63 x0 manual windrock

1. Portable Analyzer DA/HA/MA/PA/VA Operations Manual Windrock, Inc. 2011 1/12/2011

2. Legal Notices Copyright 1997-2011 by Windrock Incorporated, All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into 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 and the computer systems on which they may be used. Any unauthorized duplication or use of Windrock software or firmware 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 with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Windrock, Incorporated shall not be liable for errors, omissions, or inconsistencies which may be contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. Information in this document is subject to change without notice and does not represent a commitment on the part of Windrock, Incorporated. Any software described in this document is furnished under a license agreement or nondisclosure agreement. The software may be used or copied only in accordance with the terms of the agreement. Portable Analyzer DA/HA/MA/PA/VA Operations Manual If you have comments about this documentation, the software, or products it describes, please contact the Customer Support Group at Windrock. 3. 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Table of Contents Contents I Part I Customer Information 1 1 Introduction ............................................................................................................................. ...... 1 2 Customer Assistance.............................................................................................................1 3 Returning Items ................................................................................................................... .......... 2 4 Handling Precautions ............................................................................................................3 5 Warnings ............................................................................................................................. ...... 4 Part II Read This First 4 1 Special Terms ............................................................................................................................. ... 4 2 Care 3 Unpacking ............................................................................................................................. ...... 5 ............................................................................................................................. ...... 5 4 Batteries & Charging..............................................................................................................6 Batteries E-Moli Charger .......................................................................................................................................................... 7 ......................................................................................................................................................... 8 .......................................................................................................................................................... 8 Energy Access.....................................................................................................................................................8 Part III Getting Started 10 1 Connections ........................................................................................................................ 10 2 Keypad Functions................................................................................................................ 12 3 Hardware Configuration, 6310 ................................................................................................... 13 4 System Configuration, 6320 ....................................................................................................... 16 System Options........................................................................................................................................................18 Printer Management.................................................................................................................................................20 Set Date Set Time .......................................................................................................................................................... 20 .......................................................................................................................................................... 21 Set Time Zone...........................................................................................................................................................21 System Information ............................................................................................................................................. 22 Database Backup / Restore......................................................................................................................................22 5 Calibration ............................................................................................................................. ...... 23 6 Stations & Machines ................................................................................................................... 24 Station & Machine Setup .................................................................................................................................... 25 Part IV Setup Database 26 1 Machine Configuration ........................................................................................................ 27 General Configuration.............................................................................................................................................27 Engine Configuration...............................................................................................................................................30 Articulation .......................................................................................................................................................... 36 Compressor Configuration......................................................................................................................................40 Miscellaneous Engine and Compressor ........................................................................................................... 43 2 Sensor Point Setup .............................................................................................................. 44 Overview .......................................................................................................................................................... 44 Engine Sensor Points ......................................................................................................................................... 48 4. 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II Portable Analyzer DA/HA/MA/PA/VA Operations Manual Compressor Sensor Points ................................................................................................................................ 52 Temperature and Panel Points................................................................................................................................54 3 Collection / Plot / FFT Setup................................................................................................. 56 Collection Point Editor.............................................................................................................................................57 Group Plot Setup......................................................................................................................................................58 FFT route setup........................................................................................................................................................59 4 Fixed Data Scale Input ................................................................................................................ 59 5 Gas Composition Setup ....................................................................................................... 63 6 Compressor Calculations Setup .......................................................................................... 64 7 Software Configuration........................................................................................................ 65 Part V Data Collection menu 71 1 General ............................................................................................................................. ...... 71 2 Manual / Temperature Data.................................................................................................. 73 3 Zero DC Pressure ........................................................................................................................ 76 Two Point DC Pressure Calibration........................................................................................................................77 4 Take New Data ............................................................................................................................. 81 5 Special Collection Modes ........................................................................................................... 84 Overview O-Scope .......................................................................................................................................................... 84 .......................................................................................................................................................... 85 Timebase / FFT Mode, 6310 Only ....................................................................................................................... 