Professional Documents
Culture Documents
DA/HA/MA/PA/VA
Operations
Manual
Windrock, Inc. 2013
10/9/2013
Legal Notices
Copyright
1997-2013 by Windrock Incorporated, All rights reserved.
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into any language in any form by any means without the written permission of Windrock, Incorporated.
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the computer systems on which they may be used. Any unauthorized duplication or use of Windrock software or
firmware in whole or in part, in print, or in any other storage and retrieval system, is forbidden.
Disclaimer
This manual is provided for informational purposes. Windrock, Incorporated, makes no warranty of any kind with
regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a
particular purpose. Windrock, Incorporated shall not be liable for errors, omissions, or inconsistencies which may
be contained herein or for incidental or consequential damages in connection with the furnishing, performance, or
use of this material. Information in this document is subject to change without notice and does not represent a
commitment on the part of Windrock, Incorporated. Any software described in this document is furnished under a
license agreement or nondisclosure agreement. The software may be used or copied only in accordance with the
terms of the agreement.
Portable Analyzer DA/HA/MA/PA/VA Operations Manual
If you have comments about this documentation, the software, or products it describes, please contact the
Customer Support Group at Windrock.
Contents
Table of Contents
Part I Customer Information
1 Introduction ................................................................................................................................... 1
2 Customer Assistance
................................................................................................................................... 1
3 Returning Items
................................................................................................................................... 2
4 Handling Precautions
................................................................................................................................... 3
5 Warnings
................................................................................................................................... 4
1 Special Terms................................................................................................................................... 4
2 Care
................................................................................................................................... 5
3 Unpacking
................................................................................................................................... 5
.......................................................................................................................................................... 6
......................................................................................................................................................... 7
Charger
.......................................................................................................................................................... 8
Energy Access
......................................................................................................................................................... 8
1 Connections ................................................................................................................................... 9
2 Keypad Functions
................................................................................................................................... 11
3 System Configuration
................................................................................................................................... 11
System Options
.......................................................................................................................................................... 13
Printer Management
.......................................................................................................................................................... 15
Set Date and ..........................................................................................................................................................
Time
15
Set Time Zone
.......................................................................................................................................................... 15
System Information
.......................................................................................................................................................... 16
Database Backup
..........................................................................................................................................................
/ Restore
17
4 Calibration ................................................................................................................................... 17
5 Stations & Machines
................................................................................................................................... 18
Station & Machine
..........................................................................................................................................................
Setup
19
Manage or.........................................................................................................................................................
Add Station
21
Manage or.........................................................................................................................................................
Add Machine
22
24
1 Machine Configuration
................................................................................................................................... 25
General Configuration
.......................................................................................................................................................... 25
Engine Configuration
.......................................................................................................................................................... 28
Articulation Table
.......................................................................................................................................................... 33
Articulation .......................................................................................................................................................... 39
Compressor Configuration
.......................................................................................................................................................... 41
Miscellaneous
..........................................................................................................................................................
Engine and Compressor
44
2 Sensor Point...................................................................................................................................
Setup
45
Overview
.......................................................................................................................................................... 45
II
3 Collection / Plot
...................................................................................................................................
/ FFT Setup
57
Collection Point
..........................................................................................................................................................
Editor
58
Group Plot Setup
.......................................................................................................................................................... 59
FFT route setup
.......................................................................................................................................................... 59
71
................................................................................................................................... 71
2 Manual / Temperature
...................................................................................................................................
Data
72
3 Zero DC Pressure
................................................................................................................................... 75
Two Point DC..........................................................................................................................................................
Pressure Calibration
76
6 Notes
................................................................................................................................... 132
Collecting Notes
.......................................................................................................................................................... 132
Customizing..........................................................................................................................................................
Notes
134
7 Route-based
...................................................................................................................................
FFT
136
FFT Overview
.......................................................................................................................................................... 136
Adding FFT ..........................................................................................................................................................
Collection Points
136
FFT Data Collection
.......................................................................................................................................................... 141
Transient Data
..........................................................................................................................................................
Collection
143
FFT Sensor ..........................................................................................................................................................
Selection
147
Contents
III
8 Graphical Data
...................................................................................................................................
Screen
148
154
1 Graphical Data
...................................................................................................................................
Screen
154
159
1 View Manual
...................................................................................................................................
/ Temperature Data
159
2 View Notes ................................................................................................................................... 161
3 View FFT data
................................................................................................................................... 163
167
170
1 Direct Channel
...................................................................................................................................
Read
170
2 Power Cylinder
...................................................................................................................................
Monitor
173
3 System Information
................................................................................................................................... 173
4 X Engineering
...................................................................................................................................
Mode
173
173
1 Shaft Encoder
................................................................................................................................... 173
2 Multi-Event................................................................................................................................... 174
3 Magnetic Pickup
................................................................................................................................... 176
4 Optical Pickup
................................................................................................................................... 176
5 Timing Light
................................................................................................................................... 176
6 Setting Machine
...................................................................................................................................
TDC
177
7 A 6042 Wireless
...................................................................................................................................
Transmitter
180
184
1 Windows Install
................................................................................................................................... 184
184
................................................................................................................................... 184
................................................................................................................................... 185
186
1 Data Collection
...................................................................................................................................
Techniques
186
2 Class 1, Div...................................................................................................................................
II Information
187
Hazardous Location
..........................................................................................................................................................
Information
188
Control Drawing
.......................................................................................................................................................... 189
III
IV
................................................................................................................................... 189
Accelerometer
.......................................................................................................................................................... 191
Compressor..........................................................................................................................................................
DC Pressure Sensor
195
Infrared Temperature
..........................................................................................................................................................
Sensor
197
Magnetic Pickup
.......................................................................................................................................................... 201
Primary Ignition
..........................................................................................................................................................
Sensor
204
Secondary Ignition
..........................................................................................................................................................
Sensor
204
Ultrasonic Sensor
.......................................................................................................................................................... 204
Velocity Sensor
.......................................................................................................................................................... 207
Water-cooled
..........................................................................................................................................................
Pressure Sensor
208
Displacement
..........................................................................................................................................................
Probe
208
4 Specifications
...................................................................................................................................
- 6320
208
5 Specifications
...................................................................................................................................
- Sensors
210
6 Specifications
...................................................................................................................................
- Wireless Transmitter
211
7 Terms and Conditions
................................................................................................................................... 212
214
226
Customer Information
Customer Information
1.1
Introduction
Caution! A caution indicates actions that may have a major impact on the hardware,
software, database files, etc.
1.2
Customer Assistance
Direct any questions you may have about the product you have purchased to Windrock's Product
Support department at (865) 330-1100 Ext. 1114
Hardware
1. Please have the serial number of your analyzer available when you call. The serial number is
located either on the back of the analyzer and/or on the sliding battery door.
2. If you have a problem, explain the exact nature of your problem. For example, what are the
error messages? When do they occur? What you were doing when the problem occurred?
For example, what mode were you in? What steps did you go through? Try to determine
before you call whether the problem is repeatable.
Software
1. Please have the number of the current version of your software ready when you call. The
version of the software appears under the system information screen.
2. If you have a problem, explain the exact nature of your problem. For example, what are the
error messages? When do they occur? What you were doing when the problem occurred?
For example, what mode were you in? What steps did you go through? Try to determine
before you call whether the problem is repeatable.
3. Please have your analyzer ready and any accessories in question when you call. We can
serve you better when we can work through the problem together.
1.3
Returning Items
For Repair
1. Call Product Support at (865) 330-1100 Ext. 1114 to obtain a return materials authorization
number (RMA). Please write it clearly and prominently on the outside of the shipping
container.
2. Please enclose a letter that describes the reason(s) you are returning the item.
3. Insure your package for return shipment. Shipping costs and any losses during shipment are
your responsibility. COD packages cannot be accepted and will be returned unopened.
For Credit
1. Call Product Support at (865) 330-1100 Ext. 1114 to obtain a return materials authorization
number (RMA). Please write it clearly and prominently on the outside of the shipping
container.
2. Return all accessories originally shipped with the item(s). Include cables, software diskettes,
manuals, etc.
3. Enclose a note that describes the reason(s) you are returning the item(s) for credit.
Hardware Repair
Windrock repairs its hardware products free for one year from the date of shipment. This service
warranty includes minor hardware improvement, modification, correction, re-calibration, updates,
and maintenance for normal wear. This service warranty excludes repair of damage from misuse,
abuse, neglect, carelessness, or modification performed by anyone other than Windrock.
Windrock automatically sends updated manuals on the software update CD-ROM in electronic
format to all customers who are under warranty.
After the one year service warranty expires, each return of a Windrock hardware product is subject
to a minimum service fee. If the cost of repair exceeds this minimum fee, we will call you with an
estimate before performing any work. Contact Product Support for information concerning the
current rates.
Refer to the Warranty section of the Terms and Conditions section of this manual for a complete
description of your warranty.
Extended Service Plan
Windrock offers an Extended Service Plan (ESP) on analyzer equipment. Software benefits
include program corrections and improvements, modifications, manual revisions and telephone
Customer Information
assistance. Hardware benefits cover malfunctions due to normal wear, annual calibration, and
updates. Contact Inside Sales at (865) 330-1100 Ext. 1143 for information concerning the current
cost of Extended Service Plan.
1.4
Handling Precautions
STATIC ELECTRICITY
The CMOS integrated circuits in the analyzer can be damaged by exposure to electrostatic
discharges.
LITHIUM-ION BATTERIES
The analyzer contains a Lithum-ion cell pack which can create a fire or explosion hazard if
improperly handled.
Do not expose battery to temperatures in excess of 100 degrees Celsius or dispose of in fire.
Do not attempt to charge pack with a charger other than specified or modify battery-related circuitry
on the analyzer.
Do not short circuit battery.
Dispose of properly - do not throw away in the trash (please recycle to help the environment)
LOOSE CLOTHING AND LONG HAIR (MOVING PARTS)
Be careful not to get hands, hair, or clothes near any moving parts such as fan blades, belts, pulleys,
or fly wheels. Never wear neckties or loose clothing when working around machinery.
ElectroMagnetic Interference (EMI)
Do not attempt repairs on the analyzer. Any loosening of the exterior metal case may damage the
EMI protection of the case and interconnecting pieces.
1.5
Warnings
Caution!
The pressure sensor used with this kit may become hot when used on either an engine,
compressor, or any related piping. The sensor, when hot, may cause severe burns to the
hands or other body parts that come in contact with the hot surface. Use precautions
such as leather gloves to handle the sensor.
When using the water-cooled pressure sensor, the water used for cooling may become
hot and cause scalding. Use precaution when handling the sensor to prevent the hot
water from contacting the skin.
Caution!
The shaft encoder used with this kit comes in contact with a high-powered rotating
element. Keep all clothing and hair away from the rotating parts as they may become
tangled with the rotating parts and cause severe injury or death.
Keep hands away from the rotating equipment at all times to prevent injury.
Caution!
The timing light used with this kit may be used near high-powered rotating elements.
Keep all clothing and hair away from the rotating parts as they may become tangled with
the rotating parts and cause severe injury or death.
Keep hands away from the rotating equipment at all times to prevent injury.
Caution!
Several cables are used with the analyzer and shaft encoder that may be used near highpowered rotating elements. Keep all clothing and hair away from the rotating parts as
they may become tangled with the rotating parts and cause severe injury or death.
Keep hands and cables away from the rotating equipment at all times to prevent injury.
Be aware of the trip hazard cables on the floor can create.
2.1
Special Terms
6320
Portable analyzer
Collection Point Setup
A grouping of sensor inputs pre-defined for easy data collection
FFT
Fast Fourier Transform. A method of converting the time domain signal into its individual
frequency components
Parallel Port
Printer and communications link between the analyzer and host computer
Shaft Encoder
Device used to convert crankshaft position into electrical impulses
Transducer / Sensor
Device used to convert mechanical measurements into electrical signals
USB
A communications link between the analyzer and host computer
VGA
Video Graphics Array, or common computer color monitor type
2.2
Care
Use only a damp rag with a mild soap to clean the surfaces. Strong degreaser and other chemicals
may damage the keypad and clear display window.
2.3
Unpacking
Check to verify the following items are in the instrument case upon arrival. Refer to the enclosed
packing list for exact parts and / or options shipped. Compare the shipment to what parts were
ordered.
6320
A6320-00/PA
A6301-02
A6312-00
04100004
02202110
A6306-03-00
A6304-01
A6305-00
A6045-01-06
A6096-00-00
A905-02
A6095-00-00
A905-01
A6061-00-06
A6060-00-08
A6050-04-06
A6082-XX-00
A6082-XX-01
A6320-00-M/PA
A6320-00-SW/PA
Other parts may be present depending on the options selected and/or purchased.
2.4
E-Moli Li-Ion
2.4.1
Energy Access
Batteries
For Optimum Performance of Your Batteries
This battery needs to be charged before use. Refer to the "Instructions for Use of the Battery
Recharger" section of this manual for charging instructions.
When the battery is charged for the first time, the charger may indicate that charging has been
completed after just 10 to 15 minutes. This is normal and can happen with any rechargeable battery
when it is first charged or if it has been stored unused for a prolonged period. Simply remove the
battery from the charger and repeat the charging procedure. There is no need to discharge this
battery between these charges.
Best charging results are obtained at normal room temperature, 70F (21C) +/- 8F (2C). Charging
beyond this range is permissible but will not result in the battery's full capacity being reached.
Charging at temperatures below 50F (10C) or above 95F (35C) is not recommended.
It is normal for the battery to become warm during charging or after use.
It is not necessary to fully discharge this Li-ion battery before recharging. However, top-off type
charging can confuse the battery if charged this way consistently.
All rechargeable batteries will gradually lose their charge over time when they are left in storage. If this
battery will be left in storage for more than a few days prior to use, a top-off charge to regain full
capacity is recommended.
Wipe the metal terminals with a soft, dry cloth if they become dirty.
Safety Precautions for the Batteries
E-Moli
You may identify the Lithium-ion battery by the all black case and the "MOLICEL" logo on the top.
These batteries are Smart Technology batteries. There is a capacity bar on the right and is
activated by pressing the ON/OFF or RED button. The Li-ion battery is lighter in weight and higher
in capacity.
Caution!
Do not attempt to charge the Li-ion battery in a non-Li-ion charger (use only
the EnergyAccess charger supplied). There is a great potential for the
battery to EXPLODE. Use only a charger specified for this type of battery.
A battery may become deactivated and go into the "off state" as indicated by a red flashing light on the
charger . This means that the battery will not work until it is re-activated. To do this, insert the battery
into the left charger bay and press and hold the "Re-calibrate" button for 15 to 20 seconds. Remove
the battery and place it in the right side of the charger and let charge fully. It should then operate
correctly.
2.4.2
Charger
2.4.2.1
Energy Access
Newer units shipped are supplied with one or more Lithium-ion batteries. These are the latest high
capacity lightweight batteries available. They also have a special charger made just for Lithium-ion
batteries.
No battery detected
Fast charging
Fully charged
Re-calibrating
Re-calibrated
Standby
Error
Caution! Connection other than indicated may result in permanent damage to the
unit.
Re-calibration:
SMBus Smart Batteries contain a microchip that monitors battery usage and tracks how much
capacity is available from the pack. It is possible for this process to accumulate errors due to
temperature fluctuations, aging, self-discharge, and other factors.
To keep the internal information as accurate as possible, it is occasionally necessary to run the
pack through the calibration cycle. This involves fully charging the pack, completely discharging it,
and then recharging it again. The charger performs these steps automatically when a calibration
is initiated.
To calibrate a pack, place it in the left bay and push the red (or blue) arrow located between the
bays. This process can take 16 hours. Some packs do not have the capability to be re-calibrated.
The charger automatically senses this and simply drops back into the normal charge mode.
Specifications
SMBus:
Charge Rate:
2 Bays:
Charge Time:
Recalibration:
Recal Time:
Weight:
Material:
Color:
Dimension Inches:
Dimension mm:
Getting Started
3.1
Connections
Level 3
3.0 Amps
Sequential
3 hours each
SMBus 12v@1.2A
9 hours
9.5 oz
ABS GSM
Black
4.89 x 6.89 x 2.02
124 x 175 x 50
Several connections are provided on the analyzer unit. See the figures below for placement of the
connections. The portable analyzer series have the following layouts:
/PA
/MA
/DA
/CA
A standard USB keyboard may be used by connecting it to the USB port found on the left side of the
analyzer.
Caution!
Do not connect the external keyboard while near engine ignition systems.
This may damage both the keyboard and the analyzer.
Next, there are five round six-pin (referred to as "Lemo") transducer input connectors. These
connectors are for the transducers and shaft (crank-angle) encoder provided in the analyzer kit.
The connector labeled "ANT" is for the wireless encoder receiver antenna. Attach the supplied
antenna by screwing it on hand tight.
Caution!
Do not over-tighten the antenna. The antenna only needs to be finger tight.
There is potential to break the connector by over-tightening.
On the far left, an external AC-adapter connector is provided for use with the supplied charger power
pack. You may simply unplug the power pack from the charger base and plug it directly into the
analyzer. This will provide sufficient power to leave the instrument on for reviewing stored data
without using up the battery.
Caution!
Make sure to keep a battery in the analyzer when using the external power
adapter.
