147451877-63X0-CA-Manual

© Windrock, Inc. 2009

Portable AnalyzerCA Operations

Manual

1/29/2009

Legal NoticesCopyright

1997-2009 by Windrock Incorporated, All rights reserved.

No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translatedinto any language in any form by any means without the written permission of Windrock, Incorporated.

Software and Firmware License Notice

Your license agreement with Windrock, Incorporated, authorizes the number of copies which can be made andthe computer systems on which they may be used. Any unauthorized duplication or use of Windrock software orfirmware in whole or in part, in print, or in any other storage and retrieval system, is forbidden.

Disclaimer

This manual is provided for informational purposes. Windrock, Incorporated, makes no warranty of any kind withregard to this material, including, but not limited to, the implied warranties of merchantability and fitness for aparticular purpose. Windrock, Incorporated shall not be liable for errors, omissions, or inconsistencies which maybe contained herein or for incidental or consequential damages in connection with the furnishing, performance, oruse of this material. Information in this document is subject to change without notice and does not represent acommitment on the part of Windrock, Incorporated. Any software described in this document is furnished under alicense agreement or nondisclosure agreement. The software may be used or copied only in accordance with theterms of the agreement.

Portable Analyzer CA Operations Manual

If you have comments about this documentation, the software, or products it describes, please contact theCustomer Support Group at Windrock.

IContents

I


Table of Contents

Part I Customer Information 1................................................................................................................................... 11 Introduction

................................................................................................................................... 12 Customer Assistance

................................................................................................................................... 23 Returning Items

................................................................................................................................... 34 Hazardous Location Information, 6320 only

................................................................................................................................... 35 Handling Precautions

................................................................................................................................... 56 Warnings

Part II Read This First 6................................................................................................................................... 61 Special Terms

................................................................................................................................... 62 Care

................................................................................................................................... 63 Unpacking

................................................................................................................................... 74 Batteries & Charging

.......................................................................................................................................................... 7Batteries

......................................................................................................................................................... 8E-Moli

.......................................................................................................................................................... 9Charger

Part III Getting Started 11................................................................................................................................... 111 Connections

................................................................................................................................... 142 Keypad Functions

................................................................................................................................... 143 Hardware Configuration

................................................................................................................................... 164 Stations & Machines

.......................................................................................................................................................... 17Station & Machine Setup

Part IV Machine Setup, 63X0/CA with encoder only 19................................................................................................................................... 191 Setting Up a Machine, 63X0/CA with encoder only

.......................................................................................................................................................... 19Machine Setup Menu

Part V Balancer/Spark Setup and Data Collection 21................................................................................................................................... 211 Overview

.......................................................................................................................................................... 22Setup

.......................................................................................................................................................... 27Engine Balance

......................................................................................................................................................... 27Engine Balancer - Non encoder

......................................................................................................................................................... 37Restart Balance Run

......................................................................................................................................................... 38Recall Old Balance Data

......................................................................................................................................................... 40Power Cylinder Monitor

.......................................................................................................................................................... 42Spark Menu

......................................................................................................................................................... 44Spark Survey

......................................................................................................................................................... 51Ignition Survey Report Definitions

......................................................................................................................................................... 52Restart Spark Survey

......................................................................................................................................................... 54Recall Spark Survey

Part VI Encoder-based Balance 55

Portable Analyzer CA Operations ManualII


................................................................................................................................... 551 Special Collection Modes

................................................................................................................................... 562 Spark

Part VII Utility Menu Options 59................................................................................................................................... 591 Direct Channel Read

................................................................................................................................... 612 Connect to Windows 6310 only

................................................................................................................................... 623 Power Cylinder Monitor

................................................................................................................................... 624 Discharge Battery 6310 only

................................................................................................................................... 625 Check for Bad EXE's 6310 only

Part VIII Encoder Setup 63................................................................................................................................... 631 Shaft Encoder

................................................................................................................................... 642 Multi-Event

................................................................................................................................... 653 Magnetic Pickup

................................................................................................................................... 654 Timing Light

Part IX Loading New Software 66................................................................................................................................... 661 Windows Install 6310 only

................................................................................................................................... 662 Windows Install 6320 only

Part X Operating System Commands 67................................................................................................................................... 671 Machine Template 6310 only

................................................................................................................................... 672 Setting Time and Date 6310 only

................................................................................................................................... 683 Set Date, Time or Time Zone 6320 only

................................................................................................................................... 684 Printing 6310

................................................................................................................................... 715 Printing 6320

Part XI Appendix 73................................................................................................................................... 731 Data Collection Techniques

................................................................................................................................... 732 Sensors

.......................................................................................................................................................... 74Magnetic Pickup

.......................................................................................................................................................... 76Secondary Ignition Sensor

.......................................................................................................................................................... 77Water Cooled Pressure Sensor

................................................................................................................................... 773 Specifications - 6310/CA

................................................................................................................................... 784 Specifications - 6320/CA

................................................................................................................................... 805 Specifications - Sensors

Part XII Glossary of Terms 81

Index 88

Customer Information 1


1 Customer Information

1.1 Introduction

Portable Analyzer Manual

The following sections briefly summarize the functions you will use to set up and operate yourportable CA analyzer by Windrock, Inc. This help version is 3.0.

Data storage and machine setups are stored locally to the analyzer thus no host PC is required.Data stored within the analyzer can be directly backed up to such devices as zip drives if youranalyzer is a 6310 or to a flash drive for the 6320.

Special Emphasis

These conventions are used throughout this manual to call attention to adjacent text:

Note: A note indicates special comments or instructions.

Caution! A caution indicates actions that may have a major impact on the hardware,software, database files, etc.

Prerequisites

The manual is written with the assumption that you are familiar with the basic operation of apersonal computer and is not intended to be a substitute for the documentation supplied with acomputer or software.

If you are unfamiliar with a personal computer or peripheral hardware, Windrock stronglyrecommends review of the appropriate documentation before using the analyzer and software.

1.2 Customer Assistance

Direct any questions you may have about the product you have purchased to Windrock's ProductSupport department at (865) 539-5944 Ext. 4019.

Hardware

1. Please have the serial number of your analyzer available when you call. The serial number islocated either on the back of the analyzer and/or on the sliding battery door.

2. If you have a problem, explain the exact nature of your problem. For example, what are theerror messages? When do they occur? What you were doing when the problem occurred. Forexample, what mode were you in? What steps did you go through? Try to determine beforeyou call whether the problem is repeatable.

Software

1. Please have the number of the current version of your software ready when you call. Theversion of the software appears at the top of the main menu screen.

2. If you have a problem, explain the exact nature of your problem. For example, what are theerror messages? When do they occur? What you were doing when the problem occurred. Forexample, what mode were you in? What steps did you go through? Try to determine before

Portable Analyzer CA Operations Manual2


you call whether the problem is repeatable.

3. Please have your analyzer ready and any accessories in question when you call. We canserve you better when we can work through the problem together.

1.3 Returning Items

For Repair

1. Call Product Support at (865) 539-5944 Ext. 4019 to obtain a return authorization number.Please write it clearly and prominently on the outside of the shipping container.

2. Please enclose a letter that describes the reason(s) you are returning the item.

3. Insure your package for return shipment. Shipping costs and any losses during shipment areyour responsibility. COD packages cannot be accepted and will be returned unopened.

For Credit

1. Call Product Support at (865) 539-5944 Ext 4019 to obtain a return authorization number.Please write it clearly and prominently on the outside of the shipping container.

2. Return all accessories originally shipped with the item(s). Include cables, software diskettes,manuals, etc.

3. Enclose a note that describes the reason(s) you are returning the item(s) for credit.

4. Insure your package for return shipment. Shipping costs and any losses during shipment areyour responsibility. COD packages cannot be accepted and will be returned unopened.

Hardware Repair

Windrock repairs its hardware products free for one year from the date of shipment. This servicewarranty includes minor hardware improvement, modification, correction, re-calibration, updates,and maintenance for normal wear. This service warranty excludes repair of damage from misuse,abuse, neglect, carelessness, or modification performed by anyone other than Windrock. Windrock automatically sends updated manuals on the software update CDROM in electronicformat to all customers who are under warranty.

After the one year service warranty expires, each return of a Windrock hardware product is subjectto a minimum service fee. If the cost of repair exceeds this minimum fee, we will call you with anestimate before performing any work. Contact Product Support for information concerning thecurrent rates.

Refer to the Warranty section of the Terms and Conditions section of this manual for a completedescription of your warranty.

Extended Service Plan

Windrock offers Extended Service Plans (ESP) on analyzer equipment. Software benefits includeprogram corrections and improvements, modifications, manual revisions and telephoneassistance. Hardware benefits cover malfunctions due to normal wear, annual calibration, andupdates. Contact (865) 539-5944 Ext. 4030 for information concerning the current cost ofExtended Service Plans.



1.4 Hazardous Location Information, 6320 only

Caution! If your 6320 Analyzer has been approved for use in a hazardous location, Class 1 Div. 2,there will be a hazardous atmosphere warning label on the back of the analyzer. If there isno warning label on your analyzer, fallow all hazards atmosphere precautions prior to andwhile using your analyzer.

Caution! 1. THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION 2, GROUPS A, B, C, D

HAZARDOUS LOCATIONS ONLY

2. WARNING - EXPLOSION HAZARD – SUBSTITUTION OF COMPONENTS MAY IMPAIRSUITABILITY FOR CLASS I, DIVISION 2, andAVERTISSEMENT - RISQUE D’EXPLOSION – LA SUBSTITUTION DECOMPOSANTSPEUT RENDRE CE MATÉRIEL INACCEPTABLE POUR LES EMPLACEMENTSDECLASSE I, DIVISION 2

Caution! 3. WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS

POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BENON-HAZARDOUS, and AVERTISSEMENT - RISQUE D’EXPLOSION - AVANT DE DÉCONNECTER L’EQUIPEMENT, COUPER LE COURANT OU S’ASSURER QUE L’EMPLACEMENT ESTDÉSIGNÉ NON DANGEREUX

4. WARNING - EXPLOSION HAZARD - DO NOT RE PLACE BATTERY UNLESS POWERHAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS; andAVERTISSEMENT - RISQUE D’EXPLOSION - COUPER LE COURANT OU S’ASSURERQUE L‘EMPLACEMENT EST DÉSIGNÉ NON DANGEREUX AVANT DE REPLACER LABATTERIE

1.5 Handling Precautions

STATIC ELECTRICITY

The CMOS integrated circuits in the analyzer can be damaged by exposure to electrostaticdischarges.

LITHIUM-ION BATTERIES

The analyzer contains a Lithium-ion cell pack which can create a fire or explosion hazard ifimproperly handled.

Do not expose battery to temperatures in excess of 100 degrees Celsius or dispose of in fire.

Do not attempt to charge pack with a charger other than specified or modify battery-related circuitryon the analyzer.



Do not short circuit battery.

Dispose of properly - do not throw away in the trash (please recycle to help the environment).

LOOSE CLOTHING AND LONG HAIR (MOVING PARTS)

Be careful not to get hands, hair, or clothes near any moving parts such as fan blades, belts, pulleys,or fly wheels. Never wear neckties or loose clothing when working around machinery.

ElectroMagnetic Interference (EMI)

Do not attempt repairs on the analyzer. Any loosening of the exterior metal case may damage theEMI protection of the case and interconnecting pieces.



1.6 Warnings

Caution!

The pressure sensor used with this kit may become hot when used oneither an engine, compressor, or any related piping. The sensor, whenhot, may cause severe burns to the hands or other body parts that comein contact with the hot surface. Use precautions such as insulated glovesto handle the sensor.

When using the water cooled pressure sensor, the water used for coolingmay become hot and cause scalding. Use precaution when handling thesensor to prevent the hot water from contacting the skin.

Caution!

The shaft encoder that may be included with this kit comes in contact witha rotating element. Keep all clothing and hair away from the rotating partsas they may become tangled with the rotating parts and cause severeinjury or death.

Keep hands away from the rotating equipment at all times to preventinjury.

Caution!

The timing light that may be included with this kit may be used nearrotating elements. Keep all clothing and hair away from the rotating partsas they may become tangled with the rotating parts and cause severeinjury or death.

Keep hands away from the rotating equipment at all times to preventinjury.

Caution!

Several cables are used with the analyzer and shaft encoder that may beused near rotating element. Keep all clothing and hair away from therotating parts as they may become tangled with the rotating parts andcause severe injury or death.

Keep hands and cables away from the rotating equipment at all times toprevent injury. Be aware of the trip hazard cables on the floor can create.



2 Read This First

2.1 Special Terms

6310 / 6320 AnalyzerPortable data collection instrument or analyzer.

Shaft EncoderDevice used to convert crankshaft position into electrical impulses.

Parallel PortPrinter and communications link between the analyzer and host computer.

Transducer / SensorDevice used to convert mechanical measurements into electrical signals.

USBUniversal Serial Bus

VGAVideo Graphics Array or common computer color monitor type.

2.2 Care

Use only a damp rag with a mild soap to clean the surfaces. Strong degreaser and other chemicalsmay damage the keypad and clear display window.

2.3 Unpacking

Check to verify the following items are in the instrument case upon arrival.

PARTS LIST (Standard Package)

Part 6320Analyzer A6320-00/CABattery/Batteries A6301-02Battery Charger A6312-00Carrying Case with Cut Foam MP630030-00USB Communications Cable A6306-03-00Leather Case (on analyzer) A6304-01Carry Strap A6305-00DC Pressure Cable A6060-00-08DC Pressure Sensor (High Temp) A6082-XX-01Manual A6310-00-M/CASoftware CD-ROM A6310-00-SW/CASecondary Ignition Pickup A6030-01-06

Other parts may be present depending on the options selected and/or purchased.

Read This First 7


Note: 6310 only. A battery is typically shipped in the analyzer. Under normal circumstances, abattery should be kept in the analyzer when not in use. Having a battery in the unit will helpkeep the internal CPU's CMOS coin cell charged and the operating configurationparameters intact for many years. Leaving the battery out of the unit may shorten the lifeof this coin cell requiring replacement and loss of the operating configuration parameters.

2.4 Batteries & Charging

General Battery Care information.

The analyzer kit contains one or more of the pictured batteries and charger shown below.

