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CA Operations
Manual
Windrock, Inc. 2013
3/1/2013
Legal Notices
Copyright
1997-2013 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 CA Operations Manual
If you have comments about this documentation, the software, or products it describes, please contact the
Customer Support Group at Windrock.
Contents
Table of Contents
1
1 Introduction ................................................................................................................................... 1
2 Customer Assistance
................................................................................................................................... 1
3 Returning Items
................................................................................................................................... 2
4 Handling Precautions
................................................................................................................................... 3
5 Warnings
................................................................................................................................... 4
1 Special Terms................................................................................................................................... 5
2 Care
................................................................................................................................... 5
3 Unpacking
................................................................................................................................... 5
..........................................................................................................................................................
.........................................................................................................................................................
..........................................................................................................................................................
6
7
8
10
1 Connections................................................................................................................................... 10
2 Keypad Functions
................................................................................................................................... 13
3 Hardware Configuration
................................................................................................................................... 13
4 Stations & Machines
................................................................................................................................... 15
Station & Machine
..........................................................................................................................................................
Setup
16
18
1 Setting Up a ...................................................................................................................................
Machine, 63X0/CA with encoder only
18
Machine Setup
..........................................................................................................................................................
Menu
18
20
................................................................................................................................... 20
Setup
..........................................................................................................................................................
Engine Balance
..........................................................................................................................................................
Engine Balancer
.........................................................................................................................................................
- Non encoder
Restart Balance
.........................................................................................................................................................
Run
Recall Old.........................................................................................................................................................
Balance Data
Power Cylinder
.........................................................................................................................................................
Monitor
Spark Menu ..........................................................................................................................................................
Spark Survey
.........................................................................................................................................................
Ignition Survey
.........................................................................................................................................................
Report Definitions
Restart Spark
.........................................................................................................................................................
Survey
Recall Spark
.........................................................................................................................................................
Survey
21
26
26
36
37
39
41
43
50
51
53
54
1 Special Collection
...................................................................................................................................
Modes
54
II
................................................................................................................................... 55
58
1 Direct Channel
...................................................................................................................................
Read
58
2 Power Cylinder
...................................................................................................................................
Monitor
60
61
1 Shaft Encoder
................................................................................................................................... 61
2 Multi-Event ................................................................................................................................... 62
3 Magnetic Pickup
................................................................................................................................... 63
4 Timing Light................................................................................................................................... 63
64
1 Windows Install
...................................................................................................................................
6310 only
64
2 Windows Install
...................................................................................................................................
6320 only
64
65
1 Machine Template
...................................................................................................................................
6310 only
65
2 Setting Time...................................................................................................................................
and Date 6310 only
65
3 Set Date, Time
...................................................................................................................................
or Time Zone 6320 only
66
4 Printing 6310................................................................................................................................... 66
5 Printing 6320................................................................................................................................... 69
71
Part XI Appendix
1 Data Collection
...................................................................................................................................
Techniques
71
2 Class 1, Div 2
...................................................................................................................................
Information
71
Hazardous Location
..........................................................................................................................................................
Information
Control Drawing
..........................................................................................................................................................
3 Sensors
71
73
................................................................................................................................... 74
Magnetic Pickup
..........................................................................................................................................................
Secondary Ignition
..........................................................................................................................................................
Sensor
Water Cooled..........................................................................................................................................................
Pressure Sensor
75
77
78
4 Specifications
...................................................................................................................................
- 6310/CA
78
5 Specifications
...................................................................................................................................
- 6320/CA
79
6 Specifications
...................................................................................................................................
- Sensors
81
82
89
Customer Information
Customer Information
1.1
Introduction
Caution! A caution indicates actions that may have a major impact on the hardware,
software, database files, etc.
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 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 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 the
error messages? When do they occur? What you were doing when the problem occurred. For
1.3
Returning Items
For Repair
1. Call Product Support at (865) 330-1100 Ext. 1114 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 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 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 are
your 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 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 CDROM 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.
Extended Service Plan
Windrock offers Extended Service Plans (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 (865) 330-1100 Ext. 1117 for information concerning the current cost of
Extended Service Plans.
Customer Information
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 Lithium-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.
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 insulated gloves
to 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 that may be included with this kit comes in contact with
a 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 times to prevent
injury.
Caution!
The timing light that may be included with this kit may be used near
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 times to prevent
injury.
Caution!
Several cables are used with the analyzer and shaft encoder that may be
used near 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 and cables away from the rotating equipment at all times to
prevent injury. Be aware of the trip hazard cables on the floor can create.
2.1
Special Terms
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.
6320
A6320-00/CA
A6301-02
A6312-00
MP630030-00
A6306-03-00
A6304-01
A6305-00
A6060-00-08
A6082-XX-01
A6310-00-M/CA
A6310-00-SW/CA
A6030-01-06
Other parts may be present depending on the options selected and/or purchased.
2.4
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.
E-Moli Li-ion
2.4.1
Energy Access
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.
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 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 this
battery. For instructions on how to recycle this battery, call your local battery recycler.
2.4.1.1
E-Moli
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". This means that the battery will not work
until it is turned on. To do this, insert the battery into the left charger bay and press the "Re-calibrate"
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 high
capacity lightweight batteries available. They also have a special charger made just for Lithium-ion
batteries.
