63X0 CA Manual

Portable Analyzer CA Operations Manual
Windrock, Inc. 2009
1/29/2009
Legal Notices
Copyright 1997-2009 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
Part I Customer Information 1
1 Introduction ................................................................................................................................... 1 2 Customer Assistance ................................................................................................................................... 1 3 Returning Items ................................................................................................................................... 2 4 Hazardous Location ................................................................................................................................... Information, 6320 only 3 5 Handling Precautions ................................................................................................................................... 3 6 Warnings ................................................................................................................................... 5
Part II Read This First

2 Care 3 Unpacking
Batteries E-Moli Charger
1 Special Terms ................................................................................................................................... 6 ................................................................................................................................... 6 ................................................................................................................................... 6

.......................................................................................................................................................... ......................................................................................................................................................... .......................................................................................................................................................... 7 8 9
4 Batteries & Charging ................................................................................................................................... 7
Part III Getting Started
11
1 Connections................................................................................................................................... 11 2 Keypad Functions ................................................................................................................................... 14 3 Hardware Configuration ................................................................................................................................... 14 4 Stations & Machines ................................................................................................................................... 16
Station & Machine .......................................................................................................................................................... Setup 17
Part IV Machine Setup, 63X0/CA with encoder only

Machine Setup .......................................................................................................................................................... Menu
19
19
1 Setting Up a ................................................................................................................................... Machine, 63X0/CA with encoder only 19
Part V Balancer/Spark Setup and Data Collection

1 Overview
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
22 27 27 37 38 40 42 44 51 52 54
................................................................................................................................... 21
Part VI Encoder-based Balance
55
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II
Portable Analyzer CA Operations Manual 1 Special Collection ................................................................................................................................... Modes 55 2 Spark ................................................................................................................................... 56
Part VII Utility Menu Options
59
1 Direct Channel ................................................................................................................................... Read 59 2 Connect to Windows ................................................................................................................................... 6310 only 61 3 Power Cylinder ................................................................................................................................... Monitor 62 4 Discharge Battery ................................................................................................................................... 6310 only 62 5 Check for Bad ................................................................................................................................... EXE's 6310 only 62
Part VIII Encoder Setup
63
1 Shaft Encoder ................................................................................................................................... 63 2 Multi-Event ................................................................................................................................... 64 3 Magnetic Pickup ................................................................................................................................... 65 4 Timing Light................................................................................................................................... 65
Part IX Loading New Software
66
1 Windows Install ................................................................................................................................... 6310 only 66 2 Windows Install ................................................................................................................................... 6320 only 66
Part X Operating System Commands
67
1 Machine Template ................................................................................................................................... 6310 only 67 2 Setting Time................................................................................................................................... and Date 6310 only 67 3 Set Date, Time ................................................................................................................................... or Time Zone 6320 only 68 4 Printing 6310 ................................................................................................................................... 68 5 Printing 6320 ................................................................................................................................... 71
Part XI Appendix
2 Sensors
73
1 Data Collection ................................................................................................................................... Techniques 73 ................................................................................................................................... 73

74 76 77 Magnetic Pickup .......................................................................................................................................................... Secondary Ignition .......................................................................................................................................................... Sensor Water Cooled.......................................................................................................................................................... Pressure Sensor
3 Specifications ................................................................................................................................... - 6310/CA 77 4 Specifications ................................................................................................................................... - 6320/CA 78 5 Specifications ................................................................................................................................... - Sensors 80
Part XII Glossary of Terms Index
81 88
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Customer Information
1
1.1
Introduction
Portable Analyzer Manual The following sections briefly summarize the functions you will use to set up and operate your portable CA analyzer by Windrock, Inc. This help version is 3.0. Data storage and machine setups are stored locally to the analyzer thus no host PC is required. Data stored within the analyzer can be directly backed up to such devices as zip drives if 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. Prerequisites The manual is written with the assumption that you are familiar with the basic operation of a personal computer and is not intended to be a substitute for the documentation supplied with a computer or 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) 539-5944 Ext. 4019. 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 example, what mode were you in? What steps did you go through? Try to determine before
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Portable Analyzer CA Operations Manual 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) 539-5944 Ext. 4019 to obtain a return authorization number. Please write it clearly and prominently on the outside of the shipping container. 2. Please enclose a letter that describes the reason(s) you are returning the item. 3. Insure your package for return shipment. Shipping costs and any losses during shipment are your responsibility. COD packages cannot be accepted and will be returned unopened. For Credit 1. Call Product Support at (865) 539-5944 Ext 4019 to obtain a return authorization number. Please write it clearly and prominently on the outside of the shipping container. 2. Return all accessories originally shipped with the item(s). Include cables, software diskettes, manuals, etc. 3. Enclose a note that describes the reason(s) you are returning the item(s) for credit. 4. Insure your package for return shipment. Shipping costs and any losses during shipment 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) 539-5944 Ext. 4030 for information concerning the current cost of Extended Service Plans.
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1.4
Hazardous Location Information, 6320 only
Caution!
If your 6320 Analyzer has been approved for use in a hazardous location, Class 1 Div. 2, there will be a hazardous atmosphere warning label on the back of the analyzer. If there is no warning label on your analyzer, fallow all hazards atmosphere precautions prior to and while using your analyzer.
Caution!
1. THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION 2, GROUPS A, B, C, D HAZARDOUS LOCATIONS ONLY 2. WARNING - EXPLOSION HAZARD SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2, and AVERTISSEMENT - RISQUE DEXPLOSION LA SUBSTITUTION DECOMPOSANTS PEUT RENDRE CE MATRIEL INACCEPTABLE POUR LES EMPLACEMENTSDE CLASSE I, DIVISION 2
Caution!
3. WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS, and AVERTISSEMENT - RISQUE DEXPLOSION - AVANT DE DCONNECTER L EQUIPEMENT, COUPER LE COURANT OU SASSURER QUE LEMPLACEMENT EST DSIGN NON DANGEREUX 4. WARNING - EXPLOSION HAZARD - DO NOT RE PLACE BATTERY UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS; and AVERTISSEMENT - RISQUE DEXPLOSION - COUPER LE COURANT OU SASSURER QUE LEMPLACEMENT EST DSIGN NON DANGEREUX AVANT DE REPLACER LA BATTERIE
1.5
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.
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Portable Analyzer CA Operations Manual 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.
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1.6
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.
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2.1
Read This First

Special Terms
6310 / 6320 Analyzer Portable data collection instrument or analyzer. Shaft Encoder Device used to convert crankshaft position into electrical impulses. Parallel Port Printer and communications link between the analyzer and host computer. Transducer / Sensor Device used to convert mechanical measurements into electrical signals. USB Universal Serial Bus 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.
PARTS LIST (Standard Package)