E-Moli Li-ion Energy Access

2.4.1 Batteries

For Optimum Performance of Your Batteries

This battery needs to be charged before use. Refer to the "Instructions for Use of the BatteryRecharger" section of this manual for charging instructions.

When the battery is charged for the first time, the charger may indicate that charging has beencompleted after just 10 to 15 minutes. This is normal and can happen with any rechargeable batterywhen it is first charged or if it has been stored unused for a prolonged period. Simply remove thebattery from the charger and repeat the charging procedure. There is no need to discharge thisbattery between these charges.

Best charging results are obtained at normal room temperature, 70°F (21°C) +/- 8°F (2°C). Chargingbeyond this range is permissible, but will not result in the battery's full capacity being reached. Charging at temperatures below 50°F (10°C) or above 95°F (35°C) is not recommended.

It is normal for the battery to become warm during charging or after use.

It is not necessary to fully discharge this Li-ion battery before recharging. However, top-off typecharging can confuse the battery if charged this way consistently.

All rechargeable batteries will gradually lose their charge over time when they are left in storage. If thisbattery will be left in storage for more than a few days prior to use, a top-off charge to regain fullcapacity is recommended.



Note: 6310 only. A battery is typically shipped in the analyzer. Under normal circumstances, abattery should be kept in the analyzer when not in use. Having a battery in the unit will helpkeep the internal CPU's CMOS coin cell charged and the operating configurationparameters intact for many years. Leaving the battery out of the unit may shorten the lifeof this coin cell requiring replacement and loss of the operating configuration parameters.

Wipe the metal terminals with a soft, dry cloth if they become dirty.

Safety Precautions for the Batteries

Do not disassemble or attempt to open the battery under any circumstances.

The battery can explode, leak or catch fire if heated or exposed to fire or high temperatures. Do notshort circuit the battery by directly connecting the metal terminals (+,-). Be certain that no metalobjects such as coins, paper clips, etc., touch the terminals.

Only use the charger recommended by the device manufacturer.

To Avoid Damage to Battery

Do not drop battery or subject it to mechanical shock.Use battery only with equipment that specifies its use.

Recycling Information

Windrock is committed to environmental responsibility and would like our customers to recycle thisbattery. For instructions on how to recycle this battery, call your local battery recycler.

2.4.1.1 E-Moli

LITHIUM-ION STYLE BATTERY

You may identify the Lithium-Ion battery by the all black case and the "MOLICEL" logo on the top. These batteries are Smart Technology batteries. There is a capacity bar on the right and is activatedby pressing the ON/OFF or RED button. The Li-ion battery is lighter in weight and higher in capacity.

Caution! Do not attempt to charge the Li-ion battery in a non-Li-ion charger (use onlythe EnergyAccess charger supplied). There is a great potential for thebattery to EXPLODE. Use only a charger specified for this type of battery.

A battery may become deactivated and go into the "off state". This means that the battery will not workuntil it is turned on. To do this, insert the battery into the left charger bay and press the "Re-calibrate"

Read This First 9


button and let the battery sit for 15 to 20 seconds. Remove the battery and place it in the right side ofthe charger and let charge fully. It should then operate correctly.

2.4.2 Charger

Lithium-ion Battery Charger (Energy Access)

Newer units shipped are supplied with one or more Lithium-ion batteries. These are the latest highcapacity lightweight batteries available. They also have a special charger made just for Lithium-ionbatteries.

Caution! Use of other charger may result in an explosion.

To use the Energy Access battery charger, plug the power supply (use the power supply - PS2524only) into an outlet (100VAC - 240VAC/50-60Hz) and insert plug end of the power cable into the DCpower jack on the charger. Insert a battery in one of the two bays. The LED will illuminate to indicatethe status of the battery as follows:

Off: No battery detectedGreen Flash: Fast chargingGreen Solid: Fully chargedYellow Flash: Re-calibratingYellow/Green: Re-calibratedYellow Solid: StandbyRed Flash: Error

Caution! Connection other than indicated may result in permanent damage to theunit.

Re-calibration:

SMBus Smart Batteries contain a microchip that monitors battery usage and tracks how muchcapacity is available from the pack. It is possible for this process to accumulate errors due totemperature fluctuations, aging, self-discharge, and other factors.

To keep the internal information as accurate as possible, it is occasionally necessary to run thepack through the calibration cycle. This involves fully charging the pack, completely discharging it,and then recharging it again. The charger performs these steps automatically when a calibrationis initiated.

To calibrate a pack, place it in the left bay and push the red (or blue) arrow located between thebays. This process can take 16 hours. Some packs do not have the capability to be re-calibrated.



The charger automatically senses this and simply drops back into the normal charge mode.

Specifications

SMBus: Level 3Charge Rate: 3.0 Amps2 Bays: SequentialCharge Time: 3 hours eachRecalibration: SMBus [email protected] Time: 9 hoursWeight: 9.5 ozMaterial: ABS GSMColor: BlackDimension Inches: 4.89 x 6.89 x 2.02Dimension mm: 124 x 175 x 50

Getting Started 11


3 Getting Started

3.1 Connections

6310 OnlySeveral connections are provided on the portable analyzer unit. See the figures below for placementof the connections. Looking at the rear panel to the far left, a connector labeled "KBD" is used forattachment of an external PS2 style keyboard. If a PS2 style keyboard is not available, a standard PCkeyboard may be used, but the number pad on the right of a large keyboard is not supported (NumLock will do nothing). The connector on older style keyboards is a 5-pin DIN style and an adapter willbe needed. These are available at most office supply or computer retailers. You may also contactWindrock, Inc. to purchase this adapter.

6320 OnlyA standard USB keyboard may be used by connecting it to the USB port found on the left side of theanalyzer.

Caution! Do not connect the external keyboard while near engine ignition systems.This may damage both the keyboard and the portable analyzer.

Next, there are two round "Lemo" transducer input connectors. These connectors are for thetransducers and shaft (crank-angle) encoder which may be provided in the portable analyzer kit.

The connector labeled "ANT" is for an optional wireless receiver antenna.

Caution! Do not over-tighten the antenna. The antenna only needs to be finger tight.There is potential to break the connector by over-tightening.

On the far right, an external AC-adapter connector is provided for use with the supplied charger powerpack. You may unplug the power pack from the charger base and plug it directly into the portableanalyzer. This will provide sufficient power to leave the instrument on for reviewing stored data withoutusing up the battery.

Caution! Make sure to keep a battery in the analyzer when using the external poweradapter.



A6310-00/CA and A6320-00/CA Rear Panel Connectors

6310 6320 VGA Port USB Port

A6320-00 Left Side

The 6310 has a 25 pin parallel printer port / communications connection, where the 6320 has a USBport, and both have an external VGA color monitor connection located together on the left side of theanalyzer behind the sliding door. A USB keyboard may be connected here on the 6320 analyzer.

A standard VGA / SVGA monitor may be connected to the portable analyzer for larger desktop screenviewing. The operating software is set for 640 x 480 pixels of resolution. There are no settings tochange this resolution for different monitor types. However, both color and B&W are supported.

Please see the chapter on Utility Menu Options for use of the 25 pin parallel port for file transfer toWindows and Operating System Commands chapter on Printing from the parallel port of your 6310.For information on printing from the 6320, see the chapter on Operating System Commands, Printing6320.

The 6310 and 6320 battery compartment is located on the right side of the analyzer behind the slidingdoor. The battery compartment has a spring located in the bottom to pop the battery out when thedoor is open. The battery will have to be pushed in and held while closing the sliding door. This maybe tight and is normal operation.

Note: The sliding doors on the sides are provided to protect against EMI when around ignitionsystems. The doors should remain closed while operating.

Getting Started 13




3.2 Keypad Functions

ESC The escape key operates as a cancel function and gives the user the ability toback up one step or menu. If you are in an operation that may cause data loss(setup screens), a warning is given for user acknowledgment.

ON/OFF Turns the analyzer on or off.

Yes No The 6320 has separate Yes and No keys.

ENTER Accepts the user entry or selects the current option.

+/- Changes the sign of numeric inputs or adds a hyphen character to text entries.

END Drops the user to the end of a screen or to the end of a list.

HOME Brings the user to the beginning of a screen or to the beginning of a list. (Specialnote: The HOME key is also used to bring up a list of alphabetic characters fortext entry when a keyboard is not available)

p q Used to move the cursor up and down for selections.

t u Used to move the cursor right and left and increment and decrement numericentries. The right arrow is also used to bring up pop-up list selections on certaindata entry fields.

ÓTAB Ñ

Advances the user ahead multiple entries or multiple pages.

ÔTAB Ò

Returns the user back multiple entries or multiple pages.

Period Enters a decimal point as needed for numeric entries.

NumericKeys

Enters the numeric character in data entry fields and provides short cutmenu/function selections. If the user is on a menu screen, simply pressing thenumber associated with the option will execute the option.

Note: If the entry screen has multiple lines requiring duplicate entries, you can press the"ENTER" key and all the data from the previous line will be transferred to the newline. For example, each cylinder's bore, stroke, and connecting rod length may becopied from line to line since they may all be of the same values.

3.3 Hardware Configuration

Before using the analyzer, take the time to become familiar with the basic operation and set up. Thereare a number of options, setup entries, and keystrokes with which you should be familiar prior to takingyour first set of data.

When you first receive your analyzer and turn it on, you will be in a "Windrock Test Station" and "TestMachine" area. However, prior to your data collection, you must first set up your own stations andmachines in the database. Subsequently, when the analyzer is turned on, you will be positioned at themenu for the last used station and machine. This enables you to power down the analyzer toexchange batteries and power back up to the current machine and station. From this menu, you canselect a new machine or station by pressing "ESC" once or twice, respectively.

Getting Started 15


Note: The "Windrock Test Station" and "Test Machine" should not be deleted or used for datastorage. This area is set up for initial and subsequent calibration of the analyzer.

There are basic configuration parameters that may be set on the analyzer to optimize the operation foryour needs located in the Hardware Configuration option of the Station Selection Menu.

Use backlight: Typically set to YES. Setting to NO will turn off the LCD back lightand the screen image may be hard to see - this mode conservesbattery power.

Monitor type: Typically set to LCD for black and white units, Color1 or Color2 forcolor units or when an external VGA monitor is used. B&W can beused to improve contrast in some cases.

Use power save: Typically set to NO. If set to no, the processor runs at full speedand the back light will not turn off after one minute.

Caution! Power can be shut off to the encoder when in power save mode and theuser returns to a menu screen. It is possible to lose the phase setting(exhaust vs. compression cycle) of the encoder when collecting data ona 4-stroke engine. You must check the phase before continuing withdata collection if this occurs.

Use blinking: Typically set to YES. You may prefer to not have the cursor barblink. If so, set this option to NO.

Screen width: Typically set to 40 column.

Text Cursor Style: The style of the cursor may be changed between ARROW, BAR,



or BOX.

Peak pressure only: This is set to YES for a CA Lite and NO for a CA with encoderoption and want to configure the analyzer to make crank-anglebased measurements (IHP, peak angle, ignition timing).

Autoscan first in take data: This option controls how the data collection process runs. Whenset to YES, entering the data collection process will automaticallystart the analyzer auto scanning data and update the screen witheach collection of data until the 3 key [STOP AUTOSCAN] ispressed. Once the auto scan is stopped, the user is prompted tosave the latest data capture. The data collection process thencontinues to collect the statistical data and display it.

Use unit conversion: NO uses the default standard units that have always beenavailable. Setting to YES will allow selecting from different

conversion groups (see "Unit group" below).

Unit group: Allows selecting either Standard or Metric Units.

DC Sensor correction: Set to Zero Only for zero only balancing of the pressure sensor inthe CA mode. There is no zero function available in the CA (LITE)mode.

Is this a CA with encoder: This default is NO. Set to YES if using an encoder.

Setup (D6) files warning: This is set to YES to receive a reminder to transfer the setups tothe computer after setups have changed in the analyzer.

The analyzer contains a status line at the bottom of the display. This line contains information aboutthe battery capacity and the date and time. The battery capacity is monitored when the unit isoperating from the battery. If the unit is on AC power, the status line will add "Using AC" to the batteryvoltage value. If the battery capacity drops to approximately 9 volts, a warning will be displayed andthe analyzer will automatically turn off.

Caution! When the battery goes below 10.0V, save the current data and changethe battery. Any data stored up to this point is safe. Only data that iscurrently being collected and displayed or setup information currentlybeing entered could be lost.

3.4 Stations & Machines

Stations and Machines are laid out in a tree structure. The first level in the tree structure is the Stationlist. There are from 0 to 199 folders (starting with a 0 base) and each folder contains a station. Withineach Station, there contains from 0 to 199 machines (starting with a 0 base). Within each Machine,there resides the setup files and crank angle related data collected files.

Getting Started 17


The structure looks like this:

/EVPORT|Station 000 (S000)| || Machine 000 (M000)| | || | Setup| | Crank angle data| || || Machine 001 (M001)| || Machine 002 (M003)| || ...Station 001|...

The database is a flat file structure for fast and easy data retrieval. All data is stored in this format andcan be easily accessed. This structure is automatically created by the software.

3.4.1 Station & Machine Setup

The first steps in setting up a new station and machine are described in the following steps.

Note: This must be done prior to being able to duplicate (copy) a previous setup from anotherstation/machine. See the section on machine database in the Win63X0 manual forcopying setups. This section applies to all 63X0/CA models.

Station Selection Menu

From the "Machine Menu", press "ESC" twiceto return to the "Station Selection Menu".

Select "2-Add a station".

Enter a station name of up to 30 charactersfollowed by pressing "ENTER".

You will be returned back to the "StationSelection Menu".

Select "1-Select a station" and pick the newstation you just added from the list.

Caution! If you are a Win63X0 software user, make sure the name entered is not alteredwithout also changing the Windows database. In order to connect Windows tothe portable analyzer, these names must match exactly (character and case) ora connection will not be allowed.



Machine Selection Menu

You will now be brought to the "MachineSelection Menu".

Select "2-Add a machine".

Enter a machine name of up to 30characters followed by pressing "ENTER".

You will be returned back to the "MachineSelection Menu".

Select "1-Select a machine" and pick thenew machine you just added from the list.

Note: You will need to come back tothis menu to add each machine you willanalyze.

