63X0 CA Manual

Windrock, Inc. 2009

Portable AnalyzerCA Operations

Manual

1/29/2009

Legal NoticesCopyright

1997-2009 by Windrock Incorporated, All rights reserved.

No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translatedinto any language in any form by any means without the written permission of Windrock, Incorporated.

Software and Firmware License Notice

Your license agreement with Windrock, Incorporated, authorizes the number of copies which can be made andthe computer systems on which they may be used. Any unauthorized duplication or use of Windrock software orfirmware 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 withregard to this material, including, but not limited to, the implied warranties of merchantability and fitness for aparticular purpose. Windrock, Incorporated shall not be liable for errors, omissions, or inconsistencies which maybe contained herein or for incidental or consequential damages in connection with the furnishing, performance, oruse of this material. Information in this document is subject to change without notice and does not represent acommitment on the part of Windrock, Incorporated. Any software described in this document is furnished under alicense agreement or nondisclosure agreement. The software may be used or copied only in accordance with theterms of the agreement.

Portable Analyzer CA Operations Manual

If you have comments about this documentation, the software, or products it describes, please contact theCustomer Support Group at Windrock.

IContents

I

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Table of ContentsPart I Customer Information 1

................................................................................................................................... 11 Introduction

................................................................................................................................... 12 Customer Assistance

................................................................................................................................... 23 Returning Items

................................................................................................................................... 34 Hazardous Location Information, 6320 only

................................................................................................................................... 35 Handling Precautions

................................................................................................................................... 56 Warnings

Part II Read This First 6................................................................................................................................... 61 Special Terms ................................................................................................................................... 62 Care ................................................................................................................................... 63 Unpacking ................................................................................................................................... 74 Batteries & Charging

.......................................................................................................................................................... 7Batteries ......................................................................................................................................................... 8E-Moli

.......................................................................................................................................................... 9Charger

Part III Getting Started 11................................................................................................................................... 111 Connections ................................................................................................................................... 142 Keypad Functions ................................................................................................................................... 143 Hardware Configuration ................................................................................................................................... 164 Stations & Machines

.......................................................................................................................................................... 17Station & Machine Setup

Part IV Machine Setup, 63X0/CA with encoder only 19................................................................................................................................... 191 Setting Up a Machine, 63X0/CA with encoder only

.......................................................................................................................................................... 19Machine Setup Menu

Part V Balancer/Spark Setup and Data Collection 21................................................................................................................................... 211 Overview

.......................................................................................................................................................... 22Setup

.......................................................................................................................................................... 27Engine Balance ......................................................................................................................................................... 27Engine Balancer - Non encoder......................................................................................................................................................... 37Restart Balance Run......................................................................................................................................................... 38Recall Old Balance Data......................................................................................................................................................... 40Power Cylinder Monitor

.......................................................................................................................................................... 42Spark Menu ......................................................................................................................................................... 44Spark Survey......................................................................................................................................................... 51Ignition Survey Report Definitions......................................................................................................................................................... 52Restart Spark Survey......................................................................................................................................................... 54Recall Spark Survey

Part VI Encoder-based Balance 55

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................................................................................................................................... 551 Special Collection Modes

................................................................................................................................... 562 Spark

Part VII Utility Menu Options 59................................................................................................................................... 591 Direct Channel Read ................................................................................................................................... 612 Connect to Windows 6310 only ................................................................................................................................... 623 Power Cylinder Monitor ................................................................................................................................... 624 Discharge Battery 6310 only ................................................................................................................................... 625 Check for Bad EXE's 6310 only

Part VIII Encoder Setup 63................................................................................................................................... 631 Shaft Encoder ................................................................................................................................... 642 Multi-Event ................................................................................................................................... 653 Magnetic Pickup ................................................................................................................................... 654 Timing Light

Part IX Loading New Software 66................................................................................................................................... 661 Windows Install 6310 only ................................................................................................................................... 662 Windows Install 6320 only

Part X Operating System Commands 67................................................................................................................................... 671 Machine Template 6310 only ................................................................................................................................... 672 Setting Time and Date 6310 only ................................................................................................................................... 683 Set Date, Time or Time Zone 6320 only ................................................................................................................................... 684 Printing 6310 ................................................................................................................................... 715 Printing 6320

Part XI Appendix 73................................................................................................................................... 731 Data Collection Techniques ................................................................................................................................... 732 Sensors

.......................................................................................................................................................... 74Magnetic Pickup

.......................................................................................................................................................... 76Secondary Ignition Sensor

.......................................................................................................................................................... 77Water Cooled Pressure Sensor ................................................................................................................................... 773 Specifications - 6310/CA ................................................................................................................................... 784 Specifications - 6320/CA ................................................................................................................................... 805 Specifications - Sensors

Part XII Glossary of Terms 81

Index 88

Customer Information 1

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1 Customer Information

1.1 IntroductionPortable Analyzer Manual

The following sections briefly summarize the functions you will use to set up and operate yourportable CA analyzer by Windrock, Inc. This help version is 3.0.

Data storage and machine setups are stored locally to the analyzer thus no host PC is required.Data stored within the analyzer can be directly backed up to such devices as zip drives if youranalyzer is a 6310 or to a flash drive for the 6320.

Special Emphasis

These conventions are used throughout this manual to call attention to adjacent text:

Note: A note indicates special comments or instructions.

Caution! A caution indicates actions that may have a major impact on the hardware,software, database files, etc.

Prerequisites

The manual is written with the assumption that you are familiar with the basic operation of apersonal computer and is not intended to be a substitute for the documentation supplied with acomputer or software.

If you are unfamiliar with a personal computer or peripheral hardware, Windrock stronglyrecommends review of the appropriate documentation before using the analyzer and software.

1.2 Customer AssistanceDirect any questions you may have about the product you have purchased to Windrock's ProductSupport department at (865) 539-5944 Ext. 4019.

Hardware

1. Please have the serial number of your analyzer available when you call. The serial number islocated 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 theerror messages? When do they occur? What you were doing when the problem occurred. Forexample, what mode were you in? What steps did you go through? Try to determine beforeyou call whether the problem is repeatable.

Software

1. Please have the number of the current version of your software ready when you call. Theversion of the software appears at the top of the main menu screen.

2. If you have a problem, explain the exact nature of your problem. For example, what are theerror messages? When do they occur? What you were doing when the problem occurred. Forexample, what mode were you in? What steps did you go through? Try to determine before

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you call whether the problem is repeatable.

3. Please have your analyzer ready and any accessories in question when you call. We canserve you better when we can work through the problem together.

1.3 Returning ItemsFor Repair

1. Call Product Support at (865) 539-5944 Ext. 4019 to obtain a return authorization number.Please write it clearly and prominently on the outside of the shipping container.

2. Please enclose a letter that describes the reason(s) you are returning the item.

3. Insure your package for return shipment. Shipping costs and any losses during shipment areyour responsibility. COD packages cannot be accepted and will be returned unopened.

For Credit

1. Call Product Support at (865) 539-5944 Ext 4019 to obtain a return authorization number.Please write it clearly and prominently on the outside of the shipping container.

2. Return all accessories originally shipped with the item(s). Include cables, software diskettes,manuals, etc.

3. Enclose a note that describes the reason(s) you are returning the item(s) for credit.

4. Insure your package for return shipment. Shipping costs and any losses during shipment areyour responsibility. COD packages cannot be accepted and will be returned unopened.

Hardware Repair

Windrock repairs its hardware products free for one year from the date of shipment. This servicewarranty includes minor hardware improvement, modification, correction, re-calibration, updates,and maintenance for normal wear. This service warranty excludes repair of damage from misuse,abuse, neglect, carelessness, or modification performed by anyone other than Windrock. Windrock automatically sends updated manuals on the software update CDROM in electronicformat to all customers who are under warranty.