88 Spark Trace Mode ....................................................................................................................................................90 Encoder Based Balance...........................................................................................................................................93 Overview ............................................................................................................................................................93 Balance Engine w ith encoder.............................................................................................................................93 Balance with existing encoder data..................................................................................................................100 Recall old encoder data....................................................................................................................................104 Setup engine report..........................................................................................................................................105 Non-Encoder Balance, and Spark in 6310............................................................................................................106 Overview ..........................................................................................................................................................106 Engine Balancer - Non encoder.......................................................................................................................108 Restart Balance Run........................................................................................................................................117 Recall Old Balance Data ..................................................................................................................................118 Pow er Cylinder Monitor ....................................................................................................................................120 Spark Menu......................................................................................................................................................121 Spark Survey...................................................................................................................................................123 Ignition Survey Report Definitions....................................................................................................................129 Restart Spark Survey.......................................................................................................................................131 Recall Spark Survey.........................................................................................................................................132 Setup ......................................................................................................................................................... 134 6 Notes ................................................................................................................................... 139 Collecting Notes ................................................................................................................................................ 139 Customizing Notes.................................................................................................................................................141 7 Route-based FFT ....................................................................................................................... 144 FFT Overview..........................................................................................................................................................144 Adding FFT Collection Points................................................................................................................................144 FFT Data Collection................................................................................................................................................148 Transient Data Collection ................................................................................................................................. 150 FFT Sensor Selection.............................................................................................................................................154 5. 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Contents III 8 Graphical Data Screen .............................................................................................................. 155 Part VI Plot Historical Data 161 1 Graphical Data Screen .............................................................................................................. 161 PartVII ViewManual,Temp, Notes,FFT Data 166 1 View Manual / Temperature Data 2 View Notes ............................................................................................. 166 168 3 View FFT data ............................................................................................................................ 170 Part VIII Performance Reports 174 1 Reporting ............................................................................................................................. ...... 174 2 Compressor Setup ............................................................................................................. 176 3 Engine Setup ..................................................................................................................... 176 4 Ignition Setup..................................................................................................................... 177 Part IX Utility Menu Options 177 1 Direct Channel Read .......................................................................................................... 178 2 Connect to Windows6310 only .......................................................................................... 180 3 Power Cylinder Monitor ............................................................................................................ 181 4 System Information 6320 only ............................................................................................ 181 5 X Engineering Mode 6320 only ........................................................................................... 181 6 Discharge Battery 6310 only............................................................................................... 181 7 Check for Bad EXE's 6310 only........................................................................................... 182 Part X Encoder Setup 183 1 Shaft Encoder ............................................................................................................................ 183 2 Multi-Event ............................................................................................................................. .... 184 3 Magnetic Pickup ........................................................................................................................ 186 4 Optical Pickup.................................................................................................................... 186 5 Timing Light....................................................................................................................... 186 6 Setting Machine TDC.......................................................................................................... 187 7 WirelessTransmitter.......................................................................................................... 190 PartXI Loading New Analyzer Software 190 1 WindowsInstall 6310 only.................................................................................................. 191 2 WindowsInstall 6320 only.................................................................................................. 191 Part XII OperatingSystem Commands 191 1 Backup 6310 only 2 Backup 6320 only ...................................................................................................................... 191 ...................................................................................................................... 193 3 Machine Template 6310 only .............................................................................................. 193 4 Setting Time and Date 6310 only......................................................................................... 193 6. 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IV Portable Analyzer DA/HA/MA/PA/VA Operations Manual 5 Set Date, Time or Time Zone 6320 only .............................................................................. 194 6 Printing 6310 7 Printing 6320 ............................................................................................................................. . 195 ............................................................................................................................. . 197 Part XIII Appendix 199 1 Data Collection Techniques ..................................................................................................... 199 2 Class 1, Div II Information .................................................................................................. 200 Hazardous Location Information,6320 only ................................................................................................... 200 Control Drawing.....................................................................................................................................................201 3 Sensors ............................................................................................................................. ...... 201 Accelerometer.........................................................................................................................................................203 Compressor DC Pressure Sensor.........................................................................................................................207 Infrared Temperature Sensor ........................................................................................................................... 209 Magnetic Pickup ................................................................................................................................................ 