Note: If your analyzer is a 63X0/CA non encoder balancer, proceed to the section on"Balancer/Spark Setup and Data Collection". Skip the "Machine Setup, 63X0/CAw/encoder" section. If your analyzer is a 63X0/CA w/encoder, proceed to the section on"Machine Setup, 63X0/CA plus encoder". After following those instructions, then proceedto the section on "Balancer/Spark Setup and Data Collection".

Machine Setup, 63X0/CA with encoder only 19


4 Machine Setup, 63X0/CA with encoder only

4.1 Setting Up a Machine, 63X0/CA with encoder only

4.1.1 Machine Setup Menu

The analyzer will power on to the "Last Station" and the "Last Machine" it was in prior to powering theunit off. In the case of the /CA, the screen below will be shown after power up. Alternately, you canuse the Win63X0/CA software auto generate features.

Machine Menu, Analyzer CA withEncoder only

You will now be brought to the "MachineMenu" as shown in the figure.

At this point, you must select "2-Setupdatabase" to enter all the informationabout the machine.

This would include engine & compressorgeometry, points for data collection, gascomposition, etc.

This is the minimum required to collect data with the analyzer. Further customization may be requiredto meet your setup needs.

If you find that the names you have entered need to be changed, you may use the "Edit a stationname" and "Edit a machine name" as necessary.

The machine menu is the entry point when turning on the analyzer. At this point, you may take one ofseveral actions. The menu options are outlined below:

Option 1: "Data collection menu" is the point where data collection begins after a setup hasbeen entered for the selected machine.

Option 2: "Setup database" is a set of menu options to configure the machines geometry,sensor points, collection points, fixed scaling, and other related setup details.

Option 7: "Utilities" are a set of utilities for calibration of sensors, connecting the analyzer to adesktop computer, battery conditioning, and other helpful items.

Option 8: "Select different machine" takes the analyzer back one menu level to select a newmachine. The Machine database setup is a set of menu options to configure themachine's geometry, sensor points, collection points, fixed scaling, calculation, andother related setup details.



The machine configuration data can beobtained from the manufacturer's datasheets. Occasionally, not all theinformation is available from this source.It may be necessary to call themanufacturer to enlist their help with themissing information. As a last resort,there are databases that have beendeveloped that can help you obtainmissing information. When you use thisinformation, it is up to you to verify theaccuracy.

Below is an outline to setting up the machine database. It is a guide to organizing your data beforecontinuing. We suggest you gather the required data prior to starting the entry process. This Menuapplies to the /CA with encoder analyzer, but does not apply to the /CA Lite analyzer.

Note: In the following setup screens, use the left or right arrow keys to select from the choicesavailable or enter the numeric values as required.

Menu Key Menu Option Description

1 Machine Configuration Number of cylinders, bore, stroke, etc.

2 Machine Sensor Setup Define individual sensor points

3 Collection point / Plot Setup Setup route for data collection

1 - Point setup Arrange groups of sensor points for collection 2 - Autoplot setup Arrange groups of sensor points for plotting3 - Generate default autoplots Automatically create a default set4 - Empty autoplots Erase all existing autoplots and start over

4 Fixed Data Scales Setup predefined scales for display of data.

5 Not available MA/CA Does not apply to /CA analyzer

6 Not available MA/CA Does not apply to /CA analyzer

7 Software Configuration Modify standard defaults for this machine only

8 Return to machine menu Returns analyzer to machine menu

Balancer/Spark Setup and Data Collection 21


5 Balancer/Spark Setup and Data Collection

All non-encoder functions must be set up in the analyzer and the set ups transferred to the Win63X0/CA program.

5.1 Overview

The analyzer will power on to the "Last Station" and the "Last Machine" it was in prior to powering theunit off. In the case of the /CA Lite, the screen below will be shown after power up.

In the case of the /CA with encoder model, from the power up menu, navigate through the followingmenu options to reach the menu shown below:

1. 1 - Data collection menu2. 4 - Balancer menu3. 4 - Balancer / Bal & spark menu4. 2 - Nonencoder balance and spark



The balancer mode has several menu options from which to choose. It is best to start with the setupmenu first when using the analyzer for the first time on a new unit. After the setup has been completed,it only needs to be entered to make changes.

Menu Key Menu Option Description

1 Setup balancer / spark Enter configuration parameters for the program

2 Balance engine nonencoder Balance an engine using pressure sensor with out crankangle position

3 Restart balance run Used to start the program after a battery change at thelast cylinder data that was collected

4 Recall old balance data Recall data that has been stored on the analyzer from aprevious balance

5 Spark menu Enter the spark survey menu

6 Utilities A set of analyzer utilities - specifically, connection to theWindows application software, Win63X0/CA.

7 Online balance Link Connects the analyzer to an "online" system

8, CA lite Select different machine Use to select a different unit on which to run a survey

8, CA Return to special data menu Returns to previous menu

5.1.1 Setup

Press the "1" key or the "ENTER" key if the menu item is highlighted to select the (1 – Setupbalancer/spark)

Every new machine added will have to be set up in the portable analyzer prior to running a peakpressure balance and/or a spark survey. Once the new machine is set up, the set up information willremain the same unless changed.



MAX SENSOR PRESSURE: Select the desired pressure sensor range (1000, 2000, or3000 psig @ 20ma) by pressing the "LEFT or RIGHT Arrow"keys.

NUM POW CYL: Select the number of power cylinders (1 – 20) for the machineby pressing the "LEFT or RIGHT Arrow" keys.

CYL LAYOUT: Select the power cylinder numbering scheme (STRAIGHT,LEFT/RIGHT, ODD/EVEN) by pressing the "LEFT or RIGHTArrow" keys.

USE SPIKE FILTER: Select the use of the spike filter (NO or YES or YES-HEAVY)by pressing the "LEFT or RIGHT Arrow" keys. The spike filtershould be used when indicator tube detonation is present onthe pressure trace (i.e. – IR-KVS, Nordberg).

PERCENT +/- OK BAND: Select the desired maximum percentage of power cylinderimbalance (0 – 10) by pressing the "LEFT or RIGHT Arrow"keys.

2 OR 4 CYCLE ENGINE: Select the proper number of cycles (2 CY., 4 CY.) by pressingthe "LEFT or RIGHT Arrow" keys.

DEBOUNCE FACTOR: Select the desired debounce factor (1 – 33) by pressing the"LEFT or RIGHT Arrow" keys. The debounce factor defaultsto 3 and should work satisfactorily on the majority ofmachines. This is the number of consecutive pressures thatmust exceed the trigger level (psi) before the peak detectorengages or ends.



TRIGGER LEVEL (psi): Select the desired trigger level (30 – 100) by pressing the"LEFT or RIGHT Arrow" keys. The trigger level defaults to 30and should work satisfactorily on the majority of machines.This is the trigger level that pressure must exceed before thepeak detector is enabled. It is also the level that pressuremust fall below to reset the peak detector. The level is in psi. It is normally set somewhere between 30-60 psi.

SHOW CURVES: Select the desired viewing option (NO, YES no pause, YESwith pause, NO pause, NO SD, Pause, NO SD) by pressingthe "LEFT or RIGHT Arrow" keys.

NO – When taking data, the peak pressure text data only willbe present on the screen. When finished with the datasample, it will automatically go to the select cylinder list.

YES no pause – When taking data, the peak pressure curveswill be present on the screen. When finished with the datasample, it will automatically go to the select cylinder list.

YES with pause – When taking data, the peak pressurecurves will be present on the screen. When finished with thedata sample, it will be necessary to hit any key to return to theselect cylinder list.

NO pause, NO SD – When taking data, the peak pressurecurves will be present on the screen. Standard deviation willnot be displayed. When finished with the data sample, it willautomatically go to the select cylinder list.

Pause, NO SD – When taking data, the peak pressure curveswill be present on the screen. Standard deviation will not bedisplayed. When finished with the data sample, it will benecessary to hit any key to return to the select cylinder list.

REDUCED SCALE ON CURVES: Select the desired scaling option (NO, HALF, 3/8, QUARTER,5/8, 3/4) by pressing the "LEFT or RIGHT Arrow" keys.

This scaling factor is used for the pressure curves verticalscale. When set to NO, the vertical pressure scale will bezero up to the "MAX SENSOR PRESSURE" that has beenselected. Other scale selections will scale to the selectedfraction of the "MAX SENSOR PRESSURE".

# SPARK PER CYLINDER: Select the desired number of spark plugs per cylinder (0, 1, 2)by pressing the "LEFT or RIGHT Arrow" keys.

SPARK LAYOUT: Select the desired spark plug layout and naming convention(Use Side/Center, Use Left Right, Use A/B, Use Top/Bottom,Use CS/OCS) by pressing the "LEFT or RIGHT Arrow" keys.

SHORT SPARK DURATION: Select the desired horizontal scaling factor (NO, YES) bypressing the "LEFT or RIGHT Arrow" keys. Most CD(capacitor discharge) ignition systems have 500 Us or lessarc durations and the SHORT DURATION can be set to YES.

This will be the default scaling factor while taking data,



however, this scaling factor can be changed while takingdata.

MULTI STRIKE SPARK: Select the proper machine spark type (NO, YES) by pressingthe "LEFT or RIGHT Arrow" keys. When using the sparksurvey on a multi-strike ignition system, the software willattempt to analyze the first ignition event of the series.

FAST RAMP TIME: This is typically set to NO. YES should only be used ifdirected so by Windrock Customer Support or Engineering. Ifthis is set to YES, the Ramp Time will not be shown on thereports.

PRESS CUTOFF LOW Select the low pressure cutoff value for the report by pressingthe “LEFT or RIGHT Arrow” key. The balancer will report thenumber of cycles that the peak pressure was below the lowcutoff value.

PRESS CUTOFF HIGH Select the high pressure cutoff value for the report bypressing the “LEFT or RIGHT Arrow” key. The balancer willreport the number of cycles that the peak pressure was abovethe high cutoff value.

RECORD PANEL POINTS Select the PANEL POINT OPTION (NO, YES) by pressingthe “LEFT or RIGHT Arrow” key. Selecting “YES” will allowrecording “as found” and “as left” panel data including fuelusage and bsfc values. Selecting NO will deactivate panelpoints in collection routine. There are 12 predefined panelpoints to choose from, 6 user defined points, and exhausttemperatures for each cylinder.

FINISHED: Select the desired option (NO, YES hit enter) by pressing the"LEFT or RIGHT Arrow" keys. If "YES hit enter", follow bypressing the "ENTER" key to finish the machine set up, andreturn to the initial Balance and Spark Menu screen. If theRECORD PANEL POINTS option was selected, additionalscreens will be displayed to define the panel points to beselected.

If you hit "ESC", the program will then prompt a "WARNING –Escape was hit - If you have made changes they will be lost.Save changes? (Y/N)"

If you want to save the set up changes, press the"HOME-YES" key.

If you do not want to save the set up changes, press the"END-NO" key.

Pressing the "HOME-YES" key or the "END-NO" key willreturn to the initial Balance and Spark Menu screen.

Note: Every new machine will have to be set up in the portable analyzer prior to running aPeak Pressure Balance and/or a Spark Survey. Once the new machine is set up, theset up information will remain the same unless changed.



If you selected "YES" to "Record Panel Points", the following setup screens will allow you to definethose selections prior to returning to the Spark Menu screen.

Turn individual selections to “YES” or sequence number by using the "LEFT or RIGHT Arrow" keys ifyou want the point added to the panel report. Panel points will show up in the order of their sequencenumber. Go to the next page to continue the setup.

Identify the names of the user panel points selected on the previous menu page. The HOME key isused to bring up a list of alphabetic characters for text entry when a keyboard is not available. Lookingat the rear panel to the far right, a connector labeled "KBD" is used for attachment of an external PS2style keyboard.



Est Fuel Savings: If panel fuel flow is recorded, you may estimate the fuelsavings from the "AS FOUND" readings to the "AS LEFT"readings by using the "LEFT or RIGHT Arrow" keys to tab tothe correct measurement unit. (YES ft3/min, Yes ft3/hr, YesMMft3/day, Yes m3/min, Yes m3/hr, Yes MMm3/day, or No).

Fuel Cost ($/unit): Enter the current fuel cost in $/MSCF or $/Mm3.

FINISHED: Select the desired option (NO, YES hit enter) by pressing the"LEFT or RIGHT Arrow" keys. If "YES hit enter", follow bypressing the "ENTER" key to finish the machine set up andreturn the 6310/CA to the initial Balance and Spark Menuscreen.

If you hit "ESC", the program will then prompt a "WARNING –Escape was hit - If you have made changes they will be lost.Save changes? (Y/N)"

If you want to save the set up changes, press the"HOME-YES" key.

If you do not want to save the set up changes, press the"END-NO" key.

Pressing the "HOME-YES" key or the "END-NO" key willreturn to the initial Balance and Spark Menu screen.

5.1.2 Engine Balance

5.1.2.1 Engine Balancer - Non encoder

This is the option to select when you are ready to balance the engine.

Note: If "record panel points" is selected in the setup, you will be prompted to record thosereadings before taking 'As Found data'.

In taking data, there are three main steps in balancing:

1. Take "AS FOUND" data. This is the engine balance before any adjustments are made. Ifrecord panel points is selected in the setup, you will be prompted to record those readings.

2. Adjust cylinders. This is when the cylinders are adjusted to even out the peak pressures.

3. Take "AS LEFT" data. This is the engine balance after all adjustments are made.

Note: If record panel points is selected in the setup, you will be prompted to record thosereadings.

Note: You can bring up the last "AS FOUND" and "AS LEFT" balance run for the day on theanalyzer. Other run numbers are available for viewing in the Windows softwarepackage.

When first starting, the engine speed is determined by sampling the pressure curves. This enginespeed will then appear on the 'As Found' report.



The first screen you see will ask you to connect thepressure transducer to a power cylinder and applypressure. After you hit any key, the estimatespeed routine will run. This function will count thenumber of pressure peaks within a measured timeframe and calculate an estimated RPM.

Note: The pressure sensor must be attached to channel one.

This will take 10 seconds. If the estimated speed is not close to the known speed, then you need togo back and adjust the debounce factor and trigger level in ENGINE SETUP. This speed is reportedon the 'As Found' or 'As Left' reports depending on where you are in the sequence.

Note: The pressure sensor must be attached to the power cylinder and the indicator valvemust be opened to apply pressure.

