6320 CA Manual

Portable Analyzer
CA Operations
Manual
Windrock, Inc. 2013
3/1/2013
Legal Notices
Copyright
1997-2013 by Windrock Incorporated, All rights reserved.
No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated
into any language in any form by any means without the written permission of Windrock, Incorporated.
Software and Firmware License Notice
Your license agreement with Windrock, Incorporated, authorizes the number of copies which can be made and
the computer systems on which they may be used. Any unauthorized duplication or use of Windrock software or
firmware in whole or in part, in print, or in any other storage and retrieval system, is forbidden.
Disclaimer
This manual is provided for informational purposes. Windrock, Incorporated, makes no warranty of any kind with
regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a
particular purpose. Windrock, Incorporated shall not be liable for errors, omissions, or inconsistencies which may
be contained herein or for incidental or consequential damages in connection with the furnishing, performance, or
use of this material. Information in this document is subject to change without notice and does not represent a
commitment on the part of Windrock, Incorporated. Any software described in this document is furnished under a
license agreement or nondisclosure agreement. The software may be used or copied only in accordance with the
terms of the agreement.
Portable Analyzer CA Operations Manual
If you have comments about this documentation, the software, or products it describes, please contact the
Customer Support Group at Windrock.
Contents
Table of Contents
1
Part I Customer Information
1 Introduction ................................................................................................................................... 1
2 Customer Assistance
................................................................................................................................... 1
3 Returning Items
................................................................................................................................... 2
4 Handling Precautions
................................................................................................................................... 3
5 Warnings
................................................................................................................................... 4
Part II Read This First
1 Special Terms................................................................................................................................... 5
2 Care
................................................................................................................................... 5
3 Unpacking
................................................................................................................................... 5
4 Batteries & Charging

................................................................................................................................... 6
Batteries
E-Moli
Charger
..........................................................................................................................................................
.........................................................................................................................................................
..........................................................................................................................................................
Part III Getting Started
6
7
8
10
1 Connections................................................................................................................................... 10
2 Keypad Functions
................................................................................................................................... 13
3 Hardware Configuration
................................................................................................................................... 13
4 Stations & Machines
................................................................................................................................... 15
Station & Machine
..........................................................................................................................................................
Setup
Part IV Machine Setup, 63X0/CA with encoder only
16
18
1 Setting Up a ...................................................................................................................................
Machine, 63X0/CA with encoder only
18
Machine Setup
..........................................................................................................................................................
Menu
Part V Balancer/Spark Setup and Data Collection

1 Overview
18
20
................................................................................................................................... 20
Setup
..........................................................................................................................................................
Engine Balance
..........................................................................................................................................................
Engine Balancer
.........................................................................................................................................................
- Non encoder
Restart Balance
.........................................................................................................................................................
Run
Recall Old.........................................................................................................................................................
Balance Data
Power Cylinder
.........................................................................................................................................................
Monitor
Spark Menu ..........................................................................................................................................................
Spark Survey
.........................................................................................................................................................
Ignition Survey
.........................................................................................................................................................
Report Definitions
Restart Spark
.........................................................................................................................................................
Survey
Recall Spark
.........................................................................................................................................................
Survey
Part VI Encoder-based Balance
21
26
26
36
37
39
41
43
50
51
53
54
1 Special Collection
...................................................................................................................................
Modes
54
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II

2 Spark
................................................................................................................................... 55
58
Part VII Utility Menu Options
1 Direct Channel
...................................................................................................................................
Read
58
2 Power Cylinder
...................................................................................................................................
Monitor
60
61
Part VIII Encoder Setup
1 Shaft Encoder
................................................................................................................................... 61
2 Multi-Event ................................................................................................................................... 62
3 Magnetic Pickup
................................................................................................................................... 63
4 Timing Light................................................................................................................................... 63
64
Part IX Loading New Software
1 Windows Install
...................................................................................................................................
6310 only
64
2 Windows Install
...................................................................................................................................
6320 only
64
65
Part X Operating System Commands
1 Machine Template
...................................................................................................................................
6310 only
65
2 Setting Time...................................................................................................................................
and Date 6310 only
65
3 Set Date, Time
...................................................................................................................................
or Time Zone 6320 only
66
4 Printing 6310................................................................................................................................... 66
5 Printing 6320................................................................................................................................... 69
71
Part XI Appendix
1 Data Collection
...................................................................................................................................
Techniques
71
2 Class 1, Div 2
...................................................................................................................................
Information
71
Hazardous Location
..........................................................................................................................................................
Information
Control Drawing
..........................................................................................................................................................
3 Sensors
71
73
................................................................................................................................... 74
Magnetic Pickup
..........................................................................................................................................................
Secondary Ignition
..........................................................................................................................................................
Sensor
Water Cooled..........................................................................................................................................................
Pressure Sensor
75
77
78
4 Specifications
...................................................................................................................................
- 6310/CA
78
5 Specifications
...................................................................................................................................
- 6320/CA
79
6 Specifications
...................................................................................................................................
- Sensors
81
Part XII Glossary of Terms

Index
82
89
Windrock, Inc. 2013
Customer Information
1.1
Introduction
Portable Analyzer Manual

The following sections briefly summarize the functions you will use to set up and operate your
portable CA analyzer by Windrock, Inc. This help version is 4.0.
Data storage and machine setups are stored locally to the analyzer thus no host PC is required.
Data stored within the analyzer can be directly backed up to such devices as zip drives if your
analyzer is a 6310 or to a flash drive for the 6320.
Special Emphasis
These conventions are used throughout this manual to call attention to adjacent text:
Note:
A note indicates special comments or instructions.
Caution! A caution indicates actions that may have a major impact on the hardware,
software, database files, etc.
Warning! A warning indication a condition which has severe impact on hardware, or

safety.
Prerequisites
The manual is written with the assumption that you are familiar with the basic operation of a
personal computer and is not intended to be a substitute for the documentation supplied with a
computer or software.
If you are unfamiliar with a personal computer or peripheral hardware, Windrock strongly
recommends review of the appropriate documentation before using the analyzer and software.
1.2
Customer Assistance
Direct any questions you may have about the product you have purchased to Windrock's Product
Support department at (865) 330-1100 Ext. 1114
Hardware
1. Please have the serial number of your analyzer available when you call. The serial number is
located either on the back of the analyzer and/or on the sliding battery door.
2. If you have a problem, explain the exact nature of your problem. For example, what are the
error messages? When do they occur? What you were doing when the problem occurred. For
example, what mode were you in? What steps did you go through? Try to determine before
you call whether the problem is repeatable.
Software
1. Please have the number of the current version of your software ready when you call. The
version of the software appears at the top of the main menu screen.
2. If you have a problem, explain the exact nature of your problem. For example, what are the
error messages? When do they occur? What you were doing when the problem occurred. For
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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 authorization number.
Please write it clearly and prominently on the outside of the shipping container.
2. Please enclose a letter that describes the reason(s) you are returning the item.
3. Insure your package for return shipment. Shipping costs and any losses during shipment are
your responsibility. COD packages cannot be accepted and will be returned unopened.
For Credit
1. Call Product Support at (865) 330-1100 Ext. 1114 to obtain a return authorization number.
Please write it clearly and prominently on the outside of the shipping container.
2. Return all accessories originally shipped with the item(s). Include cables, software diskettes,
manuals, etc.
3. Enclose a note that describes the reason(s) you are returning the item(s) for credit.
4. Insure your package for return shipment. Shipping costs and any losses during shipment are
your responsibility. COD packages cannot be accepted and will be returned unopened.
Hardware Repair
Windrock repairs its hardware products free for one year from the date of shipment. This service
warranty includes minor hardware improvement, modification, correction, re-calibration, updates,
and maintenance for normal wear. This service warranty excludes repair of damage from misuse,
abuse, neglect, carelessness, or modification performed by anyone other than Windrock.
Windrock automatically sends updated manuals on the software update CDROM in electronic
format to all customers who are under warranty.
After the one year service warranty expires, each return of a Windrock hardware product is subject
to a minimum service fee. If the cost of repair exceeds this minimum fee, we will call you with an
estimate before performing any work. Contact Product Support for information concerning the
current rates.
Refer to the Warranty section of the Terms and Conditions section of this manual for a complete
description of your warranty.
Extended Service Plan
Windrock offers Extended Service Plans (ESP) on analyzer equipment. Software benefits include
program corrections and improvements, modifications, manual revisions and telephone
assistance. Hardware benefits cover malfunctions due to normal wear, annual calibration, and
updates. Contact (865) 330-1100 Ext. 1117 for information concerning the current cost of
Extended Service Plans.
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1.4
Handling Precautions
STATIC ELECTRICITY
The CMOS integrated circuits in the analyzer can be damaged by exposure to electrostatic
discharges.
LITHIUM-ION BATTERIES
The analyzer contains a Lithium-ion cell pack which can create a fire or explosion hazard if
improperly handled.
Do not expose battery to temperatures in excess of 100 degrees Celsius or dispose of in fire.
Do not attempt to charge pack with a charger other than specified or modify battery-related circuitry
on the analyzer.
Do not short circuit battery.
Dispose of properly - do not throw away in the trash (please recycle to help the environment).
LOOSE CLOTHING AND LONG HAIR (MOVING PARTS)
Be careful not to get hands, hair, or clothes near any moving parts such as fan blades, belts, pulleys,
or fly wheels. Never wear neckties or loose clothing when working around machinery.
ElectroMagnetic Interference (EMI)
Do not attempt repairs on the analyzer. Any loosening of the exterior metal case may damage the
EMI protection of the case and interconnecting pieces.
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1.5
Warnings
Caution!
The pressure sensor used with this kit may become hot when used on
either an engine, compressor, or any related piping. The sensor, when
hot, may cause severe burns to the hands or other body parts that come
in contact with the hot surface. Use precautions such as insulated gloves
to handle the sensor.
When using the water cooled pressure sensor, the water used for cooling
may become hot and cause scalding. Use precaution when handling the
sensor to prevent the hot water from contacting the skin.
Caution!
The shaft encoder that may be included with this kit comes in contact with
a rotating element. Keep all clothing and hair away from the rotating parts
as they may become tangled with the rotating parts and cause severe
injury or death.
Keep hands away from the rotating equipment at all times to prevent
injury.
Caution!
The timing light that may be included with this kit may be used near
rotating elements. Keep all clothing and hair away from the rotating parts
as they may become tangled with the rotating parts and cause severe
injury or death.
Keep hands away from the rotating equipment at all times to prevent
injury.
Caution!
Several cables are used with the analyzer and shaft encoder that may be
used near rotating element. Keep all clothing and hair away from the
rotating parts as they may become tangled with the rotating parts and
cause severe injury or death.
Keep hands and cables away from the rotating equipment at all times to
prevent injury. Be aware of the trip hazard cables on the floor can create.
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Read This First
Read This First
2.1
Special Terms
6310 / 6320 Analyzer

Portable data collection instrument or analyzer.
Shaft Encoder
Device used to convert crankshaft position into electrical impulses.
Parallel Port
Printer and communications link between the analyzer and host computer.
Transducer / Sensor
Device used to convert mechanical measurements into electrical signals.
USB
Universal Serial Bus
VGA
Video Graphics Array or common computer color monitor type.
2.2
Care
Use only a damp rag with a mild soap to clean the surfaces. Strong degreaser and other chemicals
may damage the keypad and clear display window.
2.3
Unpacking
Check to verify the following items are in the instrument case upon arrival.
PARTS LIST (Standard Package)

Part
Analyzer
Battery/Batteries
Battery Charger
Carrying Case with Cut Foam
USB Communications Cable
Leather Case (on analyzer)
Carry Strap
DC Pressure Cable
DC Pressure Sensor (High Temp)
Manual
Software CD-ROM
Secondary Ignition Pickup
6320
A6320-00/CA
A6301-02
A6312-00
MP630030-00
A6306-03-00
A6304-01
A6305-00
A6060-00-08
A6082-XX-01
A6310-00-M/CA
A6310-00-SW/CA
A6030-01-06
Other parts may be present depending on the options selected and/or purchased.
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Note:
2.4
6310 only. A battery is typically shipped in the analyzer. Under normal circumstances, a
battery should be kept in the analyzer when not in use. Having a battery in the unit will help
keep the internal CPU's CMOS coin cell charged and the operating configuration
parameters intact for many years. Leaving the battery out of the unit may shorten the life
of this coin cell requiring replacement and loss of the operating configuration parameters.
Batteries & Charging

General Battery Care information.
The analyzer kit contains one or more of the pictured batteries and charger shown below.
E-Moli Li-ion
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.
Windrock, Inc. 2013
Read This First

Note:
6310 only. A battery is typically shipped in the analyzer. Under normal circumstances, a
battery should be kept in the analyzer when not in use. Having a battery in the unit will help
keep the internal CPU's CMOS coin cell charged and the operating configuration
parameters intact for many years. Leaving the battery out of the unit may shorten the life
of this coin cell requiring replacement and loss of the operating configuration parameters.
Wipe the metal terminals with a soft, dry cloth if they become dirty.
Safety Precautions for the Batteries
Do not disassemble or attempt to open the battery under any circumstances.
The battery can explode, leak or catch fire if heated or exposed to fire or high temperatures. Do not
short circuit the battery by directly connecting the metal terminals (+,-). Be certain that no metal
objects such as coins, paper clips, etc., touch the terminals.
Only use the charger recommended by the device manufacturer.
To Avoid Damage to Battery
Do not drop battery or subject it to mechanical shock.
Use battery only with equipment that specifies its use.
Recycling Information
Windrock is committed to environmental responsibility and would like our customers to recycle this
battery. For instructions on how to recycle this battery, call your local battery recycler.
2.4.1.1
E-Moli
LITHIUM-ION STYLE BATTERY
You may identify the Lithium-Ion battery by the all black case and the "MOLICEL" logo on the top.
These batteries are Smart Technology batteries. There is a capacity bar on the right and is activated
by pressing the ON/OFF or RED button. The Li-ion battery is lighter in weight and higher in capacity.
Caution!
Do not attempt to charge the Li-ion battery in a non-Li-ion charger (use only
the EnergyAccess charger supplied). There is a great potential for the
battery to EXPLODE. Use only a charger specified for this type of battery.
A battery may become deactivated and go into the "off state". This means that the battery will not work
until it is turned on. To do this, insert the battery into the left charger bay and press the "Re-calibrate"
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button and let the battery sit for 15 to 20 seconds. Remove the battery and place it in the right side of
the charger and let charge fully. It should then operate correctly.
2.4.2
Charger
Lithium-ion Battery Charger (Energy Access)
Newer units shipped are supplied with one or more Lithium-ion batteries. These are the latest high
capacity lightweight batteries available. They also have a special charger made just for Lithium-ion
batteries.
Caution! Use of other charger may result in an explosion.