Part Analyzer Battery/Batteries Battery Charger Carrying Case with Cut Foam USB Communications Cable Leather Case (on analyzer) Carry Strap DC Pressure Cable DC Pressure Sensor (High Temp) Manual Software CD-ROM Secondary Ignition Pickup 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.
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Read This First 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. The analyzer kit contains one or more of the pictured batteries and charger shown below.
E-Moli Li-ion
Energy Access
2.4.1
Batteries
For Optimum Performance of Your Batteries This battery needs to be charged before use. Refer to the "Instructions for Use of the 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.
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Portable Analyzer CA Operations Manual 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 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
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". 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"
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Read This First
button and let the battery sit 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 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.
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: Green Flash: Green Solid: Yellow Flash: Yellow/Green: Yellow Solid: Red Flash: 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.
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Portable Analyzer CA Operations Manual The charger automatically senses this and simply drops back into the normal charge mode. Specifications SMBus: Charge Rate: 2 Bays: Charge Time: Recalibration: Recal Time: Weight: Material: Color: Dimension Inches: Dimension mm: 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
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Getting Started
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3
3.1
Getting Started
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.
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A6310-00/CA and A6320-00/CA Rear Panel Connectors 6310

VGA Port
6320
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 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.
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Getting Started
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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. +/END HOME Changes the sign of numeric inputs or adds a hyphen character to text entries. Drops the user to the end of a screen or to the end of a list. 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 to move 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. Advances the user ahead multiple entries or multiple pages. Returns the user back multiple entries or multiple pages. Enters a decimal point as needed for numeric entries.
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: 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
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.
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Getting Started Note:
15
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. 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. 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. Typically set to YES. You may prefer to not have the cursor bar blink. If so, set this option to NO. Typically set to 40 column. The style of the cursor may be changed between ARROW, BAR,
Monitor type:
Use power save:
Caution!
Use blinking: Screen width: Text Cursor Style:
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Portable Analyzer CA Operations Manual or BOX. Peak pressure only: This is set to YES for a CA Lite and NO for a CA with encoder option and want to configure the analyzer to make crank-angle based measurements (IHP, peak angle, ignition timing). 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. 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). Allows selecting either Standard or Metric Units. 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. This default is NO. Set to YES if using an encoder. This is set to YES to receive a reminder to transfer the setups to the computer after setups have changed in the analyzer.
Autoscan first in take data:
Use unit conversion:
Unit group: DC Sensor correction:
Is this a CA with encoder: Setup (D6) files warning:
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
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 from 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 and crank angle related data collected files.
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Getting Started The structure looks like this: /EVPORT | Station 000 (S000) | | | Machine 000 (M000) | | | | | Setup | | Crank angle data | | | | | Machine 001 (M001) | | | Machine 002 (M003) | | | ... Station 001 | ...
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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. This structure is automatically created by the software.
3.4.1
Station & Machine Setup

The first steps in setting up a new station and machine are described in the following steps. Note: This must be done prior to being able to duplicate (copy) a previous setup from 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-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 is not altered without also changing the Windows database. In order to connect Windows to the portable analyzer, these names must match exactly (character and case) or a connection will not be allowed.
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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. Note: If your analyzer is a 63X0/CA non encoder balancer, proceed to the section on "Balancer/Spark Setup and Data Collection". Skip the "Machine Setup, 63X0/CA w/encoder" section. If your analyzer is a 63X0/CA w/encoder, proceed to the section on "Machine Setup, 63X0/CA plus encoder". After following those instructions, then proceed to the section on "Balancer/Spark Setup and Data Collection".
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Machine Setup, 63X0/CA with encoder only
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4
4.1
4.1.1
Machine Setup, 63X0/CA with encoder only