After the speed has been estimated,the starting balancer screen willappear. Hit any key to go to the "selectnumber of cycles to take" screen. Thedefault number is pre-selected. Simplyhit enter to continue. If a differentnumber of cycles is to be collected,select it now by using the up / downarrow keys (for one step at a time) orthe “UP or DOWN TAB” keys (for fivesteps at a time) and pressing enter.

Note: The number of cycles selectedin this screen will be the numberof cycles used in the "ASFOUND", "Adjust cylinder", and"AS LEFT" data collectionmodes.



After you have set the number ofcycles, a list of the cylinders will beshown. Select the first one to startcollecting data.

A '?' represents a point for which datahas not been taken.

A '*' represents a point for which datahas been already taken.

Once the point has been selected, youare given the option to change thecylinder selection or the load step beforeactually collecting the data. On thisscreen, the cylinder selection can bechanged by placing the cursor on the"Chan 1 >" field and pressing theright/left arrow keys. The current loadstep may also be changed by placing thecursor on the appropriate field andpressing the right/left arrow keys.



As pressure data is collected, the curve and peak pressure are displayed (if the 'Show Curves' optionis set to Yes in the setup) along with the cylinder number as shown in figure below. Once all samplesare collected, the screen will return to the point selection list unless the 'Show curves with pause'option is selected. If so, the screen will show the curves for viewing until a key is pressed.

The "Pick Cylinder" screen willappear and the "?" indicator willchange to a "*" showing that thedata has been collected and thecursor bar will advance to the nextcylinder. Any cylinders with a "?"still require data to be taken.



When the last cylinder's data iscollected, the screen will show amessage box with "Finishedcollecting as found data, Now adjustcylinders, Hit any key to continue". Pressing any key will display the "ASFOUND" balance report shown belowor Hit the "END/NO" key to resamplethe last point.

Below is a sample of an "AS FOUND" report. Once the last cylinder is collected, a screen will pop upshowing the "AS FOUND" balance results. Each cylinder will have the average peak pressuredisplayed for that cylinder. If the average pressure is outside the OK band, that cylinder should beadjusted. After the adjustments are made, take "AS LEFT" pressure data.



Report Column Explanations

Top Box (Text Information Section)

Power Cylinder Name: This is the cylinder ID for identification.

Peak Pressure - Mean: The mean (average) peak firing pressure for each cylinderbased on the number of cycles selected.

Peak Pressure - Diff: The difference each cylinder's PFP is from the engine averagemean peak pressure.

Peak Pressure - SD: The standard deviation of the cylinder's peak pressure samplebased on the number of cycles selected.

Peak Pressure - Spread: The cylinder's difference from the high to low peak pressures ofthe number of cycles selected.

Center Box (Bar chart statistics section) Shows the individual cylinder values in bar chart format on the left side.

On the right side is a single bar summing the individual cylinders.

Bottom Box (Individual cylinder balance bars) This shows the OK band based on the +/-% values

On the right side are the engine parameters: speed, pressure spread, run number, andload step.

Menu "Hot Box" Keys

The menu section of the "AS FOUND REPORT" has many menu options.

0-Options:

A submenu will pop up with the following selections:

"0- CHANGE PRESSURE MAXIMUM"

This is for changing the maximum pressurescale on the statistical bar graph.

"1-CHANGE PRESSURE PERCENTBAND"

This is for changing the plus and minus percentbands on the cylinder balance bars.

"2-CHANGE PRESSURE MINIMUM"This is for changing the minimum pressurescale on the statistical bar graph.

2 - Adjust cylinder When you select this, a list of the cylinders pop up. Highlight thecylinder that you wish to adjust then, when you have the pressuretransducer attached, hit the enter key. A screen will then pop upcontinuously showing you the average peak firing pressure for that



cylinder. It will also show you the engine average (this will notchange; it is based on the "as found data" or "as left data" only). Usethis screen to adjust the cylinder. When you have finished adjustingthe cylinder, hit any key. You will return to the report showing data forall the cylinders. The cylinder you have just adjusted will now bemarked with DONE. You can readjust this cylinder if you wish byselecting it again.

4 - Take As Left When you have finished adjusting cylinders, hit this option to take the"AS LEFT" report. You will be indexed again through each cylinder totake data. When done, the screen will reappear listing the results ofall cylinders. If the balance is OK, you are done. Hit the ESC to exit. If the balance still looks off, use the 2-Adjust cylinder option again toadjust the power cylinders. When finished adjusting, take another"AS LEFT" report. Repeat this cycle until a satisfactory "AS LEFT"report is obtained, then hit the ESC key to exit. You are now ready toconnect the analyzer to the PC and print your reports.

6 - Est. Speed This will run the estimate speed routine again. The new speed valueis then displayed and written in the "AS LEFT" report.

7 - Print If a printer is attached and configured, pressing the "7" key will makea hard copy of the current screen to the printer. "AS FOUND" and "ASLEFT" report data can be transferred to a PC running ApplicationWin63X0/CA software. Printouts can then be made from Windows.

8 - Show hi/lo # This will change the display and replace the SD and Spread columnswith the hi/lo pressure count data.

9 - Exit This will exit the program back to the main menu.



Using the information on the "As Found Report" to determine which cylinders need to be adjusted,select the "2-ADJUST CYL" option. The next screen in the adjust cylinder mode is the cylinderselection list. This list is a pop up selection in which you must use the cursor keys to select whichcylinder to adjust.



The "U" - UNADJUSTED shows that the listed cylinder has not been adjusted. The "A" - ADJUSTEDshows that the listed cylinder has been adjusted and data saved. Select the cylinder to adjust and thenext screen will come up. Live data will be displayed on the screen.



The target zone is the area in which you want to keep the peak pressure.

The cylinder balance bar shows where the current cylinder's pressure is relative to the engine average.It also shows the OK band within which you are trying to stay.

The current peak pressure is the actual pressure being measured. This allows reading the pressurewhile adjusting the fuel valve.

The engine average mean peak pressure is the value you are trying to attain on this individual cylinder.

If adjusting another cylinder, the next screen in the "ADJUST CYLINDER" mode is the cylinderselection list and will indicate that a cylinder has been adjusted. Select the cylinder to adjust bypressing the "UP or DOWN Arrow" keys to highlight the cylinder and then press the "ENTER" key.

"U – UNADJUSTED""A – ADJUSTED"

When finished adjusting the desired cylinders, press the "4-TAKE AS LEFT" key to finish taking a finalset of balance data. Taking "AS LEFT" data is the same as taking "AS FOUND" data. After the lastcylinder is taken the "AS LEFT" report will display.



If more cylinders are adjusted after the "Take as Left" has been performed, it will be necessary toretake the "AS LEFT" data for all cylinders to get an accurate "AS LEFT REPORT".

5.1.2.2 Restart Balance Run

If a partial balance run is performed and, for any reason, the portable analyzer is turned off (i.e. –phone call, dead battery, etc.), when the unit is powered back on, press the “3” key “3-rEstart abalance run” to resume the balance run that was in progress.

The next screen in the restart a balance run mode is the “ESTIMATE SPEED” screen. This functionwill count the number of peak pressures within a measured time and calculate an estimated RPM. Tocontinue, press any key.

Note: The pressure sensor must be attached to the power cylinder and the indicator valvemust be opened to apply pressure. “Hit any key when ready”.



The next screen in the restart a balance run mode will appear as below. “Hit any key to continue”.

The next screen in the restart a balance run mode will appear as below. The program will automaticallysearch and find where the balance run was stopped, “Hit any key to continue”.

If a complete “As Found collection”, “Cylinder adjustment”, and “As Left collection” has beenperformed, the restart a balance run will display the message below. More cylinders can be adjusted.

· If more cylinders are adjusted after the “Take as Left” has been performed, it is necessary toretake the “AS LEFT” data for all cylinders to get an accurate “AS LEFT REPORT”.

5.1.2.3 Recall Old Balance Data

The portable analyzer will save all the "AS FOUND" and "AS LEFT" balance runs for each machine. Torecall an existing balance run, on the main menu, press the "4" key or press the "UP or DOWN Arrow"key to highlight the "4-recall Old balance data" and then press the "ENTER" key.



The next screen in the "recall Old balance data" will appear as below. The message "PICK DAY TOEXTRACT BALANCE DATA" will appear. Press the "UP or DOWN Arrow" keys to highlight the desiredday, then press the "ENTER" key to select.



The next screen in the "recall Old balance data" will be the "As Found Report" for the day selected. Torecall the "As Left Report", press the "4" key or press the "LEFT or RIGHT Arrow" keys to highlight the4-RECALL AS LEFT" with the HOTBOX, then press the "ENTER" key to select.

5.1.2.4 Power Cylinder Monitor

The "Power Cylinder Monitor" is a stand-alone pressure monitoring utility that can be used to checkindividual cylinders without entering the "Balance engine nonencoder" mode.

When first starting, the engine speed is determined by sampling the pressure curves.

The first screen will tell you to connect the pressuretransducer to a power cylinder and apply pressure. After you hit any key, the estimate speed routine willrun. This function will count the number of pressurepeaks within a measured time frame and calculatean estimated RPM.

Note: The pressure sensor must be attached to channel one.

This will take 10 seconds. If the estimated speed is not close to the known speed, you need to goback and adjust the debounce factor and trigger level in ENGINE SETUP.



Note: The pressure sensor must be attached to the power cylinder and the indicator valvemust be opened to apply pressure.



The next screen in the "Power Cylinder Monitor" mode will display the live data collection. This willcontinuously cycle until any key is hit to exit.

There are six menu items with Control keys assigned.

Key Function Response1 Reset Reference to Running

Averagepress to reset the running average bar

4 Increase Cycles press to increase the cycle averages (5 cycle steps)6 Decrease Cycles press to decrease the cycle averages (5 cycle steps)5 Increase Pressure Range press to raise the pressure range of the sample average

bars7 Decrease Pressure Range press to lower the pressure range of the sample average

bars8 Increase SD Range press to raise the standard deviation range

5.1.3 Spark Menu

The Spark Survey mode is used for a detailed evaluation of the condition and integrity of thesecondary ignition system of a spark-ignited (SI) engine.

The Spark Survey Mode is an automated function that allows the user to simply connect the secondaryignition capacitive clip to each spark plug lead and collect all the important parameters of thesecondary ignition signal. Once the user performs the set-up of the machine in the portable analyzerfor each machine the first time, the on-screen menus will instruct the operation of the collection of the



spark data. When the user is finished collecting the data on each spark plug, the user will have accessto eight reports showing detailed ignition statistical parameters including:

1. Ionization Voltage2. Arc Duration3. Arc Voltage4. Rise Time (Ionization Time)5. Arc Slope6. Ring Down Voltage7. No Arc, Voltage Problems8. Arc Flyback

The major benefits of the Spark Survey Mode is to allow any individual to collect spark data quicklyand have intuitive information about the secondary ignition system. This reduces the need for anignition specialist to analyze the detailed secondary spark traces. With the computer performing all thevoltage measurements automatically on each parameter, this feature saves the time of having tomanually record these parameters. The analyzer will store these reports in memory for recalling oldspark surveys and trending of the secondary ignition system data.

The spark survey function is designed to perform one spark survey per machine per day. Every timethe "1 – Take spark survey" is selected, it initiates a spark survey run and a new run number. You canbring up any report run for the day by run number.

From the Spark Menu, select one of the options listed.

Key Function1 Start a secondary ignition survey2 To resume the spark survey that is in progress3 Recall saved data for display and reporting4 Jump to the oscilloscope mode for continuous display of a single point5 Return to previous menu



5.1.3.1 Spark Survey

The first screen in the ignition survey mode is the "START IGNITION SURVEY" screen. Press any keyto continue.

The next screen in the spark survey mode will display the message "Set number of cycles to collect".The number of cycles can be set from 10 to 250 by pressing the "UP or DOWN Arrow" keys (one stepat a time) or the "UP or DOWN TAB" keys (five steps at a time). When the desired number of cycles ishighlighted, press the "ENTER" key to select.



The next screen in the spark survey mode will display the message "Pick cylinder to collect data". Thedesired spark plug can be selected by pressing the "UP or DOWN Arrow" keys (one step at a time), orthe "UP or DOWN TAB" keys (five steps at a time). When the desired spark plug is highlighted, pressthe "ENTER" key to select.

Note: The spark plug will display a question mark before taking data "? – NEED DATA"

Note: The spark plug will display an asterisk after taking data "* - HAVE DATA"



The next screen in the spark survey mode will display the message "Hit enter to take data". Pressingthe "ENTER" key will continue the display of the live data collection screen.

Note: The secondary ignition sensor must be attached to the spark plug lead beforeproceeding. Press the "ENTER" key when ready.

Note: The spark plug selection can be changed on this screen by pressing the "UP orDOWN Arrow" keys to highlight "Chan 1 > L1 Side", then pressing the "RIGHT orLEFT Arrow" keys to select the desired spark plug.

Note: The loadstep selection can be changed on this screen by pressing the "UP or DOWNArrow" keys to highlight "Current loadstep > 1", then pressing the "RIGHT or LEFTArrow" keys to select the desired loadstep.



Live data collection screen

Below are explanations of the values shown on the plot:

Negative Pulling – The voltage is pulled negative with reference to ground.This is the normal polarity of a secondary circuit. This means the current is going from the sparkplug's center electrode to the ground electrode.

Positive Pulling – The voltage and current is going from negative to positive.This is reverse polarity of a secondary circuit. This means the current is going from the groundelectrode to the spark plug's center electrode.

Ionization Voltage – The voltage level reached to ionize the gas molecules in the spark gap (5-20 KV)

Rise Time – The time required to ionize the spark gap (8-40 Us)

Arc Duration – The time duration the actual arc occurs

Arc Voltage – The voltage level across the spark gap during the arc

Slope – The slope of the arc duration (Flat, Positive, Negative)



In the spark survey mode, live data collection screen, the Time Scale (Micro-seconds) and/or theVoltage Scale (Kilovolts) can be changed at any time during the data sample.

· To change the time scale, press the "0" key. The time scale will toggle through the availablescales each time the "0" key is pressed.

· To change the voltage scale, press the "1" key. The voltage scale will toggle through theavailable scales each time the "1" key is pressed.

Following the live data collection screen, the screen will return to the pick cylinder list. Continuecollecting data for all the spark plugs with a question mark "?"



