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PowerNet 2.

0
Engine Dynamometer
Data Acquisition and Control
Operator's and Administrator's Manual

Copyright 2006, PowerTest, Inc.


PNWS0612

CD Operators
Operators
PowerNet CD
Manual
Contents
Manual
Contents
Table of Contents ........................................................................................................................... iii-iv
Chapter 1 - System Overview ........................................................................................................... 1
Data Acquisition and Control System Components ...................................................................................... 3
Software Overview ........................................................................................................................................ 4
The PowerNet File System .......................................................................................................................... 6

Chapter 2 - Basic Operation .............................................................................................................. 7


Starting the Commander Computer .............................................................................................................. 9
Connections .............................................................................................................................................. 10
Test Procedure .......................................................................................................................................... 12

Chapter 3 - Main Display .................................................................................................................. 13


The Main Display Window ......................................................................................................................... 15
Floating Pull-Down Menus ......................................................................................................................... 16
The File Menu ...................................................................................................................................... 16
The View Menu .................................................................................................................................... 18
Configuring Sensors ........................................................................................................................ 20
Alarms ............................................................................................................................................ 21
The Data Menu .................................................................................................................................... 23
The Window Menu ............................................................................................................................... 24
The Add-Ins Menu ................................................................................................................................ 25
The Help Menu ..................................................................................................................................... 25

Chapter 4 - Controller Interface ....................................................................................................... 27


Controller Interface Window ....................................................................................................................... 29
Controlling the Dynamometer .................................................................................................................... 30
Throttle Control Modes ......................................................................................................................... 30
Dynamometer Control Modes ............................................................................................................... 30
Controller Interface Window Pull-Down Menus ........................................................................................... 31
The View Menu .................................................................................................................................... 32
Control Mode .................................................................................................................................. 32
Tuning Parameters .......................................................................................................................... 33
Settings .......................................................................................................................................... 36
Ramping ......................................................................................................................................... 37
Statistics ........................................................................................................................................ 37

Chapter 5 - Pattern Runner .............................................................................................................. 39


The Pattern Runner Interface Window ........................................................................................................ 41
Pattern Runner Pull-Down Menus .............................................................................................................. 42
The File Menu ...................................................................................................................................... 42
The Edit Menu ...................................................................................................................................... 42
Creating a New PowerNet Pattern ................................................................................................... 43
Saving a PowerNet Pattern ............................................................................................................. 45
Running a PowerNet Pattern ........................................................................................................... 45
The Tools Menu .............................................................................................................................. 45

Chapter 6 - Report Generator .......................................................................................................... 47


The Report Generator Program .................................................................................................................. 49
The Report Generator Window Pull-Down Menus ....................................................................................... 49
The File Menu ...................................................................................................................................... 49

iii

Contents
Chapter 6 - Report Generator
The Edit Menu ......................................................................................................................................
Using the Edit Report Window ..........................................................................................................
Creating a New User Table ................................................................................................................
Editing User Tables ...........................................................................................................................
Creating a New Data Table ................................................................................................................
Reference Sensors ....................................................................................................................
Editing Data Tables ...................................................................................................................
Phases ......................................................................................................................................
Function List .............................................................................................................................
Creating a New Graph .......................................................................................................................
Editing Graphs ..................................................................................................................................
Creating a New Spreadsheet .............................................................................................................
Editing Spreadsheets ........................................................................................................................
Creating a New Paragraph ................................................................................................................
Editing Paragraphs ...........................................................................................................................
The View Menu ....................................................................................................................................
New Graph View ...............................................................................................................................
New Graph View Properties ..............................................................................................................
Creating a New Graph View ..............................................................................................................
Editing a New Graph View ................................................................................................................
The Import Menu ..................................................................................................................................
The Export Menu ..................................................................................................................................
Ignore List ............................................................................................................................................

50
51
52
53
54
54
55
55
55
56
57
58
59
60
61
62
62
62
63
64
64
64
64

Chapter 7 - Workstation ................................................................................................................... 65


The PowerNet Workstation ........................................................................................................................ 67
Using the Workstation Touch Screen ......................................................................................................... 68
Connections .............................................................................................................................................. 68
Workstation Main Menu ............................................................................................................................ 69
Run Mode .................................................................................................................................................. 70
Run Mode Function Buttons ................................................................................................................. 70
Calibration ................................................................................................................................................. 71
Methods of Calibrations ........................................................................................................................ 71
Valve/Throttle Calibration ...................................................................................................................... 72
Smart Throttle Calibration ............................................................................................................... 73
Pressure Calibration ............................................................................................................................. 74
Temperature Calibration ........................................................................................................................ 75
Primaries Calibration ............................................................................................................................ 76
Dynamometer Setup .................................................................................................................................. 77
Advanced Dynamometer Setup ............................................................................................................ 78

Chapter 8 - Add-In Programs ........................................................................................................... 79


The Add-in Programs ................................................................................................................................. 81
Security Editor .......................................................................................................................................... 81
ECM Communicator .................................................................................................................................. 82
Gas Analyzer ............................................................................................................................................. 85
Calculated Sensors ................................................................................................................................... 85
Fuel Controller ........................................................................................................................................... 87
Correction Factors ..................................................................................................................................... 89
Reference Data Builder .............................................................................................................................. 91

Copyright 2006 by Power Test, Inc. All rights reserved. This manual may not be copied, photographed, reproduced, translated or
converted to any electronic media or machine-readable format in whole or in part without prior written approval of Power Test, Inc.
iv

System Overview

PowerNet 2.0
Data Acquisition and Control
- CHAPTER 1 System Overview

System Overview

System Overview
Data Acquisition and Control System Components
The system is divided into three groups: the Commander Computer, the PowerNet Workstation and optional components.
Commander Computer
This terminal interfaces with the Workstation and the dynamometer and performs all of the
embedded control functions. It is also the location where new tests and reports are generated,
manipulated, stored, run, and printed.

The PowerNet Workstation


The Workstation contains the systems pressure and temperature sensors. The sensors are housed in an
industrial cabinet and supplied with quick disconnect connections. Information is collected from the sensors
and ECM (Optional), and combined with torque, speed and power measurements from the dynamometer
and sent to the Commander Computer.

Optional Components
Power Test offers a wide range of optional components and accessories for the PowerNet Data Acquisition and Software
System, including:
ECM Communicator

Smoke Opacity Meters

Auxiliary Outputs

Fuel Measurement System

Five Gas Analyzer

Alarms

Additional Sensors
- Temperature
- Pressure
- Vibration
- Speed
- Crankcase Blow By

Electronic Throttle Interfaces

PC Upgrades

Our in-house manufacturing and electronics department guarantees that we will be able to provide a data acquisition and
control system for nearly any application. For more information, contact your Power Test representative, or visit us on the
web at www.pwrtst.com.

System Overview
Software Overview
The PowerNet Software Package is a complete data acquisition and control program for dynamometers and engines. PowerNet
transforms a standard computer and specially designed electronic components into a highly efficient engine development and
qualification tool.
The software is comprised of several programs running at the same time, the Main Display, Controller Interface, Pattern
Runner and Report Generator. There may be other programs running minimized in the background (operational, but hidden)
according to what is listed under the add-ins menu of the Main Display, such as Correction Factors, ECM Communicator,
etc.
Main Display

Pattern Runner

Controller Interface

Report Generator

System Overview
Main Display
The Main Display contains the readings for all of the available
visible sensors. All of the sensor parameters and configurations
can be modified from this window by right-clicking on the individual sensor readings. Additionally, this window is used to open
and save PowerNet Templates and DataSpaces, as well as exit
the Commander program. The details of the functions and features of the Main Display are discussed in Chapter 3.

Controller Interface
The Controller Interface provides essential control functions for the dynamometer. This window
identifies the dynamometers active load control mode and the current setpoint. It is possible
for a user at the Commander Computer to control the dynamometer and engine using the mode
buttons and the input box directly from the Controller Interface. The details of the functions and
features of the Controller Interface are discussed in Chapter 4.

The Pattern Runner Interface Window


The Pattern Runner program allows the user to create, load, save and execute
PowerNet Patterns. PowerNet Patterns are pre-configured tests that are designed to run in a specific order. The details of the functions and features of the
Pattern Runner are discussed in Chapter 5.

The Report Generator Interface Window


The PowerNet Report Generator allows the operator to arrange the data into a
meaningful visual format. The data can be arranged as spreadsheets and/or
graphs, while any customer and vehicle information can be put into paragraphs
and/or tables. The details of the functions and features of the Report Generator
are discussed in Chapter 6.

System Overview
The PowerNet File System
The PowerNet File System consists of the following components: PowerNet Templates, PowerNet DataSpaces, and PowerNet Patterns. It is important to understand the function of each of these file types.
PowerNet Template (.tds)
A Template is a file containing pre-configured, basic test information. All Templates can be customized with information
applicable to the kind of test you wish to perform. This may include sensor configurations and report formats and patterns.
Templates are created by the administrator. Templates do not contain any data. Once a test is performed, data can then be
collected and saved in the form of a DataSpace.
PowerNet DataSpace (.pds)
After a Template has been used to acquire data, it is then saved as a DataSpace. A DataSpace contains the same information
as the Template with the addition of specific test data. A DataSpace is utilized whenever an operator wishes to save new test
data, or recall data from a previously saved test and is the area where live data is stored.
PowerNet Pattern (.pcp)
Patterns are pre-configured tests that are designed to run in a specific order. Patterns are created by the administrator and
they can be saved within a Template or as individual files to be loaded into existing Templates.
PowerNet Tuning Files (.pct)
Tuning Files are individual files storing dynamometer tuning parameters. The tuning parameters should not be modified unless
otherwise instructed to do so by Power Test.
PowerNet ECM Information (.pei)
Specific vehicle ECM Communication configurations can be saved and loaded as individual files.
NOTE: All file types should be stored in the C:\Program Files\PowerNet\Commander 2.0 directory.

PowerNet 2.0
Data Acquisition and Control
- CHAPTER 2 Basic Operation

Basic Operation

Basic Operation
Starting the Commander Computer
Once the Commander Computer and all related components have been
installed and set up by your PTI representative, you are ready to turn on
the Commander Computer. At this time, make sure the monitor and
printer are also on.
Note: Each program on the computer utilizes a system of command
choices, called Menus. If you click on a Menu, and it drops down with
multiple choices for you, it is called a pull-down menu. To make the
computer follow instructions, simply point the mouse and click on the
menu selections you wish to have performed.

PowerNet Commander Splash Screen


The computer should automatically execute the PowerNet 2.0 w/Workstation program, and the splash screen will become
visible during the time the program is loading. Once closed, the program may be restarted by clicking on the P icon on your
screen. Double click that icon to launch the software. For administrative functions, a log-in name and password are required.
Note: If the program does not automatically start, or the icon does not appear, contact your Power Test representative.
Once you have powered up (for operators) or logged-in (as an
administrator), the default PowerNet Template should be loaded
and visible (right).
The program will automatically open the default template upon
start-up. Typically, the operator will open one of several templates created by the administrator and select a template based
on the type of engine or test being performed.

Note: Depending on the operating system used, the software may have a slightly different appearance than the examples in this
manual. This does not affect the performance of the program in any manner.

Basic Operation
Connections
Note: Before performing a test, the following connections may need to be made.
Thermocouples
To connect a temperature probe, first set the depth of the probe into the compression fitting. The depth of the probe into the
compression fitting will be determined by the location of the fluid being measured. Once a compression fitting has been crimped
on a probe, it cannot be relocated. The probe can be used over and over again, but the depth will be fixed. After the compression
fitting is assembled on the probe, NPT adapters will need to be provided to match the probe connection to its final location. With
the probe in place, simply plug the female end of the yellow extension cord into the probe and the male end into the control box.

Temperature Connection
at Engine

Temperature Connection at
the Workstation

Pressure Connections
To connect to a pressure port, first set the length of the pressure tube. A pressure tube consists of " flexible tube with
compression fittings on each end, one end terminating in a male NPT fitting (engine) and the other terminating with a quickdisconnect (control box). Simply, route the tube to the pressure (or vacuum) source and adapt accordingly.

Pressure Connection at
the Workstation

10

Pressure Connection
at Engine

Basic Operation
Engine Connections
In most circumstances, an engine start relay (not required if using air starting) and a fuel stop solenoid will have to be connected
prior to testing an engine.

Engine Start Relay

Fuel Stop Solenoid

LT Relay Connection Diagram

The start wires (white/red/black) are connected to the Engine Start Relay on the base of the Workstation for the engine being
tested, as shown in the diagram above.
The stop wires (blue/brown/green) are connected to the ECM power connection or the Fuel Stop Relay for the engine being
tested, as shown above.

ECM Connection (Optional)


To connect to the vehicles ECM, plug the ECM cable (provided by Power Test) into the Workstation (labeled ECM) on one end,
and to the appropriate diagnostic adapter (available separately from Power Test) on the other end.
Other Connections Please refer to a specific components installation manual for other connections.