No battery detected
Fast charging
Fully charged
Re-calibrating
Re-calibrated
Standby
Error
Caution! Connection other than indicated may result in permanent damage to the
unit.
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.
Level 3
3.0 Amps
Sequential
3 hours each
SMBus 12v@1.2A
9 hours
9.5 oz
ABS GSM
Black
4.89 x 6.89 x 2.02
124 x 175 x 50
10
Getting Started
3.1
Connections
6310 Only
Several connections are provided on the portable analyzer unit. See the figures below for placement
of the connections. Looking at the rear panel to the far left, a connector labeled "KBD" is used for
attachment of an external PS2 style keyboard. 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 style keyboards 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 portable analyzer.
Next, there are two round "Lemo" transducer input connectors. These connectors are for the
transducers 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 power
pack. You may unplug the power pack from the charger base and plug it directly into the portable
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.
Getting Started
11
6320
VGA Port
USB Port
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 portable analyzer for larger desktop screen
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 Utility Menu Options for use of the 25 pin parallel port for file transfer to
Windows 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, Printing
6320.
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 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.
12
Getting Started
3.2
13
Keypad Functions
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.
ESC
Changes the sign of numeric inputs or adds a hyphen character to text entries.
END
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)
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
TAB
Period
Numeric 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
Keys
number associated with the option will execute the option.
Note:
3.3
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.
Hardware Configuration
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 and turn it on, you will be in a "Windrock Test Station" and "Test
Machine" area. However, prior to your data collection, you must first set up your own stations and
machines in the database. 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 and station. From this menu, you can
select a new machine or station by pressing "ESC" once or twice, respectively.
14
The "Windrock Test Station" and "Test Machine" should not be deleted or used for data
storage. 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 for
your 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 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. B&W can be
used to improve contrast in some cases.
Typically set to NO. If set to no, the processor runs at full speed
and 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.
Use blinking:
Typically set to YES. You may prefer to not have the cursor bar
blink. If so, set this option to NO.
Screen width:
Getting Started
15
or BOX.
Peak pressure only:
This option controls how the data collection process runs. When
set to YES, entering the data collection process will automatically
start the analyzer auto scanning data and update the screen with
each collection of data until the 3 key [STOP AUTOSCAN] is
pressed. Once the auto scan is stopped, the user is prompted to
save the latest data capture. The data collection process then
continues to collect the statistical data and display it.
Unit group:
DC Sensor correction:
Set to Zero Only for zero only balancing of the pressure sensor in
the CA mode. There is no zero function available in the CA (LITE)
mode.
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!
3.4
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.
16
3.4.1
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/CA models.
Station Selection Menu
From the "Machine Menu", press
"ESC" twice to return to the "Station
Selection Menu".
Select "2-Manage or 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 is not altered
without also changing the Windows database. In order to connect Windows to
Getting Started
17
the portable analyzer, 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-Manage or 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.
Note:
18
4.1
4.1.1
This is the minimum required to collect data with the analyzer. Further customization 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.
The machine menu is the entry point when turning on the analyzer. At this point, you may take one of
several actions. The menu options are outlined below:
Option 1:
"Data collection menu" is the point where data collection begins after a setup has
been entered for the selected machine.
Option 2:
Option 7:
"Utilities" are a set of utilities for calibration of sensors, connecting the analyzer to a
desktop computer, battery conditioning, and other helpful items.
Option 8:
"Select different machine" takes the analyzer back one menu level to select a new
machine. The Machine database setup is a set of menu options to configure the
machine's geometry, sensor points, collection points, fixed scaling, calculation, and
other related setup details.
19
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. This Menu
applies 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 choices
available or enter the numeric values as required.
Description
Machine Configuration
1 - Point setup
2 - Autoplot setup
3 - Generate default autoplots
4 - Empty autoplots
Software Configuration
20
5.1
Overview
The analyzer will power on to the "Last Station" and the "Last Machine" it was in prior to powering the
unit 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 following
menu options to reach the menu shown below:
1.
2.
3.
4.
21
The balancer mode has several menu options from which to choose. It is best to start with the setup
menu 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.
5.1.1
Menu Key
Menu Option
Description
Spark menu
Utilities
8, CA lite
8, CA
Setup
Press the "1" key or the "ENTER" key if the menu item is highlighted to select the (1 Setup
balancer/spark)
Every new machine added will have to be set up in the portable analyzer prior to running a peak
pressure balance and/or a spark survey. Once the new machine is set up, the set up information will
remain the same unless changed.
22
CYL LAYOUT:
2 OR 4 CYCLE ENGINE:
DEBOUNCE FACTOR:
23
SHOW CURVES:
SPARK LAYOUT:
24
Select the low pressure cutoff value for the report by pressing
the LEFT or RIGHT Arrow key. The balancer will report the
number of cycles that the peak pressure was below the low
cutoff value.
FINISHED:
Select the desired option (NO, YES hit enter) by pressing the
"LEFT or RIGHT Arrow" keys. If "YES hit enter", follow by
pressing the "ENTER" key to finish the machine set up, and
return to the initial Balance and Spark Menu screen. If the
RECORD PANEL POINTS option was selected, additional
screens will be displayed to define the panel points to be
selected.
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 will
return 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 a
Peak Pressure Balance and/or a Spark Survey. Once the new machine is set up, the
set up information will remain the same unless changed.