When the final spark plug is finished with live data collection, the message will pop up, "Finishedcollecting spark survey, Hit any key to continue"

The next screen in the spark survey mode is the "Ionization Voltage Report". The values shown arederived from the portion of the spark example trace shown to the right in the square box.



Menu "Hot Box" Keys

The menu section of the "Ignition Survey Reports" has many menu options.

0-Options: To select "0-Options", press the "0" key or press the "LEFT orRIGHT Arrow" keys to highlight with the "HOTBOX", then press the"ENTER" key. The option menu selection pops up a screen as abovefor selecting the following options:

"0- CHANGE KV MAXIMUM". This is for changing the maximumkilo-volt scale on the statistical bar graph.

"1-CHANGE KV PERCENT BAND". This is for changing the plus andminus percent bands on the spark plug statistical bars.

"2-CHANGE KV MINIMUM". This is for changing the minimumkilo-volt scale on the statistical bar graph.

2-Report Type: To select "2-Report Type", press the "2" key or press the "LEFT orRIGHT Arrow" keys to highlight with the "HOTBOX", then press the"ENTER" key. The option menu selection pops up a screen as abovefor selecting the following options: To select, press the associatednumber key or highlight and press the "ENTER" key.

Note: Report definitions are further described in the next section. Each report can be viewed and printed as necessary.

3-Restart: To select "3-Restart", press the "3" key or press the "LEFT or RIGHTArrow" keys to highlight with the "HOTBOX", then press the "ENTER"key. The next screen will display the message "PICK DAY TOEXTRACT SPARK DATA". Highlight the desired day and press the"ENTER" key.

5-Single Sample: To select "5-Single Sample", press the "5" key or press the "LEFT orRIGHT Arrow" keys to highlight with the "HOTBOX", then press the"ENTER" key.

The next screen will display a single sample of the spark plugsecondary trace. Pressing the "5" key or the "ENTER" key will takeanother single sample.

Note: Single samples are for troubleshooting purposes and will not affect statistical reports.



7-Print: To select "7-PRINT", press the "7" key or press the "LEFT or RIGHTArrow" keys to highlight with the "HOTBOX", then press the "ENTER"key. If a compatible printer is set up and connected to the printer port,the "Selected Ignition Report" will print directly from the portableanalyzer.

9-Exit: Press the "9" key or press the "LEFT or RIGHT Arrow" keys tohighlight the "9-EXIT" with the HOTBOX. Then press the "ENTER"key to select.

5.1.3.2 Ignition Survey Report Definitions

The following report descriptions give the details of what is displayed and the meanings of the values.

Ionization Voltage – The voltage level required to ionize the compressed air/fuel molecules within thegap of the spark plug. This is also referred to as the ignition breakdown voltage. Ionization refers to thesplitting apart of the molecules to enable a current path for arcing of the spark plug. Higher ionizationvoltages produce a higher rise time.The typical units are in Kilo-Volts (Kv).

In a controlled environment:

1. The wider the spark plug gap, the more voltage required to ionize the gap.

2. The narrower the spark plug gap, the less voltage required to ionize the gap.

3. Typical voltage measurements will range from 5,000 to 25,000 volts, with voltages over20,000 indicating wide gaps and a greater potential for external flashover.

Note: In a non-controlled environment, the air/fuel ratio and mixture consistency can affect the ionization voltage level from cycle-to-cycle measurements.

4. This voltage should go negative (-) with respect to ground if the secondary circuit is wiredproperly. If the voltage is going positive (+) with respect to ground, this is referred to asreverse polarity and indicates the wiring to the coil is reversed and may result in shorterspark plug life.

Arc Duration – The measured time period the actual arcing of the spark plug occurs. This is the timemeasured between ionization voltage (breakdown) and the beginning of the ring-down voltage. The arcduration is inversely proportional to the ionization voltage and rise time. The typical units are inmicro-seconds (uS)


1. The wider the spark plug gap, the shorter the arc duration.

2. The narrower the spark plug gap, the longer the arc duration.

3. Typical arc duration measurements will range from 125 micro-seconds to 700micro-seconds for different ignition systems. When measured times reduce, this indicateswidening gap and/or excessive ionization voltage requirements. As measured timesincrease, this indicates a narrow gap and/or an incorrect measurement due to a lowring-down voltage level.



Arc Voltage – The voltage level required to maintain the arcing of the spark plug gap. This is thevoltage measured between the zero reference line and the arc duration level. This voltage is typicallyless than 1 KV with high current flow. The typical units is in volts.

Rise Time - The measured time required to ionize the compressed air/fuel molecules within the gapof the spark plug. This is also referred to as the ionization time. Ionization refers to the splitting apart ofthe molecules to enable a current path for arcing of the spark plug. The rise time increases with anincrease in the ionization voltage. The typical units are in micro-seconds (uS)


1. The wider the spark plug gap, the more time required to ionize the gap.

2. The narrower the spark plug gap, the less less required to ionize the gap.

3. Typical rise time measurements will range from 5 to 50 micro seconds (uS). With rise timesover 40 uS indicating wide gaps and a greater potential for external flashover.

Arc Slope – The measured slope of the arc duration. The measured slope can be one of the following:

1 – Flat. This indicates the voltage level during the arc duration remained constant as thevoltage requirements to maintain the arc did not change during the arc.

0 – Negative. This indicates the voltage level during the arc duration started at a lower voltageand increased as the voltage requirements to maintain the arc increased during the arc. This is an indication of high resistance across the spark plug gap.

2 – Positive. This indicates the voltage level during the arc duration started at a higher voltageand decreased as the voltage requirements to maintain the arc decreased during the arc. This is an indication of high resistance in the secondary wiring and connections exclusive ofthe plug gap.

Ring Down Voltage – The measured peak voltage of the ring down oscillation of the coil. This is alsoreferred to as coil oscillation and/or unused energy. This is the energy remaining after the spark plugarc demands cannot be maintained. The typical units are in volts peak. Anything that affects the R-Ctime constant affects the amplitude and frequency of the ring down oscillations. A lack of ring downtypically indicates a poor plug wire connection in the coil tower.

No Arc, Voltage Problems Report – This report identifies problems with spark plugs and/or othersecondary ignition components based on ionization voltage levels and arc duration measurements.Please refer to the report for detailed description of each of the problems identified.

Arc Flyback – This report identifies the number of times each coil has a flyback following theionization ramp. Please refer to the report for detailed description of the problem.

5.1.3.3 Restart Spark Survey

If a partial spark survey is performed and, for any reason, the portable analyzer is turned off (i.e –phone call, dead battery, etc.), when the unit is powered back on, press the “2” key “2-rEstart sparksurvey” to resume the spark survey that was in progress.



The next screen in the restart spark survey mode is the “TO RESTART IGNITION SURVEY” screen.To continue, press any key.

The next screen in the restart spark survey mode is the “RESTART OF DATA COLLECTION FORSPARK SURVEY” screen. To continue, press any key.

The next screen in the restart spark survey mode is the “Pick cylinder to collect data” screen. Thespark plugs that have data will have an asterisk (*), and the spark plugs the need data will have aquestion mark (?). Select the desired spark plug by highlighting to continue the data collection process.

At this point, continue on as normal during a spark survey.



5.1.3.4 Recall Spark Survey

The portable analyzer will save all the "Spark Surveys" for each machine. To recall an existing sparksurvey, on the main spark menu, press the "3" key or press the "UP or DOWN Arrow" key to highlightthe "3 – recall Old spark survey". Then press the "ENTER" key. A popup box will display all dates fordata taken and stored on the analyzer. Use the up / down arrow keys to highlight the date to view andpress the ENTER key.

The next screen will be the "Arc Duration Report" for the desired day. From this screen, the menuoptions are the same as when the data was taken. See the section on spark survey for more details.

Encoder-based Balance 55


6 Encoder-based Balance

6.1 Special Collection Modes

This menu allows access toseveral special modes for theanalyzer. With these modes,several detail functions may beaccomplished that arenon-crankangle related.

Spark trace mode: This function is used to collect and display ignition data. See thefollowing sections for a complete description of the functionsavailable.

Balancer menu: This is a submenu with two main functions for balancing an engineusing peak firing pressure and ignition survey mode to look at ignitionsystem details.



6.2 Spark

The Spark module is used to observe the waveform and voltage levels of the secondary ignitiontraces. When the Spark program is started, the user is shown 3 options:

NEW SCAN: Take new data.

PLOT OLD DATA: Recall stored data.

EXIT PROGRAM: Return to the menu.

Encoder-based Balance 57


Selecting "NEW SCAN" brings up the following sample screen and has several menu options.

While in the Spark trace window, the cursor is active and is moved with the TAB and arrow keys.

Key Function1 To zoom in on the signal, set the cursor to the left side and press 1. The

zoom will then occur. To restore the original, press 1 a third time.

2 To resample the signal.3 To change run number.

4, ESC Return to the setup menu5 Turn on autoscan to sample the signal continuously.6 This option will overlay six consecutive traces, then clear the screen and

repeat another six traces.7 To store the trace.8 To print the display to a printer if setup and connected.

9 Toggle the grid off/on.



Select 4-Menu brings up the following screen.

Step Size: This is a fixed field and is shown only for information. It is the time betweendigitized samples.

Count: This is the number of digitized samples that are taken for a trace. For a longerview select, increase this number. For multi-strike systems, increase thisnumber to about 1200. Maximum number is 5,000.

Scale: Use the RIGHT TAB key to bring up the scale selection box. This allows youto pick the vertical scale of the graph. You may select from the followingscales.

Use the "UP or DOWN TAB" to change. When the desired scale ishighlighted, press the "ENTER" key to select.

When you are ready to collect data, hit the "END" key.

Utility Menu Options 59


7 Utility Menu Options

The options listed in the menu to the left providethe user with extra utilities to help with sensorcalibration, data transfer, battery management,and operating software integrity.

7.1 Direct Channel Read

This function allows the user to directly read out a sensor's static voltage or current. The primary useof direct channel read is for verifying calibration and proper operation of pressure transducers.

First, pick a sensor from the sensor list todisplay. By picking the sensor from the sensorlist, calibration parameters and engineeringunits are used from the database previouslyset up.



Second, select the channel to which the sensoris physically attached on the rear panel. Forthe 63X0/CA, use channel one.

Third, a screen appears as shown above updating continuously with the input. Depending on thesensor type, there may be variations to the screen shown.

For DC pressure sensors, the screen shown has the following information:

Utility Menu Options 61


The channel number being used, the sensor point name, three columns of data, the zero factor(explained below), and the current mode.

The left column shows the zero adjusted values. If the "Zero dc press sensors" menu option under"Data Collection Menu" was used (CA with encoder only), an atmospheric reference point is applied. The center column is non-zero adjusted. No correction is applied and the raw values are listed. Thethird column shows the line's value type. For most cases, the "Engr. Units" (engineering units) line isused. This will show the actual readout of the pressure applied to the sensor.

The additional three lines are used by Windrock in calibration of the analyzer and other types ofsensors.

The Zero Factor line shows the bit count of the correction applied when the sensor was zeroed. Bitcount is a digital electronics value.

At the top of the display, a bar graph will display the current sensor value and will update based on themode selected. By default, the bar graph is in continuous mode. Below the bar graph is a small barshowing the peak value reached until the [9-Reset Bar] hot key is pressed to reset the bar to zero.

The mode line shows the current mode of the screen updating process. There are several modeswhich can be used for various purposes. Below are explanations.

Key Function Description0 Single Scan Updates the screen one time per hit of the key1 Continuous Updates the screen continuously2 Peak Scan Updates the screen if the new value exceeds the previous value3 Low Scan Updates the screen if the new value is less than the previous value4 Exit Exits the direct channel read function5 Run/Hold Stops the screen update temporarily7 Next Allows selection of a different sensor point

7.2 Connect to Windows 6310 only

Provides a link to Win63X0 Windows analysis software for the analyzer. This allows the transfer ofdata and setups between the analyzer and a Windows desktop/laptop.

When the screen is first shown, it will show the current Station and Machine in which it is operating. Toselect a different machine, press ESC to go back to the Station and/or Machine selection menus.



The Station number and Machine number are shown to help the user identify the sub-directory wherethe data is stored (Refer to the Data Backup Procedure for more information on the directorystructure). The station name and machine name are listed to insure the correct station and machineare selected.

Note: If the directory is changed remotely from the Win63X0 software, the change will bereflected on this screen.

The current directory is listed on the last line to show where the data is coming from or going to in theanalyzer (depending on the current Win63X0 applications function selected).

MODE: You may select the connection mode by going to Hardware configuration menu.

7.3 Power Cylinder Monitor

Refer to the previous section on the power cylinder monitor under engine balance for more details.

7.4 Discharge Battery 6310 only

This option helps in completely discharging a battery to a minimum amount. Use this only if directed toby Windrock Product Support.

7.5 Check for Bad EXE's 6310 only

This function will check the analyzer for proper operating software. The operating software iscomprised of several individual modules which must be from the same date. If the files become mixedor corrupted, this utility will notify the user when the check is run. Any files that are incorrect will bedisplayed on the screen below. These files should be reported to Windrock immediately.

Caution: If files are found to be mixed or corrupted, DO NOT continue using theanalyzer. Unexpected results may occur or collected data will be invalid.

Encoder Setup 63


8 Encoder Setup

8.1 Shaft Encoder

Several fittings have been provided for adapting the encoder to your needs. It is preferred that afriction connection be used over a direct connection. It is possible that a friction connection can slip. Check the TDC mark with a timing light if you suspect slippage. When using the friction connection,clean the flywheel surface to remove any grease or oils that could cause slippage.

Mount the encoder assembly on the tripod provided. Adjust the tripod height to center the encodershaft with the center of the flywheel. If needed, use the provided elastic cord to provide additionalstability by placing the cord around the tripod neck and securing it to the machine frame.

Once the encoder is set up, attach the 50-foot encoder cable to the connection marked "To Analyzer". Prior to taking data, make sure the "STROKE 4 - 2" switch is set properly for the engine type (definedin the machine setup). Also make sure that the number of pulses per revolution is set to the correctnumber.

Caution! On four stroke machines, do not switch the encoder or change the softwareconfiguration when moving from the engine to the compressor. The analyzerand software know the difference between the engine 4-stroke 0 to 720degrees and compressor 0 to 360 degrees .