To use the Energy Access battery charger, plug the power supply (use the power supply - PS2524
only) into an outlet (100VAC - 240VAC/50-60Hz) and insert plug end of the power cable into the DC
power jack on the charger. Insert a battery in one of the two bays. The LED will illuminate to indicate
the status of the battery as follows:
Off:
Green Flash:
Green Solid:
Yellow Flash:
Yellow/Green:
Yellow Solid:
Red Flash:
No battery detected
Fast charging
Fully charged
Re-calibrating
Re-calibrated
Standby
Error
Caution! Connection other than indicated may result in permanent damage to the
unit.
Re-calibration:
SMBus Smart Batteries contain a microchip that monitors battery usage and tracks how much
capacity is available from the pack. It is possible for this process to accumulate errors due to
temperature fluctuations, aging, self-discharge, and other factors.
To keep the internal information as accurate as possible, it is occasionally necessary to run the
pack through the calibration cycle. This involves fully charging the pack, completely discharging it,
and then recharging it again. The charger performs these steps automatically when a calibration
is initiated.
To calibrate a pack, place it in the left bay and push the red (or blue) arrow located between the
bays. This process can take 16 hours. Some packs do not have the capability to be re-calibrated.
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Read This First

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:
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Level 3
3.0 Amps
Sequential
3 hours each
SMBus 12v@1.2A
9 hours
9.5 oz
ABS GSM
Black
4.89 x 6.89 x 2.02
124 x 175 x 50
10
Getting Started
3.1
Connections
6310 Only
Several connections are provided on the portable analyzer unit. See the figures below for placement
of the connections. Looking at the rear panel to the far left, a connector labeled "KBD" is used for
attachment of an external PS2 style keyboard. If a PS2 style keyboard is not available, a standard PC
keyboard may be used, but the number pad on the right of a large keyboard is not supported (Num
Lock will do nothing). The connector on older style keyboards is a 5-pin DIN style and an adapter will
be needed. These are available at most office supply or computer retailers. You may also contact
Windrock, Inc. to purchase this adapter.
6320 Only
A standard USB keyboard may be used by connecting it to the USB port found on the left side of the
analyzer.
Caution!
Do not connect the external keyboard while near engine ignition systems.
This may damage both the keyboard and the portable analyzer.
Next, there are two round "Lemo" transducer input connectors. These connectors are for the
transducers and shaft (crank-angle) encoder which may be provided in the portable analyzer kit.
The connector labeled "ANT" is for an optional wireless receiver antenna.
Caution!
Do not over-tighten the antenna. The antenna only needs to be finger tight.
There is potential to break the connector by over-tightening.
On the far right, an external AC-adapter connector is provided for use with the supplied charger power
pack. You may unplug the power pack from the charger base and plug it directly into the portable
analyzer. This will provide sufficient power to leave the instrument on for reviewing stored data without
using up the battery.
Caution!
Make sure to keep a battery in the analyzer when using the external power
adapter.
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Getting Started
11
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 USB
port, and both have an external VGA color monitor connection located together on the left side of the
analyzer behind the sliding door. A USB keyboard may be connected here on the 6320 analyzer.
A standard VGA / SVGA monitor may be connected to the portable analyzer for larger desktop screen
viewing. The operating software is set for 640 x 480 pixels of resolution. There are no settings to
change this resolution for different monitor types. However, both color and B&W are supported.
Please see the chapter on Utility Menu Options for use of the 25 pin parallel port for file transfer to
Windows and Operating System Commands chapter on Printing from the parallel port of your 6310.
For information on printing from the 6320, see the chapter on Operating System Commands, Printing
6320.
The 6310 and 6320 battery compartment is located on the right side of the analyzer behind the sliding
door. The battery compartment has a spring located in the bottom to pop the battery out when the
door is open. The battery will have to be pushed in and held while closing the sliding door. This may
be tight and is normal operation.
Note:
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The sliding doors on the sides are provided to protect against EMI when around ignition
systems. The doors should remain closed while operating.
12
Windrock, Inc. 2013
Getting Started
3.2
13
Keypad Functions
The escape key operates as a cancel function and gives the user the ability to
back up one step or menu. If you are in an operation that may cause data loss
(setup screens), a warning is given for user acknowledgment.
ESC
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. (Special
note: The HOME key is also used to bring up a list of alphabetic characters for
text entry when a keyboard is not available)
p q Used to move the cursor up and down for selections.

t
u Used to move the cursor right and left and increment and decrement numeric
entries. The right arrow is also used to bring up pop-up list selections on certain
data entry fields.
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.
Numeric Enters the numeric character in data entry fields and provides short cut
menu/function selections. If the user is on a menu screen, simply pressing the
Keys
number associated with the option will execute the option.
Note:
3.3
If the entry screen has multiple lines requiring duplicate entries, you can press the
"ENTER" key and all the data from the previous line will be transferred to the new
line. For example, each cylinder's bore, stroke, and connecting rod length may be
copied from line to line since they may all be of the same values.
Hardware Configuration
Before using the analyzer, take the time to become familiar with the basic operation and set up. There
are a number of options, setup entries, and keystrokes with which you should be familiar prior to taking
your first set of data.
When you first receive your analyzer and turn it on, you will be in a "Windrock Test Station" and "Test
Machine" area. However, prior to your data collection, you must first set up your own stations and
machines in the database. Subsequently, when the analyzer is turned on, you will be positioned at the
menu for the last used station and machine. This enables you to power down the analyzer to
exchange batteries and power back up to the current machine and station. From this menu, you can
select a new machine or station by pressing "ESC" once or twice, respectively.
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14

Note:
The "Windrock Test Station" and "Test Machine" should not be deleted or used for data
storage. This area is set up for initial and subsequent calibration of the analyzer.
There are basic configuration parameters that may be set on the analyzer to optimize the operation for
your needs located in the Hardware Configuration option of the Station Selection Menu.
Use backlight:
Typically set to YES. Setting to NO will turn off the LCD back light
and the screen image may be hard to see - this mode conserves
battery power.
Monitor type:
Typically set to LCD for black and white units, Color1 or Color2 for
color units or when an external VGA monitor is used. B&W can be
used to improve contrast in some cases.
Use power save:
Typically set to NO. If set to no, the processor runs at full speed
and the back light will not turn off after one minute.
Caution!
Power can be shut off to the encoder when in power save mode and the
user returns to a menu screen. It is possible to lose the phase setting
(exhaust vs. compression cycle) of the encoder when collecting data on
a 4-stroke engine. You must check the phase before continuing with
data collection if this occurs.
Use blinking:
Typically set to YES. You may prefer to not have the cursor bar
blink. If so, set this option to NO.
Screen width:
Typically set to 40 column.
Text Cursor Style:
The style of the cursor may be changed between ARROW, BAR,
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Getting Started
15
or BOX.
Peak pressure only:
This is set to YES for a CA Lite and NO for a CA with encoder

option and want to configure the analyzer to make crank-angle
based measurements (IHP, peak angle, ignition timing).
Autoscan first in take data:
This option controls how the data collection process runs. When
set to YES, entering the data collection process will automatically
start the analyzer auto scanning data and update the screen with
each collection of data until the 3 key [STOP AUTOSCAN] is
pressed. Once the auto scan is stopped, the user is prompted to
save the latest data capture. The data collection process then
continues to collect the statistical data and display it.
Use unit conversion:
NO uses the default standard units that have always been

available. Setting to YES will allow selecting from different
conversion groups (see "Unit group" below).
Unit group:
Allows selecting either Standard or Metric Units.
DC Sensor correction:
Set to Zero Only for zero only balancing of the pressure sensor in
the CA mode. There is no zero function available in the CA (LITE)
mode.
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 to

the computer after setups have changed in the analyzer.
The analyzer contains a status line at the bottom of the display. This line contains information about
the battery capacity and the date and time. The battery capacity is monitored when the unit is
operating from the battery. If the unit is on AC power, the status line will add "Using AC" to the battery
voltage value. If the battery capacity drops to approximately 9 volts, a warning will be displayed and
the analyzer will automatically turn off.
Caution!
3.4
When the battery goes below 10.0V, save the current data and change
the battery. Any data stored up to this point is safe. Only data that is
currently being collected and displayed or setup information currently
being entered could be lost.
Stations & Machines

Stations and Machines are laid out in a tree structure. The first level in the tree structure is the Station
list. There are from 0 to 199 folders (starting with a 0 base) and each folder contains a station. Within
each Station, there contains from 0 to 199 machines (starting with a 0 base). Within each Machine,
there resides the setup files and crank angle related data collected files.
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16

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 and
can be easily accessed. This structure is automatically created by the software.
3.4.1
Station & Machine Setup

The first steps in setting up a new station and machine are described in the following steps.
Note:
This must be done prior to being able to duplicate (copy) a previous setup from another
station/machine. See the section on machine database in the Win63X0 manual for
copying setups. This section applies to all 63X0/CA models.
Station Selection Menu
From the "Machine Menu", press
"ESC" twice to return to the "Station
Selection Menu".
Select "2-Manage or a station".
Enter a station name of up to 30
characters followed by pressing
"ENTER".
You will be returned back to the
"Station Selection Menu".
Select "1-Select a station" and pick
the new station you just added from
the list.
Caution!
If you are a Win63X0 software user, make sure the name entered is not altered
without also changing the Windows database. In order to connect Windows to
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Getting Started
17
the portable analyzer, these names must match exactly (character and case) or
a connection will not be allowed.
Machine Selection Menu
You will now be brought to the
"Machine Selection Menu".
Select "2-Manage or add a
machine".
Enter a machine name of up to 30
characters followed by pressing
"ENTER".
You will be returned back to the
"Machine Selection Menu".
Select "1-Select a machine" and
pick the new machine you just
added from the list.
Note: You will need to come
back to this menu to add each
machine you will analyze.
Note:
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If your analyzer is a 63X0/CA non encoder balancer, proceed to the section on

"Balancer/Spark Setup and Data Collection". Skip the "Machine Setup, 63X0/CA
w/encoder" section. If your analyzer is a 63X0/CA w/encoder, proceed to the section on
"Machine Setup, 63X0/CA plus encoder". After following those instructions, then proceed
to the section on "Balancer/Spark Setup and Data Collection".
18
Machine Setup, 63X0/CA with encoder only
4.1
Setting Up a Machine, 63X0/CA with encoder only
4.1.1
Machine Setup Menu

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

Encoder only
You will now be brought to the "Machine
Menu" as shown in the figure.
At this point, you must select "2-Setup
database" to enter all the information
about the machine.
This would include engine & compressor
geometry, points for data collection, gas
composition, etc.
This is the minimum required to collect data with the analyzer. Further customization may be required
to meet your setup needs.
If you find that the names you have entered need to be changed, you may use the "Edit a station
name" and "Edit a machine name" as necessary.
The machine menu is the entry point when turning on the analyzer. At this point, you may take one of
several actions. The menu options are outlined below:
Option 1:
"Data collection menu" is the point where data collection begins after a setup has
been 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 a
desktop computer, battery conditioning, and other helpful items.
Option 8:
"Select different machine" takes the analyzer back one menu level to select a new
machine. The Machine database setup is a set of menu options to configure the
machine's geometry, sensor points, collection points, fixed scaling, calculation, and
other related setup details.
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Machine Setup, 63X0/CA with encoder only
19
The machine configuration data can be

obtained from the manufacturer's data
sheets. Occasionally, not all the
information is available from this source.
It may be necessary to call the
manufacturer to enlist their help with the
missing information. As a last resort,
there are databases that have been
developed that can help you obtain
missing information. When you use this
information, it is up to you to verify the
accuracy.
Below is an outline to setting up the machine database. It is a guide to organizing your data before
continuing. We suggest you gather the required data prior to starting the entry process. This Menu
applies to the /CA with encoder analyzer, but does not apply to the /CA Lite analyzer.
Note:
In the following setup screens, use the left or right arrow keys to select from the choices
available or enter the numeric values as required.
Menu Key Menu Option
Description
Machine Configuration
Number of cylinders, bore, stroke, etc.
Machine Sensor Setup
Define individual sensor points
Collection point / Plot Setup
Setup route for data collection
1 - Point setup
2 - Autoplot setup
3 - Generate default autoplots
4 - Empty autoplots
Arrange groups of sensor points for collection