25
If you selected "YES" to "Record Panel Points", the following setup screens will allow you to define
those 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 if
you want the point added to the panel report. Panel points will show up in the order of their sequence
number. 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 is
used to bring up a list of alphabetic characters for text entry when a keyboard is not available. Looking
at the rear panel to the far right, a connector labeled "KBD" is used for attachment of an external PS2
style keyboard.
26
FINISHED:
Select the desired option (NO, YES hit enter) by pressing the
"LEFT or RIGHT Arrow" keys. If "YES hit enter", follow by
pressing the "ENTER" key to finish the machine set up and
return the 6310/CA to the initial Balance and Spark Menu
screen.
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 will
return to the initial Balance and Spark Menu screen.
5.1.2
Engine Balance
5.1.2.1
If "record panel points" is selected in the setup, you will be prompted to record those
readings before taking 'As Found data'.
If record panel points is selected in the setup, you will be prompted to record those
readings.
Note:
You can bring up the last "AS FOUND" and "AS LEFT" balance run for the day on the
analyzer. Other run numbers are available for viewing in the Windows software
package.
When first starting, the engine speed is determined by sampling the pressure curves. This engine
speed will then appear on the 'As Found' report.
27
The first screen you see will ask you to connect the
pressure transducer to a power cylinder and apply
pressure. After you hit any key, the estimate
speed routine will run. This function will count the
number of pressure peaks within a measured time
frame and calculate an estimated RPM.
Note:
This will take 10 seconds. If the estimated speed is not close to the known speed, then you need to
go back and adjust the debounce factor and trigger level in ENGINE SETUP. This speed is reported
on 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 valve
must be opened to apply pressure.
28
29
As pressure data is collected, the curve and peak pressure are displayed (if the 'Show Curves' option
is set to Yes in the setup) along with the cylinder number as shown in figure below. Once all samples
are 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.
30
Below is a sample of an "AS FOUND" report. Once the last cylinder is collected, a screen will pop up
showing the "AS FOUND" balance results. Each cylinder will have the average peak pressure
displayed for that cylinder. If the average pressure is outside the OK band, that cylinder should be
adjusted. After the adjustments are made, take "AS LEFT" pressure data.
31
Peak Pressure - Spread: The cylinder's difference from the high to low peak pressures of
the 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, and
load step.
2 - Adjust cylinder
When you select this, a list of the cylinders pop up. Highlight the
cylinder that you wish to adjust then, when you have the pressure
transducer attached, hit the enter key. A screen will then pop up
continuously showing you the average peak firing pressure for that
32
When you have finished adjusting cylinders, hit this option to take the
"AS LEFT" report. You will be indexed again through each cylinder to
take data. When done, the screen will reappear listing the results of
all 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 to
adjust 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 to
connect the analyzer to the PC and print your reports.
6 - Est. Speed
This will run the estimate speed routine again. The new speed value
is then displayed and written in the "AS LEFT" report.
7 - Print
If a printer is attached and configured, pressing the "7" key will make
a hard copy of the current screen to the printer. "AS FOUND" and "AS
LEFT" report data can be transferred to a PC running Application
Win63X0/CA software. Printouts can then be made from Windows.
8 - Show hi/lo #
This will change the display and replace the SD and Spread columns
with the hi/lo pressure count data.
9 - Exit
33
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 cylinder
selection list. This list is a pop up selection in which you must use the cursor keys to select which
cylinder to adjust.
34
The "U" - UNADJUSTED shows that the listed cylinder has not been adjusted. The "A" - ADJUSTED
shows that the listed cylinder has been adjusted and data saved. Select the cylinder to adjust and the
next screen will come up. Live data will be displayed on the screen.
35
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 pressure
while 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 cylinder
selection list and will indicate that a cylinder has been adjusted. Select the cylinder to adjust by
pressing 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 final
set of balance data. Taking "AS LEFT" data is the same as taking "AS FOUND" data. After the last
cylinder is taken the "AS LEFT" report will display.
36
If more cylinders are adjusted after the "Take as Left" has been performed, it will be necessary to
retake the "AS LEFT" data for all cylinders to get an accurate "AS LEFT REPORT".
5.1.2.2
The pressure sensor must be attached to the power cylinder and the indicator valve
must be opened to apply pressure. Hit any key when ready.
37
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 automatically
search 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 been
performed, the restart a balance run will display the message below. More cylinders can be adjusted.
5.1.2.3
If more cylinders are adjusted after the Take as Left has been performed, it is necessary to
retake the AS LEFT data for all cylinders to get an accurate AS LEFT REPORT.
38
39
The next screen in the "recall Old balance data" will be the "As Found Report" for the day selected. To
recall the "As Left Report", press the "4" key or press the "LEFT or RIGHT Arrow" keys to highlight the
4-RECALL AS LEFT" with the HOTBOX, then press the "ENTER" key to select.
5.1.2.4
Note:
This will take 10 seconds. If the estimated speed is not close to the known speed, you need to go
back and adjust the debounce factor and trigger level in ENGINE SETUP.
40
Note:
The pressure sensor must be attached to the power cylinder and the indicator valve
must be opened to apply pressure.
41
The next screen in the "Power Cylinder Monitor" mode will display the live data collection. This will
continuously cycle until any key is hit to exit.