10
DC Power Input
Wireless Receiver Antenna
Encoder Input
Channel 4 Input
5 Channel 3 Input
6 Channel 2 Input
7 Channel 1 Input
6320
VGA Port
USB Port
The battery compartment is located on the right side of the analyzer behind the sliding door. The
battery compartment has a spring located in the bottom provided to pop the battery out when the
door is open. The battery will have to be pushed in and held while closing the sliding door. This
may be tight and is normal operation.
Note:
The sliding doors on the sides are provided to protect against EMI when around ignition
systems. The doors should remain closed while operating.
Getting Started
3.2
11
Keypad Functions
ESC
The escape key operates as a cancel function and gives the user the ability
to back up one step or menu. If you are in an operation that may cause data
loss (setup screens), a warning is given for user acknowledgment
ON/OFF
Yes
ENTER
+/-
END
HOME
Note:
3.3
TAB
TAB
Period
Numeric
Keys
Enters the numeric character in data entry fields and provides short cut
menu/function selections. If the user is on a menu screen, simply pressing
the number associated with the option will execute the option
If the entry screen has multiple lines requiring duplicate entries, you can press the
"ENTER" key and all the data from the previous line will be transferred to the new
line. For example, each cylinder's bore, stroke, and connecting rod length may be
copied from line to line since they may all be of the same values.
System Configuration
Before using the analyzer, take the time to become familiar with the basic operation and set up. There
are a number of options, setup entries, and keystrokes with which you should be familiar prior to taking
your first set of data.
When you first receive your analyzer prior to your data collection, you must first set up your own
stations, machines, and databases for those machines. Subsequently, when the analyzer is turned on,
you will be positioned at the menu for the last used station and machine. This enables you to power
down the analyzer to exchange batteries and power back up to the current machine or station, thus
12
You have access to the system options menu, printer menu, set date, time, time zone and database
backup and restore. The backup / restore lets the user archive the entire evport database to an
external flash drive or reload the evport database from an external flash drive.
Getting Started
3.3.1
13
System Options
Color scheme:
Typically set to LCD for black and white units, Color1 or Color2 for
color units or when an external VGA monitor is used, and B&W
can be used to improve contrast in some cases.
Typically set to no. If set to no, the back light will not turn off after
one minute.
Caution!
Power can be shut off to the encoder when in power save mode and the
user returns to a menu screen. It is possible to lose the phase setting
(exhaust vs. compression cycle) of the encoder when collecting data on
a 4-stroke engine. You must check the phase before continuing with
data collection if this occurs and power save is set to YES.
14
DC Sensor correction:
In the 6320 the noise floor can be raised. This is used when
converting the FFT's from acceleration to other display units.
In the 6320 the noise floor can be raised. This is used when
converting the FFT's from velocity to other display units.
The analyzer contains a status line at the bottom of the display. This line contains information about
the battery capacity and the date and time. The battery capacity is monitored when the unit is
operating from the battery. If the unit is on AC power, the status line will add "Using AC" to the battery
voltage value. If the battery capacity drops to approximately 9 volts, a warning will be displayed and
the analyzer will automatically turn off.
Getting Started
Caution!
When the battery goes below 10.0V, save the current data and change
the battery. Any data stored up to this point is safe. Only data that is
currently being collected and displayed or setup information currently
being entered could be lost.
3.3.2
Printer Management
3.3.3
3.3.4
15
16
3.3.5
System Information
Getting Started
3.3.6
17
3.4
Calibration
From the "Startup menu", hit escape twice to get to the "Station Selection Menu".
Select 4 to Calibrate the IR (infrared) sensor.
This menu option allows for entries of transducer calibration factors.
These values are used throughout the program as defaults.
18
For the infrared temperature sensor A6045-01-06 (Raytek model), use 0 for the 4mA entry and 1000
for the 20 mA entry.
The values should be entered in degrees Fahrenheit.
3.5
Getting Started
19
This must be done prior to being able to duplicate (copy) a previous setup from another
station/machine. See the section on machine database in the Windrock MD manual for
copying setups.
Station Selection Menu
From the "Machine Menu", press "ESC" twice to return
to the "Station Selection Menu".
Select "2-Add a station"
Enter a station name, followed by pressing "ENTER".
(See Manage or Add Station for more options.)
You will be returned back to the "Station Selection
Menu".
Select "1-Select a station" and pick the new station you
just added from the list.
Caution!
If you are a Windrock MD software user, make sure the name entered is
not altered without also changing the Windows database. In order to
connect Windows to the 6310, these names must match exactly
20
This is the minimum required to collect data with the analyzer. Further customizing may be required to
meet your setup needs.
If you find that the names you have entered need to be changed, you may use the "Edit a station
name" and "Edit a machine name" as necessary.
Getting Started
3.5.1.1
21
22
3.5.1.2
Getting Started
23
24
Setup Database
Note: The simplest and most effective way to create, edit, and manage the data base setup's is to
use the Windrock MD Windows software supplied with your analyzer, and then transfer the
setups from Windows to the analyzer. The following is how to setup, edit and manage the
setups using the analyzer software.
Note: After making changes in the analyzer setup, the setup files need to be copied to the windows
database.
The Machine database setup is a set of menu
options to configure the machine's geometry,
sensor points, collection points, fixed scaling,
gas analysis, calculation, and other related
setup details.
The machine configuration data can be
obtained from the manufacturer's data sheets.
Occasionally, not all the information is available
from this source. It may be necessary to call
the manufacturer to enlist their help with the
missing information. As a last resort, there are
databases that have been developed that can
help you obtain missing information. When you
use this information, it is up to you to verify the
accuracy.
Prior to actually setting up machine configuration, it would be prudent to read the section on "Fixed
data scale input" and "Gas composition setup" as these are used in the machine configuration
portion of the setup.
Setup Database
25
Below is an outline to setting up the machine database. It is a guide to organizing your data before
continuing. We suggest you gather the required data prior to starting the entry process.
Menu Key Menu Option
Description
Machine Configuration
Collection point / Plot / FFT Setup Set up route or FFT points for data collection
1 - Collection Point setup
2 - Group Plots setup
3 - FFT route setup
4 - Return to machine setup
Software Configuration
4.1
Machine Configuration
4.1.1
General Configuration
The machine configuration data can be obtained from the manufacturer's data sheets. Occasionally,
not all of the information is available from this source. It may be necessary to call the manufacturer to
enlist their help with the missing information. As a last resort, there are databases that have been
developed that can help you obtain missing information. When you use this information, it is up to you
to verify the accuracy.
Using the left or right arrow key, select from the choices available. If you are using an encoder, select
360 pulses per revolution and, if you are using a magnetic speed pickup, select 1 pulse per revolution.
If you have no power cylinders, set this to zero.
If you have no compressor cylinders, set this to zero.
Industry standards for efficiencies are:
Overall Efficiency
Mechanical Efficiency
85%
95%
26
Note: The angle values entered for the engine and compressor phase angles, engine event
angles, ignition timing angle and power cylinder pressure tracking angles are to be entered
as degrees after TDC. On four-stroke engines the angles are after TDC of the
compression stroke using a range of 0 to 720 degrees.
Strokes per cyl 2/4: is used to set the analyzer up for either a two-cycle or four-cycle machine. Note
that all compressor data is automatically set to two-cycle mode regardless of this setting. If the shaft
encoder is used, the switch on the side should always be left in four-stroke mode even if on the
compressor of an integral style machine. See the section on encoders for more information.
Note:
In the following setup screens, use the left or right arrow keys to select from the choices
available, or enter the numeric values as required.
Power cylinder layout: is set according to how the cylinders are labeled and selected by pressing
the right arrow to bring up the menu shown below. Options are Left/Right, Straight, Odd/Even,
Opposed MEP, Tandem and A/B.
Note:
Setup Database
27
Power cylinder articulated: If you have an engine with articulated connecting rods, select yes for
Power cyl articulated. This will require additional information and additional "Machine
Configuration" screens to be present. See articulation setup information later in this section.
Rated Load: Enter the rated load from manufacturer's specifications.
Rated Speed: Enter the rated speed from manufacturer's specifications.
Note:
encoder pulses. If the user's rated speed is too high for per degree mode,
then the user will have to change to once per turn mode themselves (by
changing Pulses Per Rev to 1).
Depending on the Articulation setting, the following screens are displayed next.
Articulated
Non-Articulated
Engine Mech Eff: Is the product of the mechanical and compression efficiency. By convention,
the overall efficiency of industrial compressors is set at 0.85.
Comp Mech Eff: Is the ratio of the indicated horsepower (IHP) to the brake horsepower (BHP).
By convention, the mechanical efficiency of industrial compressors is set at 0.95.
Auxiliary load (HP): Enter the total BHP of any additional pieces of equipment driven from the
crankshaft.
Note:
28
4.1.2
If the articulation setting is set to Yes, please refer to the end of this section for the
data entry screens that will require entries.
Engine Configuration
Engine specific information must now be entered using the following screens and information.
Note:
For Articulated engines see the section that follows on Articulated Engine Setup.
Setup Database
29
The portable analyzer has additional features which may be set up to help in the analysis process.
These features do not necessarily need to be set up but can be very helpful for analysis. The events
and angles entered on the next three screens will be available on graphics screens or in reports.
30
Setup Database
Note:
31
With the master rod at TDC position, the angle between the master
rod centerline and the right or left articulated pin centerline
link radius: The radius from the center of the rod bearing and the centerline of the link rod
pins
rod length:
The length of the master rod from center of pin to center of bearing
link rod:
32
Input the:
Setup Database
33
Enter the side that the Master Rod is on while looking at the engine
from the flywheel end. All bank and bale angles are based on this
positioning.
This setting takes the guess work out of trying to figure out different
angles based on right or left geometry. Simply input the smallest angle
from the master to the articulated rod.
4.1.3
Articulation Table
Power Bank
Rod Type Master Rod Rotation Master Rod Master Rod Articulated Articulated
as viewed from
FW
Location
Bank
Bale
Viewed at
Length
Stroke
Radius
Rod Lgth
Angle
Angle
Flywheel
(inches)
(inches)
(inches)
(inches)
(deg)
(deg)
CW
34.00
14.00
7.750
35.125
120.00
120.00
CW
34.00
14.00
7.750
35.125
60.00
60.00
CooperBessemer
GMV (Short
Stroke)
Left
Articulated
Right
Articulated
Right
Comp
Right
Comp
34
CW
34.00
14.00
8.500
34.375
120.00
130.00
CW
34.00
14.00
8.500
34.375
60.00
70.00
CW
34.00
14.00
8.500
34.375
60.00
70.00
CW
34.00
14.00
8.500
34.375
120.00
130.00
CW
25.00
10.50
6.875
24.000
120.00
120.00
CW
25.00
10.50
6.875
24.000
60.00
60.00
CW
35.00
14.00
10.625
31.875
120.00
130.00
CW
35.00
14.00
10.625
31.875
60.00
70.00
Left
Right
Comp
Articulated
Right
Comp
Articulated Left Comp
CW
35.00
14.00
10.625
31.875
60.00
70.00
Right
CW
35.00
14.00
10.625
31.875
120.00
130.00
Right
Articulated
Right
Articulated
Right
Comp
Right
Comp
GMVM, QUAD
Left
Right
Articulated
Setup Database
Power Bank
as viewed from
FW
Location
Rotation
35
Bank
Bale
Viewed at
Angle
Angle
Flywheel
(inches)
(inches)
(inches)
(inches)
(deg)
(deg)
CW
50.00
20.00
12.250
50.000
108.00
119.00
CW
50.00
20.00
12.250
50.000
72.00
83.00
CooperBessemer
GMW, GMWA, GMWC, GMWE, GMWH,
V250, V275, W330
Left
Articulated
Right
Comp
Right
Articulated
Right
Comp
Left
Articulated Left Comp
CW
50.00
20.00
12.250
50.000
72.00
83.00
CW
50.00
20.00
12.250
50.000
108.00
119.00
Left
Articulated
CW
62.25
20.00
12.250
50.000
36.00
41.40
Right
Master
CW
62.25
20.00
Articulated
CW
50.00
20.00
15.062
40.937
110.00
120.83
CW
50.00
20.00
15.062
40.937
70.00
80.83
Left
Right
Comp
Articulated
Right
Comp
Articulated Left Comp
CW
50.00
20.00
15.062
40.937
70.00
80.83
Right
CW
50.00
20.00
15.062
40.937
110.00
120.83
Left
Articulated
CW
41.00
16.60
10.437
30.500
5.00
53.16
Right
Master
CW
41.00
16.50
Left
Articulated
CW
55.00
22.00
11.750
43.211
36.00
42.75
Right
Master
CW
55.00
22.00
Right
Right
Power
GMYK, Z330
Left
Right
KSV
Right
Power
LSV
Right
Power
36
Power Bank
Rod Type Master Rod Rotation Master Rod Master Rod Articulated Articulated
as viewed from
FW
Location
Bank
Bale
Viewed at
Length
Stroke
Radius
Rod Lgth
Angle
Angle
Flywheel
(inches)
(inches)
(inches)
(inches)
(deg)
(deg)
13.954
34.600
45.00
49.50
13.954
34.600
45.00
49.50
10.996
26.188
45.00
43.69
14.660
48.125
45.00
47.00
DelavalInterprise
DMVR
Left
Articulated
CW
48.13
21.00
Right
Master
CW
48.13
21.00
Right
Articulated
CCW
48.13
21.00
Left
Master
CCW
48.13
21.00
HVA, HVC
Left
Articulated
CW
37.00
15.00
Right
Master
CW
37.00
15.00
Left
Articulated
CW
50.00
21.00
Right
Master
CW
50.00
21.00
RV4
Setup Database
Power Bank
Rod Type Master Rod Rotation Master Rod Master Rod Articulated Articulated
Location
37
Bank
Bale
Viewed at
Length
Stroke
Radius
Rod Lgth
Angle
Angle
Flywheel
(inches)
(inches)
(inches)
(inches)
(deg)
(deg)
IngersollRand
XVG
Compressor Side Articulated Left Comp
CCW
30.00
12.00
6.875
26.000
60.00
70.00
CCW
30.00
12.00
6.875
26.000
120.00
130.00
Free Side
JVG
CCW
20.25
8.50
5.687
19.125
60.00
60.00
CCW
20.25
8.50
5.687
19.125
120.00
120.00
CCW
27.00
12.00
7.750
26.000
60.00
70.00
CCW
27.00
12.00
7.750
26.000
120.00
130.00
5.562
19.125
60.00
69.00
7.500
26.000
60.00
69.20
Free Side
SVG
Free Side
PJVG
Left
Articulated
CCW
24.69
9.00
Right
Master
CCW
24.69
9.00
Left
Articulated
CCW
33.50
12.50
Right
Master
CCW
33.50
12.50
PSVG
38
Power Bank
Rod Type Master Rod Rotation Master Rod Master Rod Articulated Articulated
Location
Bank
Bale
Viewed at
Length
Stroke
Radius
Rod Lgth
Angle
Angle
Flywheel
(inches)
(inches)
(inches)
(inches)
(deg)
(deg)
CW
50.00
19.00
13.500
36.687
50.00
50.00
CW
50.00
19.00
CW
50.00
19.00
13.500
36.687
50.00
50.00
DresserRand
TCV, TCVD, TPV
Left
Right
Right
Articulated
Right
Power
Master
Articulated Left Power
Left
Master
CW
50.00
19.00
Left
Articulated
CW
37.75
15.00
9.625
35.000
120.00
120.00
CW
37.75
15.00
9.625
35.000
60.00
60.00
Left
Right
Comp
Articulated
Right
Comp
Articulated Left Comp
CW
37.75
15.00
9.625
35.000
60.00
60.00
Right
CW
37.75
15.00
9.625
35.000
120.00
120.00
VRA
Right
Setup Database
4.1.4
Articulation
Articulation Diagrams
39
40
For articulated integral engine/compressors, the articulation information must be entered into the
machine set up. The figure above shows the angles that are needed by the 6310 software to
calculate the swept volume of the power cylinders. The angles and lengths required are:
Master rod length:
Articulated radius:
The radius from the center of the master rod bearing and the
centerline of the link radius rod bearings
Articulated rod length: The length of the articulated power link rod in inches
Setup Database
4.1.5
41
Bank angle:
The angle between the master rod centerline and the power piston
centerline
Bale angle:
The angle between the master rod centerline and the centerline of the
link radius rod bearings
Compressor Configuration
Compressor specific information must now be entered using the following screens and
information.
Input the phase angles for the head end only. The crank end is always assumed to be 180 degrees
different. A manufacturer's schematic will usually have the information necessary to calculate the
angles at which each cylinder will be at outer dead center when referenced to one cylinder.
Note:
Phase angles are associated to a cylinder name (i.e. CH1). You will need to remember
this for other parts of the setup.
Should a unit have two pistons in line, the tail rod diameter needs to be subtracted out of the bore size
for that cylinder end.
Maximum allowable rod load in compression and tension are available in the manufacturer's data
sheets.
Enter the mass of the reciprocating parts for a cylinder to calculate inertia forces into the rod load
calculations. The reciprocating parts typically include the piston, rod, and other pieces as known.
A gas analysis needs to be setup in "Gas Composition" and the names that we established there will
be available here. It is possible to have different cylinders or cylinder ends that are moving different
gases.