Arrange groups of sensor points for plotting
Automatically create a default set
Erase all existing autoplots and start over
Fixed Data Scales
Setup predefined scales for display of data.
Not available MA/CA
Does not apply to /CA analyzer
Not available MA/CA
Does not apply to /CA analyzer
Software Configuration
Modify standard defaults for this machine only
Return to machine menu
Returns analyzer to machine menu
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Balancer/Spark Setup and Data Collection

All non-encoder functions must be set up in the analyzer and the set ups transferred to the Win63X0/
CA program.
5.1
Overview
The analyzer will power on to the "Last Station" and the "Last Machine" it was in prior to powering the
unit off. In the case of the /CA Lite, the screen below will be shown after power up.
In the case of the /CA with encoder model, from the power up menu, navigate through the following
menu options to reach the menu shown below:
1.
2.
3.
4.
1 - Data collection menu

4 - Balancer menu
4 - Balancer / Bal & spark menu
2 - Nonencoder balance and spark
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The balancer mode has several menu options from which to choose. It is best to start with the setup
menu first when using the analyzer for the first time on a new unit. After the setup has been completed,
it only needs to be entered to make changes.
5.1.1
Menu Key
Menu Option
Description
Setup balancer / spark
Enter configuration parameters for the program
Balance engine nonencoder
Balance an engine using pressure sensor with out crank

angle position
Restart balance run
Used to start the program after a battery change at the

last cylinder data that was collected
Recall old balance data
Recall data that has been stored on the analyzer from a

previous balance
Spark menu
Enter the spark survey menu
Utilities
A set of analyzer utilities - specifically, connection to the

Windows application software, Win63X0/CA.
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
Setup
Press the "1" key or the "ENTER" key if the menu item is highlighted to select the (1 Setup
balancer/spark)
Every new machine added will have to be set up in the portable analyzer prior to running a peak
pressure balance and/or a spark survey. Once the new machine is set up, the set up information will
remain the same unless changed.
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MAX SENSOR PRESSURE:
Select the desired pressure sensor range (1000, 2000, or

3000 psig @ 20ma) by pressing the "LEFT or RIGHT Arrow"
keys.
NUM POW CYL:
Select the number of power cylinders (1 20) for the machine

by 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 RIGHT
Arrow" 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 filter
should be used when indicator tube detonation is present on
the pressure trace (i.e. IR-KVS, Nordberg).
PERCENT +/- OK BAND:
Select the desired maximum percentage of power cylinder

imbalance (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 pressing

the "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 defaults
to 3 and should work satisfactorily on the majority of
machines. This is the number of consecutive pressures that
must exceed the trigger level (psi) before the peak detector
engages or ends.
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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 30
and should work satisfactorily on the majority of machines.
This is the trigger level that pressure must exceed before the
peak detector is enabled. It is also the level that pressure
must fall below to reset the peak detector. The level is in psi.
It is normally set somewhere between 30-60 psi.
SHOW CURVES:
Select the desired viewing option (NO, YES no pause, YES

with pause, NO pause, NO SD, Pause, NO SD) by pressing
the "LEFT or RIGHT Arrow" keys.
NO When taking data, the peak pressure text data only will
be present on the screen. When finished with the data
sample, it will automatically go to the select cylinder list.
YES no pause When taking data, the peak pressure curves
will be present on the screen. When finished with the data
sample, it will automatically go to the select cylinder list.
YES with pause When taking data, the peak pressure
curves will be present on the screen. When finished with the
data sample, it will be necessary to hit any key to return to the
select cylinder list.
NO pause, NO SD When taking data, the peak pressure
curves will be present on the screen. Standard deviation will
not be displayed. When finished with the data sample, it will
automatically go to the select cylinder list.
Pause, NO SD When taking data, the peak pressure curves
will be present on the screen. Standard deviation will not be
displayed. When finished with the data sample, it will be
necessary to hit any key to return to the select cylinder list.
REDUCED SCALE ON CURVES:
Select the desired scaling option (NO, HALF, 3/8, QUARTER,

5/8, 3/4) by pressing the "LEFT or RIGHT Arrow" keys.
This scaling factor is used for the pressure curves vertical
scale. When set to NO, the vertical pressure scale will be
zero up to the "MAX SENSOR PRESSURE" that has been
selected. Other scale selections will scale to the selected
fraction of the "MAX SENSOR PRESSURE".
# SPARK PER CYLINDER:
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) by

pressing the "LEFT or RIGHT Arrow" keys. Most CD
(capacitor discharge) ignition systems have 500 Us or less
arc durations and the SHORT DURATION can be set to YES.
This will be the default scaling factor while taking data,
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however, this scaling factor can be changed while taking
data.
MULTI STRIKE SPARK:
Select the proper machine spark type (NO, YES) by pressing

the "LEFT or RIGHT Arrow" keys. When using the spark
survey on a multi-strike ignition system, the software will
attempt to analyze the first ignition event of the series.
FAST RAMP TIME:
This is typically set to NO. YES should only be used if

directed so by Windrock Customer Support or Engineering. If
this is set to YES, the Ramp Time will not be shown on the
reports.
PRESS CUTOFF LOW
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.
PRESS CUTOFF HIGH
Select the high pressure cutoff value for the report by

pressing the LEFT or RIGHT Arrow key. The balancer will
report the number of cycles that the peak pressure was above
the high cutoff value.
RECORD PANEL POINTS
Select the PANEL POINT OPTION (NO, YES) by pressing

the LEFT or RIGHT Arrow key. Selecting YES will allow
recording as found and as left panel data including fuel
usage and bsfc values. Selecting NO will deactivate panel
points in collection routine. There are 12 predefined panel
points to choose from, 6 user defined points, and exhaust
temperatures for each cylinder.
FINISHED:
Select the desired option (NO, YES hit enter) by pressing the
"LEFT or RIGHT Arrow" keys. If "YES hit enter", follow by
pressing the "ENTER" key to finish the machine set up, and
return to the initial Balance and Spark Menu screen. If the
RECORD PANEL POINTS option was selected, additional
screens will be displayed to define the panel points to be
selected.
If you hit "ESC", the program will then prompt a "WARNING
Escape was hit - If you have made changes they will be lost.
Save changes? (Y/N)"
If you want to save the set up changes, press the
"HOME-YES" key.
If you do not want to save the set up changes, press the
"END-NO" key.
Pressing the "HOME-YES" key or the "END-NO" key will
return to the initial Balance and Spark Menu screen.
Note:
Every new machine will have to be set up in the portable analyzer prior to running a
Peak Pressure Balance and/or a Spark Survey. Once the new machine is set up, the
set up information will remain the same unless changed.
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If you selected "YES" to "Record Panel Points", the following setup screens will allow you to define
those selections prior to returning to the Spark Menu screen.
Turn individual selections to YES or sequence number by using the "LEFT or RIGHT Arrow" keys if
you want the point added to the panel report. Panel points will show up in the order of their sequence
number. Go to the next page to continue the setup.
Identify the names of the user panel points selected on the previous menu page. The HOME key is
used to bring up a list of alphabetic characters for text entry when a keyboard is not available. Looking
at the rear panel to the far right, a connector labeled "KBD" is used for attachment of an external PS2
style keyboard.
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Est Fuel Savings:
If panel fuel flow is recorded, you may estimate the fuel

savings from the "AS FOUND" readings to the "AS LEFT"
readings by using the "LEFT or RIGHT Arrow" keys to tab to
the correct measurement unit. (YES ft3/min, Yes ft3/hr, Yes
MMft3/day, Yes m3/min, Yes m3/hr, Yes MMm3/day, or No).
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 by
pressing the "ENTER" key to finish the machine set up and
return the 6310/CA to the initial Balance and Spark Menu
screen.
If you hit "ESC", the program will then prompt a "WARNING
Escape was hit - If you have made changes they will be lost.
Save changes? (Y/N)"
If you want to save the set up changes, press the
"HOME-YES" key.
If you do not want to save the set up changes, press the
"END-NO" key.
Pressing the "HOME-YES" key or the "END-NO" key will
return to the initial Balance and Spark Menu screen.
5.1.2
Engine Balance
5.1.2.1
Engine Balancer - Non encoder

This is the option to select when you are ready to balance the engine.
Note:
If "record panel points" is selected in the setup, you will be prompted to record those
readings before taking 'As Found data'.
In taking data, there are three main steps in balancing:

1. Take "AS FOUND" data. This is the engine balance before any adjustments are made. If
record panel points is selected in the setup, you will be prompted to record those readings.
2. Adjust cylinders. This is when the cylinders are adjusted to even out the peak pressures.
3. Take "AS LEFT" data. This is the engine balance after all adjustments are made.
Note:
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.
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The first screen you see will ask you to connect the
pressure transducer to a power cylinder and apply
pressure. After you hit any key, the estimate
speed routine will run. This function will count the
number of pressure peaks within a measured time
frame and calculate an estimated RPM.
Note:
The pressure sensor must be attached to channel one.
This will take 10 seconds. If the estimated speed is not close to the known speed, then you need to
go back and adjust the debounce factor and trigger level in ENGINE SETUP. This speed is reported
on the 'As Found' or 'As Left' reports depending on where you are in the sequence.
Note:
The pressure sensor must be attached to the power cylinder and the indicator valve
must be opened to apply pressure.
After the speed has been estimated,

the starting balancer screen will
appear. Hit any key to go to the "select
number of cycles to take" screen. The
default number is pre-selected. Simply
hit enter to continue. If a different
number of cycles is to be collected,
select it now by using the up / down
arrow keys (for one step at a time) or
the UP or DOWN TAB keys (for five
steps at a time) and pressing enter.
Note: The number of cycles selected
in this screen will be the number
of cycles used in the "AS
FOUND", "Adjust cylinder", and
"AS LEFT" data collection
modes.
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After you have set the number of

cycles, a list of the cylinders will be
shown. Select the first one to start
collecting data.
A '?' represents a point for which data
has not been taken.
A '*' represents a point for which data
has been already taken.
Once the point has been selected, you

are given the option to change the
cylinder selection or the load step before
actually collecting the data. On this
screen, the cylinder selection can be
changed by placing the cursor on the
"Chan 1 >" field and pressing the
right/left arrow keys. The current load
step may also be changed by placing the
cursor on the appropriate field and
pressing the right/left arrow keys.
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As pressure data is collected, the curve and peak pressure are displayed (if the 'Show Curves' option
is set to Yes in the setup) along with the cylinder number as shown in figure below. Once all samples
are collected, the screen will return to the point selection list unless the 'Show curves with pause'
option is selected. If so, the screen will show the curves for viewing until a key is pressed.
The "Pick Cylinder" screen will

appear and the "?" indicator will
change to a "*" showing that the
data has been collected and the
cursor bar will advance to the next
cylinder. Any cylinders with a "?"
still require data to be taken.
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When the last cylinder's data is

collected, the screen will show a
message box with "Finished
collecting as found data, Now adjust
cylinders, Hit any key to continue".
Pressing any key will display the "AS
FOUND" balance report shown below
or Hit the "END/NO" key to resample
the last point.
Below is a sample of an "AS FOUND" report. Once the last cylinder is collected, a screen will pop up
showing the "AS FOUND" balance results. Each cylinder will have the average peak pressure
displayed for that cylinder. If the average pressure is outside the OK band, that cylinder should be
adjusted. After the adjustments are made, take "AS LEFT" pressure data.
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Report Column Explanations

Top Box (Text Information Section)
Power Cylinder Name:
This is the cylinder ID for identification.
Peak Pressure - Mean:
The mean (average) peak firing pressure for each cylinder

based on the number of cycles selected.
Peak Pressure - Diff:
The difference each cylinder's PFP is from the engine average

mean peak pressure.
Peak Pressure - SD:
The standard deviation of the cylinder's peak pressure sample

based on the number of cycles selected.
Peak Pressure - Spread: The cylinder's difference from the high to low peak pressures of
the number of cycles selected.
Center Box (Bar chart statistics section)
Shows the individual cylinder values in bar chart format on the left side.
On the right side is a single bar summing the individual cylinders.
Bottom Box (Individual cylinder balance bars)
This shows the OK band based on the +/-% values
On the right side are the engine parameters: speed, pressure spread, run number, and
load step.
Menu "Hot Box" Keys