213 Primary Ignition Sensor.........................................................................................................................................216 Secondary Ignition Sensor ............................................................................................................................... 216 Ultrasonic Sensor...................................................................................................................................................216 Velocity Sensor.......................................................................................................................................................219 Water-cooled Pressure Sensor ........................................................................................................................ 220 Displacement Probe...............................................................................................................................................220 4 Specifications - 6310 5 Specifications - 6320 ................................................................................................................. 220 ................................................................................................................. 222 6 Specifications - Sensors.................................................................................................... 224 7 Specifications - Wireless Transmitter ................................................................................ 225 8 PKZIP 6310 only................................................................................................................. 225 9 Terms and Conditions ....................................................................................................... 227 Part XIV Glossary ofTerms 228 Index 241 7. Windrock, Inc. 2011 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 your portable analyzer DA/HA/MA/PA/VA by Windrock, Inc. This help version is 3.3. The analyzer is a low-power instrument used for analyzing reciprocating machinery. The analyzer can obtain four simultaneously sampled sensor inputs as related to crank shaft position. In addition, the analyzer can sample vibration in both oscilloscope mode and FFT mode. If your analyzer is approved for use in a hazardous location, you MUST read and follow the information in the Appendix section Class 1, Div II Information. 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 your analyzer 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. Warning! A warning indication a condition which has severe impact on hardware, or safety. Prerequisites The manual is written with the assumption that you are familiar with the basic operation of a personal computer. A brief review of MS-DOS commands is included in the appendix for convenience; however, it is not intended to be a substitute for the documentation supplied with a computer or MS-DOS software. If you are unfamiliar with a personal computer or peripheral hardware, Windrock strongly recommends 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 Product Support department at (865) 330-1100 Ext. 1114 Hardware 1. Please have the serial number of your analyzer available when you call. The serial number is located 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 the error messages? When do they occur? What you were doing when the problem occurred? For example, what mode were you in? What steps did you go through? Try to determine 8. Windrock, Inc. 2011 2 Portable Analyzer DA/HA/MA/PA/VA Operations Manual before you call whether the problem is repeatable. Software 1. Please have the number of the current version of your software ready when you call. The version of the software appears under the system information screen. 2. If you have a problem, explain the exact nature of your problem. For example, what are the error messages? When do they occur? What you were doing when the problem occurred? For example, what mode were you in? What steps did you go through? Try to determine before you call whether the problem is repeatable. 3. Please have your analyzer ready and any accessories in question when you call. We can serve you better when we can work through the problem together. 1.3 Returning Items For Repair 1. Call Product Support at (865) 330-1100 Ext. 1114 to obtain a return materials authorization number (RMA). 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 are your responsibility. COD packages cannot be accepted and will be returned unopened. For Credit 1. Call Product Support at (865) 330-1100 Ext. 1114 to obtain a return materials authorization number (RMA). 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. Hardware Repair Windrock repairs its hardware products free for one year from the date of shipment. This service warranty 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 CD-ROM in electronic format to all customers who are under warranty. After the one year service warranty expires, each return of a Windrock hardware product is subject to a minimum service fee. If the cost of repair exceeds this minimum fee, we will call you with an estimate before performing any work. Contact Product Support for information concerning the current rates. Refer to the Warranty section of the Terms and Conditions section of this manual for a complete description of your warranty. 9. Windrock, Inc. 2011 Customer Information 3 Extended Service Plan Windrock offers an Extended Service Plan (ESP) on analyzer equipment. Software benefits include program corrections and improvements, modifications, manual revisions and telephone assistance. Hardware benefits cover malfunctions due to normal wear, annual calibration, and updates. Contact Inside Sales at (865) 330-1100 Ext. 1143 for information concerning the current cost of Extended Service Plan. 1.4 Handling Precautions STATIC ELECTRICITY The CMOS integrated circuits in the analyzer can be damaged by exposure to electrostatic discharges. LITHIUM-ION BATTERIES The analyzer contains a Lithum-ion cell pack which can create a fire or explosion hazard if improperly 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 circuitry on 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 the EMI protection of the case and interconnecting pieces. 10. Windrock, Inc. 2011 4 Portable Analyzer DA/HA/MA/PA/VA Operations Manual 1.5 Warnings Caution! The pressure sensor used with this kit may become hot when used on either an engine, compressor, or any related piping. The sensor, when hot, may cause severe burns to the hands or other body parts that come in contact with the hot surface. Use precautions such as leather glovesto handle the sensor. When using the water-cooled pressure sensor, the water used for cooling may become hot and cause scalding. Use precaution when handling the sensor to prevent the hot water from contacting the skin. Caution! The shaft encoder used with this kit comes in contact with a high-powered rotating element. Keep all clothing and hair away from the rotating parts as they may become tangled with the rotating parts and cause severe injury or death. Keep hands away from the rotating equipment at all timesto prevent injury. Caution! The timing light used with this kit may be used near high-powered rotating elements. Keep all clothing and hair away from the rotating parts as they may become tangled with the rotating parts and cause severe injury or death. Keep hands away from the rotating equipment at all timesto prevent injury. Caution! Several cablesare used with the analyzer and shaft encoder that may be used near high-powered rotating elements. Keep all clothing and hair away from the rotating parts as they may become tangled with the rotating parts and cause severe injury or death. Keep hands and cables away from the rotating equipment at all timesto prevent injury. Be aware of the trip hazard cableson the floor can create. 2 Read This First 2.1 SpecialTerms 6310 / 6320 Portable analyzer Collection Point Setup A grouping of sensor inputs pre-defined for easy data collection FFT 11. Windrock, Inc. 2011 Read ThisFirst 5 Fast Fourier Transform. A method of converting the time domain signal into its individual frequency components Parallel Port Printer and communications link between the analyzer and host computer Shaft Encoder Device used to convert crankshaft position into electrical impulses Transducer / Sensor Device used to convert mechanical measurements into electrical signals USB A communications link between the analyzer and host computer VGA Video 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 chemicals may damage the keypad and clear display window. 2.3 Unpacking Check to verify the following items are in the instrument case upon arrival. Refer to the enclosed packing list for exact parts and / or options shipped. Compare the shipment to what parts were ordered. 12. Windrock, Inc. 2011 6 Portable Analyzer DA/HA/MA/PA/VA Operations Manual PARTS LIST (Standard Package) Part 6310 6320 Analyzer A6310-00/PA A6320-00/PA Battery A6301-02 Battery Charger A6312-00 Carrying Case 04100004 Keyboard 02200006 02202110 USB to parallel communications cable A6306-02-06 Leather Case (on analyzer) A6304-01 Carry Strap A6305-00 Infrared Temperature Sensor A6045-01-06 Accelerometer A6096-00-00 Magnetic Base 1" Round Flat A905-02 Velocity Sensor A6095-00-00 Magnetic Base 1" Round 2-Pole A905-01 Accelerometer Cable A6061-00-06 DC Pressure Cable A6060-00-08 Ultrasonic Pick Up A6050-04-06 DC Pressure Sensor A6082-XX-00 DC Pressure Sensor (High Temp) A6082-XX-01 Manual A6310-00-M/PA Software CD-ROM A6310-00-SW/PA USB to USB Cable A6306-03-00 Other parts may be present depending on the options selected and/or purchased. Note: 6310 only. A battery is typically shipped in the analyzer. Under normal circumstances, a battery should be kept in the analyzer when not in use. Having a battery in the unit will help keep the internal CPU's CMOS coin cell charged and the operating configuration parameters intact for many years. Leaving the battery out of the unit may shorten the life of this coin cell requiring replacement and loss of the operating configuration parameters. 2.4 Batteries & Charging General Battery Care information. Each kit may contain one of the pictured batteries and chargers shown below. 