Setting Up a Machine, 63X0/CA with encoder only
Machine Setup Menu
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, the screen below will be shown after power up. Alternately, you can use the Win63X0/CA software auto generate features.
Machine Menu, Analyzer CA with Encoder only 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 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: Option 2: Option 7: Option 8: "Data collection menu" is the point where data collection begins after a setup has been entered for the selected machine. "Setup database" is a set of menu options to configure the machines geometry, sensor points, collection points, fixed scaling, and other related setup details. "Utilities" are a set of utilities for calibration of sensors, connecting the analyzer to a desktop computer, battery conditioning, and other helpful items. "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.
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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.
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 Number of cylinders, bore, stroke, etc. Define individual sensor points Setup route for data collection Arrange groups of sensor points for collection Arrange groups of sensor points for plotting Automatically create a default set Erase all existing autoplots and start over Setup predefined scales for display of data. Does not apply to /CA analyzer Does not apply to /CA analyzer Modify standard defaults for this machine only Returns analyzer to machine menu
Menu Key Menu Option 1 2 3 Machine Configuration Machine Sensor Setup Collection point / Plot Setup 1 - Point setup 2 - Autoplot setup 3 - Generate default autoplots 4 - Empty autoplots 4 5 6 7 8 Fixed Data Scales Not available MA/CA Not available MA/CA Software Configuration Return to machine menu
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Balancer/Spark Setup and Data Collection
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All non-encoder functions must be set up in the analyzer and the set ups transferred to the Win63X0/ CA program.
5.1
Overview
The analyzer will power on to the "Last Station" and the "Last Machine" it was in prior to powering 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. 1 - Data collection menu 4 - Balancer menu 4 - Balancer / Bal & spark menu 2 - Nonencoder balance and spark
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Portable Analyzer CA Operations Manual 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. Menu Key 1 2 Menu Option Setup balancer / spark Balance engine nonencoder Description Enter configuration parameters for the program Balance an engine using pressure sensor with out crank angle position Used to start the program after a battery change at the last cylinder data that was collected Recall data that has been stored on the analyzer from a previous balance Enter the spark survey menu A set of analyzer utilities - specifically, connection to the Windows application software, Win63X0/CA. Connects the analyzer to an "online" system Use to select a different unit on which to run a survey
Restart balance run
Recall old balance data
5 6
Spark menu Utilities
7 8, CA lite 8, CA
Online balance Link Select different machine
Return to special data menu Returns to previous menu
5.1.1
Setup
Press the "1" key or the "ENTER" key if the menu item is highlighted to select the (1 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.
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MAX SENSOR PRESSURE:
Select the desired pressure sensor range (1000, 2000, or 3000 psig @ 20ma) by pressing the "LEFT or RIGHT Arrow" keys. Select the number of power cylinders (1 20) for the machine by pressing the "LEFT or RIGHT Arrow" keys. Select the power cylinder numbering scheme (STRAIGHT, LEFT/RIGHT, ODD/EVEN) by pressing the "LEFT or RIGHT Arrow" keys. Select the use of the spike filter (NO or YES or YES-HEAVY) by pressing the "LEFT or RIGHT Arrow" keys. The spike filter should be used when indicator tube detonation is present on the pressure trace (i.e. IR-KVS, Nordberg). Select the desired maximum percentage of power cylinder imbalance (0 10) by pressing the "LEFT or RIGHT Arrow" keys. Select the proper number of cycles (2 CY., 4 CY.) by pressing the "LEFT or RIGHT Arrow" keys. Select the desired debounce factor (1 33) by pressing the "LEFT or RIGHT Arrow" keys. The debounce factor defaults to 3 and should work satisfactorily on the majority of machines. This is the number of consecutive pressures that must exceed the trigger level (psi) before the peak detector engages or ends.
NUM POW CYL: CYL LAYOUT:
USE SPIKE FILTER:
PERCENT +/- OK BAND:
2 OR 4 CYCLE ENGINE: DEBOUNCE FACTOR:
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Portable Analyzer CA Operations Manual TRIGGER LEVEL (psi): Select the desired trigger level (30 100) by pressing the "LEFT or RIGHT Arrow" keys. The trigger level defaults to 30 and should work satisfactorily on the majority of machines. This is the trigger level that pressure must exceed before the peak detector is enabled. It is also the level that pressure must fall below to reset the peak detector. The level is in psi. It is normally set somewhere between 30-60 psi. Select the desired viewing option (NO, YES no pause, YES with pause, NO pause, NO SD, Pause, NO SD) by pressing the "LEFT or RIGHT Arrow" keys. NO When taking data, the peak pressure text data only will be present on the screen. When finished with the data sample, it will automatically go to the select cylinder list. YES no pause When taking data, the peak pressure curves will be present on the screen. When finished with the data sample, it will automatically go to the select cylinder list. YES with pause When taking data, the peak pressure curves will be present on the screen. When finished with the data sample, it will be necessary to hit any key to return to the select cylinder list. NO pause, NO SD When taking data, the peak pressure curves will be present on the screen. Standard deviation will not be displayed. When finished with the data sample, it will automatically go to the select cylinder list. Pause, NO SD When taking data, the peak pressure curves will be present on the screen. Standard deviation will not be displayed. When finished with the data sample, it will be necessary to hit any key to return to the select cylinder list. REDUCED SCALE ON CURVES: Select the desired scaling option (NO, HALF, 3/8, QUARTER, 5/8, 3/4) by pressing the "LEFT or RIGHT Arrow" keys. This scaling factor is used for the pressure curves vertical scale. When set to NO, the vertical pressure scale will be zero up to the "MAX SENSOR PRESSURE" that has been selected. Other scale selections will scale to the selected fraction of the "MAX SENSOR PRESSURE". # SPARK PER CYLINDER: SPARK LAYOUT: Select the desired number of spark plugs per cylinder (0, 1, 2) by pressing the "LEFT or RIGHT Arrow" keys. Select the desired spark plug layout and naming convention (Use Side/Center, Use Left Right, Use A/B, Use Top/Bottom, Use CS/OCS) by pressing the "LEFT or RIGHT Arrow" keys. Select the desired horizontal scaling factor (NO, YES) by pressing the "LEFT or RIGHT Arrow" keys. Most CD (capacitor discharge) ignition systems have 500 Us or less arc durations and the SHORT DURATION can be set to YES. This will be the default scaling factor while taking data,
SHOW CURVES:
SHORT SPARK DURATION:
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Balancer/Spark Setup and Data Collection however, this scaling factor can be changed while taking data. MULTI STRIKE SPARK:
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Select the proper machine spark type (NO, YES) by pressing the "LEFT or RIGHT Arrow" keys. When using the spark survey on a multi-strike ignition system, the software will attempt to analyze the first ignition event of the series. This is typically set to NO. YES should only be used if directed so by Windrock Customer Support or Engineering. If this is set to YES, the Ramp Time will not be shown on the reports. 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. Select the high 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 above the high cutoff value. Select the PANEL POINT OPTION (NO, YES) by pressing the LEFT or RIGHT Arrow key. Selecting YES will allow recording as found and as left panel data including fuel usage and bsfc values. Selecting NO will deactivate panel points in collection routine. There are 12 predefined panel points to choose from, 6 user defined points, and exhaust temperatures for each cylinder. 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.
FAST RAMP TIME:
PRESS CUTOFF LOW
PRESS CUTOFF HIGH
RECORD PANEL POINTS
FINISHED:
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.
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Portable Analyzer CA Operations Manual 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.
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Balancer/Spark Setup and Data Collection Est Fuel Savings:
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If panel fuel flow is recorded, you may estimate the fuel savings from the "AS FOUND" readings to the "AS LEFT" readings by using the "LEFT or RIGHT Arrow" keys to tab to the correct measurement unit. (YES ft3/min, Yes ft3/hr, Yes MMft3/day, Yes m3/min, Yes m3/hr, Yes MMm3/day, or No). Enter the current fuel cost in $/MSCF or $/Mm3. Select the desired option (NO, YES hit enter) by pressing the "LEFT or RIGHT Arrow" keys. If "YES hit enter", follow by pressing the "ENTER" key to finish the machine set up and return the 6310/CA to the initial Balance and Spark Menu screen. If you hit "ESC", the program will then prompt a "WARNING Escape was hit - If you have made changes they will be lost. Save changes? (Y/N)" If you want to save the set up changes, press the "HOME-YES" key. If you do not want to save the set up changes, press the "END-NO" key. Pressing the "HOME-YES" key or the "END-NO" key will return to the initial Balance and Spark Menu screen.
Fuel Cost ($/unit): FINISHED:
5.1.2
5.1.2.1
Engine Balance
Engine Balancer - Non encoder This is the option to select when you are ready to balance the engine. Note: If "record panel points" is selected in the setup, you will be prompted to record those readings before taking 'As Found data'.
In taking data, there are three main steps in balancing: 1. Take "AS FOUND" data. This is the engine balance before any adjustments are made. If record panel points is selected in the setup, you will be prompted to record those readings. 2. Adjust cylinders. This is when the cylinders are adjusted to even out the peak pressures. 3. Take "AS LEFT" data. This is the engine balance after all adjustments are made. Note: Note: If record panel points is selected in the setup, you will be prompted to record those readings. 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.
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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:
The pressure sensor must be attached to channel one.
This will take 10 seconds. If the estimated speed is not close to the known speed, then you need 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.
After the speed has been estimated, the starting balancer screen will appear. Hit any key to go to the "select number of cycles to take" screen. The default number is pre-selected. Simply hit enter to continue. If a different number of cycles is to be collected, select it now by using the up / down arrow keys (for one step at a time) or the UP or DOWN TAB keys (for five steps at a time) and pressing enter. Note: The number of cycles selected in this screen will be the number of cycles used in the "AS FOUND", "Adjust cylinder", and "AS LEFT" data collection modes.
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After you have set the number of cycles, a list of the cylinders will be shown. Select the first one to start collecting data. A '?' represents a point for which data has not been taken. A '*' represents a point for which data has been already taken.
Once the point has been selected, you are given the option to change the cylinder selection or the load step before actually collecting the data. On this screen, the cylinder selection can be changed by placing the cursor on the "Chan 1 >" field and pressing the right/left arrow keys. The current load step may also be changed by placing the cursor on the appropriate field and pressing the right/left arrow keys.
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Portable Analyzer CA Operations Manual 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.
The "Pick Cylinder" screen will appear and the "?" indicator will change to a "*" showing that the data has been collected and the cursor bar will advance to the next cylinder. Any cylinders with a "?" still require data to be taken.
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When the last cylinder's data is collected, the screen will show a message box with "Finished collecting as found data, Now adjust cylinders, Hit any key to continue". Pressing any key will display the "AS FOUND" balance report shown below or Hit the "END/NO" key to resample the last point.
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.
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Report Column Explanations