The menu section of the "AS FOUND REPORT" has many menu options.
0-Options:
A submenu will pop up with the following selections:
"0- CHANGE PRESSURE MAXIMUM"
This is for changing the maximum pressure

scale on the statistical bar graph.
"1-CHANGE PRESSURE PERCENT

BAND"
This is for changing the plus and minus percent

bands on the cylinder balance bars.
"2-CHANGE PRESSURE MINIMUM"
This is for changing the minimum pressure

scale on the statistical bar graph.
2 - Adjust cylinder
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When you select this, a list of the cylinders pop up. Highlight the
cylinder that you wish to adjust then, when you have the pressure
transducer attached, hit the enter key. A screen will then pop up
continuously showing you the average peak firing pressure for that
32

cylinder. It will also show you the engine average (this will not
change; it is based on the "as found data" or "as left data" only). Use
this screen to adjust the cylinder. When you have finished adjusting
the cylinder, hit any key. You will return to the report showing data for
all the cylinders. The cylinder you have just adjusted will now be
marked with DONE. You can readjust this cylinder if you wish by
selecting it again.
4 - Take As Left
When you have finished adjusting cylinders, hit this option to take the
"AS LEFT" report. You will be indexed again through each cylinder to
take data. When done, the screen will reappear listing the results of
all cylinders. If the balance is OK, you are done. Hit the ESC to exit.
If the balance still looks off, use the 2-Adjust cylinder option again to
adjust the power cylinders. When finished adjusting, take another
"AS LEFT" report. Repeat this cycle until a satisfactory "AS LEFT"
report is obtained, then hit the ESC key to exit. You are now ready to
connect the analyzer to the PC and print your reports.
6 - Est. Speed
This will run the estimate speed routine again. The new speed value
is then displayed and written in the "AS LEFT" report.
7 - Print
If a printer is attached and configured, pressing the "7" key will make
a hard copy of the current screen to the printer. "AS FOUND" and "AS
LEFT" report data can be transferred to a PC running Application
Win63X0/CA software. Printouts can then be made from Windows.
8 - Show hi/lo #
This will change the display and replace the SD and Spread columns
with the hi/lo pressure count data.
9 - Exit
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 cylinder
selection list. This list is a pop up selection in which you must use the cursor keys to select which
cylinder to adjust.
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The "U" - UNADJUSTED shows that the listed cylinder has not been adjusted. The "A" - ADJUSTED
shows that the listed cylinder has been adjusted and data saved. Select the cylinder to adjust and the
next screen will come up. Live data will be displayed on the screen.
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The target zone is the area in which you want to keep the peak pressure.
The cylinder balance bar shows where the current cylinder's pressure is relative to the engine average.
It also shows the OK band within which you are trying to stay.
The current peak pressure is the actual pressure being measured. This allows reading the pressure
while adjusting the fuel valve.
The engine average mean peak pressure is the value you are trying to attain on this individual cylinder.
If adjusting another cylinder, the next screen in the "ADJUST CYLINDER" mode is the cylinder
selection list and will indicate that a cylinder has been adjusted. Select the cylinder to adjust by
pressing the "UP or DOWN Arrow" keys to highlight the cylinder and then press the "ENTER" key.
"U UNADJUSTED"
"A ADJUSTED"
When finished adjusting the desired cylinders, press the "4-TAKE AS LEFT" key to finish taking a final
set of balance data. Taking "AS LEFT" data is the same as taking "AS FOUND" data. After the last
cylinder is taken the "AS LEFT" report will display.
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If more cylinders are adjusted after the "Take as Left" has been performed, it will be necessary to
retake the "AS LEFT" data for all cylinders to get an accurate "AS LEFT REPORT".
5.1.2.2
Restart Balance Run

If a partial balance run is performed and, for any reason, the portable analyzer is turned off (i.e.
phone call, dead battery, etc.), when the unit is powered back on, press the 3 key 3-rEstart a
balance run to resume the balance run that was in progress.
The next screen in the restart a balance run mode is the ESTIMATE SPEED screen. This function
will count the number of peak pressures within a measured time and calculate an estimated RPM. To
continue, press any key.
Note:
must 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 automatically
search and find where the balance run was stopped, Hit any key to continue.
If a complete As Found collection, Cylinder adjustment, and As Left collection has been
performed, the restart a balance run will display the message below. More cylinders can be adjusted.
5.1.2.3
If more cylinders are adjusted after the Take as Left has been performed, it is necessary to
retake the AS LEFT data for all cylinders to get an accurate AS LEFT REPORT.
Recall Old Balance Data

The portable analyzer will save all the "AS FOUND" and "AS LEFT" balance runs for each machine. To
recall an existing balance run, on the main menu, press the "4" key or press the "UP or DOWN Arrow"
key to highlight the "4-recall Old balance data" and then press the "ENTER" key.
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The next screen in the "recall Old balance data" will appear as below. The message "PICK DAY TO
EXTRACT BALANCE DATA" will appear. Press the "UP or DOWN Arrow" keys to highlight the desired
day, then press the "ENTER" key to select.
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The next screen in the "recall Old balance data" will be the "As Found Report" for the day selected. To
recall the "As Left Report", press the "4" key or press the "LEFT or RIGHT Arrow" keys to highlight the
4-RECALL AS LEFT" with the HOTBOX, then press the "ENTER" key to select.
5.1.2.4
Power Cylinder Monitor

The "Power Cylinder Monitor" is a stand-alone pressure monitoring utility that can be used to check
individual cylinders without entering the "Balance engine nonencoder" mode.
When first starting, the engine speed is determined by sampling the pressure curves.
The first screen will tell you to connect the pressure
transducer to a power cylinder and apply pressure.
After you hit any key, the estimate speed routine will
run. This function will count the number of pressure
peaks within a measured time frame and calculate
an estimated RPM.
Note:
The pressure sensor must be attached to channel one.
This will take 10 seconds. If the estimated speed is not close to the known speed, you need to go
back and adjust the debounce factor and trigger level in ENGINE SETUP.
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Note:
must be opened to apply pressure.
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The next screen in the "Power Cylinder Monitor" mode will display the live data collection. This will
continuously cycle until any key is hit to exit.
There are six menu items with Control keys assigned.

Key Function
1 Reset Reference to Running
Average
4 Increase Cycles
6 Decrease Cycles
5 Increase Pressure Range
5.1.3
Decrease Pressure Range
Increase SD Range
Response
press to reset the running average bar
press to increase the cycle averages (5 cycle steps)
press to decrease the cycle averages (5 cycle steps)
press to raise the pressure range of the sample average
bars
press to lower the pressure range of the sample average
bars
press to raise the standard deviation range
Spark Menu
The Spark Survey mode is used for a detailed evaluation of the condition and integrity of the
secondary ignition system of a spark-ignited (SI) engine.
The Spark Survey Mode is an automated function that allows the user to simply connect the secondary
ignition capacitive clip to each spark plug lead and collect all the important parameters of the
secondary ignition signal. Once the user performs the set-up of the machine in the portable analyzer
for each machine the first time, the on-screen menus will instruct the operation of the collection of the
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spark data. When the user is finished collecting the data on each spark plug, the user will have access
to eight reports showing detailed ignition statistical parameters including:
1.
2.
3.
4.
5.
6.
7.
8.
Ionization Voltage
Arc Duration
Arc Voltage
Rise Time (Ionization Time)
Arc Slope
Ring Down Voltage
No Arc, Voltage Problems
Arc Flyback
The major benefits of the Spark Survey Mode is to allow any individual to collect spark data quickly
and have intuitive information about the secondary ignition system. This reduces the need for an
ignition specialist to analyze the detailed secondary spark traces. With the computer performing all the
voltage measurements automatically on each parameter, this feature saves the time of having to
manually record these parameters. The analyzer will store these reports in memory for recalling old
spark surveys and trending of the secondary ignition system data.
The spark survey function is designed to perform one spark survey per machine per day. Every time
the "1 Take spark survey" is selected, it initiates a spark survey run and a new run number. You can
bring up any report run for the day by run number.
From the Spark Menu, select one of the options listed.

Key
1
2
3
4
5
Function
Start a secondary ignition survey
To resume the spark survey that is in progress
Recall saved data for display and reporting
Jump to the oscilloscope mode for continuous display of a single point
Return to previous menu
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5.1.3.1
43
Spark Survey
The first screen in the ignition survey mode is the "START IGNITION SURVEY" screen. Press any key
to continue.
The next screen in the spark survey mode will display the message "Set number of cycles to collect".
The number of cycles can be set from 10 to 250 by pressing the "UP or DOWN Arrow" keys (one step
at a time) or the "UP or DOWN TAB" keys (five steps at a time). When the desired number of cycles is
highlighted, press the "ENTER" key to select.
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44

The next screen in the spark survey mode will display the message "Pick cylinder to collect data". The
desired spark plug can be selected by pressing the "UP or DOWN Arrow" keys (one step at a time), or
the "UP or DOWN TAB" keys (five steps at a time). When the desired spark plug is highlighted, press
the "ENTER" key to select.
Note:
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". Pressing
the "ENTER" key will continue the display of the live data collection screen.
Note:
The secondary ignition sensor must be attached to the spark plug lead before
proceeding. Press the "ENTER" key when ready.
Note:
The spark plug selection can be changed on this screen by pressing the "UP or
DOWN Arrow" keys to highlight "Chan 1 > L1 Side", then pressing the "RIGHT or
LEFT Arrow" keys to select the desired spark plug.
Note:
The loadstep selection can be changed on this screen by pressing the "UP or DOWN
Arrow" keys to highlight "Current loadstep > 1", then pressing the "RIGHT or LEFT
Arrow" keys to select the desired loadstep.
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46
Live data collection screen

Below are explanations of the values shown on the plot:
Negative Pulling The voltage is pulled negative with reference to ground.
This is the normal polarity of a secondary circuit. This means the current is going from the spark
plug's center electrode to the ground electrode.
Positive Pulling The voltage and current is going from negative to positive.
This is reverse polarity of a secondary circuit. This means the current is going from the ground
electrode to the spark plug's center electrode.
Ionization Voltage The voltage level reached to ionize the gas molecules in the spark gap (5-20 KV)
Rise Time The time required to ionize the spark gap (8-40 Us)
Arc Duration The time duration the actual arc occurs
Arc Voltage The voltage level across the spark gap during the arc
Slope The slope of the arc duration (Flat, Positive, Negative)
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In the spark survey mode, live data collection screen, the Time Scale (Micro-seconds) and/or the
Voltage Scale (Kilovolts) can be changed at any time during the data sample.
To change the time scale, press the "0" key. The time scale will toggle through the available
scales each time the "0" key is pressed.
To change the voltage scale, press the "1" key. The voltage scale will toggle through the
available scales each time the "1" key is pressed.
Following the live data collection screen, the screen will return to the pick cylinder list. Continue
collecting data for all the spark plugs with a question mark "?"
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48

When the final spark plug is finished with live data collection, the message will pop up, "Finished
collecting spark survey, Hit any key to continue"
The next screen in the spark survey mode is the "Ionization Voltage Report". The values shown are
derived from the portion of the spark example trace shown to the right in the square box.
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Menu "Hot Box" Keys

The menu section of the "Ignition Survey Reports" has many menu options.
0-Options:
To select "0-Options", press the "0" key or press the "LEFT or

RIGHT Arrow" keys to highlight with the "HOTBOX", then press the
"ENTER" key. The option menu selection pops up a screen as above
for selecting the following options:
"0- CHANGE KV MAXIMUM". This is for changing the maximum
kilo-volt scale on the statistical bar graph.
"1-CHANGE KV PERCENT BAND". This is for changing the plus and
minus percent bands on the spark plug statistical bars.
"2-CHANGE KV MINIMUM". This is for changing the minimum
kilo-volt scale on the statistical bar graph.
2-Report Type:
To select "2-Report Type", press the "2" key or press the "LEFT or
"ENTER" key. The option menu selection pops up a screen as above
for selecting the following options: To select, press the associated
number key or highlight and press the "ENTER" key.
Note:
Report definitions are further described in the next section.

Each report can be viewed and printed as necessary.
3-Restart:
To select "3-Restart", press the "3" key or press the "LEFT or RIGHT
Arrow" keys to highlight with the "HOTBOX", then press the "ENTER"
key. The next screen will display the message "PICK DAY TO
EXTRACT SPARK DATA". Highlight the desired day and press the
"ENTER" key.
5-Single Sample:
To select "5-Single Sample", press the "5" key or press the "LEFT or
"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:
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Single samples are for troubleshooting purposes and will not

affect statistical reports.
50
5.1.3.2
7-Print:
To select "7-PRINT", press the "7" key or press the "LEFT or RIGHT
Arrow" keys to highlight with the "HOTBOX", then press the "ENTER"
key. If a compatible printer is set up and connected to the printer port,
the "Selected Ignition Report" will print directly from the portable
analyzer.
9-Exit:
Press the "9" key or press the "LEFT or RIGHT Arrow" keys to
highlight the "9-EXIT" with the HOTBOX. Then press the "ENTER"
key to select.
Ignition Survey Report Definitions