11

Basic Operation
Test Procedure
Once the engine has been prepared for testing, including mounting the engine to the engine cart/stand and installation of all
components (flywheel, engine adaptors, drive shafts, engine cooling system, etc.), the next step of the process is to perform the
actual engine test. Once the safety and integrity of all of the systems, connections, supplies and the engine are verified, you are
ready to begin. The following information outlines a typical test sequence.
Prepare for Testing
Connect Throttle Cable to Engine
If a throttle actuator is used, set the throttle actuator to the low idle position (slack removed from cable).
Turn on the PowerNet Workstation
To turn on the Workstation, press the black button on the outside of the box, below the emergency stop button.
Turn on the Commander Computer
Turn on the computer, monitor and printer. The PowerNet Data Acquisition and Control Software will load automatically.
Enter in Your User Password
Login to the systems from the Main Display menu. Enter your assigned user name and password.
Load a PowerNet Template
Load an appropriate template by selecting File > Open > Template from the Main Display. This Template is normally identified
by engine model. If an appropriate Template does not exist, one must be created by the System Administrator.
Calibrate the Throttle
Prior to starting the engine, the throttle must be calibrated with each new type being tested. This is to ensure proper operation
during testing that could possibly be affected by the distance between each new engine and the actuator. Calibration procedures are outlined in Chapter Four, Controller Interface.
Turn on the Support Systems
Turn on the water recirculation system (if applicable), including cooling towers, pumps, etc. Additionally, ensure that all
ventilation equipment is operable. Turn on the Fuel System. Once the throttle has been calibrated and the support systems
have been turned on, start the engine.
Begin Testing
If a closed loop test is being run, click the Play button in the Pattern Runner program. If the appropriate Pattern is not visible,
select a Pattern from the file or consult the administrator. If a manual test is being run, test the engine as specified by your
supervisor.
After Testing is Completed
Shut off the Engine
Once the cool down period has completed, shut down the engine
Turn off the Support Systems
Turn off the water supply to the dyno. If the cooling tower fans or pump are running, leave that part of the system on.
Edit Data
Enter any test specific data using the Report Generator program. Use the Print Preview function to view the edited report.
Save Test Data
From the Main Display, click File > Save As > Data Space. Assign a file name, typically determined by work order #, etc. If
desired, print a hard copy of the report by selecting File > Print from the Report Generator program.
Shut down the Commander Computer
Shut down the computer by clicking File > Shut Down System in the Main Display window.
Turn off the PowerNet Workstation
To turn off the Workstation, touch the Shut Down Workstation button on the Main Menu Screen.
12

Main Display

PowerNet 2.0
Data Acquisition and Control
- CHAPTER 3 Main Display

13

Main Display

14

Main Display
The Main Display Window
The Main Display Window contains all of the sensors that are connected to the system. The Sensors can be displayed in two
formats. The Single Main Form format displays all of the individual gauges in fixed format. The Floating Form format
allows the user to customize the size and location of the individual gauges on the screen. Each of these sensors can be
displayed in one of four available gauge types as explained on page 20, Sensor Properties.

Example of the Single Main Form Format

Example of the Floating Form Format


NOTE: The illustrations throughout the rest of this manual will display sensors in the floating form format. This may or may
not represent how your system is configured.
15

Main Display
Main Display Window - Pull-down Menus
The pull-down menus are located in the header of the Main Display when the Single Main Form format is applied, or in a
floating window if the Floating Forms format is applied (as illustrated throughout this manual). If the floating window is
selected, the full pull-down menus will appear by putting your cursor on the "P" icon. The pull down menus consist of: File,
View, Data, Window, Add-Ins and Help.

Single Main Form Pull Down Menu

Floating Form Pull Down Menu and Icon

The File Menu


File Menu: From the File Menu, many of the file management tools needed to operate Commander can be accessed. The
File Menu consists of Log in, New, Open Template, Open DataSpace, Save, Save As Template, Save As DataSpace,
Revert to Saved, Shut Down System and Exit.
File > Login: Opens the Login screen so an administrator can login to perform administrative functions.
* Note: Without logging in, many menu items will be
grayed out and the corresponding administrative functions can not be performed. All functions requiring login
will be noted with an * throughout the rest of this chapter.

File > New: Creates a new blank Template.

* File > Open > Template: Loads an existing Template


from which to use for running a pre-configured test. If
not logged in, the user will only have the option of opening a Template within the program directory. If logged
in, the user will have the ability to search the Commander
Computer and all removable drives for a Template.
File > Open > DataSpace: Loads an existing DataSpace
that contains previously saved test data.

Open Template Screen


16

Open Template Screen (logged in)

Open DataSpace Screen

Main Display
The File Menu - (continued)
* File > Save: Saves the current active DataSpace or
Template, overwriting the current file.
Note: Use caution when using the Save function. Once
changes have been saved and the original file has been
overwritten, the original file can not be retrieved.

File > Save As >Template or DataSpace: Saves the


active Template or DataSpace as a new Template or
DataSpace. The user will be prompted to name the new
file before saving. In addition to the new file being saved
to the system, the original file will still exist.

File > Revert to Saved: Ignores recent changes in the


active Template or DataSpace and reverts back to the
previously saved version.

File > Shut Down System: Closes the software program and powers down the Commander Computer.

File > Exit: Closes the program and returns the user to
the Windows Desktop. If changes have been made to
the current open DataSpace, the user will be given the
option of saving the changes before closing the program.

17

Main Display
The View Menu
View Menu: From the View Menu, hidden sensors can be made visible and the sensor layout can be changed. The View
Menu consists of More Sensors, Display Layout, Chart, Find Overlapped Sensor(s) and Lock Sensors Positions.
View > More Sensors: Produces a pop-up window
(shown below) that allows the user to make hidden sensors visible. Check the boxes of the sensors you wish to
show and click OK.
Note: A sensor does not
have to be visible for its
data to be shown in the
Report.

View > Display Layout: Clicking Display Layout will


automatically open the Sensor Order window (shown
below). There are two options in the Sensor Order window, Sensor Order and Sensor Configuration.

The Single Main Form


There are two formats to display the sensors: Single
Main Form and Floating Forms. In the Single Main
Form format, all of the available sensors are grouped
together in the Main Display window. To display all sensors in a Single Main Form, click on the Sensor Configuration tab and click on the All Sensors check box.
To change the order in which sensors appear in a Main Form, click on the Sensor Order tab. To change the order, highlight
a sensor by clicking on it, then use the navigational buttons at the right of the window. Click OK when finished to save the
new sensor order, or click cancel to disregard changes.
Note: The Sensor Order function will not work if all sensors are displayed in a Floating Form format.

Sensor List

Move Sensor Position Up


Move Sensor Position Down

18

Main Display
The Single Main Form (continued)
From the Sensor Configuration tab, the user can select how many sensors appear in each row of the Single Main Form in
the Main Display.
If the 3 on top row (stationary) 5 on remaining rows option is selected,
a Single Main Form will display three sensors in the top row, and five
sensors in each row thereafter until all sensors are displayed. ex. If
there are 13 sensors in the Main Form, three sensors will be displayed in
the first row, five sensors will be displayed in the second row, and five
sensors will be displayed in the third row. If selected, the sensors in the
first row will all be square in size.
If the 4 on top row (stationary) 5 on remaining rows option is selected,
a Single Main Form will display four sensors in the top row, and five sensors in each row thereafter until all sensors are displayed. ex. If there
are 13 sensors in the Main Form, four sensors will be displayed in the
first row, five sensors will be displayed in the second row, and four sensors will be displayed in the third row. If selected, the sensors in the first
row will all be square in size.
If the 5 on top row (stationary) 5 on remaining rows option is selected,
a Single Main Form will display five sensors in the top row, and five sensors in each row thereafter until all sensors are displayed. ex. If there
are 13 sensors in the Main Form, five sensors will be displayed in the first
row, five sensors will be displayed in the second row, and three sensors
will be displayed in the third row. If selected, the sensors in the first row
will all be square in size.
If the 5 on all rows (non-stationary) option is selected, a Single Main Form will display five sensors in each row . ex. If
there are 13 sensors in the Main Form, five sensors will be displayed in the first row, five sensors will be displayed in the
second row, and three sensors will be displayed in the third row. If selected, each sensor will be equal in size, regardless of
number selected.

Floating Forms
Floating Forms can exist anywhere on screen and can be sized individually. The use of the Floating Form format allows a
highly customizable appearance to the Main Display. A Single Main Form display and Floating Forms display can exist
together.
The Sensor Display frame of the Sensor Configuration tab is used to determine how many sensors will be displayed on
the Single Main Form display and how many Floating Forms exist. If the All Sensors check box is selected, all sensors
will be displayed in a Single Main Form mode. To display sensors in both a Single Main Form and Floating Forms format,
enter the number of sensors that should remain in the Single Main Form in the Number of Sensors on Main Form text box.
ex. If there are 13 sensors available, and a number of six is entered into the Number of Sensors on Main Form text box,
then six sensors will be displayed in the Single Main Form, and the remaining seven sensors will exist as Floating Forms.
To change which sensors appear in the Single Main Form, click on the Sensor Order tab and rearrange the sensors.
To have all sensors display as Floating Forms, un check the All Sensors check box and enter the number zero (0) into the
Number of Sensors on Main Form text box.
To move a sensor's position in the Floating Form format, confirm that the Lock Sensor Positions option in the View Menu
is unchecked. Clicking on Lock Sensor Positions will check or un check that option. If it is not unchecked, click on Lock
Sensor Positions to unlock the sensors. This will allow the sensors to be placed anywhere on the screen. Next, click on the
sensor and drag it to its new location. To change the size of a sensor, click on an edge or corner of the sensor window, and
drag it to the desired size. Once all sensors have been placed, click on Lock Sensors Positions from the View Menu. This
will lock the sensors in their current position, and help to avoid the possibility of accidentally moving, re-sizing, or hiding a
sensor.
19

Main Display
Sensor Properties
Right-clicking on any of the sensors allows the user to modify the sensors properties. Right-clicking brings up the option box
shown below right.
Properties: Selecting Properties will open the Sensor Properties window.
Hide: Selecting Hide will remove that sensor from the Main Display window and return it to the list of sensors under More
Sensors on the Main Display windows View Menu. Select View > More Sensors to undo the hide sensor command.
Sensors displaying readings with an Optimal (an administrator defined "normal") range will display in GREY. Sensors in a
Low alarm range will display BLUE. Sensors in a High alarm range will display RED.
Sensor Properties Window: The Sensor Properties window contains five tabs that allow the user to customize the
sensor. The tabs are Gauge, Display, Units, Low Alarm and High Alarm. In addition, the name of the sensor can be
changed by entering the new name into the Sensor Name input box.
Display: This is where the operator can select which type of gauge should be displayed for a
sensor. The operator can select from a Digital, Sweep Dial, Round Dial or Bar gauge.
Note: Bar gauges are only available as Floating Forms.

Digital

Sweep Dial

Round Dial

Bar

Gauge: This tab provides the operator options to define the displayed range and multiplier for
the gauge. Maximum Reading: Establishes the top, or highest number displayed in a dial or
bar gauge. Minimum Reading: Establishes the bottom, or lowest number displayed in a dial
or bar gauge. Display Multiplier: The number by which the numbers in a display are divided
by, ex. A multiplier of ten will display 1000 RPM as 100 RPM. This will also change the display
unit to RPM x 10 (or whichever multiplier is chosen). Decimal Places without Display Multiplier: The number of decimal places to which is displayed as determined by the number entered in the input box. ex. If a value of three (3) is entered in the input box, data will be
displayed to .000, or thousandths.

Units: This is where the user defines the units displayed for the gauge display. Common standard units can be chosen by selecting Use List and picking from the menu. To define a custom
unit, select Custom and enter a unit name, description and display symbol. Enter the values
that the sensors standard unit must be multiplied by and/or added to achieve the custom unit.
Once all information is entered, the custom unit can be added to the list of standard units. To
find the base unit, select units from the Use List until you find one with adder of zero and a
multiplier of one (usually, the first listing).

20

Main Display
Sensor Properties (continued)
Low Alarm/High Alarm: These tabs are where the user defines what
actions (explained below) will be taken during a Low Alarm/High
Alarm state.
When finished, select OK to keep changes or Cancel to disregard
any changes.

Alarms
As soon as the sensor travels out of its operational range, it will change color. Blue indicates it has fallen below its operational range (Low Alarm) while red indicates it has exceeded its operational range (High Alarm). There will be two options
available to the operator, Hold (suspend) or Reset the alarm. If the Hold button is clicked during alarm state, the software
will suspend the alarm Action for the period of time indicated in the Suspend Time. Reset clears the alarm condition.
Shown below are examples of alarm conditions and the resulting alarm buttons that may be displayed on screen. To remove
the condition, simply click on one of the function buttons, either Hold or Reset.
The user has the option of setting a high and low alarm to activate during an engine test. As previously discussed, they are
located by right clicking on a sensor in the Main Display Window. The user may then choose from the following options:
Trigger Point, Wait Secs Before Action, Suspend Time, a variety of Actions to perform, Grab Data Point if Triggered,
and Auto Reset. In both the Low Alarm and High Alarm state, the administrator has the following options available.
Trigger Point: The value at which the software will indicate that the sensor is out of the operational range. The units of the
value entered are selected from the Units tab. For example, if the sensor is configured in RPM, then the value entered will
reflect RPM.
Wait Secs Before Action: Indicates how many seconds the software should wait before performing the alarm Action.
Suspend Time: Indicates how long the alarm action will be delayed if the Hold button is clicked.
Action: The Action state of the alarm allows the administrator to set the following actions to be performed by the software
after the number of Wait Secs Before Action has completed.
None: Indicates no action is to be performed and only a color change is indicated on the screen.
Soft Stop: When the alarm is triggered, the software will first apply the "Wait Secs Before Action" value, then perform a soft
stop. Both the speed control and the dyno control return to zero and the Stop relays fire automatically. These actions stop
the engine as if it were shut down normally, as no load is applied during a soft stop. If selected, an alarm will sound.
E Stop: The throttle returns to zero and the valve is fully opened, applying a preset load to the engine, the stop relays are
fired, and the engine is brought to an abrupt stop. If selected, an alarm will sound.
Warning Only: In this condition, only an alarm warning is displayed on screen, no actions are performed.
Grab Data Point if Triggered: If checked, the software will immediately grab data if the Trigger Point is reached. Grabbing
data once a trigger point has been reached will help in identifying the problem area, and cause of the alarm. If Grab Data
Point if Triggered is not checked, the data will be gathered normally.
Auto Reset: If checked, the software will automatically reset the alarm after the sensor limit has returned to normal.
21

Main Display
The View Menu (continued)
View > Chart:
By selecting Chart under the View Menu, the Real-Time
Chart (shown below) will be displayed. This chart displays the real-time data change. Additionally, Reference
Data Can be viewed on the Real Time Chart.