After the one year service warranty expires, each return of a Windrock hardware product is subjectto a minimum service fee. If the cost of repair exceeds this minimum fee, we will call you with anestimate before performing any work. Contact Product Support for information concerning thecurrent rates.

Refer to the Warranty section of the Terms and Conditions section of this manual for a completedescription of your warranty.

Extended Service Plan

Windrock offers Extended Service Plans (ESP) on analyzer equipment. Software benefits includeprogram corrections and improvements, modifications, manual revisions and telephoneassistance. Hardware benefits cover malfunctions due to normal wear, annual calibration, andupdates. Contact (865) 539-5944 Ext. 4030 for information concerning the current cost ofExtended Service Plans.


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1.4 Hazardous Location Information, 6320 only

Caution! If your 6320 Analyzer has been approved for use in a hazardous location, Class 1 Div. 2,there will be a hazardous atmosphere warning label on the back of the analyzer. If there isno warning label on your analyzer, fallow all hazards atmosphere precautions prior to andwhile using your analyzer.

Caution! 1. THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION 2, GROUPS A, B, C, D

HAZARDOUS LOCATIONS ONLY

2. WARNING - EXPLOSION HAZARD SUBSTITUTION OF COMPONENTS MAY IMPAIRSUITABILITY FOR CLASS I, DIVISION 2, andAVERTISSEMENT - RISQUE DEXPLOSION LA SUBSTITUTION DECOMPOSANTSPEUT RENDRE CE MATRIEL INACCEPTABLE POUR LES EMPLACEMENTSDECLASSE I, DIVISION 2

Caution! 3. WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS

POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BENON-HAZARDOUS, and AVERTISSEMENT - RISQUE DEXPLOSION - AVANT DE DCONNECTER LEQUIPEMENT, COUPER LE COURANT OU SASSURER QUE LEMPLACEMENT ESTDSIGN NON DANGEREUX

4. WARNING - EXPLOSION HAZARD - DO NOT RE PLACE BATTERY UNLESS POWERHAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS; andAVERTISSEMENT - RISQUE DEXPLOSION - COUPER LE COURANT OU SASSURERQUE LEMPLACEMENT EST DSIGN NON DANGEREUX AVANT DE REPLACER LABATTERIE

1.5 Handling PrecautionsSTATIC ELECTRICITY

The CMOS integrated circuits in the analyzer can be damaged by exposure to electrostaticdischarges.

LITHIUM-ION BATTERIES

The analyzer contains a Lithium-ion cell pack which can create a fire or explosion hazard ifimproperly 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 circuitryon the analyzer.


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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 theEMI protection of the case and interconnecting pieces.


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1.6 Warnings

Caution! The pressure sensor used with this kit may become hot when used oneither an engine, compressor, or any related piping. The sensor, whenhot, may cause severe burns to the hands or other body parts that comein contact with the hot surface. Use precautions such as insulated glovesto handle the sensor.

When using the water cooled pressure sensor, the water used for coolingmay become hot and cause scalding. Use precaution when handling thesensor to prevent the hot water from contacting the skin.

Caution! The shaft encoder that may be included with this kit comes in contact witha rotating element. Keep all clothing and hair away from the rotating partsas they may become tangled with the rotating parts and cause severeinjury or death.

Keep hands away from the rotating equipment at all times to preventinjury.

Caution! The timing light that may be included with this kit may be used nearrotating elements. Keep all clothing and hair away from the rotating partsas they may become tangled with the rotating parts and cause severeinjury or death.

Keep hands away from the rotating equipment at all times to preventinjury.

Caution! Several cables are used with the analyzer and shaft encoder that may beused near rotating element. Keep all clothing and hair away from therotating parts as they may become tangled with the rotating parts andcause severe injury or death.

Keep hands and cables away from the rotating equipment at all times toprevent injury. Be aware of the trip hazard cables on the floor can create.


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2 Read This First

2.1 Special Terms6310 / 6320 AnalyzerPortable data collection instrument or analyzer.

Shaft EncoderDevice used to convert crankshaft position into electrical impulses.

Parallel PortPrinter and communications link between the analyzer and host computer.

Transducer / SensorDevice used to convert mechanical measurements into electrical signals.

USBUniversal Serial Bus

VGAVideo Graphics Array or common computer color monitor type.

2.2 CareUse only a damp rag with a mild soap to clean the surfaces. Strong degreaser and other chemicalsmay damage the keypad and clear display window.

2.3 UnpackingCheck to verify the following items are in the instrument case upon arrival.

PARTS LIST (Standard Package)

Part 6320Analyzer A6320-00/CABattery/Batteries A6301-02Battery Charger A6312-00Carrying Case with Cut Foam MP630030-00USB Communications Cable A6306-03-00Leather Case (on analyzer) A6304-01Carry Strap A6305-00DC Pressure Cable A6060-00-08DC Pressure Sensor (High Temp) A6082-XX-01Manual A6310-00-M/CASoftware CD-ROM A6310-00-SW/CASecondary Ignition Pickup A6030-01-06

Other parts may be present depending on the options selected and/or purchased.

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Note: 6310 only. A battery is typically shipped in the analyzer. Under normal circumstances, abattery should be kept in the analyzer when not in use. Having a battery in the unit will helpkeep the internal CPU's CMOS coin cell charged and the operating configurationparameters intact for many years. Leaving the battery out of the unit may shorten the lifeof this coin cell requiring replacement and loss of the operating configuration parameters.

2.4 Batteries & ChargingGeneral Battery Care information.

The analyzer kit contains one or more of the pictured batteries and charger shown below.

E-Moli Li-ion Energy Access

2.4.1 BatteriesFor Optimum Performance of Your Batteries

This battery needs to be charged before use. Refer to the "Instructions for Use of the BatteryRecharger" section of this manual for charging instructions.

When the battery is charged for the first time, the charger may indicate that charging has beencompleted after just 10 to 15 minutes. This is normal and can happen with any rechargeable batterywhen it is first charged or if it has been stored unused for a prolonged period. Simply remove thebattery from the charger and repeat the charging procedure. There is no need to discharge thisbattery between these charges.

Best charging results are obtained at normal room temperature, 70F (21C) +/- 8F (2C). Chargingbeyond 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 typecharging 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 thisbattery will be left in storage for more than a few days prior to use, a top-off charge to regain fullcapacity is recommended.


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Note: 6310 only. A battery is typically shipped in the analyzer. Under normal circumstances, abattery should be kept in the analyzer when not in use. Having a battery in the unit will helpkeep the internal CPU's CMOS coin cell charged and the operating configurationparameters intact for many years. Leaving the battery out of the unit may shorten the lifeof this coin cell requiring replacement and loss of the operating configuration parameters.

Wipe the metal terminals with a soft, dry cloth if they become dirty.

Safety Precautions for the Batteries

Do not disassemble or attempt to open the battery under any circumstances.

The battery can explode, leak or catch fire if heated or exposed to fire or high temperatures. Do notshort circuit the battery by directly connecting the metal terminals (+,-). Be certain that no metalobjects such as coins, paper clips, etc., touch the terminals.

Only use the charger recommended by the device manufacturer.

To Avoid Damage to Battery

Do not drop battery or subject it to mechanical shock.Use battery only with equipment that specifies its use.

Recycling Information

Windrock is committed to environmental responsibility and would like our customers to recycle thisbattery. For instructions on how to recycle this battery, call your local battery recycler.

2.4.1.1 E-Moli

LITHIUM-ION STYLE BATTERY

You may identify the Lithium-Ion battery by the all black case and the "MOLICEL" logo on the top. These batteries are Smart Technology batteries. There is a capacity bar on the right and is activatedby 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 onlythe EnergyAccess charger supplied). There is a great potential for thebattery to EXPLODE. Use only a charger specified for this type of battery.