42
Input the phase angles for the head end only. The crank
end is always assumed to be 180 degrees different. A
manufacturer's schematic will usually have the
information necessary to calculate the angles at which
each cylinder will be at outer dead center when
referenced to one cylinder.
Note:
Enter the load steps into the table for each cylinder's
end. Use the tab key to shift the screen right or left to
the next set of cylinder ends. Select next page to enter
the set of 16-30 and so on up to 90 load steps
maximum.
If the global setting for "Loadstep in" is set for percent
clearance, enter these values in percent. Otherwise, for
cubic inches, enter these values in cubic inches.
Setup Database
43
44
4.1.6
Setup Database
45
4.2
4.2.1
Overview
Machine sensor points are the identifiers in the software for external sensors attached to the analyzer.
The sensor point requires information to be set defining the type of point and parameters for that type
of sensor. Once set, the analyzer knows how the data that is electronically sampled should be
displayed and calculated. Each point requires the following parameters:
The sensor point list has a maximum number of 800 points per machine. If more points are required,
you may wish to separate the engine and compressor into separate database machines.
Once all the points are entered, the next step is to group the points into a planned collection route.
This will be done with the "Collection point editor" later in this section.
46
Setup Database
47
Voltage sensor vs. Crank is the measurement using a sensor type with voltage output vs. crank
angle.
Manual panel reading input is a panel gauge reading entered via the keypad.
Infrared temperature input is a temperature value entered via the infrared temperature sensor.
Vibration in velocity vs. Crank uses a velocity sensor to take a vibration reading vs. crankangle
in ips engineering units.
Proximity probe vs. Crank uses a proximity displacement sensor to take a gap readings vs.
crankangle in mil engineering units.
Point engineering units
Sets the display units for the type of sensor being used (e.g. pressure in PSI, vibration in g's,
ignition in volts, etc.).
Phasing reference
Sets the TDC reference for the point. For
example, when sampling pressure on the head
end of #4 compressor cylinder, set the phasing
to CH4. When displaying data, the curves will
plot correctly. If the phase is not set correct,
incorrect data will be displayed and reporting will
generate errors. Use the right arrow key to bring
up the pick box and select the proper phasing
from the list.
48
Units-low
Units low should be set to the zero point of the sensor being used. Typically this is 0.
Units-high
Units high should be set to the full scale of the sensor being used.
Some notes on the sensor point list:
1. Once entered, the list cannot be re-arranged (use collection point list to group and form
routes)
2. Sensor names can be changed anytime
3. Additional sensor points can be added to the end of the list
4. Scales and point type will affect collected data
On the next several pages are examples of sensor points that would be used in engine analysis.
Setup Database
4.2.2
49
DC Pressure Point
50
AC Pressure Point
Setup Database
51
52
Set up a spark plug voltage vs. crank angle for each spark
plug. Distinguish the plugs so that they are easily identified:
Top/Bottom, Right/Left, Right/Center Left, etc.
Note: The maximum voltage is typically set to 50,000 but
may need to be adjusted depending on the diameter of
the secondary ignition wire.
Spark Point
Setup Database
53
4.2.3
54
Vibration Point
Setup Database
Note:
55
Ultrasonic Point
4.2.4
A temperature point should be set up for each stage suction and cylinder discharge.
When taking data from a compressor, these temperatures should be entered prior to
collecting pressure crankangle data. The temperatures are used in calculations of
capacity, flow balance, etc. and may be displayed on the screen while looking at PV
cards. If the temperatures are entered later, these calculation results will not be
available for display while collecting data.
Set up suction temperatures per stage as manual
inputs. A sample setup may look like this:
1st Stage Suction Temp
Note:
56
Infrared Temperature
Setup Database
57
4.3
58
4.3.1
Each of the 6320's two (MA, CA, DA) or four (PA, HA) channels are identical; any sensor type may be
used on any channel.
The 6320 has two exceptions to the conditions stated above. First, the 6320's sampling rate for
spark (secondary ignition) data is much higher. The extra processing this requires, you can only use
one spark sensor at a time, and you cannot combine it with other sensor points. Second, because
the 6320 takes angular velocity data at the same time as other types of data, you cannot set up a
collection point that uses all four regular channels and channel 5 (angular velocity) at the same
time. (You can, however, assign an angular velocity sensor point to any of channels 1 through 5, and
you can mix an angular velocity sensor point with up to three other sensor points in the same
collection point.)
Analyzing an engine requires the use of statistics obtained from the pressure time curve and
secondary ignition data. As you will notice, the first data collection point setup screen has only cylinder
pressure and secondary ignition test points. The "Number of Cycle in Average" is set to 30. The
"Number of Cycles in Average" is a user defined number up to 250.
The second data collection test point setup is on the same cylinder. It collects data from the head bolt
in both high frequency and ultrasonic, as well as cylinder pressures. This configuration will only take
one cycle of data for display.
Continue the sequence for all remaining cylinders.
Setup Database
4.3.2
59
4.3.3
60
4.4
Setup Database
61
62
Set up pressure range scales that make sense for your unit.
You can use stage pressure ranges as a guideline. These
fixed scales allow for consistent displays for viewing
patterns. It is not a problem to change the scales after data
collection if they are either too small or too large for scale.
Setup Database
63
4.5
64
The gas mixtures must be entered in either percent or mole fractions. The total must be 100 or 1.00
respectively. If they are not, a warning will appear when trying to save the setup.
Setup Database
4.6
65
66
4.7
Software Options
Software configuration which is found in the set up menu, allows several factors to be preset for
the graphical display. These are permanent settings vs. temporary (i.e. they become the defaults).
Below are explanations of each setting and how they affect the displayed data. These settings do
not affect the stored data; only the data displayed and reported on.
Auto strip chart: "YES" will set the display to plot data as if it were on a strip chart recorder.
"NO", will set the display to overlay plot data one on top the other.
Setup Database
67
Number of strip charts: This tells the display how many strip charts to allow. The range is 2 to
10. Using a higher value will tend to make the plots more unreadable.
Note:
Include non-pressure curve in PVs: Switch to "YES" to show only pressure curves on volume
plots. A setting of "NO" will show all curves vs. volume.
Theoretical model: You may pre define which theoretical model to use or select ask each time .
Smoothing Factor: These are the default settings used in plotting and reporting. The settings
may be changed individually as desired. They may be temporarily changed from the graphical plot
screen as needed. Typically, the default is set to one.
Smoothing factor is a factor used in averaging out the data. If, for instance a factor of 2 is used,
two data points before and two data points after are used to average out the data for each point in
the curve. A smoothing factor can be set for each type of curve displayed. Typically, the default is
set to one.
Smoothing is used to remove any high frequency sinusoid that can occur in the data traces. The
smoothing filter acts like a low pass filter. Care must be taken not to over-smooth the data since
information can be lost. A good rule to follow for compressor and power pressure curves is that it
is safe to increase the smoothing factor as long as the horsepower being calculated does not
change significantly (less than 1%). Generally, a smoothing factor of 3 will remove most
compressor related channel resonance on a slow speed unit (300 rpm or lower); a factor of 10-11
will remove most channel resonance on high speed compressors (1000-1200 rpm) without overly
affecting the IHP.
A smoothing of 1 takes one point before and one point after and averages it with the given point to
obtain a smoothed value at that point. A factor of 2 takes two points before and two points after,
and so forth. A smoothing factor of zero means no smoothing occurs. Generally, you do not want
to smooth vibration or ultrasonic curves but the option is available to do so. Sometimes increasing
the compressor factor helps to improve the toe point pick for compressor pressure curves.
Smoothing and spike filters should not be used if not needed.
Note:
The smoothing filter cannot be used at the same time as the spike filter.
Spike Filter: These are the default settings used in plotting and reporting. The settings may be
changed individually as desired. They may be temporarily changed from the graphical plot screen
as needed.
The spike filter is used to remove sudden changes in value of the data that occurs for a single data
point. If a data point exceeds a three percent change from the linear fit of the previous point to the
next point, it is replaced with the interpolated value. If a spike consists of more that a single data
point, this filter is not effective and smoothing should be used.
68
Raw vibration sample density 6320 only: Pressing the right or left arrow key will select different
raw vibration sample density. The choices are 1, 2, and 4 samples per degree.
Pin Power Press curves: The power cylinder pressure curves can be pinned to a manifold
pressure. If the engine is natural aspirated four stroke cycle, the correct manifold pressure would
be zero.
Manifold Press for Pin (PSI): Enter the manifold pressure to which to pin the power cylinder
pressure curves to.
Enable Late Combustion check: The default is "YES". When set to YES, the software will look
for another peak in the firing pressure which is later and lower than compression pressure. If set to
"NO" and there is a late firing pressure which is lower than the compression pressure, the peak
firing pressure and angle will be reported for what is actually compression pressure.
Setup Database
69
GPSA Calculate clearances using formulas from the GPSA Engineering Data Book. These
formulas include the ratio of the suction Z value (compressibility value) to the discharge Z
70
value.
84-10a based Calculate clearances using formulas based on Southwest Research Institutes
Technical Report 84-10a. These formulas do not include the Z ratio. (Windrocks 84-10a
based method differs from 84-10a in that it uses the k value instead of nec.)
The GPSA clearance calculation method works better for adiabatic compression, such as occurs
in most natural gas compressors. The 84-10a based method works better for unusual cases
where the gas mixtures compressibility changes significantly from suction to discharge.
Use nozzle trace: There are three options available; "No", "Yes-loss only", "Yes-loss & VE".
Setting this option will use nozzle pressure traces in the calculations associated with pressure
data.
Use bad or mis-phased compressor data in report: When this box is checked, all compressor
curves are used to calculate and show horsepower. If there is a phasing error or an unloaded end
showing negative horsepower, the horsepower is still reported and a warning message is included
on the report.
Show gas phase warning: The default is "YES". If there is/are component/s in the gas sample
that do not converge at the current pressure and temperature conditions, a warning is displayed
when calculations are made that require the use of a gas sample. To disable the warnings, choose
the "NO" option. Calculations will be made without a warning display. The calculations will ignore
the component(s) that are not in convergence.
Volumetric efficiency settings: These factors are used in determining the unloaded state for a
compressor cylinder end. The default is 98. Some machines will stretch these tolerances beyond
the default settings. If this occurs, the reports and calculations will say "unloaded" when the
compressor end is loaded. In this case, you may need to set the defaults differently to
accommodate this condition.
Rod Load / Rod or Pen Reversal Calculations: You can choose to use Windrock's standard rod
load calculations (using either gas forces or total gas plus inertial forces), the method
recommended by your OEM, or a custom format. You can also configure the rod reversal
requirements for your compressor.
Rod load calculation methods and rod reversal requirements are provided for several OEMs.
For rod load inertial forces, you can choose to calculate rod load (using the piston and rod mass)
or the pin load (using the piston, rod, and cross head mass). Cross head mass can be entered
Setup Database
71
5.1
General
Data Collection is used to acquire data from the machine being analyzed. There are certain
requirements associated with data collection to which you must adhered. These will be pointed out in
the following paragraphs.
The "Data Collection Menu" is arranged in an order to help facilitate the process of data collection.
First, collection of manual data such as temperatures (suction and discharge) will provide more
specific on-screen calculation information.
Second, the DC pressure sensors must be zeroed.
Third, new data is collected.
Below are detailed descriptions of each menu selection.
Input manual data:
72
5.2
Sub-menu for additional functions related to data collection, OScope mode, FFT/Timebase mode, Spark mode
Notes on machine:
This selection allows the user to enter notes for the sensor point
and/or the machine in general.
73
Function
Description
Single Scan
Continuous
Peak Scan
Low SCAN
Updates the screen if the new values is less than the previous
value.
Exit
Run/Hold
New Run #
Save/Next
New Date/Time
Allows changing of date and time stamp for the current and
succeeding data sample. This new date and time will be used
until another menu is selected or until the date and time is
manually updated.
Manual Input
74
When the input box appears, enter the value and press
"ENTER".
Caution:
Verification Screen
75
"Input panel reading" provides a pop up point selection list and data entry screen for entering values
similar to input manual temperatures.
5.3
Zero DC Pressure
This function is used to set the reference pressure point for DC pressure sensors. The reference zero
pressure is atmospheric pressure. This is critical in acquiring accurate pressure measurements. If
zeroing is not done, the PT data acquired may have an arbitrary offset.
Note: This procedure reduces the effect of thermal or calibration drift in the sensor.
The typical procedure for this function is to warm the sensor up to operating temperature by placing
the sensor on the indicator port and exposing it to the hot gas. After a short period (two to three
minutes), remove the sensor from the pressure and zero the input channel using the following
procedure:
76
5.3.1
77
78
79
80
The high and low readings can NOT be the same. You
will be prompted to recalibrate.
5.4
81
82
Caution!
Be careful that the proper run number is assigned to the data being
collected. If the run number is changed by mistake, the data collected
will not be grouped together for reporting and will result in data being
split between run numbers. The same is true for the load step.
Hitting "END" and pressing "ENTER" will start the acquisition of data.
5.5
5.5.1
Overview
83
O-Scope mode:
This function is used to collect and display oscilloscope style data. See
the following sections for a complete description of the functions
available.
Spark Menu:
This function is used to collect and display ignition data. See the
following sections for a complete description of the functions available.
Encoder based balance: This menu is for balancing an engine using encoder referenced peak
firing pressure.
Non encoder balance
5.5.2
This menu is for balancing an engine using only peak firing pressure.
O-Scope
The O-scope mode allows the user to utilize the analyzer as a digitizing oscilloscope. Any signal
(pressure, vibration, ultrasonic, temperature, etc.) that can be used with the analyzer may be viewed in
a time-domain mode by the digitizing O-scope mode. Examples of the utility of O-scope are viewing
ultrasonic real-time signals to detect leaks; viewing multiple real-time traces of cylinder pressure to
observe variability of cycles; and observing real-time vibration signals to find knocking or detonation.
84
When O-scope is started, there are several options and choices displayed. Using the right/left arrow
keys, you may set up this mode as required. Below are a list of the possible settings.
STEP SIZE:
The time between digitized samples of the signal. For a 300 RPM
engine, 1 milli sec is a good selection.
Options:
TRIGGER:
COUNT:
PA 1, 2, 3, 4 or MA 1,2
FILTER (6320):
200
INPUT:
0.0000
The number of samples that one window displays. The time length of
a screen window is the STEP SIZE X COUNT. Normally on a recip,
one wants the screen window to be at least one rotation of the
machine. If more rotations are desired, either increase the STEP
SIZE or increase the COUNT.
Typical:
CHANNEL:
85
Options:
none, 78, 156, 312, 625, 1,250, 2,500, 5,000, and
10,000 Hz, low pass
and band pass filters starting at .5, 2, and 4 kHz,
and ending at 4, 6, 8, 10, and 15 kHz.
TRIGGER TYPE:
UPPER SCALE:
UPPER SCALE is the voltage level of the top of the o-scope window.
Full scale is 5.000.
Typical:
LOWER SCALE:
5.00000
ACCEL GAIN:
1, 5
Options (6320):
None
When the selections are correct, press END to start the real-time signal display. While the display is
shown, the user may do one of the hot box menu options:
Key
2
9
4, ESC
5.5.3
Function
Hold the display (toggle between run and pause the scan)
Toggle the grid off/on
Return to the setup menu
Spark Menu
The Spark Survey mode is used for a detailed evaluation of the condition and integrity of the
secondary ignition system of a spark ignited (SI) engine.
The Spark Survey Mode is an automated function that allows the user to simply connect the secondary
ignition capacitive clip to each spark plug lead and collect all the important parameters of the
secondary ignition signal. Once the user performs the set-up of the machine in the 63X0/CA/MA/PA
analyzer for each machine the first time, the on-screen menus will instruct the operation of the
collection of the spark data. When the user is finished collecting the data on each spark plug, the user
will have access to eight reports showing detailed ignition statistical parameters including:
1. Ionization Voltage
2. Arc Duration
3. Arc Voltage
86
The major benefits of the Spark Survey Mode is to allow any individual to collect spark data quickly
and have intuitive information about the secondary ignition system. This eliminates the need for having
an ignition specialist to understand the detailed secondary spark traces to evaluate the condition of
each spark plug. With the computer performing all the timing and voltage measurements automatically
on each parameter, this feature saves the time of having to manually record these parameters. The
analyzer will store these reports in memory for recalling old spark surveys and trending of the
secondary ignition system.
The spark survey function is designed to perform multiple spark survey per machine per day.
Function
Start a secondary ignition survey
Re-start and already in progress survey
Recall saved data for display and reporting
Jump to the oscilloscope mode for continuous display of a single point
Setup balancer and ignition parameters.
Spark Survey
The first screen in the ignition survey mode is the "START IGNITION SURVEY" screen. Press any key
to continue.
87
The next screen in the spark survey mode will display the message "Set number of cycles to collect".
The number of cycles can be set from 10 to 250 by pressing the "UP or DOWN Arrow" keys (one step
at a time) or the "UP or DOWN TAB" keys (five steps at a time). When the desired number of cycles is
highlighted, press the "ENTER" key to select.
The next screen in the spark survey mode will display the message "Pick cylinder to collect data". The
desired spark plug can be selected by pressing the "UP or DOWN Arrow" keys (one step at a time) or
the "UP or DOWN TAB" keys (five steps at a time). When the desired spark plu is highlighted, press
the "ENTER" key to select.