13. Windrock, Inc. 2011 Read ThisFirst 7 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 Battery Recharger" section of this manual for charging instructions. When the battery is charged for the first time, the charger may indicate that charging has been completed after just 10 to 15 minutes. This is normal and can happen with any rechargeable battery when it is first charged or if it has been stored unused for a prolonged period. Simply remove the battery from the charger and repeat the charging procedure. There is no need to discharge this battery between these charges. Best charging results are obtained at normal room temperature, 70F (21C) +/- 8F (2C). Charging beyond this range is permissible but will not result in the battery's full capacity being reached. Charging at temperatures below 50F (10C) or above 95F (35C) 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 type charging 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 this battery will be left in storage for more than a few days prior to use, a top-off charge to regain full capacity is recommended. Note: 6310 only A battery is typically shipped in the analyzer. Under normal circumstances, a battery should be kept in the analyzer when not in use. Having a battery in the unit will help keep the internal CPU's CMOS coin cell charged and the operating configuration parameters intact for many years. Leaving the battery out of the unit may shorten the life of 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 not short circuit the battery by directly connecting the metal terminals (+,-). Be certain that no metal objects such as coins, paper clips, etc., touch the terminals. Only use the charger recommended by the device manufacturer. To Avoid Damage to this Battery Do not drop this battery or subject it to mechanical shock. Use this battery only with equipment that specifies its use. Recycling Information Windrock is committed to environmental responsibility and would like our customers to recycle this 14. Windrock, Inc. 2011 8 Portable Analyzer DA/HA/MA/PA/VA Operations Manual battery. 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 activated by 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 only the EnergyAccess charger supplied). There is a great potential for the battery to EXPLODE. Use only a charger specified for this type of battery. A battery may become deactivated and go into the "off state" as indicated by a red flashing light on the charger . This means that the battery will not work until it is re-activated. To do this, insert the battery into the left charger bay and press and hold the "Re-calibrate" button for 15 to 20 seconds. Remove the battery and place it in the right side of the charger and let charge fully. It should then operate correctly. 2.4.2 Charger 2.4.2.1 Energy Access Lithium-ion Battery Charger (Energy Access) Newer units shipped are supplied with one or more Lithium-ion batteries. These are the latest high 15. Windrock, Inc. 2011 Read ThisFirst 9 capacity lightweight batteries available. They also have a special charger made just for Lithium-ion batteries. 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 - PS2524 only) into an outlet (100VAC - 240VAC/50-60Hz) and insert plug end of the power cable into the DC power jack on the charger. Insert a battery in one of the two bays. The LED will illuminate to indicate the status of the battery as follows: Off: No battery detected Green Flash: Fast charging Green Solid: Fully charged Yellow Flash: Re-calibrating Yellow/Green: Re-calibrated Yellow Solid: Standby Red Flash: Error Caution! Connection other than indicated may result in permanent damage to the unit. 16. Windrock, Inc. 2011 10 Portable Analyzer DA/HA/MA/PA/VA Operations Manual Re-calibration: SMBus Smart Batteries contain a microchip that monitors battery usage and tracks how much capacity is available from the pack. It is possible for this process to accumulate errors due to temperature fluctuations, aging, self-discharge, and other factors. To keep the internal information as accurate as possible, it is occasionally necessary to run the pack 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 calibration is initiated. To calibrate a pack, place it in the left bay and push the red (or blue) arrow located between the bays. 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 3 Charge Rate: 3.0 Amps 2 Bays: Sequential Charge Time: 3 hours each Recalibration: SMBus [email protected] Recal Time: 9 hours Weight: 9.5 oz Material: ABS GSM Color: Black Dimension Inches: 4.89 x 6.89 x 2.02 3 Dimension mm: Getting Started 124 x 175 x 50 3.1 Connections Several connections are provided on the analyzer unit. See the figures below for placement of the connections. The portable analyzer series have the following layouts: /PA (Performance analyzer) contains all connections shown below /MA (Maintenance analyzer) does not have channels 3 or 4 installed /CA (Combustion analyzer) does not have channels 2, 3, or 4 installed 6310 Only Looking at the rear panel to the far right, a connector labeled "KBD" is used for attachment of an external PS2 style keyboard (included in the /PA & /MA kits only). If a PS2 style keyboard is not available, a standard PC keyboard may be used, but the number pad on the right of a large keyboard is not supported (Num Lock will do nothing). The connector on older stylekeyboards is a 5 pin DIN style and an adapter will be needed. These are available at most office supply or computer retailers. You may also contact Windrock, Inc. to purchase this adapter. 6320 Only A standard USB keyboard may be used by connecting it to the USB port found on the left side of the analyzer. Caution! Do not connect the external keyboard while near engine ignition systems. This may damage both the keyboard and the analyzer. 17. Windrock, Inc. 2011 Getting Started 11 Next, there are five round six-pin (referred to as "Lemo") transducer input connectors. These connectors are for the transducers and shaft (crank-angle) encoder provided in the analyzer kit. The connector labeled "ANT" is for the wireless encoder receiver antenna. Attach the supplied antenna by screwing it on hand tight. 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 left, an external AC-adapter connector is provided for use with the supplied charger power pack. You may simply unplug the power pack from the charger base and plug it directly into the analyzer. This will provide sufficient power to leave the instrument on for reviewing stored data without using up the battery. Caution! Make sure to keep a battery in the analyzer when using the external power adapter. A6310-00/PA and A6320-00/PA Rear Panel Connectors Refer to the figure above for the connector positions listed. 1 DC Power Input 5 Channel 3 Input 2 Wireless Receiver Antenna 6 Channel 2 Input 3 Encoder Input 7 Channel 1 Input 4 Channel 4 Input 8 External Keyboard Connection, 6310 only 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 USB port, and both have an external VGA color monitor connection located together on the left side of the analyzer 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 analyzer for larger desktop screen 18. Windrock, Inc. 2011 12 Portable Analyzer DA/HA/MA/PA/VA Operations Manual viewing. The operating software is set for 640 x 480 pixels of resolution. There are no settings to change this resolution for different monitor types. However, both color and B&W are supported. Please see the chapter on "Utilities" in this manual for use of the 25 pin parallel port for file transfer to Windows and "Hardware Configuration" later in this chapter on printing from the parallel port of your 6310. For information on use of the USB port see the Appendix in the Windows software manual. The 6310 and 6320 battery compartment is located on the right side of the analyzer behind the sliding door. The battery compartment has a spring located in the bottom provided to pop the battery out when the door is open. The battery will have to be pushed in and held while closing the sliding door. This may be tight and is normal operation. Note: The sliding doors on the sides are provided to protect against EMI when around ignition systems. The doors should remain closed while operating. 3.2 Keypad Functions ESC The escape key operates as a cancel function and gives the user the ability to back 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. (Special note: The HOME key is also used to bring up a list of alphabetic characters for text entry when a keyboard is not available) p q Used tomove the cursor up and down for selections t u Used to move the cursor right and left and increment and decrement numeric entries. The right arrow is also used to bring up pop-up list selections on certain data entry fields TAB Advances the user ahead multiple entries or multiple pages 19. Windrock, Inc. 2011 Getting Started 13 TAB Returns the user back multiple entries or multiple pages Period Enters a decimal point as needed for numeric entries Numeric Keys Enters the numeric character in data entry fields and provides short cut menu/function selections. If the user is on a menu screen, simply pressing the number 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 new line. For example, each cylinder's bore, stroke, and connecting rod length may be copied from line to line since they may all be of the same values. 