Top Box (Text Information Section) Power Cylinder Name: Peak Pressure - Mean: Peak Pressure - Diff: Peak Pressure - SD: This is the cylinder ID for identification. The mean (average) peak firing pressure for each cylinder based on the number of cycles selected. The difference each cylinder's PFP is from the engine average mean peak pressure. The standard deviation of the cylinder's peak pressure sample based on the number of cycles selected.
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.
Menu "Hot Box" Keys

The menu section of the "AS FOUND REPORT" has many menu options. 0-Options: A submenu will pop up with the following selections: This is for changing the maximum pressure scale on the statistical bar graph. This is for changing the plus and minus percent bands on the cylinder balance bars. This is for changing the minimum pressure scale on the statistical bar graph.
"0- CHANGE PRESSURE MAXIMUM"
"1-CHANGE PRESSURE PERCENT BAND"
"2-CHANGE PRESSURE MINIMUM"
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
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cylinder. It will also show you the engine average (this will not change; it is based on the "as found data" or "as left data" only). Use this screen to adjust the cylinder. When you have finished adjusting the cylinder, hit any key. You will return to the report showing data for all the cylinders. The cylinder you have just adjusted will now be marked with DONE. You can readjust this cylinder if you wish by selecting it again. 4 - Take As Left When you have finished adjusting cylinders, hit this option to take the "AS LEFT" report. You will be indexed again through each cylinder 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. This will run the estimate speed routine again. The new speed value is then displayed and written in the "AS LEFT" report. 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. This will change the display and replace the SD and Spread columns with the hi/lo pressure count data. This will exit the program back to the main menu.
6 - Est. Speed 7 - Print
8 - Show hi/lo # 9 - Exit
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Portable Analyzer CA Operations Manual 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.
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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.
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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.
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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 Restart Balance Run If a partial balance run is performed and, for any reason, the portable analyzer is turned off (i.e. phone call, dead battery, etc.), when the unit is powered back on, press the 3 key 3-rEstart a balance run to resume the balance run that was in progress. The next screen in the restart a balance run mode is the ESTIMATE SPEED screen. This function will count the number of peak pressures within a measured time and calculate an estimated RPM. To continue, press any key. Note: 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.
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Portable Analyzer CA Operations Manual 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. 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.
5.1.2.3
Recall Old Balance Data The portable analyzer will save all the "AS FOUND" and "AS LEFT" balance runs for each machine. To recall an existing balance run, on the main menu, press the "4" key or press the "UP or DOWN Arrow" key to highlight the "4-recall Old balance data" and then press the "ENTER" key.
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The next screen in the "recall Old balance data" will appear as below. The message "PICK DAY TO EXTRACT BALANCE DATA" will appear. Press the "UP or DOWN Arrow" keys to highlight the desired day, then press the "ENTER" key to select.
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Portable Analyzer CA Operations Manual 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
Power Cylinder Monitor The "Power Cylinder Monitor" is a stand-alone pressure monitoring utility that can be used to check individual cylinders without entering the "Balance engine nonencoder" mode. When first starting, the engine speed is determined by sampling the pressure curves. The first screen will tell you to connect the 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:
The pressure sensor must be attached to channel one.
This will take 10 seconds. If the estimated speed is not close to the known speed, you need to go back and adjust the debounce factor and trigger level in ENGINE SETUP.
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Note:
The pressure sensor must be attached to the power cylinder and the indicator valve must be opened to apply pressure.
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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.
There are six menu items with Control keys assigned. Key Function 1 Reset Reference to Running Average 4 Increase Cycles 6 Decrease Cycles 5 Increase Pressure Range 7 8 Decrease Pressure Range 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
5.1.3
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
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spark data. When the user is finished collecting the data on each spark plug, the user will have access to eight reports showing detailed ignition statistical parameters including: 1. 2. 3. 4. 5. 6. 7. 8. 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.
From the Spark Menu, select one of the options listed. Key 1 2 3 4 5 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
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Portable Analyzer CA Operations Manual 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.
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The next screen in the spark survey mode will display the message "Pick cylinder to collect data". The desired spark plug can be selected 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 spark plug is highlighted, press the "ENTER" key to select. Note: Note: The spark plug will display a question mark before taking data "? NEED DATA" The spark plug will display an asterisk after taking data "* - HAVE DATA"
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Portable Analyzer CA Operations Manual 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: Note: The secondary ignition sensor must be attached to the spark plug lead before proceeding. Press the "ENTER" key when ready. 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. 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.
Note:
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Live data collection screen

Below are explanations of the values shown on the plot: Negative Pulling The voltage is pulled negative with reference to ground. This is the normal polarity of a secondary circuit. This means the current is going from the spark plug's center electrode to the ground electrode. Positive Pulling The voltage and current is going from negative to positive. This is reverse polarity of a secondary circuit. This means the current is going from the ground electrode to the spark plug's center electrode. Ionization Voltage The voltage level reached to ionize the gas molecules in the spark gap (5-20 KV) Rise Time The time required to ionize the spark gap (8-40 Us) Arc Duration The time duration the actual arc occurs Arc Voltage The voltage level across the spark gap during the arc Slope The slope of the arc duration (Flat, Positive, Negative)
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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 "?"
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Balancer/Spark Setup and Data Collection When the final spark plug is finished with live data collection, the message will pop up, "Finished collecting spark survey, Hit any key to continue"
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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.
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Menu "Hot Box" Keys