Note:
The spark plug will display a question mark before taking data "? NEED DATA"
Note:
The spark plug will display an asterisk after taking data "* - HAVE DATA"
88
The next screen in the spark survey mode will display the message "Hit enter to take data". Pressing
the "ENTER" key will continue the display of the live data collection screen.
Note:
The secondary ignition sensor must be attached to the spark plug lead before
proceeding. Press the "ENTER" key when ready.
Note:
The spark plug selection can be changed on this screen by pressing the "UP or
DOWN Arrow" keys to highlight "Chan 1 > L1 Side", then pressing the "RIGHT or
LEFT Arrow" keys to select the desired spark plug.
Note:
The loadstep selection can be changed on this screen by pressing the "UP or DOWN
Arrow" keys to highlight "Current loadstep > 0", then pressing the "RIGHT or LEFT
Arrow" keys to select the desired loadstep.
89
90
In the spark survey mode live data collection screen, the Time scale (Micro-seconds) and/or the
Voltage scale (Kilovolts) can be changed at any time during the data sample.
To change the time scale, press the "0" key to select "HIT 0 TO INDEX TIME SCALE
(usec)". The time scale will toggle through the available scales each time the "0" key is
pressed.
To change the voltage scale, press the "1" key to select "HIT 1 TO INDEX VOLTAGE
SCALE (KV)". The time scale will toggle through the available scales each time the "0" key is
pressed.
91
Following the live data collection screen, the next screen in the spark survey mode will return to the
pick cylinder list. Continue collecting data for all the spark plugs with a question mark "?"
Note:
The spark plug will display a question mark before taking data "? NEED DATA"
Note:
The spark plug will display an asterisk after taking data "* - HAVE DATA
"
When the final spark plug is finished with live data collection, the following message will pop up:
"Finished collecting spark survey, Hit any key to continue"
92
The menu section of the "Ignition Survey Reports" has many menu options.
To select "0-Options", press the "0" key or press the "LEFT or RIGHT Arrow" keys to highlight with
the "HOTBOX" then press the "ENTER" key. The option menu selection pops up a screen as above
for selecting the following options:
"0- CHANGE KV MAXIMUM" This is for changing the maximum kilo-volt scale on the statistical
bar graph.
"1-CHANGE KV PERCENT BAND" This is for changing the plus and minus percent bands on the
spark plug statistical bars.
"2-CHANGE KV MINIMUM" This is for changing the minimum kilo-volt scale on the statistical bar
graph.
To select "2-Report Type", press the "2" key or press the "LEFT or RIGHT Arrow" keys to highlight
with the "HOTBOX" then press the "ENTER" key. The option menu selection pops up a screen as
above for selecting the following options: To select, press the associated number key or highlight and
press the "ENTER" key.
93
Report definitions are further described in the next section. Each report can be viewed
and printed as necessary.
To select "3-Restart", press the "3" key or press the "LEFT or RIGHT Arrow" keys to highlight with the
"HOTBOX" then press the "ENTER" key. The next screen will display the message "PICK DAY TO
EXTRACT SPARK DATA". Highlight the desired day and press the "ENTER" key.
To select "5-Single Sample", press the "5" key or press the "LEFT or RIGHT Arrow" keys to highlight
with the "HOTBOX" then press the "ENTER" key.
The next screen will display a single sample of the spark plug secondary trace. Pressing the
"5" key or the "ENTER" key will take another single sample.
Note:
Single samples are for troubleshooting purposes and will not affect to statistical
reports.
To select "7-PRINT", press the "7" key or press the "LEFT or RIGHT Arrow" keys to highlight with the
"HOTBOX" then press the "ENTER" key. If a compatible printer is set up and connected to the printer
port, the "Selected Ignition Report" will print directly from the 6310/CA/MA/PA.
Press the "9" key or press the LEFT or RIGHT Arrow" keys to highlight the "9-EXIT" with the HOTBOX,
then press the "ENTER" key to select.
5.5.3.2
The next screen in the restart spark survey mode is the RESTART OF DATA COLLECTION FOR
SPARK SURVEY screen. To continue, press any key.
94
The next screen in the restart spark survey mode is the Pick cylinder to collect data screen. The
spark plugs that have data will have an asterisk (*), and the spark plugs the need data will have a
question mark (?). Select the desired spark plug by highlighting to continue the data collection process.
The next screen will be the "Arc Duration Report" for the desired day. From this screen, the menu
options are the same as for when the data was taken. See the section on spark survey for more
details.
95
96
5.5.3.4
NEW SCAN:
EXIT:
While in the spark trace window, the cursor is active and is moved with the TAB and arrow keys.
97
Function
To zoom in on the signal, set the cursor to the left side and press 1 - the zoom will
then occur. To restore the original view, press 1 a third time.
To resample the signal
This option will overlay six consecutive traces, then clear the screen and repeat
another six traces
98
5.5.3.5
The wider the spark plug gap, the more voltage required to ionize the gap.
2.
The narrower the spark plug gap, the less voltage required to ionize the gap.
3.
Typical voltage measurements will range from 5,000 to 25,000 volts, with voltages over
20,000 indicating wide gaps and a greater potential for external flashover.
4.
Note: In a non-controlled environment, the air/fuel ratio and mixture consistency can
affect the ionization voltage level from cycle-to-cycle measurements.
5. This voltage should go negative (-) with respect to ground if the secondary circuit is wired
properly. If the voltage is going positive (+) with respect to ground, this is referred to as
reverse polarity and indicates the wiring to the coil is reversed and may result in shorter
spark plug life.
Arc Duration The measured time period the actual arcing of the spark plug occurs. This is the time
measured between ionization voltage (breakdown) and the beginning of the ring-down voltage. The arc
duration is inversely proportional to the ionization voltage and rise time. The typical units is in microseconds (uS)
In a controlled environment:
1. The wider the spark plug gap, the shorter the arc duration.
2. The narrower the spark plug gap, the longer the arc D\duration.
3. Typical arc duration measurements will range from 125 micro-seconds to 700 microseconds for different ignition systems. When measured times reduce, this indicates
widening gap and/or excessive Ionization voltage requirements. As measured times
increase, this indicates a narrow gap and/or an incorrect measurement due to a low ringdown voltage level.
Arc Voltage The voltage level required to maintain the arcing of the spark plug gap. This is the
voltage measured between the zero reference line and the arc duration level. This voltage is typically
less than 1 KV with high current flow. The typical units is in volts.
Rise Time - The measured time required to Ionize the compressed air/fuel molecules within the gap
of the spark plug. This is also referred to as the ionization time. Ionization refers to the splitting apart of
the molecules to enable a current path for arcing of the spark plug. The rise time increases with an
increase in the ionization voltage. The typical units is in micro-seconds (uS)
In a controlled environment:
1. The wider the spark plug gap, the more time required to ionize the gap.
99
2. The narrower the spark plug gap, the less less required to ionize the gap.
3. Typical rise time measurements will range from 5 to 50 micro seconds (uS). With rise times
over 40 uS indicating wide gaps and a greater potential for external flashover.
Arc Slope The measured slope of the arc duration. The measured slope can be one of the following:
1 Flat. This indicates the voltage level during the arc duration remained constant as the
voltage requirements to maintain the arc did not change during the arc.
0 Negative. This indicates the voltage level during the arc duration started at a lower voltage
and increased as the voltage requirements to maintain the Arc increased during the arc.
This is an indication of high resistance across the spark plug gap.
2 Positive. This indicates the voltage level during the arc duration started at a higher voltage
and decreased as the voltage requirements to maintain the arc decreased during the arc.
This is an indication of high resistance in the secondary wiring and connections, exclusive
of the plug gap.
Ring Down Voltage The measured peak-to-peak voltage of the ring down oscillation of the coil. This
is also referred to as coil oscillation and or unused energy. This is the energy remaining after the spark
plug arc demands cannot be maintained. The typical units is in volts peak-to-peak. Anything that
affects the R-C time constant affects the amplitude and frequency of the ring down oscillations. A lack
of ring down typically indicates a poor plug wire connection in the coil tower.
No Arc, Voltage Problems Report This report identifies problems with spark plugs and/or other
secondary ignition components based on ionization voltage levels and arc duration measurements.
Please refer to the report for detailed description of each of the problems identified.
Arc Flyback This report identifies the number of times each coil has a flyback following the
ionization ramp. Please refer to the report for detailed description of the problem.
5.5.4
5.5.4.1
Overview
The analyzer will power on to the "Last Station" and the "Last Machine" it was in prior to powering the
unit off.
In the case of the /MA and /PA models navigate through the following menu options to reach the menu
shown below:
Data collection menu
Special collection modes
Encoder based balance
100
5.5.4.2
101
102
103
104
Peak Pressure - Spread: The cylinder's difference from the high to low peak pressures of
the number of cycles selected
105
"1-CHANGE PRESSURE PERCENT BAND", this is for changing the plus and minus
percent bands on the cylinder balance bars.
"2-CHANGE PRESSURE MINIMUM",
2 - Adjust cylinder
When you select this, a list of the cylinders pop up. Highlight the
cylinder that you wish to adjust, then when you have the pressure
transducer attached, hit the enter key. A screen will then pop up
showing you the average peak firing pressure continuously for that
cylinder. It will also show you the engine average (this will not change,
it is based on the as found data or as left data only). Use this screen
to adjust the cylinder. When you have finished adjusting the cylinder,
hit any key. You will return to the report showing data for all the
cylinders. The cylinder you have just adjusted will now be marked
with "A" for adjusted . You can readjust this cylinder if you wish by
selecting it again.
4 - Take As Left
When you have finished adjusting cylinders, hit this option to take the
as left report. You will be indexed again through each cylinder to take
data. When done, the screen will reappear listing the results of all
cylinders. If the balance is OK, you are done. Hit the ESC to exit. If
the balance still looks off, use the 2-Adjust cylinder option again to
adjust the power cylinders. When finished adjusting, take another as
left report. Repeat this cycle until a satisfactory as left report is
obtained. Then hit the ESC key to exit. You are now ready to connect
the 6310 to the PC and print your reports.
7 - Print
If a printer is attached and configured' pressing the "7" key will make
a hardcopy of the current screen to the printer. As Found and As Left
report data can be transferred to a PC running Application Windrock
MD/CA software. Printouts can then be made from Windows.
106
Using the information on the "As Found Report" to determine which cylinders need to be adjusted,
select the "2-ADJUST CYL" option. The next screen in the adjust cylinder mode is the cylinder
selection list. This list is a pop up selection in which you must use the cursor keys to select which
cylinder to adjust.
The "U" - UNADJUSTED shows that the listed cylinder has not been adjusted yet. The "A" ADJUSTED shows that the listed cylinder has been adjusted and new data saved. Select the cylinder
to adjust and the next screen will come up. On the screen will be live data.
If adjusting another cylinder, the next screen "ADJUST CYLINDER" is the cylinder selection list and will
indicate that a cylinder has been adjusted. Select the cylinder to adjust by pressing the "UP or DOWN
Arrow" keys to highlight the cylinder and then press the "ENTER" key.
"U UNADJUSTED"
"A ADJUSTED"
When finished adjusting the desired cylinders, press the "4-TAKE AS LEFT" key to move on to taking
a final set of balance data. Taking as left data is the same as taking "AS FOUND" data. After the last
cylinder is taken, the "AS LEFT" report will display.
If more cylinders are adjusted once the "Take as Left" has been performed, it will be necessary to
retake the "As Left" data for all cylinders to get an accurate "AS LEFT REPORT".
107
108
Peak Pressure - Spread: The cylinder's difference from the high to low peak pressures of
the number of cycles selected
109
"1-CHANGE PRESSURE PERCENT BAND", this is for changing the plus and minus
percent bands on the cylinder balance bars.
"2-CHANGE PRESSURE MINIMUM",
2 - Adjust cylinder
When you select this, a list of the cylinders pop up. Highlight the
cylinder that you wish to adjust, then when you have the pressure
transducer attached, hit the enter key. A screen will then pop up
showing you the average peak firing pressure continuously for that
cylinder. It will also show you the engine average (this will not change,
it is based on the as found data or as left data only). Use this screen
to adjust the cylinder. When you have finished adjusting the cylinder,
hit any key. You will return to the report showing data for all the
cylinders. The cylinder you have just adjusted will now be marked
with "A" for adjusted . You can readjust this cylinder if you wish by
selecting it again.
4 - Take As Left
When you have finished adjusting cylinders, hit this option to take the
as left report. You will be indexed again through each cylinder to take
data. When done, the screen will reappear listing the results of all
cylinders. If the balance is OK, you are done. Hit the ESC to exit. If
the balance still looks off, use the 2-Adjust cylinder option again to
adjust the power cylinders. When finished adjusting, take another as
left report. Repeat this cycle until a satisfactory as left report is
obtained. Then hit the ESC key to exit. You are now ready to connect
the portable analyzer to the PC and print your reports.
7 - Print
If a printer is attached and configured' pressing the "7" key will make
a hardcopy of the current screen to the printer. As Found and As Left
report data can be transferred to a PC running Application Windrock
MD/CA software. Printouts can then be made from Windows.
9 - Exit
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The "U" - UNADJUSTED shows that the listed cylinder has not been adjusted yet. The "A" ADJUSTED shows that the listed cylinder has been adjusted and new data saved. Select the cylinder
to adjust and the next screen will come up. On the screen will be live data.
If adjusting another cylinder, the next screen "ADJUST CYLINDER" is the cylinder selection list and will
indicate that a cylinder has been adjusted. Select the cylinder to adjust by pressing the "UP or DOWN
Arrow" keys to highlight the cylinder and then press the "ENTER" key.
"U UNADJUSTED"
"A ADJUSTED"
When finished adjusting the desired cylinders, press the "4-TAKE AS LEFT" key to move on to taking
a final set of balance data. Taking as left data is the same as taking "AS FOUND" data. After the last
cylinder is taken, the "AS LEFT" report will display.
If more cylinders are adjusted once the "Take as Left" has been performed, it will be necessary to
retake the "As Left" data for all cylinders to get an accurate "AS LEFT REPORT".
111
112
5.5.4.5
5.5.5
Non-Encoder Balance
5.5.5.1
Overview
113
The analyzer will power on to the "Last Station" and the "Last Machine" it was in prior to powering the
unit off. In the case of the /CA, the screen below will be shown after power up.
In the case of the /MA and /PA models, navigate through the following menu options to reach this
menu shown below:
The balancer mode has several menu options from which to choose. It is best to start with the setup
menu first when using the analyzer for the first time on a new unit. After the setup has been completed,
it need only be entered to make changes as needed.
Menu Item
Function
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5.5.5.2
NOx sensor
The NOx sensor menu option lets the 6320 receive NOx and
O2 readings wirelessly from Windrocks NOx sensor. The 6320
will continuously receive and display readings on its screen;
press Esc to exit this mode.
If record panel points is selected in the setup, you will be prompted to record those
readings before taking 'As Found data'.
this is when the cylinders are adjusted to even out the peak
pressures.
Note:
If record panel points is selected in the setup, you will be prompted to record those
readings.
Note:
You can bring up the last as found and as left balance run for the day on the analyzer.
Other run numbers are available for viewing in the Windows software package.
When first starting, the engine speed is determined by sampling the pressure curves. This engine
speed will then appear on the 'As Found' report.
The first screen you see will ask you to connect the pressure
transducer to a power cylinder and apply pressure. After you hit
any key, the estimate speed routine will run. This function will
count the number of pressure peaks within a measured time
frame and calculate an estimated RPM.
Note:
This will take 5 to 15 seconds. If the estimated speed is not close to the known speed, then you need
to go back and adjust the debounce factor and trigger level in ENGINE SETUP. This speed is
reported on the 'As Found' or 'As Left' reports depending in which part of the sequence you are.
Note:
115
The pressure sensor must be attached to the power cylinder and the indicator valve
must be opened to apply pressure.
116
As pressure data is collected, the curve and peak pressure are displayed (if the 'Show Curves' option
is set to Yes in the setup) along with the cylinder number as shown in figure below. Once all samples
are collected, the screen will return to the point selection list unless the 'Show curves with pause'
option is selected. If so, the screen will show the curves for viewing until a key is pressed.
117
The "Pick Cylinder" screen will appear and the "?" indicator will
change to a "*" showing that the data has been collected and the
cursor bar will advance to the next cylinder. Any cylinders with a
"?" still require data to be taken.
When the last cylinder's data is collected, the screen will show a
message box with "Finished collecting as found data, Now adjust
cylinders, Hit any key to continue". Press any key to display the "As
Found" balance report shown below or Hit the "END/NO" key to
resample the last point.
118
Peak Pressure - Spread: The cylinder's difference from the high to low peak pressures of
the number of cycles selected
119
"1-CHANGE PRESSURE PERCENT BAND", this is for changing the plus and minus
percent bands on the cylinder balance bars.
"2-CHANGE PRESSURE MINIMUM",
2 - Adjust cylinder
When you select this, a list of the cylinders pop up. Highlight the
cylinder that you wish to adjust, then when you have the pressure
transducer attached, hit the enter key. A screen will then pop up
showing you the average peak firing pressure continuously for that
cylinder. It will also show you the engine average (this will not change,
it is based on the as found data or as left data only). Use this screen
to adjust the cylinder. When you have finished adjusting the cylinder,
hit any key. You will return to the report showing data for all the
cylinders. The cylinder you have just adjusted will now be marked
with "A" for adjusted . You can readjust this cylinder if you wish by
selecting it again.