Also, it must be noted here that, in order to collect angular velocity information, you must be able tocollect more than one pulse per revolution.

The "PHASE A-B" switch is provided to give the user the ability to shift data collection 360 degrees onfour-cycle engines, as necessary; for instance, if you are collecting data on a 4-cycle diesel engine andare unsure as to which stroke TDC is set.

The "Hole-Pin" switch is used to set the correct polarity of the first half of the trigger signal.

The shaft encoder is directly powered by the analyzer or the wireless transmitter. Note that, if theencoder cable is disconnected, the encoder will retain its settings and TDC for up to one hour. Thisallows the analyzer to be disconnected and reconnected as necessary without disruption except ascautioned above.

Please note that in four-cycle mode, the encoder uses the A/B switch to switch between the power andexhaust stroke. This setting is retained as long as the encoder is powered up.

Caution! Note that the software uses power conservation methods which will powerdown the encoder while outside the data collection menu (this will turn offpower to the encoder). Either of these situations will re-power the encoder



in a undetermined state for the power/exhaust cycle. To avoid thissituation, do not disconnect the encoder and set the power save settingunder hardware configuration to NO.

Caution! Make sure the BNC terminator (a shorting connector) is placed on the "MAGPU" input when not in use. This will reduce ignition interference in theencoder.

Note: It is strongly recommended that TDC be checked periodically; at a minimum, priorto and after data collection.

8.2 Multi-Event

The multi-event encoder provides for attachment of either an optical pickup (WRI P/N: A6056-01-08)or a magnetic pickup (WRI P/N: A3012-00-00) for TDC measurement. In addition, a magnetic pickupcan be used to measure individual teeth on a gear or flywheel for more resolution of crankangle.

A strobe light can be attached to the multi-event encoder to check the positioning of the TDC event. Note that the forward/reverse switch has no effect on the TDC offset of the older model, but willadvance or retard the TDC of the new (Black case) model.

Once the multi-event encoder is set up, attach the 50-foot encoder cable to the connection marked "ToAnalyzer". Prior to taking data, make sure the "STROKE 4 - 2" switch is set properly for the enginetype (defined in the machine setup). Also, make sure that the number of pulses per revolution is set tothe correct number.

Caution! On four-cycle machines, do not switch the encoder or change thesoftware configuration when moving from the engine to the compressor.The analyzer and software know the difference between the engine4-cycle 0 to 720 degrees and compressor 0 to 360 degrees.

Encoder Setup 65


Also, it must be noted here that, in order to collect angular velocity information, you must be able tocollect more than one pulse per revolution.

The "PHASE A-B" switch is provided to give the user the ability to shift data collection 360 degrees onfour-cycle engines, as necessary; for instance, if you are collecting data on a 4-cycle diesel engine andare unsure as to which stroke TDC is set.

Caution! Make sure the BNC terminator (a shorting connector) is placed on the"MAG PU" input when not in use. This will reduce ignition interference inthe encoder.

8.3 Magnetic Pickup

A magnetic or hall effect sensor may be used with the shaft encoder or the multi-event encoder.To use these devices, they must be placed on the machine with a known reference to TDC toensure proper timing information. Connect these devices to the connector marked "MAGPICKUP".

A self-contained optical type pickup with a TTL output may be used with the shaft encoder or themulti-event encoder. The optical sensor may be used directly with the multi-event encoder. To usethis type device, it must be placed on the machine with a known reference to TDC to ensureproper timing information. If the self-contained style pickup is used, connect this device to theconnector marked "MAG PICKUP". Reflective tape must be placed on the flywheel or rotatingelement at the TDC position for proper timing information.

8.4 Timing Light

With the encoder set up, attach the timing light to the connectormarked "STROBE". Aim the timing light at the timing marks on theengine flywheel and pull the trigger switch.

With the trigger switch pulled and while observing the flywheel, lookfor the timing marks. Using the arrow buttons, you can adjustmovement clockwise or counterclockwise as necessary to bring thetiming marks into view.

Once TDC has been found, the timing light should be disconnectedfrom the encoder to conserve battery power.

Caution! The timing mark is crucial for accurate analysis. Make sure that there isonly one timing mark on the observed surface. Having more than onetiming mark will cause confusion and create the possibility of collectingdata based on the wrong TDC of the machine.



9 Loading New Software

9.1 Windows Install 6310 only

Prior to starting, make sure the update has been installed on the desktop/laptop. There should be twoor more new files located in the Windrock\Win63xx\EXE folder that were part of the upgrade CD ROM.

On the analyzer:

1. Attach parallel interlink or USB cable between desktop and 63102. Turn the analyzer on3. Select 7 "Utilities" from the menu and press Enter4. Select 2 "Connect to windows" from the menu and press Enter

In the Win63X0 Windows application:

5. Before opening a database, select "Utilities" from the menu bar6. Select "Connect to analyzer" from the menu7. Press the "Connect now" button (the connection should be established - note this by a

box listing files on the analyzer appearing to the right of the window)8. Select "Transfer" from the menu bar9. Select "Update EXE's" on the menu

Transfer will now begin and may take several minutes to complete. Insure that the Windows softwareindicates that the transfer process is complete. Do not disturb the analyzer or Windows 6310 softwarewhile the transfer is in progress. Once the process has completed, exit the function inWindrock\Win63xx and restart the analyzer by turning it off then back on. The new operating softwarewill be in place.

Note: Verify the version on the startup screen to make sure the update has beentransferred.

9.2 Windows Install 6320 only

Prior to starting, make sure the update has been installed on the desktop/laptop. Follow theinstructions found in the Win63X0 manual under "Connect with closed database" and then "Sendsoftware updates to Analyzer".

Operating System Commands 67


10 Operating System Commands

10.1 Machine Template 6310 only

To copy a setup from one machine to another, use the following procedure.

C:\EVPORT is the main directory where the data files are kept. Each station and machine are put intosub..sub directories as shown below.

C: \ EVPORT \ S000 \ S001 \ M000

\ M001\ M002

Where S000 is the first station in the list, M000 is the first machine for the station. The easiest way tofind which subdirectory belongs to a machine is to select the station and machine of interest and, atthe 'Station Selection Menu', select "X-engineering mode". The subdirectory displayed is the currentmachine. These would be the files for that machine including setup and data.

You must then re-enter the 6300/6310 program by typing '0' and Enter. Back up in the menu to "Add anew station" and/or "Add a new machine". Add the new machine and select it. Repeat the aboveprocedure to determine in which subdirectory you are located.

At the DOS prompt type: copy c:\evport\sxxx\mxxxx\d6*.dat

The "xxx" should represent the directory from which you want to copy. Once the copy function iscomplete, type '0' and Enter to re-start the program. When the program is started, you must nowselect the new station/machine. It will have a complete copy of the other machine's setup.

10.2 Setting Time and Date 6310 only

To set the date and time in the analyzer, use the following steps:

1. Plug the small keyboard into the analyzer2. Return to the upper-most menu level by hitting the "ESC" key twice from the "Machine Menu"3. Select 6, (5 in the 6310/CA Lite) "X engineering mode"4. At the "C:\EVPORT\SXXX\MXXX\" prompt, type time and press Enter5. At the time prompt, enter the time in 24 hour format (HH:MM:SS) and press Enter 6. At the "C:\EVPORT\SXXX\MXXX\" prompt, type date and press Enter7. At the date prompt, enter the date using the format (MM-DD-YYYY) and press Enter

Note: The year must be entered using four digit format to comply with year 2000. If only thelast two digits are entered, the date will be incorrectly set.

Once the time and date have been set, press the "0" key and then press the "Enter" key to restart theanalyzer.



10.3 Set Date, Time or Time Zone 6320 only

To manually set the Date, Time, or Time Zone:

From the startup menu, hit "Escape" twice, to access the Station Selection Menu.

Select "System Configuration" at this menu.

10.4 Printing 6310

To print directly from the analyzer, there must be a printer driver loaded prior to running the software. Once this has been done, pressing the PRINT function key will print out the current graphics or reportscreen. The analyzer must be in LCD mode to print in proper black and white. You cannot use theprint function to print to a PostScript type printer.



Using the GRAPHICS command:

The GRAPHICS command loads a program into upper memory that allows the analyzer to print theinformation displayed on the screen. To load the GRAPHICS driver, you may do it one of two waysusing the syntax that follows. The first method requires the word GRAPHICS be typed in at thecommand prompt. The second method requires adding the GRAPHICS command to theautoexec.bat file in the root directory of the analyzer.

Syntax:

LOADHIGH C:\DOS\GRAPHICS [type] (example: LOADHIGH C:\DOS\GRAPHICSLASERJETII )

Type:Specifies the type of printer. The following list shows each valid value for this parameter andgives a brief description of its meaning:

HPDEFAULT Any Hewlett-Packard PCL printer.

DESKJET Hewlett-Packard DeskJet printer

GRAPHICS An IBM Personal Graphics Printer, IBM Proprinter, or IBMQuietwriter printer

LASERJET A Hewlett-Packard LaserJet printer

LASERJETII A Hewlett-Packard LaserJet II printer

PAINTJET A Hewlett-Packard PaintJet printer

THINKJET A Hewlett-Packard ThinkJet printer

Installing the GRAPHICS command on the analyzer requires the following steps:

1. Press the "ESC" key until the "Select a station" menu is reached2. Attach the small keyboard to the analyzer3. Press the "6" key, (5 in the 6310/CA Lite) "X engineering mode"4. Type CD C:\ and press the "Enter" key5. Type EDIT AUTOEXEC.BAT and press the "Enter" key6. Press the "Down Arrow" key until the M_P line is highlighted and press the "Enter" key7. Press the "Up Arrow" key to the blank line 8. Type LOADHIGH C:\DOS\GRAPHICS LASERJETII (or the type from the above list)9. Type Mode LPT1 RETRY=R10. Press and hold the "ALT" and "F" keys together to bring up the File menu.11. Press and hold the "ALT" and "X" keys together and select "Save and exit", press the "Enter"

key to return to the DOS prompt12. Turn the analyzer off then on or press the "CTRL" + "ALT" + "DEL" keys to reboot the analyzer

At this point, try printing by pressing the "PRTSC" key. It may take a few seconds to start printing.

Loading a different printer profile:

If you have already loaded a printer profile and you want to load another one by using theGRAPHICS command, repeat the above steps.

Batch file before adding "Printer" command.



Batch file after adding "Printer" command and "Mode" command

Alt-F for "File Menu"Alt-X for "Exit"



Select "Y" for YES or "N" for NO and hit ENTER.

10.5 Printing 6320

To print directly from the analyzer, there must be a printer driver loaded. Once this has been done,selecting PRINT from the menu will PRINT the current graphics or report screen. The analyzer mustbe in B & W or Color 2 mode to print properly.

To set up a printer:

From the startup menu, hit "Escape" twice to access the Station Selection Menu.

Select "System Configuration" at this menu.



Select "Printer Management" at this menu.

Select the option you need and follow the on-screen instructions.

Appendix 73


11 Appendix

11.1 Data Collection Techniques

Before getting started with data collection on a machine, there are some helpful guidelines whichshould aid you in collecting good data.

Pressure Measurement, 63X0/CA (Encoder-based HP measurement)You must ZERO the Dynamic DC pressure sensor prior to collecting pressure data. The purposeof zeroing the sensor is to establish a reference pressure for the data at operating temperature. The reference zero pressure is atmospheric pressure. If the sensor is not zeroed, there is apossibility of a thermal offset causing the pressure data to be slightly elevated.

11.2 Sensors

Transducer Scaling Entries:

SENSOR TYPE UNITS ZERO FULL 4mA 20mASCALE or 1V or 5V

Engine AC AC PSI 0 1000 200 1000Engine DC DC PSI 0 1000 0 1000Spark DC Volts 0 50,000 0 50,000

Secondary Ignition SensorA6030-01-06

Water Cooled Pressure SensorA6082W-XX-01

Compressor Pressure SensorA6082-XX-00



11.2.1 Magnetic Pickup

GENERAL DESCRIPTION

Completely self-powered, VRS (magnetic) sensors are rugged devices that do not require an externalvoltage source for operation. They are generally used to provide speed, timing or synchronization datato a display (or control circuitry) in the form of a pulse train.

PRINCIPLE OF OPERATION

The output signal of a VRS sensor is an AC voltage that varies in amplitude and wave shape as thespeed of the monitored device changes and is usually expressed in peak to peak voltage (V P-P). Onecomplete waveform (cycle) occurs as each actuator passes the sensing area (pole piece) of thesensor. The most commonly used actuator is a metal gear, but also appropriate are bolt heads (capscrews are not recommended), keys, keyways, magnets, holes in a metal disc, and turbine blades. Inall cases, the target material must be a ferrous metal, preferably unhardened.

A permanent magnet is the heart of a VRS sensor and establishes a fixed magnetic field. An outputsignal is generated by changing the strength of this field. This is caused by the approach and passingof a ferrous metal target near the sensing area (pole piece). The alternating presence and absence offerrous metal (gear tooth) varies the reluctance or "resistance of flow" of the magnetic field, whichdynamically changes the magnetic field strength. This change in magnetic field strength induces acurrent into a coil winding which is attached to the output terminals. If a standard gear is used as anactuator, this output signal would resemble a sine wave if viewed on an oscilloscope.

APPLICATION CONSIDERATIONS

VRS sensors are not designed for sensing extremely low speeds. The target passing the pole piece ofthe sensor must be traveling at a minimum velocity, or surface speed, to provide an adequate outputvoltage. Typical minimum surface speeds for each sensor type can be found in the specificationssection. The bottom line in proper VRS sensor selection is to choose one that will meet the followingtwo conditions:

1) Provide the required peak-to-peak voltage at the minimum speed of interest.

2) Will still function properly at the maximum operating frequency of the application.

To choose an appropriate sensor, the following data must be obtained:

1) Minimum and maximum speed of interest.

2) Diameter of gear (or shaft) and number of teeth (or actuators) per revolution.

Appendix 75


3) Load resistance and the input resistance of the device being driven.

4) Air gap setting (pole piece clearance) and distance between sensor face (pole piece) and topof gear tooth (or other actuator).

5) Minimum acceptable peak-to-peak voltage level (V P-P) of the device being driven andtypically a display or frequency to DC converter.