3.3 HardwareConfiguration, 6310 Before using the analyzer, take the time to become familiar with the basic operation and set up. There are a number of options, setup entries, and keystrokes with which you should be familiar prior to taking your first set of data. When you first receive your analyzer prior to your data collection, you must first set up your own stations, machines, and databases for those machines. Subsequently, when the analyzer is turned on, you will be positioned at the menu for the last used station and machine. This enables you to power down the analyzer to exchange batteries and power back up to the current machine or station, thus saving time in selecting the same station and machine again. From this menu, you can select a new machine or station by pressing "ESC" once or twice, respectively. There is a basic set of configuration parameters that may be set on the analyzer to optimize the operation for your needs. These are located in the Hardware Configuration option of the Station Selection Menu. 20. Windrock, Inc. 2011 14 Portable Analyzer DA/HA/MA/PA/VA Operations Manual Use backlight Typically set to Yes. Setting to No will turn off the LCD back light and the screen image may be hard to see - this mode conserves battery power. Monitor type: Typically set to LCD for black and white units, Color1 or Color2 for color units or when an external VGA monitor is used, and B&W can be used to improve contrast in some cases. Use power save: Typically set to no. If set to no, 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 the user returns to a menu screen. It is possible to lose the phase setting (exhaust vs. compression cycle) of the encoder when collecting data on a 4-stroke engine. You must check the phase before continuing with data collection if this occurs and power save is set to YES. Use blinking Typically set to yes. You may prefer not to have the cursor bar blink. If so, set this option to NO 21. Windrock, Inc. 2011 Getting Started 15 Screen width Typically set to 40 column Text Cursor Style The style of the cursor may be changed between ARROW, BAR, or BOX Enable run numbers: This allows the collection of data using run numbers. A run is an individual set of data collected in sequence on the same day. By assigning a run number, the data sets are then separated and recalled for reporting individually. If this option is turned on, the user will be prompted to enter a run number at the time the data is collected. Run numbers start with 1 and can be incremented at any time by the user. If one hour has passed without collecting data, the user will be prompted "Do you want to change run number?". At that time, you may continue with the same run number or change it if needed Start load steps with: "Load steps" are a control mechanism for many compressors and each load step has clearance data associated with it. In the "Compressor Setup" section, a load step table is used to hold this clearance data. This option, to start with ZERO, ONE, or a LETTER for the load step increment, should be set prior to doing compressor setups. Load steps in: Clearance data for each end of a cylinder is entered in the "Compressor Setup" section. The clearance may be entered in either "Percent clearance" (percent of swept volume) or "Cubic inches". Autoscan first in take data: This option controls how the data collection process runs. ' Autoscan first in take data' has four options. 1. When set to yes, entering the data collection process will automatically start the analyzer auto scanning data and updating the screen with each collection of data until the 3 key [STOP AUTOSCAN] is pressed. 2. 'Yes auto save' If this is selected during take data, the last single scan of auto scanning will be saved before taking the normal data without asking if you want it saved. 3. 'Yes no save' will not save the last single autoscan and proceed to taking normal data without asking. 4. 'No' turns off "Autoscan" Use unit conversion: NO uses the default standard units that have always been available. Setting to YES will allow selecting from different conversion groups (see "Unit group" below). Unit group: Allows selecting either Standard or Metric Units. If you have added additional custom groups in the Win63X0PA software and downloaded them to the analyzer, those custom groups will also be available for selection. DC Sensor correction: Allows you to select from three choices. 1. "Zero Only" allows you to reference the zero pressure to the current atmospheric pressure. 2. "Two Point one channel" allows you to provide known pressures for calibration, one channel at a time. 3. "Two Point four channel" allows you to provide known pressures for calibration, four channels at a time. 22. Windrock, Inc. 2011 16 Portable Analyzer DA/HA/MA/PA/VA Operations Manual For multi cycle scans: You have the options of "Average multi scans" or "Use a representative scan". (D6) files warning This is set to yes to receive a reminder to transfer the setups to the computer after setups have changed in the analyzer. The analyzer contains a status line at the bottom of the display. This line contains information about the battery capacity and the date and time. The battery capacity is monitored when the unit is operating from the battery. If the unit is on AC power, the status line will add "Using AC" to the battery voltage value. If the battery capacity drops to approximately 9 volts, a warning will be displayed and the analyzer will automatically turn off. Caution! When the battery goes below 10.0V, save the current data and change the battery. Any data stored up to this point is safe. Only data that is currently being collected and displayed or setup information currently being entered could be lost. 3.4 System Configuration, 6320 Before using the analyzer, take the time to become familiar with the basic operation and set up. There are a number of options, setup entries, and keystrokes with which you should be familiar prior to taking your first set of data. When you first receive your analyzer prior to your data collection, you must first set up your own stations, machines, and databases for those machines. Subsequently, when the analyzer is turned on, you will be positioned at the menu for the last used station and machine. This enables you to power down the analyzer to exchange batteries and power back up to the current machine or station, thus saving time in selecting the same station and machine again. From this menu, you can select a new machine or station by pressing "ESC" once or twice, respectively. There is a basic set of configuration parameters that may be set on the analyzer to optimize the operation for your needs. These are located in the System Configuration option of the Station Selection Menu. 23. Windrock, Inc. 2011 Getting Started 17 In the 6320 you have access to the system options menu, printer menu, set date, time, time zone and database backup and restore. The backup / restore letsthe userarchive the entire evportdatabase to an external flashdrive orreloadthe evport database fromanexternal flashdrive orconnected 6310 or 6320. 24. Windrock, Inc. 2011 18 Portable Analyzer DA/HA/MA/PA/VA Operations Manual 3.4.1 System Options Color scheme: Typically set to LCD for black and white units, Color1 or Color2 for color units or when an external VGA monitor is used, and B&W can be used to improve contrast in some cases. Use power save: Typically set to no. If set to no, 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 the user returns to a menu screen. It is possible to lose the phase setting (exhaust vs. compression cycle) of the encoder when collecting data on a 4-stroke engine. You must check the phase before continuing with data collection if this occurs and power save is set to YES. Enable run numbers: This allows the collection of data using run numbers. A run is an individual set of data collected in sequence on the same day. By assigning a run number, the data sets are then separated and recalled for reporting individually. If this option is turned on, the user will be prompted to enter a run number at the time the data is collected. Run numbers start with 1 and can be incremented at any time by the user. If one hour has passed without collecting data, the user will be prompted "Do you want to change run number?". At that time, you may continue with the same run number or change it if needed 25. Windrock, Inc. 2011 Getting Started 19 26. Windrock, Inc. 2011 20 Portable Analyzer DA/HA/MA/PA/VA Operations Manual Caution! When the battery goes below 10.0V, save the current data and change the battery. Any data stored up to this point is safe. Only data that is currently being collected and displayed or setup information currently being entered could be lost. 3.4.2 Printer Management 3.4.3 Set Date 27. Windrock, Inc. 2011 Getting Started 21 3.4.4 Set Time 3.4.5 Set Time Zone 28. Windrock, Inc. 2011 22 Portable Analyzer DA/HA/MA/PA/VA Operations Manual 3.4.6 System Information 3.4.7 Database Backup / Restore The backup / restore letsthe userarchive the entire evportdatabase toanexternal flashdriveor reloadthe evportdatabase fromanexternal flashdriveorconnected6310 or 6320. 29. Windrock, Inc. 2011 Getting Started 23 3.5 Calibration From the "Startup menu", hit escape twice to get to the "Station Selection Menu". Select 5 to Calibrate the IR (infrared) sensor. This menu option allows for entries of transducer calibration factors. These values are used throughout the program as defaults. 30. Windrock, Inc. 2011 24 Portable Analyzer DA/HA/MA/PA/VA Operations Manual For the infrared temperature sensor A6045-01-06 (Raytek model), use 0 for the 4mA entry and 1000 for the 20 mA entry. The values should be entered in degrees Fahrenheit. 3.6 Stations & Machines Stations and Machines are laid out in a tree structure. The first level in the tree structure is the station list. There are 0 to 199 folders (starting with a 0 base) and each folder contains a station. Within each station, there contains from 0 to 199 machines (starting with a 0 base). Within each machine, there resides the setup files, crank angle related data collected files, and vibration related files. The structure looks like this: /EVPORT | Station 000 (S000) | | | Machine 000 (M000) | | | | | Setup | | Crank angle data | | Vibration data | | | Machine 001 (M001) | | | Machine 002 (M002) | | | ... Station 001 | ... The database is a flat file structure for fast and easy data retrieval. All data is stored in this format and can be easily accessed. Caution: DO NOT alter this structure. 