5.1.3
Increase SD Range
Response
press to reset the running average bar
press to increase the cycle averages (5 cycle steps)
press to decrease the cycle averages (5 cycle steps)
press to raise the pressure range of the sample average
bars
press to lower the pressure range of the sample average
bars
press to raise the standard deviation range
Spark Menu
The Spark Survey mode is used for a detailed evaluation of the condition and integrity of the
secondary ignition system of a spark-ignited (SI) engine.
The Spark Survey Mode is an automated function that allows the user to simply connect the secondary
ignition capacitive clip to each spark plug lead and collect all the important parameters of the
secondary ignition signal. Once the user performs the set-up of the machine in the portable analyzer
for each machine the first time, the on-screen menus will instruct the operation of the collection of the
42
Ionization Voltage
Arc Duration
Arc Voltage
Rise Time (Ionization Time)
Arc Slope
Ring Down Voltage
No Arc, Voltage Problems
Arc Flyback
The major benefits of the Spark Survey Mode is to allow any individual to collect spark data quickly
and have intuitive information about the secondary ignition system. This reduces the need for an
ignition specialist to analyze the detailed secondary spark traces. With the computer performing all the
voltage measurements automatically on each parameter, this feature saves the time of having to
manually record these parameters. The analyzer will store these reports in memory for recalling old
spark 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 time
the "1 Take spark survey" is selected, it initiates a spark survey run and a new run number. You can
bring up any report run for the day by run number.
Function
Start a secondary ignition survey
To resume the spark survey that is in progress
Recall saved data for display and reporting
Jump to the oscilloscope mode for continuous display of a single point
Return to previous menu
43
Spark Survey
The first screen in the ignition survey mode is the "START IGNITION SURVEY" screen. Press any key
to 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 step
at a time) or the "UP or DOWN TAB" keys (five steps at a time). When the desired number of cycles is
highlighted, press the "ENTER" key to select.
44
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"
45
The next screen in the spark survey mode will display the message "Hit enter to take data". Pressing
the "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 before
proceeding. Press the "ENTER" key when ready.
Note:
The spark plug selection can be changed on this screen by pressing the "UP or
DOWN Arrow" keys to highlight "Chan 1 > L1 Side", then pressing the "RIGHT or
LEFT Arrow" keys to select the desired spark plug.
Note:
The loadstep selection can be changed on this screen by pressing the "UP or DOWN
Arrow" keys to highlight "Current loadstep > 1", then pressing the "RIGHT or LEFT
Arrow" keys to select the desired loadstep.
46
47
In the spark survey mode, live data collection screen, the Time Scale (Micro-seconds) and/or the
Voltage 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 available
scales each time the "0" key is pressed.
To change the voltage scale, press the "1" key. The voltage scale will toggle through the
available scales each time the "1" key is pressed.
Following the live data collection screen, the screen will return to the pick cylinder list. Continue
collecting data for all the spark plugs with a question mark "?"
48
The next screen in the spark survey mode is the "Ionization Voltage Report". The values shown are
derived from the portion of the spark example trace shown to the right in the square box.
49
0-Options:
2-Report Type:
To select "2-Report Type", press the "2" key or press the "LEFT or
RIGHT Arrow" keys to highlight with the "HOTBOX", then press the
"ENTER" key. The option menu selection pops up a screen as above
for selecting the following options: To select, press the associated
number key or highlight and press the "ENTER" key.
Note:
3-Restart:
To select "3-Restart", press the "3" key or press the "LEFT or RIGHT
Arrow" keys to highlight with the "HOTBOX", then press the "ENTER"
key. The next screen will display the message "PICK DAY TO
EXTRACT 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 or
RIGHT Arrow" keys to highlight with the "HOTBOX", then press the
"ENTER" key.
The next screen will display a single sample of the spark plug
secondary trace. Pressing the "5" key or the "ENTER" key will take
another single sample.
Note:
50
5.1.3.2
7-Print:
To select "7-PRINT", press the "7" key or press the "LEFT or RIGHT
Arrow" 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 portable
analyzer.
9-Exit:
Press the "9" key or press the "LEFT or RIGHT Arrow" keys to
highlight the "9-EXIT" with the HOTBOX. Then press the "ENTER"
key to select.
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 over
20,000 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 wired
properly. If the voltage is going positive (+) with respect to ground, this is referred to as
reverse polarity and indicates the wiring to the coil is reversed and may result in shorter
spark plug life.
Arc Duration The measured time period the actual arcing of the spark plug occurs. This is the time
measured between ionization voltage (breakdown) and the beginning of the ring-down voltage. The arc
duration is inversely proportional to the ionization voltage and rise time. The typical units are in
micro-seconds (uS)
In a controlled environment:
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 700
micro-seconds for different ignition systems. When measured times reduce, this indicates
widening gap and/or excessive ionization voltage requirements. As measured times
increase, this indicates a narrow gap and/or an incorrect measurement due to a low
ring-down voltage level.
51
Arc Voltage The voltage level required to maintain the arcing of the spark plug gap. This is the
voltage measured between the zero reference line and the arc duration level. This voltage is typically
less 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 gap
of the spark plug. This is also referred to as the ionization time. Ionization refers to the splitting apart of
the molecules to enable a current path for arcing of the spark plug. The rise time increases with an
increase in the ionization voltage. The typical units are in micro-seconds (uS)
In a controlled environment:
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 times
over 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 the
voltage 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 voltage
and 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 voltage
and 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 of
the plug gap.