To customize the Real-Time Chart, right click the chart and


choose Properties. The user has the option to choose what
information will appear on the X (horizontal) axis and Y (vertical) axis of the Chart.
From the Points frame, the user is able to select how many Points appear in the
Real Time Chart. The number of Points (30, 60 or 90) will determine the actual
width of the Chart. From the Speed frame, the user can select the speed (Medium or Fast) at which the system updates and displays data. The actual ranges
of the Chart are determined by the minimum and maximum values of the sensor
as established in the Sensor Properties Window.
To display the information from the Current Active Data Space as it is being recorded, select Rolling Time Chart from the X Axis list. If Rolling Time Chart is
selected, the chart will scroll to the left as data selected as the Y Axis is being
displayed.
Note: Real-Time graphing consumes a greater amount of processor speed as the number of sensors and the update rate
are increased.
Selecting Chart Reference Data will display Reference Data on the chart in addition to Data from the Current Active Data
Space. More information on Reference Data can be found on page 24 and in Chapter 7, Add-In Programs
To hide the real-time chart, right click the chart and choose Hide.
View > Find Overlapped Sensor(s): This menu item
will be active only if there are some sensors displayed
as Floating Forms. In this case, some visible sensors
may be overlapped by other sensors. This selection will
point out the positions of overlapped sensors. As shown
in the figure far right, the positions of the overlapped
sensors are marked by the Overlap symbol. Clicking
the Overlap symbol will cause the overlapped sensor
to appear.

View > Lock Sensors Positions: This menu item will


be active only if there are some sensors displayed as
Floating Forms. Normally, the positions of sensors shown
as Floating Forms can be any size or anywhere on the
screen. Checking this menu item will disable the ability
to size or move floating sensors.
22

Main Display
The Data Menu
Data Menu: Test data from the sensors can be cleared and recorded from the Data Menu . The Data Menu consists of
Clear Data, Grab Data , AutoGrab, Delete Data Point(s), Load Reference Data and Assign Sensors to Reference Data.
This data is later used in reports and graphs.
Data > Clear Data: Erases any stored data in the current open DataSpace. This change will not be saved
until the current DataSpace is saved.
WARNING: Once data has been erased, it can not be
recovered.

Data > Grab Data: Instantly records the current data


readings. The Grab Data function can be performed by
clicking on this menu item or by using the Windows keyboard shortcut keys Ctrl + G.

Data > AutoGrab: Allows you to turn AutoGrab off


or select an interval in which data will be recorded.
The user is able to choose one of several preset
intervals or custom configure time intervals.
AutoGrab only records data when the engine is running.

Note: The data you grab is saved into the current


active DataSpace and can be printed using the Report Generator program, as described in Chapter 6.

Data > Delete Data Points: Deletes data points or data


phases. If this function is selected, a pop-up window
(shown below) will appear. The user can choose to delete individual data points or delete entire phases.
Note: Phases are only available with the Advanced Pattern Runner.
To delete Data Points, enter the Data Point number and
click the Delete button. A confirmation window will appear. If the information in the window is correct, click
OK. The selected point will be deleted. Data Points are
numbered consecutively.
To delete a Data Phase, select the Delete Phase option. A window (shown right) will list the available phases
to delete. Highlight the phase to delete and click the
Delete button. Confirm the selection by clicking OK in
the confirmation window. .
23

Main Display
The Data Menu (continued)
* Data > Load Reference Data: This menu item allows
the user to load Reference Data into the report from an
external data source.
Reference Data is data that is typically used for comparing results of a test to accepted standards when viewing a graph. This data can be imported from a
DataSpace, a text file created in Excel, or created by
the administrator using the Reference Data Builder feature found in the Add Ins Menu. Further details can be
found in Chapter 7, The Add Ins Menu.

Once reference data has been loaded to the DataSpace, the Assign Sensors to Reference Data window will automatically
open. The user is given the choice of available sensors to assign reference data to.

* Data > Assign Sensors to Reference Data: To


change sensors assigned to the reference data after it
has been loaded, select Assign Sensors to Reference
Data... from the Data menu. After the reference data is
loaded, this menu item will become active. It is used to
associate the reference data to existing sensors.

Note: Once Reference Data has been assigned to a specific sensor, it will appear in any Graph in which that sensor is
assigned if the Use Reference Data check box is checked in the Graph Properties window found in the Report Generator.

The Window Menu


Window Menu: From the Window Menu, the arrangement of the Main Display Window can be modified. The Window
Menu consists of Default Positions and Show Main Form (which toggles to Hide Main Form) and AutoHide.
Window > Default Positions: If the active windows have
been modified or moved by the user, selecting the Default Positions will return them to their default display
positions.

24

Main Display
The Window Menu (continued)
Window > Show Main Form: If the sensors are only
displayed in a Floating Form format, the Main Form will
remain empty. To display the Main Form, select the
Show Main Form option. To hide the Main Form, select the Hide Main Form function.
After the main form appears, the Show Main Form menu
item will change to Hide Main Form. By selecting Hide
Main Form, the Main Form will be hidden again.
Window > Auto Hide: Checking Auto Hide will reduce
the floating menu to an icon (shown below) after a short
period of time. To reactivate it, simply place your cursor
over the icon.

The Add-Ins Menu


Add-Ins Menu: The selections in the Add-Ins menu
may vary with different embedded programs. Any optional component programs that do not come standard
will be listed under the Add-Ins Menu. Programs found
in the Add-Ins Menu are explained in Chapter 7, AddIn Programs.
Note: For instructions and specifications for specific
hardware included with your system, please consult
the information provided with the equipment.

The Help Menu


Help: The Help menu of the Main User Interface Window shows the Versions of the programs and the Release Notes.
Help > Show Versions: Displays the current version specifications of the software (shown below).

Help > Release Notes: Opens a .txt file that contains the historical changes to the software program. This is used as a reference file by PTI employees.

25

Main Display

26

Controller Interface

PowerNet 2.0
Data Acquisition and Control
- CHAPTER 4 Controller Interface

27

Controller Interface

28

Controller Interface
Controller Interface Window
The Controller Interface window provides essential control functions for the dynamometer. This window identifies the
dynamometers active load control mode and the current setpoint.
It is possible for a user at the Commander computer to control the dynamometer using the mode buttons and the input box
directly from the Controller Interface window. Additionally, the dynamometer tuning parameters can be accessed from this
window.

29

Controller Interface
Controlling the Dynamometer
There are two methods for manually controlling the dynamometer and/or engine directly from the Controller Interface. The first
method is by entering a number in the Setpoint Entry Box directly above the Start, Home and Soft Stop buttons. Entering a
value in this window and pressing enter on the keyboard will move the yellow Slide Bar to the desired set point. Additionally,
a blue bar will display the progress of the change being made. The second method for controlling the dynamometer and/or
engine is by clicking on the Slide Bar and dragging it to the desired set point. As the Slide Bar is moved, its position will be
displayed in the Setpoint Entry Box. A blue bar will display the progress of the change being made. Additionally, clicking on the
arrows at the top and bottom of the Slide will move the Slide Bar 5% for each click.
Note: The system can only be controlled using the Slide Bar in the Throttle Position and Dynamometer Valve Position modes
as described below.

Throttle Control Modes


There are two standard and two optional methods by which the engine operating speed may be controlled during testing:
1) Position: A method of controlling the engine in which the throttle is set at a percentage of the pre-calibrated throttle range and
is maintained at this position during testing. Speed adjustment may be made by using the Slide Bar or entering the percentage
value.
2) Speed: A method of controlling the engine in which an actual speed in RPM is entered and the system will move the throttle
in an effort to maintain the entered value during testing.
3) Torque Mode (Optional): A method of controlling the engine in which a torque set point is entered and the throttle tries to
maintain that amount of load, regardless of the engines speed or its ability to achieve that load (may overload engine if set point
is too large).
4) Horse Power Mode (Optional): A method of controlling the engine in which a horsepower set point is entered and the
throttle tries to maintain that amount of load, regardless of the dynamometers speed or the engines ability to achieve that load.

Dynamometer Control Modes


Whether performing automated or manual setpoint operation, the dynamometer will ultimately be controlled by one of the
following four modes:
1) Position (Valve Mode): A method of controlling the dynamometer in which the dynamometer water valve position is directly
controlled by valve percentage (manual load method). Load adjustment may be adjusted by using the Slide Bar or entering the
percentage value.
2) Torque Mode: A method of controlling the dynamometer in which a torque set point is entered and the dynamometer tries
to maintain that amount of load, regardless of the engines speed or its ability to achieve that load (may overload engine if set
point is too large).
3) Horse Power Mode: A method of controlling the dynamometer in which a horsepower set point is entered and the dynamometer tries to maintain that amount of load, regardless of the engines speed or its ability to achieve that load. This is
typically used for endurance testing or warm up and may overload the engine if the set point is too large.
4) Engine Speed Mode: A method of controlling the dynamometer in which an engine speed is entered and the dynamometer
tries to maintain the engine speed (dynamometer must be reading engine speed either through the engines ECM or the
dynamometers speed pickup). If the engine speed is higher than the set point, the dynamometer will load the engine until the
engine speed set point is achieved. If the engine speed is lower than the set point, the dynamometer will unload the engine until
the engine speed is achieved. This mode is typically used for maximum power pulls.

30

Controller Interface
Controller Interface Window Pull-Down Menus
The Controller Interface Window consists of the File and View menus.

The File Menu


File Menu: The File pull-down menu allows the operator to load and save sets of tuning parameter values. The File pull-down
menu consists of Open Tuning, Save Tuning, Save Tuning As, Import 1.2 Tuning, Request Auxiliary Names From
WorkStation and Send Auxiliary Names To WorkStation. Tuning is explained on page .
File > Open Tuning: Will open a previously saved set of tuning parameters.

File > Save Tuning: Saves over the currently active set of tuning parameters as a file with the same name.
Note: Use caution when using the Save function. Once changes have
been saved and the original file has been overwritten, the original file can
not be retrieved.

File > Save As Tuning: Saves the active set of Tuning Parameters as a
new set of Tuning Parameters. The user will be prompted to name the
new file before saving.

File > Import 1.2 Tuning: Imports an older version of the tuning file (from
PowerNet 1.2). After importing the file, the 1.2 tuning file can be used with
the PowerNet 2.0 software.

31

Controller Interface
The File Menu (contd)
File > Request Auxiliary Names from WorkStation: Requests sensor
names from the WorkStation and assigns them to sensors displayed in
the Main Display window.

File > Send Auxiliary Names to WorkStation: Sends sensor names


from the Main Display window to the WorkStation to update the sensor to
have the same name.

The View Menu


View Menu: From the View menu, the user can switch between viewing the Control, Tuning and Setting modes. This modes
can be also be accessed by using the three tabs below the pull-down menu bar (bottom left). The View pull-down menu
consists of Control, Tuning, Settings, Ramp and Status.
View > Control: Displays the control mode of the Controller Interface.
After viewing the Tuning or Settings modes, the Controller Interface must
be returned to the Control Mode (shown below) in order to perform test.

32

Controller Interface
The View Menu (contd)
View > Tuning: Displays the dynamometer tuning parameters. The
PowerNet Data Acquisition and Control software utilizes a Proportional
Integral Derivative controller. The PID controller compares a measured
value from a process with a reference setpoint value. The difference or
error signal is then used to calculate a new value for the throttle or valve.
The PID loop occurs many times/second.
Note: Tuning parameters should not be modified or shown, unless instructed to do so, AND THEN DONE SO BY THE ADMINISTRATOR
ONLY.
The Proportional, or gain, positions the throttle or valve at a percentage
proportional to the error.
The Integral is the rate at which the dynamometer will reach that setpoint.
Derivative controls the rate of change.
I2 has the same properties as Integral, but has a greater effect the further it is from the setpoint.
The Lim%/Sec is the actual rate at which the valve moves.
Determining the appropriate settings for P and I can be a difficult task. A
simple method for tuning is to first set the I and D values to zero. Increase
the P until the system begins to oscillate, and then divide by 2. Then
increase I until oscillation starts, and divide by 2. A fast PID loop tuning
usually overshoots slightly to reach the setpoint more quickly; however,
some systems cannot accept overshoot. If this is the case, the tuning will
need to be slower.

33

Controller Interface
The View Menu (contd)
View > Tuning (contd):
The tuning display contains nine separate sections: Positive, Negative, Engine, Throttle,
Span, Constants, Dynamometer Properties,
Valve and Misc.
Positive: Represents the positive error, or the distance beyond the setpoint.
Negative: Represents the negative error, or the
distance away from the setpoint.
Note: In most circumstances, the Positive and
Negative tuning ratios should be identical.
The Positive and Negative tuning parameters
directly affect the control of the dynamometer
when in torque or power mode.
Engine: The P, I and D settings for the Engine
tuning section produce a torque setpoint, applied
to the Positive and Negative tuning parameters.
The Engine tuning parameters affect the control
of the dynamometer when in Dyno Speed Control mode.
Span: The Span Speed setting determines the
maximum speed at which the system will allow
the dynamometer to operate. The Span Torque
setting determines the maximum torque that each
rotor in the dynamometer will absorb. This number is multiplied by the value entered in the Rtr
Num box.
ex. If the system is controlling a 50X02 (two rotor) dynamometer, a value of two would be entered in the Rtr Num box. If a value of 2000 is
entered into the Torque Span box, the total torque
that the system could control would be 4000. If
the dynamometer exceeds 4000 ft-lbs of torque,
the system will use the P tuning parameter found
under the Valve section with a setpoint of 4000.

Throttle: The P, I and D settings for the Throttle tuning parameters affect the control of the dynamometer when in Throttle
Speed Control mode.
Constants: The PD LSM (Lower Speed Multipliers) and I LSM (Lower Speed Multipliers) determine a gain or reduction on the
PID before it reaches the Tune Speed as specified by Tune Spd in the Misc. section. During a sweep, up until the time the Tune
Speed is reached, the P, I and D is multiplied by the LSM.