USE OF MAGNETIC PICKUP WITH WINDROCK INSTRUMENTATION

When using the magnetic pickup for TDC (top dead center) triggering in reciprocating machineanalysis, it is extremely important that the pickup triggers data acquisition exactly at TDC. Errors ofonly 2 degrees can produce measurement errors of up to 5% in horsepower and throughputcalculations.

For the magnetic pickup to operate properly with Windrock analyzers, several issues must beaddressed.

PICKUP DISTANCE FROM TARGET

Often, the magnetic pickup is placed too close to the target. When this happens, the pickup can triggerdata acquisition on scratches, nicks, or magnetic deformities in the flywheel or shaft. Usually, a gap ofabout 1/4 inch is sufficient.

TARGET TYPE

Some sort of target must be placed on the flywheel or shaft to trigger the magnetic pickup. The targetmust be of a ferrous material. It may be a hole drilled into the flywheel or shaft or may be a protrudingobject such as a bolt head. Either way, the target must produce the largest magnetic interference ofany other scratch, hole, or deformity in the flywheel or shaft. The center of the hole or bolt head mustbe placed at TDC of the machine. A hole is preferred because it is always round and the center of thehole is the magnetic center of the target. A good choice for hole size is 1/4" diameter X 1/4" deep.Sometimes, when using a bolt head, the flats of the bolt causes the magnetic center to be other thanthe geometric center of the bolt.

Sometimes, we have seen a sharp edge used as a target. This is OK, but due to the small magneticinterference, the gap must be smaller in order to get a sufficient signal.

SIGNAL POLARITY

This is where many problems occur when using a magnetic pickup. The circuit in the Windrockanalyzer arms itself on a POSITIVE-going signal. The actual trigger occurs upon ZERO-CROSSINGafter the circuit is armed. Zero-crossing occurs at the magnetic center of the magnetic pickup or whenthe magnetic pickup is centered on the target.

When using a hole as a target, pin A of the magnetic pickup is the signal.

When using a protruding object as a target, pin B of the magnetic pickup is the signal.



If in doubt, use the analyzer in o-scope mode, or an oscilloscope, to view the signal. The signal shouldlook like the figure below. If the polarity is reversed from this, use the hole/pin switch on the encoderor reverse the A and B leads in the cable to reverse the signal to the proper polarity. The synch lightwill flash at the center of hole or pin if proper setup is obtained.

SIZE OF SIGNAL

The magnetic pickup contains a permanent magnet with a coil. When the magnetic field changes dueto the pickup going over a hole or object, a voltage is generated in the coil. The size of the signal isproportional to the magnetic field change. Several factors determine the field change: permanentmagnet strength, number of turns in the coil, gap from pickup to target, material of target, and size oftarget.

The bottom line is that you want a signal of about 1V peak and it must be at least 10 times the size ofany other noise or spurious signals in the output of the pickup. If the polarity of the signal is reversed,the trigger point will be much later than actual TDC.

11.2.2 Secondary Ignition Sensor

The calibrated secondary ignition capacitive clipis used to accurately measure the secondaryignition voltages. The attenuation is 10,000 timesand the voltage range is 50 kilo volts. Thecapacitive clip is clipped around the spark plugwire. The alligator clip may be connected toengine ground but is not usually necessary.

Appendix 77


11.2.3 Water Cooled Pressure Sensor

This pressure sensor used with Windrockportable analyzer is for conditions of extremetemperature for extended periods of time. Thisdevice outputs a 4 mA to 20 mA electrical signalthat is directed to the analyzer. The pressuretransducer is typically connected to kiene orother indicator valve type on the power cylinders.

11.3 Specifications - 6310/CA

Basic Capabilities:

The data acquisition capabilities of the instrument are based upon 1-channel dynamic signalcapture as a function of crank angle position. The crank angle position is captured via an opticalshaft encoder coupled mechanically to the machine being analyzed or magnetic/optical pickup. The signal input can be pressure, vibration, ultrasonic, or other voltage or current signal. Angularvelocity measurements are captured and displayed using the encoder information.

Input SignalsChannel 1: Software selectable between current loop, constant current, voltage input, ignition

(primary and secondary). Secondary ignition uses capacitive voltage clip.

Channel 5: Supplies 12 VDC to encoder or magnetic/optical pickup conditioner. There are 2inputs, TTL compatible with 10Kohm pull-ups.

Current loop inputRange: 0-20 milliampFrequency response: DC to 5 Kilohertz (kHz) Supply voltage: 24 VDCOver-voltage protection to 2000VCurrent loop input is used for the DC pressure sensorInput impedance 470 ohm

Secondary Ignition using capacitive coupling probeRange: 1 Kilovolts to 50 Kilovolts (kV)Software selectable for positive or negative ignition systems Secondary Ignition data capture rate is 75 Kilohertz (kHz)Over voltage protection

Voltage InputRange: 0-10VFrequency response: DC to 5 Kilohertz (kHz)Supply voltage: 24 VDCOver-voltage protection to 2000VVoltage input is used for voltage signalsInput impedance: >1M ohm

Memory Capacity16 Megabytes on-board RAM memory2 Gigabytes of internal disk storage



CommunicationsParallel interface or USB for host communications

Power Supply12V Lithium Ion rechargeable 3200 milliamp-hour batteryOne battery standardBattery is removableExternal charger provided - 1.5 hr recharge timeExternal power input 12 - 18 VDCBattery life: approximately 6 hours depending on use

Operating ConditionsTemperature: 15-120 FHumidity: 0-90% non-condensing

Display8.25" diagonal LCD, color. Backlight automatically turned off after 30 seconds of non-useSize of display: 8.25" diagonalPixels: 640 x 480Contrast: software controlled

Processor133 MHz AMD 586 with (2) Microchip RISC signal conditioning processors

ChassisMaterial: EMI hardened anodized aluminumSize and Weight: 10.5" X 8.5" X 2" (6.75 lbs.)Power: Long-life, field replaceable, rechargeable Li-ion batteryKeypad: 25 keys

11.4 Specifications - 6320/CA

Basic Capabilities, 6320:

The data acquisition capabilities of the instrument are based upon 1-channel simultaneousdynamic signal capture as a function of crank angle position. The crank angle position is capturedvia a shaft encoder coupled mechanically to the machine being analyzed or magnetic/opticalpickup. The signal input can be pressure, vibration, ultrasonic, or other voltage or current signals.Angular velocity measurements are captured and displayed using the encoder information.

Input SignalsChannel 1: Software selectable between Current Loop, Constant Current, Voltage Input,

Ignition primary and secondary (secondary uses a capacitive voltage clip).Channel 5: Supplies 12 VDC to encoder or magnetic/optical pickup conditioner 2 inputs,

TTL compatible with 10 Kohm pull-ups

Current loop inputRange: 0-20 mAFrequency response: DC to 5 KHz Supply voltage: 24 VDCOver-voltage protection to 2000VCurrent loop input is used for the DC pressure sensorInput impedance 470 ohm

Ignition secondary using capacitive coupling probe

Appendix 79


Range: 1 KV to 50 KVSoftware selectable for positive or negative ignition systems Secondary ignition data capture rate is 1 mHzOver voltage protection

Voltage inputRange: 0-10VFrequency response: DC to 5 KHzSupply voltage: 24 VDCOver voltage protection to 2000VVoltage input is used for voltage signalsInput impedance: >1 Meg ohm

Memory Capacity256 Mb on-board RAM memory4 Gb flash memory storage

CommunicationsUSB interface for host communications

Power Supply12V Lithium Ion rechargeable 3200 milliamp-hour batteryTwo batteries standardBattery is removableExternal charger provided - 1.5 hr recharge timeExternal power input 12 - 18 VDCBattery life: approximately 6 hours depending on use

Operating ConditionsTemperature: 15-120 FHumidity: 0-90% non-condensing

Display8.25" diagonal LDC, transmissive, with back light, color optionSize of display: 8.25" diagonalPixels: 640 x 480Contrast: software controlled

ChassisMaterial: EMI hardened anodized aluminumSize and Weight: 10.5" X 8.5" X 2" (6.75 lbs.)Power: Long-life, field replaceable, rechargeable Lithium ion batteryKeypad: 28 keys

Resolution 16 bitsHF vibration channels 1Pressure, ultrasonic, prox channels 1Ignition analysis channels 1HF vibration filters unlimited (DSP programmable)Ignition analysis speed 1 MhzOperating system LinuxReal-time speed 1800 RPMBattery life 7 hoursData transfer method USB - USBPrinters supported USB printer w/ Linux driverSignal processing technology quad DSP processors



Main user interface processor AMD Geode 500 MhzCrankangle samples per degree 1, 2, or 4A/D converters 8

Debian GNU/Linux software included on the 6320 Portable Analyzer is covered by the GNUGeneral Public License, the GNU Lesser General Public License, and other licenses. Additional software libraries included on the 6320 Portable Analyzer are covered by the GNULesser General Public License. Copies of relevant licenses are available under/usr/share/doc/*/copyright on the Portable Analyzer file system. To receive a DVD containingthe source code used to build the Debian GNU/Linux software and additional softwarelibraries, mail a copy of this page and a check for $10 shipping and handling to the followingaddress:

Windrock, Inc.431 Park Village Drive, Suite LKnoxville, TN (USA) 37923

11.5 Specifications - Sensors

DC Pressure Sensor for Power Cylinder PT/PV MeasurementRange: 0-2000 psi (other ranges available 1000, 3000)Response time: <0.5 ms (A6082-XX-01 <0.1ms)Accuracy: 1%Linearity: <1% full scaleCycle life: >1.5 billion cyclesOperating Temperature Range: 0-450 F (temperature compensated)Pressure fitting: Kiene adapterOutput: 4-20 mA, loop powered

Secondary Ignition Capacitive PickupAttenuation: 10,000 timesRange: 50 KVOutput Connector: BNCTemperature Range: 200 FCable Length: 6 ft

Glossary of Terms 81


12 Glossary of Terms

After Top Dead Center - After a piston in a reciprocating engine has reached the top of its travel andstarts downward. Abbreviated ATDC.

Air Manifold Pressure - The pressure present in an engine's air manifold.

Air Manifold Temperature - The temperature of the air present in an air manifold.

Ambient Temperature - Typically referred to as the present atmospheric temperature.

Angular Velocity - The change in angular velocity measured in RPM as the machine rotates in a singlerevolution.

Articulated Connecting Rod - A connecting rod that attaches to a master rod. An articulated rod on anengine with integral mounted compressors is always a power connecting rod.

Articulation - In an integral engine/compressor, the irregular movement of the power pistons in relationcompressor piston due to the manner in which the power rods are connected to the compressor rodinstead of directly to the crank shaft.

Atmospheric Pressure - The weight of air measured at your location.

Balancing - Adjusting the amount of fuel being admitted into an individual power cylinder in order toadjust peak firing pressures.

Before Top Dead Center - Before a piston in a reciprocating engine has reached the top of its travel.Abbreviated BTDC.

Blowdown Event - The detail of the pressure curve during and just after the exhaust port (or valve) isopened.

Bore - The width or diameter of a hole on an engine or compressor cylinder.

Bottom Dead Center - When a piston in a reciprocating engine reaches the bottom of its stroke.

Brake Horsepower (BHP) - The usable output of an engine as measured at the crankshaft or flywheel.

Brake Mean Effective Pressure (BMEP) - That theoretical constant pressure that can be imaginedexerted during each power stroke of the cylinder to produce power at the flywheel or crankshaft. BMEPis the IMEP less all friction and parasitic losses. BMEP cannot be measured. It must be calculated.

Brake Specific Fuel Consumption (BSFC)- As applied to internal combustion engines, it is the amountof BTU's (lower heating value) required to make one (1) brake horsepower for an hour. Measured inBTU/BHP/Hr.

British Thermal Unit (Btu) - The amount of heat required to raise the temperature of one pound ofwater one degree Fahrenheit.

Channel Resonance - Distortions of the pressure information caused by the excitation of the acousticresonance in the gas passage connecting the indicator transducer and the cylinder volume.

Clearance Volume - The volume in cubic inches remaining in the compressor cylinder at the end of thedischarge stroke; the space between the piston head end and the end of the cylinder plus the spacethat exists around the valves, which are located near the cylinder ends.



Combustion - The burning of gas in which the fuel is converted into heat energy by rapid oxidization.

Combustion Chamber - The space at top dead center in a reciprocating internal combustion enginewhere combustion takes place.

Compression - As applied to internal combustion engines, it is the mechanical ability of combustionchamber components to hold pressure by the upward motion of the piston at the end of thecompression stroke. Compression in reciprocating engines can be measured dry (engine is downwithout lubrication) or running (engine is running with lubrication).

Compression Pressure - The pressure of the air/fuel charge at the end of the compression stroke withno ignition of the mixture. In a compressor cylinder, this is the pressure of the gas charge at the end ofthe compression stroke.

Compression Ratio - The ratio of the volume of the charge at the beginning of the compression stroketo that at the end of the compression stroke in an internal combustion engine.

Compression/Tension - The force in pounds that the compressor rod is undergoing due to pressuredifferential on each side of the piston and the inertial acceleration of the reciprocating motion. Theforce is displayed as pounds compression and pounds tension.

Connecting Rod - The connection between the piston and the crankshaft in an engine or between thecrosshead and the crankshaft in a compressor.

COV - Coefficient of Variation (or Variance) in statistics. COV is the magnitude of variance or

dispersion relative to the mean or average. CV = SD/Avg.

We use COV in two different ways:

1. In a spark ignited (SI) engine, we use COV to measure the peak firing pressure stability.

A normal COV would be from ten to twenty. A high COV indicates a mechanical problem

and/or a lean air fuel mixture in the main or pre-combustion chamber.

2. When using vibration history to set warning and alarm levels, a COV of less than .33 is

desired. If the COV is greater than .33, the average times 1.5 may give a better warning

level (with less false vibrations alarms) than using the average plus three standard

deviations where there are no malfunctions present in the equipment.

Crank Angle Encoder - A device used on an engine analyzer to generate a signal per degree ofrotation on a crankshaft.

Crankcase - The lower part of the engine that acts as an oil reservoir and holds the crankshaft.

Crosshead - The part of a compressor that connects the piston rod to the main rod.

Crank End (CE) - That end of the compressor cylinder nearest the engine or frame.

Cubic Inch - Abbreviated Cu. In.