Ring Down Voltage The measured peak voltage of the ring down oscillation of the coil. This is also
referred to as coil oscillation and/or unused energy. This is the energy remaining after the spark plug
arc demands cannot be maintained. The typical units are in volts peak. Anything that affects the R-C
time constant affects the amplitude and frequency of the ring down oscillations. A lack of ring down
typically indicates a poor plug wire connection in the coil tower.
No Arc, Voltage Problems Report This report identifies problems with spark plugs and/or other
secondary 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 the
ionization ramp. Please refer to the report for detailed description of the problem.
5.1.3.3
52
The next screen in the restart spark survey mode is the RESTART OF DATA COLLECTION FOR
SPARK SURVEY screen. To continue, press any key.
The next screen in the restart spark survey mode is the Pick cylinder to collect data screen. The
spark plugs that have data will have an asterisk (*), and the spark plugs the need data will have a
question mark (?). Select the desired spark plug by highlighting to continue the data collection process.
53
The next screen will be the "Arc Duration Report" for the desired day. From this screen, the menu
options are the same as when the data was taken. See the section on spark survey for more details.
54
Encoder-based Balance
6.1
This function is used to collect and display ignition data. See the
following sections for a complete description of the functions
available.
Balancer menu:
Encoder-based Balance
6.2
Spark
The Spark module is used to observe the waveform and voltage levels of the secondary ignition
traces. When the Spark program is started, the user is shown 3 options:
NEW SCAN:
EXIT PROGRAM:
55
56
While in the Spark trace window, the cursor is active and is moved with the TAB and arrow keys.
Key
1
2
3
4, ESC
5
6
7
8
9
Function
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.
To resample the signal.
To change run number.
Return to the setup menu
Turn on autoscan to sample the signal continuously.
This option will overlay six consecutive traces, then clear the screen and
repeat another six traces.
To store the trace.
To print the display to a printer if setup and connected.
Toggle the grid off/on.
Encoder-based Balance
57
Step Size:
This is a fixed field and is shown only for information. It is the time between
digitized samples.
Count:
This is the number of digitized samples that are taken for a trace. For a longer
view select, increase this number. For multi-strike systems, increase this
number to about 1200. Maximum number is 5,000.
Scale:
Use the RIGHT TAB key to bring up the scale selection box. This allows you
to pick the vertical scale of the graph. You may select from the following
scales.
Use the "UP or DOWN TAB" to change. When the desired scale is
highlighted, press the "ENTER" key to select.
When you are ready to collect data, hit the "END" key.
58
7.1
59
Third, a screen appears as shown above updating continuously with the input. Depending on the
sensor type, there may be variations to the screen shown.
For DC pressure sensors, the screen shown has the following information:
60
7.2
Function
Single Scan
Continuous
Peak Scan
Low Scan
Exit
Run/Hold
Next
Description
Updates the screen one time per hit of the key
Updates the screen continuously
Updates the screen if the new value exceeds the previous value
Updates the screen if the new value is less than the previous value
Exits the direct channel read function
Stops the screen update temporarily
Allows selection of a different sensor point
Encoder Setup
Encoder Setup
8.1
Shaft Encoder
61
Several fittings have been provided for adapting the encoder to your needs. It is preferred that a
friction 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 encoder
shaft with the center of the flywheel. If needed, use the provided elastic cord to provide additional
stability 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 (defined
in the machine setup). Also make sure that the number of pulses per revolution is set to the correct
number.
Caution!
On four stroke machines, do not switch the encoder or change the software
configuration when moving from the engine to the compressor. The analyzer
and software know the difference between the engine 4-stroke 0 to 720
degrees and compressor 0 to 360 degrees .
Also, it must be noted here that, in order to collect angular velocity information, you must be able to
collect 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 on
four-cycle engines, as necessary; for instance, if you are collecting data on a 4-cycle diesel engine and
are 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 the
encoder cable is disconnected, the encoder will retain its settings and TDC for up to one hour. This
allows the analyzer to be disconnected and reconnected as necessary without disruption except as
cautioned above.
Please note that in four-cycle mode, the encoder uses the A/B switch to switch between the power and
exhaust stroke. This setting is retained as long as the encoder is powered up.
Caution! Note that the software uses power conservation methods which will power
down the encoder while outside the data collection menu (this will turn off
power to the encoder). Either of these situations will re-power the encoder
62
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 in the
encoder.
Note:
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 pickup
can 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 will
advance 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 "To
Analyzer". Prior to taking data, make sure the "STROKE 4 - 2" switch is set properly for the engine
type (defined in the machine setup). Also, make sure that the number of pulses per revolution is set to
the correct number.
Caution!
Encoder Setup
63
Also, it must be noted here that, in order to collect angular velocity information, you must be able to
collect 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 on
four-cycle engines, as necessary; for instance, if you are collecting data on a 4-cycle diesel engine and
are unsure as to which stroke TDC is set.
Caution!
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 to
ensure proper timing information. Connect these devices to the connector marked "MAG
PICKUP".
A self-contained optical type pickup with a TTL output may be used with the shaft encoder or the
multi-event encoder. The optical sensor may be used directly with the multi-event encoder. To use
this type device, it must be placed on the machine with a known reference to TDC to ensure
proper timing information. If the self-contained style pickup is used, connect this device to the
connector marked "MAG PICKUP". Reflective tape must be placed on the flywheel or rotating
element at the TDC position for proper timing information.
