernet stability
- Check continuity across digital I/O wires using a multimeter