Cycle -A series of events that repeat themselves in a regular sequence. Four-stroke cycle: intake,compression, power and exhaust. Two-stroke cycle: intake/compression and power/exhaust.

Cylinder - A chamber in which a piston travels.

Detonation - Uncontrolled, rapid combustion rate. It is spontaneous combustion of the remaining



portion of the charge of air and fuel causing too rapid a combustion rate, extremely high flame frontspeed and excessively high pressure within the cylinder.

Discharge Pressure - The pressure at which compressed gas is forced out of a cylinder.

Discharge Valve - A valve through which compressed gas leaves the cylinder.

Discharge Temperature (TD) - The temperature of the gas leaving the cylinder through the dischargevalve. Typically this is measured at or near the discharge bottle or nozzle.

Double Acting - Indicates that the piston pumps gas on both ends; i.e., as the gas discharges out thevalve on the head end, the piston draws gas into the cylinder through the suction valve on the crankend. The reverse happens as the piston strokes toward the crank end or the engine.

Dynamic Compression Pressure - The pressure in the cylinder at the end of the compression strokewith normal combustion occurring. Dynamic compression is usually higher than cranking compressiondue to temperature and combustion.

Engine Derating - Reducing the standard horsepower or speed ratings on an engine because of thekind of service it performs or existing ambient conditions. For example: An intermittent rating will behigher than a continuous rating on an engine. An engine rating at high altitude or high ambienttemperatures will be rated for a lower output.

Exhaust - The stroke or portion of the stroke in an internal combustion engine in which burnt gases leftover from combustion are released from the cylinder.

Exhaust Port - An opening in the cylinder wall through which exhaust gas is expelled when the exhaustport is uncovered by the piston.

Exhaust Valve - The part of a four-stroke-cycle engine which releases exhaust from a combustionchamber into the exhaust manifold.

Fixed-Volume Pocket - A fixed-volume chamber or a chamber with a valve that can be opened orclosed by a handwheel or air cylinder from outside the cylinder. A fixed-volume pocket adds a specificvolume to the cylinder when it is open.

Flame Front - The leading edge of a flame propagating from its ignition source.

Foot-Pound - This is the amount of energy or work required to lift one pound a distance of one foot.

Four-stroke (Cycle) Engine - An engine that requires four piston strokes and two complete crankshaftrevolutions to complete each cycle.

Friction Horsepower - Power consumed within an engine or compressor from friction of its movingparts.

Fuel Event - The event measure in degrees of crank angle where fuel is entering the combustionchamber.

Fuel Injector - A device which sprays fuel into the combustion chamber.

Fuel Valve - A cam-actuated valve that allows fuel to enter the combustion chamber.

Flywheel - The round massive component used to provide inertia that damps angular velocity changesof the machine.

Gas - A substance that changes volume and shape according to temperature and pressure applied to



it. Often, a combustible substance.

Gas Analysis - Mole Fractions of each gas contained in the mix of gases passing through thecompressor.

Governor - A device (either mechanical, electrical, or hydraulic) to control and regulate speed (RPM).

Head End (HE) - That end of the compressor cylinder away from the engine or frame.

Horsepower - The energy required to lift 550 lbs. one foot in one second or 33,000 lbs. one foot in oneminute.

Horizontal Engines - An engine with cylinders lying in the horizontal plane.

Hydraulic Lifters - A mechanical device used to (1) compensate for changes in temperatures, valvewear and valve recession as it maintains a zero lash (clearance), and (2) cushion the opening andclosing of the various valves (intake, exhaust, etc.)

Ignition - The combustion of the fuel mixture in the combustion chamber. In a spark ignited engine,ignition is the electrical spark that provides the source of igniting the air/fuel mixture.

Ignition Delay - The time from initial injection of air and fuel to actual ignition of the mixture in acompression ignited engine. In a spark ignited engine, it is the total time required from the initial sparkuntil a pressure rise occurs due to combustion. It is the total time required for the physical andchemical reactions required to propagate a flame front.

Ignition Timing - The point at which the ignition systems delivers a spark to the spark plug to beginburning the air/fuel mixture, in relationship to crankshaft rotation or TDC.

Indicated Horsepower - The actual horsepower developed on the surface of the piston in areciprocating power cylinder or consumed surface of the piston in a reciprocating compressor cylinder.

Indicated Mean Effective Pressure (IMEP) - That theoretical constant pressure that can be imaginedexerted on the piston during each power stroke of the cylinder to produce power equal to the indicatedpower. It is the average pressure exerted on the piston through the functional cycle.

Indicator Port - A direct connection from the outside to the inside of the cylinder clearance area. Theport is used for connection of instrumentation to investigate pressures inside the cylinder.

Injection Valve - A device used to inject fuel into the combustion chamber of an engine.

In-line Engines - An engine design where all the power cylinders are in a block or frame located onebehind the other.

Intake Manifold - The manifold that holds air or air and fuel before it enters the combustion chamber.

Intake Port - An opening in the cylinder wall through which gas flows into the cylinder when the intakeport is uncovered by the piston on a two-stroke engine.

Intake Valve - The valve which permits air to enter the cylinder of an engine.

Integral - A compressor having a common crankshaft for both power and compressor cylinder orcylinders. The prime mover and the compressor are combined into a single frame.

Jacket Water - The water system of the engine used for cooling the cylinder, head, and other parts.

Jacket Water Pressure - Pressure produced normally by a centrifugal pump to circulate jacket water



throughout an engine.

Kiene Valve - A special valve used in the indicator port for connection to pressure transducers.

Liner - A replaceable cylinder in an engine block.

L/R Ratio - The L/R ratio is the ratio of the connecting rod length to the radius of the crankshaft throw.

Main Bearing - Bearings which act as the support on a crankshaft.

Manometer - A device used to measure vacuum or lesser pressures. It is a U-shaped tube partiallyfilled with a fluid. One end is open to atmosphere, the other to the pressure or vacuum beingmeasured. Readings are given in inches of the liquid in the tube (i.e., inches of mercury).

Mean Effective Pressure (MEP) - The MEP of a cycle or stroke of a heat engine is the average netpressure in pounds per unit area that operates on the piston through its stroke.

Mechanical Efficiency - The ratio of brake horsepower delivered by an engine to the indicatedhorsepower developed.

Misfire - Absence of combustion in a power cylinder. The condition may be intermittent or continuous.

Naturally Aspirated Engine - An engine without a supercharger, turbocharger, or reciprocatingscavenging cylinder. At the start of compression, these units operate on a cylinder air charge at apressure slightly below atmospheric pressure.

Nozzle - The passage that provides an inlet or outlet to the compressor cylinder.

Oil Cooler - A shell and tube type heat exchanger in which cooling water passes through the tubeswhile lube oil flows around the tubes to transfer heat from the oil to the water. Subsequently, the wateris typically cooled by fans.

Once-Per-Turn - Transducer to generate one pulse per revolution of the crankshaft. This usually is inline with TDC on the flywheel.

Opposed Piston Engine - An engine consisting power cylinders containing two pistons which drive twodifferent crankshafts, connected at one end with a vertical shaft. Combustion occurs between the twopistons.

Parasitic Horsepower - Horsepower used to drive auxiliary equipment such as pumps, generators,motors, etc.

Peak Firing Pressure (PFP) - The maximum pressure developed in a power cylinder due tocombustion of the mixture. Under normal conditions, peak pressure occurs between 10 to 25' after topdead center on a spark ignited cylinder. The precise degree of crankshaft rotation will be affected byspeed, combustion chamber design, and fuel.

Piston - A cylindrical part closed at one end which is connected to the crankshaft by the connectingrod. It is the force from combustion, exerted on the closed end of the piston, which causes theconnecting rod to move the crankshaft.

Piston Displacement - The volume of air moved or displaced by movement of the piston as it goesfrom bottom dead center to top dead center.

Pounds per Square Inch Absolute - Pounds per square inch gauge plus atmospheric pressure.Abbreviated PSIA.



Pounds per Square Inch Gauge - Pounds per square inch gauge. Abbreviated PSIG.

Power Valves - The combination of all valves (intake and exhaust) on a four-stroke-cycle engine.

Pre-lgnition - A common fault with a spark ignited engine where the mixture begins to burn prior to anelectrical spark being introduced into the cylinder. The usual cause is overheated parts or particles inthe combustion chamber.

Pressure Versus Crank Angle - A function of the engine analyzer to display pressure as it relates todegrees of crankshaft rotation.

Pressure Volume - A function of the engine analyzer to display pressure in relation to volume of acylinder.

PT - (Pressure vs. Time trace) The dynamic pressure inside a cylinder referenced to crank-angleposition.

Pulsation - The pressure fluctuation in the nozzles, bottles, and pipping due to the flow variations in thegas from the reciprocating compressor.

Pulsation Bottle - A receiver or vessel mounted directly to the flanges of a cylinder to minimizepulsations. Sometimes called a pulsation damper.

PV - (Pressure vs. Volume) curve (sometimes referred to as "PV Cards"). It is the pressure in poundsper square inch times volume in cubic feet. Pressure volume is used as an indication of workperformed.

Pyrometers - Used to indicate cylinder exhaust and manifold temperatures.

Rack - A type of gear that is flat, usually associated with a pinion gear to convert rotational motion tolinearmotion .

Rated Horsepower - The value used by engine manufacturers and operators to rate the power of anengine, allowing for safe and efficient operations.

Ratio - The relation or proportion of one number or quantity to another.

Reciprocating - To move back and forth alternately, such as the action of a piston in a cylinder.

Rich Mixture - A mixture with a volumetric air/fuel ratio with less parts air than 10:1 (i.e., 9:1).

Rod Diameter - The diameter of the piston rod.

RPM - Revolutions per minute.

Scavenging - Removal of exhaust gases from the cylinder, usually by a flow of air.

Scavenging Air -The air induced into a cylinder for three major purposes (1) To help purge the cylinderof the contaminated gases from the previous combustion cycle; (2) To cool the internal surfaces of thecylinder; (3) To fill the cylinder with a fresh charge of oxygen filled air.

Separable - A compressor that is built into a frame that is separate from the driver.

Spark Plug - An electrical device used to ignite the air/fuel mixture in an internal combustion engine.



SQ. FT. - Area measurement in square feet.

SQ. IN. - Area measurement in square inches.

Standard Deviation - Is a statistic that tells you how tightly all the various examples are clusteredaround the mean in a set of data. When the examples are pretty tightly bunched together and thebell-shaped curve is steep, the standard deviation is small. When the examples are spread apart andthe bell curve is relatively flat, that tells you you have a relatively large standard deviation. Thestandard deviation is kind of the "mean of the mean," and often can help you find the story behind thedata.

Stroke - The movement of the reciprocating machine during one rotation of the flywheel.

Suction Pressure - The pressure of a gas entering the suction valve of a compressor.

Suction Temperature (TS) - The temperature of the gas entering the suctions valve of a compressor.Typically, this is measured at or near the suction bottle or nozzle.

Top Dead Center (TDC) - A marking indicating that the lead cylinder is at it's most extended position.A mark is usually placed on the flywheel indicating this position.

Torque - A moment of force applied to the rotation of a shaft by a lever arm.

Two-stroke (Cycle) Engine - An engine requiring only one complete revolution of the crankshaft tocomplete a cycle of combustion events.

Unloader - A device used to cause gas to surge into and out of the compressor cylinder without goingthrough the discharge valve. An unloader has plungers that hold the valve plates or channels open.

"V" Engine - An engine that consists of two banks of cylinders connected to the same crankshaft whichgives the appearance of a "V".

Vacuum - Pressure less than atmospheric pressure.

Variable Pocket - A chamber that adds clearance volume in direct proportion to its setting. The settingmay be adjusted to any volume within the limits of the pocket.

Volumetric Efficiency - The ratio of the volume of gas actually drawn into a cylinder to the total cylindervolume.

Work - Force times distance.



Index- 6 -63X0/CA with encoder 19

- A -Assistance 1

- B -Balance Engine Nonencoder 21

Balancer 21

Battery 7

Care 7

Discharging 62

E-Moli 8

Performance 7

Battery Charger 9

- C -Care 6

Charger 9

Check for Bad EXE's 62

Class 1, Div 2 Information 3

Cleaning 6

Configuration

Hardware 14

Connect to Windows 61

Connections

6310 11

Customer 1

Assistance 1

Repairs 1

Trouble 1

- D -Data Collection 73

Database 17

Date 67

Direct Channel Read 59

- E -Encoder 6

Multi-Event 64

Shaft Encoder 63

Engine Balancer 21

ESP 2

Extended Service Plan 2

- H -Handling 3

Hardware Configuration 14

Hazardous Location Information 3

Hole-Pin 63

- I -Ignition Survey 44

Introduction 1

- K -Keyboard 14

Keypad 14

- M -Machine 17

Machine Setup Menu 19

Magnetic Pickup 65

Measuring 73

Pressure 73

Temperature 73

Vibration 73

- O -Optical Pickup 65

Options

Hardware 14

Index 89


- P -Parallel Port 6

PHASE A-B 63

Power Cylinder Monitor 40

Pressure Measurements 73

Printing

6310 68

6320 71

Problems 1

- R -Repairs 2

Return Material Authorization 2

Returning Products 2

- S -Safety 3, 5

Sensor 73

Magnetic Pickup 74

Pressure Water Cooled 77

Scaling 73

Secondary Ignition 76

Specifications 80

Settings

Date 6310 67

Date 6320 68

Time 6310 67

Time 6320 68

Time Zone 6320 68

Setup

General Machine 19

Setup Balancer/Spark 21

Software

Windows 6310 66

Windows 6320 66

Spark Mode 56

Spark Survey 44

Special Collection Modes 55

Speciifications

6310 77

6320 78

Sensors 80

Station 17

Strobe Light 65

- T -TDC 63, 65

Temperature Measurements 73

Templates 67

Terms 6

Time 67

Timing Light 65

- U -Unpacking 6

USB 6

Utilities

Check for Bad EXE's 62

Connect to Windows 61

Direct Channel Read 59

Discharging Battery 62

Power Cylinder Monitor 62

- V -VGA 6

Vibration Measurements 73

- W -Warnings 5

Encoder 5

Multi-Event 64

Pressure Sensor 5

Shaft Encoder 63

Timing Light 5, 65

Windows 61, 66

147451877-63X0-CA-Manual

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Transcript of 147451877-63X0-CA-Manual