8.4
Timing Light
With the encoder set up, attach the timing light to the connector
marked "STROBE". Aim the timing light at the timing marks on the
engine flywheel and pull the trigger switch.
With the trigger switch pulled and while observing the flywheel, look
for the timing marks. Using the arrow buttons, you can adjust
movement clockwise or counterclockwise as necessary to bring the
timing marks into view.
Once TDC has been found, the timing light should be disconnected
from the encoder to conserve battery power.
Caution!
The timing mark is crucial for accurate analysis. Make sure that there is
only one timing mark on the observed surface. Having more than one
timing mark will cause confusion and create the possibility of collecting
data based on the wrong TDC of the machine.
64
9.1
Transfer will now begin and may take several minutes to complete. Insure that the Windows software
indicates that the transfer process is complete. Do not disturb the analyzer or Windows 6310 software
while the transfer is in progress. Once the process has completed, exit the function in
Windrock\Win63xx and restart the analyzer by turning it off then back on. The new operating software
will be in place.
Note:
9.2
Verify the version on the startup screen to make sure the update has been
transferred.
10
10.1
65
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 into
sub..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 to
find which subdirectory belongs to a machine is to select the station and machine of interest and, at
the 'Station Selection Menu', select "X-engineering mode". The subdirectory displayed is the current
machine. 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 a
new station" and/or "Add a new machine". Add the new machine and select it. Repeat the above
procedure 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 is
complete, type '0' and Enter to re-start the program. When the program is started, you must now
select the new station/machine. It will have a complete copy of the other machine's setup.
10.2
Once the time and date have been set, press the "0" key and then press the "Enter" key to restart the
analyzer.
66
10.3
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 report
screen. The analyzer must be in LCD mode to print in proper black and white. You cannot use the
print function to print to a PostScript type printer.
67
DESKJET
GRAPHICS
LASERJET
LASERJETII
PAINTJET
THINKJET
Installing the GRAPHICS command on the analyzer requires the following steps:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Press the "ESC" key until the "Select a station" menu is reached
Attach the small keyboard to the analyzer
Press the "6" key, (5 in the 6310/CA Lite) "X engineering mode"
Type CD C:\ and press the "Enter" key
Type EDIT AUTOEXEC.BAT and press the "Enter" key
Press the "Down Arrow" key until the M_P line is highlighted and press the "Enter" key
Press the "Up Arrow" key to the blank line
Type LOADHIGH C:\DOS\GRAPHICS LASERJETII (or the type from the above list)
Type Mode LPT1 RETRY=R
Press and hold the "ALT" and "F" keys together to bring up the File menu.
Press and hold the "ALT" and "X" keys together and select "Save and exit", press the "Enter"
key to return to the DOS prompt
12. 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 the
GRAPHICS command, repeat the above steps.
Batch file before adding "Printer" command.
68
69
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 must
be 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.
70
Select the option you need and follow the on-screen instructions.
Appendix
11
Appendix
11.1
71
Before getting started with data collection on a machine, there are some helpful guidelines which
should 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 purpose
of 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 a
possibility of a thermal offset causing the pressure data to be slightly elevated.
11.2
Warning!
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 is
no warning label on your analyzer, follow all hazards atmosphere precautions prior to and
while using your analyzer.
Warning!
1. THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION 2, GROUPS A, B, C, D,
T4A HAZARDOUS LOCATIONS ONLY
2. WARNING - EXPLOSION HAZARD SUBSTITUTION OF COMPONENTS MAY IMPAIR
SUITABILITY FOR CLASS I, DIVISION 2, (MOLICEL LI-ION BATTERY MODEL ME202C)
and
AVERTISSEMENT - RISQUE DEXPLOSION LA SUBSTITUTION DECOMPOSANTS
PEUT RENDRE CE MATRIEL INACCEPTABLE POUR LES EMPLACEMENTSDE
CLASSE I, DIVISION 2 (MOLICEL LI-ION BATTERY MODEL ME202C)
3. WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT (AC POWER,
USB, VGA, ETHERNET, OR BATTERY) FROM ANALYZER UNLESS POWER HAS BEEN
72
Appendix
73
74
11.3
Sensors
Transducer Scaling Entries:
SENSOR
TYPE
UNITS ZERO
SCALE or 1V
FULL 4mA
or 5V
20mA
Engine AC
Engine DC
Spark
AC
DC
DC
PSI
PSI
Volts
1000 200
1000 0
50,000 0
1000
1000
50,000
0
0
0
Appendix
75
Completely self-powered, VRS (magnetic) sensors are rugged devices that do not require an external
voltage source for operation. They are generally used to provide speed, timing or synchronization data
to 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 the
speed of the monitored device changes and is usually expressed in peak to peak voltage (V P-P). One
complete waveform (cycle) occurs as each actuator passes the sensing area (pole piece) of the
sensor. The most commonly used actuator is a metal gear, but also appropriate are bolt heads (cap
screws are not recommended), keys, keyways, magnets, holes in a metal disc, and turbine blades. In
all 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 output
signal is generated by changing the strength of this field. This is caused by the approach and passing
of a ferrous metal target near the sensing area (pole piece). The alternating presence and absence of
ferrous metal (gear tooth) varies the reluctance or "resistance of flow" of the magnetic field, which
dynamically changes the magnetic field strength. This change in magnetic field strength induces a
current into a coil winding which is attached to the output terminals. If a standard gear is used as an
actuator, 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 of
the sensor must be traveling at a minimum velocity, or surface speed, to provide an adequate output
voltage. Typical minimum surface speeds for each sensor type can be found in the specifications
section. The bottom line in proper VRS sensor selection is to choose one that will meet the following
two 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.