The menu section of the "Ignition Survey Reports" has many menu options.
0-Options:
To select "0-Options", press the "0" key or press the "LEFT 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: "0- CHANGE KV MAXIMUM". This is for changing the maximum kilo-volt scale on the statistical bar graph. "1-CHANGE KV PERCENT BAND". This is for changing the plus and minus percent bands on the spark plug statistical bars. "2-CHANGE KV MINIMUM". This is for changing the minimum kilo-volt scale on the statistical bar graph.
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: Report definitions are further described in the next section. Each report can be viewed and printed as necessary.
3-Restart:
To select "3-Restart", press the "3" key or press the "LEFT or 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. 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: Single samples are for troubleshooting purposes and will not affect statistical reports.
5-Single Sample:
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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. 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.
9-Exit:
5.1.3.2
Ignition Survey Report Definitions The following report descriptions give the details of what is displayed and the meanings of the values. Ionization Voltage The voltage level required to ionize the compressed air/fuel molecules within the gap of the spark plug. This is also referred to as the ignition breakdown voltage. Ionization refers to the splitting apart of the molecules to enable a current path for arcing of the spark plug. Higher ionization voltages produce a higher rise time.The typical units are in Kilo-Volts (Kv). In a controlled environment: 1. 2. 3. The wider the spark plug gap, the more voltage required to ionize the gap. The narrower the spark plug gap, the less voltage required to ionize the gap. 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.
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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
Restart Spark Survey If a partial spark survey is performed and, for any reason, the portable analyzer is turned off (i.e phone call, dead battery, etc.), when the unit is powered back on, press the 2 key 2-rEstart spark survey to resume the spark survey that was in progress.
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The next screen in the restart spark survey mode is the TO RESTART IGNITION SURVEY screen. To continue, press any key.
The next screen in the restart spark survey mode is the RESTART OF DATA COLLECTION 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.
At this point, continue on as normal during a spark survey.
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Portable Analyzer CA Operations Manual Recall Spark Survey The portable analyzer will save all the "Spark Surveys" for each machine. To recall an existing spark survey, on the main spark menu, press the "3" key or press the "UP or DOWN Arrow" key to highlight the "3 recall Old spark survey". Then press the "ENTER" key. A popup box will display all dates for data taken and stored on the analyzer. Use the up / down arrow keys to highlight the date to view and press the ENTER key.
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.
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Encoder-based Balance
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6
6.1
Encoder-based Balance
Special Collection Modes
This menu allows access to several special modes for the analyzer. With these modes, several detail functions may be accomplished that are non-crankangle related.
Spark trace mode:
This function is used to collect and display ignition data. See the following sections for a complete description of the functions available. This is a submenu with two main functions for balancing an engine using peak firing pressure and ignition survey mode to look at ignition system details.
Balancer menu:
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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: PLOT OLD DATA: EXIT PROGRAM:
Take new data. Recall stored data. Return to the menu.
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Encoder-based Balance Selecting "NEW SCAN" brings up the following sample screen and has several menu options.
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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.
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Portable Analyzer CA Operations Manual Select 4-Menu brings up the following screen.
Step Size: Count:
This is a fixed field and is shown only for information. It is the time between digitized samples. 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. 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.
Scale:
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.
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Utility Menu Options
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Utility Menu Options
The options listed in the menu to the left provide the user with extra utilities to help with sensor calibration, data transfer, battery management, and operating software integrity.
7.1
Direct Channel Read

This function allows the user to directly read out a sensor's static voltage or current. The primary use of direct channel read is for verifying calibration and proper operation of pressure transducers.
First, pick a sensor from the sensor list to display. By picking the sensor from the sensor list, calibration parameters and engineering units are used from the database previously set up.
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Second, select the channel to which the sensor is physically attached on the rear panel. For the 63X0/CA, use channel one.
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:
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Utility Menu Options The channel number being used, the sensor point name, three columns of data, the zero factor (explained below), and the current mode.
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The left column shows the zero adjusted values. If the "Zero dc press sensors" menu option under "Data Collection Menu" was used (CA with encoder only), an atmospheric reference point is applied. The center column is non-zero adjusted. No correction is applied and the raw values are listed. The third column shows the line's value type. For most cases, the "Engr. Units" (engineering units) line is used. This will show the actual readout of the pressure applied to the sensor. The additional three lines are used by Windrock in calibration of the analyzer and other types of sensors. The Zero Factor line shows the bit count of the correction applied when the sensor was zeroed. Bit count is a digital electronics value. At the top of the display, a bar graph will display the current sensor value and will update based on the mode selected. By default, the bar graph is in continuous mode. Below the bar graph is a small bar showing the peak value reached until the [9-Reset Bar] hot key is pressed to reset the bar to zero. The mode line shows the current mode of the screen updating process. There are several modes which can be used for various purposes. Below are explanations. Key 0 1 2 3 4 5 7 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
7.2
Connect to Windows 6310 only

Provides a link to Win63X0 Windows analysis software for the analyzer. This allows the transfer of data and setups between the analyzer and a Windows desktop/laptop.
When the screen is first shown, it will show the current Station and Machine in which it is operating. To select a different machine, press ESC to go back to the Station and/or Machine selection menus.
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Portable Analyzer CA Operations Manual The Station number and Machine number are shown to help the user identify the sub-directory where the data is stored (Refer to the Data Backup Procedure for more information on the directory structure). The station name and machine name are listed to insure the correct station and machine are selected. Note: If the directory is changed remotely from the Win63X0 software, the change will be reflected on this screen.
The current directory is listed on the last line to show where the data is coming from or going to in the analyzer (depending on the current Win63X0 applications function selected). MODE: You may select the connection mode by going to Hardware configuration menu.
7.3 7.4
Power Cylinder Monitor

Refer to the previous section on the power cylinder monitor under engine balance for more details.
Discharge Battery 6310 only

This option helps in completely discharging a battery to a minimum amount. Use this only if directed to by Windrock Product Support.
7.5
Check for Bad EXE's 6310 only

This function will check the analyzer for proper operating software. The operating software is comprised of several individual modules which must be from the same date. If the files become mixed or corrupted, this utility will notify the user when the check is run. Any files that are incorrect will be displayed on the screen below. These files should be reported to Windrock immediately.
Caution:
If files are found to be mixed or corrupted, DO NOT continue using the analyzer. Unexpected results may occur or collected data will be invalid.
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Encoder Setup
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8
8.1
Encoder Setup
Shaft Encoder
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
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Portable Analyzer CA Operations Manual in a undetermined state for the power/exhaust cycle. To avoid this situation, do not disconnect the encoder and set the power save setting under hardware configuration to NO.
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: It is strongly recommended that TDC be checked periodically; at a minimum, prior to and after data collection.
8.2
Multi-Event
The multi-event encoder provides for attachment of either an optical pickup (WRI P/N: A6056-01-08) or a magnetic pickup (WRI P/N: A3012-00-00) for TDC measurement. In addition, a magnetic 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!
On four-cycle 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-cycle 0 to 720 degrees and compressor 0 to 360 degrees.
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Encoder Setup
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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!
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.
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.
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9
9.1
Loading New Software

Windows Install 6310 only
Prior to starting, make sure the update has been installed on the desktop/laptop. There should be two or more new files located in the Windrock\Win63xx\EXE folder that were part of the upgrade CD ROM. On the analyzer: 1. 2. 3. 4. Attach parallel interlink or USB cable between desktop and 6310 Turn the analyzer on Select 7 "Utilities" from the menu and press Enter Select 2 "Connect to windows" from the menu and press Enter
In the Win63X0 Windows application: 5. 6. 7. 8. 9. Before opening a database, select "Utilities" from the menu bar Select "Connect to analyzer" from the menu Press the "Connect now" button (the connection should be established - note this by a box listing files on the analyzer appearing to the right of the window) Select "Transfer" from the menu bar Select "Update EXE's" on the menu
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: Verify the version on the startup screen to make sure the update has been transferred.
9.2
Windows Install 6320 only

Prior to starting, make sure the update has been installed on the desktop/laptop. Follow the instructions found in the Win63X0 manual under "Connect with closed database" and then "Send software updates to Analyzer".
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Operating System Commands
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10
10.1
Operating System Commands

Machine Template 6310 only
To copy a setup from one machine to another, use the following procedure. C:\EVPORT is the main directory where the data files are kept. Each station and machine are put 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
Setting Time and Date 6310 only

To set the date and time in the analyzer, use the following steps: 1. 2. 3. 4. 5. 6. 7. Plug the small keyboard into the analyzer Return to the upper-most menu level by hitting the "ESC" key twice from the "Machine Menu" Select 6, (5 in the 6310/CA Lite) "X engineering mode" At the "C:\EVPORT\SXXX\MXXX\" prompt, type time and press Enter At the time prompt, enter the time in 24 hour format (HH:MM:SS) and press Enter At the "C:\EVPORT\SXXX\MXXX\" prompt, type date and press Enter At the date prompt, enter the date using the format (MM-DD-YYYY) and press Enter Note: The year must be entered using four digit format to comply with year 2000. If only the last two digits are entered, the date will be incorrectly set. Once the time and date have been set, press the "0" key and then press the "Enter" key to restart the analyzer.
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10.3
Set Date, Time or Time Zone 6320 only

To manually set the Date, Time, or Time Zone: From the startup menu, hit "Escape" twice, to access the Station Selection Menu.
Select "System Configuration" at this menu.
10.4
Printing 6310
To print directly from the analyzer, there must be a printer driver loaded prior to running the software. Once this has been done, pressing the PRINT function key will print out the current graphics or 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.
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Operating System Commands Using the GRAPHICS command:
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The GRAPHICS command loads a program into upper memory that allows the analyzer to print the information displayed on the screen. To load the GRAPHICS driver, you may do it one of two ways using the syntax that follows. The first method requires the word GRAPHICS be typed in at the command prompt. The second method requires adding the GRAPHICS command to the autoexec.bat file in the root directory of the analyzer. Syntax: LOADHIGH C:\DOS\GRAPHICS [type] (example: LOADHIGH C:\DOS\GRAPHICS LASERJETII ) Type: Specifies the type of printer. The following list shows each valid value for this parameter and gives a brief description of its meaning: HPDEFAULT DESKJET GRAPHICS LASERJET LASERJETII PAINTJET THINKJET Any Hewlett-Packard PCL printer. Hewlett-Packard DeskJet printer An IBM Personal Graphics Printer, IBM Proprinter, or IBM Quietwriter printer A Hewlett-Packard LaserJet printer A Hewlett-Packard LaserJet II printer A Hewlett-Packard PaintJet printer A Hewlett-Packard ThinkJet printer
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.
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Batch file after adding "Printer" command and "Mode" command
Alt-F for "File Menu" Alt-X for "Exit"
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Operating System Commands Select "Y" for YES or "N" for NO and hit ENTER.
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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.
Select "System Configuration" at this menu.
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Select "Printer Management" at this menu.
Select the option you need and follow the on-screen instructions.
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Appendix
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11
11.1
Appendix
Data Collection Techniques
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
Sensors
Transducer Scaling Entries: SENSOR Engine AC Engine DC Spark TYPE AC DC DC UNITS ZERO SCALE or 1V PSI PSI Volts 0 0 0 FULL 4mA or 5V 1000 200 1000 0 50,000 0 20mA 1000 1000 50,000
Secondary Ignition Sensor A6030-01-06
Water Cooled Pressure Sensor A6082W-XX-01
Compressor Pressure Sensor A6082-XX-00
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11.2.1 Magnetic Pickup

GENERAL DESCRIPTION
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.
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Appendix 3) Load resistance and the input resistance of the device being driven.
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4) Air gap setting (pole piece clearance) and distance between sensor face (pole piece) and top of gear tooth (or other actuator). 5) Minimum acceptable peak-to-peak voltage level (V P-P) of the device being driven and typically a display or frequency to DC converter. USE OF MAGNETIC PICKUP WITH WINDROCK INSTRUMENTATION When using the magnetic pickup for TDC (top dead center) triggering in reciprocating machine analysis, it is extremely important that the pickup triggers data acquisition exactly at TDC. Errors of only 2 degrees can produce measurement errors of up to 5% in horsepower and throughput calculations. For the magnetic pickup to operate properly with Windrock analyzers, several issues must be addressed. PICKUP DISTANCE FROM TARGET Often, the magnetic pickup is placed too close to the target. When this happens, the pickup can trigger data acquisition on scratches, nicks, or magnetic deformities in the flywheel or shaft. Usually, a gap of about 1/4 inch is sufficient. TARGET TYPE Some sort of target must be placed on the flywheel or shaft to trigger the magnetic pickup. The target must be of a ferrous material. It may be a hole drilled into the flywheel or shaft or may be a protruding object such as a bolt head. Either way, the target must produce the largest magnetic interference of any other scratch, hole, or deformity in the flywheel or shaft. The center of the hole or bolt head must be placed at TDC of the machine. A hole is preferred because it is always round and the center of the hole is the magnetic center of the target. A good choice for hole size is 1/4" diameter X 1/4" deep. Sometimes, when using a bolt head, the flats of the bolt causes the magnetic center to be other than the geometric center of the bolt. Sometimes, we have seen a sharp edge used as a target. This is OK, but due to the small magnetic interference, the gap must be smaller in order to get a sufficient signal.
SIGNAL POLARITY This is where many problems occur when using a magnetic pickup. The circuit in the Windrock analyzer arms itself on a POSITIVE-going signal. The actual trigger occurs upon ZERO-CROSSING after the circuit is armed. Zero-crossing occurs at the magnetic center of the magnetic pickup or when the magnetic pickup is centered on the target. When using a hole as a target, pin A of the magnetic pickup is the signal. When using a protruding object as a target, pin B of the magnetic pickup is the signal.
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Portable Analyzer CA Operations Manual 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.
11.2.2 Secondary Ignition Sensor

The calibrated secondary ignition capacitive clip is used to accurately measure the secondary ignition voltages. The attenuation is 10,000 times and the voltage range is 50 kilo volts. The capacitive clip is clipped around the spark plug wire. The alligator clip may be connected to engine ground but is not usually necessary.
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Appendix
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11.2.3 Water Cooled Pressure Sensor

This pressure sensor used with Windrock portable analyzer is for conditions of extreme temperature for extended periods of time. This device outputs a 4 mA to 20 mA electrical signal that is directed to the analyzer. The pressure transducer is typically connected to kiene or other indicator valve type on the power cylinders.
11.3
Specifications - 6310/CA
Basic Capabilities: The data acquisition capabilities of the instrument are based upon 1-channel dynamic 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
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Portable Analyzer CA Operations Manual 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
11.4
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
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Appendix Range: 1 KV to 50 KV Software selectable for positive or negative ignition systems Secondary ignition data capture rate is 1 mHz Over voltage protection Voltage input Range: 0-10V Frequency response: DC to 5 KHz Supply voltage: 24 VDC Over voltage protection to 2000V Voltage input is used for voltage signals Input impedance: >1 Meg ohm Memory Capacity 256 Mb on-board RAM memory 4 Gb flash memory storage Communications USB interface for host communications Power Supply 12V Lithium Ion rechargeable 3200 milliamp-hour battery Two batteries 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 LDC, transmissive, with back light, color option Size of display: 8.25" diagonal Pixels: 640 x 480 Contrast: software controlled 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 Lithium ion battery Keypad: 28 keys Resolution HF vibration channels Pressure, ultrasonic, prox channels Ignition analysis channels HF vibration filters Ignition analysis speed Operating system Real-time speed Battery life Data transfer method Printers supported Signal processing technology 16 bits 1 1 1 unlimited (DSP programmable) 1 Mhz Linux 1800 RPM 7 hours USB - USB USB printer w/ Linux driver quad DSP processors
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Portable Analyzer CA Operations Manual Main user interface processor Crankangle samples per degree A/D converters AMD Geode 500 Mhz 1, 2, or 4 8
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. 431 Park Village Drive, Suite L Knoxville, TN (USA) 37923
11.5
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
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Glossary of Terms
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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.
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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
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Glossary of Terms
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portion of the charge of air and fuel causing too rapid a combustion rate, extremely high flame front speed and excessively high pressure within the cylinder. Discharge Pressure - The pressure at which compressed gas is forced out of a cylinder. Discharge Valve - A valve through which compressed gas leaves the cylinder. Discharge Temperature (TD) - The temperature of the gas leaving the cylinder through the discharge valve. Typically this is measured at or near the discharge bottle or nozzle. Double Acting - Indicates that the piston pumps gas on both ends; i.e., as the gas discharges out the valve on the head end, the piston draws gas into the cylinder through the suction valve on the crank end. The reverse happens as the piston strokes toward the crank end or the engine. Dynamic Compression Pressure - The pressure in the cylinder at the end of the compression stroke with normal combustion occurring. Dynamic compression is usually higher than cranking compression due to temperature and combustion. Engine Derating - Reducing the standard horsepower or speed ratings on an engine because of the kind of service it performs or existing ambient conditions. For example: An intermittent rating will be higher than a continuous rating on an engine. An engine rating at high altitude or high ambient temperatures will be rated for a lower output. Exhaust - The stroke or portion of the stroke in an internal combustion engine in which burnt gases left over from combustion are released from the cylinder. Exhaust Port - An opening in the cylinder wall through which exhaust gas is expelled when the exhaust port is uncovered by the piston. Exhaust Valve - The part of a four-stroke-cycle engine which releases exhaust from a combustion chamber into the exhaust manifold. Fixed-Volume Pocket - A fixed-volume chamber or a chamber with a valve that can be opened or closed by a handwheel or air cylinder from outside the cylinder. A fixed-volume pocket adds a specific volume to the cylinder when it is open. Flame Front - The leading edge of a flame propagating from its ignition source. Foot-Pound - This is the amount of energy or work required to lift one pound a distance of one foot. Four-stroke (Cycle) Engine - An engine that requires four piston strokes and two complete crankshaft revolutions to complete each cycle. Friction Horsepower - Power consumed within an engine or compressor from friction of its moving parts. Fuel Event - The event measure in degrees of crank angle where fuel is entering the combustion chamber. Fuel Injector - A device which sprays fuel into the combustion chamber. Fuel Valve - A cam-actuated valve that allows fuel to enter the combustion chamber. Flywheel - The round massive component used to provide inertia that damps angular velocity changes of the machine. Gas - A substance that changes volume and shape according to temperature and pressure applied to
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Portable Analyzer CA Operations Manual it. Often, a combustible substance. Gas Analysis - Mole Fractions of each gas contained in the mix of gases passing through the compressor. Governor - A device (either mechanical, electrical, or hydraulic) to control and regulate speed (RPM). Head End (HE) - That end of the compressor cylinder away from the engine or frame. Horsepower - The energy required to lift 550 lbs. one foot in one second or 33,000 lbs. one foot in one minute. Horizontal Engines - An engine with cylinders lying in the horizontal plane. Hydraulic Lifters - A mechanical device used to (1) compensate for changes in temperatures, valve wear and valve recession as it maintains a zero lash (clearance), and (2) cushion the opening and closing of the various valves (intake, exhaust, etc.) Ignition - The combustion of the fuel mixture in the combustion chamber. In a spark ignited engine, ignition is the electrical spark that provides the source of igniting the air/fuel mixture. Ignition Delay - The time from initial injection of air and fuel to actual ignition of the mixture in a compression ignited engine. In a spark ignited engine, it is the total time required from the initial spark until a pressure rise occurs due to combustion. It is the total time required for the physical and chemical reactions required to propagate a flame front. Ignition Timing - The point at which the ignition systems delivers a spark to the spark plug to begin burning the air/fuel mixture, in relationship to crankshaft rotation or TDC. Indicated Horsepower - The actual horsepower developed on the surface of the piston in a reciprocating power cylinder or consumed surface of the piston in a reciprocating compressor cylinder. Indicated Mean Effective Pressure (IMEP) - That theoretical constant pressure that can be imagined exerted on the piston during each power stroke of the cylinder to produce power equal to the indicated power. It is the average pressure exerted on the piston through the functional cycle. Indicator Port - A direct connection from the outside to the inside of the cylinder clearance area. The port is used for connection of instrumentation to investigate pressures inside the cylinder. Injection Valve - A device used to inject fuel into the combustion chamber of an engine. In-line Engines - An engine design where all the power cylinders are in a block or frame located one behind the other. Intake Manifold - The manifold that holds air or air and fuel before it enters the combustion chamber. Intake Port - An opening in the cylinder wall through which gas flows into the cylinder when the intake port is uncovered by the piston on a two-stroke engine. Intake Valve - The valve which permits air to enter the cylinder of an engine. Integral - A compressor having a common crankshaft for both power and compressor cylinder or cylinders. The prime mover and the compressor are combined into a single frame. Jacket Water - The water system of the engine used for cooling the cylinder, head, and other parts. Jacket Water Pressure - Pressure produced normally by a centrifugal pump to circulate jacket water
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Glossary of Terms throughout an engine. Kiene Valve - A special valve used in the indicator port for connection to pressure transducers. Liner - A replaceable cylinder in an engine block.
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L/R Ratio - The L/R ratio is the ratio of the connecting rod length to the radius of the crankshaft throw. Main Bearing - Bearings which act as the support on a crankshaft. Manometer - A device used to measure vacuum or lesser pressures. It is a U-shaped tube partially filled with a fluid. One end is open to atmosphere, the other to the pressure or vacuum being measured. Readings are given in inches of the liquid in the tube (i.e., inches of mercury). Mean Effective Pressure (MEP) - The MEP of a cycle or stroke of a heat engine is the average net pressure in pounds per unit area that operates on the piston through its stroke. Mechanical Efficiency - The ratio of brake horsepower delivered by an engine to the indicated horsepower developed. Misfire - Absence of combustion in a power cylinder. The condition may be intermittent or continuous. Naturally Aspirated Engine - An engine without a supercharger, turbocharger, or reciprocating scavenging cylinder. At the start of compression, these units operate on a cylinder air charge at a pressure slightly below atmospheric pressure. Nozzle - The passage that provides an inlet or outlet to the compressor cylinder. Oil Cooler - A shell and tube type heat exchanger in which cooling water passes through the tubes while lube oil flows around the tubes to transfer heat from the oil to the water. Subsequently, the water is typically cooled by fans. Once-Per-Turn - Transducer to generate one pulse per revolution of the crankshaft. This usually is in line with TDC on the flywheel. Opposed Piston Engine - An engine consisting power cylinders containing two pistons which drive two different crankshafts, connected at one end with a vertical shaft. Combustion occurs between the two pistons. Parasitic Horsepower - Horsepower used to drive auxiliary equipment such as pumps, generators, motors, etc. Peak Firing Pressure (PFP) - The maximum pressure developed in a power cylinder due to combustion of the mixture. Under normal conditions, peak pressure occurs between 10 to 25' after top dead center on a spark ignited cylinder. The precise degree of crankshaft rotation will be affected by speed, combustion chamber design, and fuel. Piston - A cylindrical part closed at one end which is connected to the crankshaft by the connecting rod. It is the force from combustion, exerted on the closed end of the piston, which causes the connecting rod to move the crankshaft. Piston Displacement - The volume of air moved or displaced by movement of the piston as it goes from bottom dead center to top dead center. Pounds per Square Inch Absolute - Pounds per square inch gauge plus atmospheric pressure. Abbreviated PSIA.
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Portable Analyzer CA Operations Manual 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.
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Glossary of Terms SQ. FT. - Area measurement in square feet. SQ. IN. - Area measurement in square inches.
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Standard Deviation - Is a statistic that tells you how tightly all the various examples are clustered around the mean in a set of data. When the examples are pretty tightly bunched together and the bell-shaped curve is steep, the standard deviation is small. When the examples are spread apart and the bell curve is relatively flat, that tells you you have a relatively large standard deviation. The standard deviation is kind of the "mean of the mean," and often can help you find the story behind the data. Stroke - The movement of the reciprocating machine during one rotation of the flywheel. Suction Pressure - The pressure of a gas entering the suction valve of a compressor. Suction Temperature (TS) - The temperature of the gas entering the suctions valve of a compressor. Typically, this is measured at or near the suction bottle or nozzle. Top Dead Center (TDC) - A marking indicating that the lead cylinder is at it's most extended position. A mark is usually placed on the flywheel indicating this position. Torque - A moment of force applied to the rotation of a shaft by a lever arm. Two-stroke (Cycle) Engine - An engine requiring only one complete revolution of the crankshaft to complete a cycle of combustion events. Unloader - A device used to cause gas to surge into and out of the compressor cylinder without going through the discharge valve. An unloader has plungers that hold the valve plates or channels open. "V" Engine - An engine that consists of two banks of cylinders connected to the same crankshaft which gives the appearance of a "V". Vacuum - Pressure less than atmospheric pressure. Variable Pocket - A chamber that adds clearance volume in direct proportion to its setting. The setting may be adjusted to any volume within the limits of the pocket. Volumetric Efficiency - The ratio of the volume of gas actually drawn into a cylinder to the total cylinder volume. Work - Force times distance.
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Portable Analyzer CA Operations Manual Direct Channel Read 59
Index
-663X0/CA with encoder 19
-EEncoder 6 Multi-Event 64 Shaft Encoder 63 Engine Balancer 21 ESP 2 Extended Service Plan
-AAssistance 1
-BBalance Engine Nonencoder Balancer 21 Battery 7 Care 7 Discharging 62 E-Moli 8 Performance 7 Battery Charger 9 21
-HHandling 3 Hardware Configuration 14 Hazardous Location Information Hole-Pin 63 3
-IIgnition Survey 44 Introduction 1
-CCare 6 Charger 9 Check for Bad EXE's 62 Class 1, Div 2 Information Cleaning 6 Configuration Hardware 14 Connect to Windows 61 Connections 6310 11 Customer 1 Assistance 1 Repairs 1 Trouble 1 3
-KKeyboard 14 Keypad 14
-MMachine 17 Machine Setup Menu 19 Magnetic Pickup 65 Measuring 73 Pressure 73 Temperature 73 Vibration 73
-OOptical Pickup 65 Options Hardware 14
-DData Collection Database 17 Date 67 73
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Index Station 17 Strobe Light
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-PParallel Port 6 PHASE A-B 63 Power Cylinder Monitor 40 Pressure Measurements 73 Printing 6310 68 6320 71 Problems 1
65
-TTDC 63, 65 Temperature Measurements Templates 67 Terms 6 Time 67 Timing Light 65 73
-RRepairs 2 Return Material Authorization Returning Products 2 2
-UUnpacking 6 USB 6 Utilities Check for Bad EXE's 62 Connect to Windows 61 Direct Channel Read 59 Discharging Battery 62 Power Cylinder Monitor 62
-SSafety 3, 5 Sensor 73 Magnetic Pickup 74 Pressure Water Cooled 77 Scaling 73 Secondary Ignition 76 Specifications 80 Settings Date 6310 67 Date 6320 68 Time 6310 67 Time 6320 68 Time Zone 6320 68 Setup General Machine 19 Setup Balancer/Spark 21 Software Windows 6310 66 Windows 6320 66 Spark Mode 56 Spark Survey 44 Special Collection Modes 55 Speciifications 6310 77 6320 78 Sensors 80
-VVGA 6 Vibration Measurements 73
-WWarnings 5 Encoder 5 Multi-Event 64 Pressure Sensor 5 Shaft Encoder 63 Timing Light 5, 65 Windows 61, 66
Windrock, Inc. 2009

63X0 CA Manual

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Portable Analyzer CA Operations Manual

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Part II Read This First

4 Batteries & Charging ................................................................................................................................... 7

Part III Getting Started

Part IV Machine Setup, 63X0/CA with encoder only

1 Setting Up a ................................................................................................................................... Machine, 63X0/CA with encoder only 19

Part V Balancer/Spark Setup and Data Collection

Part VI Encoder-based Balance

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Part VII Utility Menu Options

Part VIII Encoder Setup

Part IX Loading New Software

Part X Operating System Commands

1 Data Collection ................................................................................................................................... Techniques 73 ................................................................................................................................... 73

Part XII Glossary of Terms Index

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Hazardous Location Information, 6320 only

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Portable Analyzer CA Operations Manual

Read This First

PARTS LIST (Standard Package)

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Read This First Note:

Batteries & Charging

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LITHIUM-ION STYLE BATTERY

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Read This First

Charger Lithium-ion Battery Charger (Energy Access)

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

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Portable Analyzer CA Operations Manual

A6310-00/CA and A6320-00/CA Rear Panel Connectors 6310

A6320-00 Left Side

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Portable Analyzer CA Operations Manual

TAB TAB Period

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Getting Started Note:

Use power save:

Use blinking: Screen width: Text Cursor Style:

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Autoscan first in take data:

Use unit conversion:

Unit group: DC Sensor correction:

Is this a CA with encoder: Setup (D6) files warning:

Stations & Machines

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Station & Machine Setup

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Portable Analyzer CA Operations Manual

Windrock, Inc. 2009

Machine Setup, 63X0/CA with encoder only

Machine Setup, 63X0/CA with encoder only

Windrock, Inc. 2009