4 - Take As Left
When you have finished adjusting cylinders, hit this option to take the
as left report. You will be indexed again through each cylinder to take
data. When done, the screen will reappear listing the results of all
cylinders. If the balance is OK, you are done. Hit the ESC to exit. If
the balance still looks off, use the 2-Adjust cylinder option again to
adjust the power cylinders. When finished adjusting, take another as
left report. Repeat this cycle until a satisfactory as left report is
obtained. Then hit the ESC key to exit. You are now ready to connect
the 6310 to the PC and print your reports.
6 - Est. Speed
This will run the estimate speed routine again (it takes 60 seconds)
and the new speed value is then displayed and written in the as left
report.
7 - Print
If a printer is attached and configured' pressing the "7" key will make
120
This will change the display and replace the SD and Spread columns
with the hi/lo pressure count data
9 - Exit
Using the information on the "As Found Report" to determine which cylinders need to be adjusted,
select the "2-ADJUST CYL" option. The next screen in the adjust cylinder mode is the cylinder
selection list. This list is a pop up selection in which you must use the cursor keys to select which
cylinder to adjust.
121
The "U" - UNADJUSTED shows that the listed cylinder has not been adjusted yet. The "A" ADJUSTED shows that the listed cylinder has been adjusted and new data saved. Select the cylinder
to adjust and the next screen will come up. On the screen will be live data.
122
The target zone is the area in which you want to keep the peak pressure within.
The cylinder balance bar shows where the current cylinder's pressure is relative to the engine average.
It also shows the OK band that you are trying to stay within.
The current peak pressure is the actual pressure being measured. This allows reading the pressure
while adjusting the fuel valve.
The engine average mean peak pressure is the value you are trying to attain on this individual cylinder.
If adjusting another cylinder, the next screen "ADJUST CYLINDER" is the cylinder selection list and will
indicate that a cylinder has been adjusted. Select the cylinder to adjust by pressing the "UP or DOWN
Arrow" keys to highlight the cylinder and then press the "ENTER" key.
"U UNADJUSTED"
"A ADJUSTED"
When finished adjusting the desired cylinders, press the "4-TAKE AS LEFT" key to move on to taking
a final set of balance data. Taking as left data is the same as taking "AS FOUND" data. After the last
cylinder is taken, the "AS LEFT" report will display.
123
If more cylinders are adjusted once the "Take as Left" has been performed, it will be necessary to
retake the "As Left" data for all cylinders to get an accurate "AS LEFT REPORT".
5.5.5.3
The pressure sensor must be attached to the power cylinder and the indicator valve
must be opened to apply pressure. Hit any key when ready.
124
The next screen in the restart a balance run mode will appear as below. The program will automatically
search and find where the balance run was stopped. Hit any key to continue.
If a complete As Found collection, Cylinder adjustment, and As Left collection has been
performed, the "restart a balance run" will display the message below. More cylinders can be adjusted.
If more cylinder are adjusted once Take as Left has been performed, it's necessary to retake
the As Left data for all cylinder, to get an accurate AS LEFT REPORT.
5.5.5.4
125
The next screen will be the "As Found Report" for the desired day. From this screen, the menu options
are the same as when the data was taken. See the section on Engine Balancing for more details. Use
the menu option "Recall as left" to see the final report.
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5.5.5.5
Note:
This will take 10 seconds. If the estimated speed is not close to the known speed, then you need to
go back and adjust the debounce factor and trigger level in ENGINE SETUP.
Note:
The pressure sensor must be attached to the power cylinder and the indicator valve
must be opened to apply pressure.
The next screen in the "Power Cylinder Monitor" mode will display the live data collection. This will
continuously cycle until any key is hit to exit.
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5.5.5.6
Response
press to reset the running average bar
Decrease Cycles
Increase SD Range
Setup
Press the "1" key or the "ENTER" key if the menu item is highlighted to select the 1 Setup balancer/
spark
Every new machine added will have to be set up in the analyzer non-encoder balance mode prior to
128
CYL LAYOUT:
129
keys
2 OR 4 CYCLE ENGINE:
DEBOUNCE FACTOR:
SPARK LAYOUT:
130
Select the low pressure cutoff value for the report by pressing
the LEFT or RIGHT Arrow key. The balancer will report the
number of cycles that the peak pressure was below the low
cutoff value.
FINISHED:
Select the desired option (NO, YES hit enter) by pressing the
"LEFT or RIGHT Arrow" keys. If "YES hit enter", follow by
pressing the "ENTER" key to finish the machine set up, and
return the analyzer to the initial Balance and Spark Menu
screen. If the RECORD PANEL POINTS option was selected,
additional screens will be displayed to define the panel points
to be selected.
If you hit "ESC", the program will then prompt a "WARNING
Escape was hit - If you have made changes, they will be lost.
Save changes? (Y/N)"
If you want to save the set up changes, press the "HOMEYES" key
If you do not want to save the set up changes, press the
"END-NO" key
Pressing the "HOME-YES" key or the "END-NO" key will
return the 6310/CA to the initial Balance and Spark Menu
screen.
Note:
Every new machine will have to be set up in the 63X0/CA prior to running a peak
pressure balance and/or a spark survey. Once the new machine is set up, the set up
information will remain the same unless changed.
If you selected "YES" to "Record Panel Points", the following setup screens will allow you to define
those selections prior to returning to the Spark Menu screen.
131
Turn individual selections to YES or sequence number by using the "LEFT or RIGHT Arrow" keys if
you want the point added to the panel report. Panel points will show up in the order of their sequence
number. Go to the next page to continue the setup.
Identify the names of the user panel points selected on the previous menu page. The HOME key is
used to bring up a list of alphabetic characters for text entry when a keyboard is not available. Looking
at the rear panel to the far right, a connector labeled "KBD" is used for attachment of an external PS2
style keyboard.
Est Fuel Savings:
132
FINISHED:
Select the desired option (NO, YES hit enter) by pressing the
"LEFT or RIGHT Arrow" keys. If "YES hit enter", follow by
pressing the "ENTER" key to finish the machine set up, and
return the analyzer to the initial Balance and Spark Menu
screen.
If you hit "ESC" the program will then prompt a "WARNING
Escape was hit - If you have made changes they will be lost.
Save changes? (Y/N)"
If you want to save the set up changes, press the "HOMEYES" key
If you do not want to save the set up changes, press the
"END-NO" key
Pressing the "HOME-YES" key or the "END-NO" key will
return the analyzer to the initial Balance and Spark Menu
screen.
5.6
Notes
5.6.1
Collecting Notes
Entering notes for the data collected
133
Select the date for which to enter the note. This will
associate the note with the selected point and selected
day on which the data was taken.
134
5.6.2
Customizing Notes
Modifying the default note files
You can input up to 40 one-line notes for each of five categories. Each line can be up to 78 characters
long. Use a text editor to create a file using the names shown below. After you have input your one-line
comments, place an extra line at the bottom with "end of list".
Category
1)Angular Velocity
2)Compressor Points
3)Temperature Points
4)Power Points
5)Spark Points
File name
->
->
->
->
->
d6atext.dat
d6ctext.dat
d6ttext.dat
d6ptext.dat
d6stext.dat
Once you have created your files, place them in the /var/evport directory on your analyzer. Remember
this replaces the system default comments. You do not have to create all five files. For the categories
for which you do not create a file for, the system default comments will be available.
The system defaults are as follows:
Angular Velocity Notes
File: D6ATEXT
MANUALLY INPUT A SENSOR NOTE
Excess spread from hi to lo
Pattern has changed
Possible encoder slippage
end of list
Compressor Notes
File: D6CTEXT
MANUALLY INPUT A SENSOR NOTE
Valve leakage suction
135
136
Spark Notes
File: D6STEXT
MANUALLY INPUT A SENSOR NOTE
Late timing
Early timing
Excessive timing spread
Long arc duration
Short arc duration
No arc
Defective plug wire
Excessive ionization voltage
Intermittent no arc
Leaking gasket
High arc resistance
Poor ringdown
High secondary circuit resistance
Low primary voltage
Primary capacitor leakage
Missing primary discharge event
Weak/defective coil indicated
end of list
Temperature Notes
File: D6TTEXT
MANUALLY INPUT A SENSOR NOTE
Reading seems high
Reading seems low
Check against historical levels
end of list
5.7
Route-based FFT
5.7.1
FFT Overview
The route-based FFT allows you to use a predefined setup to collect FFT, time wave form, and
transient data. If there are NO predefined setups, you can edit the test or first setup in the analyzer or
create the data points in the Windows software.
5.7.2
137
1. In the Windrock MD software. This is the most convenient way to generate several test points at
once using the auto generator. Or, you may edit the current data points which includes changing their
order in the list. The new setup must then be transferred to the analyzer.
2. In the Analyzer you can edit the setup in the analyzer. At "FINISHED?", use the right/left arrow key
to change the selection to "Update Setup in Route" or "Add Setup to Route". The new collection point
will be added to the bottom of the collection point list. Any time new collection points are added, or a
point is updated, you will need to transfer them to the Windrock MD software as you transfer the
vibration data. Changing the order of the points in the list is still done in the Windrock MD software.
POINT SETUP
Point Name
# Channels
Run RPM
Run Number
Scale
Sensor
Units
138
139
140
5.7.3
141
142
143
Menu Selections
0-SCALING
0 - Autoscale
1 - Manual scale. You will be prompted for the full scale Y axis value.
1-SET ZOOM
2-CONTINUOUS
3-UNZOOM
5.7.4
5-MULTIPLES
6-ORDERS
7-SAVE / NEXT
8-X CH PHASE
ESC-EXIT
Exits to the Pick a Route Point selection box without saving current data
144
Equipment Needed:
1. 6320/VA or PA/VA Analyzer
2. One cable, BNC to BNC
3. One cable, Lemo to Lemo (Encoder)
4. Two or four cables, BNC to Lemo
5. Prox Trigger module
Connect to Bentley:
1. Connect the Key phaser to the prox
trigger box.
2. Adjust trigger level for a dim light, check
RPM reading
3. Connect channels 1 through 4 to the
appropriate BNC channel connector
145
Adjust Level
The Key phaser output is a negative 18 volts
DC signal. The minimum voltage is
dependent on the probe gap and it's distance
from the target shaft. When the trigger level
is correct, the light will be dim. It actually is
flashing on and off as the key phaser slot
passes below the probe. At this point, the
RPM reading should match other tachometer
readings.
146
147
5.7.5
148
5.8
The top row of keys (5 - 9) are toggle keys. This means that you simply hit the key once to turn that
function on or off. The bottom row of keys (0-4) are option keys that have many selections available to
the user.
To exit back to the menu, simply hit the "ESC" key and you will return back to the "Data Collection
Menu".
This screen and many of its options are the same as the "Plot historical" menu option. Please note,
that the "HISTORICAL" key will, in fact, allow you to bring up previously stored data for overlay with the
current data.
FUNCTION POP-UPS:
5.-PT/PV:
6.-CALC OFF:
1.-ZOOM/CURSOR:
Allows the user to set both LEFT and RIGHT cursor bars
149
and expand the plot. To move the cursor bars, use the
TAB key for large moves and the ARROW keys for small
moves. Hit enter to advance through the prompts.
0-OPTIONS:
Use the up/down arrow keys to select the option or press the number key associated with the
option. The current state is shown in parentheses( ).
0.-RESET:
1.-AUTOSCALE:
2.-MANUAL RESCALE:
3.-SMOOTHING:
Shows the toe point and highlights the area under the
150
7.-REMOVE LINE FROM DATABASE: This removes the selected data from the database.
Caution! The data is NOT recoverable. This function is used to delete bad data from
reports and statistical information.
9-ANALYZE:
Selecting the cylinder end will bring up the rod load plot, Log P vs. Log V, or the Power Stats Box.
151
4-FORMAT:
0.-OVERLAY:
1.-PHASING:
2.-TDC shift:
3.-STRIP CHART:
4.-Theoretical:
5.-Show TDC:
152
Envelope Only
8.-Show IR Temp:
153
2-RESAMPLE:
4.-AUTOSCAN (NO MULTI SAMPLES):This option will sample data and display it, erasing the
previous. This will continue until the "3" key is pressed or
the "ESC" key is pressed.
5.-AUTOSCAN (w MULTI SAMPLES): This option will sample data based on the number of
averages preset and will display the averaged trace,
erasing the previous. This will continue until the "3" key is
pressed or the "ESC" key is pressed.
6.-CHANGE SETUP AND RESCAN:
Allows the rescan of the last single line of data that was
taken. This will not work with collection points where you
are taking multiple channels at the same time. It is
intended for overlaying single pressure traces to look for
pocket volume changes. (ie. MA Users)
Note:
7-SAVE/NEXT:
Hit the "7" key or enter when "Save/Next" is the hot key will save the latest data capture and return
you to the point selection list with the next collection point highlighted. At this time, you can hit
enter to select the collection point highlighted or use the up/down arrow keys to select another
point. If you are finished collecting route data, hit escape to return you to the "Data Collection
Menu".
154
6.1
This is the plot historical screen. It is very similar to the data collection screen. There are several
options available at this point. Each is described in the following segments. Each of the function
keys at the bottom may be selected simply by pressing the number key on the keypad.
The top row of keys (5 - 9) are toggle keys. This means that you simply hit the key once to turn that
function on or off. The bottom row of keys (0-4) are option keys that have many selections available
to the user.
To exit back to the menu, simply hit the "ESC" key and you will return back to the "Data Collection
Menu".
Function pop-ups:
5-PT/PV:
Switches the display between a pressure vs. time (PT) and pressure vs.
volume (PV).
155
6-CALC OFF:
Displays the calculated results for the pressure curves displayed. This
would include IHP, peak pressures, flow balance, volumetric efficiencies,
etc.
7-PRINT:
1-ZOOM/CURSOR:
Allows the user to set both LEFT and RIGHT cursor bars and expand the
plot. To move the cursor bars, use the TAB key for large moves and the
ARROW keys for small moves. Hit enter to advance through the prompts.
3-HISTORICAL:
This function allows you to select multiple points from the previously
sampled data. The point may be of different types and dates.
2-NEXT PLOT:
This function takes you back to the list of group plots where you can select
the next plot to view.
0-OPTIONS:
Use the up/down arrow keys to select the option or press the number key associated with the option.
The current state is shown in parentheses( ).
0.-RESET:
This function resets all settings to original defaults.
1.-AUTOSCALE:
Autoscale ON changes the plots to fit the full screen. Autoscale OFF uses the predefined scales
from the Fixed Data Scale configuration. This is a toggle-type function.
2.-MANUAL RESCALE:
Allows the scale for the selected trace to be set manually. If more than one plot is shown, an
individually selected plot may be rescaled or all plots may be rescaled at the same time.
3.-SMOOTHING OR SPIKE FILTER:
The smoothing factor used is as defined in the "Software Configuration" or it can be manually set
at this point by selecting the type of curve and selecting a smoothing factor from the list.
Smoothing can also be set per sensor point.
156
Caution!
The data is not recoverable. This function is used to delete bad data from
reports and statistical information.
9-ANALYZE:
Selecting the cylinder end will bring up the rod load plot, Log P vs. Log V, or the power stats box.
157
For rod load plots, select the cylinder head end and
crank end point to bring up the rod load plot.
4-FORMAT:
158
2.-TDC shift:
Data is normally displayed with '0' degrees on the left axis. This option shifts 0-3600 to be (-1800
0 +1800 ) and 0-7200 to be (-3600 0 +3600 ).
3.-STRIPCHART:
Allows clearing of individual strip charts and manually forcing a plot to be strip charted.
4.-Theoretical:
Turns on /off the theoretical curves for PV and LogP-LogV diagrams.
5.-Show TDC:
This toggles the vertical dashed lines indicating each individual cylinders TDC position in relation
to the other cylinders. Turning on TDC, select one of the following options:
0. Don't Show TDC
1. Show Power TDC
2. Show Compressor TDC
3. Show Power and Compressor TDC
6.-Line / Plot Styles:
Changes the way the vibration and ultrasonic traces are displayed on the screen.
Envelope Only
159
7.1
160
161
7.2
View Notes
General machine or sensor specific notes may be viewed as illustrated below.
162
163
0 - Page Down
1 - Page up
4 - Exit
7 - Next
7.3
164
165
In the 6320 you may plot the historical FFT data. You have the option of selecting the sensor point,
date and run number. After the data has been re-plotted you may use the left / right arrows to move
the cursor and option 5 will present you with multiples of the current curser position. Option 6 will
present you orders of run speed and option 4 will toggle the display between FFT and time waveform.
Option 8 presents you with cross channel phase information when multiple channels of data are taken
simultaneously using the 6320 analyzer. To use the ZOOM, first use the left/right arrows to set the
curser at the start of the zoom frequency and select 1, then use the right arrow to set the end zoom
frequency and again select 1. Select 3 to un-zoom. When two channels are displayed use the up/down
arrows to select the active window, which is indicated by a small triangle in the top left corner of the
window.
166
Cross channel phase information requires an accurate RPM and a predominant one times run speed
(1x) vibration level. A TDC sync is not needed.