31. Windrock, Inc. 2011 Getting Started 25 3.6.1 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 another station/machine. See the section on machine database in the Win63X0 manual for copying setups. This section applies to all 63X0 models. Station Selection Menu From the "Machine Menu", press "ESC" twice to return to the "Station Selection Menu". Select "2-Add a station" Enter a station name of up to 30 characters, followed by pressing "ENTER". You will be returned back to the "Station Selection Menu". Select "1-Select a station" and pick the new station you just added from the list. Caution! If you are a Win63X0 software user, make sure the name entered isnot altered without also changing the Windows database. In order to connect Windows to the 6310, these names must match exactly (character and case) or a connection will not be allowed. Machine Selection Menu You will now be brought to the "Machine Selection Menu". Select "2-Add a machine". Enter a machine name of up to 30 characters, followed by pressing "ENTER". You will be returned back to the "Machine Selection Menu". Select "1-Select a machine" and pick the new machine you just added from the list. Note; You will need to come back to this menu to add each machine you will analyze. 32. Windrock, Inc. 2011 26 Portable Analyzer DA/HA/MA/PA/VA Operations Manual Machine Menu, (Power up menu) You will now be brought to the "Machine Menu" as shown in the figure. At this point you must select "2 - Setup database" to enter all the information about the machine. This would include engine & compressor geometry, points for data collection, gas composition, etc. This is the minimum required to collect data with the analyzer. Further customizing may be required to meet your setup needs. If you find that the names you have entered need to be changed, you may use the "Edit a station name" and "Edit a machine name" as necessary. 4 Setup Database Note: The simplest and most effective way to create, edit, and manage the data base setup's is to use the Win63X0 Windows software supplied with your analyzer, and then transfer the setups from Windows to the analyzer. The following is how to setup, edit and manage the setups using the analyzer software. Note: After making changes in the analyzer setup, the setup files need to be copied to the windows database. The Machine database setup is a set of menu options to configure the machine's geometry, sensor points, collection points, fixed scaling, gas analysis, calculation, and other related setup details. The machine configuration data can be obtained from the manufacturer's data sheets. Occasionally, not all the information is available from this source. It may be necessary to call the manufacturer to enlist their help with the missing information. As a last resort, there are databases that have been developed that can help you obtain missing information. When you use this information, it is up to you to verify the accuracy. 33. Windrock, Inc. 2011 Setup Database 27 Prior to actually setting up machine configuration, it would be prudent to read the section on "Fixed data scale input" and "Gas composition setup" as these are used in the machine configuration portion of the setup. Below is an outline to setting up the machine database. It is a guide to organizing your data before continuing. We suggest you gather the required data prior to starting the entry process. 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 / FFT Setup Set up route or FFT points for data collection 1 - Collection Point setup Arrange groups of sensor points for collection 2 - Group Plots setup Arrange groups of sensor points for plotting 3 - FFT route setup Edit or add FFT points 4 - Return to machine setup Goes back to previous menu 4 Fixed Data Scales Set up predefined scales for display of data 5 Gas Composition Setup Set up gas composition table 6 Compressor Calculations Setup Associate temperature points with cylinders. 7 Software Configuration Modify standard defaults for this machine only.. 8 Return to machine menu Returns analyzer to machine menu. 4.1 Machine Configuration 4.1.1 General Configuration The machine configuration data can be obtained from the manufacturer's data sheets. Occasionally, not all of the information is available from this source. It may be necessary to call the manufacturer to enlist their help with the missing information. As a last resort, there are databases that have been developed that can help you obtain missing information. When you use this information, it is up to you to verify the accuracy. Using the left or right arrow key, select from the choices available. If you are using an encoder, select 360 pulses per revolution and, if you are using a magnetic speed pickup, select 1 pulse per revolution. If you have no power cylinders, set this to zero. If you have no compressor cylinders, set this to zero. Industry standards for efficiencies are: Overall Efficiency 85% Mechanical Efficiency 95% These can be something different should you choose. Auxiliary load (HP) is anything that was added on to the unit that is not factored into the rated horsepower at a rated speed. 34. Windrock, Inc. 2011 28 Portable Analyzer DA/HA/MA/PA/VA Operations Manual This is information that is usually easy to obtain but, should you have trouble obtaining a connecting rod length, a general rule of thumb is 2-1/2 times the length of the stroke. Verify this information. The screen and entries listed below relate to the engine portion of the setup. The compressor configuration, if required, continues in the next section. Note: The angle values entered for the engine and compressor phase angles, engine event angles, ignition timing angle and power cylinder pressure tracking angles are to be entered as degrees after TDC. On four-stroke engines the angles are after TDC of the compression stroke using a range of 0 to 720 degrees. Strokes per cyl 2/4: is used to set the analyzer up for either a two-cycle or four-cycle machine. Note that all compressor data is automatically set to two-cycle mode regardless of this setting. If the shaft encoder is used, the switch on the side should always be left in four-stroke mode even if on the compressor of an integral style machine. See the section on encoders for more information. Note: In the following setup screens, use the left or right arrow keys to select from the choices available, or enter the numeric values as required. Pulses per rev: sets the sampling per degree of the analyzer. If using the shaft encoder, select 360 pulses per revolution; if using a magnetic speed pickup, select 1 pulse per revolution. When using the "Multi-Event Encoder", you may enter 'n' number of pulses (e.g. a gear with 300 teeth, enter 300 here). It is NOT recommended to use less than 300 points per revolution, or 300 teeth. Offset: is used in cases where TDC is shifted from its normal position. For example, a magnetic pickup can't be physically mounted at TDC. Therefore, there is a known offset plus or minus from TDC. Num of power cylinders: set to zero if this is a motor- driven compressor. It will then reduce the number of setup screens required. Num of compressors cyl: set to zero if there are no compressor cylinders attached. It will then reduce the number of setup screens required. Power cylinder layout: is set according to how the cylinders are labeled and selected by pressing the right arrow to bring up the menu shown below. Options are Left/Right, Straight, Odd/Even, Opposed MEP, Tandem and A/B. 35. Windrock, Inc. 2011 Setup Database 29 Note: Ingersol-Rand "V" style should use straight for sequential numbering. Power cylinder articulated: If you have an engine with articulated connecting rods, select yes for Power cyl articulated. This will require additional information and additional "Machine Configuration" screens to be present. See articulation setup information later in this section. Rated Load: Enter the rated load from manufacturer's specifications. Rated Speed: Enter the rated speed from manufacturer's specifications. Note: Under normal circumstances, we couldgo up to1500 RPM withoutlosing encoderpulses. If the user'sratedspeed istoohighforperdegree mode, thenthe userwill have tochange to once per turnmode themselves (by changingPulsesPerRev to1). Depending on the Articulation setting, the following screens are displayed next. Articulated Non-Articulated Engine Mech Eff: Is the product of the mechanical and compression efficiency. By convention, the overall efficiency of industrial compressors is set at 0.85. Comp Mech Eff: Is the ratio of the indicated horsepower (IHP) to the brake horsepower (BHP). By convention, the mechanical efficiency of industrial compressors is set at 0.95. 36. Windrock, Inc. 2011 30 Portable Analyzer DA/HA/MA/PA/VA Operations Manual Auxiliaryload (HP): Enter the total BHP of any additional pieces of equipment driven from the crankshaft. Note: Engine mechanical efficiency, compressor mechanical efficiency, and auxiliary horsepower are used for compressor calculations only. For non-articulated engines: Bore, stroke and rod length equal for all power cylinders: This selection gives the user the ability to enter a common size bore for all power cylinders, or the ability to enter each individual power cylinder's bore. This would be important if power cylinder(s) have been rebuilt and are a different size. An additional screen will be available later in the setup for entering the bores. Or for articulated engines enter: Power cyl bore (in): This is the power cylinder's bore in inches. Number of spark plugs: Select the number of spark plugs located on each cylinder. The options are 0, 1, or 2 plugs per cylinder. Ignition system neg pulling: (6310 Only) Enter YES if the ignition system you are analyzing goes negative with respect to ground. Power cylinder clearance: This entry is used for the display of LogP-LogV curves of a power cylinder. This value is not used in any power cylinder calculations. Atmospheric pressure: This is the atmospheric pressure reported at the location of the engine. Standard pressure: The weight of air as measured at sea level. This is typically set at 14.696 PSI. Note: If the articulation setting is set to Yes, please refer to the end of this section for the data entry screens that will require entries. 4.1.2 Engine Configuration Engine specific information must now be entered using the following screens and information. 