76
Appendix
77
If in doubt, use the analyzer in o-scope mode, or an oscilloscope, to view the signal. The signal should
look like the figure below. If the polarity is reversed from this, use the hole/pin switch on the encoder
or reverse the A and B leads in the cable to reverse the signal to the proper polarity. The synch light
will 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 due
to the pickup going over a hole or object, a voltage is generated in the coil. The size of the signal is
proportional to the magnetic field change. Several factors determine the field change: permanent
magnet strength, number of turns in the coil, gap from pickup to target, material of target, and size of
target.
The bottom line is that you want a signal of about 1V peak and it must be at least 10 times the size of
any 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.
78
11.4
Specifications - 6310/CA
Basic Capabilities:
The data acquisition capabilities of the instrument are based upon 1-channel dynamic signal
capture as a function of crank angle position. The crank angle position is captured via an optical
shaft 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. Angular
velocity measurements are captured and displayed using the encoder information.
Input Signals
Channel 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 2
inputs, TTL compatible with 10Kohm pull-ups.
Current loop input
Range: 0-20 milliamp
Frequency response: DC to 5 Kilohertz (kHz)
Supply voltage: 24 VDC
Over-voltage protection to 2000V
Current loop input is used for the DC pressure sensor
Input impedance 470 ohm
Secondary Ignition using capacitive coupling probe
Range: 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 Input
Range: 0-10V
Frequency response: DC to 5 Kilohertz (kHz)
Supply voltage: 24 VDC
Over-voltage protection to 2000V
Voltage input is used for voltage signals
Input impedance: >1M ohm
Memory Capacity
16 Megabytes on-board RAM memory
2 Gigabytes of internal disk storage
Appendix
79
Communications
Parallel interface or USB for host communications
Power Supply
12V Lithium Ion rechargeable 3200 milliamp-hour battery
One battery standard
Battery is removable
External charger provided - 1.5 hr recharge time
External power input 12 - 18 VDC
Battery life: approximately 6 hours depending on use
Operating Conditions
Temperature: 15-120 F
Humidity: 0-90% non-condensing
Display
8.25" diagonal LCD, color.
Backlight automatically turned off after 30 seconds of non-use
Size of display: 8.25" diagonal
Pixels: 640 x 480
Contrast: software controlled
Processor
133 MHz AMD 586 with (2) Microchip RISC signal conditioning processors
Chassis
Material: EMI hardened anodized aluminum
Size and Weight: 10.5" X 8.5" X 2"
(6.75 lbs.)
Power: Long-life, field replaceable, rechargeable Li-ion battery
Keypad: 25 keys
11.5
Specifications - 6320/CA
Basic Capabilities, 6320:
The data acquisition capabilities of the instrument are based upon 1-channel simultaneous
dynamic signal capture as a function of crank angle position. The crank angle position is captured
via a shaft 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 signals.
Angular velocity measurements are captured and displayed using the encoder information.
Input Signals
Channel 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 input
Range: 0-20 mA
Frequency response: DC to 5 KHz
Supply voltage: 24 VDC
Over-voltage protection to 2000V
Current loop input is used for the DC pressure sensor
Input impedance 470 ohm
Ignition secondary using capacitive coupling probe
80
16 bits
1
1
1
unlimited (DSP programmable)
1 Mhz
Linux
1800 RPM
7 hours
USB - USB
USB printer w/ Linux driver
DSP processors
Appendix
Main user interface processor
Crankangle samples per degree
A/D converters
81
Debian GNU/Linux software included on the 6320 Portable Analyzer is covered by the GNU
General Public License, the GNU Lesser General Public License, and other licenses.
Additional software libraries included on the 6320 Portable Analyzer are covered by the GNU
Lesser General Public License. Copies of relevant licenses are available under
/usr/share/doc/*/copyright on the Portable Analyzer file system. To receive a DVD containing
the source code used to build the Debian GNU/Linux software and additional software
libraries, mail a copy of this page and a check for $10 shipping and handling to the following
address:
Windrock, Inc.
Suite 102
1832 Midpark Road
Knoxville, TN (USA) 37921
11.6
Specifications - Sensors
DC Pressure Sensor for Power Cylinder PT/PV Measurement
Range: 0-2000 psi (other ranges available 1000, 3000)
Response time: <0.5 ms (A6082-XX-01 <0.1ms)
Accuracy: 1%
Linearity: <1% full scale
Cycle life: >1.5 billion cycles
Operating Temperature Range: 0-450 F (temperature compensated)
Pressure fitting: Kiene adapter
Output: 4-20 mA, loop powered
Secondary Ignition Capacitive Pickup
Attenuation: 10,000 times
Range: 50 KV
Output Connector: BNC
Temperature Range: 200 F
Cable Length: 6 ft
82
12
Glossary of Terms
After Top Dead Center - After a piston in a reciprocating engine has reached the top of its travel and
starts 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 single
revolution.
Articulated Connecting Rod - A connecting rod that attaches to a master rod. An articulated rod on an
engine with integral mounted compressors is always a power connecting rod.