Performance Reports
8.1
Reporting
167
This section covers the type of reports available and the steps required to set up the reports. There
are four types of reports currently available in the analyzer. They are:
Compressor Report
Engine Report
Ignition Report
Manual Panel Reading / Temperature Report
The "Compressor Report" gives details about the compressor's performance based on the data
collected. This is a tabular listing of parameters associated with the compressor such as IHP, BHP,
Flow Balance, etc.
The "Engine Report" gives details about the engine's performance based on the data collected. This
is a tabular listing of parameters associated with the engine such as IHP, peak firing pressure, etc.
The "Ignition Report" gives details about the ignition performance such as statistical values, peaks,
timing, etc. This is a tabular listing.
The "Manual Panel Reading Report" displays a tabular list of values entered during a data collection
168
Running Reports
After data has been collected, several reports are available to run. To run a report, select the report
type from the menu. The selections are:
Compressor Report
Engine Report
Ignition Report
Manual Panel/temp Report
A selection box will appear to select the "LAST MULTI DATA" or run number to use for the report. If
run numbers were not used, select "LAST MULTI DATA". The next selection box to appear will be
the date selection box (if more than one date exists). Pick the required date and hit enter. The report
will be calculated and displayed one page at a time.
"USE LAST MULTI DATA" is the last available set of data the
user collected regardless of run number assigned.
Run number is the run number that was assigned to the data
when it was collected.
Performance Reports
8.2
169
Compressor Setup
Select "Setup Compressor Report" from the menu. The screen shown below will appear and the
entries must be filled in.
Match the pressure test point from the pop-up list with the
cylinder name as defined in "Machine Configuration".
Use the right arrow key to bring up the pop-up list. Additional
cylinders are listed on the next page of entries.
8.3
Engine Setup
Select "Setup Engine Report" from the menu. The screen shown below will appear and the entries
must be filled in.
Match the pressure test point from the pop-up list with a
cylinder number. The cylinder numbers are listed in numeric
order and must be matched to your naming convention. A
sample is shown in the figure.
Use the right arrow key to display the pop-up list.
8.4
Ignition Setup
Select "Setup Ignition Report" from the menu. The screen shown below will appear and the entries
must be filled in.
170
Match the spark plug test point from the pop-up list with the
cylinder number. Spark plug test points are referenced with
"S".
Use the right arrow key to dispay the pop-up list.
9.1
171
172
Third, a screen appears as shown above updating continuously with the input. Depending on the
sensor type, there may be variations to the screen shown.
For DC pressure sensors, the screen shown has the following information:
The channel number being used, the sensor point name, three columns of data, the zero factor
(explained below), and the current mode.
The left column shows the zero adjusted values. If the "Zero dc press sensors" menu option under
"Data Collection Menu" was used, an atmospheric reference point is applied. The center column is
non zero adjusted. No correction is applied and the raw values are listed. The third column show the
line's value type. For most cases, the "Engr. Units" (engineering units) line is used. This will show
the actual readout of the pressure applied to the sensor.
The additional three lines are used by Windrock in calibration of the analyzer and other types of
sensors.
The Zero Factor line shows the bit count of the correction applied when the sensor was zeroed. Bit
count is a digital electronics value.
At the top of the display, a bar graph will display the current sensor value and will update based on
the mode selected. By default, the bar graph is in continuous mode. Below the bar graph is a small
bar showing the peak value reached until the [9-Reset Bar] hot key is pressed to reset the bar to
zero.
The mode line shows the current mode of the screen updating process. There are several modes
which can be used for various purposes. Below are explanations.
Key
0
1
2
3
4
5
6
Function
Single Scan
Continuous
Peak Scan
Description
Updates the screen one time per hit of the key
Updates the screen continuously
Updates the screen if the new value exceeds the previous
value
Low Scan
Updates the screen if the new value is less than the previous
value
Exit
Exits the direct channel read function
Run/Hold
Stops the screen update temporarily
1 or 4 channel Allows selection number of channels.
mode
9.2
Next
Bar Range
Reset Bar
173
9.3
System Information
The system information provides information on software and hardware versions.
9.4
X Engineering Mode
The Engineering mode provides access to the command prompt. Hitting the zero and enter keys will
return you to the menu system.
10
Encoder Setup
10.1
Shaft Encoder
Several fittings have been provided for adapting the encoder to your needs. It is preferred that a direct
connection be used over a friction connection. It is possible that a friction connection can slip, causing
instability in the encoder signal. If the friction connection must be used, clean the flywheel surface to
remove any grease or oils that could cause slippage.
Mount the encoder assembly on the tripod provided. Adjust the tripod height to center the encoder
shaft with the center of the flywheel. If needed, use the provided elastic cord to provide additional
stability by placing the cord around the tripod neck and securing it to the machine frame.
Once the encoder is set up, attach the 50 foot encoder cable to the connection marked "To Analyzer".
Prior to taking data, make sure the "STROKE 4 - 2" switch is set properly for the engine type (defined
in the machine setup). Also make sure that the number of pulses per revolution is set to the correct
number.
Caution!
Also, it must be noted here that in order to collect angular velocity information, you must be able to
collect more than one pulse per revolution.
The "PHASE A-B" switch is provided to give the user the ability to shift data collection 360 degrees on
four-cycle engines as necessary; for instance, if you are collecting data on a 4-cycle diesel engine and
are unsure as to which stroke TDC is set.
174
The shaft encoder is directly powered by the analyzer. Note that, if the encoder cable is disconnected,
the encoder will retain its settings and TDC for up to one hour. This allows the analyzer to be
disconnected and reconnected as necessary without disruption except as cautioned above.
Please note that in four-cycle mode, the encoder uses the A/B switch to swap between the power and
exhaust stroke. This setting is retained as long as the encoder is connected to the analyzer and
powered up.
10.2
Caution!
Note that the software uses power conservation methods which will power
down the encoder while outside the data collection menu (this will turn off
power to the encoder). Either of these situations will re-power the encoder in a
undetermined state for the power/exhaust cycle. To avoid this situation, do not
disconnect the encoder and use the power save setting under hardware
configuration and set it to NO.
Caution!
Make sure the BNC terminator (a shorting connector) is placed on the "MAG
PU" input when not in use. This will reduce ignition interference in the
encoder.
Note:
Note:
Multi-Event
The multi-event encoder provides for attachment of either an optical pickup (WRI P/N: A6056-01-08)
or a magnetic pickup (WRI P/N: A3012-00-00) for TDC measurement. In addition, a magnetic pickup
can be used to measure individual teeth on a gear or flywheel for more resolution of crankangle.
Encoder Setup
175
A strobe light can be attached to the multi-event encoder to check the positioning of the TDC event.
Note that the forward/reverse switch has no effect on the TDC offset of the older model, but will
advance or retard the TDC of the new (Black case) model.
Once the multi-event encoder is set up, attach the 50-foot encoder cable to the connection marked "To
Analyzer". Prior to taking data, make sure the "STROKE 4 - 2" switch is set properly for the engine
type (defined in the machine setup). Also, make sure that the number of pulses per revolution is set to
the correct number.
Caution!
Also, it must be noted here that in order to collect angular velocity information, you must be able to
collect more than one pulse per revolution.
The "PHASE A-B" switch is provided to give the user the ability to shift data collection 360 degrees on
four-cycle engines as necessary; for instance, if you are collecting data on a 4-cycle diesel engine and
are unsure as to which stroke TDC is set.
Caution!
Make sure the BNC terminator (a shorting connector) is placed on the "MAG
PU" input when not in use. This will reduce ignition interference in the encoder.
176
10.3
Magnetic Pickup
A magnetic or hall effect sensor may be used with the shaft encoder or the multi-event encoder.
To use these devices, they must be placed on the machine with a known reference to TDC to
ensure proper timing information. Connect these devices to the connector marked "MAG
PICKUP".
10.4
Optical Pickup
A self-contained optical type pickup with a TTL output may be used with the shaft encoder or the
multi-event encoder. The Windrock optical sensor may be used directly with the multi-event
encoder. To use this type device, it must be placed on the machine with a known reference to TDC
to ensure proper timing information. If the self-contained style pickup is used, connect this device
to the connector marked "MAG PICKUP". Reflective tape must be placed on the flywheel or
rotating element with the leading edge at the TDC position for proper timing information.
10.5
Timing Light
With the encoder set up, attach the timing light to the connector marked "STROBE". Aim the timing
light at the timing marks on the engine flywheel and pull the trigger switch.
Encoder Setup
177
With the trigger switch pulled and while observing the flywheel, look for the timing marks. Using the
toggle switch or the up/down arrow buttons, you can adjust movement clockwise or counterclockwise
as necessary to bring the timing marks into view. Each toggle of the switch moves one-half degree of
rotation.
Once TDC has been found, the timing light should be disconnected from the encoder to conserve
battery power.
Caution!
10.6
The timing mark is crucial for accurate analysis. Make sure that there is only
one timing mark on the observed surface. Having more than one timing mark
will cause confusion and create the possibility of collecting data based on the
wrong TDC of the machine.
Choose a reference compressor cylinder and remove the dog house door. Typically,
you should chose the compressor closest to the flywheel.
2.)
3.)
Choose a location on the flywheel guard to make a reference mark. Allow 6-10"
between the reference mark and location where the flywheel is covered by the guard.
Mark the reference mark/line with a permanent marker.
4.)
5.)
Set up dial indicator mechanism so that the indicator displays the linear movement of
the compressor rod with respect to the fixed housing.
6.)
Case a.)
Indicator fixed to crosshead with indicator shaft against dog house door
frame.
Case b.)
Indicator fixed to dog house door frame with indicator shaft against
crosshead.
Be sure that the tip of the dial indicator is screwed on tight. Set dial to "0". Manipulate
178
Make a mark/line on the flywheel at the reference "0" mark/line to represent the initial
flywheel position.
8.)
Slowly roll flywheel through head end TDC. The pointer will turn in one direction and will
reverse direction after passing through TDC. Rotate flywheel slowly until dial returns to
the initial "0" position. If you pass "0", you will have to completely start over since the
engine must be rolled in the normal direction of rotation.
Note:
a.) It is best to perform the final positioning (last .050 or so) by rolling the
unit with a bar or hydraulic jack since stopping at exactly the "0" position is
difficult to do with an air jack.
b.) The pointer may go around more than once. Be sure to travel the same
distance after TDC as before. If pointer turns several times and does not
appear to be slowing down or nearing TDC, stop, reset to "0", and make a
new initial mark/line on the flywheel at the reference mark/line.
9.)
Make a mark on the flywheel at the reference mark/line to represent the final flywheel
position.
10.) Use a tape measure or flexible straight edge to measure the distance (on the flywheel)
between initial and final positions. Make a mark/line exactly halfway between the initial
and final mark/lines.
THIS IS TOP DEAD CENTER
All other cylinders will be referenced to this cylinder.
11.) After removing the dial indicator, roll the engine in the same direction and repeat the
process until you are sure of the TDC mark/line. Do not roll the engine backwards.
Encoder Setup
Note:
179
When repeating the process, use the previous initial mark/line to select a
new initial position. Try to keep the measurement between initial and final
mark/line between 6-10".
12.) Upon confirmation of the TDC position, make a mark/line with permanent marker. Put
the dog house door back on and close the Kiene valves.
Caution!
The timing mark is crucial for accurate analysis. Make sure that
there is only one timing mark on the observed surface. Having
more than one timing mark will cause confusion and create the
possibility of collecting data based on the wrong TDC of the
machine.
Be sure all the valves that have been installed on the compressors and piping are in the
closed position.
2.)
Make sure you have opened the main fuel valve and closed the Kiene valves.
3.)
Have the operator pressure up the compressor cylinders slowly, then leak check the
valves and fittings to make sure they are all sealed properly.
4.)
Fix any leaks and have the operator bring the unit back on line.
180
10.7
Battery
WARNING EXPLOSION HAZARD DO NOT replace or remove battery and antenna unless
the area is known to be non hazardous.
CAUTION DO NOT substitute battery. Use only Molicel Li-ion battery model ME202C.
ATTENTION ne substituez pas la batterie.
The battery is accessed via a door at the base of the enclosure.
Encoder Setup
A battery door lock is based on the bottom of the enclosure to prevent accidental access in a
hazardous area. A screwdriver is necessary to disable the lock.
181
182
Caution!
Operation
When the A6042 wireless transmitter is connected to the A6021 shaft encoder, the LED on the front of
the unit will flash in response to encoder signals. When the transmitter detects TDC only (once per
turn) operation, the LED will blink rapidly and faintly. When the transmitter detects degree pulse
operation, the LED will flash slowly and brightly. On occasion, the transmitter and encoder will start in
the wrong mode of operation, and it will be necessary to unplug the transmitter and plug it back in.
When operating properly, the LED near the antenna on the A6320 portable analyzer will also blink in
sequence with the encoders RPM. Inconsistent LED operation is an indicator of a bad wireless
connection which can result from interference from other RF transmitters or other sources between the
transmitter and portable analyzer. An unobstructed line-of-sight between the transmitter and the
portable analyzer will give the best results, but RF signals can also be corrupted by other RF sources
or reflections within a highly metal environment.
Encoder Setup
183
184
11
11.1
Windows Install
Prior to starting, make sure the update has been installed on the desktop/laptop. Follow the
instructions found in the Windrock MD manual, under "Connect with closed database" and then
"Send software updates to Analyzer".
12
12.1
Backup
For information on backing up the data in your 6320 see Database Backup / Restore.
12.2
12.3
185
Printing
To print directly from the analyzer, there must be a printer driver loaded. Once this has been done,
PRINT from the menu will PRINT the current graphics or report screen. The analyzer must be in B &
W or Color 2 mode to print properly.
To set up a printer:
From the startup menu, hit "Escape" twice to access the Station Selection Menu.
186
Select the option you need and follow the on-screen instructions.
13
Appendix
13.1
Appendix
187
Temperature measurement is critical in obtaining accurate analysis information. There are several
ways to obtain this type of reading.
Method 1: Gauge readings are typically available on most units. However, many gauges are not
very accurate and sometimes broken. Also, gauges are typically inserted into the gas
stream providing internal temperature. This placement provides for a more accurate
gas temperature vs. skin temperatures.
Method 2: Infrared temperature devices are very common in plants and one is supplied with the
analyzer kit. A few things should be noted about these type devices. First, the
response varies with both paint thickness and color. For best accuracy, use flat black
paint on the surface where reading the temperatures. Second, holding the probe in
direct contact can heat the probe tip providing for false readings as the sensor itself
has become heated. A good distance is approximately one inch from the surface.
Third, this type measurement is measuring the "skin" temperature. This may be
somewhat cooler or warmer than the actual gas temperature.
Note:
Pressure Measurement
You must ZERO the Dynamic DC pressure sensor prior to collecting pressure data. The purpose
of zeroing the sensor is to establish a reference pressure for the data at operating temperature.
The reference zero pressure is atmospheric pressure. If the sensor is not zeroed, there is a
possibility of a thermal offset causing the pressure data to be slightly elevated.
Vibration Measurement
Make sure the accelerometer is well mounted (i.e., no rocking, rough surface, etc.). To extend
the life and accuracy of the accelerometer, do not drop, "plunk" down on the surface, and keep
retaining washer ("keeper") on the sensor when not in use. Do not overheat.
13.2
188
Warning!
If your 6320 analyzer has been approved for use in a hazardous location, Class 1 Div. II,
there will be a hazardous atmosphere warning label on the back of the analyzer. If there is
no warning label on your analyzer, follow all hazardous atmosphere precautions prior to
and while using your analyzer.
Warning!
1. THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION II, GROUPS A, B, C, D,
T5 HAZARDOUS LOCATIONS ONLY.
2. WARNING - EXPLOSION HAZARD SUBSTITUTION OF COMPONENTS MAY IMPAIR
SUITABILITY FOR CLASS I, DIVISION II, (MOLICEL LI-ION BATTERY MODEL ME202C)
and
AVERTISSEMENT - RISQUE DEXPLOSION LA SUBSTITUTION DECOMPOSANTS
PEUT RENDRE CE MATRIEL INACCEPTABLE POUR LES EMPLACEMENTSDE
CLASSE I, DIVISION II (MOLICEL LI-ION BATTERY MODEL ME202C).
3. WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT (AC POWER,
USB, VGA, ETHERNET, OR BATTERY) FROM ANALYZER UNLESS POWER HAS BEEN
SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS AND FREE OF
IGNITABLE CONCENTRATIONS OF FLAMMABLE SUBSTANCES, and
AVERTISSEMENT - RISQUE DEXPLOSION - AVANT DE DCONNECTER
LEQUIPEMENT, (AC POWER, USB, VGA, OUETHERNET, OR BATTERIE) COUPER LE
COURANT OU SASSURER QUE LEMPLACEMENT EST DSIGN NON DANGEREUX.
4. WARNING - EXPLOSION HAZARD - DO NOT REPLACE BATTERY UNLESS POWER HAS
BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS AND FREE
OF IGNITABLE CONCENTRATIONS OF FLAMMABLE SUBSTANCES, and
AVERTISSEMENT - RISQUE DEXPLOSION - COUPER LE COURANT OU SASSURER
QUE LEMPLACEMENT EST DSIGN NON DANGEREUX AVANT DE REPLACER LA
BATTERIE.