34

Controller Interface
The View Menu (contd)
View > Tuning (contd):
Misc: The Misc. tuning section contains the Thr.
Rate, V. Rate, Bal. Rate and Tune Spd tuning
parameters. The Thr. Rate and V. Rate parameters determine the percentage rate at which the
throttle and valve increase per second.
ex. If a value of 10 in entered in the Thr. Rate
box, and the throttle is changed from 0% to 100%
from the control window, the system will take ten
seconds to reach full throttle.
The Bal. Rate function does not apply to the PowerNet 2.0 software.
The Tune Spd. is the speed at which the PID
settings take effect. Up until the time that the
Tune Speed is reached, the PID is multiplied by
the PD LSM (Lower Speed Multipliers) and I LSM
(Lower Speed Multipliers) found in the Constants
section.
Dynamometer Properties: The Dynamometer
Properties section contains the Hp/Rtr, Lb-Ft/Rtr,
and Rtr Num tuning parameters.
The Hp/Rtr and Lb-Ft/Rtr tuning parameters do
not apply to the PowerNet 2.0 software.
The number of rotors of the dynamometer being
used is entered into the Rtr Num box. This value
is entered and multiplied by the value entered in
the Torque box found in the Span section.
ex. If the system is controlling a 50X02 (two rotor) dynamometer, a value of two would be entered in the Rtr Num box.
Valve: The Valve tuning section contains the Proportional tuning parameter for the valve. If the
system exceeds the torque specified by the values entered in the Span and Rtr Num tuning parameters, the value entered into the Valve P box
will be applied to the system.

35

Controller Interface
The View Menu (contd)
View > Settings: Shows the currently active Interface Settings. Allows
the operator to precisely refine the Inertia compensation, Maximum
Speed, Overspeed Reset, and Minumum Run Speed.

Inertia: A value is entered in this box to compensate for the


Inertia of the spinning components of the engine.
If possible, obtain the rotational inertia of each component from
the manufacturer. Some simple rules for calculating the system
inertia:
Add up the inertia values of all rotating components, including:
dynamometer, flywheel or flexplate, engine adapter, crankshaft,
vibration dampener, pulleys, etc.
The inertia of any belt or gear driven components must be
multiplied by the square of their respective drive ratio.
If the inertia information is not available for a component, almost
all rotating components on an engine/dynamometer system have
geometry similar to, or can be approximated by, a ring or rings.
To calculate the rotational inertia, the mass (Lbs) and the dimensions (Inches) must be known.

Maximum Speed: The value enetered in the Maxmum Run Speed window sets the maximum speed (in RPM) that the
system will allow the engine to run. If the speed of the engine exceeds the determined value, the system will fire the Engine Stop
relay until the engine speed falls below the operated speed as determined by the Overspeed Reset.
Overspeed Reset: If the engine accelerates beyond the Maximum Speed, the sytem will not return to normal operation until
the engine speed falls below that as determined by the value entered in the Overspeed Reset box.
ex. If a value of 4000 is entered in the Maximum Speed box and a value of 100 is entered in the Overspeed Reset box, the
engine spped must fall below 3900 RPM before the system will return to normal operation.
Minumum Run Speed: Once the engine being tested achieves the RPM entered in the Minumum Run Speed box, the
systems starting rel

36

Controller Interface
The View Menu (contd)
View > Ramp: Clicking on Ramp displays the Ramping (shown below),
or percentage of change per second, of the value being changed.
ex. Entering a throttle value of 50 in the Setpoint Entry Box and a value of
10 in the %/sec Entry Box will increase the throttle percentage by 10
percent every second, acheiving the set value of 50% throttle in five seconds.

View > Statistics: This menu item is used to display a form that shows
the status of the controller (shown below).

37

Controller Interface

38

Pattern Runner

PowerNet 2.0
Data Acquisition and Control
- CHAPTER 5 Pattern Runner

39

Pattern Runner

40

Pattern Runner
The Pattern Runner Interface Window
The Pattern Runner program allows the user to create, load, save and execute PowerNet Patterns. Patterns are preconfigured load and speed set-points that are designed to automatically run in order. Each of these set-points is represents an
action executed by the Controller Interface. Once a Pattern has been created, that Pattern is used to run individual commands
of the Controller Interface.
NOTE: A thorough understanding of the dynamometer load and throttle controls, modes of operation, and effects on the engine
are required before creating new Patterns. When creating new Patterns, it is recommended to insert many small steps between
changes in RPM and load. It is also recommended that the time interval (Point Duration) is set long is set long enough to allow
for each step to stabilize before advancing to the next.

Example of a PowerNet Test Pattern


Each row represents one point in the Pattern. Each row is divided into as many as five columns.
The first column represents the Point, or step of the pattern. ex. 1), 3), etc....
The second column represents the Throttle mode. In the above example, Th:, represents the Throttle position during the test.
The throttle value can be set by either the percentage of the throttle that is desired (%), or by a set speed (RPM).
The third column, represents the Unit of measure for each Control Mode. ex. HP, RPM and %. In the example above, V:,
represents position of the load control valve. There are four settings for determining the valve position: Valve position, Torque,
Power, and Speed.
Note: The units for each of these settings are selected from the Sensor properties menu of the Main Display. To access a
Sensors properties, right click on the sensor and select the appropriate unit from the Units tab.
The fourth column represents the Duration, or the elapsed time during each step of the pattern. ex. 30, 01:00, etc... In the
exapmle above, Wait, represents the Duration, or the elapsed time during each step of the pattern.
Column five indicates whether or not data will be recorded, including activation of the AutoGrab feature.

41

Pattern Runner
Pattern Runner Window Pull-Down Menus
The Pattern Runner Window consists of three (3) pull down menus, the File, Edit, and Tools.

The File Menu


File Menu: There are four options within the File Menu, New, Open, Save, and Save As.
File > New: Clears the current Pattern to allow the user to create a new Pattern, as
explained on the following page.

File > Open: Allows the operator to open an existing PowerNet Pattern.

File > Save: Overwrites the active PowerNet Pattern with a file having the same name.
Note: Use caution when using the Save function. Once changes have been saved and
the original file has been overwritten, the original file can not be retrieved.

File > Save As: Saves a copy of the current PowerNet Pattern as a new Pattern. The
user will be prompted to name the new file before saving.

The Edit Menu


Edit Menu: There is one option available for the Edit menu, Edit Full Pattern.
Edit > Edit Full Pattern: This allows the operator to edit the active Pattern. Selecting
Edit > Edit Full Pattern brings up the Edit Pattern Window as shown on the following
page. The procedure for editing an existing Pattern is similar to creating a new Pattern.

42

Pattern Runner
Creating a New PowerNet Pattern
A new PowerNet Pattern can be created from scratch or by modifying an existing Pattern and saving it as a new file name. To
create a new Pattern from scratch, click on New under Pattern Runners File pull-down menu. To modify an existing Pattern,
select Open from the File pull-down menu and open the Pattern to be modified. In any case, the Pattern must be edited. (See
Edit > Edit Full Pattern on the previous page).

C
C how long to hold the setpoint
Each Pattern Point must indicate the control mode, the setpoint, and
before proceeding to the next
C
setpoint. The Pattern Point also must indicate if data is to be recorded during the point (Auto Grab or Grab) and it should include
instructions for the Operator (Operator Prompt) and designate the Phase.

The first line of the Edit Pattern Window displays the Current Point. ex. Current Point 1 in the example above. The Function
Buttons on the bottom of the Edit Report window are used to Add, Delete and toggle (Previous/Next) between Pattern Points.
When the current point has been modified, click on the OK button.
The options for controlling the engine operating speed are located directly below the Current Point heading. There are two
options for controlling the engine operating speed: Throttle (%), and Speed (RPM). By using different variations of load control
methods (Valve (%), Torque (ft-lbs), Power (Hp), or Speed (RPM)) in combination with these settings, the operator can run
a variety of tests. To the right of the Control Modes there is a box to enter the appropriate Unit of value for the current Point. For
more information about control modes, see Chapter 4, The Controller Interface.
The center of the Edit Pattern window displays the options for the Duration of the current Point. The administrator has the
option to chose from a variety of factors affecting the start of the current Point, including Stability, Operator Prompt, and Point
Duration. Details for each of these sections are described in detail on the following page.
Below the Duration sections are the AutoGrab, Point Duration, Go to info, and Digital Outs sections. The AutoGrab
function allows the administrator to determine if Data is to be grabbed at the end of each Point (No Change if Grab Data at the
end of this point is checked beneath the Point Duration box), throughout the duration of the Point (At the start of point grab
data every ___ secs), or not at all (Off).
The elapsed time of each Point is entered in the Point Duration (secs) box. The determines the amount of time required before
the next Point begins.
Go to Info allows the administrator to create a new Point that makes the Pattern return to a previous point. This allows the
administrator to duplicate stages of a Pattern without having to create them again. How many times a section of the Pattern
repeats is determined by the number entered in the Go to count box.
The Digital Outs section allows the administrator to automatically turn relays on/off as part of a Point.
43

Pattern Runner
Duration Settings
In order to provide the administrator with greater flexibility, there are three setting that define how long the setpoint should be held
before proceeding to the next Point: Stability, Operator Prompt, and Phase.

Stability: The settings entered in the Stability section cause the system to wait to perform the functions specified in the current
point until the requirements specified by the administrator are met. The Stability section includes the Wait for Sensor, Wait
for Setpoint, and None check boxes.
If the Wait for Sensor box is checked, the setpoint will be held until a selected sensor has reached a predetermined value
(Goal), within a certain tolerance (Tolerance), for a certain duration (Wait stability Secs). When using Wait for Sensor, the
Wait Stability Secs wont begin counting down until the sensor value is within the range defined by the Goal and the Tolerance.
If the sensor value drifts outside the range during the wait time, the wait time will start over once the setpoint is back within the
range.
If the Wait for Setpoint box is checked, the setpoint will be held until its value is reached within a certain Tolerance (Tolerance),
for a certain duration (Wait Stability Secs). When using Wait for Setpoint, the Wait Stability Secs wont begin counting down
until the indicated control mode value is within the range determined by the setpoint and the tolerance. If the control mode value drifts
outside the tolerance during the wait time, the wait time will start over once the control mode value is back within the range.
Note: If a Pattern is suspended or restarted after a particular sensor or setpoint has been reached, the system may not be able
to resume if the sensor or SetPoint value has traveled outside of its specified Goal and Tolerance. ex. If a point was set to
begin when the engine temperature has reached 180 with a setpoint of 180 and a tolerance of five, and the Pattern has been
suspended after the engine temperature has reached 205, the Point will not Proceed to the next Point if the test is restarted
without allowing sufficient time for the engine to cool.
Operator Prompt: The settings entered in the Operator Prompt section allow the administrator to display instructions for the
operator and to pause the current pattern until the operator responds. The Operator Prompt section includes the Operator
Prompt text box and the Show Status on Handheld, Wait for Continue, and Allow skip of ___ points check boxes.
If the Wait for Continue box is checked, the Pattern will not proceed to the next point until the Operator touches the Continue
button that will be displayed on the Handheld Controller.
If the Allow Skip of Points box is checked, a skip button will appear on the Handheld Controller. If the Operator touches the
Skip button, the Pattern will skip the indicated number of Pattern points.
44

Pattern Runner
Duration Settings (continued)
Point Duration: In this method, the administrator simply enters how many seconds the current setpoint is to be held before
continuing to the next pattern point. The number of seconds is entered at the Point Duration input box.
Note: It is possible to use any of the above methods for determining setpoint duration simultaneously. The dynamometer will
first try to satisfy the Stability settings, then the Operator Prompt settings, and finally the Point Duration settings as they appear
in the Edit Report window, from left to right.

Grabbing Data Points


The AutoGrab function allows the administrator to determine if Data is to be grabbed at the end of each Point (No Change if
Grab Data at the end of this point is checked beneath the Point Duration box), throughout the duration of the Point (At the start
of point grab data every ___ secs), or not at all (Off).
Selecting No Change keeps the AutoGrab setting the same as in the preceding Pattern point.
Selecting At the start of point grab data every ___ secs and entering a value defines the time interval that data will be
captured during the current Pattern point.
Selecting Off disables the AutoGrab feature.

Phases
Phases allow acquired data to be grouped for reporting purposes. To assign the data collected during the current setpoint to a
particular Phase, simply select the desired Phase from the pull-down. To create a new Phase, type the name of the new phase
in the pull-down menu. Phases are explained in detail in Chapter 6, Report Generator.

Function Buttons
Previous: Makes the preceding Pattern point active (if one exists) to allow it to be edited. Click once to restart the current point.
To activate the previous point, click twice.
Next: Advances to the next Pattern point (if one exists) to allow it to be edited.
Add: Inserts a copy of the current Pattern point and makes it active for editing.
Delete: Deletes the current Pattern point.
OK: Exits the Edit Pattern window.

Saving a PowerNet Pattern


When finished editing the Pattern, it will be saved with the active DataSpace or Template. The Pattern can also be saved as its own file by selecting Save As from Pattern
Runners File pull-down menu.

Running a PowerNet Pattern


When all of the Pattern Points have been edited and saved, the Pattern is now ready to run. To run a Pattern, click on the Play
tab. This will display the time remaining for the current Pattern Point. Clicking the Pause tab pauses the current Pattern and
changes the function of the Play tab to Stop. To resume the Pattern, click the Pause tab again. To stop the Pattern, click on
the Stop tab. The <<Previous and Next>> tabs are used to navigate to different points in the Pattern.

The Tools Menu


The Tools Menuis currently grayed oiut, as there are no options available at this time.
45

Pattern Runner

46

Report Generator

PowerNet 2.0
Data Acquisition and Control
- CHAPTER 6 Report Generator

47

Report Generator

48

Report Generator
The Report Generator Program
A copy of the data recorded during a dynamometer test should be saved following each test session. The Report Generator
allows the operator to arrange the data into a meaningful visual format. Customer, engine, and set up information can be put into
User Tables and Paragraphs. The information gathered during a test can then be arranged in a Data Table, Spreadsheet,
and/or Graph. Report formats can be created and edited before or after a DataSpace has been created.

Report Generator Window

There are two types of information tables, a User Table and a Data Table. A User Table provides blanks for the operator to
enter specific information about the test being performed. This can include, but is not limited to: Customer Information, Engine
Information, Test Specific Information, etc. A Data Table contains information gathered from the attached sensors during a
test, and displays only that information that is specified for that particular Data Table, such as maximum and minimum values.
The data gathered during a test can also be arranged in a Spreadsheet and/or Graph. A Spreadsheet is a computer
generated arrangement of the test data into rows and columns. A Graph is a drawing representing the relationship between two
sets of data. One set, such as gathered information, is represented on a vertical scale or axis, the other, such as time or other
data, is represented on a horizontal scale or axis.
In addition to tables, graphs, and spreadsheets, information can also be entered into a Paragraph. A Paragraph is typically
used to enter notes, disclaimers, descriptions, etc. relating to a specific test or stage of testing.

Report Generator Window Pull-Down Menus


The Report Generator Window consists of the File, Edit, View, Import, Export, and Ignore List menus.

The File Menu


File Menu: The File Menu allows the user to access the Reporter print
features. The menu consists of Print Preview, Print, and Print Screen.
File > Print Preview: This selection allows the user to view the printed
report on screen. Once selected, a report preview appears (below right).
From the preview, the user can print a hard copy of the report by clicking
on Print in the upper left-hand corner.
The operator may print out reports that can be configured to display your
companys logo and contact information. Contact your Power Test representative for assistance in creating a custom header.

49

Report Generator
File > Print: Displays a preview of the report and opens up the print
properties screen.

File > Print Screen: Sends a snapshot of the entire Commander screen
to the printer. It makes no difference which interface windows are open,
some may be minimized. It simply takes a screen capture of whatever is
on the screen at the time.

The Edit Menu


Edit Menu: The Edit Menu consists of one selection, Edit Report.
*Edit > Edit Report: This function allows the administrator to modify the
active data report.
* Note: Without logging in, many menu items will be grayed out and the
corresponding administrative functions can not be performed. All functions requiring login will be noted with an * throughout the rest of this
chapter.

Click on Edit Report and a new window will appear. The Edit Report
window (shown right) allows the user to configure the printed reports and
the entry fields of User Tables, Data Tables, Graphs, Spreadsheets and
Paragraphs.

50

Report Generator
Using the Edit Report Window
From the Edit Report Window, the user can move, add, delete, copy and edit sections. The information displayed on the
report will display as it appears in the list. Clicking on a section highlights that section, and enables the function buttons on the
left side of the window.

Report Sections
Move Section Up
Move Section Down

Delete Section
Add Section

Copy Section
Edit Section

Edit Report Window

Edit Report Function Buttons


Move Section Up: Clicking this button will move the highlighted section up, changing the order in which information appears on
the final report.
Move Section Down: Clicking this button will move the highlighted section down, changing the order in which information
appears on the final report.
Delete Section: Clicking this button will delete the highlighted section.
Add Section: Clicking this button will bring up the Add Section window (above left), allowing the user the option of adding one
of five section types: User Table, Data Table, Graph/Spreadsheet, Paragraph, and Page Break, all of which are explained
throughout this chapter.
Copy Section: Clicking this button makes a copy of the highlighted section and all of its properties. This is useful for creating
a similar section without having to create it from new.
Edit Section: Clicking this button allows the user to edit the particular section of the report that is highlighted. Additionally, the
edit report window can also be accessed by double clicking on any highlighted section.

Creating and Editing Report Section Types


Details for creating and editing User Tables, Data Tables, Graphs, Spreadsheets and Paragraphs are explained in detail on
the following pages.

51

Report Generator
Creating a New User Table
To create a new User Table, select User Table from the list of section types under the Add Section (+) function of the main
Edit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the new User Table
to edit the new User Table.

Table Name
Field Name

Number of Columns Assigned to the Table


Report Fields

Navigational Buttons

Begin by assigning a name to the new User Table by entering a name in the Table Name text box. This will name the new
User Table. To change the name of a Report Field, click on the field name in the Report Field box. Entering a name in the
Field Name text box will change the name of the Report Field.
To add a Report Field, click on the Add Section (+) button. Report Fields can be also be moved up/down and deleted from the
User Table using the navigational buttons. The navigational buttons perform the same function as previously described in
Using The Edit Report Window section, found on page 49.
The user also has the option to choose how many columns are assigned to the table.
Note: It is recommended to keep the number of columns in a User Table a multiple of the number of fields. i.e. 3 fields - 1 or
3 columns; 4 fields - 1,2 or 4 columns. This will help to ensure that the data is presented in an organized manner.

52

Report Generator
Editing User Tables
To edit a User Table, highlight the desired table, and either click on the Edit Section button, or double click on the highlighted
selection itself. The Edit Report window (shown below) will appear. The navigational buttons perform the same function as
previously described in Using The Edit Report Window section, found on page 49.
To change the name of the User Table, highlight
the current name in the Table Name text box and
either press the delete key, or overwrite the current name with the new name.
To change the name of a Report Field, click on
the field name in the Report Field box. Next,
either press the delete key, or overwrite the current name with the new name.
To add a new Report Field to the User Table, click
on the Add Section (+) button. Report Fields can
be also be moved up/down and deleted from the
User Table using the navigational buttons.
Note: A User Table is limited to 12 Report Fields.
The user also has the option to choose how many
columns are assigned to the table.
Note: It is recommended to keep the number of
columns in a User Table a multiple of the number
of fields. i.e. 3 fields - 1 or 3 columns; 4 fields 1,2 or 4 columns. This will help to ensure that the
data is presented in an organized manner.
Sample User Table

Examples of User Tables - As Printed (left) and On Screen (right)

53

Report Generator
Creating a New Data Table
To create a new Data Table, select Data Table from the list of section types under the Add Section (+) function of the main
Edit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the new Data Table
to edit the table.

Table Name
Number of Columns Assigned to Table
Function
Available Sensors
Reference Sensor
Add Sensors to the Data Table Sensors List

Available Phases
Data Table Sensors
Navigational Buttons
Remove Sensors from the list of Sensors
*Plot Individual Phases
*Requires Advanced Pattern Runner
Assign a name to the new Data Table by entering a name in the Table Name text box. This will name the new Data Table.
Report data is gathered from the sensors displayed in the Available Sensors list. This list displays all of the sensors
connected to the system at the time of the reports creation (available sensors may vary depending on version of software). The
Data Table Sensors list displays all of the sensors whose data will be displayed on the final report. To add a sensor to the Data
Table Sensors list, first click on a sensor from the Available Sensors list. The Available Sensors list displays all of the
sensors currently connected to the system. Next, select a function to be performed on the sensor from the Function list
(explained on the following page). Then click the Add button to add the selected sensor and function to be performed to the list
of Data Table Sensors. To change the order in which the Data Table Sensor information appears on the printed report,
highlight a sensor in the list, and click on the Navigational Buttons to the left of the Data Table Sensors list.
The user also has the option to choose how many columns are assigned to the table.
Note: It is recommended to keep the number of columns in a User Table a multiple of the number of fields. i.e. 3 fields - 1 or
3 columns; 4 fields - 1,2 or 4 columns. This will help to ensure that the data is presented in an organized manner.

Reference Sensors
Selecting the Reference Sensor function will display a particular sensor values and its correlation to another sensors greater
or lower value. i.e. Speed at Peak Torque.
To display Reference Sensor data in the final report, choose a Reference Sensor from the drop-down menu. The list of sensors
available as Reference Sensors is the same as the list of sensors available in the Available Sensors list. When the desired
reference sensor has been selected, click on Hi Ref to display the peak value, or Lo Ref to display the low value.

54

Report Generator
Editing Data Tables
To edit a Data Table, highlight the desired table, and either click on the Edit Highlighted Section button, or double click on the
highlighted selection itself. The Edit Report window (shown below) will appear. The navigational buttons perform the same
function as previously described in Using The Edit Report Window section, found on page 49.
To add a sensor to the Data Table Sensors list,
first click on a sensor from the Available Sensors list. Next, select a function to be performed
on the sensor from the Function list (explained
below). Then click the Add button to add the
selected sensor and function to be performed to
the list of Data Table Sensors. To change the
order in which the Data Table Sensor information appears on the printed report, highlight a sensor in the list, and click on the Navigational Buttons to the left of the Data Table Sensors list.

Phases (Optional)
A Phase represents a segment of the data gathered during a test. The Phases section displays
the list of stored phases from the current
DataSpace. Selecting a phase will include it in
the generated report. If the Individual Phases
box is left unchecked, all function values for the
included Data Table Sensors will be calculated
by grouping data from the selected phases. If the
Individual Phases box is checked, the function
values will be calculated on a per phase basis.
i.e. If there were six phases selected, and three
sensors in the Data Table Sensors list, the report
would yield a total of 18 values.

Sample Data Table

The Function List


The Function List defines which data points will be displayed in the Data Table.
First: This will display the first value of the sensor selected. If Individual Phases is also selected, it will display the first
value of the sensor selected for each selected phase.
Last: This will display the last value of the sensor selected. If Individual Phases is also selected, it will display the last
value of the sensor selected for each selected phase.
Delta: This will display the difference between the first and last value of the sensor selected. If Individual Phases is
also selected, it will display the difference between the first and last value of the sensor selected for each selected
phase.
Average: This will display the average value of the sensor selected. If Individual Phases is also selected, it will
display the average value of the sensor selected for each selected phase.
Peak: This will display the largest value of the sensor selected. If Individual Phases is also selected, it will display the
largest value of the sensor selected for each selected phase.
Low: This will display the lowest value of the sensor selected. If Individual Phases is also selected, it will display the
lowest value of the sensor selected for each selected phase.
55

Report Generator
Creating a New Graph
To create a new Graph, select Graph/Spreadsheet from the list of section types under the Add Section (+) function of the
main Edit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the new Graph
to edit the graph.

Graph Name
Section Type (Graph/Spreadsheet)
X-Axis
Available Sensors
Use Reference Data
Hide Symbols
Plot Individual Phases

Available Phases
Y2
Included Sensors

Size (Height/Width)
Copy to Graph View

Begin by selecting Graph under Section Type. Next, create a name for the new Graph by entering a name in the Heading
text box.
Choose which sensors to display on the X Axis and Y Axis of the Graph. The X Axis menu contains the sensors available for
display on the X (horizontal) axis of the Graph. The graph can only display 1 (one) sensor on the X axis per graph. Select a
sensor from the X Axis pull-down menu. Clicking on the Hide Symbols box will create lines on the graph without showing a
symbol at the individual points. If the Plot Individual Phases box is left unchecked, the graph will show each Included
Sensor as a continuous line throughout all of the phases selected. If the Plot Individual Phases box is checked, each
Included Sensor will be graphed with multiple lines corresponding to each phase selected.
A Phase represents a segment of the data gathered during a test. The Phases section displays the list of stored phases
from the current DataSpace. Selecting a phase will include the selected phase in the generated report.
Note: Phases are only available with the Advanced Pattern Runner software.
The Available Sensors list displays the sensors available for display on the Y (vertical) Axis. The sensor displayed on the Y
Axis is displayed on the left side of the graph. To add a sensor to the Included Sensors list, click on a sensor from the
Available Sensors list, then click on the Add button. To remove a sensor from the Included Sensors list, click on the sensor
to be removed, and click the Remove button.
Clicking the Use Reference Data check box will plot Reference Data on the Graph in addition to the data being recorded
during the test. Reference Data is data that is typically used for monitoring and comparing the results of the test. Instructions
for creating and loading Reference Data can be found in Chapter 3, Main Display and is further discussed in Chapter 7, AddIn Programs.
The Y2 feature allows the user to display a second sensors data on the Y2 (vertical, right) axis of the Graph. To assign a sensor
to the Y2 Axis, click on that sensor in the Included Sensors box, then check the Y2 box.
The user has the option of setting the Height and Width of the Graph, determining the size of the Graph on the generated report.
56

Report Generator
Editing Graphs
To edit a Graph, highlight the desired graph, and either click on the Edit Highlighted Section button, or double click on the
highlighted selection itself. The Edit Report window (shown below) will appear. The navigational buttons perform the same
function as previously described in Using The Edit Report Window section, found on page 49.
If a Graph is selected the user has the ability to
decide which sensors they wish to display on the
X Axis and Y Axis of the Graph. The X Axis
menu contains the sensors available for display
on the X (horizontal) axis of the Graph. The graph
can only display 1 (one) sensor on the X axis per
graph. Clicking on the Hide Symbols box will
create lines on the graph without showing a symbol at the individual points. If the Plot Individual
Phases box is left unchecked, the graph will show
each Included Sensor as a continuous line
throughout all of the phases selected. If the Plot
Individual Phases box is checked, each Included Sensor will be graphed with multiple lines
corresponding to each phase selected.
The Available Sensors list displays the sensors
available for display on the Y (vertical) Axis. To
add a sensor to the Included Sensors list, click
on a sensor from the Available Sensors list, then
click on the Add button. To remove a sensor from
the Included Sensors list, click on the sensor to
be removed, and click the Remove button.

Sample Graph

Clicking on the Copy To Graph View tab takes the data created from the report and displays it in a new window. The New
Graph View will have all of the same properties of the graph it was created from. A Graph View displays recorded data from a
test and is refreshed every time a data point is recorded. This is different from the real-time chart, which displays data
regardless if data points are recorded or not.
Note: Clicking Copy To Graph View opens a Graph in a new window. Any changes made to the New Graph View will not be
saved as part of the report. Consequently, any changes made to the Graph from the Edit Graph window will not appear on the
New Graph View unless the Copy To Graph View tab is clicked again, opening a New Graph View in a new window.
All functions and properties of the graph created by clicking the Copy To Graph View button are the same as those for a New
Graph View, as described on page 60.
57

Report Generator
Creating a New Spreadsheet
To create a new Spreadsheet, select Graph/Spreadsheet from the list of section types under the Add Section (+) function
of the main Edit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the new
Spreadsheet to edit the spreadsheet.

Spreadsheet Name
Section Type (Graph/Spreadsheet)
Enable Grouping
Available Sensors
Key Sensor
Group By Sensor
*Group By Phase

*Available Phases
Included Sensors

Remove from the List of Sensors

*Requires Advanced Pattern Runner


Begin by selecting Spreadsheet under Section Type. Next, create a name for the new Spreadsheet by entering a name in
the Heading text box.
The Available Sensors list displays the sensors available for display on the Spreadsheet. To add a sensor to the Included
Sensors list, click on a sensor from the Available Sensors list, then click on the Add button. To remove a sensor from the
Included Sensors list, click on the sensor to be removed, and click the Remove button.
If a Spreadsheet is selected from the Section Type, the user has the option of clicking on the Enable Grouping check box. If
the Enable Grouping check box is not selected, the Included Sensors will display as a continuous column throughout the
whole Spreadsheet. If the Enable Grouping check box is selected, the user will have option to the select a Key Sensor (the
sensor that data is matched to, typically speed), and whether the data will be grouped by Sensor or Phase in the final report.
By selecting Sensor, the data is paired by sensors and displayed under each phase. By selecting Phase, the data is grouped
by phase under each sensor.

58

Report Generator
Editing Spreadsheets
To edit a Spreadsheet, highlight the desired spreadsheet, and either click on the Edit Highlighted Section button, or double
click on the highlighted selection itself. The Edit Report window (shown below) will appear. The navigational buttons
perform the same function as previously described in Using The Edit Report Window section, found on page 49.
The Available Sensors list displays the sensors
available for display on the Spreadsheet. To add
a sensor to the Included Sensors list, click on a
sensor from the Available Sensors list, then click
on the Add button. To remove a sensor from the
Included Sensors list, click on the sensor to be
removed, and click the Remove button.
If a Spreadsheet is selected from the Section
Type, the user has the option of clicking on the
Enable Grouping check box. If the Enable Grouping check box is not selected, the Included Sensors will display as a continuous column throughout the whole Spreadsheet. If the Enable Grouping check box is selected, the user will have option to the select a Key Sensor (the sensor that
data is matched to, typically speed), and whether
the data will be grouped by Sensor or Phase in
the final report. By selecting Sensor, the data is
paired by sensors and displayed under each
phase. By selecting Phase, the data is grouped
by phase under each sensor.

Example of a Spreadsheet (Grouped by Sensor)

Example of a Spreadsheet (Grouped by Phase)

59

Report Generator
Creating a New Paragraph
To create a new Paragraph, select Paragraph from the list of section types under the Add Section (+) function of the main
Edit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the new Paragraph
to edit the Paragraph.

Paragraph Name
Text Input Box

Browse for Text File


Make Paragraph Importable

Assign a name to the new Paragraph by entering the name in the first box. This will name the new Paragraph. To create a
new Paragraph, click anywhere in the Text Input Box and enter the information you wish to appear on the report.
Clicking the Browse for text file opens a window (shown below) which displays available text files. Opening the .txt file will
import the text into the box.

Selecting the Importable option displays the paragraph input box on the main form of the Report Generator, as explained on
page 58. From this window, the user can import text without having to go into the edit feature.
60

Report Generator
Editing Paragraphs
To edit a Paragraph, highlight the desired table, and either click on the Edit Highlighted Section button, or double click on
the highlighted selection itself. The following Edit Report window (shown below) will appear.

The name of the paragraph can be changed by


entering a new name into the Paragraph Name
test box. The paragraph text can be entered into
the Text Input Box.
Clicking the Browse for text file opens a window which displays available text files. Opening
the .txt file will import the text into the box.
Selecting the Importable option displays the
paragraph input box on the main form of the Report Generator, as explained on page 62. From
this window, the user can import text without having to go into the edit feature.

61

Report Generator
The View Menu
The View Menu: The View menu item lists only one option - New Graph View.
View > New Graph View: Automatically creates a new Live Graph and
opens the Properties window of that graph (described below). In addition,
right-clicking the New Graph View will display the Options window.

New Graph View


New Graph View displays recorded data from a test and is refreshed every time a data point is recorded. This is different from
the real-time chart, which displays data regardless if data points are recorded or not.

Example of a New Graph View

New Graph View Options

New Graph View Properties


The Properties window opens automatically when a new graph is created. In addition, right-clicking the New Graph View will
display the Properties window. The users has the following options for modifying the New Graph View.
Print: Prints the current New Graph View
Symbols: Displays the symbols indicating each point where data has been recorded.
Legend & Title: Displays the Legend (displayed at the bottom of the graph) and the Title (displayed at the top) of the graph.
Grid Lines: Displays the grid lines of the New Graph View.
Undo All Changes: Resets any changes made using the Zoom, Move and Scale functions.
Zoom: Allows the user to zoom-in on a specific point on the graph while retaining the X axis and Y axis.
Move: Allows the New Graph View to be repositioned within the window.
Scale: Allows the New Graph View to be re-sized, enlarging and reducing the actual size of the graph.
Properties: Opens the Properties window.
62

Report Generator
Creating a New Graph View
To create a New Graph View, select New Graph View from the View Menu in the Report Generator. This will automatically
open the Properties window for the New Graph. Begin by creating a name for the New Graph View by entering a name in the
Graph Name text box.

Graph Name
X-Axis
Use Reference Data
Plot Individual Phases
Available Sensors
Add Sensor to the List of Included Sensors
Y2

Included Sensors
*Phases
Remove Sensors from the List of Included Sensors

*Requires Advanced Pattern Runner


Choose which sensors to display on the X Axis and Y Axis of the New Graph. The X Axis menu contains the sensors
available for display on the X (horizontal) axis of the New Graph. The graph can only display 1 (one) sensor on the X axis per
graph. The Available Sensors list displays the sensors available for display on the Y (vertical) axis. The sensor displayed on
the Y Axis is displayed on the left side of the graph. To add an additional sensor to the list of Included Sensors, click on a sensor
from the Available Sensors list, then click on the Add button. The Y2 feature allows the user to display a sensors data on the
Y2 (vertical, right) axis of the New Graph. To assign a sensor to the Y2 Axis, click on that sensor in the Included Sensors box,
then check the Y2 box.
Below the X Axis pull down menu are two options: Use Reference Data and Plot Individual Phases. Clicking the Use
Reference Data check box will plot Reference Data on the Graph in addition to the data being recorded during the test.
Reference Data is data that is typically used for monitoring and comparing the results of the test. Instructions for creating and
loading Reference Data can be found in Chapter 3, Main Display and further discussed in Chapter 7, Add-In Programs. If the
Plot Individual Phases box is left unchecked, the graph will show each Included Sensor as a continuous line throughout all
of the phases selected. If the Plot Individual Phases box is checked, each Included Sensor will be graphed with multiple
lines corresponding to each phase selected.

Editing a New Graph View


To change the name of the New Graph, enter the new name in the Graph Name text box. Choose which sensors to display on
the X Axis and Y Axis of the New Graph. To add an additional sensor to the list of Included Sensors, click on a sensor from
the Available Sensors list, then click on the Add button. The Y2 feature allows the user to display a sensors data on the Y2
(vertical, right) axis of the New Graph. To assign a sensor to the Y2 Axis, click on that sensor in the Included Sensors box,
then check the Y2 box.
Clicking the Use Reference Data check box will plot Reference Data on the Graph in addition to the data being recorded
during the test. If the Plot Individual Phases box is left unchecked, the graph will show each Included Sensor as a
continuous line throughout all of the phases selected. If the Plot Individual Phases box is checked, each Included Sensor
will be graphed with multiple lines corresponding to each phase selected.

63

Report Generator
The Import Menu
Import Menu: The Import Menu contains one option, Text File.
Import > Text File: If a Paragraph has been made importable (as
introduced on page 59), this menu item will become active and the
name of the paragraph will be listed in this menu. If there is text within
the saved paragraph, a check mark will appear next to its name. If no
importable paragraphs are available, the tab will display the text No
Importable Paragraphs.

The Export Menu


Export Menu: There are three options available for the Export Menu: As .chm file, Excel and Text File. By selecting those
options, the user can export the report to the desired file type.
Export > As .chm file: This menu item gives the user the option to export
a report as a .chm file. A .chm file is a compressed html page. This type
of file normally used by Microsoft to create help files is perfect for creating
small files easily e-mailed. By compressing the html page, not only is the
file size made significantly smaller, it also includes all of the support files.
To create a .chm file simply click on the menu item and choose a file name.
The Reporter program will then recreate the html page, compress it and
save it to the location specified. A .chm file may be requested by your
Power Test representative when providing technical assistance.
Export > Excel: This allows the user to
export data directly into Microsoft Excel. The administrator must choose
which Excel template will be available
to the operator to export the data into.
All available Excel templates (.xlt files)
will be listed under the arrow of the Select Template menu.
Note: All available templates must have
a sheet labeled Data.
Export > Text File: This allows the operator to export all the data from a
DataSpace to a tab delimited text file (.txt). By exporting data to this type
of file, the data may be imported into virtually any spreadsheet program.
Simply click on the Text File... menu item, select a file name and click
on Save. The default path is C:\Program\PowerNet\Commander 2.0.

The Ignore List


*Ignore List: The Ignore List lists all of the phases in the DataSpace. If
a phase is added to the Ignore List, the data from that particular phase
will not be displayed in the entire report. To eliminate (but not delete) any
particular phase from the entire report, simply check the phase name
under this menu item.
*Requires Advanced Pattern Runner software.

64

PowerNet 2.0
Data Acquisition and Control
- CHAPTER 7 Workstation

Workstation

66

Workstation
The PowerNet Workstation
The PowerNet Workstation is a pedestal mounted unit that is placed inside the test cell next to the dynamometer. The
Workstation performs all sensor calibration, dynamometer control, and data acquisition. It sends data and receives commands
via an ethernet link with the PowerNet Commander PC.
The Workstation is engineered to stand up to the harsh environments inside of the test
cell. The unit houses a 10.4" color touch screen and front-mounted temperature and
pressure input jacks. The pedestal mount allows its display to rotate 350 for viewing at
any angle.
The Emergency Stop Button is used to activate PowerNets emergency shut down sequence in the event of an emergency. The Button will remain locked, preventing the
system from operating until it is physically pulled out to the run position.
The System Power Switch, located below the Emergency Stop Button, is used to activate
the Work Station. Pressing the button will apply power to all of the Work Stations components and begin the start-up cycle.
The Work Station is equipped with a color LCD Touch Screen for displaying data and
accepting user input. The Touch Screen has been designed to provide a simple, easy-touse interface between the operator and the PowerNet system. Buttons are pressed by
lightly touching the touch screen in the desired area. The Touch Screen is a highly accurate
device that must be kept clean to ensure proper operation.

Workstation Welcome Screen

67

Workstation
Using the Workstation Touch Screen
The PowerNet Workstation uses a color flat-panel LCD touch screen to display important information and accept operator
input. The touch screen has a sealed gasket to prevent damage from liquids entering the cabinet. Proper operating and
maintenance procedures should be observed to keep the touch screen in peak operating condition.
The touch screen accepts user input by sensing the electrical resistance generated by an object touching the screen. This
resistance generates values on an x and y axis, allowing the Work Station to compute where the screen is being touched.
Note: The touch screen works by sensing electrical resistance and not by sensing pressure. There is no need to apply
pressure to the screen.
Touch screen maintenance is a simple yet important procedure. The build up of foreign matter on the screens surface is
inevitable in an industrial environment. This buildup inhibits the screens function. If the buildup is large enough, the touch
screen will see this as a resistance and mistake it for an operators finger. Use nonabrasive glass cleaner and a soft, lint-free
cloth to remove any smudges or fingerprints from the screens surface. Do not use a petroleum based cleaner on the touch
screen. Always shut down the Workstation before cleaning the screen.

Connections
The various input jacks and wiring connectors on the Workstation allow the unit to send and receive data with its various
sensors and controls:
T/C Inputs: Accepts Type K thermocouple probes
Pressure Inputs: Accepts male pressure couple
Ethernet Jack: Accepts coax Ethernet cable
Load Valve and Throttle Actuator Jacks: Accepts threaded connector
Speed and Load Sensor Jacks: Accepts sensor input from magnetic speed pickups and strain gauge load cell
Relayed Power Binding Posts:
Accepts stripped wire or banana plugs.
The System Power Switch is used to activate the Work Station. Pressing the button will apply power to all of the Work Stations
components and begin the start-up cycle.

68

Workstation
Workstation Main Menu
After activating the PowerNet Workstation, the Welcome Screen (shown below) will be displayed. From the Welcome
Screen, the user has can select from the following options: Run Mode, Valve/Throttle calibration, Pressures calibration,
Temperature calibration, and Primaries calibration.

In addition to the options displayed on the left hand of the screen, the operator is provided with a Help function. The Help
screen provides the user with information regarding the function of each of the touch screen menu options. To use the Help
screen, touch a button at the bottom of the screen, then touch an area where assisted is needed. A Help window will appear.

69

Workstation

Run Mode
Touching the Run Mode button will open the run mode screen, activating a series of events that begin testing. The screens
background color indicates the status of the Work Station. Red indicates that Emergency Stop has been activated, green
indicates that a test is underway (engine speed >25rpm) and yellow (as shown below) indicates that PowerNet is ready to
begin testing.
Speed Display
Torque Display
Power Display

Engine Start Button


Torque Tare Button
Engine Stop Button

Emergency Stop Button

Return to Main Menu Button

Temp Display

Valve Indicators Pressure Display

Run Mode Function Buttons


Engine Start Button: Touching this button activates the engines starting system if equipped.
Engine Stop Button: Touching this button stops the engine if equipped.
Emergency Stop Button: Touching this button activates the Emergency Stop procedure.
Return to Main Menu Button: Touching this button returns the Workstation to the Main Menu but does not stop the
current test.
Speed Display: Displays engine speed in RPM.
Torque Display: Displays engine torque in foot pounds (ft-lbs).
Power (Hp) Display: Displays engine power in horsepower (HP).
Temp Display: Displays available temperatures in degrees Fahrenheit (F). To display alternate temperatures, press
either side of the box to advance or return to an alternate temperature reading.
Manual/Automatic Throttle and Valve Indicators: Indicates throttle/valve position and if PowerNet is in manual or
automatic throttle control/valve mode.

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Workstation
Run Mode Function Buttons (continued)
Pressure Display: Displays available pressures in pounds per square inch (psi). To display alternate pressures, press
either side of the box to advance or return to an alternate pressure reading.
Torque Tare Button: Touching this button sets the current torque reading to zero.

Calibration
Calibration procedures have been provided for each of sensor. Proper calibration is necessary for accurate operation. Each
type of sensor has its own specific calibration procedure. The Primary, Pressure and Temperature calibration screens
include on-screen instructions that guide you through the calibrate procedure.

Methods of Calibration
Simple Offset Procedure: Using the Simple Offset Procedure, a sensors offset is calculated using one point. The proper
reading for the sensor being offset is entered in the actual display. The Workstation then calculates the offset and applies it
to the sensor.
Two Point Procedure: Using the Two Point Procedure is a more accurate method of calibration. It uses the same
procedure for calculating offset as the simple offset method but adds a second point to the calibration and calculates the
sensors rise over the run between the two points (multiplier). This second point is usually set with a known input (regulated
pressure for pressures, hand tach reading for speed, etc.). The points entered should be within the range intended for use
during a typical engine test.
Multiplier Procedure: The sensors supplied with PowerNet are factory calibrated for a high level of accuracy. The Sensor
Multiplier Table (shown below) displays the correct multiplier values for each of your sensors. Enter this value in the
multiplier box and set the sensor offset using the simple offset method.
Touching any of the input boxes will open the numeric keypad (shown right). Enter the desired
value using the keypad and click Clear to clear the current value, Accept to accept the current
value and return to the Calibrations screen, or Cancel to return to the Calibrations screen without
entering a value.

SENSOR

MULTIPLIER VALUE

STANDARD SPEED
5K LOAD CELL (TORQUE)
4K LOAD CELL (TORQUE)
500 PSI
250 PSI
200 PSI
50 PSI
5 PSI
2 PSI
BAROMETRIC PRESSURE (ATM)
+/- 15 PSI

400
291,667
233,333
100
50
40
10
1
.4
.8702
6

Sensor Multiplier Table


71

Workstation
Valve/Throttle Calibration
Touching the Valve/Throttle button in the Main Menu calls up the Valve and Throttle Calibration Screen. This screen allows
the operator to calibrate PowerNets throttle control motor and high speed load control valve. The slider bars to the right
display the current position of throttle and valve. Touching on either of the sections allows the operator to manually control
the throttle and valve positions.
Zero Valve
Cycle Valve

Analog Throttle Adjustment

Non-Analog Throttle Adjustment

Return to Main Menu

Valve Calibration
Zero Valve: Touching this button cuts the power to the load valve, allowing the operator to set the zero point of the servo valve.
The zero point is manually set by matching the alignment marks on the load controllers gear faces.
Cycle Valve: Touching this button cycles the high speed load control valve.
Note: During periods of low usage, it is recommended to cycle the valve at regular intervals to prevent binding.

Throttle Adjustment
If There is No Analog Throttle Controller is selected from the Dynamometer Setup section of the Primaries Calibration Screen, the
throttle will need to be manually adjusted using the span and zero sliders shown in the example above. Instructions are provided
on the following page for calibrating the Analog Smart Throttle.
With each new engine being tested, the Throttle Actuator span and zero position will need to be adjusted. This is to ensure proper
operation during testing that could possibly be affected by the distance between each new engine and the actuator.
Before making any adjustments to the Throttle, the throttle position must be set at zero percent (0%) at the Workstation in
order to avoid any confusion of throttle placement.
Make a visual inspection of the actuator. There should be little-to-no slack in the cable between the two connection points. In
most cases, a value of 0 will be entered in the first three boxes. If your engine is shut down using the throttle, or requires a
slight increase to start the engine, these values will vary according to application.

72

Workstation
Throttle Calibration
The 1st box, Zero Throttle Pos, represents the position of the actuator when set at 0% throttle, or low idle. This value must be
greater than or equal to the value entered in the 2nd box.
The 2nd box, Start Throttle Pos, represents the position of the actuator required to start the engine. In some circumstances, an
increase in throttle is required to start the engine. This value should be greater than or equal to the value entered in the 1st box.
The 3rd box, Stop Throttle Pos, represents the position of the actuator required to stop the engine. In some circumstances, the
throttle will return beyond the low idle position, resulting in stopping the engine.
The 4th box, Full Throttle Pos, represents the position of the actuator that is full throttle. This number will always be 100%.
Note: On most engines, the first 3 settings shown at the left will be at zero. The last
setting, Actuator % that is 100% Throttle, will be directly dependent upon your
adjustment of the throttle control actuator and your engine being tested. You will
want to visually inspect the throttle control actuator before each engine test and
readjust before the performance testing of each NEW engine.

Smart Throttle Calibration (if equipped with Smart Throttle)


With each new engine being tested, the Smart Throttle will need to be adjusted. This is to
ensure proper operation during testing that could possibly be affected by the distance
between each new engine and the actuator.
Before making any adjustments to the Smart Throttle, the throttle position must be set
at zero percent (0%) at the Controller Interface in order to avoid any confusion of
throttle placement.
Make a visual inspection of the actuator. There should be little-to-no slack in the cable
between the two connection points. In most cases, a value of 0 will be entered in
the first three boxes. If your engine is shut down using the throttle, or requires a slight
increase to start the engine, these values will vary according to application. The throttle span and zero position can be adjusted
directly from the back of the throttle control actuator as described below.
Note: Before adjusting to 100% throttle from the actuator, begin by pressing the decrease span button for 10 seconds. This will
decrease the span, and reduce the risk of damaging the engines throttle as a result of over travel.
Depress the Throttle Override switch to the 0% position. When depressed, the shaft
will release, allowing the operator to adjust the zero position by hand. When released,
the throttle actuator will return to the position specified at the Controller Interface,
which should be 0%.
To set the maximum throttle, depress the Throttle Override switch to the 100% position. This will move the throttle position to 100 percent. Keeping the Override switch
at 100%, depress the throttle span switch in either direction to obtain the correct span.
When the Throttle Override switch is released, the throttle actuator will return to the
position specified at the Controller Interface, which should be 0%.

73

Workstation
Pressure Calibration
Pressure calibration can be achieved with three methods. A Simple Offset Procedure can be exercised by simply entering the
correct pressure and selecting adjust offset only. A Two Point calibration procedure allows you to enter two calibration points
with a known pressure input. The Multiplier based calibration uses the factory specified multiplier value to determine proper
sensor reading. The multiplier method is recommended. Touching the Pressures button in the Main Menu calls up the
Pressure Calibration Screen. This screen allows the operator to calibrate each of PowerNets pressure transducers.
Current Value

Previous Current Next

Offset Only Button


Slope/Offset Button
Enter Actual Value Here
Accept Button
Enter Known Value Here
Accept Button
Multiplier Display

Return to Main Menu

Sensor Voltage Undo Change Return to Default


Current Value: Displays the current pressure value for the selected sensor
Previous/Next Buttons: Touching this button toggles between the available pressures.
Current: Displays the current pressure sensor number
Offset Only Button: Touching this button activates single point offset calculation, allowing the user to set the sensors offset
with one input value instead of using the two point calibration method.
Slope/Offset Button: Touching this button activates the two point slop calibration method. Enter a value in the window to the
right and click the Accept button to accept the entered value.
Multiplier Display: Factory calibrated gauges have specific multiplier values based on the senors operating range. A sensor
can be calibrated by touching this box and entering the proper value. Once entered, press the Accept button to accept the
entered value.
Sensor Voltage Display: Displays the selected sensors voltage.
Undo Change: Touching this button reverses the most recent calibration change.
Return to Default: Touching this button all settings to their factory calibrated values.
Return to Main Menu: Touching this button returns to the Main Menu screen.
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Workstation
Temperature Calibration
Temperature calibration is a simple offset calculation procedure. The thermocouples supplied with PowerNet are factory
calibrated for proper operation. If a thermocouple is reporting an incorrect temperature, it can be corrected with a simple, one
point offset calculation procedure. Touching the Temperatures button in the Main Menu calls up the Temperature Calibration
Screen. This screen allows the operator to calibrate the offset for each of PowerNets thermocouple probes.

Current Temp

Previous Current Next

Enter Offset Value Here

Adjust Button
Reset Button

Return to Main Menu

Sensor Voltage Undo Change Return to Default


Current Value: Displays the current temperature value for the selected sensor
Previous/Next Buttons: Touching this button toggles between the available pressures.
Current: Displays the current temperature sensor number
Enter Offset Value Here: Touching this button activates the keypad, allowing the user to enter the determined temperature.
Adjust Button: Touching this button sets the current sensor to display the temperature entered in the Enter Offset Value
Here box.
Reset Button: Touching this button resets the current sensor to its factory calibrated values.
Sensor Voltage Display: Displays the selected sensors voltage.
Undo Change: Touching this button reverses the most recent calibration change.
Return to Default: Touching this button all settings to their factory calibrated values.
Return to Main Menu: Touching this button returns to the Main Menu screen.

75

Workstation
Primaries Calibration
The Primaries Calibration screen contains the calibration sections for all other sensors connected to the system, including,
but not limited to: Speed, Torque, and Auxiliary sensors. Touching any of the Sensor Selection Buttons will open the
calibrations screen for that particular sensor. If more than six (6) sensors are connected, the toggle buttons (as previously
explained) will appear.
In addition to sensor calibrations, the operator can view the Calibration Log, reset the system to Factory Defaults, and enter
the Dynamometer Setup screens.

Sensor Selection Buttons

View Calibration Log

Return to Main Menu

Return to Default

Dyno Setup

Sensor Selection Buttons: Touching any of the Sensor Selection Buttons will open the calibrations screen for that particular
sensor.
View Calibration Log: Touching this button opens the calibration log (shown below), allowing the operator to view what
calibration changes have been made.

Dyno Setup: Touching this button opens the Dyno Setup screen, as explained on the following page.
Return to Default: Touching this button all settings to their factory calibrated values.
Return to Main Menu: Touching this button returns to the Main Menu screen.

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Workstation
Dynamometer Setup
Touching the Dynamometer Setup button on the Primaries Calibration screen opens the Dynamometer Setup screen. From
this screen, the operator can choose the settings the valve position during an E-Stop, Remote Start, and OverSpeed Reset.
Additionally, the operator can choose how many dynamometers are part of the system, what type of throttle controller is
being used (analog or non-analog), and whether or not the Stop Relay is to be used with OverSpeed.
Touching the Advanced Dynamometer Setup button opens the Advanced Dynamometer Setup screen.

E-Stop Valve Open: This setting determines


how much the valve opens during an Emergency
Stop. ex. A setting of 100% opens the valve
completely during an E-Stop, flooding the water
brake and abruptly stopping rotation of the
engine.
Remote Start Max On Time: This setting
determines how long the remote start will engage
when depressed. If the engine does not start
within the time allowed, the starting circuit will
reset and the start button will need to be pressed
again.
Remote Start Arm Time: This setting
determines the amount of time the operator has
to return to the Commander PC and start the
engine before having to reset the starting
sequence from the Workstation.

Throttle Controller Button: Touching this button sets whether or not there is an analog or non-analog starter throttle in use.
If a non-analog throttle is being used, the throttle will have to be calibrated from the Throttle Calibrations screen.
Stop Relay w/OverSpeed: Touching this button selects whether or not the Stop relay will engage is an OverSpeed is
detected.

77

Workstation
Advanced Dynamometer Setup
Touching the Advanced Dyno Setup button on the Dynamometer Setup screen opens the Advanced Dynamometer Setup
screen (shown below). From the Advanced Dynamometer Setup screen, the operator can set the values for the Fast and Slow
Acquisition Rates, Manage IP Connections, and name and assign averaging values to available sensors.
Additionally, the operator can choose which servo is being used, customize E-Stop functions, and choose to display the Real
Time Graph in Run Mode.

Fast Acquisition Rate: This setting determines


the fast rate at which data is being acquired by
the system. Fast acquisition is used in the Run
Screen only. In most cases, this setting should
not be changed from the factory default setting.
Slow Acquisition Rate: This setting determines
the slow rate at which data is being acquired by
the system. Slow acquisition is used in all other
screens. In most cases, this setting should not
be changed from the factory default setting.
Managing Connections by Number: Touching
this button opens a keypad, allowing the operator
to enter the IP address from which the
Workstation is to communicate with. In most
cases, this setting should not be changed from
the factory default setting.
Previous/Next: Touching this button toggles
between the available sensors.
Standard Sensors: Touching the sensor list opens a keypad, allowing the operator to assign a name and number to the
current available sensor.
Number to Average: Touching this section opens a keypad, allowing the operator to enter the averaging value.]
The buttons on the left side of the screen perform the following functions.
First Button - Servo Selection: Touching this button sets whether or not the system is using a Silver or Gold servo.
Second Button - Emergency Stop will/will Not be triggered when there is no connection: Touching this button selects
whether or not the E-Stop relay will engage if connection to the system is lost.
Third Button - Emergency Stop will/will NOT be triggered when exiting Run Mode: Touching this button selects
whether or not the E-Stop relay will engage when exiting Run Mode.
Fourth Button - Emergency Stop will/will Not be triggered when there is no connection: Touching this button selects
whether or not the E-Stop relay will engage if connection to the system is lost.
Fifth Button - The E-Stop Relay will be triggered whenever E-Stop is triggered/only when engine is running: Touching
this button selects whether or not the E-Stop relay will engage at any time, or only if the engine is running.
Sixth Button - The Real Time Graph will/will NOT be shown in Run Mode: Touching this button selects whether or not
the Real Time Graph will be displayed during Run Mode.
78

Add-in Programs

PowerNet 2.0
Data Acquisition and Control
- CHAPTER 8 Add-in Programs

79

Add-in Programs

80

Add-in Programs
The Add-In Programs
In this chapter, some add-in programs will be introduced. For some systems, Security Editor and ECM Communicator are
standard components. All other add-in programs are optional, such as the Smoke Check Transfer program, Fuel Controller
and Gas Analyzer. All existing add-in programs are listed in the Add-Ins menu in the Main Display Window.
NOTE: The following are some examples of add-in options available for Power Test data acquisition systems. For instructions
and specifications for specified equipment, please consult the information provided with the option.

Security Editor
Security Editor: The Security Editor is an administrative tool used to assign rights to operators.
To access the Security Editor program, the user must have full administrative rights. The administrator has to log in, even if they have logged in to the
program.

Edit Users: The administrator can add, delete, or edit user


names, passwords, and security levels. To add a new user,
click Add, and a New User will be added to the list of current
users. To delete a user, highlight the user name and click
Delete.
NOTE: If there is only one user with full administrative rights in
the list, the program will not allow you to delete their security
level. If an attempt is made to do so, the following warning will
appear (shown below).

To edit a users security levels, highlight the user whose levels you want to edit and click Properties. The Edit Security Levels window (shown right) will appear, in which the users name, password and security can be assigned. Edit the user name and password and check the appropriate
boxes to grant those individual security rights to the user. When finished editing, click OK to keep
the changes or Cancel to ignore them
NOTE: If there is only one user with full administrative rights in the list, the program will not allow
you to edit their security level. If an attempt is made to do so, the following warning will appear
(shown below).

81

Add-in Programs
ECM Communicator (if included)
ECM Communicator: This program is designed to communicate with the engines ECM system using the SAE 1708 or SAE
1939 protocol. The program has four pull-down menus: File, Edit, View and Protocol.

The File Menu


File Menu: The File Menu allows the user to open or save an ECM communication file. The menu consists of Open, Save
and Save As.
File > Open: opens a previously saved ECM communication sensor list
file

File > Save: Overwrites the current ECM communication sensor list as a
file having the same name.

File > Save As: Saves a copy of the current ECM communication sensor
list as a new file. The user will be prompted to name the new file before
saving.

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Add-in Programs
ECM Communicator (continued)
The Edit Menu
Edit Menu: The Edit Menu consists of the following options : Add Sensors, ECM Connections, and Local MID.
Edit > Add Sensors: Adds sensors from the ECM to the data acquisition
system. To add a sensor to the system, click the Add Sensors menu
item. The Add Sensor window will appear. The left drop-down box contains the possible modules connecting to the communication bus to the
system. If you are connecting to the engine module, choose 128: Engine
#1. The right drop-down box contains a list of parameters or sensors.
Choose the sensor you wish to monitor through the data acquisition system and click the Apply button. Continue this process to add all desired
sensors, and click OK to make the additions permanent.

Edit > ECM Connections: When the ECM Connection is selected, the
Connections window will appear. If the ECM Communicator is connected
through an ethernet connection, use 123.123.123.129:10004 as the ECM
Address. If connected to a serial port, enter the serial port number. If an
ECM communicator is not connected, click on the Reset Connection
button to disconnect and reconnect to the ECM. Status lines below the
ECM Address input box will indicate the current state of the ECM Connection.

Edit > Local MID: In order for the ECM Communicator to enter into the
ECM communication bus, the Local MID must be 180.

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Add-in Programs
ECM Communicator (continued)
The View Menu
View Menu: There are three options under the View menu. The menu consists of the Summary, All Info, and Show
Reserved PID Fault Codes menus.
View > Summary: If Summary is selected, only the sensors added to
the system will be displayed in the communicator.

View > All Info: If All Info is selected, all sensors (or parameters) being
read by the ECM will be displayed.

View > Show Reserved PID Fault Codes: Fault codes can also be
displayed if Show Reserved PID Fault Codes is checked. (PID 194
under MID 128 must be added to display fault codes.

The Protocol Menu


Protocol: Allows the operator to choose the proper communication protocol for the system. Available protocols are: 1708, 1708 Intelligent and
1939. When communicating in SAE 1708 protocol, either 1708 or 1708
Intelligent will work. 1708 intelligent uses additional hardware to speed up
and simplify communication between the ECM and computer. If the connection is lost while changing from one protocol to another, it maybe necessary to cycle the power on Controller Box.

84

Add-in Programs
Gas Analyzer (if included):
This program is designed to communicate with the Gas Analyzer.
Once this program is started, the system will begin to communicate
with the Gas Analyzer and show the real time gas analysis result
(shown right).

85

Add-in Programs
Calculated Sensors
Calculated Sensors: This program has the ability to take two sensors or typed values and add, subtract, multiply, divide or
power the two values. The user must choose a sensor type, determining what type of units to use on the new calculated sensor.
When a Calculated Sensor is created, it is permanently added to the list of available sensors.

A user must be logged in to access the Calculated Sensors program. To begin calculating sensors, click View > Edit.
Clicking the Add Sensor button will allow the user to configure the sensors. By selecting the Sensor Input or Typed Input,
either a sensor value or a literal value can be used in the calculation. Select the calculation function by clicking on the various
option buttons in the Operator section. Clicking the Add Sensor button saves the new Calculated Sensor.
To add additional sensors, click on the Add Sensor button. The name of the new sensor is assigned ex. CALC0, CALC1, etc.
The name of the sensor, as well as its variables and calculations used to determine the value of the calculated sensor can be
edited from the Sensor Properties function in the Main Display. Additionally, a custom unit can be assigned to a Calculated
Sensor from the Sensor Properties function in the Main Display. Any custom unit can be assigned by choosing the Custom
option button on the Units tab. If the Sensor name has been changed, it will not be renamed until the DataSpace has been
reopened.
If more than one sensor is added, the Previous and Next buttons allow navigation from one Calculated Sensor to the next.
If two like sensors are selected and either add or subtract is selected as an operator, all calculations are performed on the base
unit. ex. if two volume flow sensors are added or subtracted, the units selected for each individual sensor would have no effect
on the outcome of the calculated sensor. If the two like sensors are divided, a ratio will be assigned.
Example:

20 degrees C = 68 degrees F
Subtracting two sensors with a value of 20 degrees C would be 68 - 68 = 0 0 Degrees F = -18 Degrees C

If the program has determined that it will use a generic sensor type, all operations are performed based on the displayed value.
For instance, if 10 is added to a temperature sensor with units of degrees F displaying 68 degrees, the calculated sensor would
read 78. Changing the temperature sensors units to degrees C would change the value of the display to 20. The added 10 would
still have the same effect, causing the calculated sensor to read 30.
Note: There is no way to remove a sensor. Sensors can only be added. If a calculated sensor is no longer needed, a new
template must be created from an existing template not containing the calculated sensor.

86

Add-in Programs
Fuel Controller (if included)
Fuel Controller: This program is designed to communicate with PTI fuel system. When the fuel system is operating, the
following data can be measured and shown in the Main Display as sensors:
Volume Burn Rate

Volume Burn Rate is defined as the total volume of fuel being burned by the engine during testing.
The default unit is measured in gallons/hour.

Mass Burn Rate

Mass Burn Rate is defined as the total weight of fuel being burned by the engine during testing.
The default unit is measured in pounds/hour.

Fuel Density

Fuel Density is defined as the total density of fuel being used by the engine during the test.
The default unit is measured in pounds/gallon.

Total Volume

Total Volume is defined as the total volume of fuel being used by the engine during the entire test run.
The default unit is measured in cubic gallons.

Fuel API

Fuel API is a standard method established by the American Petroleum Institute to measure fuel
quality.
The default unit is a standard number measured in API degrees.

BSFC

BSFC is defined as Brake Specific Fuel Consumption. This number represents the overall efficiency of
the engine at the time of the test. The unit is measured in Pounds/Horsepower Hour.

DPV

Distance Per Volume is the distance that the vehicle travels on the chassis dynamometer virtual
road and is measured in miles/gallon. (Chassis dynos only)

Fuel Controller Interface Buttons


There are three buttons located on the Fuel Controller Interface window. They are as follows: Empty Fuel System - purges the
fuel in the system. Fill Fuel System -readies the system to run. Shut Down System - empties the fuel system, then shuts
down the power to the fuel system only.

The Setup Menu


Setup: The Fuel Controller program only has a Setup menu. The Setup Menu contains the following options: Power Sensor,
Speed Sensor, Average Rates, and Calibration Density.
Power Sensor: This allows the operator to select the source of
power for the fuel controller. If there is only one source of power,
there will be only one calculating BSFC selection in the menu.

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Add-in Programs
Fuel Controller (continued)
The Setup Menu (continued)
Speed Sensor: This selection allows the operator to set the source
of the speed sensor. For use in calculating DPV.

Average Rates: This menu selection allows the operator to choose


the average time period that the sensors sample the readings for
mass and volume burn rate. The time periods are either none, 5, 10
or 30 seconds, and there is a custom option to allow the operator to
enter a custom time period.

Calibration Density: The calibrate density choice initiates the procedure for calibrating fuel density. The measurement is manually
entered. The operator indicates the temperature in degrees Fahrenheit and the fuel specific gravity from a sample of the fuel to be used
in the testing.

88

Add-in Programs
Correction Factors (If included)
The Correction Factors option allows the user to apply SAE or custom corrections to torque and horsepower readings, and creates a five new sensors: Corrected Gross Torque, Corrected Gross Horsepower, Corrected Net Torque, Corrected Net Horsepower and the Correction Factor itself.
Note: Corrected Net Torque and Corrected Net Horsepower are only used in some custom corrections, and
are normally not available.

The Configuration Menu: The Configuration


Menu contains the following options: SAE, Custom
Correction, Search for Custom Correction and
Rebuild All.
Configuration > SAE: Allows the user to select correction formulas as specified in SAE documents J607 and J1995/J1394.
SAE J607 is intended for spark ignition engines only. SAE J1995/J1394 allows for both spark and compression ignition
systems.
To apply the correction factor settings to a particular engine type, select the appropriate options from the sub-menus as
illustrated below.

Configuration > Custom Correction: Allows the user to select a Correction file containing a custom formula for determining Corrected Power
and Corrected Torque. These files can been created by your Power Test
representative to your administrators specifications.

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Add-in Programs
Correction Factors (continued)
Configuration > Search for Custom Correction: Searches all removable drives for any Custom Correction files.

Configuration > Rebuild All: Refreshes the sensor names in the Sensor Input drop down lists.
NOTE: If changes are made in the Main Display to sensors names that
correspond to those listed in the Sensor Input drop down boxes, the user
must click on the Rebuild All menu item to reflect the changes made.

Correction Factor Inputs


After applying all necessary SAE correction settings, all Correction Factor formula inputs will be listed on the main form of the
Correction Factors program. The first button, Sensor Input, allows the user to select a sensor to obtain information needed for
the correction formula. The second button, Typed Input, allows the user to enter a fixed value and the unit of measurement
applied to the correction formula.

Sensor Input

Typed Input

NOTE: A simple method for configuring Correction Factors is to select J1995/J1394 - Spark Ignition, regardless of ignition type
(illustrated below). This configuration allows for atmospheric correction only, yet is an effective method of establishing corrections for atmospheric corrections only.

90

Add-in Programs
Reference Data Builder
Reference Data is data that is typically used
for comparing the results of a test.
The Reference Data Builder creates a file
containing reference data that can be displayed in Charts, Report Graphs, and Graph
Views. Reference Data can be obtained from
an existing DataSpace, a tab delimited file
created in a spreadsheet program such as
Microsoft Excel, or manually entered by the
user.

The File Menu


The File Menu contains the following options: New, Open, Save, Save As, Import From DataSpace, Import Tab Delimited
File and Exit.
File > New: Clears the current Reference Data file to allow the user to create a
new Reference Data file.

File > Open: Prompts the user to open an existing Reference Data file.

File > Save: Overwrites the current Reference Data file as a file having the same
name.

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Add-in Programs
Reference Data Builder (continued)
File > Save As: Saves a copy of the current Reference Data file as a new file. The
user will be prompted to name the new file before saving.

File > Import from DataSpace: This menu item allows the user to import Reference Data into the report from an existing DataSpace by opening the Choose
Traces and Phases window, as described on page 62.

File > Import Tab Delimited File: This menu item allows the user to import
Reference Data into the report from a program such as Excel.

File > Exit: Provides the user with the option to save their data (shown below),
and closes the Reference Data Builder program.

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Add-in Programs
Reference Data Builder (continued)
Importing Reference Data from a DataSpace
To import data from an existing DataSpace,
click on File > Import from DataSpace. The
Choose Traces and Phases window (shown
right) will appear.
Select the Sensors and Phases to be included
in the Reference Data File. Assign a preface
to the sensor name ex. Ref. in the Trace Preface input box. When finished, click OK.

Traces
A Trace is a line on a graph representing a specific sensors values.
To add a trace to a Reference Data File, click on the Add Trace
button. This will open the Add Trace window (shown right). From the
Add Trace window, the user will be able to assign a name to the new
Trace, and select the Sensor type.

To edit an existing trace, highlight the Trace and click the Edit Trace
button. This will open the Edit Trace window (shown right). From the
Edit Trace window, the user can edit the Trace Name and Sensor
Type of the selected Trace.

To delete a Trace, highlight the Trace and click the Delete Trace
button.
Individual Data Points can be edited by manually entering values directly into the text box.
To add Data Points, the user can click on the
Insert Data Point at End button.
Clicking on the numeral to the left of the Data
Point will highlight that particular line and
change the button to Insert Data Point Before Selection.

NOTE: To load Reference Data into a DataSpace or Template, refer to the Data Menu section of Chapter Three, The Main
Display.
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Add-in Programs

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