Articulation - In an integral engine/compressor, the irregular movement of the power pistons in relation
compressor piston due to the manner in which the power rods are connected to the compressor rod
instead 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 to
adjust 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) is
opened.
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 imagined
exerted during each power stroke of the cylinder to produce power at the flywheel or crankshaft. BMEP
is 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 amount
of BTU's (lower heating value) required to make one (1) brake horsepower for an hour. Measured in
BTU/BHP/Hr.
British Thermal Unit (Btu) - The amount of heat required to raise the temperature of one pound of
water one degree Fahrenheit.
Channel Resonance - Distortions of the pressure information caused by the excitation of the acoustic
resonance 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 the
discharge stroke; the space between the piston head end and the end of the cylinder plus the space
that exists around the valves, which are located near the cylinder ends.
Glossary of Terms
83
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 engine
where combustion takes place.
Compression - As applied to internal combustion engines, it is the mechanical ability of combustion
chamber components to hold pressure by the upward motion of the piston at the end of the
compression stroke. Compression in reciprocating engines can be measured dry (engine is down
without lubrication) or running (engine is running with lubrication).
Compression Pressure - The pressure of the air/fuel charge at the end of the compression stroke with
no ignition of the mixture. In a compressor cylinder, this is the pressure of the gas charge at the end of
the compression stroke.
Compression Ratio - The ratio of the volume of the charge at the beginning of the compression stroke
to 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 pressure
differential on each side of the piston and the inertial acceleration of the reciprocating motion. The
force is displayed as pounds compression and pounds tension.
Connecting Rod - The connection between the piston and the crankshaft in an engine or between the
crosshead 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 of
rotation 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
84
Glossary of Terms
85
86
Glossary of Terms
87
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 an
electrical spark being introduced into the cylinder. The usual cause is overheated parts or particles in
the combustion chamber.
Pressure Versus Crank Angle - A function of the engine analyzer to display pressure as it relates to
degrees of crankshaft rotation.
Pressure Volume - A function of the engine analyzer to display pressure in relation to volume of a
cylinder.
PT - (Pressure vs. Time trace) The dynamic pressure inside a cylinder referenced to crank-angle
position.
Pulsation - The pressure fluctuation in the nozzles, bottles, and pipping due to the flow variations in the
gas from the reciprocating compressor.
Pulsation Bottle - A receiver or vessel mounted directly to the flanges of a cylinder to minimize
pulsations. Sometimes called a pulsation damper.
PV - (Pressure vs. Volume) curve (sometimes referred to as "PV Cards"). It is the pressure in pounds
per square inch times volume in cubic feet. Pressure volume is used as an indication of work
performed.
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 to
linear
motion .
Rated Horsepower - The value used by engine manufacturers and operators to rate the power of an
engine, 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 cylinder
of the contaminated gases from the previous combustion cycle; (2) To cool the internal surfaces of the
cylinder; (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.
88
Index
Direct Channel Read
Index
-E-
Encoder 5
Multi-Event 62
Shaft Encoder 61
Engine Balancer 20
ESP 2
Extended Service Plan
18
-AAssistance 1
Avertissement
Risque D'Explosion
20
Handling 3
Hardware Configuration 13
Hazardous Location Information
Hole-Pin 61
-IIgnition Survey 43
Introduction 1
-K-
-CCare 5
Charger 8
Class 1, Div 2 Information
Cleaning 5
Configuration
Hardware 13
Connections
6310 10
Control Drawing 73
Customer 1
Assistance 1
Repairs 1
Trouble 1
-D-
-H-
71
-B-
Data Collection
Database 16
Date 65
58
71
Keyboard 13
Keypad 13
71
-MMachine 16
Machine Setup Menu 18
Magnetic Pickup 63
Measuring 71
Pressure 71
Temperature 71
Vibration 71
-OOperating Temperature
6320 71
Optical Pickup 63
Options
Hardware 13
71
89
90
-P-
-T-
Parallel Port 5
PHASE A-B 61
Power Cylinder Monitor 39
Pressure Measurements 71
Printing
6310 66
6320 69
Problems 1
TDC 61, 63
Temperature Measurements
Templates 65
Terms 5
Time 65
Timing Light 63
-RRepairs 2
Return Material Authorization
Returning Products 2
63
71
-U2
-SSafety 3, 4
Sensor 74
Magnetic Pickup 75
Pressure Water Cooled 78
Scaling 74
Secondary Ignition 77
Specifications 81
Settings
Date 6310 65
Date 6320 66
Time 6310 65
Time 6320 66
Time Zone 6320 66
Setup
General Machine 18
Setup Balancer/Spark 20
Software
Windows 6310 64
Windows 6320 64
Spark Mode 55
Spark Survey 43
Special Collection Modes 54
Speciifications
6310 78
6320 79
Sensors 81
Unpacking 5
USB 5
Utilities
Direct Channel Read 58
Power Cylinder Monitor 60
-VVGA 5
Vibration Measurements
71
-WWarning
AC Power 71
Battery Replacement 71
Battery Substitution 71
Board repair / replacement / modification 71
Cables used with sensors and encoder 71
Ethernet 71
Explosion Hazard 71
Hazardous atmosphere 71
Unit repair / modification 71
USB 71
VGA 71
Warnings 4
Encoder 4
Multi-Event 62
Pressure Sensor 4
Shaft Encoder 61
Timing Light 4, 63
Windows 64