5. DO NOT modify / replace / repair any parts on PC board. (All repairs / modifications of
board components must be preformed by Windrock personnel).
6. DO NOT attempt repair / modification of this unit. (All repairs / modifications must be
preformed by Windrock personnel).
7. USE ONLY cables and connectors supplied by Windrock for connections to J1, J2, J3,
J4 (sensor input channels 1 through 4) and encoder. Windrock cables will EXCLUDE
Aluminum, Cadmium, Magnesium and Zinc for any make / break connections.
8. Normal operating range is -20 to 50 degrees C (-4 to 122 degrees F).
9. The analyzer must be used while encased in the protective leather case.
Appendix
189
13.3
Sensors
Transducer Scaling Entries:
SENSOR
TYPE
UNITS ZERO
SCALE or 1V
FULL 4mA
or 5V
20mA
Engine AC
Engine DC
Compressor
Accelerometer
Ultrasonic
Other Voltage
Other Current
Spark
AC
DC
DC
AC
DC
AC
DC
DC
PSI
PSI
PSI
g's
uPIS
Volts
ma
Volts
1000
1000
2000
5
10
max
max
50,000
1000
1000
2000
5
5
0
0
0
0
0
min
min
0
200
0
0
0
0
20%max
min
0
max
50,000
Ultrasonic Sensor
A6050-04-06
190
Accelerometer
A6096-00-00
Velocity Sensor
A6093-00-00
Displacement Probe
Appendix
191
13.3.1 Accelerometer
GENERAL DESCRIPTION
Proper sensor selection requires special attention to three main areas: sensor design, dynamic
expectations, and application environment.
192
MAGNETIC MOUNT
Magnetic mounting provides a convenient means for making portable measurements and is
commonly used for machinery monitoring and other portable or trending applications.
Note: The correct magnet choice and an adequately prepared mounting surface is critical for
obtaining reliable measurements, especially at high frequencies. Poor installations can
cause as much as a 50% drop in the sensor frequency range.
Appendix
193
Not every magnet is suitable for all applications. For example, rare earth magnets are commonly
used because of their high strength. Flat magnets work well on smooth, flat surfaces, while dualrail magnets are required for curved surfaces. In the case of non-magnetic or rough surfaces, it is
recommended that the user first weld, epoxy, or otherwise adhere a steel mounting pad to the test
surface. This provides a smooth and repeatable location for mounting (figure 3).
194
Appendix
195
196
Caution!: Make sure the pressure is removed from the sensor prior to removing.
STEP 2: Unscrew the connector assembly from the sensor body. This is done by removing the
four (4) outer screws on the top connector assembly and sliding the assembly out using
caution not to extend the wires too far causing breakage.
STEP 3: Attach cable to sensor and connect per figure 1 making sure to observe proper polarity.
Figure 1
Caution!: Reversing the polarity may cause permanent damage to the sensor.
STEP4: Adjust ZERO pot until 4.00 mA is displayed on meter. Refer to Figure 2 for ZERO and
SPAN pot locations.
Figure 2
STEP5: Place sensor on deadweight tester and apply full scale pressure. Adjust SPAN pot for
20.00mA on meter.
Appendix
197
Repeat steps 4 and 5 once more to verify zero and full scale. Reassemble the sensor.
2.
3. To remove any severe contamination use a clean, soft cloth dampened with distilled water.
In any case, do not scratch the lens surface!
For fingerprints or other grease, use any of the following:
Denatured alcohol
Ethanol
198
Caution!
Do not use any ammonia or any cleaners containing ammonia to clean the
lens. This may result in permanent damage to the lens' surface.
Determine the actual temperature of the material using an RTD (PT100), a thermocouple,
or any other suitable method. Next, measure the object's temperature and adjust the
emissivity setting until the correct temperature value is reached. This is the correct
emissivity for the measured material.
2.
For relatively low temperatures (up to 260 degrees Celsius, 500 degrees Fahrenheit), place
a plastic sticker on the object to be measured. This sticker should be large enough to cover
the target spot. Next, measure the sticker's temperature using an emissivity setting of 0.95.
Finally, measure the temperature of an adjacent area on the object and adjust the
emissivity setting until the same temperature is reached. This is the correct emissivity for
the measured material.
3. If possible, apply flat black paint to a portion of the surface of the object. The emissivity of
the paint must be above 0.98. Next, measure the temperature of the painted area using an
emissivity setting of 0.98. Finally, measure the temperature of an adjacent area on the
object and adjust the emissivity until the same temperature is reached. This is the correct
emissivity for the measured material.
Appendix
199
Temperature
Angle of measurement
Geometry (plane, concave, convex)
Thickness
Surface quality (polished, rough, oxidized, sandblasted)
Spectral range of measurement
Transmissivity (e.g., thin films, plastics)
Aluminum
Brass Polished
Brass Burnished
Chromium
Copper Polished
Copper Oxidized
Iron Oxidized
Iron Unoxidized
Rust
Iron Cast
Iron, Wrought
Steel Cold rolled
Steel Polished
Steel Stainless
Asbestos
Asphalt
Carbon
Paint
Plastic opaque
Wood
0.02 0.1
0.01-0.05
0.3
0.02-0.2
0.03
0.01-0.1
0.5-0.9
0.05-0.2
0.5-0.7
0.6-0.95
0.9
0.7-0.9
0.1
0.1-0.8
0.95
0.95
0.8-0.9
0.9-0.95
0.95
0.9-0.95
200
Appendix
201
Completely self-powered, the VRS (magnetic) sensor are rugged devices that do not require an
external voltage source for operation. They are generally used to provide speed, timing or
synchronization data to a display (or control circuitry) in the form of a pulse train.
PRINCIPLE OF OPERATION
The output signal of a VRS sensor is an AC voltage that varies in amplitude and wave shape as
the speed of the monitored device changes and is usually expressed in peak-to-peak voltage (V
P-P). One complete waveform (cycle) occurs as each actuator passes the sensing area (pole
piece) of the sensor. The most commonly used actuator is a metal gear, but also appropriate are
bolt heads (cap screws are not recommended), keys, keyways, magnets, holes in a metal disc,
and turbine blades. In all cases, the target material must be a ferrous metal, preferably
unhardened.
A permanent magnet is the heart of a VRS sensor and establishes a fixed magnetic field. An
output signal is generated by changing the strength of this field. This is caused by the approach
and passing of a ferrous metal target near the sensing area (pole piece). The alternating presence
and absence of ferrous metal (gear tooth) varies the reluctance, or "resistance of flow", of the
magnetic field which dynamically changes the magnetic field strength. This change in magnetic
field strength induces a current into a coil winding which is attached to the output terminals. If a
standard gear is used as an actuator, this output signal would resemble a sine wave if viewed on
an oscilloscope.
202
Appendix
203
analyzers arms itself on a POSITIVE going signal. The actual trigger occurs upon ZEROCROSSING after the circuit is armed. Zero-crossing occurs at the magnetic center of the
magnetic pickup or when the magnetic pickup is centered on the target.
When using a hole as a target, pin A of the magnetic pickup is the signal.
When using a protruding object as a target, pin B of the magnetic pickup is the signal.
If in doubt, use the analyzer in o-scope mode, or an oscilloscope to view the signal. The signal
should look like the figure below. If the polarity is reversed from this, swap the signal, lead and
ground leads in the connector.
SIZE OF SIGNAL
The magnetic pickup contains a permanent magnet with a coil. When the magnetic field changes
due to the pickup going over a hole or object, a voltage is generated in the coil. The size of the
signal is proportional to the magnetic field change. Several factors determine the field change:
permanent magnet strength, number of turns in the coil, gap from pickup to target, material of
target, and size of target.
The bottom line is that you want a signal of about 1V peak and it must be at least 10 times the
size of any other noise or spurious signals in the output of the pickup. If the polarity of the signal is
reversed, the trigger point will be much later than actual TDC.
204
Appendix
205
206
Caution: Make sure calibration is done in a quiet room without high pitch noises such as
computer monitors.
STEP 1: Unscrew the rear cap holding the connector assembly from the sensor body. There are
approximately six turns.
STEP 2: Attach cable to sensor and connect to the portable analyzer and use direct channel read
mode.
Appendix
207
STEP 3: Attach frequency counter between ground (case) and test point indicated in figure 2.
Adjust R22 for 41.4kHz on display of frequency counter. Refer to figure 1 for R22
location.
Figure 1
STEP4:
Reassemble sensor.
The output of the ultrasonic can be directed to the headset, direct channel read output, the display
screen or any two combinations of these.
208
13.4
Specifications - 6320
Basic Capabilities, 6320:
The data acquisition capabilities of the instrument are based upon 4-channel simultaneous
dynamic signal capture as a function of crank angle position. The crank angle position is captured
via a shaft encoder coupled mechanically to the machine being analyzed or magnetic/optical
pickup. The 4 simultaneous signal inputs can be a combination of pressure, vibration, ultrasonic,
or other voltage or current signals. Four channel simultaneous vibration spectral analysis for
auxiliary rotating machines is supported in the /VA option. Angular velocity measurements are
captured and displayed using the encoder information.
Appendix
209
Input Signals
Channel 1-4:
Software selectable between Current Loop, Constant Current, Voltage Input,
Ignition primary and secondary (secondary uses a capacitive voltage clip).
Channel 5:
Supplies 12 VDC to encoder or magnetic/optical pickup conditioner 2 inputs,
TTL compatible with 10 Kohm pull-ups
Current loop input
Range: 0-20 mA
Frequency response: DC to 5 KHz
Supply voltage: 24 VDC
Over-voltage protection to 2000V
Current loop input is used for the DC pressure sensor
Input impedance 470 ohm
Ignition secondary using capacitive coupling probe
Range: 1 KV to 50 KV
Software selectable for positive or negative ignition systems
Secondary ignition data capture rate is 1 mHz
Over voltage protection
Voltage input
Range: 0-10V
Frequency response: DC to 5 KHz
Supply voltage: 24 VDC
Over voltage protection to 2000V
Voltage input is used for voltage signals
Input impedance: >1 Meg ohm
Memory Capacity
256 Mb on-board RAM memory
4 Gb flash memory storage
Communications
USB interface for host communications
Power Supply
12V Lithium Ion rechargeable 3200 milliamp-hour battery
Three batteries standard
Battery is removable
External charger provided - 1.5 hr recharge time
External power input 12 - 18 VDC
Battery life: approximately 6 hours depending on use
Operating Conditions
Temperature: 15-120 F
Humidity: 0-90% non-condensing
Display
8.25" diagonal LDC, transmissive, with back light, color option
Size of display: 8.25" diagonal
Pixels: 640 x 480
Contrast: software controlled
Chassis
Material: EMI hardened anodized aluminum
Size and Weight: 10.5" X 8.5" X 2"
(6.75 lbs.)
Power: Long-life, field replaceable, rechargeable Lithium ion battery
210
16 bits
4
4
4
unlimited (DSP programmable)
1 Mhz
Linux
1800 RPM
7 hours
USB - USB
USB printer w/ Linux driver
quad DSP processors
AMD Geode 500 Mhz
1, 2, or 4
8
Debian GNU/Linux software included on the 6320 Portable Analyzer is covered by the GNU
General Public License, the GNU Lesser General Public License, and other licenses.
Additional software libraries included on the 6320 Portable Analyzer are covered by the GNU
Lesser General Public License. Copies of relevant licenses are available under /usr/share/
doc/*/copyright on the Portable Analyzer file system. To receive a DVD containing the source
code used to build the Debian GNU/Linux software and additional software libraries, mail a
copy of this page and a check for $10 shipping and handling to the following address:
Windrock, Inc.
Suite 102
1832 Midpark Road
Knoxville, TN (USA) 37921
13.5
Specifications - Sensors
AC Pressure Sensor for Power Cylinder PT/PV Measurement
Range: 0-2000 psi (other ranges available 3000)
Frequency Response: 12 Khz
Resolution: 0.01 psi
Linearity: <1 % full scale
Acceleration Sensitivity: .05 psi/g
Operating Temperature Range: -65 to 600 F
Connector: 2-pin military
Pressure fitting: Kiene adapter
DC Pressure Sensor for Power Cylinder PT/PV Measurement
Range: 0-2000 psi (other ranges available 1000, 3000) (A 5000 psi sensor is also available in the
water cooled model)
Response Time: <0.5 ms (A6082-XX-01 <0.1ms)
Accuracy: 1%
Linearity: <1% full scale
Cycle Life: >1.5 billion cycles
Operating Temperature Range: 0-450 F (temperature compensated)
Pressure Fitting: Kiene adapter
Output: 4-20 mA, loop powered
Appendix
DC Pressure Sensor for Compressor Cylinder PT/PV Measurement
Range: 0-2000 psi (other ranges available 300, 500, 1000, 3000, 5000)
Response Time: <0.5 ms (A6082-XX-XX <0.1ms)
Accuracy: 1%
Linearity: <1% full scale
Cycle Life: >1.5 billion cycles
Operating Temperature Range: 0-212 F (temperature compensated)
Pressure Fitting: Kiene adapter
Output: 4-20 mA, loop powered
Accelerometer:
Sensitivity: 100 mV/g
Range: +/- 50 g
Frequency Range (3 db) : 0.4 hz to 14 Khz
Linearity: 1% full scale
Off-axis Sensitivity: <5%
Shock Limit: 5000 g
Temperature Range: -65 to 250 F
Excitation Voltage: 18 to 28 V
Connector: 2-pin MIL-C-5015
Ultrasonic:
Sensitivity: -75 dbv / mbar
Frequency Response: 35 Khz to 45 Khz
Temperature Range: -40 to 120 C
Power Requirement: 24V power supplied by analyzer
Cable Length: 6 ft
Secondary Ignition Capacitive Pickup
Attenuation: 10,000 times
Range: 50 KV
Output Connector: BNC
Temperature Range: 200 F
Cable Length: 6 ft
13.6
921.37 MHz
36mW
Transmitter 12VDC Ni-MH rechargeable 3500 mA-hr battery
Power from Analyzer
Antenna
VSWR:
Type:
<1.3
1/4 Wave Omnidirectional
Environmental
Weight:
Transmitter 1 lb
Operating Conditions
Temperature: 150F - 1200F
Humidity:
0-90% non-condensing
INFORMATION TO USER
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two
211
212
Any changes or modifications not expressly approved by the party responsible for compliance could
void the users authority to operate the equipment.
This device has been designed to operate with the antennas supplied by Windrock. Antennas not
supplied by Windrock are strictly prohibited for use with this device. The required antenna impedance
is 50 ohms.
13.7
Appendix
213
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214
14
Glossary of Terms
Absolute Pressure - Pressure in psi above zero pressure (or complete vacuum) that amounts to the
weight of air in pounds per square inch at sea level under normal barometric conditions. (i.e., 14.7 psi.)
Absolute Temperature - In theoretical calculations related to gases, the absolute or Rankine scale is
used. On the Fahrenheit scale, the absolute temperature is -4600F.
Accelerometer - A sensor that detects vibrational energy and outputs an electrical signal proportional
to g's. A "g" is the acceleration of gravity at approximately 32.2 feet per second.
Advanced Ignition Timing - Ignition timing before normal ignition (i.e.100 BTDC is 20 advance of 80).
Aftercooler - A heat exchanger which cools air that has been compressed; used on turbocharged
engines.
After Top Dead Center - After a piston in a reciprocating engine has reached the top of its travel and
starts downward. Abbreviated ATDC.
Air Filter - A device used for filtering, cleaning, and removing dust particles from the air admitted into
an engine.
Air/Fuel Ratio - The ratio of air to fuel by weight or volume which is significant to proper combustion of
a fuel.
Air Manifold Pressure - The pressure present in an engine's air manifold.
Air Manifold Temperature - The temperature of the air present in an air manifold.
Air Starting Valve - A valve that introduces air into the combustion chamber of an engine, normally
after top dead center of the power stroke, in order to roll the engine for start-up.
Ambient Temperature - Typically referred to as the present atmospheric temperature.
Analyst - A person who collects engine/compressor data using an analyzer and reviews the data for
machinery malfunctions.
Angular Velocity - The change in angular velocity measured in RPM as the machine rotates in a single
revolution.
Articulated Connecting Rod - A connecting rod that attaches to a master rod. An articulated rod on an
engine with integral mounted compressors is always a power connecting rod.
Articulation - In an integral engine/compressor, the irregular movement of the power pistons in relation
to the compressor piston due to the manner in which the power rods are connected to the compressor
rod instead of directly to the crank shaft.
Atmospheric Pressure - The weight of air measured at sea level; about 14.7 psi.
Glossary of Terms
215
Bacarach - A trade name for a device or indicator used to measure peak firing pressures in a power
cylinder.
Backfire - Ignition of a mixture in the intake manifold.
Balancing - Adjusting the amount of fuel being admitted into an individual power cylinder in order to
maintain peak firing pressures.
Bearing - A part in which a journal or pivot turns or moves.
Before Top Dead Center - Before a piston in a reciprocating engine has reached the top of its travel.
Abbreviated BTDC.
Blow-by - The leakage or loss of pressure (either combustion or peak firing pressure) past the rings
into the crankcase.
Blowdown Event - The detail of the pressure curve during and just after the exhaust port (or valve) is
opened.