37. Windrock, Inc. 2011 Setup Database 31 If the setting for "Power cylinder articulated" is set to No and the setting for "Bore, stroke and rod length equal for all power cylinders" is set to YES, then this screen will appear for data entry. Enter the power cylinder bore, power cylinder stroke, and power connecting rod length. Note: For Articulated engines see the section that follows on Articulated Engine Setup. If the setting for "Power cylinder articulated" is set to No and the setting for "Bore, stroke and rod length equal for all power cylinders" is set to No, then this screen will appear for data entry. Enter the bore, stroke, and connecting rod length. Note: If you input each cylinder's bore, stroke, and connecting rod length individually, you can press the "ENTER" key and all the data from the previous line will be transferred to the new line. The phase of each cylinder is the angle by which TDC of the cylinder lags the reference for the lead cylinder. The lead cylinder reference (TDC) is usually set to zero. The schematic given by the manufacturer will 38. Windrock, Inc. 2011 32 Portable Analyzer DA/HA/MA/PA/VA Operations Manual usually have the information necessary to calculate the angles at which each cylinder will be at TDC when referenced to the number one cylinder. Note: Phase angles are associated to a cylinder name (i.e. PL1 = Power Cylinder Left Bank #1). You will need to remember this for other parts of the setup. The portable analyzer has additional features which may be set up to help in the analysis process. These features do not necessarily need to be set up but can be very helpful for analysis. The events and angles entered on the next three screens will be available on graphics screens or in reports. Input manufacturer's timing events for "Port and Valve Opening and Closing". This information will provide on-screen references for events. 39. Windrock, Inc. 2011 Articulated Engine Setup: SetupDatabase 33 Should you have a "Fuel Valve", input the manufacturer's recommended timing. This information will provide on-screen references for events. As an analyst, you may want to take advantage of the report feature which enables you to report up to 10 of the most important pressures of the PT curve. Enter up to ten angles which will have the pressure values printed in the report after data has been collected. Note: The angle 0.0 is a default in the report (as it is the TDC reference) so do not enter it here. For articulated integral engine/compressors, the articulation information must be entered into the machine set up. The figure above shows the angles that are needed by the analyzer software to calculate the swept volume of the power cylinders. The angles and lengths required are: bank angle (right or left): The angle between the master rod centerline and the right or left power piston centerline bale angle (right or left): With the master rod at TDC position, the angle between the master 40. Windrock, Inc. 2011 34 Portable Analyzer DA/HA/MA/PA/VA Operations Manual rod centerline and the right or left articulated pin centerline link radius: The radius from the center of the rod bearing and the centerline of the link rod pins rod length: The length of the master rod from center of pin to center of bearing link rod: The length of the power link rod centerline-to-centerline Refer to the table and diagrams in the Articulation appendix. Identify each connecting rod as a master or as articulated. This setup is a sample in which two of the rods are masters. Input the: Master Rod Length Master Stroke Link Radius or Articulation Radius Link Rod Length or Articulation Rod Length 41. Windrock, Inc. 2011 Setup Database 35 For articulated rods, you need to input the bank and bale angle for that cylinder. Enter the side that the Master Rod is on while looking at the engine from the flywheel end. All bank and bale angles are based on this positioning. This setting takes the guess work out of trying to figure out different angles based on right or left geometry. Simply input the smallest angle from the master to the articulated rod. 42. Windrock, Inc. 2011 36 Portable Analyzer DA/HA/MA/PA/VA Operations Manual 4.1.3 Articulation Table of Standard Articulation Values for use in Windrock Analyzers 43. Windrock, Inc. 2011 Setup Database 37 Table of Standard Articulation Values for use in Windrock Analyzers 44. Windrock, Inc. 2011 38 Portable Analyzer DA/HA/MA/PA/VA Operations Manual Articulation Diagrams 45. Windrock, Inc. 2011 Setup Database 39 For articulated integral engine/compressors, the articulation information must be entered into the machine set up. The figure above shows the angles that are needed by the 6310 software to calculate the swept volume of the power cylinders. The angles and lengths required are: Master rod length: The length of the master rod in inches Articulated radius: The radius from the center of the master rod bearing and the centerline of the link radius rod bearings Articulated rod length: The length of the articulated power link rod in inches 46. Windrock, Inc. 2011 40 Portable Analyzer DA/HA/MA/PA/VA Operations Manual Bank angle: The angle between the master rod centerline and the power piston centerline Bale angle: The angle between the master rod centerline and the centerline of the link radius rod bearings 4.1.4 Compressor Configuration Compressor specific information must now be entered using the following screens and information. Input the phase angles for the head end only. The crank end is always assumed to be 180 degrees different. A manufacturer's schematic will usually have the information necessary to calculate the angles at which each cylinder will be at outer dead center when referenced to one cylinder. Note: Phase angles are associated to a cylinder name (i.e. CH1). You will need to remember this for other parts of the setup. Should a unit have two pistons in line, the tail rod diameter needs to be subtracted out of the bore size for that cylinder end. Maximum allowable rod load in compression and tension are available in the manufacturer's data sheets. Enter the mass of the reciprocating parts for a cylinder to calculate inertia forces into the rod load calculations. The reciprocating parts typically include the piston, rod, and other pieces as known. A gas analysis needs to be setup in "Gas Composition" and the names that we established there will be available here. It is possible to have different cylinders or cylinder ends that are moving different gases. This is information that is usually easy to obtain but, should you have trouble obtaining a connecting rod length, a general rule of thumb is 2-1/2 times the length of the stroke. Verify this information. 47. Windrock, Inc. 2011 Setup Database 41 Input the phase angles for the head end only. The crank end is always assumed to be 180 degrees different. A manufacturer's schematic will usually have the information necessary to calculate the angles at which each cylinder will be at outer dead center when referenced to one cylinder. Note: Phase angles are associated to a cylinder name (i.e. CH1). You will need to remember this for other parts of the setup. Enter the load steps into the table for each cylinder's end. Use the tab key to shift the screen right or left to the next set of cylinder ends. Select next page to enter the set of 16-30 and so on up to 90 load steps maximum. If the global setting for "Loadstep in" is set for percent clearance, enter these values in percent. Otherwise, for cubic inches, enter these values in cubic inches. 48. Windrock, Inc. 2011 42 Portable Analyzer DA/HA/MA/PA/VA Operations Manual Should a unit have two pistons in line, the tail rod diameter needs to be subtracted out of the bore size for that cylinder end. Maximum allowable rod load in compression and tension are available in the manufacturer's data sheets. Enter the mass of the reciprocating parts for a cylinder to calculate inertia forces into the rod load calculations. The reciprocating parts typically include the piston, rod, and other pieces as known. For reporting purposes, each cylinder end may be assigned a stage from 1 to 10. On the reports, the capacity will be summed by this stage assignment. 49. Windrock, Inc. 2011 Setup Database 43 A gas analysis needs to be set up using the "Gas Composition" setup menu option. The names that have been entered there will be available here for selection. It is possible to have different cylinders or cylinder ends that are moving different gases. See Section 6 "Gas composition setup" for entering gas analyses. 4.1.5 Miscellaneous Engine and Compressor Power Cyl Recip Mass: Enter the mass, in pounds, of the power cylinder reciprocating parts. This value is used in the power rod loading calculation. Crankcase pressure: Enter the pressure, in PSI, of the crank case. This value is used in the power rod loading calculation. Suggested Spark Timing: Enter the expected value of the timing event. This value is used for piston animation only. Crankshaft is offset: The default setting is NO. Very few engine/compressor combinations will require a setting of YES (the IR KVT/KVH and other compressor uses this feature). If you select YES, then you will have the option to enter the vertical offset in inches of either the engine or compressor crankshaft centerline related to the corresponding cylinder centerline. Example: If the cross head centerline is 1 inch below the crankshaft centerline, then enter +1 as the compressor crankshaft offset value. 50. Windrock, Inc. 2011 44 Portable Analyzer DA/HA/MA/PA/VA Operations Manual 4.2 SensorPointSetup If the crankshaft offset is set to "YES", you will be able to input the offset for compressor or engine. If you select "YES" for finished or if you hit the "ESC" key, you will be asked if you want to save the changes. If changes are made in the analyzer, the next time yow download data to your computer, be sure to download the setup "d6*.*" files Sensor points may be added or edited in two ways. 1. In the Win63X0 software: This is the most convenient way to generate several sensor points at once using the auto generator. This will reduce the data base set up time. The auto generator will also setup collection points, fixed data scales and group plots. 2. In the 63X0 analyzer: All setups can be completed and / or edited in the analyzer. 