The following report descriptions give the details of what is displayed and the meanings of the values.
Ionization Voltage The voltage level required to ionize the compressed air/fuel molecules within the
gap of the spark plug. This is also referred to as the ignition breakdown voltage. Ionization refers to the
splitting apart of the molecules to enable a current path for arcing of the spark plug. Higher ionization
voltages produce a higher rise time.The typical units are in Kilo-Volts (Kv).
In a controlled environment:
1.
The wider the spark plug gap, the more voltage required to ionize the gap.
2.
The narrower the spark plug gap, the less voltage required to ionize the gap.
3.
Typical voltage measurements will range from 5,000 to 25,000 volts, with voltages over
20,000 indicating wide gaps and a greater potential for external flashover.
Note: In a non-controlled environment, the air/fuel ratio and mixture consistency can
affect the ionization voltage level from cycle-to-cycle measurements.
4. This voltage should go negative (-) with respect to ground if the secondary circuit is wired
properly. If the voltage is going positive (+) with respect to ground, this is referred to as
reverse polarity and indicates the wiring to the coil is reversed and may result in shorter
spark plug life.
Arc Duration The measured time period the actual arcing of the spark plug occurs. This is the time
measured between ionization voltage (breakdown) and the beginning of the ring-down voltage. The arc
duration is inversely proportional to the ionization voltage and rise time. The typical units are in
micro-seconds (uS)
1. The wider the spark plug gap, the shorter the arc duration.
2. The narrower the spark plug gap, the longer the arc duration.
3. Typical arc duration measurements will range from 125 micro-seconds to 700
micro-seconds for different ignition systems. When measured times reduce, this indicates
widening gap and/or excessive ionization voltage requirements. As measured times
increase, this indicates a narrow gap and/or an incorrect measurement due to a low
ring-down voltage level.
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Arc Voltage The voltage level required to maintain the arcing of the spark plug gap. This is the
voltage measured between the zero reference line and the arc duration level. This voltage is typically
less than 1 KV with high current flow. The typical units is in volts.
Rise Time - The measured time required to ionize the compressed air/fuel molecules within the gap
of the spark plug. This is also referred to as the ionization time. Ionization refers to the splitting apart of
the molecules to enable a current path for arcing of the spark plug. The rise time increases with an
increase in the ionization voltage. The typical units are in micro-seconds (uS)
1. The wider the spark plug gap, the more time required to ionize the gap.
2. The narrower the spark plug gap, the less less required to ionize the gap.
3. Typical rise time measurements will range from 5 to 50 micro seconds (uS). With rise times
over 40 uS indicating wide gaps and a greater potential for external flashover.
Arc Slope The measured slope of the arc duration. The measured slope can be one of the following:
1 Flat. This indicates the voltage level during the arc duration remained constant as the
voltage requirements to maintain the arc did not change during the arc.
0 Negative. This indicates the voltage level during the arc duration started at a lower voltage
and increased as the voltage requirements to maintain the arc increased during the arc.
This is an indication of high resistance across the spark plug gap.
2 Positive. This indicates the voltage level during the arc duration started at a higher voltage
and decreased as the voltage requirements to maintain the arc decreased during the arc.
This is an indication of high resistance in the secondary wiring and connections exclusive of
the plug gap.
Ring Down Voltage The measured peak voltage of the ring down oscillation of the coil. This is also
referred to as coil oscillation and/or unused energy. This is the energy remaining after the spark plug
arc demands cannot be maintained. The typical units are in volts peak. Anything that affects the R-C
time constant affects the amplitude and frequency of the ring down oscillations. A lack of ring down
typically indicates a poor plug wire connection in the coil tower.
No Arc, Voltage Problems Report This report identifies problems with spark plugs and/or other
secondary ignition components based on ionization voltage levels and arc duration measurements.
Please refer to the report for detailed description of each of the problems identified.
Arc Flyback This report identifies the number of times each coil has a flyback following the
ionization ramp. Please refer to the report for detailed description of the problem.
5.1.3.3
Restart Spark Survey

If a partial spark survey is performed and, for any reason, the portable analyzer is turned off (i.e
phone call, dead battery, etc.), when the unit is powered back on, press the 2 key 2-rEstart spark
survey to resume the spark survey that was in progress.
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The next screen in the restart spark survey mode is the TO RESTART IGNITION SURVEY screen.
To continue, press any key.
The next screen in the restart spark survey mode is the RESTART OF DATA COLLECTION FOR
SPARK SURVEY screen. To continue, press any key.
The next screen in the restart spark survey mode is the Pick cylinder to collect data screen. The
spark plugs that have data will have an asterisk (*), and the spark plugs the need data will have a
question mark (?). Select the desired spark plug by highlighting to continue the data collection process.
At this point, continue on as normal during a spark survey.
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5.1.3.4
53
Recall Spark Survey

The portable analyzer will save all the "Spark Surveys" for each machine. To recall an existing spark
survey, on the main spark menu, press the "3" key or press the "UP or DOWN Arrow" key to highlight
the "3 recall Old spark survey". Then press the "ENTER" key. A popup box will display all dates for
data taken and stored on the analyzer. Use the up / down arrow keys to highlight the date to view and
press the ENTER key.
The next screen will be the "Arc Duration Report" for the desired day. From this screen, the menu
options are the same as when the data was taken. See the section on spark survey for more details.
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Encoder-based Balance
6.1
Special Collection Modes
This menu allows access to

several special modes for the
analyzer. With these modes,
several detail functions may be
accomplished that are
non-crankangle related.
Spark trace mode:
This function is used to collect and display ignition data. See the
following sections for a complete description of the functions
available.
Balancer menu:
This is a submenu with two main functions for balancing an engine

using peak firing pressure and ignition survey mode to look at ignition
system details.
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6.2
Spark
The Spark module is used to observe the waveform and voltage levels of the secondary ignition
traces. When the Spark program is started, the user is shown 3 options:
NEW SCAN:
Take new data.
PLOT OLD DATA:
Recall stored data.
EXIT PROGRAM:
Return to the menu.
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56

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
1
2
3
4, ESC
5
6
7
8
9
Function
To zoom in on the signal, set the cursor to the left side and press 1. The
zoom will then occur. To restore the original, press 1 a third time.
To resample the signal.
To change run number.
Return to the setup menu
Turn on autoscan to sample the signal continuously.
This option will overlay six consecutive traces, then clear the screen and
repeat another six traces.
To store the trace.
To print the display to a printer if setup and connected.
Toggle the grid off/on.
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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 between
digitized samples.
Count:
This is the number of digitized samples that are taken for a trace. For a longer
view select, increase this number. For multi-strike systems, increase this
number to about 1200. Maximum number is 5,000.
Scale:
Use the RIGHT TAB key to bring up the scale selection box. This allows you
to pick the vertical scale of the graph. You may select from the following
scales.
Use the "UP or DOWN TAB" to change. When the desired scale is
highlighted, press the "ENTER" key to select.
When you are ready to collect data, hit the "END" key.
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Utility Menu Options
The options listed in the

menu to the left provide
the user with extra utilities.
7.1
Direct Channel Read

This function allows the user to directly read out a sensor's static voltage or current. The primary use
of direct channel read is for verifying calibration and proper operation of pressure transducers.
First, pick a sensor from the sensor list to

display. By picking the sensor from the sensor
list, calibration parameters and engineering
units are used from the database previously
set up.
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Utility Menu Options
59
Second, select the channel to which the sensor

is physically attached on the rear panel. For
the 63X0/CA, use channel one.
Third, a screen appears as shown above updating continuously with the input. Depending on the
sensor type, there may be variations to the screen shown.
For DC pressure sensors, the screen shown has the following information:
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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 (CA with encoder only), an atmospheric reference point is applied.
The center column is non-zero adjusted. No correction is applied and the raw values are listed. The
third column shows the line's value type. For most cases, the "Engr. Units" (engineering units) line is
used. This will show the actual readout of the pressure applied to the sensor.
The additional three lines are used by Windrock in calibration of the analyzer and other types of
sensors.
The Zero Factor line shows the bit count of the correction applied when the sensor was zeroed. Bit
count is a digital electronics value.
At the top of the display, a bar graph will display the current sensor value and will update based on the
mode selected. By default, the bar graph is in continuous mode. Below the bar graph is a small bar
showing the peak value reached until the [9-Reset Bar] hot key is pressed to reset the bar to zero.
The mode line shows the current mode of the screen updating process. There are several modes
which can be used for various purposes. Below are explanations.
Key
0
1
2
3
4
5
7
7.2
Function
Single Scan
Continuous
Peak Scan
Low Scan
Exit
Run/Hold
Next
Description
Updates the screen one time per hit of the key
Updates the screen continuously
Updates the screen if the new value exceeds the previous value
Updates the screen if the new value is less than the previous value
Exits the direct channel read function
Stops the screen update temporarily
Allows selection of a different sensor point
Power Cylinder Monitor

Refer to the previous section on the power cylinder monitor under engine balance for more details.
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Encoder Setup
Encoder Setup
8.1
Shaft Encoder
61
Several fittings have been provided for adapting the encoder to your needs. It is preferred that a
friction connection be used over a direct connection. It is possible that a friction connection can slip.
Check the TDC mark with a timing light if you suspect slippage. When using the friction connection,
clean the flywheel surface to remove any grease or oils that could cause slippage.
Mount the encoder assembly on the tripod provided. Adjust the tripod height to center the encoder
shaft with the center of the flywheel. If needed, use the provided elastic cord to provide additional
stability by placing the cord around the tripod neck and securing it to the machine frame.
Once the encoder is set up, attach the 50-foot encoder cable to the connection marked "To Analyzer".
Prior to taking data, make sure the "STROKE 4 - 2" switch is set properly for the engine type (defined
in the machine setup). Also make sure that the number of pulses per revolution is set to the correct
number.
Caution!
On four stroke machines, do not switch the encoder or change the software
configuration when moving from the engine to the compressor. The analyzer
and software know the difference between the engine 4-stroke 0 to 720
degrees and compressor 0 to 360 degrees .
Also, it must be noted here that, in order to collect angular velocity information, you must be able to
collect more than one pulse per revolution.
The "PHASE A-B" switch is provided to give the user the ability to shift data collection 360 degrees on
four-cycle engines, as necessary; for instance, if you are collecting data on a 4-cycle diesel engine and
are unsure as to which stroke TDC is set.
The "Hole-Pin" switch is used to set the correct polarity of the first half of the trigger signal.
The shaft encoder is directly powered by the analyzer or the wireless transmitter. Note that, if the
encoder cable is disconnected, the encoder will retain its settings and TDC for up to one hour. This
allows the analyzer to be disconnected and reconnected as necessary without disruption except as
cautioned above.
Please note that in four-cycle mode, the encoder uses the A/B switch to switch between the power and
exhaust stroke. This setting is retained as long as the encoder is powered up.
Caution! Note that the software uses power conservation methods which will power
down the encoder while outside the data collection menu (this will turn off
power to the encoder). Either of these situations will re-power the encoder
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62

in a undetermined state for the power/exhaust cycle. To avoid this
situation, do not disconnect the encoder and set the power save setting
under hardware configuration to NO.
Caution! Make sure the BNC terminator (a shorting connector) is placed on the "MAG
PU" input when not in use. This will reduce ignition interference in the
encoder.
Note:
8.2
It is strongly recommended that TDC be checked periodically; at a minimum, prior

to and after data collection.
Multi-Event
The multi-event encoder provides for attachment of either an optical pickup (WRI P/N: A6056-01-08)
or a magnetic pickup (WRI P/N: A3012-00-00) for TDC measurement. In addition, a magnetic pickup
can be used to measure individual teeth on a gear or flywheel for more resolution of crankangle.
A strobe light can be attached to the multi-event encoder to check the positioning of the TDC event.
Note that the forward/reverse switch has no effect on the TDC offset of the older model, but will
advance or retard the TDC of the new (Black case) model.
Once the multi-event encoder is set up, attach the 50-foot encoder cable to the connection marked "To
Analyzer". Prior to taking data, make sure the "STROKE 4 - 2" switch is set properly for the engine
type (defined in the machine setup). Also, make sure that the number of pulses per revolution is set to
the correct number.
Caution!
On four-cycle machines, do not switch the encoder or change the

software configuration when moving from the engine to the compressor.
The analyzer and software know the difference between the engine
4-cycle 0 to 720 degrees and compressor 0 to 360 degrees.
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Encoder Setup
63
Also, it must be noted here that, in order to collect angular velocity information, you must be able to
collect more than one pulse per revolution.
The "PHASE A-B" switch is provided to give the user the ability to shift data collection 360 degrees on
four-cycle engines, as necessary; for instance, if you are collecting data on a 4-cycle diesel engine and
are unsure as to which stroke TDC is set.
Caution!
8.3
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.
Magnetic Pickup
A magnetic or hall effect sensor may be used with the shaft encoder or the multi-event encoder.
To use these devices, they must be placed on the machine with a known reference to TDC to
ensure proper timing information. Connect these devices to the connector marked "MAG
PICKUP".
A self-contained optical type pickup with a TTL output may be used with the shaft encoder or the
multi-event encoder. The optical sensor may be used directly with the multi-event encoder. To use
this type device, it must be placed on the machine with a known reference to TDC to ensure
proper timing information. If the self-contained style pickup is used, connect this device to the
connector marked "MAG PICKUP". Reflective tape must be placed on the flywheel or rotating
element at the TDC position for proper timing information.
8.4
Timing Light
With the encoder set up, attach the timing light to the connector
marked "STROBE". Aim the timing light at the timing marks on the
engine flywheel and pull the trigger switch.
With the trigger switch pulled and while observing the flywheel, look
for the timing marks. Using the arrow buttons, you can adjust
movement clockwise or counterclockwise as necessary to bring the
timing marks into view.
Once TDC has been found, the timing light should be disconnected
from the encoder to conserve battery power.
Caution!
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The timing mark is crucial for accurate analysis. Make sure that there is
only one timing mark on the observed surface. Having more than one
timing mark will cause confusion and create the possibility of collecting
data based on the wrong TDC of the machine.
64
Loading New Software
9.1
Windows Install 6310 only

Prior to starting, make sure the update has been installed on the desktop/laptop. There should be two
or more new files located in the Windrock\Win63xx\EXE folder that were part of the upgrade CD ROM.
On the analyzer:
1.
2.
3.
4.
Attach parallel interlink or USB cable between desktop and 6310

Turn the analyzer on
Select 7 "Utilities" from the menu and press Enter
Select 2 "Connect to windows" from the menu and press Enter
In the Win63X0 Windows application:

5.
6.
7.
8.
9.
Before opening a database, select "Utilities" from the menu bar

Select "Connect to analyzer" from the menu
Press the "Connect now" button (the connection should be established - note this by a
box listing files on the analyzer appearing to the right of the window)
Select "Transfer" from the menu bar
Select "Update EXE's" on the menu
Transfer will now begin and may take several minutes to complete. Insure that the Windows software
indicates that the transfer process is complete. Do not disturb the analyzer or Windows 6310 software
while the transfer is in progress. Once the process has completed, exit the function in
Windrock\Win63xx and restart the analyzer by turning it off then back on. The new operating software
will be in place.
Note:
9.2
Verify the version on the startup screen to make sure the update has been
transferred.
Windows Install 6320 only