Blower - A mechanically driven (gear, belt, or chain driven) centrifugal compressor used to compress
air in engines for combustion and scavenging.
Bore - The width or diameter of a hole on an engine or compressor cylinder.
Bottom Dead Center - When a piston in a reciprocating engine reaches the bottom of its stroke.
Brake Horsepower (BHP) - The usable output of an engine as measured at the crankshaft or flywheel.
Brake Mean Effective Pressure (BMEP) - That theoretical constant pressure that can be imagined
exerted during each power stroke of the cylinder to produce power at the flywheel or crankshaft. BMEP
is the IMEP less all friction and parasitic losses. BMEP cannot be measured. It must be calculated.
Brake Specific Fuel Consumption (BSFC)- As applied to internal combustion engines, it is the amount
of BTU's (lower heating value) required to make one (1) brake horsepower for an hour. Measured in
BTU/BHP/Hr.
British Thermal Unit (Btu) - The amount of heat required to raise the temperature of one pound of
water one degree Fahrenheit.
Bushing - A removable piece of soft metal used as a bearing to support a shaft.
Cam - An eccentric which changes rotary motion into linear motion.
Camshaft - A shaft containing lobes or cams which operate valves on engines.
Carbon - An element of mass 12. A byproduct of combustion which tends to accumulate on exhaust
ports and manifolds.
Carburetor - A device that controls the proportions and quantity of air/fuel mixture fed to a sparkignited internal combustion engine.
Cathode Ray Tube - The portion of an oscilloscope which graphically displays time and voltage.
Abbreviated CRT.
Channel Resonance - Distortions of the pressure information caused by the excitation of the acoustic
resonance in the gas passage connecting the indicator transducer and the cylinder volume.
216
Clearance Volume - The volume in cubic inches remaining in the compressor cylinder at the end of the
discharge stroke; the space between the piston head end and the end of the cylinder plus the space
that exists around the valves, which are located near the cylinder ends.
Clearance Volume - With the piston at top dead center, it is the remaining space which holds the
gases at full compression. This is the combustion chamber in a power cylinder.
Coking - Breaking down oil under extreme heat to a hard granular carbon.
Combustion - The burning of gas in which the fuel is converted into heat energy by rapid oxidization.
Combustion Chamber - The space at top dead center in a reciprocating internal combustion engine
where combustion takes place.
Combustion Characteristics - The effects of various aspects of engine operation on the combustion
process in a reciprocating engine.
Compression - As applied to internal combustion engines, it is the mechanical ability of combustion
chamber components to hold pressure by the upward motion of the piston at the end of the
compression stroke. Compression in reciprocating engines can be measured dry (engine is down
without lubrication) or running (engine is running with lubrication).
Compression Pressure - The pressure of the air/fuel charge at the end of the compression stroke with
no ignition of the mixture. In a compressor cylinder, this is the pressure of the gas charge at the end of
the compression stroke.
Compression Ratio - The ratio of the volume of the charge at the beginning of the compression stroke
to that at the end of the compression stroke.
Compression/Tension - The force in pounds that the compressor rod is undergoing due to pressure
differential on each side of the piston and the inertial acceleration of the reciprocating motion. The
force is displayed as pounds compression and pounds tension.
Connecting Rod - The connection between the piston and the crankshaft.
COV - Coefficient of Variation (or Variance) in statistics. COV is the magnitude of variance or
dispersion relative to the mean or average. CV = SD/Avg.
We use COV in two different ways:
1. In a spark ignited (SI) engine, we use COV to measure the peak firing pressure stability.
A normal COV would be from ten to twenty. A high COV indicates a mechanical problem
and/or a lean air fuel mixture in the main or pre-combustion chamber.
2. Engine Calculations:
Cylinder COV = Std. Dev. of the power cylinder PFP
Average of the power cylinder PFP
Engine COV = Std. Dev. of the power cylinder Std. Dev.
Average of the power cylinder Std. Dev.
3. When using vibration history to set warning and alarm levels, a COV of less than .33 is
desired. If the COV is greater than .33, the average times 1.5 may give a better warning
level (with less false vibrations alarms) than using the average plus three standard
Glossary of Terms
217
218
Glossary of Terms
219
minute.
Horizontal Engines - An engine with cylinders lying in the horizontal plane.
Hot Spots - Hot metals usually on the cylinder wall or piston created by friction from poor lubrication,
abnormal clearances, abnormal temperatures, or unusually high pressures. A common source of preignition.
Hydraulic Lifters - A mechanical device used to (1) compensate for changes in temperatures, valve
wear and valve recession as it maintains a zero lash (clearance), and (2) cushion the opening and
closing of the various valves (intake, exhaust, etc.)
Ignition - The combustion of the fuel mixture in the combustion chamber. In a spark ignited engine,
ignition is the electrical spark that provides the source of igniting the air/fuel mixture.
Ignition Delay - The time from initial injection of air and fuel to actual ignition of the mixture in a
compression-ignited engine. In a spark-ignited engine, it is the total time required from the initial spark
until a pressure rise occurs due to combustion. It is the total time required for the physical and
chemical reactions required to propagate a flame front.
Ignition Temperature - The lowest temperature at which a particular fuel in combination with air will
start combustion.
Ignition Timing - The point at which the ignition systems delivers a spark to the spark plug to begin
burning the air/fuel mixture in relationship to crankshaft rotation or TDC.
Indicated Horsepower - The actual horsepower developed on the surface of the piston in a
reciprocating power cylinder or consumed surface of the piston in a reciprocating compressor cylinder.
Indicated Mean Effective Pressure (IMEP) - That theoretical constant pressure that can be imagined
exerted on the piston during each power stroke of the cylinder to produce power equal to the indicated
power work. It is the average pressure exerted on the piston through the functional cycle.
Indicator - A device such as Bacarach , Maihak , or Beta-Trap which is used to measure peak
firing pressure for the purpose of balancing an engine.
Indicator Port - A direct connection from the outside to the inside of the cylinder clearance area. The
port is used for connection of instrumentation to investigate pressures inside the cylinder.
Inertia - A physical law which tends to keep a motionless body at rest or also tends to keep a moving
body in motion; effort is thus required to start a mass moving or to retard or stop it once it is in motion.
Injection Valve - A device used to inject fuel into the combustion chamber of an engine.
In-line Engines - An engine design where all the power cylinders are in a block or frame located one
behind the other.
Intake Manifold - The manifold that holds air or air and fuel before it enters the combustion chamber.
Intake Port - An opening in the cylinder wall through which gas flows into the cylinder when the intake
port is uncovered by the piston on a two-stroke engine.
Intake Valve - The valve which permits air to enter the cylinder of an engine.
Integral - A compressor having a common crankshaft for both power and compressor cylinder or
cylinders. The prime mover and the compressor are combined into a single frame.
220
Glossary of Terms
221
Once-Per-Turn - Transducer to generate one pulse per revolution of the crankshaft. This usually is in
line with TDC on the flywheel.
Opposed Piston Engine - An engine consisting of one power cylinder containing two pistons which
drive two different crankshafts, connected at one end with a vertical shaft. Combustion occurs
between the two pistons.
Oxidation - Indicated by oil analysis, saturation of the oil with soluble or insoluble oxy-products
associated with high heat. It is characterized by light brown to black varnish, causes sticky rings, high
oil consumption and engine wear. It is caused by high oil and water temperatures, insufficient oil flow,
scale build up in the jacket water systems, overload, excessive length of service, and localized hot
spots.
Parametric emissions monitoring (PEMS) - A computer model used in conjunction with transducers to
calculate the amount or oxygen, carbon monoxide, and nitrous oxide present in the exhaust of an
engine.
Parasitic Horsepower - Horsepower used to drive auxiliary equipment such as pumps, generators,
motors, etc.
Peak Firing Pressure (PFP) - The maximum pressure developed in a power cylinder due to
combustion of the mixture. Under normal conditions, peak pressure occurs between 100 to 250 after
top dead center on a spark ignited cylinder. The precise degree of crankshaft rotation will be affected
by speed, combustion chamber design, and fuel.
222
Glossary of Terms
223
Pressure Volume - A function of the engine analyzer to display pressure in relation to volume of a
cylinder.
PT - (Pressure vs. Time trace) The dynamic pressure inside a cylinder referenced to crank-angle
position.
Pulsation - The pressure fluctuation in the nozzles, bottles, and piping due to flow variations in the gas
from the reciprocating compressor.
Pulsation Bottle - A receiver or vessel mounted directly to the flanges of a cylinder to minimize
pulsations. Sometimes called a pulsation damper.
Push Rod - A connecting rod between the cam lobe and the power valve rocker arm assembly.
PV - (Pressure vs. Volume) curve (sometimes referred to as "PV Cards"). It is the pressure in pounds
per square inch times the displaced volume in cubic feet. Pressure volume is used as an indication of
work performed.
Pyrometers - Used to indicate exhaust cylinder and manifold temperatures.
Rack - A type of gear that is flat, usually associated with a pinion gear to convert rotational motion to
linear motion .
Rated Horsepower - The value used by engine/compressor manufacturers and operators to rate the
power of an engine or compressor allowing for safe and efficient operations.
Ratio - The relation or proportion of one number or quantity to another.
Reciprocating - To move back and forth alternately, such as the action of a piston in a cylinder.
Reciprocating Weight (Compressor)- The weight of the reciprocating components (piston nut,
compressor rod, piston, cross head assembly).
Retarded Ignition Timing - Ignition timing after normal ignition, (i.e., 100 BTDC is 20 retarded of 120)
Rich Mixture - A mixture with a volumetric air/fuel ratio with less parts air than 10:1 (i.e., 9:1).
Riderband - The bands that support the mass of the piston and rod in a reciprocating compressor.
Rings - The sealing devices which prevent gas from leaking around the piston and cylinder wall of a
reciprocating machine.
Rocker Arm - That portion of the valve linkage which acts as a fulcrum or pivot from the push rod to
the valve stem.
Rod Diameter - The diameter of the piston rod.
Rod Drop - The distance that the compressor piston rod moves over a long period of time as the rider
bands wear.
Rod Knock - A mechanical impact due to excessive clearance in the rod bearing or due to a lack of
proper lubrication of the rod bearing.
Rod Motion - The movement in the X or Y axes of the compressor rod.
Rod Runout - The dynamic movement of the piston rod of a compressor over a single stroke.
224
Glossary of Terms
225
Throw - The distance from the center of the crankshaft main bearing to the center of the connecting
rod journal.
Thrust Bearing - A bearing that controls the lateral movement of a shaft (i.e., crankshaft).
Top Dead Center (TDC) - A marking indicating that the lead cylinder is at its most extended position.
A mark is usually placed on the flywheel indicating this position.
Torque - A moment of force applied to the rotation of a shaft by a lever arm.
Theoretical PV - The ideal PV curve calculated from the suction and discharge conditions and the
equations of state of the gas mixture being used.
Turbocharging - Induction of gas in a turbulent manner. Used with reference to pressurizing the inlet
air above atmospheric pressure with an exhaust-driven blower.
Two-stroke (Cycle) Engine - An engine requiring only one complete revolution of the crankshaft to
complete a cycle of combustion events.
Ultrasonic - A sensor that detects sound above that frequency detectable by the human ear.
Unloader - A device used to cause gas to surge into and out of the compressor cylinder without going
through the discharge valve. An unloader has plungers that hold the valve plates or channels open.
"V" Engine - An engine that consists of two banks of cylinders connected to the same crankshaft which
gives the appearance of a "V".
Vacuum - Pressure less than atmospheric pressure.
Valve - A device to permit relatively unrestricted flow of gas in one direction but to block all flow of gas
in the opposite direction.
Valve Dynamics - The mechanical movement of the valve as it responds to pressure differentials.
Valve Guide - A bushing in which a valve stem travels to guide the valve to the valve seat.
Variable Pocket - A chamber that adds clearance volume in direct proportion to its setting. The setting
may be adjusted to any volume within the limits of the pocket.
Viscosity - The resistance of oil to flow.
Volumetric Efficiency - The ratio of the volume of gas actually drawn into a cylinder to the total cylinder
volume.
Work - Force times distance.
Wrist Pin - The pin and bearing connecting a power piston to the power connecting rod.
Wrist Pin Bushing - The bushing in which the wrist pin pivots, normally in the eye of the connecting
rod.
226
Index
-66320
Archive
Backup
Restore
17, 184
17, 184
17, 184
-884-10a
66
-AAnimation 154
Archive 17, 184
Articulation 39
Table 33
Assistance 1
Auto generate
Collection points 57
Autoscale 154
Autoscan 13
Avertissement
Risque D'Explosion 188
-CCalbration
Infrared
IR 17
Calculations
Calibration
17
154
Two point 76
Two point, four channel 76
Two point, one channel 76
Zero 75
Care 5
Caution
Multi-Event 174
Chargers
Energy Access 8
Class 1, Div II Information 187
Cleaning 5
Clearance Calculation 66
Collection point
Auto generate 57
Editor 58
List 58, 80
Color scheme 13
Compressor Points 53
Configuration 28
Compressor 41
Engine 28
Engine Points 49
Machine 25
Connections 9
6310 9
6320 9
Control Drawing 189
Wireless Transmitter 180
Crankcase Pressure 44
Crankshaft Offset 44
Customer 1
Assistance 1
Repairs 1
Trouble 1
Index
Date in 6320 184
DC sencor correction 13
Direct Channel Read 170
Displacement probe 208
-KKeyboard 11
Emulation 11
Keyboard Connection
Keypad 11
-EEmissivity
Adjusting 197
Determining actual value of target
Factory Default 197
Table 197
Encoder
Multi-Event 174
Shaft Encoder 173
Engine Balancer 113
Engine Points 49
-FFFT 4
adding sensor points
editing sensor points
setup 59
Fixed Data Scales 60
59
59
-HHandling 3
Hazardous Location Information
High Freq vibration
Ranges 66
Ignition Survey 86
Infrared
Calbration 17
Introduction 1
187
-Nnoise cutoff 13
noise floor 13
Non-contact eddy current probe
Notes 132
Collecting 132
Customizing 134
-OOperating Temperature
66
187
Machine 19
Adding 22
Deleting 22
Management 22
Machine Management 22
Magnetic Pickup 176
Measuring 186
Pressure 186
Temperature 186
Vibration 186
Multi scan 13
Multi spark 66
63
-I-
-L-
-M-
-GGas Analysis
GPSA 66
197
208
227
228
Operating Temperature
6320 188
T5 188
Optical Pickup 176
Oscope Mode 83
Overlay 154
-PPanel Points 55
Parallel Port 9
Phasing 154
Pin power pressures 66
Plot Historical 154
Plot Styles 154
Power Cylinder Monitor 126
Power save 13
Pressure Measurements 186
Printer
Add 15
Autodetect 15
Cancel all print jobs 15
Clear print errors 15
Default 15
Management 15
Remove 15
Printing
6320 185
Graphics 154
Problems 1
Proximity probe 208
Route 58
Run Number
Run numbers
80
13
-SSafety 3, 4
Save/Next 80
Scaling 60
Autoscale 154
Compressor 60
Engine 60
Sensor 49, 53, 189
Accelerometer 191
Compressor 53
Compressor Pressure 195
Displacement probe 208
Engine List 49
Infrared Temperature 197
Magnetic Pickup 201
Point Editor 49, 53
Pressure Water Cooled 208
Primary Ignition 204
Scaling 189
Secondary Ignition 204
Specifications 210
Ultrasonic 204
Velocity 207
Set
Date 15
Time 15
Time Zone 15
Setting TDC 177
Settings
Date in 6320 184
Time in 6320 184
Time Zone in 6320 184
Setup 41
84-10a 66
Articulation Table 33
Clearance Calculation 66
Compressor 41
Compressor Calculations 65
Engine 28
FFT 136
Gas Analysis 63
General Machine 24
Index
Setup 41
GPSA 66
High Freq vibration 66
Late Combustion Check 66
Low Freq vibration 66
Multi spark 66
Pin power pressures 66
Software Configuration 66
Theoretical Model 66
Transient FFT 143
VE 66
Volumetric Effencies 66
Smoothing 154
Software 184
6320 install 184
Installation 184
Windows 6320 184
Spark Mode 96
Spark Survey 86
Special Collection Modes 83
Speciifications
Sensors 210
Wireless Transmitter 211
Spike Filter 154
Station 19
Adding 21
Deleting 21
Management 21
Station Management 21
Stripchart 154
Strobe Light 176
-TT5 188
TDC 173, 176, 177
TDC Shift 154
Temperature Measurements
Temperature Points 55
Terms 4
Theoretical 154
Theoretical Model 66
Time 15
Time in 6320 184
Time Zone 15
Timing Light 176
Transient
186
229
-UUnits
Metric 13
Standard 13
User defined 13
Unpacking 5
USB Port 9
Utilities
Direct Channel Read 170
Power Cylinder Monitor 173
-WWarning 4
AC Power 188
Battery Replacement 188
Battery Substitution 188
Board repair / replacement / modification 188
Cables used with sensors and encoder 188
230
Warning 4
Encoder 4
Ethernet 188
Explosion Hazard 188
Hazardous atmosphere 188
Pressure Sensor 4
Shaft Encoder 173
Timing Light 4, 176
Unit repair / modification 188
USB 188
VGA 188
Wireless
Transmitter 180
-ZZoom
154