4.2.1 Overview Machine sensor points are the identifiers in the software for external sensors attached to the analyzer. The sensor point requires information to be set defining the type of point and parameters for that type of sensor. Once set, the analyzer knows how the data that is electronically sampled should be displayed and calculated. Each point requires the following parameters: Name of the point (up to 30 characters) Point type Point engineering units (e.g. pressure in PSI, vibration in g's, ignition in volts, etc.) Phasing reference (TDC reference) Scaling for plots Gain Units-low (zero) Units-high (full scale) The sensor point list has a maximum number of 800 points per machine. If more points are required, you may wish to separate the engine and compressor into separate database machines. Once all the points are entered, the next step is to group the points into a planned collection route. This will be done with the "Collection point editor" later in this section. 51. Windrock, Inc. 2011 Setup Database 45 Sensor Point Name The sensor name can be up to 30 characters in length and should be named to describe the position on the machine, type of point, and full scale (if a pressure point and there are multiple pressure range sensors in the kit). Examples of naming would be: P1L DC Pressure 1000 PSI 1H DC Pressure 2000 PSI P2L DC Pressure 1000 PSI 1C DC Pressure 2000 PSI Cyl #1 HD/BOLT (HIGH FREQ) Cyl #1 HD/BOLT (ULTRASONIC) Cyl #2 HD/BOLT (HIGH FREQ).... Cyl #2 HD/BOLT (ULTRASONIC).... Cyl #1 FUEL VALVE (ULTRASONIC) FRAME VIB (WEB #1) LOW FREQ Cyl #2 FUEL VALVE (ULTRASONIC).... FRAME VIB (WEB #2) LOW FREQ.... Point Types Angular velocity is the measurement of the speed of a crankshaft at each degree of crank angle. Manual temperature input are temperature values entered via the keypad that are to be used in compressor performance calculations. Power cylinder AC pressure vs. Crank is a AC pressure sensor measuring the pressure inside a power cylinder. This type sensor may be used with the analyzer but is not typically supplied with the kit. Power cylinder DC pressure vs. Crank is a DC pressure sensor measuring the pressure inside a power cylinder. Note that DC pressure sensors are supplied with the standard kit. Power cylinder lo frequency vs. Crank is a vibration sensor point vs. power cylinder crank angle that uses the low-pass vibration filter. The default low-pass vibration filter setting passes accelerometer frequencies from 1.5 Hz up to 2.5 KHz. Power cylinder hi frequency vs. Crank is a vibration sensor point vs. power cylinder crank angle that uses the high-pass vibration filter. The default high-pass vibration filter setting passes accelerometer frequencies from 2.5 KHz up to 10 KHz. Power cylinder ultrasonic vs. Crank is an ultrasonic sensor point vs. power cylinder crank angle that should be used for all power cylinder ultrasonic data collection. Spark plug voltage vs. Crank is the secondary ignition voltage measurement vs. crank angle. The secondary ignition clip is used for this type of measurement. Compressor nozzle trace is a pressure point for taking pressure at the suction or discharge bottle. Raw vibration vs. Crank is a vibration sensor point vs. crank angle that passes all accelerometer frequencies. Primary ignition vs. Crank is the primary ignition voltage measurement vs. crank angle. The primary ignition clip is used for this type of measurement. 4-20mA sensor vs. Crank is the measurement using a sensor type with 4-20mA output vs. crank angle. An example of this type sensor may be a proximity probe measuring connecting rod run out. 52. Windrock, Inc. 2011 46 Portable Analyzer DA/HA/MA/PA/VA Operations Manual Voltage sensor vs. Crank is the measurement using a sensor type with voltage output vs. crank angle. Manual panel reading input is a panel gauge reading entered via the keypad. Infrared temperature input is a temperature value entered via the infrared temperature sensor. Vibration in velocity vs. Crank uses a velocity sensor to take a vibration reading vs. crankangle in ips engineering units. Proximity probe vs. Crank uses a proximity displacement sensor to take a gap readings vs. crankangle in mil engineering units. Point engineering units Sets the display units for the type of sensor being used (e.g. pressure in PSI, vibration in g's, ignition in volts, etc.). Phasing reference Sets the TDC reference for the point. For example, when sampling pressure on the head end of #4 compressor cylinder, set the phasing to CH4. When displaying data, the curves will plot correctly. If the phase is not set correct, incorrect data will be displayed and reporting will generate errors. Use the right arrow key to bring up the pick box and select the proper phasing from the list. 53. Windrock, Inc. 2011 Setup Database 47 Scaling for plots Scaling for plots presets the displayed plot scale to the value. For example, a pressure point uses a 2000 PSI sensor for collecting data, but the actual pressure sampled has a maximum operating pressure of 800 PSI. Scaling to 2000 would make the curve look small and on the lower half of the screen. Setting the scale to 1000 would make the curve take up more of the screen and present more detail. The plot scale can always be changed later if needed. Also, the plotted data can be re-scaled on-the-fly at any time. Use the right arrow key to bring up the pick box and select the proper scaling from the list. Gain, 6310 Gain is used for accelerometer input types. Setting the gain higher provides more resolution of the signal. However, if the gain is too high, the input may be overloaded and distort the plot. Use the right arrow key to bring up the pick box and select the required gain from the list. Gain, 6320 The gain will be set to one in the 6320. Units-low Units low should be set to the zero point of the sensor being used. Typically this is 0. Units-high Units high should be set to the full scale of the sensor being used. Some notes on the sensor point list: 1. Once entered, the list cannot be re-arranged (use collection point list to group and form routes) 2. Sensor names can be changed anytime 3. Additional sensor points can be added to the end of the list 4. Scales and point type will affect collected data 5. Use the "CTRL + G" key (the control key and G key pressed together on the keyboard) to copy the previous point's sensor point name and paste to the new point. This speeds up entering similar names and changing only one character. Caution! Do not try to re-arrange the data point setup after taking a set of data. The point list and data are linked together. Use the collection point setup to group the points as needed. On the next several pages are examples of sensor points that would be used in engine analysis. 54. Windrock, Inc. 2011 48 Portable Analyzer DA/HA/MA/PA/VA Operations Manual 4.2.2 Engine Sensor Points DC Pressure Point The Point Type list to the left can be used in the following data point setup screens. In the "Pt. Type >" field, press the right arrow key to bring up this list and make a selection. Raw vibration has a sensor point selection of sample density of one, two, or four samples per degree. Give a detailed name that gives test point location and pressure sensor range. This will alleviate problems associated with using the wrong transducer. It may be helpful to write down a planned route before you start entering it into the computer. Distinguish cylinders 1-10 or 1L-5L and 1R-5R. Example: Cyl #1 Power Pressure (0-1000) Cyl #2 Power Pressure (0-1000) 55. Windrock, Inc. 2011 AC Pressure Point SetupDatabase 49 The 1V - 5V scales for the AC pressure transducer should be as follows: For example, if you are using a 0-3000 psi sensor, 1V = 600 and 5V = 3000. 1V is set to 20% of full scale. This sensor has a 1-5 volt output. 6320 The 6320 will only have a gain setting of one. Head Vibration Point When using high and low frequency vibration, use a gain of 5 initially. High speed (1000 RPM or greater) and diesel engines may benefit using a gain of 1. Note: Scale may be set to "Scale to exhaust blowdown" for analysts who wish to have the vibration scale automatically set to 1/4 of the mean amplitude level at the exhaust blowdown event. 6320 The 6320 will only have a gain setting of one. 56. Windrock, Inc. 2011 50 Portable Analyzer DA/HA/MA/PA/VA Operations Manual Power Cyl Ultrasonic Point When using ultrasonic, set the 4 mA line to 0 and set the 20 mA line to 10. Low Freq Vibration Point Low frequency points are used to detect mechanical knocks, such as loose wrist pins, loose piston nut, and other mechanical faults. 6320 The 6320 will only have a gain setting of one. 57. Windrock, Inc. 2011 Spark Point SetupDatabase 51 Set up a spark plug voltage vs. crank angle for each spark plug. Distinguish the plugs so that they are easily identified: Top/Bottom, Right/Left, Right/Center Left, etc. Note: The maximum voltage is typically set to 50,000 but may need to be adjusted depending on the diameter of the secondary ignition wire. Primary Ignition Point Primary ignition point is used to collect the ignition system's supply voltage pattern. 58. Windrock, Inc. 2011 52 Portable Analyzer DA/HA/MA/PA/VA Operations Manual Angular Velocity Point By having an angular velocity test point, you will be able to graphically display the speed of the flywheel over 360 degrees for two-cycles and 720 degrees for four-cycles. Note: The machine setup must have the number of pulses-per-revolution set to greater than one to acquire angular velocity. Angular velocity can not be obtained from a single magnetic pickup, a single optical pickup, or single hall effect pickup. 4.2.3 Compressor Sensor Points Cylinder Pressure Point Set up cylinder and nozzle pressures in the order in which you expect to collect the data. Give a detailed name that gives test point location and pressure sensor range. This will alleviate problems associated with using the wrong transducer. It is best to write down a planned route before you start entering it into the computer. Cyl #1 HE Pressure (0-2000) Cyl #1 CE Pressure (0-2000) Note: The 4 mA - 20 mA scales should be set to the pres

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