Prior to starting, make sure the update has been installed on the desktop/laptop. Follow the
instructions found in the Win63X0 manual under "Connect with closed database" and then "Send
software updates to Analyzer".
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Operating System Commands
10
10.1
Machine Template 6310 only
65
To copy a setup from one machine to another, use the following procedure.
C:\EVPORT is the main directory where the data files are kept. Each station and machine are put into
sub..sub directories as shown below.
C: \ EVPORT \ S000
\ S001 \ M000
\ M001
\ M002
Where S000 is the first station in the list, M000 is the first machine for the station. The easiest way to
find which subdirectory belongs to a machine is to select the station and machine of interest and, at
the 'Station Selection Menu', select "X-engineering mode". The subdirectory displayed is the current
machine. These would be the files for that machine including setup and data.
You must then re-enter the 6300/6310 program by typing '0' and Enter. Back up in the menu to "Add a
new station" and/or "Add a new machine". Add the new machine and select it. Repeat the above
procedure to determine in which subdirectory you are located.
At the DOS prompt type:
copy c:\evport\sxxx\mxxxx\d6*.dat
The "xxx" should represent the directory from which you want to copy. Once the copy function is
complete, type '0' and Enter to re-start the program. When the program is started, you must now
select the new station/machine. It will have a complete copy of the other machine's setup.
10.2
Setting Time and Date 6310 only

To set the date and time in the analyzer, use the following steps:
1.
2.
3.
4.
5.
6.
7.
Plug the small keyboard into the analyzer

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

To manually set the Date, Time, or Time Zone:
From the startup menu, hit "Escape" twice, to access the Station Selection Menu.
Select "System Configuration" at this menu.
10.4
Printing 6310
To print directly from the analyzer, there must be a printer driver loaded prior to running the software.
Once this has been done, pressing the PRINT function key will print out the current graphics or report
screen. The analyzer must be in LCD mode to print in proper black and white. You cannot use the
print function to print to a PostScript type printer.
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Using the GRAPHICS command:

The GRAPHICS command loads a program into upper memory that allows the analyzer to print the
information displayed on the screen. To load the GRAPHICS driver, you may do it one of two ways
using the syntax that follows. The first method requires the word GRAPHICS be typed in at the
command prompt. The second method requires adding the GRAPHICS command to the
autoexec.bat file in the root directory of the analyzer.
Syntax:
LOADHIGH C:\DOS\GRAPHICS [type] (example: LOADHIGH C:\DOS\GRAPHICS
LASERJETII )
Type:
Specifies the type of printer. The following list shows each valid value for this parameter and
gives a brief description of its meaning:
HPDEFAULT
Any Hewlett-Packard PCL printer.
DESKJET
Hewlett-Packard DeskJet printer
GRAPHICS
An IBM Personal Graphics Printer, IBM Proprinter, or IBM

Quietwriter printer
LASERJET
A Hewlett-Packard LaserJet printer
LASERJETII
A Hewlett-Packard LaserJet II printer
PAINTJET
A Hewlett-Packard PaintJet printer
THINKJET
A Hewlett-Packard ThinkJet printer
Installing the GRAPHICS command on the analyzer requires the following steps:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Press the "ESC" key until the "Select a station" menu is reached
Attach the small keyboard to the analyzer
Press the "6" key, (5 in the 6310/CA Lite) "X engineering mode"
Type CD C:\ and press the "Enter" key
Type EDIT AUTOEXEC.BAT and press the "Enter" key
Press the "Down Arrow" key until the M_P line is highlighted and press the "Enter" key
Press the "Up Arrow" key to the blank line
Type LOADHIGH C:\DOS\GRAPHICS LASERJETII (or the type from the above list)
Type Mode LPT1 RETRY=R
Press and hold the "ALT" and "F" keys together to bring up the File menu.
Press and hold the "ALT" and "X" keys together and select "Save and exit", press the "Enter"
key to return to the DOS prompt
12. Turn the analyzer off then on or press the "CTRL" + "ALT" + "DEL" keys to reboot the analyzer
At this point, try printing by pressing the "PRTSC" key. It may take a few seconds to start printing.
Loading a different printer profile:
If you have already loaded a printer profile and you want to load another one by using the
GRAPHICS command, repeat the above steps.
Batch file before adding "Printer" command.
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Batch file after adding "Printer" command and "Mode" command
Alt-F for "File Menu"

Alt-X for "Exit"
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Select "Y" for YES or "N" for NO and hit ENTER.
10.5
Printing 6320
To print directly from the analyzer, there must be a printer driver loaded. Once this has been done,
selecting PRINT from the menu will PRINT the current graphics or report screen. The analyzer must
be in B & W or Color 2 mode to print properly.
To set up a printer:
From the startup menu, hit "Escape" twice to access the Station Selection Menu.
Select "3 - System Configuration" at this menu.
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Select "2 - Printer Management" at this menu.
Select the option you need and follow the on-screen instructions.
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Appendix
11
Appendix
11.1
Data Collection Techniques
71
Before getting started with data collection on a machine, there are some helpful guidelines which
should aid you in collecting good data.
Pressure Measurement, 63X0/CA (Encoder-based HP measurement)
You must ZERO the Dynamic DC pressure sensor prior to collecting pressure data. The purpose
of zeroing the sensor is to establish a reference pressure for the data at operating temperature.
The reference zero pressure is atmospheric pressure. If the sensor is not zeroed, there is a
possibility of a thermal offset causing the pressure data to be slightly elevated.
11.2
Class 1, Div 2 Information

The information and requirements contained in this chapter apply only to the Windrock Portable
analyzer models:
6320-CA
6320-DA
6320-MA
6320-PA
6320-PA/VA
6320-VA
The 6320 family of analyzers are approved for indoor locations only, or areas protected from exposure
to the weather. This does NOT mean the analyzer can not be used outside, but it does mean it needs
to be protected from rain, etc.
11.2.1 Hazardous Location Information
Warning!
If your 6320 Analyzer has been approved for use in a hazardous location, Class 1 Div. 2,
there will be a hazardous atmosphere warning label on the back of the analyzer. If there is
no warning label on your analyzer, follow all hazards atmosphere precautions prior to and
while using your analyzer.
Warning!
1. THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION 2, GROUPS A, B, C, D,
T4A HAZARDOUS LOCATIONS ONLY
2. WARNING - EXPLOSION HAZARD SUBSTITUTION OF COMPONENTS MAY IMPAIR
SUITABILITY FOR CLASS I, DIVISION 2, (MOLICEL LI-ION BATTERY MODEL ME202C)
and
AVERTISSEMENT - RISQUE DEXPLOSION LA SUBSTITUTION DECOMPOSANTS
PEUT RENDRE CE MATRIEL INACCEPTABLE POUR LES EMPLACEMENTSDE
CLASSE I, DIVISION 2 (MOLICEL LI-ION BATTERY MODEL ME202C)
3. WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT (AC POWER,
USB, VGA, ETHERNET, OR BATTERY) FROM ANALYZER UNLESS POWER HAS BEEN
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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 L
EQUIPEMENT, (AC POWER, USB, VGA, OUETHERNET, OR BATTERIE) COUPER LE
COURANT OU SASSURER QUE LEMPLACEMENT EST DSIGN NON DANGEREUX
4. WARNING - EXPLOSION HAZARD - DO NOT RE PLACE BATTERY UNLESS POWER
HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS; AND
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 personal.)
6. DO NOT attempt repair / modification of this unit. (All repairs / modifications must be
preformed by Windrock personal.)
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).
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Appendix
11.2.2 Control Drawing
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74
11.3
Sensors
Transducer Scaling Entries:
SENSOR
TYPE
UNITS ZERO
SCALE or 1V
FULL 4mA
or 5V
20mA
Engine AC
Engine DC
Spark
AC
DC
DC
PSI
PSI
Volts
1000 200
1000 0
50,000 0
1000
1000
50,000
Secondary Ignition Sensor

A6030-01-06
0
0
0
Water Cooled Pressure Sensor

A6082W-XX-01
Compressor Pressure Sensor

A6082-XX-00
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Appendix
75
11.3.1 Magnetic Pickup

GENERAL DESCRIPTION
Completely self-powered, VRS (magnetic) sensors are rugged devices that do not require an external
voltage source for operation. They are generally used to provide speed, timing or synchronization data
to a display (or control circuitry) in the form of a pulse train.
PRINCIPLE OF OPERATION
The output signal of a VRS sensor is an AC voltage that varies in amplitude and wave shape as the
speed of the monitored device changes and is usually expressed in peak to peak voltage (V P-P). One
complete waveform (cycle) occurs as each actuator passes the sensing area (pole piece) of the
sensor. The most commonly used actuator is a metal gear, but also appropriate are bolt heads (cap
screws are not recommended), keys, keyways, magnets, holes in a metal disc, and turbine blades. In
all cases, the target material must be a ferrous metal, preferably unhardened.
A permanent magnet is the heart of a VRS sensor and establishes a fixed magnetic field. An output
signal is generated by changing the strength of this field. This is caused by the approach and passing
of a ferrous metal target near the sensing area (pole piece). The alternating presence and absence of
ferrous metal (gear tooth) varies the reluctance or "resistance of flow" of the magnetic field, which
dynamically changes the magnetic field strength. This change in magnetic field strength induces a
current into a coil winding which is attached to the output terminals. If a standard gear is used as an
actuator, this output signal would resemble a sine wave if viewed on an oscilloscope.
APPLICATION CONSIDERATIONS
VRS sensors are not designed for sensing extremely low speeds. The target passing the pole piece of
the sensor must be traveling at a minimum velocity, or surface speed, to provide an adequate output
voltage. Typical minimum surface speeds for each sensor type can be found in the specifications
section. The bottom line in proper VRS sensor selection is to choose one that will meet the following
two conditions:
1) Provide the required peak-to-peak voltage at the minimum speed of interest.
2) Will still function properly at the maximum operating frequency of the application.
To choose an appropriate sensor, the following data must be obtained:
1) Minimum and maximum speed of interest.
2) Diameter of gear (or shaft) and number of teeth (or actuators) per revolution.
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3) Load resistance and the input resistance of the device being driven.
4) Air gap setting (pole piece clearance) and distance between sensor face (pole piece) and top
of gear tooth (or other actuator).
5) Minimum acceptable peak-to-peak voltage level (V P-P) of the device being driven and
typically a display or frequency to DC converter.
USE OF MAGNETIC PICKUP WITH WINDROCK INSTRUMENTATION
When using the magnetic pickup for TDC (top dead center) triggering in reciprocating machine
analysis, it is extremely important that the pickup triggers data acquisition exactly at TDC. Errors of
only 2 degrees can produce measurement errors of up to 5% in horsepower and throughput
calculations.
For the magnetic pickup to operate properly with Windrock analyzers, several issues must be
addressed.
PICKUP DISTANCE FROM TARGET
Often, the magnetic pickup is placed too close to the target. When this happens, the pickup can trigger
data acquisition on scratches, nicks, or magnetic deformities in the flywheel or shaft. Usually, a gap of
about 1/4 inch is sufficient.
TARGET TYPE
Some sort of target must be placed on the flywheel or shaft to trigger the magnetic pickup. The target
must be of a ferrous material. It may be a hole drilled into the flywheel or shaft or may be a protruding
object such as a bolt head. Either way, the target must produce the largest magnetic interference of
any other scratch, hole, or deformity in the flywheel or shaft. The center of the hole or bolt head must
be placed at TDC of the machine. A hole is preferred because it is always round and the center of the
hole is the magnetic center of the target. A good choice for hole size is 1/4" diameter X 1/4" deep.
Sometimes, when using a bolt head, the flats of the bolt causes the magnetic center to be other than
the geometric center of the bolt.
SIGNAL POLARITY
This is where many problems occur when using a magnetic pickup. The circuit in the Windrock
analyzer arms itself on a POSITIVE-going signal. The actual trigger occurs upon ZERO-CROSSING
after the circuit is armed. Zero-crossing occurs at the magnetic center of the magnetic pickup or when
the magnetic pickup is centered on the target.
When using a hole as a target, pin A of the magnetic pickup is the signal.
When using a protruding object as a target, pin B of the magnetic pickup is the signal.
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Appendix
77
If in doubt, use the analyzer in o-scope mode, or an oscilloscope, to view the signal. The signal should
look like the figure below. If the polarity is reversed from this, use the hole/pin switch on the encoder
or reverse the A and B leads in the cable to reverse the signal to the proper polarity. The synch light
will flash at the center of hole or pin if proper setup is obtained.
SIZE OF SIGNAL
The magnetic pickup contains a permanent magnet with a coil. When the magnetic field changes due
to the pickup going over a hole or object, a voltage is generated in the coil. The size of the signal is
proportional to the magnetic field change. Several factors determine the field change: permanent
magnet strength, number of turns in the coil, gap from pickup to target, material of target, and size of
target.
The bottom line is that you want a signal of about 1V peak and it must be at least 10 times the size of
any other noise or spurious signals in the output of the pickup. If the polarity of the signal is reversed,
the trigger point will be much later than actual TDC.
11.3.2 Secondary Ignition Sensor