A battery may become deactivated and go into the "off state". This means that the battery will not workuntil it is turned on. To do this, insert the battery into the left charger bay and press the "Re-calibrate"

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button and let the battery sit for 15 to 20 seconds. Remove the battery and place it in the right side ofthe charger and let charge fully. It should then operate correctly.

2.4.2 Charger

Lithium-ion Battery Charger (Energy Access)

Newer units shipped are supplied with one or more Lithium-ion batteries. These are the latest highcapacity lightweight batteries available. They also have a special charger made just for Lithium-ionbatteries.

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

To use the Energy Access battery charger, plug the power supply (use the power supply - PS2524only) into an outlet (100VAC - 240VAC/50-60Hz) and insert plug end of the power cable into the DCpower jack on the charger. Insert a battery in one of the two bays. The LED will illuminate to indicatethe status of the battery as follows:

Off: No battery detectedGreen Flash: Fast chargingGreen Solid: Fully chargedYellow Flash: Re-calibratingYellow/Green: Re-calibratedYellow Solid: StandbyRed Flash: Error

Caution! Connection other than indicated may result in permanent damage to theunit.

Re-calibration:

SMBus Smart Batteries contain a microchip that monitors battery usage and tracks how muchcapacity is available from the pack. It is possible for this process to accumulate errors due totemperature fluctuations, aging, self-discharge, and other factors.

To keep the internal information as accurate as possible, it is occasionally necessary to run thepack 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 calibrationis initiated.

To calibrate a pack, place it in the left bay and push the red (or blue) arrow located between thebays. This process can take 16 hours. Some packs do not have the capability to be re-calibrated.


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The charger automatically senses this and simply drops back into the normal charge mode.

Specifications

SMBus: Level 3Charge Rate: 3.0 Amps2 Bays: SequentialCharge Time: 3 hours eachRecalibration: SMBus [email protected] Time: 9 hoursWeight: 9.5 ozMaterial: ABS GSMColor: BlackDimension Inches: 4.89 x 6.89 x 2.02Dimension mm: 124 x 175 x 50

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3 Getting Started

3.1 Connections6310 OnlySeveral connections are provided on the portable analyzer unit. See the figures below for placementof the connections. Looking at the rear panel to the far left, a connector labeled "KBD" is used forattachment of an external PS2 style keyboard. If a PS2 style keyboard is not available, a standard PCkeyboard may be used, but the number pad on the right of a large keyboard is not supported (NumLock will do nothing). The connector on older style keyboards is a 5-pin DIN style and an adapter willbe needed. These are available at most office supply or computer retailers. You may also contactWindrock, Inc. to purchase this adapter.

6320 OnlyA standard USB keyboard may be used by connecting it to the USB port found on the left side of theanalyzer.

Caution! Do not connect the external keyboard while near engine ignition systems.This may damage both the keyboard and the portable analyzer.

Next, there are two round "Lemo" transducer input connectors. These connectors are for thetransducers and shaft (crank-angle) encoder which may be provided in the portable analyzer kit.

The connector labeled "ANT" is for an optional wireless receiver antenna.

Caution! Do not over-tighten the antenna. The antenna only needs to be finger tight.There is potential to break the connector by over-tightening.

On the far right, an external AC-adapter connector is provided for use with the supplied charger powerpack. You may unplug the power pack from the charger base and plug it directly into the portableanalyzer. This will provide sufficient power to leave the instrument on for reviewing stored data withoutusing up the battery.

Caution! Make sure to keep a battery in the analyzer when using the external poweradapter.


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

6310 6320 VGA Port USB Port

A6320-00 Left Side

The 6310 has a 25 pin parallel printer port / communications connection, where the 6320 has a USBport, and both have an external VGA color monitor connection located together on the left side of theanalyzer behind the sliding door. A USB keyboard may be connected here on the 6320 analyzer.

A standard VGA / SVGA monitor may be connected to the portable analyzer for larger desktop screenviewing. The operating software is set for 640 x 480 pixels of resolution. There are no settings tochange this resolution for different monitor types. However, both color and B&W are supported.

Please see the chapter on Utility Menu Options for use of the 25 pin parallel port for file transfer toWindows and Operating System Commands chapter on Printing from the parallel port of your 6310.For information on printing from the 6320, see the chapter on Operating System Commands, Printing6320.

The 6310 and 6320 battery compartment is located on the right side of the analyzer behind the slidingdoor. The battery compartment has a spring located in the bottom to pop the battery out when thedoor is open. The battery will have to be pushed in and held while closing the sliding door. This maybe tight and is normal operation.

Note: The sliding doors on the sides are provided to protect against EMI when around ignitionsystems. The doors should remain closed while operating.

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3.2 Keypad FunctionsESC The escape key operates as a cancel function and gives the user the ability to

back up one step or menu. If you are in an operation that may cause data loss(setup screens), a warning is given for user acknowledgment.

ON/OFF Turns the analyzer on or off.

Yes No The 6320 has separate Yes and No keys.

ENTER Accepts the user entry or selects the current option.

+/- Changes the sign of numeric inputs or adds a hyphen character to text entries.

END Drops the user to the end of a screen or to the end of a list.

HOME Brings the user to the beginning of a screen or to the beginning of a list. (Specialnote: The HOME key is also used to bring up a list of alphabetic characters fortext entry when a keyboard is not available)

p q Used to move the cursor up and down for selections.

t u Used to move the cursor right and left and increment and decrement numericentries. The right arrow is also used to bring up pop-up list selections on certaindata entry fields.

TAB

Advances the user ahead multiple entries or multiple pages.

TAB

Returns the user back multiple entries or multiple pages.

Period Enters a decimal point as needed for numeric entries.

NumericKeys

Enters the numeric character in data entry fields and provides short cutmenu/function selections. If the user is on a menu screen, simply pressing thenumber associated with the option will execute the option.

Note: If the entry screen has multiple lines requiring duplicate entries, you can press the"ENTER" key and all the data from the previous line will be transferred to the newline. For example, each cylinder's bore, stroke, and connecting rod length may becopied from line to line since they may all be of the same values.

3.3 Hardware ConfigurationBefore using the analyzer, take the time to become familiar with the basic operation and set up. Thereare a number of options, setup entries, and keystrokes with which you should be familiar prior to takingyour first set of data.

When you first receive your analyzer and turn it on, you will be in a "Windrock Test Station" and "TestMachine" area. However, prior to your data collection, you must first set up your own stations andmachines in the database. Subsequently, when the analyzer is turned on, you will be positioned at themenu for the last used station and machine. This enables you to power down the analyzer toexchange batteries and power back up to the current machine and station. From this menu, you canselect a new machine or station by pressing "ESC" once or twice, respectively.

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Note: The "Windrock Test Station" and "Test Machine" should not be deleted or used for datastorage. This area is set up for initial and subsequent calibration of the analyzer.

There are basic configuration parameters that may be set on the analyzer to optimize the operation foryour needs located in the Hardware Configuration option of the Station Selection Menu.

Use backlight: Typically set to YES. Setting to NO will turn off the LCD back lightand the screen image may be hard to see - this mode conservesbattery power.

Monitor type: Typically set to LCD for black and white units, Color1 or Color2 forcolor units or when an external VGA monitor is used. B&W can beused to improve contrast in some cases.

Use power save: Typically set to NO. If set to no, the processor runs at full speedand 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 theuser returns to a menu screen. It is possible to lose the phase setting(exhaust vs. compression cycle) of the encoder when collecting data ona 4-stroke engine. You must check the phase before continuing withdata collection if this occurs.

Use blinking: Typically set to YES. You may prefer to not have the cursor barblink. If so, set this option to NO.

Screen width: Typically set to 40 column.

Text Cursor Style: The style of the cursor may be changed between ARROW, BAR,


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or BOX.

Peak pressure only: This is set to YES for a CA Lite and NO for a CA with encoderoption and want to configure the analyzer to make crank-anglebased measurements (IHP, peak angle, ignition timing).

Autoscan first in take data: This option controls how the data collection process runs. Whenset to YES, entering the data collection process will automaticallystart the analyzer auto scanning data and update the screen witheach collection of data until the 3 key [STOP AUTOSCAN] ispressed. Once the auto scan is stopped, the user is prompted tosave the latest data capture. The data collection process thencontinues to collect the statistical data and display it.

Use unit conversion: NO uses the default standard units that have always beenavailable. Setting to YES will allow selecting from differentconversion groups (see "Unit group" below).

Unit group: Allows selecting either Standard or Metric Units.

DC Sensor correction: Set to Zero Only for zero only balancing of the pressure sensor inthe CA mode. There is no zero function available in the CA (LITE)mode.

Is this a CA with encoder: This default is NO. Set to YES if using an encoder.

Setup (D6) files warning: This is set to YES to receive a reminder to transfer the setups tothe computer after setups have changed in the analyzer.

The analyzer contains a status line at the bottom of the display. This line contains information aboutthe battery capacity and the date and time. The battery capacity is monitored when the unit isoperating from the battery. If the unit is on AC power, the status line will add "Using AC" to the batteryvoltage value. If the battery capacity drops to approximately 9 volts, a warning will be displayed andthe analyzer will automatically turn off.

Caution! When the battery goes below 10.0V, save the current data and changethe battery. Any data stored up to this point is safe. Only data that iscurrently being collected and displayed or setup information currentlybeing entered could be lost.

3.4 Stations & MachinesStations and Machines are laid out in a tree structure. The first level in the tree structure is the Stationlist. There are from 0 to 199 folders (starting with a 0 base) and each folder contains a station. Withineach Station, there contains from 0 to 199 machines (starting with a 0 base). Within each Machine,there resides the setup files and crank angle related data collected files.

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The structure looks like this:

/EVPORT|Station 000 (S000)| || Machine 000 (M000)| | || | Setup| | Crank angle data| || || Machine 001 (M001)| || Machine 002 (M003)| || ...Station 001|...

The database is a flat file structure for fast and easy data retrieval. All data is stored in this format andcan be easily accessed. This structure is automatically created by the software.

3.4.1 Station & Machine SetupThe first steps in setting up a new station and machine are described in the following steps.

Note: This must be done prior to being able to duplicate (copy) a previous setup from anotherstation/machine. See the section on machine database in the Win63X0 manual forcopying setups. This section applies to all 63X0/CA models.

Station Selection Menu

From the "Machine Menu", press "ESC" twiceto return to the "Station Selection Menu".

Select "2-Add a station".

Enter a station name of up to 30 charactersfollowed by pressing "ENTER".

You will be returned back to the "StationSelection Menu".

Select "1-Select a station" and pick the newstation you just added from the list.

Caution! If you are a Win63X0 software user, make sure the name entered is not alteredwithout also changing the Windows database. In order to connect Windows tothe portable analyzer, these names must match exactly (character and case) ora connection will not be allowed.


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Machine Selection Menu

You will now be brought to the "MachineSelection Menu".

Select "2-Add a machine".

Enter a machine name of up to 30characters followed by pressing "ENTER".

You will be returned back to the "MachineSelection Menu".

Select "1-Select a machine" and pick thenew machine you just added from the list.

Note: You will need to come back tothis menu to add each machine you willanalyze.

Note: If your analyzer is a 63X0/CA non encoder balancer, proceed to the section on"Balancer/Spark Setup and Data Collection". Skip the "Machine Setup, 63X0/CAw/encoder" section. If your analyzer is a 63X0/CA w/encoder, proceed to the section on"Machine Setup, 63X0/CA plus encoder". After following those instructions, then proceedto the section on "Balancer/Spark Setup and Data Collection".

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4 Machine Setup, 63X0/CA with encoder only

4.1 Setting Up a Machine, 63X0/CA with encoder only4.1.1 Machine Setup Menu

The analyzer will power on to the "Last Station" and the "Last Machine" it was in prior to powering theunit off. In the case of the /CA, the screen below will be shown after power up. Alternately, you canuse the Win63X0/CA software auto generate features.

Machine Menu, Analyzer CA withEncoder only

You will now be brought to the "MachineMenu" as shown in the figure.

At this point, you must select "2-Setupdatabase" to enter all the informationabout the machine.

This would include engine & compressorgeometry, points for data collection, gascomposition, etc.

This is the minimum required to collect data with the analyzer. Further customization may be requiredto meet your setup needs.

If you find that the names you have entered need to be changed, you may use the "Edit a stationname" and "Edit a machine name" as necessary.

The machine menu is the entry point when turning on the analyzer. At this point, you may take one ofseveral actions. The menu options are outlined below:

Option 1: "Data collection menu" is the point where data collection begins after a setup hasbeen entered for the selected machine.

Option 2: "Setup database" is a set of menu options to configure the machines geometry,sensor points, collection points, fixed scaling, and other related setup details.

Option 7: "Utilities" are a set of utilities for calibration of sensors, connecting the analyzer to adesktop computer, battery conditioning, and other helpful items.

Option 8: "Select different machine" takes the analyzer back one menu level to select a newmachine. The Machine database setup is a set of menu options to configure themachine's geometry, sensor points, collection points, fixed scaling, calculation, andother related setup details.


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The machine configuration data can beobtained from the manufacturer's datasheets. Occasionally, not all theinformation is available from this source.It may be necessary to call themanufacturer to enlist their help with themissing information. As a last resort,there are databases that have beendeveloped that can help you obtainmissing information. When you use thisinformation, it is up to you to verify theaccuracy.

Below is an outline to setting up the machine database. It is a guide to organizing your data beforecontinuing. We suggest you gather the required data prior to starting the entry process. This Menuapplies to the /CA with encoder analyzer, but does not apply to the /CA Lite analyzer.

Note: In the following setup screens, use the left or right arrow keys to select from the choicesavailable or enter the numeric values as required.

Menu Key Menu Option Description

1 Machine Configuration Number of cylinders, bore, stroke, etc.

2 Machine Sensor Setup Define individual sensor points

3 Collection point / Plot Setup Setup route for data collection

1 - Point setup Arrange groups of sensor points for collection 2 - Autoplot setup Arrange groups of sensor points for plotting3 - Generate default autoplots Automatically create a default set4 - Empty autoplots Erase all existing autoplots and start over

4 Fixed Data Scales Setup predefined scales for display of data.

5 Not available MA/CA Does not apply to /CA analyzer

6 Not available MA/CA Does not apply to /CA analyzer

7 Software Configuration Modify standard defaults for this machine only

8 Return to machine menu Returns analyzer to machine menu

Balancer/Spark Setup and Data Collection 21

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5 Balancer/Spark Setup and Data CollectionAll non-encoder functions must be set up in the analyzer and the set ups transferred to the Win63X0/CA program.

5.1 OverviewThe analyzer will power on to the "Last Station" and the "Last Machine" it was in prior to powering theunit off. In the case of the /CA Lite, the screen below will be shown after power up.

In the case of the /CA with encoder model, from the power up menu, navigate through the followingmenu options to reach the menu shown below:

1. 1 - Data collection menu2. 4 - Balancer menu3. 4 - Balancer / Bal & spark menu4. 2 - Nonencoder balance and spark


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The balancer mode has several menu options from which to choose. It is best to start with the setupmenu first when using the analyzer for the first time on a new unit. After the setup has been completed,it only needs to be entered to make changes.

Menu Key Menu Option Description

1 Setup balancer / spark Enter configuration parameters for the program

2 Balance engine nonencoder Balance an engine using pressure sensor with out crankangle position

3 Restart balance run Used to start the program after a battery change at thelast cylinder data that was collected

4 Recall old balance data Recall data that has been stored on the analyzer from aprevious balance

5 Spark menu Enter the spark survey menu

6 Utilities A set of analyzer utilities - specifically, connection to theWindows application software, Win63X0/CA.

7 Online balance Link Connects the analyzer to an "online" system

8, CA lite Select different machine Use to select a different unit on which to run a survey

8, CA Return to special data menu Returns to previous menu

5.1.1 SetupPress the "1" key or the "ENTER" key if the menu item is highlighted to select the (1 Setupbalancer/spark)

Every new machine added will have to be set up in the portable analyzer prior to running a peakpressure balance and/or a spark survey. Once the new machine is set up, the set up information willremain the same unless changed.


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MAX SENSOR PRESSURE: Select the desired pressure sensor range (1000, 2000, or3000 psig @ 20ma) by pressing the "LEFT or RIGHT Arrow"keys.

NUM POW CYL: Select the number of power cylinders (1 20) for the machineby pressing the "LEFT or RIGHT Arrow" keys.

CYL LAYOUT: Select the power cylinder numbering scheme (STRAIGHT,LEFT/RIGHT, ODD/EVEN) by pressing the "LEFT or RIGHTArrow" keys.

USE SPIKE FILTER: Select the use of the spike filter (NO or YES or YES-HEAVY)by pressing the "LEFT or RIGHT Arrow" keys. The spike filtershould be used when indicator tube detonation is present onthe pressure trace (i.e. IR-KVS, Nordberg).

PERCENT +/- OK BAND: Select the desired maximum percentage of power cylinderimbalance (0 10) by pressing the "LEFT or RIGHT Arrow"keys.

2 OR 4 CYCLE ENGINE: Select the proper number of cycles (2 CY., 4 CY.) by pressingthe "LEFT or RIGHT Arrow" keys.

DEBOUNCE FACTOR: Select the desired debounce factor (1 33) by pressing the"LEFT or RIGHT Arrow" keys. The debounce factor defaultsto 3 and should work satisfactorily on the majority ofmachines. This is the number of consecutive pressures thatmust exceed the trigger level (psi) before the peak detectorengages or ends.


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TRIGGER LEVEL (psi): Select the desired trigger level (30 100) by pressing the"LEFT or RIGHT Arrow" keys. The trigger level defaults to 30and should work satisfactorily on the majority of machines.This is the trigger level that pressure must exceed before thepeak detector is enabled. It is also the level that pressuremust fall below to reset the peak detector. The level is in psi. It is normally set somewhere between 30-60 psi.

SHOW CURVES: Select the desired viewing option (NO, YES no pause, YESwith pause, NO pause, NO SD, Pause, NO SD) by pressingthe "LEFT or RIGHT Arrow" keys.

NO When taking data, the peak pressure text data only willbe present on the screen. When finished with the datasample, it will automatically go to the select cylinder list.

YES no pause When taking data, the peak pressure curveswill be present on the screen. When finished with the datasample, it will automatically go to the select cylinder list.

YES with pause When taking data, the peak pressurecurves will be present on the screen. When finished with thedata sample, it will be necessary to hit any key to return to theselect cylinder list.

NO pause, NO SD When taking data, the peak pressurecurves will be present on the screen. Standard deviation willnot be displayed. When finished with the data sample, it willautomatically go to the select cylinder list.

Pause, NO SD When taking data, the peak pressure curveswill be present on the screen. Standard deviation will not bedisplayed. When finished with the data sample, it will benecessary to hit any key to return to the select cylinder list.

REDUCED SCALE ON CURVES: Select the desired scaling option (NO, HALF, 3/8, QUARTER,5/8, 3/4) by pressing the "LEFT or RIGHT Arrow" keys.

This scaling factor is used for the pressure curves verticalscale. When set to NO, the vertical pressure scale will bezero up to the "MAX SENSOR PRESSURE" that has beenselected. Other scale selections will scale to the selectedfraction of the "MAX SENSOR PRESSURE".

# SPARK PER CYLINDER: Select the desired number of spark plugs per cylinder (0, 1, 2)by pressing the "LEFT or RIGHT Arrow" keys.

SPARK LAYOUT: Select the desired spark plug layout and naming convention(Use Side/Center, Use Left Right, Use A/B, Use Top/Bottom,Use CS/OCS) by pressing the "LEFT or RIGHT Arrow" keys.

SHORT SPARK DURATION: Select the desired horizontal scaling factor (NO, YES) bypressing the "LEFT or RIGHT Arrow" keys. Most CD(capacitor discharge) ignition systems have 500 Us or lessarc durations and the SHORT DURATION can be set to YES.

This will be the default scaling factor while taking data,


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however, this scaling factor can be changed while takingdata.

MULTI STRIKE SPARK: Select the proper machine spark type (NO, YES) by pressingthe "LEFT or RIGHT Arrow" keys. When using the sparksurvey on a multi-strike ignition system, the software willattempt to analyze the first ignition event of the series.

FAST RAMP TIME: This is typically set to NO. YES should only be used ifdirected so by Windrock Customer Support or Engineering. Ifthis is set to YES, the Ramp Time will not be shown on thereports.

PRESS CUTOFF LOW Select the low pressure cutoff value for the report by pressingthe LEFT or RIGHT Arrow key. The balancer will report thenumber of cycles that the peak pressure was below the lowcutoff value.

PRESS CUTOFF HIGH Select the high pressure cutoff value for the report bypressing the LEFT or RIGHT Arrow key. The balancer willreport the number of cycles that the peak pressure was abovethe high cutoff value.

RECORD PANEL POINTS Select the PANEL POINT OPTION (NO, YES) by pressingthe LEFT or RIGHT Arrow key. Selecting YES will allowrecording as found and as left panel data including fuelusage and bsfc values. Selecting NO will deactivate panelpoints in collection routine. There are 12 predefined panelpoints to choose from, 6 user defined points, and exhausttemperatures for each cylinder.

FINISHED: Select the desired option (NO, YES hit enter) by pressing the"LEFT or RIGHT Arrow" keys. If "YES hit enter", follow bypressing the "ENTER" key to finish the machine set up, andreturn to the initial Balance and Spark Menu screen. If theRECORD PANEL POINTS option was selected, additionalscreens will be displayed to define the panel points to beselected.

If you hit "ESC", the program will then prompt a "WARNING Escape was hit - If you have made changes they will be lost.Save changes? (Y/N)"

If you want to save the set up changes, press the"HOME-YES" key.

If you do not want to save the set up changes, press the"END-NO" key.

Pressing the "HOME-YES" key or the "END-NO" key willreturn to the initial Balance and Spark Menu screen.

Note: Every new machine will have to be set up in the portable analyzer prior to running aPeak Pressure Balance and/or a Spark Survey. Once the new machine is set up, theset up information will remain the same unless changed.


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If you selected "YES" to "Record Panel Points", the following setup screens will allow you to definethose selections prior to returning to the Spark Menu screen.

Turn individual selections to YES or sequence number by using the "LEFT or RIGHT Arrow" keys ifyou want the point added to the panel report. Panel points will show up in the order of their sequencenumber. 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 isused to bring up a list of alphabetic characters for text entry when a keyboard is not available. Lookingat the rear panel to the far right, a connector labeled "KBD" is used for attachment of an external PS2style keyboard.


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Est Fuel Savings: If panel fuel flow is recorded, you may estimate the fuelsavings from the "AS FOUND" readings to the "AS LEFT"readings by using the "LEFT or RIGHT Arrow" keys to tab tothe correct measurement unit. (YES ft3/min, Yes ft3/hr, YesMMft3/day, Yes m3/min, Yes m3/hr, Yes MMm3/day, or No).

Fuel Cost ($/unit): Enter the current fuel cost in $/MSCF or $/Mm3.

FINISHED: Select the desired option (NO, YES hit enter) by pressing the"LEFT or RIGHT Arrow" keys. If "YES hit enter", follow bypressing the "ENTER" key to finish the machine set up andreturn the 6310/CA to the initial Balance and Spark Menuscreen.

If you hit "ESC", the program will then prompt a "WARNING Escape was hit - If you have made changes they will be lost.Save changes? (Y/N)"

If you want to save the set up changes, press the"HOME-YES" key.

If you do not want to save the set up changes, press the"END-NO" key.

Pressing the "HOME-YES" key or the "END-NO" key willreturn to the initial Balance and Spark Menu screen.

5.1.2 Engine Balance5.1.2.1 Engine Balancer - Non encoder

This is the option to select when you are ready to balance the engine.

Note: If "record panel points" is selected in the setup, you will be prompted to record thosereadings before taking 'As Found data'.

In taking data, there are three main steps in balancing:

1. Take "AS FOUND" data. This is the engine balance before any adjustments are made. Ifrecord panel points is selected in the setup, you will be prompted to record those readings.

2. Adjust cylinders. This is when the cylinders are adjusted to even out the peak pressures.

3. Take "AS LEFT" data. This is the engine balance after all adjustments are made.

Note: If record panel points is selected in the setup, you will be prompted to record thosereadings.

Note: You can bring up the last "AS FOUND" and "AS LEFT" balance run for the day on theanalyzer. Other run numbers are available for viewing in the Windows softwarepackage.

When first starting, the engine speed is determined by sampling the pressure curves. This enginespeed will then appear on the 'As Found' report.


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The first screen you see will ask you to connect thepressure transducer to a power cylinder and applypressure. After you hit any key, the estimatespeed routine will run. This function will count thenumber of pressure peaks within a measured timeframe and calculate an estimated RPM.

Note: The pressure sensor must be attached to channel one.

This will take 10 seconds. If the estimated speed is not close to the known speed, then you need togo back and adjust the debounce factor and trigger level in ENGINE SETUP. This speed is reportedon the 'As Found' or 'As Left' reports depending on where you are in the sequence.

Note: The pressure sensor must be attached to the power cylinder and the indicator valvemust be opened to apply pressure.

After the speed has been estimated,the starting balancer screen willappear. Hit any key to go to the "selectnumber of cycles to take" screen. Thedefault number is pre-selected. Simplyhit enter to continue. If a differentnumber of cycles is to be collected,select it now by using the up / downarrow keys (for one step at a time) orthe UP or DOWN TAB keys (for fivesteps at a time) and pressing enter.

Note: The number of cycles selectedin this screen will be the numberof cycles used in the "ASFOUND", "Adjust cylinder", and"AS LEFT" data collectionmodes.


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After you have set the number ofcycles, a list of the cylinders will beshown. Select the first one to startcollecting data.

A '?' represents a point for which datahas not been taken.

A '*' represents a point for which datahas been already taken.

Once the point has been selected, youare given the option to change thecylinder selection or the load step beforeactually collecting the data. On thisscreen, the cylinder selection can bechanged by placing the cursor on the"Chan 1 >" field and pressing theright/left arrow keys. The current loadstep may also be changed by placing thecursor on the appropriate field andpressing the right/left arrow keys.


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As pressure data is collected, the curve and peak pressure are displayed (if the 'Show Curves' optionis set to Yes in the setup) along with the cylinder number as shown in figure below. Once all samplesare collected, the screen will return to the point selection list unless the 'Show curves with pause'option is selected. If so, the screen will show the curves for viewing until a key is pressed.

The "Pick Cylinder" screen willappear and the "?" indicator willchange to a "*" showing that thedata has been collected and thecursor bar will advance to the nextcylinder. Any cylinders with a "?"still require data to be taken.


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When the last cylinder's data iscollected, the screen will show amessage box with "Finishedcollecting as found data, Now adjustcylinders, Hit any key to continue". Pressing any key will display the "ASFOUND" balance report shown belowor Hit the "END/NO" key to resamplethe last point.

Below is a sample of an "AS FOUND" report. Once the last cylinder is collected, a screen will pop upshowing the "AS FOUND" balance results. Each cylinder will have the average peak pressuredisplayed for that cylinder. If the average pressure is outside the OK band, that cylinder should beadjusted. After the adjustments are made, take "AS LEFT" pressure data.


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Report Column Explanations

Top Box (Text Information Section)

Power Cylinder Name: This is the cylinder ID for identification.

Peak Pressure - Mean: The mean (average) peak firing pressure for each cylinderbased on the number of cycles selected.

Peak Pressure - Diff: The difference each cylinder's PFP is from the engine averagemean peak pressure.

Peak Pressure - SD: The standard deviation of the cylinder's peak pressure samplebased on the number of cycles selected.

Peak Pressure - Spread: The cylinder's difference from the high to low peak pressures ofthe number of cycles selected.

Center Box (Bar chart statistics section) Shows the individual cylinder values in bar chart format on the left side.

On the right side is a single bar summing the individual cylinders.

Bottom Box (Individual cylinder balance bars) This shows the OK band based on the +/-% values

On the right side are the engine parameters: speed, pressure spread, run number, andload step.

Menu "Hot Box" Keys

The menu section of the "AS FOUND REPORT" has many menu options.

0-Options:

A submenu will pop up with the following selections:

"0- CHANGE PRESSURE MAXIMUM"

This is for changing the maximum pressurescale on the statistical bar graph.

"1-CHANGE PRESSURE PERCENTBAND"

This is for changing the plus and minus percentbands on the cylinder balance bars.

"2-CHANGE PRESSURE MINIMUM" This is for changing the minimum pressurescale on the statistical bar graph.

2 - Adjust cylinder When you select this, a list of the cylinders pop up. Highlight thecylinder that you wish to adjust then, when you have the pressuretransducer attached, hit the enter key. A screen will then pop upcontinuously showing you the average peak firing pressure for that


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cylinder. It will also show you the engine average (this will notchange; it is based on the "as found data" or "as left data" only). Usethis screen to adjust the cylinder. When you have finished adjustingthe cylinder, hit any key. You will return to the report showing data forall the cylinders. The cylinder you have just adjusted will now bemarked with DONE. You can readjust this cylinder if you wish byselecting 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 totake data. When done, the screen will reappear listing the results ofall 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 toadjust 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 toconnect the analyzer to the PC and print your reports.

6 - Est. Speed This will run the estimate speed routine again. The new speed valueis then displayed and written in the "AS LEFT" report.

7 - Print If a printer is attached and configured, pressing the "7" key will makea hard copy of the current screen to the printer. "AS FOUND" and "ASLEFT" report data can be transferred to a PC running ApplicationWin63X0/CA software. Printouts can then be made from Windows.

8 - Show hi/lo # This will change the display and replace the SD and Spread columnswith the hi/lo pressure count data.

9 - Exit This will exit the program back to the main menu.


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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 cylinderselection list. This list is a pop up selection in which you must use the cursor keys to select whichcylinder to adjust.


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The "U" - UNADJUSTED shows that the listed cylinder has not been adjusted. The "A" - ADJUSTEDshows that the listed cylinder has been adjusted and data saved. Select the cylinder to adjust and thenext screen will come up. Live data will be displayed on the screen.


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The target zone is the area in which you want to keep the peak pressure.

The cylinder balance bar shows where the current cylinder's pressure is relative to the engine average.It also shows the OK band within which you are trying to stay.

The current peak pressure is the actual pressure being measured. This allows reading the pressurewhile adjusting the fuel valve.

The engine average mean peak pressure is the value you are trying to attain on this individual cylinder.

If adjusting another cylinder, the next screen in the "ADJUST CYLINDER" mode is the cylinderselection list and will indicate that a cylinder has been adjusted. Select the cylinder to adjust bypressing the "UP or DOWN Arrow" keys to highlight the cylinder and then press the "ENTER" key.

"U UNADJUSTED""A ADJUSTED"

When finished adjusting the desired cylinders, press the "4-TAKE AS LEFT" key to finish taking a finalset of balance data. Taking "AS LEFT" data is the same as taking "AS FOUND" data. After the lastcylinder is taken the "AS LEFT" report will display.


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If more cylinders are adjusted after the "Take as Left" has been performed, it will be necessary toretake the "AS LEFT" data for all cylinders to get an accurate "AS LEFT REPORT".

5.1.2.2 Restart Balance Run

If a partial balance run is performed and, for any reason, the portable analyzer is turned off (i.e. phone call, dead battery, etc.), when the unit is powered back on, press the 3 key 3-rEstart abalance run to resume the balance run that was in progress.

The next screen in the restart a balance run mode is the ESTIMATE SPEED screen. This functionwill count the number of peak pressures within a measured time and calculate an estimated RPM. Tocontinue, press any key.

Note: The pressure sensor must be attached to the power cylinder and the indicator valvemust be opened to apply pressure. Hit any key when ready.


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The next screen in the restart a balance run mode will appear as below. Hit any key to continue.

The next screen in the restart a balance run mode will appear as below. The program will automaticallysearch 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 beenperformed, the restart a balance run will display the message below. More cylinders can be adjusted.

If more cylinders are adjusted after the Take as Left has been performed, it is necessary toretake the AS LEFT data for all cylinders to get an accurate AS LEFT REPORT.

5.1.2.3 Recall Old Balance Data

The portable analyzer will save all the "AS FOUND" and "AS LEFT" balance runs for each machine. Torecall an existing balance run, on the main menu, press the "4" key or press the "UP or DOWN Arrow"key to highlight the "4-recall Old balance data" and then press the "ENTER" key.


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The next screen in the "recall Old balance data" will appear as below. The message "PICK DAY TOEXTRACT BALANCE DATA" will appear. Press the "UP or DOWN Arrow" keys to highlight the desiredday, then press the "ENTER" key to select.


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The next screen in the "recall Old balance data" will be the "As Found Report" for the day selected. Torecall the "As Left Report", press the "4" key or press the "LEFT or RIGHT Arrow" keys to highlight the4-RECALL AS LEFT" with the HOTBOX, then press the "ENTER" key to select.

5.1.2.4 Power Cylinder Monitor

The "Power Cylinder Monitor" is a stand-alone pressure monitoring utility that can be used to checkindividual cylinders without entering the "Balance engine nonencoder" mode.

When first starting, the engine speed is determined by sampling the pressure curves.

The first screen will tell you to connect the pressuretransducer to a power cylinder and apply pressure. After you hit any key, the estimate speed routine willrun. This function will count the number of pressurepeaks within a measured time frame and calculatean estimated RPM.

Note: The pressure sensor must be attached to channel one.

This will take 10 seconds. If the estimated speed is not close to the known speed, you need to goback and adjust the debounce factor and trigger level in ENGINE SETUP.


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Note: The pressure sensor must be attached to the power cylinder and the indicator valvemust be opened to apply pressure.


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The next screen in the "Power Cylinder Monitor" mode will display the live data collection. This willcontinuously cycle until any key is hit to exit.

There are six menu items with Control keys assigned.

Key Function Response1 Reset Reference to Running

Averagepress to reset the running average bar

4 Increase Cycles press to increase the cycle averages (5 cycle steps)6 Decrease Cycles press to decrease the cycle averages (5 cycle steps)5 Increase Pressure Range press to raise the pressure range of the sample average

bars7 Decrease Pressure Range press to lower the pressure range of the sample average

bars8 Increase SD Range press to raise the standard deviation range

5.1.3 Spark MenuThe Spark Survey mode is used for a detailed evaluation of the condition and integrity of thesecondary ignition system of a spark-ignited (SI) engine.

The Spark Survey Mode is an automated function that allows the user to simply connect the secondaryignition capacitive clip to each spark plug lead and collect all the important parameters of thesecondary ignition signal. Once the user performs the set-up of the machine in the portable analyzerfor each machine the first time, the on-screen menus will instruct the operation of the collection of the


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spark data. When the user is finished collecting the data on each spark plug, the user will have accessto eight reports showing detailed ignition statistical parameters including:

1. Ionization Voltage2. Arc Duration3. Arc Voltage4. Rise Time (Ionization Time)5. Arc Slope6. Ring Down Voltage7. No Arc, Voltage Problems8. Arc Flyback

The major benefits of the Spark Survey Mode is to allow any individual to collect spark data quicklyand have intuitive information about the secondary ignition system. This reduces the need for anignition specialist to analyze the detailed secondary spark traces. With the computer performing all thevoltage measurements automatically on each parameter, this feature saves the time of having tomanually record these parameters. The analyzer will store these reports in memory for recalling oldspark surveys and trending of the secondary ignition system data.

The spark survey function is designed to perform one spark survey per machine per day. Every timethe "1 Take spark survey" is selected, it initiates a spark survey run and a new run number. You canbring up any report run for the day by run number.

From the Spark Menu, select one of the options listed.

Key Function1 Start a secondary ignition survey2 To resume the spark survey that is in progress3 Recall saved data for display and reporting4 Jump to the oscilloscope mode for continuous display of a single point5 Return to previous menu


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5.1.3.1 Spark Survey

The first screen in the ignition survey mode is the "START IGNITION SURVEY" screen. Press any keyto continue.

The next screen in the spark survey mode will display the message "Set number of cycles to collect".The number of cycles can be set from 10 to 250 by pressing the "UP or DOWN Arrow" keys (one stepat a time) or the "UP or DOWN TAB" keys (five steps at a time). When the desired number of cycles ishighlighted, press the "ENTER" key to select.


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The next screen in the spark survey mode will display the message "Pick cylinder to collect data". Thedesired spark plug can be selected by pressing the "UP or DOWN Arrow" keys (one step at a time), orthe "UP or DOWN TAB" keys (five steps at a time). When the desired spark plug is highlighted, pressthe "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"


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The next screen in the spark survey mode will display the message "Hit enter to take data". Pressingthe "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 beforeproceeding. Press the "ENTER" key when ready.

Note: The spark plug selection can be changed on this screen by pressing the "UP orDOWN Arrow" keys to highlight "Chan 1 > L1 Side", then pressing the "RIGHT orLEFT Arrow" keys to select the desired spark plug.

Note: The loadstep selection can be changed on this screen by pressing the "UP or DOWNArrow" keys to highlight "Current loadstep > 1", then pressing the "RIGHT or LEFTArrow" keys to select the desired loadstep.


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Live data collection screen

Below are explanations of the values shown on the plot:

Negative Pulling The voltage is pulled negative with reference to ground.This is the normal polarity of a secondary circuit. This means the current is going from the sparkplug's center electrode to the ground electrode.

Positive Pulling The voltage and current is going from negative to positive.This is reverse polarity of a secondary circuit. This means the current is going from the groundelectrode to the spark plug's center electrode.

Ionization Voltage The voltage level reached to ionize the gas molecules in the spark gap (5-20 KV)

Rise Time The time required to ionize the spark gap (8-40 Us)

Arc Duration The time duration the actual arc occurs

Arc Voltage The voltage level across the spark gap during the arc

Slope The slope of the arc duration (Flat, Positive, Negative)


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In the spark survey mode, live data collection screen, the Time Scale (Micro-seconds) and/or theVoltage Scale (Kilovolts) can be changed at any time during the data sample.

To change the time scale, press the "0" key. The time scale will toggle through the availablescales each time the "0" key is pressed.

To change the voltage scale, press the "1" key. The voltage scale will toggle through theavailable scales each time the "1" key is pressed.

Following the live data collection screen, the screen will return to the pick cylinder list. Continuecollecting data for all the spark plugs with a question mark "?"


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When the final spark plug is finished with live data collection, the message will pop up, "Finishedcollecting spark survey, Hit any key to continue"

The next screen in the spark survey mode is the "Ionization Voltage Report". The values shown arederived from the portion of the spark example trace shown to the right in the square box.


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Menu "Hot Box" Keys

The menu section of the "Ignition Survey Reports" has many menu options.

0-Options: To select "0-Options", press the "0" key or press the "LEFT orRIGHT Arrow" keys to highlight with the "HOTBOX", then press the"ENTER" key. The option menu selection pops up a screen as abovefor selecting the following options:

"0- CHANGE KV MAXIMUM". This is for changing the maximumkilo-volt scale on the statistical bar graph.

"1-CHANGE KV PERCENT BAND". This is for changing the plus andminus percent bands on the spark plug statistical bars.

"2-CHANGE KV MINIMUM". This is for changing the minimumkilo-volt scale on the statistical bar graph.

2-Report Type: To select "2-Report Type", press the "2" key or press the "LEFT orRIGHT Arrow" keys to highlight with the "HOTBOX", then press the"ENTER" key. The option menu selection pops up a screen as abovefor selecting the following options: To select, press the associatednumber key or highlight and press the "ENTER" key.

Note: Report definitions are further described in the next section. Each report can be viewed and printed as necessary.

3-Restart: To select "3-Restart", press the "3" key or press the "LEFT or RIGHTArrow" keys to highlight with the "HOTBOX", then press the "ENTER"key. The next screen will display the message "PICK DAY TOEXTRACT SPARK DATA". Highlight the desired day and press the"ENTER" key.

5-Single Sample: To select "5-Single Sample", press the "5" key or press the "LEFT orRIGHT Arrow" keys to highlight with the "HOTBOX", then press the"ENTER" key.

The next screen will display a single sample of the spark plugsecondary trace. Pressing the "5" key or the "ENTER" key will takeanother single sample.

Note: Single samples are for troubleshooting purposes and will not affect statistical reports.


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7-Print: To select "7-PRINT", press the "7" key or press the "LEFT or RIGHTArrow" 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 portableanalyzer.

9-Exit: Press the "9" key or press the "LEFT or RIGHT Arrow" keys tohighlight the "9-EXIT" with the HOTBOX. Then press the "ENTER"key to select.

5.1.3.2 Ignition Survey Report Definitions

The following report descriptions give the details of what is displayed and the meanings of the values.

Ionization Voltage The voltage level required to ionize the compressed air/fuel molecules within thegap of the spark plug. This is also referred to as the ignition breakdown voltage. Ionization refers to thesplitting apart of the molecules to enable a current path for arcing of the spark plug. Higher ionizationvoltages produce a higher rise time.The typical units are in Kilo-Volts (Kv).

In a controlled environment:

1. 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 over20,000 indicating wide gaps and a greater potential for external flashover.

Note: In a non-controlled environment, the air/fuel ratio and mixture consistency can affect the ionization voltage level from cycle-to-cycle measurements.

4. This voltage should go negative (-) with respect to ground if the secondary circuit is wiredproperly. If the voltage is going positive (+) with respect to ground, this is referred to asreverse polarity and indicates the wiring to the coil is reversed and may result in shorterspark plug life.

Arc Duration The measured time period the actual arcing of the spark plug occurs. This is the timemeasured between ionization voltage (breakdown) and the beginning of the ring-down voltage. The arcduration is inversely proportional to the ionization voltage and rise time. The typical units are inmicro-seconds (uS)


1. The wider the spark plug gap, the shorter the arc duration.

2. The narrower the spark plug gap, the longer the arc duration.

3. Typical arc duration measurements will range from 125 micro-seconds to 700micro-seconds for different ignition systems. When measured times reduce, this indicateswidening gap and/or excessive ionization voltage requirements. As measured timesincrease, this indicates a narrow gap and/or an incorrect measurement due to a lowring-down voltage level.


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Arc Voltage The voltage level required to maintain the arcing of the spark plug gap. This is thevoltage measured between the zero reference line and the arc duration level. This voltage is typicallyless 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 gapof the spark plug. This is also referred to as the ionization time. Ionization refers to the splitting apart ofthe molecules to enable a current path for arcing of the spark plug. The rise time increases with anincrease in the ionization voltage. The typical units are in micro-seconds (uS)


1. The wider the spark plug gap, the more time required to ionize the gap.

2. The narrower the spark plug gap, the less less required to ionize the gap.

3. Typical rise time measurements will range from 5 to 50 micro seconds (uS). With rise timesover 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 thevoltage 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 voltageand 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 voltageand 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 ofthe plug gap.

Ring Down Voltage The measured peak voltage of the ring down oscillation of the coil. This is alsoreferred to as coil oscillation and/or unused energy. This is the energy remaining after the spark plugarc demands cannot be maintained. The typical units are in volts peak. Anything that affects the R-Ctime constant affects the amplitude and frequency of the ring down oscillations. A lack of ring downtypically indicates a poor plug wire connection in the coil tower.

No Arc, Voltage Problems Report This report identifies problems with spark plugs and/or othersecondary 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 theionization ramp. Please refer to the report for detailed description of the problem.

5.1.3.3 Restart Spark Survey

If a partial spark survey is performed and, for any reason, the portable analyzer is turned off (i.e phone call, dead battery, etc.), when the unit is powered back on, press the 2 key 2-rEstart sparksurvey to resume the spark survey that was in progress.


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The next screen in the restart spark survey mode is the TO RESTART IGNITION SURVEY screen.To continue, press any key.

The next screen in the restart spark survey mode is the RESTART OF DATA COLLECTION FORSPARK SURVEY screen. To continue, press any key.

The next screen in the restart spark survey mode is the Pick cylinder to collect data screen. Thespark plugs that have data will have an asterisk (*), and the spark plugs the need data will have aquestion mark (?). Select the desired spark plug by highlighting to continue the data collection process.

At this point, continue on as normal during a spark survey.


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5.1.3.4 Recall Spark Survey

The portable analyzer will save all the "Spark Surveys" for each machine. To recall an existing sparksurvey, on the main spark menu, press the "3" key or press the "UP or DOWN Arrow" key to highlightthe "3 recall Old spark survey". Then press the "ENTER" key. A popup box will display all dates fordata taken and stored on the analyzer. Use the up / down arrow keys to highlight the date to view andpress the ENTER key.

The next screen will be the "Arc Duration Report" for the desired day. From this screen, the menuoptions are the same as when the data was taken. See the section on spark survey for more details.

Encoder-based Balance 55

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6 Encoder-based Balance

6.1 Special Collection Modes

This menu allows access toseveral special modes for theanalyzer. With these modes,several detail functions may beaccomplished that arenon-crankangle related.

Spark trace mode: This function is used to collect and display ignition data. See thefollowing sections for a complete description of the functionsavailable.

Balancer menu: This is a submenu with two main functions for balancing an engineusing peak firing pressure and ignition survey mode to look at ignitionsystem details.


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6.2 SparkThe Spark module is used to observe the waveform and voltage levels of the secondary ignitiontraces. When the Spark program is started, the user is shown 3 options:

NEW SCAN: Take new data.

PLOT OLD DATA: Recall stored data.

EXIT PROGRAM: Return to the menu.

Encoder-based Balance 57

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Selecting "NEW SCAN" brings up the following sample screen and has several menu options.

While in the Spark trace window, the cursor is active and is moved with the TAB and arrow keys.

Key Function1 To zoom in on the signal, set the cursor to the left side and press 1. The

zoom will then occur. To restore the original, press 1 a third time.2 To resample the signal.3 To change run number.

4, ESC Return to the setup menu5 Turn on autoscan to sample the signal continuously.6 This option will overlay six consecutive traces, then clear the screen and

repeat another six traces.7 To store the trace.8 To print the display to a printer if setup and connected.9 Toggle the grid off/on.


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Select 4-Menu brings up the following screen.

Step Size: This is a fixed field and is shown only for information. It is the time betweendigitized samples.

Count: This is the number of digitized samples that are taken for a trace. For a longerview select, increase this number. For multi-strike systems, inc

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63X0 CA Manual

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