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

This pressure sensor used with Windrock
portable analyzer is for conditions of extreme
temperature for extended periods of time. This
device outputs a 4 mA to 20 mA electrical signal
that is directed to the analyzer. The pressure
transducer is typically connected to kiene or
other indicator valve type on the power cylinders.
11.4
Specifications - 6310/CA
Basic Capabilities:
The data acquisition capabilities of the instrument are based upon 1-channel dynamic signal
capture as a function of crank angle position. The crank angle position is captured via an optical
shaft encoder coupled mechanically to the machine being analyzed or magnetic/optical pickup.
The signal input can be pressure, vibration, ultrasonic, or other voltage or current signal. Angular
velocity measurements are captured and displayed using the encoder information.
Input Signals
Channel 1: Software selectable between current loop, constant current, voltage input, ignition
(primary and secondary). Secondary ignition uses capacitive voltage clip.
Channel 5: Supplies 12 VDC to encoder or magnetic/optical pickup conditioner. There are 2
inputs, TTL compatible with 10Kohm pull-ups.
Current loop input
Range: 0-20 milliamp
Frequency response: DC to 5 Kilohertz (kHz)
Supply voltage: 24 VDC
Over-voltage protection to 2000V
Current loop input is used for the DC pressure sensor
Input impedance 470 ohm
Secondary Ignition using capacitive coupling probe
Range: 1 Kilovolts to 50 Kilovolts (kV)
Software selectable for positive or negative ignition systems
Secondary Ignition data capture rate is 75 Kilohertz (kHz)
Over voltage protection
Voltage Input
Range: 0-10V
Frequency response: DC to 5 Kilohertz (kHz)
Voltage input is used for voltage signals
Input impedance: >1M ohm
Memory Capacity
16 Megabytes on-board RAM memory
2 Gigabytes of internal disk storage
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Appendix
79
Communications
Parallel interface or USB for host communications
Power Supply
12V Lithium Ion rechargeable 3200 milliamp-hour battery
One battery standard
Battery is removable
External charger provided - 1.5 hr recharge time
External power input 12 - 18 VDC
Battery life: approximately 6 hours depending on use
Operating Conditions
Temperature: 15-120 F
Humidity: 0-90% non-condensing
Display
8.25" diagonal LCD, color.
Backlight automatically turned off after 30 seconds of non-use
Size of display: 8.25" diagonal
Pixels: 640 x 480
Contrast: software controlled
Processor
133 MHz AMD 586 with (2) Microchip RISC signal conditioning processors
Chassis
Material: EMI hardened anodized aluminum
Size and Weight: 10.5" X 8.5" X 2"
(6.75 lbs.)
Power: Long-life, field replaceable, rechargeable Li-ion battery
Keypad: 25 keys
11.5
Specifications - 6320/CA
Basic Capabilities, 6320:
The data acquisition capabilities of the instrument are based upon 1-channel simultaneous
dynamic signal capture as a function of crank angle position. The crank angle position is captured
via a shaft encoder coupled mechanically to the machine being analyzed or magnetic/optical
pickup. The signal input can be pressure, vibration, ultrasonic, or other voltage or current signals.
Angular velocity measurements are captured and displayed using the encoder information.
Input Signals
Channel 1:
Software selectable between Current Loop, Constant Current, Voltage Input,
Ignition primary and secondary (secondary uses a capacitive voltage clip).
Channel 5:
Supplies 12 VDC to encoder or magnetic/optical pickup conditioner 2 inputs,
TTL compatible with 10 Kohm pull-ups
Current loop input
Range: 0-20 mA
Frequency response: DC to 5 KHz
Current loop input is used for the DC pressure sensor
Input impedance 470 ohm
Ignition secondary using capacitive coupling probe
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80

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
Over voltage protection to 2000V
Voltage input is used for voltage signals
Input impedance: >1 Meg ohm
Memory Capacity
256 Mb on-board RAM memory
4 Gb flash memory storage
Communications
USB interface for host communications
Power Supply
12V Lithium Ion rechargeable 3200 milliamp-hour battery
Two batteries standard
Battery is removable
External charger provided - 1.5 hr recharge time
External power input 12 - 18 VDC
Battery life: approximately 6 hours depending on use
Operating Conditions
Temperature: 15-120 F
Humidity: 0-90% non-condensing
Display
8.25" diagonal LDC, transmissive, with back light, color option
Size of display: 8.25" diagonal
Pixels: 640 x 480
Contrast: software controlled
Chassis
Material: EMI hardened anodized aluminum
Size and Weight: 10.5" X 8.5" X 2"
(6.75 lbs.)
Power: Long-life, field replaceable, rechargeable Lithium ion battery
Keypad: 28 keys
Resolution
HF vibration channels
Pressure, ultrasonic, prox channels
Ignition analysis channels
HF vibration filters
Ignition analysis speed
Operating system
Real-time speed
Battery life
Data transfer method
Printers supported
Signal processing technology
16 bits
1
1
1
unlimited (DSP programmable)
1 Mhz
Linux
1800 RPM
7 hours
USB - USB
USB printer w/ Linux driver
DSP processors
Windrock, Inc. 2013
Appendix
Main user interface processor
Crankangle samples per degree
A/D converters
81
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
11.6
Specifications - Sensors
DC Pressure Sensor for Power Cylinder PT/PV Measurement
Range: 0-2000 psi (other ranges available 1000, 3000)
Response time: <0.5 ms (A6082-XX-01 <0.1ms)
Accuracy: 1%
Linearity: <1% full scale
Cycle life: >1.5 billion cycles
Operating Temperature Range: 0-450 F (temperature compensated)
Pressure fitting: Kiene adapter
Output: 4-20 mA, loop powered
Secondary Ignition Capacitive Pickup
Attenuation: 10,000 times
Range: 50 KV
Output Connector: BNC
Temperature Range: 200 F
Cable Length: 6 ft
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12
Glossary of Terms
After Top Dead Center - After a piston in a reciprocating engine has reached the top of its travel and
starts downward. Abbreviated ATDC.
Air Manifold Pressure - The pressure present in an engine's air manifold.
Air Manifold Temperature - The temperature of the air present in an air manifold.
Ambient Temperature - Typically referred to as the present atmospheric temperature.
Angular Velocity - The change in angular velocity measured in RPM as the machine rotates in a single
revolution.
Articulated Connecting Rod - A connecting rod that attaches to a master rod. An articulated rod on an
engine with integral mounted compressors is always a power connecting rod.
Articulation - In an integral engine/compressor, the irregular movement of the power pistons in relation
compressor piston due to the manner in which the power rods are connected to the compressor rod
instead of directly to the crank shaft.
Atmospheric Pressure - The weight of air measured at your location.
Balancing - Adjusting the amount of fuel being admitted into an individual power cylinder in order to
adjust peak firing pressures.
Before Top Dead Center - Before a piston in a reciprocating engine has reached the top of its travel.
Abbreviated BTDC.
Blowdown Event - The detail of the pressure curve during and just after the exhaust port (or valve) is
opened.
Bore - The width or diameter of a hole on an engine or compressor cylinder.
Bottom Dead Center - When a piston in a reciprocating engine reaches the bottom of its stroke.
Brake Horsepower (BHP) - The usable output of an engine as measured at the crankshaft or flywheel.
Brake Mean Effective Pressure (BMEP) - That theoretical constant pressure that can be imagined
exerted during each power stroke of the cylinder to produce power at the flywheel or crankshaft. BMEP
is the IMEP less all friction and parasitic losses. BMEP cannot be measured. It must be calculated.
Brake Specific Fuel Consumption (BSFC)- As applied to internal combustion engines, it is the amount
of BTU's (lower heating value) required to make one (1) brake horsepower for an hour. Measured in
BTU/BHP/Hr.
British Thermal Unit (Btu) - The amount of heat required to raise the temperature of one pound of
water one degree Fahrenheit.
Channel Resonance - Distortions of the pressure information caused by the excitation of the acoustic
resonance in the gas passage connecting the indicator transducer and the cylinder volume.
Clearance Volume - The volume in cubic inches remaining in the compressor cylinder at the end of the
discharge stroke; the space between the piston head end and the end of the cylinder plus the space
that exists around the valves, which are located near the cylinder ends.
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Glossary of Terms
83
Combustion - The burning of gas in which the fuel is converted into heat energy by rapid oxidization.
Combustion Chamber - The space at top dead center in a reciprocating internal combustion engine
where combustion takes place.
Compression - As applied to internal combustion engines, it is the mechanical ability of combustion
chamber components to hold pressure by the upward motion of the piston at the end of the
compression stroke. Compression in reciprocating engines can be measured dry (engine is down
without lubrication) or running (engine is running with lubrication).
Compression Pressure - The pressure of the air/fuel charge at the end of the compression stroke with
no ignition of the mixture. In a compressor cylinder, this is the pressure of the gas charge at the end of
the compression stroke.
Compression Ratio - The ratio of the volume of the charge at the beginning of the compression stroke
to that at the end of the compression stroke in an internal combustion engine.
Compression/Tension - The force in pounds that the compressor rod is undergoing due to pressure
differential on each side of the piston and the inertial acceleration of the reciprocating motion. The
force is displayed as pounds compression and pounds tension.
Connecting Rod - The connection between the piston and the crankshaft in an engine or between the
crosshead and the crankshaft in a compressor.
COV - Coefficient of Variation (or Variance) in statistics. COV is the magnitude of variance or
dispersion relative to the mean or average. CV = SD/Avg.
We use COV in two different ways:
1. In a spark ignited (SI) engine, we use COV to measure the peak firing pressure stability.
A normal COV would be from ten to twenty. A high COV indicates a mechanical problem
and/or a lean air fuel mixture in the main or pre-combustion chamber.
2. When using vibration history to set warning and alarm levels, a COV of less than .33 is
desired. If the COV is greater than .33, the average times 1.5 may give a better warning
level (with less false vibrations alarms) than using the average plus three standard
deviations where there are no malfunctions present in the equipment.
Crank Angle Encoder - A device used on an engine analyzer to generate a signal per degree of
rotation on a crankshaft.
Crankcase - The lower part of the engine that acts as an oil reservoir and holds the crankshaft.
Crosshead - The part of a compressor that connects the piston rod to the main rod.
Crank End (CE) - That end of the compressor cylinder nearest the engine or frame.
Cubic Inch - Abbreviated Cu. In.
Cycle -A series of events that repeat themselves in a regular sequence. Four-stroke cycle: intake,
compression, power and exhaust. Two-stroke cycle: intake/compression and power/exhaust.
Cylinder - A chamber in which a piston travels.
Detonation - Uncontrolled, rapid combustion rate. It is spontaneous combustion of the remaining
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portion of the charge of air and fuel causing too rapid a combustion rate, extremely high flame front
speed and excessively high pressure within the cylinder.
Discharge Pressure - The pressure at which compressed gas is forced out of a cylinder.
Discharge Valve - A valve through which compressed gas leaves the cylinder.
Discharge Temperature (TD) - The temperature of the gas leaving the cylinder through the discharge
valve. Typically this is measured at or near the discharge bottle or nozzle.
Double Acting - Indicates that the piston pumps gas on both ends; i.e., as the gas discharges out the
valve on the head end, the piston draws gas into the cylinder through the suction valve on the crank
end. The reverse happens as the piston strokes toward the crank end or the engine.
Dynamic Compression Pressure - The pressure in the cylinder at the end of the compression stroke
with normal combustion occurring. Dynamic compression is usually higher than cranking compression
due to temperature and combustion.
Engine Derating - Reducing the standard horsepower or speed ratings on an engine because of the
kind of service it performs or existing ambient conditions. For example: An intermittent rating will be
higher than a continuous rating on an engine. An engine rating at high altitude or high ambient
temperatures will be rated for a lower output.
Exhaust - The stroke or portion of the stroke in an internal combustion engine in which burnt gases left
over from combustion are released from the cylinder.
Exhaust Port - An opening in the cylinder wall through which exhaust gas is expelled when the exhaust
port is uncovered by the piston.
Exhaust Valve - The part of a four-stroke-cycle engine which releases exhaust from a combustion
chamber into the exhaust manifold.
Fixed-Volume Pocket - A fixed-volume chamber or a chamber with a valve that can be opened or
closed by a handwheel or air cylinder from outside the cylinder. A fixed-volume pocket adds a specific
volume to the cylinder when it is open.
Flame Front - The leading edge of a flame propagating from its ignition source.
Foot-Pound - This is the amount of energy or work required to lift one pound a distance of one foot.
Four-stroke (Cycle) Engine - An engine that requires four piston strokes and two complete crankshaft
revolutions to complete each cycle.
Friction Horsepower - Power consumed within an engine or compressor from friction of its moving
parts.
Fuel Event - The event measure in degrees of crank angle where fuel is entering the combustion
chamber.
Fuel Injector - A device which sprays fuel into the combustion chamber.
Fuel Valve - A cam-actuated valve that allows fuel to enter the combustion chamber.
Flywheel - The round massive component used to provide inertia that damps angular velocity changes
of the machine.
Gas - A substance that changes volume and shape according to temperature and pressure applied to
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Glossary of Terms
85
it. Often, a combustible substance.

Gas Analysis - Mole Fractions of each gas contained in the mix of gases passing through the
compressor.
Governor - A device (either mechanical, electrical, or hydraulic) to control and regulate speed (RPM).
Head End (HE) - That end of the compressor cylinder away from the engine or frame.
Horsepower - The energy required to lift 550 lbs. one foot in one second or 33,000 lbs. one foot in one
minute.
Horizontal Engines - An engine with cylinders lying in the horizontal plane.
Hydraulic Lifters - A mechanical device used to (1) compensate for changes in temperatures, valve
wear and valve recession as it maintains a zero lash (clearance), and (2) cushion the opening and
closing of the various valves (intake, exhaust, etc.)
Ignition - The combustion of the fuel mixture in the combustion chamber. In a spark ignited engine,
ignition is the electrical spark that provides the source of igniting the air/fuel mixture.
Ignition Delay - The time from initial injection of air and fuel to actual ignition of the mixture in a
compression ignited engine. In a spark ignited engine, it is the total time required from the initial spark
until a pressure rise occurs due to combustion. It is the total time required for the physical and
chemical reactions required to propagate a flame front.
Ignition Timing - The point at which the ignition systems delivers a spark to the spark plug to begin
burning the air/fuel mixture, in relationship to crankshaft rotation or TDC.
Indicated Horsepower - The actual horsepower developed on the surface of the piston in a
reciprocating power cylinder or consumed surface of the piston in a reciprocating compressor cylinder.
Indicated Mean Effective Pressure (IMEP) - That theoretical constant pressure that can be imagined
exerted on the piston during each power stroke of the cylinder to produce power equal to the indicated
power. It is the average pressure exerted on the piston through the functional cycle.
Indicator Port - A direct connection from the outside to the inside of the cylinder clearance area. The
port is used for connection of instrumentation to investigate pressures inside the cylinder.
Injection Valve - A device used to inject fuel into the combustion chamber of an engine.
In-line Engines - An engine design where all the power cylinders are in a block or frame located one
behind the other.
Intake Manifold - The manifold that holds air or air and fuel before it enters the combustion chamber.
Intake Port - An opening in the cylinder wall through which gas flows into the cylinder when the intake
port is uncovered by the piston on a two-stroke engine.
Intake Valve - The valve which permits air to enter the cylinder of an engine.
Integral - A compressor having a common crankshaft for both power and compressor cylinder or
cylinders. The prime mover and the compressor are combined into a single frame.
Jacket Water - The water system of the engine used for cooling the cylinder, head, and other parts.
Jacket Water Pressure - Pressure produced normally by a centrifugal pump to circulate jacket water
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throughout an engine.
Kiene Valve - A special valve used in the indicator port for connection to pressure transducers.
Liner - A replaceable cylinder in an engine block.
L/R Ratio - The L/R ratio is the ratio of the connecting rod length to the radius of the crankshaft throw.
Main Bearing - Bearings which act as the support on a crankshaft.
Manometer - A device used to measure vacuum or lesser pressures. It is a U-shaped tube partially
filled with a fluid. One end is open to atmosphere, the other to the pressure or vacuum being
measured. Readings are given in inches of the liquid in the tube (i.e., inches of mercury).
Mean Effective Pressure (MEP) - The MEP of a cycle or stroke of a heat engine is the average net
pressure in pounds per unit area that operates on the piston through its stroke.
Mechanical Efficiency - The ratio of brake horsepower delivered by an engine to the indicated
horsepower developed.
Misfire - Absence of combustion in a power cylinder. The condition may be intermittent or continuous.
Naturally Aspirated Engine - An engine without a supercharger, turbocharger, or reciprocating
scavenging cylinder. At the start of compression, these units operate on a cylinder air charge at a
pressure slightly below atmospheric pressure.
Nozzle - The passage that provides an inlet or outlet to the compressor cylinder.
Oil Cooler - A shell and tube type heat exchanger in which cooling water passes through the tubes
while lube oil flows around the tubes to transfer heat from the oil to the water. Subsequently, the water
is typically cooled by fans.
Once-Per-Turn - Transducer to generate one pulse per revolution of the crankshaft. This usually is in
line with TDC on the flywheel.
Opposed Piston Engine - An engine consisting power cylinders containing two pistons which drive two
different crankshafts, connected at one end with a vertical shaft. Combustion occurs between the two
pistons.
Parasitic Horsepower - Horsepower used to drive auxiliary equipment such as pumps, generators,
motors, etc.
Peak Firing Pressure (PFP) - The maximum pressure developed in a power cylinder due to
combustion of the mixture. Under normal conditions, peak pressure occurs between 10 to 25' after top
dead center on a spark ignited cylinder. The precise degree of crankshaft rotation will be affected by
speed, combustion chamber design, and fuel.
Piston - A cylindrical part closed at one end which is connected to the crankshaft by the connecting
rod. It is the force from combustion, exerted on the closed end of the piston, which causes the
connecting rod to move the crankshaft.
Piston Displacement - The volume of air moved or displaced by movement of the piston as it goes
from bottom dead center to top dead center.
Pounds per Square Inch Absolute - Pounds per square inch gauge plus atmospheric pressure.
Abbreviated PSIA.
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Glossary of Terms
87
Pounds per Square Inch Gauge - Pounds per square inch gauge. Abbreviated PSIG.
Power Valves - The combination of all valves (intake and exhaust) on a four-stroke-cycle engine.
Pre-lgnition - A common fault with a spark ignited engine where the mixture begins to burn prior to an
electrical spark being introduced into the cylinder. The usual cause is overheated parts or particles in
the combustion chamber.
Pressure Versus Crank Angle - A function of the engine analyzer to display pressure as it relates to
degrees of crankshaft rotation.
Pressure Volume - A function of the engine analyzer to display pressure in relation to volume of a
cylinder.
PT - (Pressure vs. Time trace) The dynamic pressure inside a cylinder referenced to crank-angle
position.
Pulsation - The pressure fluctuation in the nozzles, bottles, and pipping due to the flow variations in the
gas from the reciprocating compressor.
Pulsation Bottle - A receiver or vessel mounted directly to the flanges of a cylinder to minimize
pulsations. Sometimes called a pulsation damper.
PV - (Pressure vs. Volume) curve (sometimes referred to as "PV Cards"). It is the pressure in pounds
per square inch times volume in cubic feet. Pressure volume is used as an indication of work
performed.
Pyrometers - Used to indicate cylinder exhaust and manifold temperatures.
Rack - A type of gear that is flat, usually associated with a pinion gear to convert rotational motion to
linear
motion .
Rated Horsepower - The value used by engine manufacturers and operators to rate the power of an
engine, allowing for safe and efficient operations.
Ratio - The relation or proportion of one number or quantity to another.
Reciprocating - To move back and forth alternately, such as the action of a piston in a cylinder.
Rich Mixture - A mixture with a volumetric air/fuel ratio with less parts air than 10:1 (i.e., 9:1).
Rod Diameter - The diameter of the piston rod.
RPM - Revolutions per minute.
Scavenging - Removal of exhaust gases from the cylinder, usually by a flow of air.
Scavenging Air -The air induced into a cylinder for three major purposes (1) To help purge the cylinder
of the contaminated gases from the previous combustion cycle; (2) To cool the internal surfaces of the
cylinder; (3) To fill the cylinder with a fresh charge of oxygen filled air.
Separable - A compressor that is built into a frame that is separate from the driver.
Spark Plug - An electrical device used to ignite the air/fuel mixture in an internal combustion engine.
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88

SQ. FT. - Area measurement in square feet.
SQ. IN. - Area measurement in square inches.
Standard Deviation - Is a statistic that tells you how tightly all the various examples are clustered
around the mean in a set of data. When the examples are pretty tightly bunched together and the
bell-shaped curve is steep, the standard deviation is small. When the examples are spread apart and
the bell curve is relatively flat, that tells you you have a relatively large standard deviation. The
standard deviation is kind of the "mean of the mean," and often can help you find the story behind the
data.
Stroke - The movement of the reciprocating machine during one rotation of the flywheel.
Suction Pressure - The pressure of a gas entering the suction valve of a compressor.
Suction Temperature (TS) - The temperature of the gas entering the suctions valve of a compressor.
Typically, this is measured at or near the suction bottle or nozzle.
Top Dead Center (TDC) - A marking indicating that the lead cylinder is at it's most extended position.
A mark is usually placed on the flywheel indicating this position.
Torque - A moment of force applied to the rotation of a shaft by a lever arm.
Two-stroke (Cycle) Engine - An engine requiring only one complete revolution of the crankshaft to
complete a cycle of combustion events.
Unloader - A device used to cause gas to surge into and out of the compressor cylinder without going
through the discharge valve. An unloader has plungers that hold the valve plates or channels open.
"V" Engine - An engine that consists of two banks of cylinders connected to the same crankshaft which
gives the appearance of a "V".
Vacuum - Pressure less than atmospheric pressure.
Variable Pocket - A chamber that adds clearance volume in direct proportion to its setting. The setting
may be adjusted to any volume within the limits of the pocket.
Volumetric Efficiency - The ratio of the volume of gas actually drawn into a cylinder to the total cylinder
volume.
Work - Force times distance.
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Index
Direct Channel Read
Index
-E-
-663X0/CA with encoder
Encoder 5
Multi-Event 62
Shaft Encoder 61
Engine Balancer 20
ESP 2
Extended Service Plan
18
-AAssistance 1
Avertissement
Risque D'Explosion
Balance Engine Nonencoder

Balancer 20
Battery 6
Care 6
E-Moli 7
Performance 6
Battery Charger 8
20
Handling 3
Hardware Configuration 13
Hazardous Location Information
Hole-Pin 61
-IIgnition Survey 43
Introduction 1
-K-
-CCare 5
Charger 8
Class 1, Div 2 Information
Cleaning 5
Configuration
Hardware 13
Connections
6310 10
Control Drawing 73
Customer 1
Assistance 1
Repairs 1
Trouble 1
-D-
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-H-
71
-B-
Data Collection
Database 16
Date 65
58
71
Keyboard 13
Keypad 13
71
-MMachine 16
Machine Setup Menu 18
Magnetic Pickup 63
Measuring 71
Pressure 71
Temperature 71
Vibration 71
-OOperating Temperature
6320 71
Optical Pickup 63
Options
Hardware 13
71
89
90

Station 16
Strobe Light
-P-
-T-
Parallel Port 5
PHASE A-B 61
Power Cylinder Monitor 39
Pressure Measurements 71
Printing
6310 66
6320 69
Problems 1
TDC 61, 63
Temperature Measurements
Templates 65
Terms 5
Time 65
Timing Light 63
-RRepairs 2
Return Material Authorization
Returning Products 2
63
71
-U2
-SSafety 3, 4
Sensor 74
Magnetic Pickup 75
Pressure Water Cooled 78
Scaling 74
Secondary Ignition 77
Specifications 81
Settings
Date 6310 65
Date 6320 66
Time 6310 65
Time 6320 66
Time Zone 6320 66
Setup
General Machine 18
Setup Balancer/Spark 20
Software
Windows 6310 64
Windows 6320 64
Spark Mode 55
Spark Survey 43
Special Collection Modes 54
Speciifications
6310 78
6320 79
Sensors 81
Unpacking 5
USB 5
Utilities
Direct Channel Read 58
Power Cylinder Monitor 60
-VVGA 5
Vibration Measurements
71
-WWarning
AC Power 71
Battery Replacement 71
Battery Substitution 71
Board repair / replacement / modification 71
Cables used with sensors and encoder 71
Ethernet 71
Explosion Hazard 71
Hazardous atmosphere 71
Unit repair / modification 71
USB 71
VGA 71
Warnings 4
Encoder 4
Multi-Event 62
Pressure Sensor 4
Shaft Encoder 61
Timing Light 4, 63
Windows 64
Windrock, Inc. 2013

6320 CA Manual

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Portable Analyzer

Part I Customer Information

Part II Read This First

4 Batteries & Charging

Part III Getting Started

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

Part V Balancer/Spark Setup and Data Collection

Part VI Encoder-based Balance

Windrock, Inc. 2013

Portable Analyzer CA Operations Manual

Part VII Utility Menu Options

Part VIII Encoder Setup

Part IX Loading New Software

Part X Operating System Commands

Part XII Glossary of Terms

Windrock, Inc. 2013

Portable Analyzer Manual

A note indicates special comments or instructions.

Warning! A warning indication a condition which has severe impact on hardware, or

Windrock, Inc. 2013

Portable Analyzer CA Operations Manual

Windrock, Inc. 2013

Windrock, Inc. 2013

Portable Analyzer CA Operations Manual

Windrock, Inc. 2013

Read This First

Read This First

6310 / 6320 Analyzer

PARTS LIST (Standard Package)

Windrock, Inc. 2013

Portable Analyzer CA Operations Manual

Batteries & Charging

Windrock, Inc. 2013

Read This First

LITHIUM-ION STYLE BATTERY

Windrock, Inc. 2013

Portable Analyzer CA Operations Manual

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

Windrock, Inc. 2013

Read This First

Windrock, Inc. 2013

Portable Analyzer CA Operations Manual

Windrock, Inc. 2013

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

A6320-00 Left Side

Windrock, Inc. 2013

Portable Analyzer CA Operations Manual

Windrock, Inc. 2013

ON/OFF Turns the analyzer on or off.

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

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

Advances the user ahead multiple entries or multiple pages.

Returns the user back multiple entries or multiple pages.

Enters a decimal point as needed for numeric entries.

Windrock, Inc. 2013

Portable Analyzer CA Operations Manual

Use power save:

Typically set to 40 column.

Text Cursor Style:

The style of the cursor may be changed between ARROW, BAR,

Windrock, Inc. 2013

This is set to YES for a CA Lite and NO for a CA with encoder

Autoscan first in take data:

Use unit conversion: