Windrock MD Manual PDF

Windrock MD
Application
Manual
© Windrock, Inc. 2017

Legal Notices
Copyright
1997-2016 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, mak es no warranty of any k ind 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.
Windrock MD Application Manual
If you have comments about this documentation, the software, or products it describes, please contact the
Customer Support Group at Windrock .
Contents I
Table of Contents
Part I Introduction 1
1 Overview
................................................................................................................................... 1
2 File Menu
................................................................................................................................... 2
3 Edit Preferences
................................................................................................................................... 3
4 View ................................................................................................................................... 8
.........................................................................................................................................................
Customizing the Toolbar 8
Part II Machine Database 9

1 Machine
...................................................................................................................................
Database Overview 9
2 Station
...................................................................................................................................
/ Machine Manager 13
3 Adding
...................................................................................................................................
Stations and Machines 15
4 Reordering
...................................................................................................................................
Stations / Machines 18
5 Locating
...................................................................................................................................
an Existing Database 18
6 Sending
...................................................................................................................................
Data via Email 19
7 Receiving
...................................................................................................................................
Data via Email (*.wrpm) 21
Part III Setting up your machine 22

1 Data Entry
...................................................................................................................................
Tips 22
2 Machine
...................................................................................................................................
Geometry 23
......................................................................................................................................................... 23
Machine Parameters
Parameter Definitions
.................................................................................................................................................. 24
Engines with.........................................................................................................................................................
Articulation 27
Articulation Entries
.................................................................................................................................................. 27
Articulation Table .................................................................................................................................................. 29
Articulation Diagrams
.................................................................................................................................................. 34
Engines without.........................................................................................................................................................
Articulation 37
Engine ......................................................................................................................................................... 38
Compressors......................................................................................................................................................... 41
Miscellaneous ......................................................................................................................................................... 44
3 Sensor
...................................................................................................................................
Points 45
Overview ......................................................................................................................................................... 46
Sensor Point.........................................................................................................................................................
Names 47
Point Types ......................................................................................................................................................... 47
Other Points......................................................................................................................................................... 49
Sensor Point.........................................................................................................................................................
Setup 52
Overview .................................................................................................................................................. 52
Engine Points .................................................................................................................................................. 54
Compressor Points
.................................................................................................................................................. 57
II Windrock MD Application Manual
Vibration Filters..................................................................................................................................................
/ Sensitivity 61
.........................................................................................................................................................
Sensor Point Generator 64
Auto Generate ..................................................................................................................................................
Sensor Point List 65
4 Collection
...................................................................................................................................
Points 77
Overview ......................................................................................................................................................... 77
.........................................................................................................................................................
Collection Point Setup 78
Unified Collection ..................................................................................................................................................
Point Route 83
.........................................................................................................................................................
Auto Generate Collection Point List 84
5 Group...................................................................................................................................
Plots 90
Overview ......................................................................................................................................................... 90
Group Plot Setup ......................................................................................................................................................... 91
......................................................................................................................................................... 95
Group Plot Reordering
View ......................................................................................................................................................... 98
Auto Generate ......................................................................................................................................................... 99
6 Fixed
...................................................................................................................................
Data Scales 100
Overview ......................................................................................................................................................... 100
Fixed Scale.........................................................................................................................................................
Editor 106
Creating A .........................................................................................................................................................
New Scale 106
7 Gas Composition
................................................................................................................................... 107
8 Compressor/Engine
...................................................................................................................................
Calculations 111
Compressor.........................................................................................................................................................
Panel Point Setup 112
Compressor.........................................................................................................................................................
Temperature Setup 113
Compressor.........................................................................................................................................................
Nozzle Trace Setup 114
Bypass Valve .........................................................................................................................................................
Setup 114
Engine Panel .........................................................................................................................................................
Points 116
Diesel Panel .........................................................................................................................................................
Points 117
.........................................................................................................................................................
Exhaust Temperature Setup 118
BSFC Setup......................................................................................................................................................... 118
Fuel Usage.........................................................................................................................................................
Curve 120
9 FFT Route
................................................................................................................................... 122
10 Software
...................................................................................................................................
Options 122
11 Economic
...................................................................................................................................
Factors 131
12 System
...................................................................................................................................
& Analyzer Options 134
13 User ...................................................................................................................................
Units (Metric) 138
14 Diagnostics
................................................................................................................................... 140
Engine Diagnostics......................................................................................................................................................... 141
Compressor.........................................................................................................................................................
Diagnostics 142
15 Balancer
...................................................................................................................................
and Spark Survey 144
16 Trend
...................................................................................................................................
Points 148
Trend Point.........................................................................................................................................................
Formulas 149
Part IV Plot 150

1 Overview
................................................................................................................................... 150
2 Major
...................................................................................................................................
Functions 152

Contents III
Plot Data ......................................................................................................................................................... 152

Group Plot ......................................................................................................................................................... 154
Plot Types ......................................................................................................................................................... 155
Modify / Remove .........................................................................................................................................................
Line 156
3 Settings
................................................................................................................................... 159
Overview ......................................................................................................................................................... 159
Scaling ......................................................................................................................................................... 160
Toe Point Adjust ......................................................................................................................................................... 161
4 Plot Views
................................................................................................................................... 162
Overlay ......................................................................................................................................................... 162
Phasing ......................................................................................................................................................... 163
Valve Events ......................................................................................................................................................... 164
TDC Shift ......................................................................................................................................................... 165
Power StatBox ......................................................................................................................................................... 165
Derivatives......................................................................................................................................................... 166
5 Plot Types
................................................................................................................................... 168
LogP-LogV......................................................................................................................................................... 168
PV ......................................................................................................................................................... 168
PT ......................................................................................................................................................... 169
Rod Load ......................................................................................................................................................... 170
.........................................................................................................................................................
Dynamic Rod Motion 171
Part V Format 172

1 B&W
...................................................................................................................................
/ Color 172
2 Grid ...................................................................................................................................
Style 172
3 Line ...................................................................................................................................
Intensity 173
4 Line ...................................................................................................................................
File Style 173
5 TDC ...................................................................................................................................
Shift 173
6 Phasing
................................................................................................................................... 173
7 Overlay
................................................................................................................................... 173
8 Smoothing
................................................................................................................................... 173
9 Show...................................................................................................................................
Valve Events 175
10 Show...................................................................................................................................
TDC Position 175
11 Use Nozzle
...................................................................................................................................
Traces 176
12 Show...................................................................................................................................
Toe Points 176
13 Show...................................................................................................................................
Power Stats Box 176
14 Theoretical
................................................................................................................................... 176
15 Adjust
...................................................................................................................................
VEs 176
16 Smoothing
...................................................................................................................................
Factors 177
17 Scaling
................................................................................................................................... 178
18 Stripcharting
................................................................................................................................... 179
19 Clearance
...................................................................................................................................
Adjustment 180
IV Windrock MD Application Manual
Part VI Tools 181

1 Cursor
...................................................................................................................................
Readout 181
2 Zoom................................................................................................................................... 184
3 Calculate
................................................................................................................................... 185
4 Show...................................................................................................................................
RPM / Loadstep 185
5 Peak...................................................................................................................................
Frequency Tool 185
6 Waterfall
...................................................................................................................................
/ 3D Plot 187
7 Adjust
...................................................................................................................................
Clearances 188
8 Show...................................................................................................................................
WindWizards 188
9 Add Annotation
................................................................................................................................... 189
10 Undo...................................................................................................................................
Last Annotation 190
11 Erase...................................................................................................................................
All Annotations 190
Part VII Reports 190

1 Full Report
................................................................................................................................... 190
2 Quick
...................................................................................................................................
Report 195
3 Trend
...................................................................................................................................
Report 195
4 Report
...................................................................................................................................
Export 195
5 Setup
...................................................................................................................................
Reports 197
Engine Report ......................................................................................................................................................... 197
Ignition Report ......................................................................................................................................................... 197
Compressor.........................................................................................................................................................
Report 198
Rod Load / .........................................................................................................................................................
Rod Drop Report 198
New Report.........................................................................................................................................................
Format 200
6 Report
...................................................................................................................................
Field Descriptions 200
......................................................................................................................................................... 200
Engine Report
......................................................................................................................................................... 202
Balance Report
......................................................................................................................................................... 203
Ignition Report
.........................................................................................................................................................
Spark Survey Report 204
.........................................................................................................................................................
Compressor Report Sections 207
Compressor Calculation
..................................................................................................................................................
Information 211
.........................................................................................................................................................
Economic Report 212
.........................................................................................................................................................
Rod Load / Rod Drop Report 213
.........................................................................................................................................................
Manual Report 214
.........................................................................................................................................................
Analyzer Notes Report 216
.........................................................................................................................................................
Report Export Format 216
.........................................................................................................................................................
Common Questions 220
7 Auto...................................................................................................................................
Printing 222
Part VIII History 222

Contents V
Part IX Window 224

1 Cascade
................................................................................................................................... 225
2 Tile ................................................................................................................................... 226
3 Arrange
...................................................................................................................................
All 226
Part X Utility 227

1 Connect
...................................................................................................................................
to Analyzer 227
2 Data ...................................................................................................................................
Explorer 229
Part XI Help 231
Part XII Appendix 231

1 Migrating
...................................................................................................................................
to a New PC or Operating System 231
2 Making
...................................................................................................................................
the Change from the 6310 to the 6320 232
3 Creating
...................................................................................................................................
Windows Shortcuts 233
4 Notes
...................................................................................................................................
on Analyzer 234
Part XIII Glossary 237
Index 245
1 Windrock MD Application Manual
1 Introduction
1.1 Overview
The following sections briefly summarize the functions you will use to set up and operate your
Windrock MD (Windrock Machine Diagnostics) Windows application by Windrock, Inc. This
Windrock MD Manual help version is 4.4.0.
The File Menu

The file menu has similar functions common to all Windows programs. File OPEN is the entry point
to a machine setup, data that has been stored from the analyzer, and plotting functions. Begin by
opening a database and setting up a machine for data collection. Multiple machines may be open at
one time. Having two databases open at one time allows you to compare plots from separate
machines on one screen. Care should be taken to enter the proper information in the selected
machine if more than one database is open at a time. The PRINT option simply prints the graphic
image in the selected orientation to full paper size.
Edit
You can customize the Windrock MD application to meet the exact requirements of your
organization. All the elements you need to enter for your company-specific information are found
under the Edit | Preferences menu. From here, you will set up and maintain your company name
and address information, program settings, etc.
View
View allows the user to turn the tool bar on and off along with Customizing The Toolbar.
Setup
Below are shortcuts to the machine's setup:
Geometry
Sensor Points
Collection Points
Group Plots
General
Fixed Data Scales
Gas Composition
Compressor/Engine Calculations
FFT Route
Software Options
Economic Factors
System & Analyzer Options
User Units (Metric)
Diagnostics
Balancer and Spark Survey
Trend Points
Plots

Introduction 2
Collected data may be recalled and formatted based on your needs. The Plot Historical function
allows you to recall specific data points while Group Plot recalls a preset group of data points. Once
plotted, the data can be reformatted using the plot settings and plot toggles.
Plot Historical
Group Plot
Plot Settings
Format
Format allows the user to change the properties of a display.
Tools
Allows the user to apply different tools to the displayed data.
Reports
Engine, Compressor, Ignition, and Process Variable reports are set up and generated with this
option.
View Reports
Quick Report
Setup Reports
Compressor
Power
Ignition
Engine/Compressor Panel Point
Exhaust Temperature
Auto Printing
Economic Report
History
Historical notes related to the machine can be entered here and viewed at a later date. This is
available as a menu item at the top of the machine plot area only when a machine database is
open.
Utility (Connect to the Analyzer)

System utilities are located here.
Help
The are several help areas available from which to select.
1.2 File Menu

The File | Open (CTRL+O) menu option is the entry point to a machine setup, data that has been
stored from the analyzer, and plotting functions. Multiple machines may be open at one time. Having
two databases open at one time allows you to compare plots from separate machines on one screen.
Care should be taken to enter the proper information in the selected machine if more than one
database is open at a time.

The File | Close (CTRL+W) menu option closes the current database.
The File | Print menu option prints the currently displayed graphic image, in the selected orientation,
to full paper size. By selecting "Landscape" mode on the printer dialog box, the graphic printout will be
full size on the printed page.
The File | Exit (Alt+F4) menu option exits the application directly closing all databases that are open.
1.3 Edit Preferences
The edit preferences menu option gives access to several program defaults that may be changed by
the user. Once the changes are made, pressing OK will update the information for future use. Once
set, the program uses these defaults to control reports, graphs, multimedia, etc. The preferences are
grouped on tabs for easy selection.

Introduction 4
Company Info Tab - (Address & Logo)
Windrock MD contains several reports. Each report that is printed has a header which contains a
company logo and address. The address lines and logo can be customized to your company's
name and logo so they will print on the reports. To change the logo, simply use the radio button to
select "None" for no logo or "Custom Logo" to use your companies logo.
Use the browse button to select the file

folder in which your logo is stored.
Select Thumbnails to view the the

available file choices.
Select the image you want to use, then

select open to use the image selected.
The analyst using the program may also enter his/her name here for printing on the reports or you
may select to use the Windows username.
MultiMedia Tab - (Options)
Checking "Sound On" will enable the audio media player if the computer is so equipped. Certain
parts of the program contain helpful audio context to use the Analyzer and software more efficiently.
Plotting Tab - (Graph Colors)
The plots in Windrock MD are set to display up to 10 individual traces. Each trace is a unique color.
The colors are predefined when the software is first installed. The colors may be changed by picking

the line number using the spinner control labeled "Select Line" and pressing the "Change color"
button. A color selection dialog box will pop up for the selection process. Custom colors may be
used.
The "Use Gray Borders" check box toggles the graphics border on the plots to have a white or gray
edge to the plots.
Show Station and Machine names on plots:

The station and machine name can be added to plots transferred using the Windows clipboard.
Once changed and OK is pressed, the colors are saved and may be changed again at any time.
Defaults Tab - (Optional Operational Parameters)
This tab contains important options that are set as defaults for the program.

Introduction 6
Show Leak Index for Compressor Pressure Curves:

Next, the "Show Leak Index for Compressor Pressure Curves" calculation can be turned on by
checking the check box. When the Show Leak Index check box is checked, the curve will be
visible when the calculate speed button is clicked.
When the Show Leak Index check box is

checked, the curve will be visible when the
calculate speed button is clicked.
Show “Explore To” in Station / Machine Manager:
Enables an “Explore To” option when you right-click on the machine directory in the
Station / Machine Manager. This offers a convenient way to access your machine directory
in case you need to perform low-level manipulation of data or setup files.
Important note: Internally, Windrock MD uses database files to store per-machine and
database-wide setups. Because most aspects of a machine's setup are in a database file,
copying individual d6 files from one machine to another will not work. Please contact
Windrock Customer Support at service@windrock.com if you have any questions or need
more information.
HELP button:
Click on the "Help" button for context sensitive help information.

Configuration Tab
If the "Check for updates automatically" box is checked, the software will automatically look at the
Windrock web site for notification of software updates. You may then be instructed on how and from
where to download software updates.
If you have disabled any messages, pressing the

"Reset" button will reset them.

Introduction 8
1.4 View
View allows the user to turn the tool bar on

and off along with Customizing The Toolbar
1.4.1 Customizing the Toolbar
You can customize the toolbars of Windrock MD by right-clicking anywhere on a toolbar and choosing
Customize. You can also show and hide individual toolbars.

The Commands section of

Customize Toolbars includes
several actions (such as Clear
Plots or Modify / Remove Line)
that were previously only
available as menu options; you
can add these to a toolbar if
you wish.
2 Machine Database
2.1 Machine Database Overview
Machine setups, such as geometry, test points, gas analysis, scales, etc., are kept in a single
subdirectory (folder) along with any data that has been collected. Using the database selection dialog
box, a particular station and machine may be selected.
To open a database, click on "File | Open" from the main menu. A Machine Selection Dialog box will
appear with several capabilities.
Creating first database;

If this is the first time the Windrock MD application has been used, it will be necessary to create (or
locate) the database folder. You will see the following message appear on the screen if the default
database folder does not exist.

Machine Database 10
Click on Yes and a new database folder will be created on drive "C:" ready for adding new stations and
machines. The next time you start the program, it will automatically go to the "Machine selection
Dialog" box. Review the next section on the "Machine Selection Dialog" box and the functions
associated with it before proceeding. After doing this, continue to "Adding Stations and Machines".
If you already have an existing database folder but it is located in a different place, click No to try to
locate the existing database folder to use.
Note: This may be the case when copying over a database from an old computer or if you
have a network drive where the database is k ept.
Then continue on to "Locating an existing database".
Creating an additional database;

1. Inside the Station / Machine Manager selection box, click on the Database drop down box where
you will find a "Create new database" option.

2. Next select the location for the new database database and select "Make New Folder" option.
3. The new folder will be created and you will have the option or renaming the folder.

Machine Database 12
4. Type in your new folder name and select OK. The new folder will contain the files required by
Windrock.

2.2 Station / Machine Manager

The "Station / Machine Manager" dialog box has several functions. Its main function is to allow the
user to find the stored data from the analyzer for a given station and machine. To do this, simply
select the drive, the directory where the data is stored and a station list will appear in the Station /
Machine Directory list box. Select a station by clicking on the appropriate name, and the machines
will appear below the station. You may either click and press OK or simply double click on the
machine name to open the database.
In the machine panel of the Station / Machine Manager dialog box, the data available will be reported
by icons along with the data dates available.
Station Level Commands
Right clicking on the station with your mouse will give you several station level commands.

Machine Database 14
Add
Allows a new station to be added to the database.
Rename
Allows the name of the station to be changed in the database.
Delete
Allows the removal of a station and its machines.
Zip Station
This function compresses the station database. The compressed data files will be stored in the
location of your choosing. After compressing the station, you will have several options which include
saving and emailing.
Station Cost Performance

This station-wide cost comparison report compares the dollar per mmscf for each unit in a station. If
you are using fuel cost as the cost basis, the BSFC option must be set up in a machine for this
report to provide a value. Currently, this report will only pull the latest data for each machine. A fuel
flow measurement for this run number needs to be available when using a fuel cost basis.
Import
A previously archived (zipped) station can be added to the current database.
Machine Level Commands

Right clicking on the machine with

your mouse will give you several
machine level commands
Add
Allows a new machine to be added to the database. You will have the option of coping an existing
machine that is in the current database. if you need to copy a machine that is in a different
database, you must first export that machine, then import into current database.
Rename
Allows the name of the machine to be changed in the database.
Delete
Allows the removal of a machine
Zip Machine
This function compresses the machine database. The compressed data files will be stored in the
location of your choosing. After compressing the machine, you will have several options which
include saving and emailing.
Import
A previously archived (zipped) machine can be added to the current station.
2.3 Adding Stations and Machines

To add a new machine to a station, you have several options.
1. Right click on the station and select Add New Machine. Select "Create a new, blank machine".
Open the new machine and add the geometry, sensor points and collection points.

Machine Database 16
2. Right click on the station and select Import zipped machine that has previously been archived.
The archived machine could be one you saved from an email or from a zip drive.

3. Right click on the station and select Add New Machine. Select copy setups from an existing
machine. Use the drop down box to select the machine to copy from the current database.
Note: There is no longer a limit on the number of stations or machines nor the length of a name.

Machine Database 18
2.4 Reordering Stations / Machines

The Station / Machine manager allows a drag-and-drop reordering of the stations and machines within a
station. Reordering in the Station / Machine manager only applies to the PC database and has no
effect in the analyzer database. To reorder the analyzer database files see Connect to Analyzer.
If you need to move a machine and its

data from one station to a different
station use the "Zip and Import" function.
2.5 Locating an Existing Database

The program defaults to drive "C:" and folder "\database" as it does on the analyzer itself. Select the
drive, if other than "C:", where the database is located using the "Hard Drive Root Folder" selection
box. This drop down box contains all the local drives on your computer and any mapped drives if the
computer is attached to a network. The "Folder View" lists all the current root folders for that drive.
Note: Windrock MD may k eep several sets of data located in many folders, either on the local
work station or on a network . This allows a user to have several analyzers and be able to
k eep each analyzer's database in its own unique folder.
If you have more than one analyzer, it might be preferred to keep each analyzer's data in a different
database folder. For instance, a directory structure as follows would be appropriate:
C:\database Analyzer 1
C:\database Analyzer 2

To change from the current file directory, click with the

mouse on the database drop down list box and then the file
folder you wish to access. The program will remember which
drive and folder you last accessed. If the folder is not listed
select "Browse...." from the menu.
If you are on a network and want to store all the data in a central location, create a data structure
similar to the one above and place the analyzer data there. Note: multiple users may easily access
the data in this fashion.
All data for a particular machine is stored in the lowest part of the directory structure (i.e., MXXX). Data
may be zipped up (compressed) and sent via email to other users or back to Windrock for analysis
and review. See the directions under the email topic.
Note: The mapping of the Station and Machine names to the actual folder on the hard drive is done
automatically by the software. In many cases, these folders (sxxx and mxxx) may not
match the analyzer's. This does not matter. It is the names that matter.
2.6 Sending Data via Email

Use the Station / Machine Manager to find and select the station or machine data base to email. Right
click on the selected file and select "Zip".
Select what data to include in the zip file.

Machine Database 20
Select the destination of the file.
If emailing to other than Windrock Customer Support, select recipients from your contacts.

2.7 Receiving Data via Email (*.wrpm)

To receive a machine setup and data via email, open the email and double click on the attachment.
When prompted, select to open the file.
The Windrock MD program will open if it is not already and the import machine dialog box will appear
where you may select what you want to do with the data you just received via email.

Machine Database 22
3 Setting up your machine

3.1 Data Entry Tips
Several setup screens use a spreadsheet style editing for easier editing.
The spreadsheet style editing offers several features:

· Copy and paste – You can copy and paste between grids or copy and paste to and from Excel.
If you are copying a gas analysis, be sure to sort the database by the same column, Gas or
Formula, before copying and pasting.
· Multi-edit – If you select a group of cells and then start typing, all cells are updated to the value
that you've entered. This is especially useful for filling out the load-step table.
· Sorting by column – Click on a column heading to sort by that column's values. This is only
permitted where the grid doesn't already have a well-defined sort order; it's useful in the Gas Mix
Editor to sort the gas components actually in use to the top of the list. DO NOT sort by
Amount when copying and pasting.
3.2 Machine Geometry
From the Setup menu, select

machine geometry and then setup.
After setting up the geometry, you

may view and print the setups.
3.2.1 Machine Parameters

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.
Note: The angle values entered for the engine and compressor phase angles, engine event angles,
ignition timing angle and power cylinder pressure tracking angles are to be entered as
degrees after TDC. On 4-stroke engines, the angles are after TDC of the compression
stroke using a range of 0 to 720 degrees.

Setting up your machine 24
The "Machine" parameters above are required as a minimum and appear on the first tab. The entries
made here will change the listed tabs according to the specific information required for the engine
and/or compressor. Use the following links for more information.
General Setup Options related to the entire machine
Engines w/ Articulation Entries related to articulated engines
Engines w/o Articulation Entries related to non-articulated engines
Engine General Options related to the engine only
Compressors Options related to the compressor only
Miscellaneous Options related to both engine and compressor
3.2.1.1 Parameter Definitions

Strokes per cyl 2/4: is used to set the analyzer up for either a two-cycle or four-cycle machine. Note
that all compressor data is automatically set to 2-cycle mode regardless of this setting. If the shaft
encoder is used, the switch on the side should always be left in 4-stroke mode even if the compressor
is an integral-style machine. See the section on encoders for more information.

In the case of diesel engines, select "DIESEL TWO" or "DIESEL FOUR", and enter information as
needed for diesel engines. Note that certain spark-ignited engine fields are now hidden.
Pulses per rev: sets the sampling per degree of the analyzer. If using the shaft encoder, select 360
pulses per revolution; if using a magnetic speed pickup, select 1 pulse per revolution. When using the
"Multi-Event Encoder", you may enter 'n' number of pulses (e.g., if using a gear with 50 teeth, enter 50
here).
Offset: is used for cases where TDC is shifted from its normal position. For example, if a magnetic
pickup can't be physically mounted at TDC, there is a known offset plus or minus from TDC. This is a
fixed offset and should not be changed from one data collection to another.
Power cylinders: set this value to the number of power cylinders on the machine. Set to zero if this
is an electric motor-driven compressor. This will then reduce the number of set up screens required.
Compressors cylinders: set this value to the number of compressor cylinders on the machine. Set to
zero if there are no compressor cylinders attached. This will then reduce the number of set up screens
required. If you have compressors numbered 1, 3, and 5, and you would like them numbered as such,
set the number of cylinders to 5, and ignore the unused cylinders (2 & 4 in this example) in the
compressor "A" setup tab, and uncheck the unused cylinders (2 & 4 in this example) during the auto-
generate.
Power cylinder layout: is set according to how the cylinders are labeled. Options are Straight,
Left/Right, Odd/Even, Opposed MEP, A/B, or Tandem.
Note: Ingersol-Rand "V" style should use straight for sequential numbering.
MEP Crank offset angle: if the layout selected is Opposed MEP, enter the crank offset angle.
Tandem: if the layout selected is Tandem, check the cylinders with crank-end orientation on the E-
phase tab. This will move the TDC to the right when plotting a power cylinder PV trace for an inboard
cylinder.
Power cylinder articulated: if you have an engine with articulated connecting rods, select yes for
Power cyl articulated. This will require additional information and other "Machine Configuration"
screens will be present. See articulation setup information later in this section.
Rated Load (bhp): enter the rated load (BHP) from manufacturer's specifications.
Rated Speed: enter the rated speed (RPM) from manufacturer's specifications.
Engine Mech Eff: is the ratio of the brake horsepower (BHP). BHP is defined as the actual usable
horsepower available at the crankshaft or flywheel to the indicated horsepower (IHP) developed on the
surface of the power cylinder pistons. By convention, the overall efficiency of industrial engines is set
at 0.85 (85%).

Compressor Mech Eff: is the ratio of the indicated horsepower (IHP) required on the internal surface
of the compressor cylinders to the brake horsepower (BHP) delivered by the driver to the compressor.
By convention, the overall efficiency of industrial compressors is set at 0.95 (95%).
Aux load: enter the total BHP of any additional pieces of equipment driven from the crankshaft.
Engine Rotation: For articulated engines only, select the rotation of the engine flywheel as looking
from the flywheel. Selections are clockwise (CW) or counter-clockwise (CCW). This rotation does not
change if you connect the encoder to the oil pump or use once per turn.
Note: Mechanical efficiency and auxiliary horsepower are used for compressor calculations
and overall efficiency is used for engine calculations.
The "Power Cylinder Articulated" entry will modify the appearance of the input screen depending on
the selection made. An additional tab, "E Articulated", will be visible if the selection is set to YES.
This tab will allow for the entry of articulation information.
For non-articulated engines:
Bore, stroke and rod length equal for all power cylinders: this selection gives the user the ability
to enter a common size bore for all power cylinders or the ability to enter each individual power
cylinder's bore. This would be important if power cylinder(s) have been rebuilt and are a different size.
An additional screen will be available later in the set up for entering the bores.
Or for articulated engines enter:
Power cyl bore (in): this is the power cylinder's bore in inches.
Number of spark plugs / Cyl: select the number of sparks plugs located on each cylinder. The
options are 0, 1, or 2 plugs per cylinder.
Power cylinder clearance: is the clearance for each power cylinder, given as a percent. It is used
for displaying LogP-LogV curves and theoretical curves and for calculating data for the extended new
engine report.
Atmospheric pressure: this is the atmospheric pressure in pounds per square inch (PSI) reported at
the location of the engine.
Standard pressure: the weight of air as measured at sea level. This is typically set at 14.696 PSI.

3.2.2 Engines with Articulation

3.2.2.1 Articulation Entries
For articulated integral engine/compressors, the articulation information must be entered into the
machine setup. This information is used in calculations, reporting, and piston animation. This part of
"Machine Configuration" deals with units that have articulated engines and will contain these additional
setup screens.
The angles and lengths required are:
Master rod length: The length of the master rod in inches
Articulated radius: The radius from the center of the master rod bearing and the centerline of the
link radius rod bearings
Articulated rod length: The length of the articulated power link rod in inches
Bank angle: The angle between the master rod and the power piston centerlines
Bale angle: The angle between the master rod centerline and the centerline of the link radius rod
bearings
On the "E Articulated" tab, identify each connecting rod as either a master rod or an articulated rod.
Enter the side that the master rod is on while looking at the engine from the flywheel end. All bank and
bale angles are based on this position.
On the "Engine Spec" tab, enter the Master Rod Length, Master Rod Stroke, Articulation Radius,
Articulation Rod Length, Bank Angle and Bale Angle for each cylinder.

Note: See the diagrams of articulation for reference.
This setting takes the guess work out of trying to figure out different angles based on right or left
geometry. Simply input the smallest angle from the master to the articulated rod.
For articulated rods, you need to input the bank and bale angle for that cylinder.
To copy a line, highlight the line, or part of the line to be copied and right click. A pop-up selection box
will appear. Select "Copy" or CTRL-C.
To paste a line, point to the beginning point of the line with the mouse pointer and right click. A pop-up
selection box will appear. Select "Paste". You may paste to several lines at ounce by highlighting the
lines.You can also use tab down then CTRL-V to paste several lines quickly.
Or you may highlight several cells, then type the number. When you hit enter, the number will be put
in each cell.

3.2.2.2 Articulation Table

Pow er Bank Rod Type Master Rod Rotation Master Rod Master Rod Articulated Articulated Bank Bale
as view ed from Location View ed at Length Stroke Radius Rod Lgth Angle Angle
FW
Flyw heel (inches) (inches) (inches) (inches) (deg) (deg)
Cooper-
Bessemer
GMV (Short
Stroke)
Left Articulated Right Comp CW 34.00 14.00 7.750 35.125 120.00 120.00
Right Articulated Right Comp CW 34.00 14.00 7.750 35.125 60.00 60.00
GMV (Long Stroke), GMVA, GMVC,

GMVH
Left Articulated Left Comp CW 34.00 14.00 8.500 34.375 60.00 70.00
Right Articulated Left Comp CW 34.00 14.00 8.500 34.375 120.00 130.00
GMX, GMXA, GMXD, GMXH

GMVM, QUAD

Pow er Bank Rod Type Master Rod Rotation Master Master Rod Articulated Articulated Bank Bale
Rod
FW
Cooper-
Bessemer
GMW, GMWA, GMWC, GMWE, GMWH,

V250, V275, W330
Left Articulated Right CW 62.25 20.00 12.250 50.000 36.00 41.40
Pow er
Right Master CW 62.25 20.00
GMYK, Z330
KSV
Pow er
LSV
Pow er

FW
Delaval-
Interprise
DMVR
Left Articulated CW 48.13 21.00 13.954 34.600 45.00 49.50
Right Articulated CCW 48.13 21.00 13.954 34.600 45.00 49.50
Left Master CCW 48.13 21.00
HVA, HVC
RV4

Location View ed at Length Stroke Radius Rod Lgth Angle Angle
Ingersoll-
Rand
XVG
Compressor Side Articulated Left Comp CCW 30.00 12.00 6.875 26.000 60.00 70.00
Free Side Articulated Left Comp CCW 30.00 12.00 6.875 26.000 120.00 130.00
JVG
SVG
PJVG
Left Articulated CCW 24.69 9.00 5.562 19.125 60.00 69.00
Right Master CCW 24.69 9.00
PSVG
Left Articulated CCW 33.50 12.50 7.500 26.000 60.00 69.20
Right Master CCW 33.50 12.50

Location View ed at Length Stroke Radius Rod Lgth Angle Angle
Dresser-
Rand
TCV, TCVD, TPV

Pow er
Right Articulated Left Pow er CW 50.00 19.00 13.500 36.687 50.00 50.00
Left Master CW 50.00 19.00
VRA

3.2.2.3 Articulation Diagrams



3.2.3 Engines without Articulation

If the setting for "Power cylinder articulated" is set to No and the setting for "Bore, stroke and rod
length equal for all power cylinders" is set to YES, this screen will appear for data entry. Enter the
power cylinder bore, power cylinder stroke, and power connecting rod length.
If the setting for "Power cylinder articulated" is set to No and the setting for "Bore, stroke and rod
length equal for all power cylinders" is set to No, this screen will appear for data entry.
Enter the bore, stroke, and connecting rod length.

Or you may highlight several cell, then type the number. When you hit enter, the number will be put in
each cell.
3.2.4 Engine
The phase of each cylinder is the angle by which TDC of the cylinder lags the reference for the lead
cylinder. The lead cylinder reference (TDC) is usually set to zero.
The schematic given by the manufacturer will usually have the information necessary to calculate the
angles at which each cylinder will be at TDC when referenced to the number one cylinder.
Note: Phase angles are associated to a cylinder name (i.e., PL1 = Power Cylinder Left Bank #1).
You will need to remember this for other parts of the set up.

The analyzer has additional features which may be set up to help in the analysis process. These
features do not necessarily need to be set up but can be very helpful for analysis. The events and
angles entered on the next three screens will be available on graphics screens or in reports.
Input manufacturer timing events for "Port and Valve Opening and Closing". This information will
provide on-screen references for events. Should you have a "Fuel Valve", input the manufacturer's
recommended timing. This information will provide on-screen references for events.

each cell
As an analyst, you may want to take advantage of the report feature which enables you to report up to
10 of the most important pressures of the PT curve.

Enter up to ten angles which will have the pressure values printed in the report after data has been
collected. The numbers entered for before top dead center "BTDC" will need to be negative ( -20).
Note: In the 63XX/DA, MA, & PA, the angle 0.0 is a default in the report (as it is the TDC
reference) so do not enter it here.
3.2.5 Compressors
This is information that is usually easy to obtain but, should you have trouble obtaining a connecting
rod length, a general rule of thumb is 2-1/2 times the length of the stroke. Verify this information.
Input the phase angles for the head end only. The crank end is always assumed to be 180 degrees
different. A manufacturer's schematic will usually have the information necessary to calculate the
angles at which each cylinder will be at outer dead center when referenced to one cylinder.
Note: Phase angles are associated to a cylinder name (i.e., CH1). You will need to remember
this for other parts of the set up.

Should a unit have two pistons in line, the tail rod diameter needs to be subtracted out of the bore size
for that cylinder end.
Maximum allowable rod load in compression and tension are available in the manufacturer's data
sheets.
Enter the mass of the reciprocating parts for a cylinder to calculate inertia forces into the rod load
calculations. The reciprocating parts typically include the piston, piston rod assembly mass in one
column and cross head assembly mass in the last column. Depending on where the bearing is located
(cross head or connecting rod), you may choose to include the pin in the cross head mass.
The inertia plot is only from the mass in the piston and rod mass column. If you want to see the total
inertia plotted, just use the piston and rod mass column for all of the mass (all reciprocating mass
except connecting rod) and put 0 in the cross head mass column. This is actually the preferred
method unless you want to calculate rod load and use only piston and rod mass in the calculation.
When the reversal calculations are made, the mass from both columns is added together, but only the
mass from the piston and rod column show up in the plot. When trying to experiment with different
masses and lining up impacts with the reversal points, use the piston and rod mass column with 0 in
the cross head column. The calculated reversal degrees are based on the criteria that you set up in the
software configuration.
A gas analysis needs to be set up using the "Gas Composition" set up menu option. The names that
have been entered there will be available for selection. It is possible to have different cylinders or
cylinder ends that are moving different gases. See the section on "Gas composition setup" for entering
gas analyses.
For reporting purposes and fixed data scale assignment, each cylinder end may be assigned to a
stage from 1 to 10. On the reports, the capacity will be summed by this stage assignment.

Enter the load steps into the table for each cylinder's end. Use the scroll to shift the screen right or left
to the next set of cylinder ends, and up or down to enter the higher load step information.
If the global setting for "load step in" is set for percent swept volume, enter these values in percent.
Otherwise, for cubic inches, enter these values in cubic inches.
The option, to start with ZERO, ONE, or a LETTER for the load step increment, should be set prior to
doing compressor set ups and can be set under System & Analyzer Options.

each cell.
3.2.6 Miscellaneous
On the "Miscellaneous" tab, enter the following items if available.
Power Cyl Recip Mass: Enter the mass in pounds of the power cylinder reciprocating parts. This
value is used in the power rod loading calculation.
Suggested Spark Timing: Enter the expected value of the timing event. This value is used for piston
animation only.
Crankshaft Offset: Enter the closest distance between the crankshaft center and piston
centerline. If the crankshaft is above, enter a positive number (+1.00). If
the crankshaft is below, enter a negative number (-1.00). Not having the
correct value in the compressor offset will affect the calculated
compressor horsepower.

Additionally, machine information may be entered and saved in the machine database for future
reference. Enter the Engine/Driver, Compressor, and location of the unit in the fields provided and click
on "OK" to save and exit.
3.3 Sensor Points

From the Setup menu, select machine sensor point.
From here you may access the sensor point editor, view and print the sensor point list, or auto generate
a sensor point list.

3.3.1 Overview
Machine sensor points are the identifiers in the software for external sensors attached to the analyzer.
The sensor point requires information to be set defining the type of point and parameters for that type
of sensor. Once set, the analyzer knows how the data that is electronically sampled should be
displayed and calculated. Each point requires the following parameters:
· Name of the point

· Point type
· Point engineering units (e.g., pressure in PSI, vibration in g's, ignition in volts, etc.)
· Phasing reference (TDC reference)
· Scaling for plots
· Units-low (zero)
· Units-high (full scale)
The sensor point list has a maximum number of 800 points per machine. If more points are required,
you may wish to separate the engine and compressor into separate database machines.
Once all the points are entered, the next step is to group the points into a planned collection route.
This will be done with the "Collection point editor" later in this section.

3.3.2 Sensor Point Names

The sensor name should describe the position on the machine, type of point, and full scale (if a
pressure point and there are multiple pressure range sensors in the kit). Examples of naming would
be:
Comp 1H Pressure
Comp 2C Pressure
Comp 1 Suc Nozzle Trace

Comp 1 Dis Nozzle Trace
Comp 1 Suction Temp

Comp 1 Discharge Temp
Comp 1 Hi Freq Vib

Comp 1 Raw Vib
Comp 1H Ultrasonic
Comp 1 XH Hi Freq Vib

Comp 1 XH Raw Vib
Comp 1C Ultrasonic
Comp 1H1S Val Hi Freq Vib

Comp 1H1S Ultrasonic
Comp 1H1S Val Cap Temp
Comp Main Brg 1 Hi Freq Vib

Comp Main Brg 1 Raw Vib
3.3.3 Point Types

Angular velocity is the measurement of the speed of a crankshaft at each degree of crank angle.
Compressor (DC) pressure vs. Crank is a DC pressure sensor measuring the head/crank end
pressure inside a cylinder.
Compressor low frequency vs. Crank is a vibration sensor point vs. compressor crank angle that
uses the low-pass vibration filter. The default low-pass vibration filter setting passes accelerometer
frequencies from .5 Hz up to 2.5 KHz.
Compressor high frequency vs. Crank is a vibration sensor point vs. compressor crank angle that
uses the high-pass vibration filter. The default high-pass vibration filter setting passes accelerometer
frequencies from 4-15 KHz.
Compressor ultrasonic vs. Crank is an ultrasonic sensor point vs. compressor crank angle that
should be used for all compressor ultrasonic data collection.

Manual temperature input are temperature values entered via the keypad that are to be used in
compressor performance calculations.
Power cylinder AC pressure vs. Crank is an AC pressure sensor measuring the pressure inside a
power cylinder. This type sensor may be used with the analyzer but is not typically supplied with the
kit.
Power cylinder DC pressure vs. Crank is a DC pressure sensor measuring the pressure inside a
power cylinder. Note that DC pressure sensors are options typically supplied with the standard kit.
Power cylinder low frequency vs. Crank is a vibration sensor point vs. power cylinder crank angle
that uses the low-pass vibration filter. The default low-pass vibration filter setting passes accelerometer
frequencies from .5 Hz up to 2.5 KHz.
Power cylinder high frequency vs. Crank is a vibration sensor point vs. power cylinder crank angle
that uses the high-pass vibration filter. The default high-pass vibration filter setting passes
accelerometer frequencies from 4-15 KHz.
Power cylinder ultrasonic vs. Crank is an ultrasonic sensor point vs. power cylinder crank angle
that should be used for all power cylinder ultrasonic data collection.
Spark plug voltage vs. Crank is the secondary ignition voltage measurement vs. crank angle. The
secondary ignition clip is used for this type of measurement.
Compressor nozzle trace is a pressure point for taking pressure at the suction or discharge bottle.
Velocity sensor vs. Crank is a vibration sensor point vs. crank angle that passes all velocity
frequencies.
Raw vibration vs. Crank is a vibration sensor point vs. crank angle that passes all accelerometer
frequencies. In the analyzer, you may select from several high-pass vibration filter ranges where the
default is .5-10 KHz., however the upper limit is settable.
Primary ignition vs. Crank is the primary ignition voltage measurement vs. crank angle. The primary
ignition clip is used for this type of measurement.
4-20mA sensor vs. Crank is the measurement using a sensor type with 4-20mA output vs. crank
angle. An example of this type sensor may be a proximity probe measuring compressor rod run out.
Voltage sensor vs. Crank is the measurement using a sensor type with voltage output vs. crank
angle.
Manual panel reading input is a panel gauge reading entered via the keypad.
Infrared temperature input is a temperature value entered via the infrared temperature sensor. Use
either a Manual scale or auto scale. To support bar charts, temperature sensor points can now be
assigned fixed scales, just like other sensor points.
Prox sensor vs. Crank is used for dynamic compressor rod movement. The choices are 50, 100 or
200 mv/mil sensitivity.

ULT-200 ultrasonic vs. Crank is an ultrasonic sensor point vs. crank angle that should be used when
utilizing a ULT-200 Recip-Trap ultrasonic sensor.
3.3.4 Other Points

Raw Vibration vs. Crank Angle
Manual Temperature Point
4-20mA Sensor vs. Crank Angle

If a proximity probe device is available that has 4-20mA current loop output, this device may be
adapted for input as a sensor to measure rod drop and/or rod motion on a compressor cylinder. Call
Windrock for details on interfacing to the analyzer.
The actual 4 to 20 mA settings will

depend on your sensor. Common
settings are 10 to 90 and -30 to +30.
Manual Panel Reading

Some typical points to set up using the Manual Panel Reading are:
· Points for the parameters to use in reporting BSFC
· Engine oil pressure in and out
· Lube oil pressure in and out
· Manifold pressure
Voltage Sensor vs. Crank Angle

An example of the voltage sensor vs. crank angle would be a proximity probe device that has 0 to -24
volts DC output. This device may be adapted for input as a sensor to measure rod drop and/or rod
motion on a compressor cylinder. Call Windrock for details on interfacing to the analyzer. The actual
voltage setting will depend on the sensor you use.
The Group plots will be auto generated at this time.

3.3.5 Sensor Point Setup

From the Setup menu, select machine sensor point, sensor point setup.
3.3.5.1 Overview
The sensor point editor gives the ability to set up and/or edit existing point lists. The edit screen
shows the selected point and its settings. If a new list is being assembled, use Add a copy to reduce
typing when entering long lists.
Caution! If you plan to use the "Collection Point Generator", do not modify the sensor list
with the editor until after you have generated the Collection Point list.

Sensor points may be added, moved up/down or reordered as desired. Sensor points can be copied
from another unit and pasted in the current unit, they can also be copied within a unit using add a
copy to create another point like a current point, and then edited.

If the software detects a sensor point with the same name the while using Copy/Paste it will ask you
how you want to handle the duplicates.
Multiple sensor points can be edited at the same time using the shift key to select concurrent points
or the control key to select other points. In the example above all pressure points can be changed to
2000 psi at the same time.
On the following pages are typical Engine Points and Compressor Points.
3.3.5.2 Engine Points

Angular Velocity
By having an angular velocity test point, you will be

able to graphically display the speed of the flywheel
over 360 degrees for two-cycles and 720 degrees for
four-cycles.
Note: The machine setup must have the

number of pulses-per-revolution set to
greater than one to acquire angular
velocity. Angular velocity can not be
obtained from a single magnetic
pick up, a single optical pick up, or
single hall effect pick up.

DC Pressure
Give a detailed name that gives test point location
and pressure sensor range. This will alleviate
problems associated with using the wrong
transducer. It may be helpful to write down a planned
route before you start entering it into the computer.
Distinguish cylinders 1-10 or 1L-5L and 1R-5R.
Example:
Cyl #1 Power Pressure (0-1000)
Cyl #2 Power Pressure (0-1000)
AC Pressure
This sensor point might be used for an engine spark

plug sensor made by IMI/PCB Electronics. The 1V -
5V scales for the AC pressure transducer should be
as follows: If you are using a 0-3000 psi sensor, 1V =
600 and 5V = 3000. 1V is set to 20% of full scale.
This sensor has a 1 - 5 volt output.

Power High Frequency Vibration
If the transducer signal comes through a panel,

select BNC panel connection as a source.
Power Low Frequency Vibration

Power Ultrasonic

Secondary Spark Plug Voltage
Set up a spark plug voltage vs. crank angle for each

spark plug. Distinguish the plugs so that they are
easily identified: Top/Bottom, Right/Left,
Right/Center Left, etc.
Primary Ignition
Primary ignition point is used to collect the ignition

system's supply voltage pattern.
3.3.5.3 Compressor Points

Compressor DC Pressure

Compressor Nozzle Trace

Set up cylinder and nozzle pressures in the order in
which you expect to collect the data. Give a detailed
name that gives test point location and pressure
sensor range. This will alleviate problems
associated with using the wrong transducer. It is
best to write down a planned route before you start
entering it into the computer.
Note: The 4 mA - 20 mA scales should be set

to the pressure sensor range. For
example, if you are using a 0-500 psi
sensor, 4 mA = 0 and 20 mA = 500.
Compressor High Frequency

Vibration

.
Compressor Low Frequency
Vibration

Compressor Ultrasonic

Infrared Temperature
Several temperature points should be taken with the
compressor data collected. Most importantly, stage
suction and cylinder discharge temperatures should
also be taken because they are required for
calculation of capacity, flow balance, etc.
Temperatures may be entered into the analyzer in
two ways; the infrared temperature sensor or panel
reading entered via the keypad.
Note: As a minimum, temperature points should be set up for each stage suction and cylinder
discharge. When tak ing data from a compressor, these temperatures should be entered
prior to collecting pressure crank angle data. The temperatures are used in calculations of
capacity, flow balance, etc. and may be displayed on the screen while look ing at PV cards.
If the temperatures are entered later, these calculation results will not be available for
display while collecting data. It is preferred to have suction and discharge nozzle
temperatures for each compressor, which should be tak en as close as possible to the
nozzle to cylinder flange.
Suction Temperature Point
Set up suction temperatures per stage as manual inputs. A sample set up may look like this:
1st Stage Suction Temp
Discharge Temperature Point

Set up discharge temperatures per cylinder as a manual input. A sample setup may look like this:
C.L. #1 Discharge Temp


Note: The infrared temperature sensor may be used instead of manual input of data. Please
refer to the "Engine Setup" section to see those set up screens. Also, compressor gauge
readings may be entered using the "Panel readings" point set up.
The infrared transducer (A6045-00-06) has a calibration sticker attached. The 4mA and 20mA values
on the calibration sticker must be entered into the calibration using the Calibration Menu Option for
proper temperature readings. They are shown above for reference only and can not be changed here.
Note: When using collection points, the sensor may be attached to the channel to which it is
assigned. See the section on "Collection Point Setup" for more details.
Vibration in Velocity
Set up cross head vibrations in the order in which

you expect to collect the data. Give a detailed name
that gives test point location and vibration frequency
range. This will help you identify the pattern. A
sample setup may look like this:
Cyl #4 XH Ve Vib

Rod Motion using Proximity

Probes
Cyl #1 Rod Motion, 4-20 mA
Set up rod motion measurements in the order in

which you expect to collect the data. Give a detailed
name that gives test point location. This will help
you identify the pattern. A sample setup may look
like this:
Cyl #1 Rod Motion, 50, 100, or 200 mV / mil

3.3.5.4 Vibration Filters / Sensitivity
The 6320 offers a wide range of filtering options for vibration data and also the ability to adjust the
sensitivity of the accelerometer and velocity sensors being used.
Filters
For raw vibration (and low frequency vibration), the following filters are available:
· VL0 — a fully adjustable filter range, which can be set under Software Options (similar to low
frequency vibration points in earlier software versions)
· VL1 — 0.5 Hz - 10 kHz (the default; this is the same as raw vibration in earlier software
versions)
· VL2 — 183 Hz - 10 kHz (to filter out some additional low-frequency background noise)
For high frequency vibration, the following options are available:

· VH0 — a fully adjustable filter range, which can be set under Software Options (similar to high
frequency vibration points in earlier software versions)
· VH1 — 4 kHz - 15 kHz (recommended for slow speed units; this was the default for high
frequency vibration in earlier software versions)
· VH2 — 6 kHz - 25 kHz (recommended for high speed units)
· VH3 — 8 kHz - 25 kHz (for high speed engines that would benefit from additional filtering)
Sensitivity
The ability to adjust the sensitivity of accelerometers and velocity sensors are also available. Windrock
standard accelerometers are 100 mV/g, however the option to choose a 10,25, or 50 mV/g
accelerometer is available if one is being used for a particular application.
You can use the Sensor Point Editor to configure these new options. Filters and sensitivity can be set
on a per sensor point basis, in case different points need different filters or sensitivity.


3.3.6 Sensor Point Generator

From the Setup menu, select sensor point, sensor point Auto Generator.

3.3.6.1 Auto Generate Sensor Point List

The auto generate function provides the ability to make a sensor point list by checking the boxes for
the type points to include. When finished, a list is generated of all the points. The points can be
modified by using the "Sensor Point Editor". This allows for fine tuning of the point list.
Prior to initializing the auto generate function, prompts are presented to allow cancellation of the
process. Once under way, all points previously entered are destroyed and re-written with new points.
You will not be allowed to continue with the auto generate until the required fields are filled in.
Caution! This is a serious issue. All existing points will be destroyed.

Select the section you wish to complete

from the menu at left, of select next to
continue down the menu list.
The Finished button is found in the
<------ other points menu item.
Controls used:

Check Boxes: Checking a box will include the point type in the final list. For instance, all
power cylinders will be assigned one of the point types checked (Select all that
apply).
Option Buttons: Allow for the selection between the listed items in the group (Select only one).
Text Boxes: Enter a value or name as indicated.
Drop Boxes: A list of options are presented for selection by clicking on the down arrow.
At any time until "Finished" is clicked, clicking "Previous" will back up one screen at a time allowing
changes to be made.
Control Descriptions:
Sensor Type: Select the type of sensor to be used where indicated. The following list describes
the types:
IR - Infrared Temperature Sensor

Gauge - Panel gauge for manual input
DC - Dynamic DC Pressure sensor (strain gauge with zero reference)
Sensor Cal: Enter the pressure sensor calibration range from the sensor in the kit. This will be
the default sensor range used for all the power cylinder pressure points.
Vibration: Vibration can be collected in three ways.
1.) RAW is used for unfiltered vibration which contains both the low and high
frequencies of the mechanical noise.
2.) LOW is used for piston slap and pin bushing bearing-type knocks in low speed
(below 1000 RPM) engines. Not recommended for high speed ( above 1000 RPM)
engines.
3.) HIGH is used for filtering out the low frequency vibrations (shaking of the unit)
and making impacting type events, valve closures, ring clips, and scuffing more
visible.
Typically, both RAW and HIGH are selected to give the best overall picture.
Ultrasonic: Checking ultrasonic will include at least one point per head. If the engine has fuel
valves, checking the fuel valve box will include a second point per head. If the engine
has a Pre-Combustion Chamber (PCC), a point will be included.
PCC: Select one or two points to be taken for the Pre-Combustion Chamber.

Ignition: Both secondary and primary ignition traces can be collected. For each cylinder,
secondary ignition can be collected on zero, one, or two plugs. The orientation must
be selected using the Plug Naming convention drop box.
Capacitors: On the primary of ignition systems, there may be one or two banks from which to
collect an ignition pattern.
Point Count: The total number of points that will be generated is listed in bottom left corner of this
menu. It is a reference so that items can be checked and unchecked as necessary,
keeping the maximum number of points possible below 800.
Note: If the point count is exceeded while selecting options, the warning box above will appear
in the bottom left corner, "Too many sensor points requested". The number of points
must be reduced to under 800.

This screen allows for the collection of additional temperature points on an engine. Checking a box
adds one additional point to the list. The sensor type defaults to gauge as there are a number of
control system readouts available from which to acquire the data.
Engine Scavenger Cylinders: Select the number of scavengers, the select Ultrasonic
vibration and / or Temperatures.

Compressor Layout: Select either a cylinder layout with all cylinders in a line or odd on one side
with even on the opposite side.
Cylinder Check: Check the box for each cylinder from which data will be collected. Note that
some cylinders are not active or do not have parts installed to operate on
some machinery. Therefore, excessive points would be created for no reason.

Pressure: When checked, a pressure point will be entered for both the head and crank
ends automatically. You will have the option of using a non standard pressure
transducer.
Nozzle Traces: Nozzle traces are the pressure points taken in the suction nozzle (bottle) and
discharge nozzle (bottle/line). They typically represent the line pressures. In
addition, if a cylinder has split stages, each cylinder end will have a different
discharge nozzle point. Select this option with the adjacent drop down box.
2.) LOW is used for piston slap and pin bushing bearing-type knocks in low
speed (below 1000 RPM) engines. Not recommended for high speed (above
1000 RPM) compressors.
3.) HIGH is used for filtering out the low frequency vibrations (shaking of the
unit) and making impacting type events, valve events, etc. more visible.
Typically, both RAW and HIGH are selected to give the best overall picture.
Ultrasonic: Checking ultrasonic will include at least one point per cylinder end.
Suction Temps: If checked, a single suction temperature for each stage and single discharge
temperature for each cylinder will be entered into the point list as default.
However, in some cases, the cylinders and cylinder ends may have individual
suctions and discharges. If this is the case, use the adjacent drop down
boxes to select how many points may be needed in the list. The options are:
Suction Discharge
Single Stage Temp Single Discharge Temp
Suction Temp per Cylinder Discharge Temp per Cylinder
Suction Temp per End Discharge Temp per End
Suction Temp per Stage Discharge Temp per Stage

Pressure Sensor: When surveying a compressor that has more than one stage, two or more
pressure sensors may be used. Each sensor will have a sensitivity more
closely related to the cylinder's pressure to gain higher accuracy. In this case,
the sensor 4 to 20 ma range being used for that cylinder should be entered in
the boxes.
Pressure Scale: Enter the normal operating pressure range for each stage of compression. This
scale value is used for display only. If needed can be edited later at Fixed
Scale Editor.

If valve ultrasonic and / or valve high frequency vibration checked, then one point for each valve cap
will be entered into the point list.
Valve Cap Temps: One point for each valve cap will be entered into the point list.
Valve Count: The actual number of suction and discharge valves located on the cylinder
end. Cylinders of varying stages may have a different number of valves.
Specifying the number will generate a point list that accurately reflects the
number of valves on the cylinder.
Valve Naming: You have the option when you generate a new sensor list to have the valves
named using the following options:
Suction 1, 2, 3 ... Discharge 1, 2, 3 ...

Rod Drop: You have the option of creating top, bottom, and side compressor rod drop
test points. Choose from 4-20 mA or 50, 100, or 200 mV/mil.
Compressor Temperatures: This screen allows for the collection of additional points on an
compressor. Checking a box adds one additional point to the list. The sensor type defaults
to gauge as there are a number of control system readouts available from which to acquire
the data.

2.) LOW is used for piston slap and pin bushing bearing-type knocks in low
speed (below 1000 RPM) engines. Not recommended for high speed (above
1000 RPM) compressors.
3.) HIGH is used for filtering out the low frequency vibrations (shaking of the
unit) and making impacting type events, valve events, etc. more visible.
Typically, both RAW and HIGH are selected to give the best overall picture

Panel Points: This screen allows for the collection of additional points. Checking a box adds one
additional point to the list.
Click on the "Finished" button to build the Sensor Point list. After the list is generated, it can be
modified using the "Sensor Point Editor" or the list can be regenerated by repeating the above sequence
of steps. However, the list should not be regenerated once any data has been collected. The
arrangement of points in the Sensor Point list is critical for associating data collected with the sensor
point.

Caution! Changing the Sensor Point list after data has been collected will destroy the
links between the data collected and the sensor point. This will render the
data collected useless and may cause confusion later when reporting on the
data collected.
Also, if you plan to use the "Collection Point Generator", do not modify the
sensor list with the editor until after you have generated the Collection Point
list.
After the sensor point list has been auto generated, the collection point auto generate sequence will
start. This sequence will provide a series of questions to help lay out the manner in which the sensor
points are grouped for collection on the machine. See Collection Point Generator for details.
3.4 Collection Points

3.4.1 Overview
Collection Point Setup is used to expedite data collection by following a predefined order with multiple
sensors selected for simultaneous data collection. See the section on using the Collection Point
Generator for more details. In this section, the Collection Point Editor will be covered.
The Collection Point setup editor has two functions.
The first function is the manual creation of a list. When a machine is first setup, a blank list
exists. If the Auto Generate function was not used during Sensor Point setup, then this is the
way to create a list.
The second function is the modification of an existing list. A new list should be created from the
Auto Generate function when setting up the sensor points. This is the quickest method to
generate an entire list. The Editor should then be used to add, modify, re-arrange, and delete
points from the already created list.

The Collection Point setup editor is selected from the main menu bar using "Setup | Collection Point |
Setup" menu. Once selected, a screen will be available with a list of points shown and several buttons
for use in modifying the list. See the next several pages for details on using the editor.
All points in the Sensor Point list are available for taking data whether or not they are available in the
Collection Point list.
You may also view and print the collection point list.
3.4.2 Collection Point Setup

Collection Point Edit
Name: Refers to the collection point's name in the list. This is the name that will show up on the
analyzer.
CH1 thru CH5: Refers to the channel number the sensor will be plugged into on the analyzer.
Num of cycles in average: Refers to the number of samples that will be taken for this set of points.

Button Descriptions
First, click on the point in the list to modify. Then select the function by clicking on one of the
following buttons:
Add New: By clicking on this button, a new blank point is inserted directly after the currently
selected point.
Add a Copy: By clicking on this button, a copy of the selected point is inserted directly after the
currently selected point.
Delete: The current point is deleted. It can not be recovered once deleted.
Move Up: The current point is moved up in the list. Multiple points can be moved together.
Move Down: The current point is moved down in the list. Multiple points can be moved together.
Other / Copy: Several collection points may be copied to the temporary list, for re-inserted into
another data base.
Other / Paste: Several copied collection points may be re-inserted as desired.
Other / Select All: All collection points may be selected for coping.
Other / Reorder: Several collection points may be moved to the temporary list, then re-inserted
as desired.

Manual panel Sensor Points in collection point list

IR Temperature Sensor Points in collection point list

Panel and temperature point order can be different in the collection point list. The auto generate will
create IR valve cap temperatures in the same order as the valve cap vibration list.
FFT/vibration Points in collection point list
Calibrate Sensors Points in collection point list
Note: Calibrate Sensors feature only available in Windrock MD 4.4 and later.

3.4.2.1 Unified Collection Point Route
Overview
The Unified Collection Point Route refers to the collection point route that will display on the the
analyzer for taking data when "Take New Data" is selected on the analyzer. This route is edited using
the Collection Point Editor accessed under the Collection Point Setup menu and allows the ability to
have Dynamic (crank-angle) data, manual/temperature data, FFT/vibration data, Route comments, and
Calibrate sensors collection point types all available in one collection route location.
The first time a machine setup is opened in Windrock MD 4.4, it will offer to update your route for you.
Clicking "Open the Collection Point Editor..." link will show a message summarizing the changes that
can be made.These changes may include adding sensor points or incorporating available temperature
points into your existing route. Clicking "OK" in the message box will open the Collection Point Editor
and further modification to the added collection points may be made at this time. Any modifications
made will not be saved until OK is clicked in the Collection Point Editor.

3.4.3 Auto Generate Collection Point List

Next in the sequence will be the building of a Collection Point list. This is similar to a "Route" or
grouping of points for collection on the machine. The list will be assembled based on a series of
selections. Once transferred to the analyzer, this list will be available when entering the data collection
mode.
Caution! This function will not be available if the sensor point list has been modified
manually.
The Collection Point list groups the sensor points that were generated previously into a route-style list.
Typically, points are taken on the engine starting first with ignition and ending on the compressor and
panel gauge readings. Each collection point will contain from one to four sensors in a related format.
For instance, collecting data on the engine would entail a head vibration, power pressure, and fuel
valve ultrasonic taken simultaneously.
A prompt is presented to verify that you want to proceed with the building of a Collection Point list.
You are asked once again to verify the overwriting of any existing Collection Point list.
Collection Point Setup Menu:

The Menu at left allows you to select which set up selection to

work on. The default is to start at the top and use "Next" button
to cycle down through the menu items.
At any time you can use the "Back" button to review your
selections, or just select from the menu shown at the left.
For an engine with secondary ignition points setup, you have the option to put these points in a
Collection Point list. They will appear at the beginning of the list before any other points such as
vibration or pressure. The strategy here is to verify that the ignition system is operational and in good
condition before proceeding with collecting other points.
Secondary ignition points should be taken with more than one sample to develop statistical information
on how repeatable the spark plug is firing. The default is set at 30 samples.

The Collection Point Generator has a set of rules for putting together a list. The above form acts as a
template to generate the list. The left pane list the already created collection points, the center pane
determines the channel assignments; and the right pane shows the remaining points for the part of the
machine selected. As points are assigned to a channel, they are removed from the right pane's list.
The collection pass located in the center pane refers to the trip around the machine and which points
will be collected that pass. If more than one pass is setup, the second pass will contain a different set
of points. For instance, pass one on power cylinder 1 left will take high frequency vibration, pressure,
and ultrasonic. Second pass might take low frequency vibration and fuel valve ultrasonic on the same
cylinder. You may also elect to take all power cylinder pressures on the first pass and then go back
for pass number 2 and collect vibration and ultrasonic on each cylinder. You may also specify a
custom pass name up to 18 characters for each pass.
Num of cycles in average refers to the number of samples that will be taken for this set of points.
The set up pane for compressor head and crank ends are smiler to the one shown for power cylinders.

This is how the collection points are to be ordered for moving around the machine.
Complete each pass at every cylinder location, will go from one cylinder to the next and repeat
the process for each group of point(s).
Complete all passes at each cylinder location, will keep you at the current cylinder and proceed
through all passes (group of point(s)) for that cylinder before moving to the next cylinder.
If there are compressor points set up, the following prompt will ask how the points are to be grouped.
Depending on positions of the compressor valves, all head end points will be taken before crank end
points. It may more beneficial to alternate between head end and crank end so as to avoid criss-
crossing the cylinder too many times.
Compressor valve will put all valve vibration, ultrasonic, and temperature points into the Collection Point
list.
Select which points to take in each pass.

You may select the order in which the compressor valves are taken. Move the valves from the center
pain to the right pane, creating the desired order in the right pane. You can copy the order to another
cylinder if you wish. Click Next when done. The compressor valve vibration, ultrasonic and
temperatures will follow the order created in the right pane.
Selecting the main bearing points you wish to collect.
if you created Scavenger cylinder sensor points, you will be asked to create scavenger collection
points.

When you select finished, you will be asked to confirm this selection.
If one or more selections are NOT completed, you will be prompted to complete those selections.
You will be taken to the menu item where the unfinished selection exists.
If the valve order is not complete you will be prompted to complete.

3.5 Group Plots

3.5.1 Overview
Select the "Auto Generate Group Plots" menu option from the Setup menu to configure automatic
plotting and defines what is printed using Reports | Auto-printing.
The group plot setup allows for a set of predefined groups (up to 10 traces per plot) of preselected
points to be configured. These groups can be selected at a later time to automatically plot all the
points in a group at one time. This saves on keystrokes during the point selection process in the plot
historical function. Each plot has a choice of including in auto printing which allows costuming your
reports.

By selecting "Other",
Group Plots can be Copied/Pasted from one unit to another.
The Group Plot list can be reordered.
3.5.2 Group Plot Setup

Give the group a name is used later in a selection list provided in the group plot function of the
application.
Select a point to plot for each of the ten lines by clicking on the down arrow to the right of the
selection box. A point list of available sensor points will appear.
Preset the type of plot, Standard ( i.e. crankangle, volume, log/log, rod load), Bar chart, Spark plot,
Trend plot, or Multiplot.
Predefine the settings you would like for the plot characteristics.
Phasing: Data is phased to the individual cylinder angles vs. TDC. This option allows,
for instance, all power cylinder plots to be lined up to TDC or as a PT
parade.
Autoscale: Autoscale ON changes the plots to fit the full screen. Autoscale OFF uses
the predefined scales from the setup. This is a toggle-type function.
Overlay: Changes the 'Y' scale from individual scales to one common scale. This
may make certain plots very small in relation to others based on the scale
differences.
TDC shift : Data is normally displayed with '0' degrees on the left axis. This option
shifts 0-360° to be (-180° +180°) and 0-720° to be (-360° 0 +360°).
Smoothing: The smoothing factor used is as defined in the "Software Configuration" or it

can be manually set at this point by selecting the type of curve and
pressing the right/left arrow keys to increase/decrease the factor.
Valve events: Turns the graphical lines showing the event timing angles on or off.
Theoretical: Turns the theoretical trace on or off.

Power stats boxes: Turns on power stats boxes by default. It is recommended to enable this
option for all power parade plots.
Capture Current Plot: This button will populate the current plot screen with the data displayed in
the current Window.
Save the setups when all points have been entered or all changes have been made.
Setting up the Bar Chart
In the Bar chart group plot:
“Display bars in groups of ” is set to 4

(and the 4 suction valve cap temperatures
are grouped together before discharge
valve cap temperatures) so that suction
and discharge temperatures will be
grouped together and colored the same.
The cylinder suction and discharge

temperatures are added as reference
lines behind the bar chart. This lets you
easily compare your valve cap
temperatures against your line or nozzle
temperatures.
To support bar charts, temperature sensor points can now be assigned fixed scales, just like other
sensor points. For example, to set up your bar charts to scale from 0° to 300°
1. Go under the Setup menu, under Fixed Data Scales, and add a new scale called “Compressor
Temperatures” with a low of 0 and a high of 300.
2. Click OK and save your changes.
3. Go under the Setup menu, under the Sensor Point Editor.
4. Select all of your compressor temperature sensor points and change their “Scale to” from
“Autoscale” to “Compressor Temperatures.”

Setting up a Trend Chart
After selecting Trend plot, select the

sensor points to include in your
trend plot.
Enter a name in the Trend plot name

text box.
Only 10 sensor points can be

included in one trend plot. To trend
more lines, add more trend plots.

Setting up a Spark Plot
After selecting Spark plot, select the sensor

points to include in your plot.
Enter a name in the Spark plot name text

box.
Only 10 sensor points can be included in one

trend plot. To plot more lines, add more spark
plots
Setting up the Group Multiplot
After selecting multiplot, select the

layout number of plots to include in
your multiplot.
Four panes are shown in the example.

You may choose between two, four,
six, nine or twelve panes to display in
your multiplot.
Enter a name in the multiplot name text

box.
Select the pane you want to set up.
To select a predefined group plot for a

pane, find the group plot in the drop
down box.

3.5.3 Group Plot Reordering

The order of the group plots can be modified several ways.
To use the temporary list, select the group plots to move, and click on a blue right arrow.
The selected group plots will be moved to the temporary list. You may add to the temporary list by
selecting more items.

To place the selected group plots back in the plot list you must highlight where you want them to end
up, then select above or below the select point or at the end of the list, using the blue left arrows.

After the reordering is completed you must save the new setup by clicking OK to close the Reordering
box and OK to close the Group Plot Editor.

3.5.4 View
Viewing and printing Group Plot Settings
Select the "View" menu option from the Setup | Group Plots" menu to view and print the group plot
setups.
Select view of all group plots or only multiplots.
Group Plot Lists can be printer to PDF or

hard copy.

3.5.5 Auto Generate
Group plots are normally auto generated at the end of the sensor point and collection point auto
generate. If no change have been made to the sensor point list, you may re-auto generate the group
plots.
You will be reminded there is a current group plot setup.

3.6 Fixed Data Scales

3.6.1 Overview
It is suggested that you set up fixed scales to provide consistent data display. Below are suggested
starting points for the scales you set up. Others may be needed depending on your particular needs.
Pressure ranges are dictated by the expected peak firing pressure. Sometimes, manufacturers provide
maximum limits. Vibration and ultrasonic ranges should be fairly consistent for all units.
Set up pressure range scales based upon expected maximum peak firing pressures for your unit. You
can change scales, if needed, after data collection.

Set up vibration range scales in g's. This scale may need to be adjusted for different units. As a
starting point, use -5g's to 5g's. You can change scales, if needed, after data collection. The low
frequency scale is typically used with low frequency and / or raw vibration sensor points.
Set up ultrasonic range scales. This scale may need to be adjusted for different units. As a starting
point, use -3 to 3. You can change scales, if needed, after data collection. This scale can be used for
engines and compressors.
NOTE: Other fixed scale definitions may be required for your set up.

Ignition scales should be set according to your expected maximum spark plug voltage. The typical
scale for a analyzer would be -15,000 to +15,000.
Set up pressure range scales that make sense for your unit. You can use stage pressure ranges as a
guideline. These fixed scales allow consistent displays for viewing patterns. It is not a problem to
change the fixed scales after data collection has been done. If they are either too small or too large,

simply change them here or use the auto scale option. If the compressor is single stages, there will be
one compressor scale. If the compressor is multi-stages there will be a fixed scale for each stage of
compression.
Set up vibration range scales in g's. This scale may need to be adjusted for different units. As a
starting point, use -5 g's to 5 g's. It is not a problem to change the scale after data collection. This
scale can be used for engines and compressors. The low frequency scale is typically used with low
frequency and / or raw vibration sensor points.

Set up ultrasonic range scales. This scale may need to be adjusted for different units. As a starting
point, use -3 to 3. It is not a problem to change the scales after data collection.
To support bar charts, temperature sensor points can now be assigned fixed scales, just like other
sensor points. For example, to set up your bar charts to scale from 0° to 300° or 550° to 850°.


3.6.2 Fixed Scale Editor
The fixed scale editor allows adding, deleting, adding a copy, or copy/paste.
3.6.3 Creating A New Scale

A manually created sensor point will sometimes require its own scale factor. Prior to creating the
sensor point, create a scale for its display. Use the Fixed Data Scale Editor to add a new blank scale
or copy an existing scale from within this unit, and fill in as needed. A fixed scale may be copied
(Imported) from another unit using the editor. Select other and copy. Then open the destination unit and
paste. Click OK to save.

3.7 Gas Composition

Set up gas analysis based upon the most current operating gas mixture of the unit. It is possible to
have more than one gas in a unit. The analyzer will accept up to six pre-defined gas mixtures per
machine.
Each of the six entries can be given a name that will be referred to in other parts of the set up
procedure.

To enter the actual gas mixture, select the tab of the gas mixture and a table will be visible where
each gas type is listed with an entry box to the right of each gas.

The gas mixtures must be entered in either percent or mole fractions. The total must be 100 or 1.00
respectively. If they are not, a warning will appear when trying to save the set up. After setting up a
gas, it may be copied to another unit.
Copying gas files from one unit to another
You can use the copy/paste function to copy gas mixtures from one unit to another.
You must sort the gas mixtures by the same column.
Copy From:

In the table you are coping from, click on the "Gas" column
header until there is an up arrow next to the Gas column
name.
Select all the Amount column data.
Copy To:
Add new gas name.
In the table you are coping to, click on the "Gas" column
header until there is an up arrow next to the Gas column
name.
Paste the values in the Amount column.
· Multi-edit – If you select a group of cells and then start typing, all cells are updated to the value that
you've entered.
· Sorting by column – Click on a column heading to sort by that column's values. This is only
permitted where the grid doesn't already have a well-defined sort order; it's useful in the Gas Mix
Editor to sort the gas components actually in use to the top of the list. DO NOT sort by
Amount when copying and pasting.

3.8 Compressor/Engine Calculations

3.8.1 Compressor Panel Point Setup
Select the "Compressor Panel Point setup" option to configure the manual panel point association for
the new reports. There can be up to 11 manual panel readings for the Compressor Report.
Compressor Panel Point Selection

3.8.2 Compressor Temperature Setup

Match suction stage temperature and cylinder discharge temperature to cylinder end as set up in
"Machine Configuration".

3.8.3 Compressor Nozzle Trace Setup

Select the "Nozzle trace setup" option to configure the nozzle point association for reports and
calculations. Associate each nozzle point to the proper cylinder for reports and calculations. Use the
right arrow key to bring up the point list.
3.8.4 Bypass Valve Setup

The 'Bypass Valve Setup' allows the user to estimate the cost of leakage through a bypass with
temperature measurements. If bypass valves are set up, these costs are also included in the
economic report. You have the option of setting up more than one 'Bypass Valve' if needed. Each
bypass valve setup will need all the compressor cylinder pressures (head end and crank end) and the
three gas temperatures that are associated with that gas stream. The 'Mixed and Suction'
temperatures should be measured at least 12 feet or more than three pipe diameters from the mixing
point. You may need to survey the temperature change the first time you use a set up to ensure you
are far enough from the mixing point. As with most of the economic features, fuel flow will need to be
measured for the unit.
Note:
For the calculations to have any accuracy, the measured gas temperatures must be
within +/- one tenth of a degree Fahrenheit of the actual gas temperatures.


3.8.5 Engine Panel Points

Select the "Engine Panel Point setup" option to configure the manual panel point association for the
new reports. There can be up to 11 manual panel readings for the Engine Report.
Additional Panel Information

3.8.6 Diesel Panel Points

Diesel Panel Points
This option lets you configure rack reading values to display on the new format engine report.

3.8.7 Exhaust Temperature Setup

Select the "Exhaust Temperature setup" option to configure the manual temperature point association
for the new reports. If the points were created with the auto generator, auto load should populate the
setup.
3.8.8 BSFC Setup

Brake Specific Fuel Consumption (BSFC) is calculated and reported on the Engine and Compressor
Reports. To set up for this feature, select "Setup | Comp/Eng Calculation Setup | BSFC Setup"
from the main menu.
· Enter the proper "Fuel Flow Sensor Point" to use. This is a manual panel reading sensor point
set up in the sensor point list.
· Click on the required "Fuel Flow in" units.
· Select the proper "Fuel Heating Value Sensor Point" or use the "Default Value". Again, this is a
manual panel reading sensor point set up in the sensor point list.

This calculation will then be displayed on the Engine and Compressor Reports using the values and
settings entered.
Select the proper fuel heating value unit of measure.
If there is no fuel heating value sensor point, input a default value to be used in the BSFC calculations.

3.8.9 Fuel Usage Curve

Fuel Curve data can be input using the following set up screen. Fuel curve data is entered as percent
load vs. BSFC or percent speed vs. BSFC. Use the one best suited to your needs.
Enter a fixed
amount or...
Fuel Curve data can come from one of two sources:

1. Data provided by the manufacturer at the time of unit delivery. This data was taken when unit was
new and in good mechanical condition.
2. Data taken during testing when the unit had just been overhauled and is in good mechanical
condition. Data should be measured data taken during steady-state operations and should reflect
how the unit runs when in good condition.
Test points should be spread over the normal operating range of the unit. The minimum number of
points to draw a curve would be four or more. More data points will result in a better curve fit.
At any time you have better data, you may edit the information and redraw the curve fit.

Adjust the "Order" until the curve best fits the data points. The best fit will result in R and R2 near
1.000 and the Deviation Chart +/- scale being smaller. Use the smallest order possible that still
gives good results. When finished, "Save Fuel Curve and Exit" to apply the data just entered.

3.9 FFT Route
See a separate manual "WinTrans / Route Based FFT Manual"
3.10 Software Options

Software configuration allows several factors to be preset for graphical display. These are permanent
settings vs. temporary (i.e., they become the defaults). Below are explanations of each setting and
how they affect the displayed data. These settings do not affect the stored data; only the data being
displayed and reported.
Note: These settings are for this machine data only and do not affect any other machines in
the database.
Plotting
Use non-pressure curve in PV: Switch to "YES" to show only pressure curves on volume plots. A
setting of "NO" will show all curves vs. volume.

Theoretical Model: lets the user pick the theoretical model to use. The user can also choose
"Ask each time" to go back to the pre-3.2 software version behavior of selecting a theoretical model
each time a theoretical plot is turned on.
Smoothing
Smoothing Factor: These are the default settings used in plotting and reporting. The settings may
be changed individually as desired. They may be temporarily changed from the graphical plot screen
as needed. Typically, the default is set to one.
Smoothing is used to remove any high frequency sinusoid that can occur in the data traces. The
smoothing filter acts like a low pass filter. Care must be taken not to "over-smooth" the data since
information can be lost. A good rule to follow for compressor and power pressure curves is that it is
safe to increase the smoothing factor as long as the horsepower being calculated does not change
significantly (less than 0.5 percent). A smoothing of 1 takes one point before and one point after and
averages it with the given point to obtain a smoothed value at that point.
A factor of 2 takes two points before and two points after and so forth. A smoothing factor of zero
means no smoothing occurs. Generally, you do not want to smooth vibration or ultrasonic curves
but the option is available. Sometimes, increasing the compressor factor helps to improve the toe
point pick for compressor pressure curves. Smoothing and spike filters should not be used if not
needed.
NOTE: The smoothing filter cannot be used at the same time as the spik e filter.

NOTE: The smoothing filter setting is used for report data.
Spike Filter: These are the default settings used in plotting and reporting. The settings may be
changed individually as desired. They may be temporarily changed from the graphical plot screen as
needed.
The spike filter is used to remove sudden changes in value of the data that occurs for a single data
point. If a data point exceeds a three percent change from the linear fit of the previous point to the
next point, it is replaced with the interpolated value. If a spike consists of more than a single data
point, this filter is not effective and smoothing should be used.
Vibration
Raw Vibration Sample density: The density of the raw vibration in the analyzer may be increased
to two or four data points per degree. This has no effect on previously created two and four per
degree sensor points.
VL0: A fully adjustable low frequency filter. The Sensor Point Editor can be used to configure low
frequency vibration and raw vibration points to use this VL0 filter.
VH0: A fully adjustable high frequency filter. The Sensor Point Editor can be used to configure high
frequency vibration points to use this VH0 filter.
Power Cylinder Pressures

Pin Power Press curves: The power cylinder pressure curves can be pinned to a manifold
pressure.
Manifold Press for Pin (PSI): Enter the manifold pressure to which to pin the power cylinder
pressure curves. If the engine is a naturally aspirated four stroke, the correct manifold pressure
would be zero.
Enable Late Combustion check: The default is "YES". When set to YES, the software will look for
another peak in the firing pressure which is later and lower than compression pressure. If set to "NO"
and there is a late firing pressure which is lower than the compression pressure, the peak firing
pressure and angle will be reported for what is actually compression pressure.

Late Combustion Check
Ignition
Minimum spark level: This is the minimum level used to recognize misfires and erroneous
adjacent plug crosstalk.

On multi-spark pick: The selections are Highest or First. If set to highest, the sampling for
secondary ignition picks the highest level for spark angle. If the setting is first, then the sampling
picks the first of several events for determining spark angle.
Calculations
Clearance calculation method: Windrock supports two clearance calculation methods:

· GPSA – Calculate clearances using formulas from the GPSA Engineering Data Book. These
formulas include the ratio of the suction Z value (compressibility value) to the discharge Z value.
· 84-10a based – Calculate clearances using formulas based on Southwest Research Institute’s
Technical Report 84-10a. These formulas do not include the Z ratio. (Windrock’s 84-10a based
method differs from 84-10a in that it uses the k value instead of nec.)
The GPSA clearance calculation method works better for adiabatic compression, such as occurs in
most natural gas compressors. The 84-10a based method works better for unusual cases where the
gas mixture’s compressibility changes significantly from suction to discharge.
Use bad or mis-phased compressor data in report: When this box is checked, all compressor
curves are used to calculate and show horsepower. If there is a phasing error or an unloaded end
showing negative horsepower, the horsepower is still reported and a warning message is included on
the report.
Show gas phase warning: The default is yes and to disable the warnings, clear the check-box. If
there is/are component(s) in the gas sample that do not converge at the current pressure and

temperature conditions, a warning is displayed when calculations are made that require the use of a
gas sample. Calculations will be made without a warning display. The calculations will ignore the
component(s) that are not in convergence.
Unloaded Cylinders
Volumetric efficiency settings: These factors are used in determining the unloaded state for a
compressor cylinder end. Some machines will stretch these tolerances beyond the default settings.
If this occurs, the reports and calculations will say "unloaded" when the compressor end is loaded. In
this case, you may need to set the defaults differently to accommodate this condition.
Ratio low limit: is a selectable ratio low limit to mark a compressor as unloaded.
Rod Load & Reversal

You can choose to use Windrock's standard rod load calculations (using either gas forces or total
gas plus inertial forces), the method recommended by your OEM, or a custom format. You can also
configure the rod reversal requirements for your compressor.
Rod load calculation methods and rod reversal requirements are provided for several OEMs:
For rod load inertial forces, you can choose to calculate rod load (using the piston and rod mass) or
the pin load (using the piston, rod, and cross head mass). Cross head mass can be entered under
the Setup menu, under the Machine Geometry screen, under the “Comp A” tab.

Leak Index
The leak index can be modified to meet your requirements. A separate smoothing factor can be
applied to the pressure traces. The starting points cam be moved further from the pressure toe
points if pulsation is affecting the toe point picks for the index. The sensitivity can be changed to
match your unit's operating condition.

3.11 Economic Factors
The Windows application, Windrock MD,

contains a feature for determining the cost
basis for the fuel penalties for various faults.
Set the values for your parameters here.
These are set for each machine
independently.
You may choose between Flow Balance,

Power/Valve loss model and Theoretical
Flow comparison.

If you choose the Flow Balance,

Power/Valve loss model, you may set the
normal loss threshold for each compressor
end. Loss will be reported if they exceed the
threshold.

If you choose to use Theoretical Flow

comparison, you can set the percent band to
use, which clearances to use, and which flow
to use for the loss calculations.
In addition, there will be a menu item to select a "Cost Analysis " page in the report. This will appear
whenever there is a compressor or engine report available. This is an economic condition report and is
based on the defaults set under the menu option Setup|Economic Factors Setup.
Compressor Report
((fabs(1-FB)-.05)*HP*24*365*CostBasisValueHP*UsageValue/100.0
where:
CostBasisValueHP = from entered value
UsageValue = from entered value
FB = calculated Flow Balance
HP = Horsepower
24 = hours/day
365 = days/year

Engine Report
((fabs(0.01 * (max deviation% -5))*HP*24*365*CostBasisValueHP*UsageValue/100.0
where:
CostBasisValueHP = from entered value
UsageValue = from entered value
max deviation = (max pressure - min pressure) / avg_peak_pressure
(all cylinders reports)
HP = Horsepower
FB = calculated Flow Balance
24 = hours/day
365 = days/year
3.12 System & Analyzer Options

All Analyzer options can be set/updated from the Windrock MD software. These options only affect the
Portable Analyzer; they have no effect on Windrock MD. If you change these options, you must
transfer your analyzer & system options to the analyzer (by going under the Utilities menu, under
Connect to Analyzer, under the Other button, and clicking “Send Analyzer & Global Options”) in order
for them to take effect. For guidance transferring your changes to the analyzer see the chapter on
Connect to Analyzer.
System Options

Load step numbering:

"Load steps" are a control mechanism for many compressors and each load step has clearance data
associated with it. In the "Compressor Setup" section, a load step table is used to hold this clearance
data. This option, to start with ZERO, ONE, or a LETTER for the load step increment, should be set
prior to doing compressor set ups.
Clearances in:
Clearance data for each end of a cylinder is entered in the "Compressor Setup" section. The clearance
may be entered in either "percent swept volume" or "Cubic inches".
6320 Preferences

Color Scheme:
Allows for changing the color of the analyzer screen.
Use Power save:

If enabled the analyzer back light will turn off after 1-minute of inactivity. Default is unchecked. Please
be cautioned that if enabled Power can be shut off to the encoder when 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.
Route Mode:
Allows for customized user flexibility in route navigation during data collection.
- Complete — Choose a collection point, review and customize the setup, and start taking data.
- Streamlined — Choose a collection point and start taking data.
Autoscan first when taking data:

This option controls how the data collection process runs.
'Autoscan first in take data' has four options.
1. 'Yes and ask to save', Entering the data collection process will automatically start the
analyzer auto scanning data and updating the screen with each collection of data until the 3 key
[STOPAUTOSCAN] is pressed. You will then have the choice of saving the last
scan.
2. 'Yes and autosave', If this is selected during taking data, the last single scan of auto scanning
will be saved before taking the normal data without asking if you want it saved.
3. 'Yes but don't save' will not save the last single auto scan and proceed to taking normal data
without asking.
4. 'No' turns off "Autoscan"
DC Sensor Correction:
Allows you to select from three choices.

1. "Zero Only" allows you to reference the zero pressure to the current atmospheric pressure.
2. "Two Point (1 channel)" allows you to provide known pressures for calibration, on e channel at
a time.
3. "Two Point (4 channel)" allows you to provide known pressures for calibration, four channels
at a time.
6320 Data Acquisition
For multi cycle scans:

Allows the choice of "Average multi scans" or "Use a representative scan".
- "Average multi scans" - The analyzer will average the number of cycles together on a degree-
by-degree basis to create a single averaged scan.
- "Use a representative scan (default)" - The analyzer selects 1 of the chosen number of cycles
that is most representative of the chosen number of cycles and displays it.
FFT Noise Floor:

- "Accel noise floor" - Allows the noise floor to be raised when converting the FFT's from
acceleration to other display units.
- "Velocity noise floor" - Allows the noise floor to be raised when converting the FFT's from
velocity to other display units.
IR Calibration

IR Calibration:
Allows the calibration range to be entered for the IR sensor being used.
3.13 User Units (Metric)

Windrock MD application software has the ability to switch between engineering units of Standard,
Metric, or User defined units. To change or add a custom units conversion, click on the main menu
bar, Setup | User Units, to bring up the set up screen.

Once the set up screen appears, there are many options from which to choose. If you find that the
Standard or Metric units will not work, click on the "Add" button to set a new conversion table. The
table created must then be saved and transferred to the analyzer.
To transfer the new setup to the analyzer, see the chapter on Connect to Analyzer.
Once in the analyzer, use the "System configuration | System options " selection found in the Station
Selection Menu to select this new units group to use on the analyzer.To scroll through the available
groups use the left/right arrow.
The Standard and Metric units group cannot be modified. If you want a new group most like the Metric
units, highlight the metric units before clicking the "Add" icon. If the new units group is to be more like
the standard Units, highlight the standard units before clicking the "Add" icon.

3.14 Diagnostics
Select "Diagnostic Setup" from the setup menu.

3.14.1 Engine Diagnostics
Check engine balance - will compare each power cylinder average peak firing pressure to the +/-
percentage of the engine average peak firing pressure. This setting would normally be the same as the
% OK band set in the Engine Balance section.
Check for cylinder instability - will compare each power cylinder peak firing pressure standard
deviation to the engine average peak firing pressure standard deviation.
Check for timing instability - will compare each peak firing pressure angle to the engine average
peak firing pressure angle.
Check compression pressure - will compare each power cylinder compression pressure to the +/-
percentage of the engine average power cylinder compression pressure.
Check for overpressure - will compare the highest cylinder peak firing pressure to this specified limit.
Disable diagnostics - will not report any errors, except overpressure, if the actual load is less than the
prescribed percent of rated load.

3.14.2 Compressor Diagnostics
Check rod load - this will check the rod load limits provided in the geometry setup in the machine
area against the calculated rod load values from the current set of dynamic pressure curves.
Check rod reversal - uses whatever rod reversal requirements have been set up under
Software Configuration. This is normally important to insure that the bearing surfaces in the
compressor linkages are being lubricated correctly.
Check for leakage using leak index - if this is checked, it allows the online diagnostics to use the
leak index on the current set of dynamic compressor pressure curves to look for leaking valves,
packing and rings.
Check for clearance disagreements - the diagnostics will use the load step table to confirm the
measured clearance values versus the expected value for the current set of dynamic compressor
pressure curves. Use the 'CLEAR%' box to set the percent difference that will trigger an alarm. Only
compressor ends that are considered healthy by leak index will be checked for clearance agreement
problems. (Suggest starting value of CLEAR% is 15 percent).
Also check set / calculated smallest volume - if this option is checked, a diagnostic will be
generated if the clearance disagreement between the measured and expected values exceeds 75
percent of the smallest pocket volume. The smallest pocket volume can be provided in either cubic

inches, cubic centimeters or have the load step table scanned for the smallest volume change seen
between any load step. If the load step table scan option is used, it is a good idea to set the maximum
number of valid Load steps in the table. Otherwise, be sure there are no invalid values in non used load
step positions in the setup. Unused positions should have a value of 3.0 or less. This is an independent
clearance check from the 'CLEAR%' that was set above.
Only warn if greater than - if this is checked, a clearance warning will not be generated unless the
volume disagreement is greater than XX percent of the smallest pocket volume as set above (or
detected in the load step table). (A value of 75 percent is suggested as the value for XX).
Enable Pulsation Correction - if this is checked, the measured VEs are compared to a theoretical
compressor curve generated VE's. If a difference greater that 2 percent is detected, the VE's of the
theoretical curves are used in the clearance calculation. This allows the software to still make
clearance problem calls in a situation where pulsation would normally cause problems.
Validate pressure sensors - this enables the pressure sensor validation diagnostics. The head and
crank end pressure sensors are checked against each other using the following parameters:
Comp rato - the head and crank end measured toe ratios must agree within this percent.
Pressure validation (10-200 psi) - if the head and crank end toe ratios agree within the above set
percent limits, the suction toes points must agree to within this many psi or a zero drift problem is
alarmed.
Temperature validation enabled - this enables the software to perform a temperature sensor
validation. Beside values outside the set ranges, a discharge temperature below the suction
temperature will generate an alarm.
Suc Low (°F), Suc High (°F) - if the suction temperature is below or above this range, an alarm will be
generated.

Dis Low (°F), Dis High (°F) - if the discharge temperature is below or above this range, an alarm will
be generated.
3.15 Balancer and Spark Survey

The Balance and Spark Survey options may now be preset or changed in Windows. Remember to
transfer any setup changes to the analyzer prior to taking data.

Balancer Options:
NUMBER OF CYCLES: Select the number of samples of data to collect.
MAX SENSOR PRESSURE: Select the desired pressure sensor range (1000, 2000, 3000,
5000, or 7500 psig @ 20ma) from the drop down list.
USE SPIKE FILTER: Select ‘use spike filter” and select None, Normal, Heavy or
Extra Heavy from the drop down list.. 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).
DEBOUNCE FACTOR: Select the desired debounce factor (1 – 33). 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.
TRIGGER LEVEL (psi): Select the desired trigger level (30 – 100). 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.
PRESS CUTOFF LOW Select the low pressure cutoff value for the report. 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. The
balancer will report the number of cycles that the peak
pressure was above the high cutoff value.
Spark Survey Options:
NUMBER OF CYCLES: Select the number of samples of data to collect.
MULTI STRIKE SPARK: Selects the proper machine spark type. When using the spark
survey on a multi-strike ignition system, the software will
attempt to analyze the first ignition event of the series.
Display options:
PAUSE AFTER EACH CYLINDER: Select the desired viewing option, pause or no pause after each
cylinder.
REDUCED SCALE ON CURVES: Select the desired scaling option (Normal, HALF, 3/8, 1/4, 5/8,
3/4, 1/8).
This scaling factor is used for the pressure curves' vertical

scale. When set to Normal, 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".

RECORD PANEL POINTS Selecting the PANEL POINT OPTION will allow recording “as
found” and “as left” panel data including fuel usage and bsfc
values. By not selecting the option, all panel points in the
collection route will be deactivated. There are 12 pre-defined
panel points as well as 6 user-defined points and 1 exhaust
temperatures per cylinder from which to select.
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 correct measurement unit.

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

Windrock MD supports trending. For online data, you can trend data collected by the Platinum hardware
as well as calculated values. For portable data, you can trend manual / temperature data and almost any
values that appear on a report. To trend data, click on the Trend toolbar button.
You can also set up trend group plots using the group plot editor. This lets you view trend data along
with your other group plots and include trend data in your auto printed reports.
The list of trend points is automatically generated from your machine setup, but you can go under the
Trend Point Editor (under the Setup menu) in case you need to make changes, such as reordering trend
points or setting warning and alarm values. Warning and alarm values are mostly useful for online data,
since the Platinum system can notify you when warning or alarm thresholds are exceeded. For portable
data, warning and alarm limits are overlaid on trend plots but are currently otherwise unused.

3.16.1 Trend Point Formulas

Function Description
average(number1, number2…) Averages one or more values
exp(number)
Gives e raised to the given
power
max(number1, number2…)
Finds the largest value from the
list of values
min(number1, number2…)
Finds the smallest value from
the list of values
sqrt(number) Square root
stdev(number1, number2…)
Sample standard deviation of
one or more values
sum(number1, number2…) Sums one or more values
You can also use spreadsheet-style ranges in these functions. For example, to take the average
of Platinum trend points 1 through 4, you can say average(s1:s4) instead of average(s1, s2, s3,
s4).
Trend points can be assigned data IDs to that they can be referred to in other formulas. For
example, if you give your Comp 1H Horsepower trend point a data ID of 1 and Comp 2H Horsepower
a data ID of 2, then you can calculate the total horsepower for that cylinder as D1 + D2.

Plot 150
4 Plot
4.1 Overview
Plot Data Plot Data brings up a Point Selection box which allows for the selection of a
point located in the database. Once the point is selected, files are checked
for the availability of dynamic data and displays the dates. Pick a date for the
point and the date is checked for the number of stored records available.
Select the record and the data is displayed.
Replace Line This function allows a plotted data line to be replaced by a new selection.
This comes in handy when comparing several dates or types of data.
Show or Hide Line Allows you to turn on/off a line in a display.

Group Plot This function provides for a fast plot of predetermined points. Points are setup
in predefined groups for easy access, plotting and printing.
Multiplot Mode Allows more than one group plot to be displayed.
Bar Plot This option creates a bar chart of the selected sensor points.
Trend Plot This option creates a trend chart of the selected sensor points.
Spark Plot Use this to pick a single spark trace to display.
Spark MultiPlot Use this to display up to 10 spark traces at the same time.
FTT (Route Mode) This will open the FFT program module.
PV This menu item is a toggle between PT graphs and PV graphs.
LogP-LogV Shows the Log of the pressure vs. Log of the volume for the compressor
pressure points.
Rod Loading Shows a Rod Load plot for the selected points. This item is only available
from the PT graph.
Rod Wear / Runout Assuming a top and bottom rod drop trace has been taken, this tool allows
the user to do compressor rod wear analysis. Dynamic rod run out is also
reported.
Derivatives This tool allows the selection of viewing the first derivative, first and second
derivative, or FFT of the selected trace. Selecting the derivative button the
second time will toggle the display off.
Modify / Remove Line The Modify / Remove line allows changes to be made to the individual data
after collection. If the data is bad, it may be removed.
Trend Plot Dump Saves the current trend data to a comma separated value file ( .scv)
Clear Plot This option clears all current plot lines and allows for new plot lines to be
chosen.
Clear All Plots This option clears all multi plots.
Show Live Data This option displays live data directly from the Platinum online system
Play Back This option plays back historical data (from an online system or from your
portable) to help you see changes over time.

Plot 152
4.2 Major Functions

4.2.1 Plot Data
When selecting Plot | Plot Data from the main menu bar or the plot speed button, the dialog
box for point selection comes up and allows for the selection of data for a point from the
database. The dialog box has three selection list boxes and several buttons.
The left list box contains a list of

points that have been configured in
the database.
The center list box will fill in with a

list of dates when data was taken
for the point selected. It also
shows the number of records stored
for that date if multiple scans were
taken.
The right list box will fill in with the

individual records for the given date
selected. It will also show the date
and time the data was taken, the
type of data collected, the run

number, and the load step at which

the data was taken.
'Single scan' indicates that one sample was taken.

'X' Averaged or Representative indicates that a number of samples 'X' have been taken and averaged.
A representative trace is a actual trace that closets represents the average.
You can select multiple points, dates, or records at once here (by dragging or shift-clicking).
Buttons and Definitions
Jump to Point Click on this button to jump to the first compressor or engine point in the
list of points.
Group Will display the selected averaged trace and all single scan traces stamped
with the same date and time.
OK Click to plot the selected line and close the dialog box.
Clear Lines Click to clear the selected plotted lines to make new selections without closing
the dialog box.
Plot Plot the selected data.
Toggle Click to turn off a selected line. This does not remove the line; it only hides it
on the display.
Next Click on the 'Next' button at the right of the pick record box. This allows the
quick picking of multiple records from the same data point when picking traces
to plot.

Plot 154
4.2.2 Group Plot

Group plot selected from the Plot | Group Plot main menu or the Group plot
speed button, will use the pre-defined plot setups to display a set of lines
automatically. This eliminates the need to select each point individually thus
speeding up recall and plot time dramatically.
Alt+F2
The next / Previous Group plot icons allow you to move between plots easer.
The drop down arrow allows you to select a plot from the list.
The next / Previous Date plot icons allow you to move between dates easer.
The drop down arrow allows you to select a date from the list.
The "Group" drop down box provides a list of predefined groupings from which to select. This list was
originally set up using the setup group plot auto generator function.
The "Point Selections" are sensor points that have been assigned to each of the 10 lines displayed.
These can be changed on-the-fly to suit your needs.
The "Date" list box lists the available dates for which data has been collected. Click on the date
required to be displayed. Double clicking on the date will automatically bring up the plot without
having to click on the OK button.
The "Run Number" drop down box provides the selection of last multiple data or individual run number if
more than one run number exists for the date selected in the date records list box.

Select "Customize" to make changes in the current display for plot type, plot options, and select
lines.
The "Plot Type" shows the pre-defined set up for this group. Again, the type may be changed to suit
your needs for the current plot.
The "Plot Options" show the pre-defined toggles for this group. Again, they may be changed to suit
your needs for the current plot.
4.2.3 Plot Types

Once a set of data has been plotted, the plot types may be changed, or toggled, between the following
types:
LogP-LogV - Shows the Log of the pressure vs. Log of the volume for the compressor pressure
points.
PV / PT - This menu item is a toggle between PT graphs and PV graphs.
Rod Loading - Shows a Rod Load plot for the selected points. This item is only available from the
PT graph.

Plot 156
4.2.4 Modify / Remove Line

The Modify / Remove line allows changes to be made to the individual data after collection. If
the data is bad, it may be removed. To change stored data, first plot the data using "Plots |
Plot Historical", select the sensor point, date, and record that is to be changed. Then
select "Plots | Modify/Remove Line" and use the drop down box to select the sensor point
(if more than one line is plotted) to change.
Note: This was the old sk ull and crossbones button on the Win6310 software. It is now
accessed as a menu item on the Windrock MD software.

The current settings for the line are in the individual boxes as shown above. Click on the item to be
changed and enter the proper value. Click on "CLICK TO UPDATE" to save the new setting.
The ability to modify timestamps to a different day and hour is under the modify button. The minute
and second will be zeroed, indicating a modified timestamp. You may also modify the value of existing
temperature and panel points or input values for missed points. You need to select a crankangle line
to enable the modify button. If you are adding a missed point, the timestamp, run number and load
step of the first plotted crankangle curve will be used when the record is written. This feature should
only be used by advanced users.

Plot 158
Any days modified should be downloaded to the analyzer. Otherwise, the changes could be lost and
the report calculated values may be different between the analyzer and the Windows based database if
you do not download modified days to the analyzer.
When you select a curve to modify, you may add a crankangle offset for that specific curve and you
may add an offset that will be applied to all curves taken during the day of the picked curve. Remember
that, if you make this type of modification to data, it should be downloaded to the analyzer. Otherwise,
the phase adjustments will not be shown when viewing the data in the analyzer. Also, these changes
could be lost by uploading data from the analyzer if it was not updated.
The group dump button will allow you to dump all lines of data in the current plot to a file.
To export the individual set of raw data to a file, use the "WRITE LINE TO FILE". Click on either the
"Engineering Units" or "Bit Counts" button to export. The data will be located in the machine's folder
on the hard drive unless another location and name are specified in the edit box. Once in the file, the
data may be imported into a spreadsheet for additional manipulation.
The "REMOVE LINE FROM DATABASE" function will permanently remove the line from the database.
This can be used to remove a data point that has been collected in error or is just bad data.
Caution! Removing a line from the database cannot be undone.
SwRI file export

This function will export curve data for use with the Southwest Research performance program. Click
on the "SwRI file export" button to bring up the following dialog box. Select the curves and data points
to output and click on the "WRITE" button. Export files will be located in the machine folder with the
format similar to "R01L03C1.dat"

The SwRI file export button is only active if you are using a 512 pulses per degree encoder.
4.3 Settings
4.3.1 Overview
These functions manipulate the plotted data as well as provide the ability to modify the stored data in
the database.
Select "Scaling" from the menu to bring up the scaling dialog box. The dialog box allows the scales of
individual lines to be changed for all lines together.

Plot 160
The "Smoothing" factor is a factor used in averaging out the data. If, for instance, a factor of 2 is used,
two data points before and two data points after are used to average out the data for each point in the
curve. A smoothing factor can be set for each type of curve displayed. Typically, the default is set to
one.
"Stripcharting" is a method displaying data as if it were being plotted with a strip chart recorder using
multiple pens and colors. This helps in visually seeing subtle differences in data.
"Toe Point Adjust" This feature will allow the user to adjust the toe pressure pick for individual
compressor cylinder ends.
4.3.2 Scaling
Select scaling from the menu, speed button to bring up the scaling dialog box. The dialog
box allows the scales of individual lines to be changed or all lines together.

All Lines
Use the "All Lines" panel to change all lines to either fixed, manual, or auto at one time. To effectively
use manual scale, proper values should be entered into the MIN and MAX boxes before pressing the
manual scale button.
Note that the vibration and ultrasonic scales will use the MAX entry for manual scaling and mirror the
MIN to the negative of MAX. MIN has no meaning for these data types.
Individual Lines
Each of the ten plot lines may be scaled to either fixed, manual, or auto individually. Upon entry, the
MIN and MAX boxes contain the current scaling values. Pressing the button for each line is required.
For manual scaling, enter a MIN and MAX value of your choice.
By clicking on one of the following buttons in the "All Lines" panel, all lines will automatically be set to
the button clicked.
Fixed - Set all lines to the predefined fixed scales that have been entered into the machine
configuration.
Man - Enter the MIN and MAX values to be used for all lines.
Auto - The program will automatically scale to the highest scale.
Max - Scales the data to the maximum value seen in any individual scan.
4.3.3 Toe Point Adjust

This feature will allow the user to adjust the toe pressure pick for individual compressor
cylinder ends.
Ctrl+A

Plot 162
When indicator passage channel resonance or cavity pulsations cause a distortion in the PV card at
TDC and/or BDC, the measured toe pressures, ratio, VE, losses, etc. could be significantly in error.
You should first try smoothing the pressure trace up to 4 times to see if a good toe pick is made by
the software. If channel resonance is causing the problem, this should eliminate any error in the toe
pressure pick. If a low frequency pulsation from the cylinder flow passage is causing the problem, then
it may be necessary to manually adjust the toe points. To aid in this process, you should have the
loss areas or the theoretical PV displayed. Use the up and down arrow buttons to adjust the toe
pressures, or adjust by dragging the toe points. The program is using the pressure/degree in the
stored trace so you may see the toe pressure rise before going down or lower before going up. Save
the adjustments before exiting. Every calculation dependent on toe pressures will automatically be
remade by the software. These adjustments can be cleared later if necessary. Beginning analysts
should contact the Windrock Technical Services Department for assistance.
4.4 Plot Views

4.4.1 Overlay
The overlay "on" mode will plot several curves regardless of scale on top of each other so
that each plot appears to have the same scale. The left side of the curve will show each
lines' min/max values.
The overlay "off" mode will have one scale on the left, plotting all curves against that one scale. This is
useful to see multiple curves in relationship to each other and having one uniform scale to compare
against.

4.4.2 Phasing
Phasing "Off" aligns all curves to their respective TDC positions.
Phasing "On" aligns all curves shown to TDC of the machine.

Plot 164
4.4.3 Valve Events

This brings up a list of current power cylinder plotted lines. Only one point may be selected at
a time. Press OK to exit and the valve events for that point will be displayed on the plot.
Valve Events are predefined in the engine set up portion of the program. The values entered in that
table are used here to display the Engine Exhaust, Intake Opening, and Fuel Valve Opening.

4.4.4 TDC Shift

Applying TDC shift to the plotted data will shift the data by 180 degrees. For power plots, this
will place the peak firing pressure in the center of the graph with -180 to the left and +180 to
the right.
4.4.5 Power StatBox

On power curves, the Power Stat Box will show the statistical information in a graphical
format. The highest and lowest peak pressure, mean, and standard deviation plus and minus
are shown. The highest and lowest peak pressure angle, mean, and standard deviation plus
and minus are also shown.

Plot 166
4.4.6 Derivatives
This tool allows the selection of viewing the first derivative, first and second derivative, or FFT of
the selected trace. Selecting the derivative button the second time will toggle the display off.
Pick from the list of displayed lines

on which to apply your selected
calculation.
Pick the type of calculation to

perform on the selected traces.

After the derivative calculations are

displayed, you may change the scale
and smoothing factor.
After the spectrum calculations are

displayed, you may change the scale,
Fmax, and turn on X markers.

Plot 168
4.5 Plot Types

4.5.1 LogP-LogV
NOTE: In the LogP-LogV plot, Zoom is based on the lower scale. Therefore, zooming on the
crank end plot will show a blank plot.
4.5.2 PV

4.5.3 PT

Plot 170
4.5.4 Rod Load

API rod reversal numbers appear on the rod load plot and in the compressor report. The API rule
basically states "The duration of the reversal should not be less than 15 degrees of crank angle,
and the amplitude of the peak combined reversal load shall be at least 3 percent of the actual
combined load in the opposite direction." On the report, the lowest compression or tension is
shown.

4.5.5 Dynamic Rod Motion

Assuming a top and bottom rod drop trace has been taken, this tool allows the user to do
compressor rod wear analysis. Dynamic rod run out is also reported.

Format 172
5 Format
5.1 B & W / Color

Toggles between black and white and color mode. This is useful when a printer can
not print in color.
5.2 Grid Style

Toggles the display grid on / off.

5.3 Line Intensity

Increases or decreases the line intensity.
5.4 Line File Style

Toggles through the line style choices.
5.5 TDC Shift

Data is normally displayed with '0' degrees on the left axis. This option shifts 0-360°
to be (-180° 0 +180° ) and 0-720° to be (-360° 0 +360° ).
5.6 Phasing
Data is phased to the individual cylinder angles vs. TDC. This option allows, for
instance, all power cylinder plots to be lined up to TDC or as a PT parade.
5.7 Overlay
Changes the 'Y' scale from individual scales to one common scale. This may make
certain plots very small in relation to others based on the scale differences.
5.8 Smoothing
Turns smoothing on or off. If on, the factors set in the configuration are used.

Format 174
The smoothing factor can also be interactively used to show how the smoothing factor changes the
trace. Click on the Smoothing speed button and an interactive dialog box will appear where
adjustments can be made.
The smoothing can be adjusted by indexed by single values. Checking the 'Ref' box will show the
unadjusted trace, along with the adjusted trace (as pictured below to the right of the dialog box). The
effective low pass filter frequency is also shown based on the unit speed and the smoothing factor
selected in both Hz and orders of unit speed (X). There is a yellow warning box that will appear if the
software estimates that an excessive smoothing factor has been set. Smoothing can be adjusted
globally or separately for each sensor point.

Clicking on the spike box will apply spike filtering

to the selected data and will disable the
smoothing.
5.9 Show Valve Events

Turns on or off the graphical lines showing the event timing angles. This is used for
engine PT data only.
5.10 Show TDC Position

This toggles the vertical dashed lines indicating each individual cylinder's TDC
position in relation to the other cylinders. Turning on TDC positions, select one of
the following options:
- Show TDC OFF

- Show TDC POWER
- Show TDC COMPRESSOR
- Show TDC POW and COMP

Format 176
5.11 Use Nozzle Traces

If nozzle (line) pressure traces were taken and displayed, they will be used in the
calculations when the "Calculator" speed button is pressed.
5.12 Show Toe Points

Shows the toe point and highlights the area under the pressure curve between the toe
point and maximum pressure. This is for compressor PV data only.
5.13 Show Power Stats Box

Toggles the power stats boxes on / off.
5.14 Theoretical
Turns on and off the theoretical curves. Turning on theoretical values, select one of
the following options:
- Theoretical OFF
- K based (isentropic) Theo ON
- N based Theoretical ON
- Averaged N based Theoretical ON
- Power Cyl Compression K model
- Eqn. of State model k Temp ON
5.15 Adjust VEs

This feature will allow the user to adjust the toe pressure pick for individual compressor
cylinder ends.

When indicator passage channel resonance or cavity pulsations cause a distortion in the PV card at
TDC and/or BDC, the measured toe pressures, ratio, VE, losses, etc. could be significantly in error.
You should first try smoothing the pressure trace up to 4 times to see if a good toe pick is made by
the software. If channel resonance is causing the problem, this should eliminate any error in the toe
pressure pick. If a low frequency pulsation from the cylinder flow passage is causing the problem, then
it may be necessary to manually adjust the toe points. To aid in this process, you should have the
loss areas or the theoretical PV displayed. Use the up and down arrow buttons to adjust the toe
pressures. The program is using the pressure/degree in the stored trace so you may see the toe
pressure rise before going down or lower before going up. Save the adjustments before exiting. Every
calculation dependent on toe pressures will automatically be remade by the software. These
adjustments can be cleared later if necessary. Beginning analysts should contact the Windrock
Technical Services Department for assistance.
5.16 Smoothing Factors

The Smoothing factor is a factor used in averaging out the data. If, for instance, a factor of
2 is used, two data points before and two data points after are used to average out the
data for each point in the curve. A smoothing factor can be set for each type of curve
displayed. Typically, the default is set to one.
Smoothing factors can be accessed from several ways:

Format 178
5.17 Scaling
Select scaling from the menu, speed button to bring up the scaling dialog box. The dialog
box allows the scales of individual lines to be changed or all lines together.
All Lines
Use the "All Lines" panel to change all lines to either fixed, manual, or auto at one time. To effectively
use manual scale, proper values should be entered into the MIN and MAX boxes before pressing the
manual scale button.
Individual Lines

Each of the ten plot lines may be scaled to either fixed, manual, or auto individually. Upon entry, the
MIN and MAX boxes contain the current scaling values. Pressing the button for each line is required.
For manual scaling, enter a MIN and MAX value of your choice.
By clicking on one of the following buttons in the "All Lines" panel, all lines will automatically be set to
the button clicked.
Fixed - Set all lines to the predefined fixed scales that have been entered into the machine
configuration.
Man - Enter the MIN and MAX values to be used for all lines.
Auto - The program will automatically scale to the highest scale.
Max - Scales the data to the maximum value seen in any individual scan.
5.18 Stripcharting
Stripchart setup allows the user to manage the current display.
In this example the ultrasonic traces are both centered, on top on each other, allowing the user to see
the difference in the two sensor points.

Format 180
5.19 Clearance Adjustment

The Adjust Clearances tool lets you easily adjust your set clearances or assign your set
clearances based on your calculated clearances, for cases where you don't have accurate
set clearance information.
The Adjust Clearances tool gives you a one-click method of assigning your geometry settings based
on the current calculated values or based on manually entered values. As always with Windrock MD,

any changes that you make here are live (theoretical plots are redrawn as you change clearance,
calculator windows immediately update, etc.).
The Adjust Clearances tool stays open as you navigate from one group plot to the next. Any
changes that you make to one cylinder's clearances remain in memory even after you navigate to
another cylinder's group plot.
Once you're happy with your clearance adjustments, click Save All to write your changes to the
machine setup. This updates the “Geometry Settings” portion of the Adjust Clearances tool with your
chosen values. You can also click Undo All to discard in-memory changes for all cylinders and
change all values back to their geometry settings.
6 Tools
6.1 Cursor Readout

Turns on or off the cursor readout box. The information included is appropriate to the
current plot.

Tools 182
The cursor readout tool has the ability to enable an unphased cursor option to help with identifying
crosstalk in vibration and ultrasonic plots.
When the unphased cursor is enabled, the cursor tracks each cylinder's position relative to
crankshaft TDC, to help you identify synchronous events occurring across the unit.
For example, in the plot below, it may be difficult to tell whether the event on the green ultrasonic
trace is a genuine event or whether it's crosstalk from another cylinder.

By using the unphased cursor, you can see that the event lines up with valve events on the pink and
light blue traces, indicating that it's crosstalk.

Tools 184
6.2 Zoom
Turns on and off the zoom mode. With zoom on, click on the image and drag the
box to zoom in on the area selected.

6.3 Calculate
Displays the calculated results for the pressure curves displayed. This would include
IHP, RPM, # of cycles, peak pressures, peak angles, and % combustion.
6.4 Show RPM / Loadstep

Brings up a message box showing the RPM, load step, and timestamp collected for
that data point.
6.5 Peak Frequency Tool

This tool can help determine the frequency of pulsation or channel resonance events. It is a
useful tool to help determine the smoothing factor setting. Events higher than 20 to 25
orders of running speed should normally be filtered out since it is due to channel
resonance.
Once the tool box is up, click on the peak point of a sinusoid in a pressure trace, then click on a
second peak. After the second peak is marked, the rotation between these points will be shown in
degrees along with the approximate frequency of the marked event in Hz, CPM milliseconds, and
orders of unit running speed.

Tools 186
To pick another two points, hit the 'RESET' button. The crank angle sampling rate is shown and the
approximate Nyquist limit. Only events happening below the Nyquist limit can be accurately seen. The
recorded RPM of the first plotted trace is used as the basis for all of these calculations.
Alternately, click on the "Auto Pick" button to let the program automatically pick out the peaks of
channel resonance in the discharge portion of the compressor curve. If the auto pick makes a bad
choice, hit the 'Reset' button and manually pick your points. Click on "Set Compressor Smoothing" to
use the picked points to set the compressor smoothing factor.

6.6 Waterfall / 3D Plot

Is used to display data in a 3 D view.
Use the adjustment boxes to change the display for a better view.

Tools 188
6.7 Adjust Clearances

The Adjust Clearances tool lets you easily adjust your set clearances or assign your set
clearances based on your calculated clearances, for cases where you don't have accurate
set clearance information.
The Adjust Clearances tool gives you a one-click method of assigning your geometry settings based
on the current calculated values or based on manually entered values. Any changes that you make
here are live (theoretical plots are redrawn as you change clearance, calculator windows immediately
update, etc.).
The Adjust Clearances tool stays open as you navigate from one group plot to the next. Any changes
that you make to one cylinder's clearances remain in memory even after you navigate to another
cylinder's group plot.
Once you're happy with your clearance adjustments, click Save All to write your changes to the
machine setup. This updates the “Geometry Settings” portion of the Adjust Clearances tool with your
chosen values. You can also click Undo All to discard in-memory changes for all cylinders and change
all values back to their geometry settings.
6.8 Show WindWizards

When lines of data have been plotted using either the group plot or plot historical and the
calculate function has been used, certain criteria have been applied to the calculated data. If
the data falls outside the criteria, you will hear a fault sound and the wizard speed button will
appear. Click on the speed button and the fault will be displayed. If there is more than one
fault, click on the "Next" button to see the rest.

6.9 Add Annotation

Add text boxes with or without arrows to your plots.
If you want to add arrows to your text box to point out items in your collected data, add your comments
to the text box, check “Draw an arrow” and click OK.
Position the cursor, which is a "+", where you want the top left corner of the text box.

Tools 190
After the text is placed, the cursor becomes an arrow pointer. Position the point of the arrow where you
want it to be placed.
The current screen with annotations may be printed or copied to the clipboard. Annotations are not
saved and will be lost when the screen is re-displayed. If another trace is added to the current display,
the trace to which the arrow is pointing will move. For best results, you should format the display before
adding comments.
6.10 Undo Last Annotation

Erases or undoes last annotation
6.11 Erase All Annotations

Erases all current annotations
7 Reports
7.1 Full Report

This section covers the type of reports available and the steps required to set up the reports.
There are eight types of reports currently available:
Ctrl+R

Engine Report, Balance Report, Ignition Report, Spark Survey, Compressor Report,
Economic Report, Rod Load/Rod Drop Report, Manual/Panel Reading Report, and Analyzer
Notes Report.
Report Type
The "Engine" report gives details about the engine's performance based on the data collected. This
is a tabular listing of parameters associated with the engine such as IHP, peak firing pressure, etc.
Page four has a graphics page to show the balance state of the engine data. If new report type is
selected, the following pages will be added to the report:
PAGE 2 - A page showing the balance state of the engine

PAGE 3 - SD (standard deviation) of the mean PFP (peak firing pressure) is shown as a percent
of mean peak firing pressure and the SD value is shown in pressure units. Also shown is the
peak firing pressure angle location, the high, low and mean for each power cylinder.
PAGE 4 - Shows the occurrence plot of the mean peak firing pressure of each cylinder for the
unit. Two new combustion parameters are also shown: CPR which is the ratio of the peak
pressure to the compression pressure of the cylinder and CQI which is the combustion quality
index.

Reports 192
PAGE 5 - Shows several parameters that can be used to study how well the engine is breathing.
PAGE 6 - Shows the compression pressure and the estimated measured compression ratio for
each power cylinder.
The "Balance" report displays a tabular list of values entered during a data collection period. This
report contains both the As Found and As Left balance condition.
The "Ignition" report is a crank angle timing and peak level report, which give details about the
ignition performance such as statistical values, peaks, timing, etc. This is a tabular listing.
The "Spark Survey" spark health report give details about the ignition performance such as Ionization
Voltage, Arc Duration, Arc Voltage, Rise Time, Arc Slope, Ring down Voltage, No Arc, Voltage
Problems, and Arc Flyback. This is a graphical display along with a tabular listing.
The "Compressor" report gives details about the compressor's performance based on the data
collected. This is a tabular listing of parameters associated with the compressor such as IHP, BHP,
Flow Balance, etc.
The "Rod Load/Rod Drop" report gives details about rod load/rod drop based on the rod load plots
and rod drop data taken.
The "Economic" report gives details about unit BSFC, fuel cost per day/hour, excess fuel usage and
cost, compressor costs, valve loss and recirculation, and total excessive costs.
The "Manual / Panel" report displays a tabular list of values entered during a data collection period.
This report will help document the panel gauge readings and general operating condition of the unit
when the dynamic data was taken. You may include / exclude points with no data.
Date
The list box shows the available dates for which there is data to report as filtered by the number of
days to list in the drop down selection box. Click a date and the "Output" buttons will enable.
Run Number
If the data for the date selected contains run numbers, a selection box will appear to select the
"LAST MULTI DATA" or run number to use for the report. If run numbers were not used, select
"LAST MULTI DATA".
"USE LAST MULTI DATA" is the last available set of data the user collected regardless of run
number assigned.
Run number is the run number that was assigned to the data when it was collected.
Note: If data appears to be missing from a report, check that the individual lines for the date
selected all have the same run number assigned. If they do not, the data can not be

grouped together as needed. Plot the line in question and use the Modify data function
to change the run number.
Report settings are available
Use Smoothing
The smoothing factor entered in the configuration will be used if this box is checked. All
calculations in the compressor and engine reports use this number.
Use new compressor / engine report format

This option allows you to use a new compressor and engine report format which includes a notes
section.
Use extended engine report format

This option should be checked if you wish to print the engine report graphics pages as part of the
New Report Format.
Include engine balance page

The selected engine report format will have a graphics page added to show the balance state of
the engine data when this option is selected.
Include cost analysis page

The selected engine report format will have a cost analysis page added to show the economics
of the engine / compressor when this option is selected.

Reports 194
Diagnostics
Data or calculations that fall outside of the limits set under "Setup - Calculation " can be viewed
or included in the compressor report.
Include diagnostics on report

When this box is checked the the automated diagnostics will be included in the report.
Comp Data Dump

The compressor data dump function will create a file called "compdump.txt" that contains the
complete compressor performance report with compressor curve data in a comma delimited
format that was used to generate the viewed compressor report. The file is saved to the folder of
your choosing.
Date
The center of the report dialog box contains a Date Selection list box. When a report type is
selected, the Date Selection list box will fill with the available dates. Click the date, run number,
and select from one of the following outputs:
Report output selections are
Preview

This will print pages of the report selected to the print preview screen. A Page-Prev and Page-
Next button allow multi-page reports to be viewed. A print button is also included to allow
printing of the report. During print preview you can print the current report to a PDF, export to the
clipboard or save as a spreadsheet CSV file. If the new report format is used, you have the
option of including notes which are saved with the report.
Print
The print button will send all pages of a selected report to the printer. A print selection box will
appear to allow a different printer to be selected.
Export
The selected report will be printed to a PDF file, copied to Clipboard, or Save as CSV
(Spreadsheet file).
Notes
To include notes in a report, they may be added during the print preview of the new report format.
7.2 Quick Report

The quick report is used to print a concise report of a plotted set of lines. This is not a full report with
all data. It is just a summary report.
To use the quick report, plot a set of data, for instance, the HE and CE of a compressor cylinder. Click
on the Calculator toolbar button to bring up the calculations, then select Quick Report. A preview
screen appears with information relative to just the plotted lines.
If calculations or time/RPM data is displayed it will be included in the report.
If there are any annotations on the screen they will be included in the report.
This screen can be printed as needed.
7.3 Trend Report

The trend report is an online daily report. It has no function in the portable software.
7.4 Report Export

Engine, Ignition, Compressor, Rod Load, and Manual/Panel reports can be exported to PDF, copied to
the Clipboard, or saved in a CSV spreadsheet. For a detailed description of what information is exported
and the corresponding columns for the exported data please review the Report Export Format section.

Reports 196

7.5 Setup Reports

7.5.1 Engine Report
To run the engine report, it must first be set up using the Reports | Setup | Engine menu option. For
each active power cylinder, select the associated sensor point using the drop down list.
7.5.2 Ignition Report

To run the ignition report, it must first be set up using the Reports | Setup | Ignition menu option.
For each active spark plug, select the associated sensor point using the drop down list.

Reports 198
7.5.3 Compressor Report

To run the compressor report, it must first be set up using the Reports | Setup | Compressor menu
option. For each active cylinder's head and crank end, select the associated sensor point using the
drop down list.
7.5.4 Rod Load / Rod Drop Report

To include the rod drop calculations on the rod load / rod drop report the machine setup will need to be
updated in the Windrock MD software by going to Setup | Compressor/Engine Calculations | Rod
Drop to assign which sensors to use for rod drop.

To include rod gap on the report ensure "Include rod gap" is enabled.

Reports 200
7.5.5 New Report Format

The setup of the New Report Format is found under Engine/Compressor Panel Point Setup where you
can select which panel points to include in the report.
7.6 Report Field Descriptions

7.6.1 Engine Report
Heading, All pages
Company Logo: The logo as it is set up in the preferences file
Company Address: The address as it is set up in the preferences file
Date Collected: The date the actual data was collected
Station: Station name as set up in the database
Machine: Machine name as set up in the database
Analyst: The name as it is set up in the preferences file

Page 1
Line: This is the number assigned to the data point for reference on each page of the report
Cylinder ID: This is a 30 character name assigned in the set up
IHP @ RPM: This is the indicated horsepower calculated for the RPM sampled
IMEP (psi): This is the indicated mean effective pressure calculated for the sample
Peak Pressure @ angle: This is the peak firing pressure in PSI and the angle after top dead center
for this sample
Date: Date stamp at the time of data collection for this point
Time: Time stamp at the time of data collection for this point
Total IHP: This is the total of all the indicated horsepower calculated for the RPM sampled
Total BHP: This is the calculated break horsepower for the engine mechanical efficiency as entered
in the machine geometry set up under the machine tab
Page 2
Cylinder ID: This is 30 a character name assigned in the set up
Cycles: Num of cycles in average refers to the number of samples that will be taken for this point
Peak Pressure:
Mean: The average value of the peak pressure for the samples collected
High: The maximum value of the peak pressure for the samples collected
Low: The lowest value of the peak pressure for the samples collected
Spread: The difference from the lowest to the highest value of the peak pressure for the samples
collected
SD: The standard deviation of the peak pressure for the samples collected
Peak Pressure Angles:
Mean: The average value of the peak pressure angles for the samples collected

Reports 202
High: The maximum value of the peak pressure angles for the samples collected
Low: The lowest value of the peak pressure angles for the samples collected
Spread: The difference from the lowest to the highest value of the peak pressure angles for the
samples collected
SD: The standard deviation of the peak pressure angles for the samples collected
Total BHP: This is the calculated brake horsepower for the engine's mechanical efficiency as entered
in the machine geometry setup under the machine tab
Average Mean Pressure: The engine average of the cylinder mean pressures
Average Mean Angle: The engine average of the cylinder mean angles
Page 3
Cylinder ID: This is a 30 character name assigned in the set up
Tracking Angle: The degrees which can be up to ten each plus TDC, will be for the angles BTDC or
ATDC entered in the machine set up under the event tracking tab
Total BHP: This is the calculated brake horsepower for the engine's mechanical efficiency as entered
in the machine geometry set up under the machine tab
7.6.2 Balance Report
Heading

7.6.3 Ignition Report
Heading
Spark Plug Name: This is a 30 character name assigned in the setup

Reports 204
Cycles/miss: Number of cycles in average refers to the number of samples that will be taken for this
point. Misfires refer to the number of samples that were below the minimum spark level as set in the
software configuration.
Peak Level Spark Event Calculations:
Mean: The average value of the peak level spark event for the samples collected
High: The maximum value of the peak level spark event for the samples collected
Low: The lowest value of the peak level spark event for the samples collected
Spread: The difference from the lowest to the highest value of the peak level spark event for the
samples collected
SD: The standard deviation of the peak level spark event for the samples collected
Timing Spark Event Calculations: (In degrees after top dead center)
Mean: The average value of the timing spark event for the samples collected
High: The maximum value of the timing spark event for the samples collected
Low: The lowest value of the timing spark event for the samples collected
Spread: The difference from the lowest to the highest value of the timing spark event for the samples
collected
SD: The standard deviation of the timing spark event for the samples collected
Spark low level cutoff: The spark level as set in the software configuration
Suggested Timing: The expected ignition timing, after top dead center, as set in the machine
geometry setup under the miscellaneous tab.
7.6.4 Spark Survey Report
Heading

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.
Typical voltage measurements will range from 5,000 to 25,000 volts, with voltages over 20,000
3. 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
4. ionization voltage level from cycle-to-cycle measurements.
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
5. indicates the wiring to the coil is reversed and may result in shorter spark plug life.
Ionization Angle - The crank angle at which the peak ionization voltage occurs.
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 a 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.

Reports 206
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 unit 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 unit is 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 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 unit is 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.

7.6.5 Compressor Report Sections
Heading
Page 1
Cylinder ID: This is 30 character name assigned in the setup
IHP @ RPM: This is the indicated horsepower calculated for the RPM sampled
IHP/MMSCFD: This is the indicated horsepower divided by the calculated flow rate in million
standard cubic feet per day. The lower the resultant number, the better
the efficiency at the current compression ratio and flow rate.
Capacity MMSCFD: This is the smaller of the calculated capacity of the suction and discharge
conditions. Capacity at suction conditions is calculated from the cylinder
displacement modified by the measured suction pressure, temperature and
volumetric efficiency. Further correction is made with the suction
compressibility factor. Discharge pressure, temperature, volumetric efficiency
and compressibility are used in the discharge flow rate calculation.
Date: Date stamp at the time of data collection for this point
Time: Time stamp at the time of data collection for this point
%VOL EFF:
- Dis Discharge Volumetric Efficiency (VEd) is the percent of the cylinder end displacement
volume that the gas was compressed into before it was expelled from the cylinder into
the discharge cavity at discharge pressure and temperature.
- Suc Suction Volumetric Efficiency (VEs) is the percent of the cylinder end displacement
volume that was filled with gas from the cylinder suction cavity at
suction pressure and temperature.
%VALVE LOSS: This is a general term to indicate the percent of the total cylinder end horsepower
required in the compression process that is a result of factors outside of the
cylinder bore. This can include valve port, valve, valve chair, cylinder cavity, flange,

Reports 208
bottle and line losses. An actual pressure overlay (nozzle trace) can be used to
calculate the losses or a theoretical line can be projected across the PV card from
the toe pressures. True valve losses (valve, port, chair) can only be measured if a
phased nozzle trace is taken from the cylinder pressure cavity directly across
from the valve.
- Dis These are losses measured on the discharge side of the compression process
- Suc These are losses measured on the suction side of the compression process
%Flow Bal: The calculated suction flow rate divided by the calculated discharge flow rate
* A result greater than 1 indicates gas leaking out of the cylinder into a low pressure area
* A result less than 1 indicates gas leaking into the cylinder
Toe Press:
- Pd The instantaneous internal cylinder pressure indicated when the piston is at the end of the
discharge stroke. Head-end degree 0 or crank-end degree 180.
- Ps The instantaneous internal cylinder pressure indicated when the piston is at the end of the
suction stroke. Head-end degree 180 or crank-end degree 0.
Comp Ratio: For each cylinder end, this is the absolute discharge toe pressure divided by the
absolute suction toe pressure.
Temp F:
- Dis Temperature measured (or entered) at the discharge line
- Suc Temperature measured (or entered) at the suction line
Rod load (%):
- Ten This is the percent of the maximum-rated tension load on the piston as a result of gas
forces during piston movement toward the crank-end of the cylinder.
- Comp This is the percent of the maximum-rated compression load on the piston as a result of
gas forces during piston movement toward the head-end of the cylinder.
Min Rod Reversal: This is the minimum number of cross head pin and bushing reversal degrees
(compression or tension) that occurred in one revolution. Both gas load and
inertia loads are used in this calculation. Reversal degrees are measured
using guidelines as set forth in under Software Options.
Page 2
Theoretical Dis Temp:

- (F) This is the calculated theoretical discharge temperature for each cylinder end. It is calculated
from user-collected suction temperature, the absolute compression ratio of the toe pressures
and the K-value derived from the current gas sample.
- (delta) This is calculated by subtracting the theoretical discharge temperature from the measured
discharge temperature.
Clearances (percent):
- Set The assumed cylinder end clearance volume set in the machine geometry. This is entered
as either the actual cubic inches of clearance volume or as a percentage calculated by
dividing the clearance volume in cubic inches by the cylinder end displaced volume.
- SwRI The calculated clearance (percent or cubic inches) using the collected pressure trace
and the Southwest Research Method of clearance calculation. This
calculation method requires an accurate set clearance.
- Calculated->Suc The calculated clearance (percent or cubic inches) using the re-expansion
line from a collected pressure trace and the users selected Method of
clearance calculation found under Software Options.
- Calculated->Dis The calculated clearance (percent or cubic inches) using the compression line
from a collected pressure trace and the users selected Method of
clearance calculation found under Software Options.
A good correlation between the suction and discharge calculations indicates a healthy cylinder
and the average can be used to fine tune the set clearance values in
the load step tables in the unit geometry setup.
Compressibility: A volume ratio which indicates the deviation of the actual gas volume from that
determined by perfect gas laws. Compressibility and K are calculated using the
current gas analysis.
-Z dis Compressibility at discharge pressure and temperature
-Z suc Compressibility at suction pressure and temperature
-Z std Compressibility at standard pressure and 60 degrees F
-K Ratio of specific heat modified by temperature
Load Step: Is a number or letter indicating the clearance volume arrangement for the compressor
cylinders.
N ratio (Exp/Comp): Is the ratio of the N value calculated from the expansion slope divided by the
N value calculated from the compression slope of the indicator card.
Theoretical:

Reports 210
- Eff For each cylinder, the calculated theoretical horsepower divided by the measured
indicated horsepower. The result is expressed as a percent.
- HP The calculated theoretical isentropic horsepower using the internal cylinder toe pressure
ratio.
STG: Is the identification of the stage of compression
Capacity:
- Suc MMSCFD flow calculated at suction conditions
- Dis MMSCFD flow calculated at discharge conditions
Polytropic: N value is often substituted for K value in theoretical calculations and is more
representative of a polytropic process. The N-value calculation requires an accurate set
clearance in the load step tables. The N ratio has a similar diagnostic benefit as flow
balance.
- Exp The N-value calculated from the actual expansion process
- Comp The N-value calculated from the actual expansion process
Footer
Stage#: The stage of compression
Capacity (MMSCFD): The total calculated average flow in million standard cubic feet per day for
each stage
Total IHP: Is the total indicated horsepower for all cylinders on the unit
Total BHP: Is the total IHP divided by the compressor efficiency value in the unit geometry data file
+ the accessory horsepower in the geometry data file
Rated BHP: Is the rated BHP at the rated RPM in the geometry setup file
Torque: Is the re-rated BHP at the average operating RPM, divided by the measured BHP
BSFC: Brake Specific Fuel Consumption in BTU/BHP/HR
Compressor report p.: Indicates the page number of the report when multiple pages are printed
Smoothing factor: Indicates the smoothing factor used when calculating the data for the report
Nozzle: Indicates "Off" if nozzle curves were not used in the calculations for the report. Indicates
"On" if nozzle curves were used in the calculations for the report.

Run number: The number assigned at the time the data was taken. All data taken with this run
number is grouped together and included in the report.
7.6.5.1 Compressor Calculation Information

IHP computation method
IHP is calculated by force-distance method which produces the same results as taking the area
enclosed by the compressor or power cycle on a PV plot (this represents the work consumed or
produced by the cycle) and multiplying by the average speed of the machine. This gives the
indicated horsepower.
VE computation
The VE is measured off the PV plot. The software picks the toe points by scanning for the min
and max volumes seen on the PV plot. A constant pressure line is drawn back from each toe point
until it crosses the process line again. The length of each of these lines are the VEs.
Volume computation
Percent of swept volume is related to crank angle by the following formula:
% volume = { (crank_arm * cos(crank_angle) + SQRT[con_rod**2 - (crank arm**2 *

(sin(crank_angle)**2)]} / stroke
% volume can be converted to volume if needed by using:
volume = (% volume * total_ swept_volume) + clearance_volume
In the case of articulated power cylinders, an effective crank arm is calculated (each degree).
Also, an effective stroke is calculated.
Computation of gas properties, BWR, RK.
Equations of state are used to calculate compressibility factors. Benedict-Webb-Rubin is used

first.
In the event this equation fails to converge or the conditions are outside the limits for BWR or
there are no BWR coefficients available, the next equation of state used is Beattie-Bridgeman.
If there is any problem with the results from the Beattie-Bridgeman equation, the Redlich-Kwong
equation is used.

Reports 212
If there is still a problem (i.e., the conditions place gas below the saturation line), the software
generates an alarm and continues using the average Z calculated up to this point as the Z for this
gas.
The specific heat ratio is calculated based on temperature only using a third order fitted
polynomial. Propane, butane_n, butane_i, and argon use an eight order polynomial. In the event
there is a problem, the K value for the gas is set to 1.3.
Total BHP=(page1_hp_total/compressor_eff)+aux_load
PercentLoad=(((page1_hp_total/compressor_eff)+aux_load)/(rated_load*(rpm_total/(float)
rpm_count)/rated_speed))*100
7.6.6 Economic Report

Unit Economic Report
To use the engine cost section of this report, you must set up the BSFC option and input a fuel curve to
use. These are located under the 'Setup' pull down menu in the machine area, under the 'Comp/Eng
Calculations Setup' selection. Also, under this menu item, is an option 'Bypass Valve Setup'. This allows
the user to estimate the cost of leakage through a bypass with temperature measurements. If bypass
valves are setup, these costs are also included in the economic report. Most of these new economic
features require the fuel flow to be measured for the unit.
The 'Window Global Defaults' selection, under the 'Setup' pull down menu in the machine area, has been
renamed to 'Economic Factors Setup'. This is used to set up some of the parameters used in the
Economic Report. You need to input the cost per 1000 cubic feet of fuel in this option. You can also
select how compressor costs are calculated with this set up screen. Shown below are the two methods
available for compressor cost evaluation:
1> Use Flow Balance, Power/Valve loss model - This option uses the same compressor cost model
based on flow balance that was previously used. However, it has added the ability to estimate the cost
of excessive power/valve loss. If this option is selected, the user may provide the normal percent loss
expected for each compressor end. Any power loss above this cutoff will be considered an excessive
operating cost.
2> Use Theoretical Flow Comparison - This approach compares the measured flow to the
theoretically calculated flow. If the measured flow is lower or higher than the theoretical flow by more
than 2 percent (options are 2(default),1 or 0.5), the difference below or above this percent mark is
considered loss or recirculating flow and is charged as an excessive operating cost.
Station Economic Report
There is now a station-wide cost comparison report available. It compares the dollar per mmscf for each
unit in a station. This option is available after you highlight a station under the Database pull down menu.
If you are using fuel cost as the cost basis, the BSFC option must be set up in a machine for this report
to provide a value. Currently, this report will only pull the latest data for each machine. A fuel flow
measurement for this run number needs to be available when using a fuel cost basis.

7.6.7 Rod Load / Rod Drop Report
Heading
Unit id: Unit id as setup in the machine geometry > miscellaneous settings
Unit Mfr: Manufacturer of unit as setup in the machine geometry > miscellaneous settings
Model: Type of model as setup in the machine geometry > miscellaneous settings
Serial No: Serial # of unit as setup in the machine geometry > miscellaneous settings
Date: The date the actual data was taken
Run No: The run # associated with the data
Page 1
Load Step: The load step selected during data collection
Cylinder: Displays the number of cylinders the data refers to
Stage: Displays the stage number associated with that cylinder
Rod load Absolute Load (lbf):
- Ten This is the pound-force of the maximum-rated tension load on the piston as a result of gas
- Comp This is the pound-force of the maximum-rated compression load on the piston as a result
of gas forces during piston movement toward the head-end of the
cylinder.
Rod load (%):
- Ten This is the percent of the maximum-rated tension load on the piston as a result of gas

Reports 214
- Comp This is the percent of the maximum-rated compression load on the piston as a result of
gas forces during piston movement toward the head-end of the cylinder.
Rod Reversal (deg.): This is the minimum number of cross head pin and bushing reversal degrees
(compression & tension) that occurred in one revolution. Both gas load and
inertia loads are used in this calculation. Reversal degrees are measured using
guidelines as set forth in under Software Options.
Rod Movement:
- Rod Gap This is the average gap for one revolution. When trended over time, this gives rod drop,
which helps detect alignment issues.
- Rod run-out This is the maximum minus minimum within one revolution. This helps detect
looseness (of the packing or of the nuts connecting piston to rod or rod
to crosshead) or improper wear in the crosshead shoes.
- Rod alignment TDC minus BDC within one revolution. This helps detect cylinder alignment
issues.
Notes: Displays the setup information for the machine based on the setups and software options that
have been chosen in the software.
7.6.8 Manual Report

The manual report will print all collected gauge readings taken for the selected date and run number.
For each line, the sensor point name, reading, date and time is printed.


Reports 216
7.6.9 Analyzer Notes Report

The notes report will print all collected notes for the selected date and run number. For each note listed,
the run number, load step, sensor point, date, time and note text is printed.
To change the available notes in the analyzer, see the section on Notes on Analyzer for details.
7.6.10 Report Export Format

When reports are exported to an Excel spreadsheet (copied to clipboard and pasted or saved as CSV
spreadsheets), the following fields are available.
Engine Report
Excel Column Description

A Sensor Point ID
B Date stamp
C Horsepower
D Speed
E Peak pressure from curve
F Peak pressure angle from curve
G # of samples taken
H Mean of peak pressure (statistics)
I High of peak pressure (statistics)
J Low of peak pressure (statistics)
K Diff high and low of peak pressure (spread)

L S.D. of peak pressure (statistics)

M Mean of peak pressure angle(statistics)
N High of peak pressure angle(statistics)
O Low of peak pressure angle(statistics)
P Diff high and low of peak pressure angle(spread)
Q S.D. of peak pressure angle(statistics)
R Pressure at TDC
S Tracking angle 1
T Pressure at tracking angle 1
U Tracking angle 2
V Pressure at tracking angle 2
W Tracking angle 3
X Pressure at tracking angle 3
Y Tracking angle 4
Z Pressure at tracking angle 4
AA Tracking angle 5
AB Pressure at tracking angle 5
AC Tracking angle 6
AD Pressure at tracking angle 6
AE Tracking angle 7
AF Pressure at tracking angle 7
AG Tracking angle 8
AH Pressure at tracking angle 8
AI Tracking angle 9
AJ Pressure at tracking angle 9
AK Tracking angle 10
AL Pressure at tracking angle 10
AM Report line # (cylinder #)
AN Run # selected
AO IMEP
AP Fuel flow data (in SCFH)
AQ Heating value (in BTU/SCF)
AR Max rise rate (for diesels)
AS Start of combustion (°BTDC, for diesels)

Reports 218
AT Exhaust Temperature (°F)
Ignition Report

A Sensor point ID
B Date Stamp
C Speed
D # samples taken
E # of misfires
F Mean of peak spark voltage (statistics)
G High of peak spark voltage (statistics)
H Low of peak spark voltage (statistics)
I Diff high and low of peak spark voltage (spread)
J S.D. of peak spark voltage (statistics)
K Mean of peak spark voltage angle(statistics)
L High of peak spark voltage angle(statistics)
M Low of peak spark voltage angle(statistics)
N Diff high and low of peak spark voltage angle(spread)
O S.D. of peak spark voltage angle(statistics)
P Peak of spark curve (from representative curve, not from
statistics)
Q Peak of spark curve angle (from representative curve, not
from statistics)
R Report line #
S Run # selected
Compressor Report

A Sensor point ID
B Date stamp
C Horsepower

D Speed
E IHP/MMSCFD
F Peak pressure from curve
G Peak pressure angle from curve
H Volumetric Efficiency discharge
I Volumetric Efficiency suction
J Valve loss % discharge
K Valve loss % suction
L Capacity
M Suction capacity
N Discharge capacity
O Flow balance
P Discharge pressure
Q Suction pressure
R Compression ratio
S Discharge temp
T Suction temp
U % rod load tension
V % rod load compression
W Theoretical discharge temperature
X Actual
Y Set clearance
Z SwRI clearance calculation
AA Suction clearance calculation
AB Discharge clearance calculation
AC Z discharge
AD Z suction
AE Z standard
AF K value
AG Load step
AH n ratio
AI n expansion
AJ n compression
AK Theoretical efficiency (isentropic)

Reports 220
AL Theoretical horsepower
AM Report line # (cylinder end #)
AN Run # selected
AO Stage number
AP Leak index
Rod Load / Rod Drop Report

A Cylinder number
B Stage
C Rod load compression
D Rod load tension
E % rod load compression
F % rod load tension
G Rod reversal compression
H Rod reversal tension
I Rod drop
J Rod run-out
K Rod alignment
Manual / Panel Report

A Sensor point ID
B Date stamp
C Value
7.6.11 Common Questions

Q: What does the error message "Comp 1 H Pressure: suction Z: failed to calculate Z for n-heptane
(0.26% of PDO); possible liquid" mean in the report and calculate functions?
A: This message will appear whenever any gas component or components do not converge during the
compressibility calculation for the specific gas pressure and temperature condition. It is possible that

this component is in a liquid state. Generally, this is one of the "heavy" components and is usually a
very small percentage of the total gas; therefore, the effect is quite small. To disable the gas phase
change warnings look under Software Configuration.
Q: What is the difference between GPSA and SwRI values in the report?
A: The GPSA method of clearance calculation is made from both the PV re-expansion slope (suction)
and the compression slope (discharge). In a healthy cylinder, these two calculations will usually agree
closely. If the actual clearances are not known, the average of the suction and discharge calculations
can be used to enter into the load step table for the theoretical PV display. (GPSA = Gas Processors
Suppliers Association)
The SwRI method of clearance calculation requires an accurate clearance already in the load step table.
If you are testing a healthy cylinder, this method will provide a result that is close to the set clearance.
If there is a problem with the collected data from either a leak or a collection error, the numbers will not
agree. (SwRI = Southwest Research)
If a good correlation exists among all 4 clearance numbers (Set, GPSA suct, GPSA disch and SwRI),
then the probability is very high that this is a healthy cylinder.
Q: Are Nozzle traces used in reports to compute valve loss IHP?
A: Nozzle traces can be used to compute valve loss IHP. Make sure "use nozzle trace" is enabled in
software options. If nozzle trace is not available, a warning box will pop up and the software will use the
84-10 straight line method.
Q: When nozzle trace is used, will EVs be computed based on actual nozzle plot intersection or on 84-
10 straight line method?
A: In Windrock MD software version 4.0 and later, the VE is always based on the 84-10 straight line
method.

Reports 222
7.7 Auto Printing
To automatically print a series of plots that have been

predefined, select Reports | Auto Printing from the
main menu bar. Click on the required settings and click
on OK. The group plot will appear and printing will begin.
This will repeat until all predefined plots have been
printed. Use the group plot set up function to predefine
the groups to plot. The output can be to a printer or a
PDF file.
8 History
Historical notes related to the machine can be entered here and viewed at a later date. This is
available as a menu item at the top of the machine plot area only when a machine database is open.
This history is kept with the machine data in the same folder. You can copy and paste text into or out
of history. The maximum number of text characters per entry is 800.


History 224
9 Window
The Window menu allows you to manage how multiply windows are displayed. This is useful when more
than one data base is open and you want to compare data from multiple units side-by-side. When
displaying multiply windows you may want to select View to un-select the toolbar display.

9.1 Cascade
Arrange plots one on top of the next so that only the plot titles are showing for all plots except
the currently active one.

Window 226
9.2 Tile
The displayed plots are arranged to fill the available screen area.
9.3 Arrange All

Select the windows to which you want the commands to apply to.

10 Utility
10.1 Connect to Analyzer
This utility facilitates the transfer of data to and from the portable analyzer. This utility will transfer all
required analyzer set up files, collected data files, and other file types such as executables. If, for
instance, a new version of analyzer software were needed to be uploaded to the analyzer, this utility
would be used. When files are uploaded from the analyzer, you will see a warning message if the
Windows and analyzer software versions do not agree.
Caution: The analyzer should be powered by a fresh battery when transferring data to
the unit. A loss of power (run down battery) to the analyzer while transferring
data could corrupt files.
The following steps are for connection while a machine database.
1. To make the connection, make sure the communications cable is connected to both the portable
analyzer and the laptop/desktop computer.
2. Click on Utility | Connect to Windrock analyzer and the following dialog box will appear.
On the left is a list of stations and machines on your computer, just like the Station / Machine Manager.
On the right is a list of stations and machines on your Portable Analyzer.

Utility 228
In the middle is a list of available options that's dynamically updated based on what stations and
machines you've selected on the left side (your computer) and the right side (the Portable Analyzer). For
example:
· If you've selected a station that doesn't exist on the Portable Analyzer, Windrock MD will offer to
create it.
· If you've selected a station that has newly created machines, Windrock MD will offer to create
those machines.
· If you've selected a machine that has new data available, Windrock MD will offer to transfer that
data.
· You can also choose to transfer data and / or setups, if you've edited setups or modified or
adjusted data.
You can right-click on the list of stations and machines to delete and rename stations and machines
(just like the Station / Machine Manager). This works for stations and machines on the Portable
Analyzer as well as stations and machines on your computer. You can also right-click on a machine on
your computer and choose Open to immediately start analyzing that machine; this makes it easy to
start analyzing a machine after you've transferred data for it from the Portable Analyzer.
Drag-and-drop reordering (just like the Station / Machine Manager) works within the Analyzer Connection
right window (so you can reorder stations and machines on the analyzer).
Unlike the old Connect to Analyzer feature, the new Analyzer Connection screen is usable with no
machines open.
If new analyzer software is available you will

be prompted to update the analyzer software.

Select the option to keep the analyzer

clock updated.
Select the Other drop down box to facilitate

sending/receiving Analyzer & System
Options.
The analyzer may also be backed up to

your hard drive, external hard drive, or
network.
Before selecting Restore, you must first

have the database listed in the left pane.
Product support options include Software

updates, Diagnostics and transfer files.
Transfer files is the old analyzer connection
menu.
10.2 Data Explorer

The Data Explorer offers a powerful way to view and edit historical data. It operates similarly to Windrock
MD's Modify/Remove Line feature, except that it lets you view all data, instead of only the current plot.

Utility 230
On the left-hand side, you can choose to view different types of data (dynamic crank-angle data, spark
traces, balancer and FFT) and switch between different dates.
The spreadsheet-style view in the middle lets you view data for that date. Similar to the Modify/Remove
Line feature, you can edit several parameters (time stamp, RPM, run number, load step, temperature,
panel values, and pressure sensor range/sensitivity). All of Windrock MD's spreadsheet-style editing
features are available: copying and pasting to and from spreadsheets, selecting a group of cells and
typing a value to update them all at once, and so on.
Modified values are highlighted in red with a yellow background. Click the Save button (disk icon) in the
toolbar to save your changes, or click Undo to undo them.
The toolbar also offers buttons for moving data to another date (if you discover that your analyzer clock
was wrong or if an analysis run lasted after midnight) and deleting data.
For portable data, single scans are grouped together under the corresponding average or representative
scan. Click the + next to a row of data to expand and view the single scans. For online data, the curves
that are saved periodically (hourly by default) by On-Guard or Platinum are grouped together; click the +
to expand and view all data for that time period.
Because the Data Explorer makes it very easy to change or delete a bunch of data at once, making a
backup of your data before editing is a very good idea. The easiest way to make a backup is to open the
Station/Machine Manager, right-click on the station, choose Zip, make sure to include the machine data
you want to back up, and save the machine archive file in a safe place. Then, if needed, you can double-
click on the machine archive file to import its data back into Windrock MD.

11 Help
There are several types of help options available in the Windrock MD program. Click on the "Help"
menu option and select one of the following types of help:
Windrock MD Help - Is a hyper link to this Help file.
What's New - Overview of major new features.
Glossary - A complete list of terms used in the reciprocating business.
Portable Analyzer Help - Is a hyper link to the analyzer manual and links to various subjects.
Shortcut Keys - A complete list of shortcut keys used in this program for reference.
Check for Updates - This option will check the Windrock web site for Windrock MD or portable analyzer
program updates.
Enter New Product Key - This option is used when you upgrade programs, example from a PA to
PA/VA.
About - Provides information about the current software version.
12 Appendix
12.1 Migrating to a New PC or Operating System
At sometime you will need to upgrade your operating system ( XP to Windows 7) and or your personal
computer (PC). You need to plan ahead and follow the steps listed below.

Appendix 232
From your current PC you will need to make a backup copy of your data (database), and if your install
disk does not have your current Windrock product key listed on the jacket, you will need to gather that
information from your current Windrock program.
You have several options for archiving your database (database), they are listed below in order of most
common practice to least common.
1. If you have access to your company's network, copy your data to a designated folder on a
network server. If you are already doing this as a best practice, then update the files.
2. If available, copy your data to an external hard drive.
3. If available, copy your data to a USB flash drive. To verify there is enough memory on the
flash drive, use Windows Explorer to find the size of the database file folder. To do this, right
click on the database folder and select properties. Many databases exceed 1.25 GB.
4. Use a USB to USB data transfer cable to quickly copy files from the host computer to the
new computer.
5. Use the Windrock MD program on the new computer to download the analyzer's database
folder to your new computer's hard drive.
To install the Windrock program you will need the original install CD. If the CD jacket does not contain
the program product key, it can be found by opening the Windrock program on the old PC, and from
menu bar, select HELP and ABOUT. The product key will be listed. After installing the original program,
you will need to access the Windrock web site to download and install the current version of the
software. If you do not have the original install CD or your service agreement has expired, contact
Windrock Customer Support at (865) 330-1100 Ext 1114.
12.2 Making the Change from the 6310 to the 6320

Menus and icons have been redesigned in the Windows program. Take the time to familiarize yourself
with them by dragging the mouse to each one and reading the explanation provided.
Changing the logo on reports has been streamlined. Under the Edit menu, Preferences, Company Info
tab, you can choose no logo or the default Windrock logo, or you can browse for a custom logo that
must be in either JPEG (.jpg) or Windows bitmap (.bmp) format. Custom images will be automatically
scaled to the right size so you don't need to worry about the image size.
The analyst’s name (as printed on reports) can come from your Windows username instead of being
manually entered. To enable this, go under Edit, Preferences, Company Info tab.
To access the Machine Selection Window, use File, Open from the Menu choices.
The “Connect to Analyzer” screen has several new features:
“Connect to Windows” no longer exists as a menu option on the analyzer. The analyzer is
automatically ready to connect whenever you plug in the USB to USB transfer cable, regardless of
what station and machine you have selected.
When connecting to a 6310 analyzer, if the selected station and machine do not match, Windrock
MD asks if it should select the matching station and machine. This means that you can start the
“Connect to Windows” screen on the analyzer without worrying about which station and machine you
have selected.

If the selected station and machine do not exist on the analyzer, Windrock MD asks if it should
create the station and machine.
Windrock MD can synchronize the date and time with Windows.
There is also an option to check for software updates.
The 6320 can take raw vibration at 2 or 4 samples per degree, providing much more detailed vibration
data. To change all existing raw vibration sensor points to use 2 or 4 samples per degree, go under the
Software Options screen in Windrock MD or under the Software Configuration Menu on the Analyzer.
You can also change individual raw vibration sensor points using the Sensor Point Editor and changing
the sensor point type to Raw vib vs. crank angle (2/pulse) or Raw vib vs. crank angle (4/pulse). Points
identified in this way will not be affected by the setting in the software options/configuration.
The 6310 always plotted spark plug voltage versus crank angle data as positive. It required that you
specify (under Machine Geometry) whether the ignition system was positive pulling or negative pulling.
The 6320 ignores this ignition pulling option and correctly plots spark plug data as positive or negative.
To make new spark plug data in existing machines plot correctly, you will need to go under Fixed Data
Scales, find the “Sparkplug voltage” scale, and change the low value to -15000 and the high value to
+15000.
The filters used for high frequency vibration and low frequency vibration are now fully configurable. Go to
the Software Options/Configuration screen (only on the Analyzer, not from Windrock MD) if you wish to
change the default filters. We recommend using the 4 kHz to 15 kHz option for general use.
The Station Selection menu in the 6320 analyzer adds several options under its new System
Configuration menu item. You can now set the system date, time, and time zone and manage printers
(for printing directly from the analyzer).
The Spark Survey mode now uses a configurable trigger and sample length. You can set these in the
“Setup balancer / spark” screen on the analyzer and may need to adjust them if Spark Survey fails to
capture the entire ignition event, captures the wrong portion of the event, or runs very slowly.
Since the underlying operating system used by the 6320 has changed, the command prompt
(“Engineering Mode”) operates very differently than before. See part 12 of the Portable Analyzer User's
Manual for details.
Remember, any changes to the setups should be transferred to the analyzer or vice versa to prevent
overwriting the changes later.
If you want to use a keyboard with the 6320, you will need a USB keyboard.
12.3 Creating Windows Shortcuts

You can create additional shortcuts to the Windrock MD software for the following purposes:
· You might want an easy way to switch between multiple database folder directories.
· You might be responsible for more than one model of analyzer (for example, a PA and a CA), so
you would have a product key for both the Windrock MD PA and the Windrock MD CA software,
and you want an easy way to use both PA and CA software. (This isn't always necessary, since
Windrock MD PA's functionality is a superset of Windrock MD CA; however, you might need
Windrock MD CA to generate 1-channel setups for your CA analyzer.)
To create a new Windrock MD shortcut for a new model or new database directory:

Appendix 234
1. Find the Windrock MD shortcut in your Start Menu or on your desktop.

2. Right-click on the shortcut and drag it where you want to place your shortcut.
3. A menu will pop up asking what you want to do. Choose "Create Shortcut."
4. Right-click on your new shortcut and choose Properties.
5. At the end of the Target line, add one or both of the following options:
· "d:\alternate-database" to use "d:\alternate-database" instead of your regular database folder
· /productkey=1234-1234-1234-1234 to use 1234-1234-1234-1234 as the product key
6. Click OK.
7. Right-click on your shortcut and choose Rename to give it a better description.
12.4 Notes on Analyzer

Modifying the default note files
You can input up to 40 one-line notes for each of five categories. Each line can be up to 78 characters
long. Use a text editor to create a file using the names shown below. After you have input your one-line
comments, place an extra line at the bottom with "end of list".
Category File name
1)Angular Velocity -> d6atext.dat

2)Compressor Points -> d6ctext.dat
3)Temperature Points -> d6ttext.dat
4)Power Points -> d6ptext.dat
5)Spark Points -> d6stext.dat
Once you have created your files, place them in the c:\database directory on your analyzer. Remember
this replaces the system default comments. You do not have to create all five files. For the categories for
which you do not create a file for, the system default comments will be available.
The system defaults are as follows:
Angular Velocity Notes

File: D6ATEXT
MANUALLY INPUT A SENSOR NOTE

Excess spread from hi to lo
Pattern has changed
Possible encoder slippage
end of list
Compressor Notes
File: D6CTEXT

Valve leakage suction

Valve leakage discharge
Valve knock
Valve late closure (spring damage)
Valve cap external leakage
Cylinder head external leakage
Packing leakage
Rings leaking
Unloaded at suction pressure
Unloaded at discharge pressure
Low VE
Unloaded due to low VE
Restricted indicator passage or valve
Reciprocating component looseness
Loose piston
Crosshead knock
Crosshead P&B non-reversal
Excessive rod load
Excessive suction losses
Excessive discharge losses
Unloader leakage
Cylinder mounting looseness
Excessive vertical rod runout
Excessive horizontal rod runout
end of list
Power Notes
File: D6PTEXT

No combustion
Late combustion
Early combustion
Pre-ignition
Detonation (post ignition knock)
Intermittent combustion cycle to cycle
Poor combustion
Valve leakage
Valve early closure
Valve late closure
Excessive valve lash
Insufficient valve lash
Valve spring damage
Excessive valve recession
Improper rocker arm bridge adjustment
Cam lobe damage indicated
Valve guide wear
Ring blow-by

Appendix 236
Piston slap
Piston to cylinder scuffing
Ring vibration
Possible stuck or missing rings
Possible broken rings
Head gasket leakage
Fuel valve base gasket leakage
Indicator valve leakage
Restricted indicator passage or valve
Exhaust manifold leak
Intake manifold leak
Fuel manifold leak
Pin & bushing knock
Cylinder mounting looseness
Early injection timing
Late injection timing
Defective injector pump
Defective injector nozzle
end of list
Spark Notes
File: D6STEXT

Late timing
Early timing
Excessive timing spread
Long arc duration
Short arc duration
No arc
Defective plug wire
Excessive ionization voltage
Intermittent no arc
Leaking gasket
High arc resistance
Poor ringdown
High secondary circuit resistance
Low primary voltage
Primary capacitor leakage
Missing primary discharge event
Weak/defective coil indicated
end of list
Temperature Notes
File: D6TTEXT


Reading seems high
Reading seems low
Check against historical levels
end of list
13 Glossary
Absolute Pressure (PSIA) - Pressure in PSI above zero pressure (or complete vacuum) that amounts to
the weight of air in pounds per square inch at sea level under normal barometric conditions. That is 14.7
psig (Zero psig. = 14.7 psia.).
Absolute Temperature - In theoretical calculations related to gases, the absolute or Rankine scale is
used. On the Fahrenheit scale, the absolute temperature is 460 F.
Accelerometer - A sensor that detects vibrational energy and outputs an electrical signal proportional to
g's. A g is the accelerations of gravity approximately 32.2 feet per second per second.
Analyst - A person who collects engine/compressor data using an analyzer and reviews the data for
machinery malfunctions.
Angular Velocity - The change in angular velocity measured in RPM as the machine rotates in a single
revolution.
Articulation - In an integral engine/compressor the irregular movement of the power pistons in relation to
the compressor piston due to the manner in which the power rods are connected to the compressor rod
instead of directly to the crank shaft.
Atmospheric Pressure - The weight of air measured at sea level; about 14.7 psia. (Zero psig.).
Blowdown Event - The detail of the pressure curve during and just after the exhaust port (or valve) is
opened.
Bore - The width or diameter on an engine or compressor cylinder.
Brake Horsepower (BHP) - The usable output of an engine as measured at the crankshaft or flywheel.
Brake Mean Effective Pressure (BMEP) - The theoretical constant pressure that can be imagined
exerted during each power stroke of the cylinder to produce power to the brake horsepower. BMEP is
the IMEP less all friction and parasitic losses. BMEP cannot be measured, it must be calculated.
British Thermal Unit (Btu) - The amount of heat required to raise the temperature of one pound of water
one degree Fahrenheit.
Cam - An eccentric which changes rotary motion into linear motion.
Camshaft - A shaft containing lobes or cams which operate valves on engines.

Glossary 238
Carbon - An element of mass 12. A byproduct of combustion which tends to accumulate on exhaust
ports and manifolds.
Clearance Volume - Power - With the piston at top dead center, it is the remaining space which holds
the gases at full compression. This is the combustion chamber in a power cylinder.
Compressor - 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.
Compression Pressure - The pressure of the air-fuel charge at the end of the compression stroke with no
ignition of the mixture. In a compressor cylinder this is the pressure of the gas charge at the end of the
compression stroke.
Compression Ratio - The ratio of the volume of the charge at the beginning of the compression stroke to
that at the end of the compression stroke.
Compression/Tension - The force in pounds that the compressor rod is undergoing due to pressure
differential on each side of the piston, and the inertial acceleration of the reciprocating motion. The force
is displayed as pounds compression and pounds tension.
Connection Rod - The connection between the piston and the crankshaft.
COV - Coefficient of Variation (or Variance) in statistics. COV is the magnitude of variance or dispersion
relative to the mean or average. CV = SD/Avg.
We use COV in two different ways:
1) In spark ignited (SI) engines, we use COV to measure the peak firing pressure stability. A normal
COV would be from ten to twenty. A high COV indicates a mechanical problem and/or a lean air-fuel
mixture in the main or pre-combustion chamber.
2) Engine Calculations:
Cylinder COV = Std. Dev. of the power cylinder PFP

Average of the power cylinder PFP
Engine COV = Std. Dev. of the power cylinder Std. Dev.

Average of the power cylinder Std. Dev.
3) When using vibration history to set warning and alarm levels, a COV of less than .33 is desired. If the
COV is greater than .33, the average times 1.5 may give a better warning level (with less false vibration
alarms) than using the average plus three standard deviations where there are no malfunctions present in
the equipment.
Crank End (CE) - The end of the compressor cylinder nearest to the engine or frame.

Crankshaft - The main shaft of an engine which, turned by the connecting rods, changes the
reciprocating motion of the pistons to rotary motion in the power train. In a compressor the motion is
transferred from the crankshaft to the pistons for compression.
Crosshead - The part of a compressor that connects the piston rod to the main rod. The crosshead
slides back and forth.
Cylinder Liner - A cylindrical lining, either wet or dry, which is inserted in the cylinder block in which the
piston slides.
Cylinder Stretch - The mechanical stretching of a compressor cylinder due to the internal pressure inside
the cylinder.
Cylinder 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.
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.
Delta Discharge Temperature (DTD) - The difference of the measured discharge temperature and the
theoretical calculated discharge temperature.
Discharge Pressure - The pressure at which compressed gas is forced out of a cylinder.
Discharge Temperature - The temperature of the gas leaving the cylinder through the discharge valve.
Typically this is measured at or near the discharge bottle or nozzle.
Discharge Valve - A valve through which compressed gas leaves a cylinder.
Displacement - The actual volume displaced by the piston as it moves from bottom dead center to top
dead center.
Double Acting - Indicates that the piston pumps gas on both ends; i.e. as the gas discharges out the
bottom valve on the head end, the piston draws gas into the cylinder through the top 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.
Encoder - Crank-angle transducer changes the rotational motion of the crankshaft into electrical pulses
(one pulse per degree of crank-angle rotation).
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

Glossary 240
than a continuous rating on an engine. An engine of rating at high altitude or high ambient temperatures
will be rated for a lower output.
Engine Displacement - The sum of the displacements of the individual cylinders which compose the
engine.
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 - A cam actuated valve that allows combustion gas to exit the combustion chamber into
the exhaust manifold.
Fixed-Volume Pocket - A fixed-volume chamber with a valve that can be opened or closed by a hand-
wheel or air cylinder from outside the cylinder. A fixed-volume pocket adds a specific volume to the
cylinder when it is open.
Flywheel - The round massive component used to provide inertia that damps angular velocity changes of
the machine.
Four-Stroke Engine - An engine that requires four piston strokes and two complete crankshaft revolutions
to complete each cycle. (720 Degrees)
Frame Front - The movement of the combustion of the gas mixture inside the combustion chamber.
Friction Horsepower - Power consumed within an engine 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.
Gas - A substance that changes volume and shape according to temperature and pressure applied to it.
Often a combustible substance.
Gas Analysis - Mole Fractions of each gas contained in the mix of gases passing through the
compressor.
Head End (HE) - The end of the compressor cylinder away from the engine or frame.
High Speed - (Over 750 RPM)
Ignition Delay - The time 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 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.

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) - The theoretical constant pressure that can be imagined
exerted on the piston during each power stroke of the cylinder to produce power equal to the indicated
power work. It is the average pressure exerted on the piston through the functional cycle.
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.
Kiene Valve - A special valve used in the indicator port for connection to pressure transducers.
Log P - Log V - A Pressure vs. Volume plot which uses log scales. The sides of a compressor Log P vs
Log V plot should be straight and parallel. If not straight and parallel, this is an indication of leaks.
L/R Ratio - The L/R ratio is the ratio of the connecting rod length to the radius of the crankshaft throw.
Low Speed - (Below 400 RPM)
Maintenance Analyzer - An analyzer with an oscilloscope that provides displays of PV, PT, Ignition, and
Vibration patterns. The displays are used to detect defective parts and poor engine operation that cause
unit malfunctions.
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.
Medium Speed - (400-750 RPM)
Naturally Aspirated - 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 very near
to or slightly below atmospheric pressure.
Nozzle - The passage that provides an inlet or outlet to the compressor cylinder.
Once-Per-Turn - Transducer to generate one pulse per revolution of the crankshaft. This usually is in
inline with TDC on the flywheel.
Parametric Emissions Monitoring (PEMS) - A computer model used in conjunction with transducers to
calculate the amount of oxygen, carbon monoxide, and nitrous oxide present in the exhaust of an
engine.

Glossary 242
Peak Firing Pressure (PFP) - The maximum pressure developed in a power cylinder due to combustion
to the mixture. Under normal conditions, peak pressure occurs between 10 to 25 degrees 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.
Performance Analyzer - A device that has all the capabilities of the maintenance analyzer plus RPM,
accurate pressure versus volume display, and digital readout of horsepower developed or consumed by a
cylinder.
Performance Calculations - Calculations that indicate the performance of a compressor or engine.
These calculations include:
· Flow Balance
· Capacity
· IHP, BHP, HP, Aux HP
PI Meter - A pendulum-dampened pressure gauge actuated by a spring loaded piston. Indicates the time
averaged cylinder pressure used for individual cylinder balance.
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.
Piston Speed - Piston speed is equal to twice the stroke times the RPM. It is a measurement of the
loading resulting from the motion of the various parts of the engine.
Plate Valve - A type of valve used in gas compressors consisting of plates and springs.
Poppet Valve - A type of valve used in gas compressors consisting of many individual small round
poppets. Each poppet has a spring and a sealing seat.
Pre-Ignition - A common fault with a spark ignited engine where the mixture begins to burn prior to an
electrical spark being induced into the cylinder. The usual cause is overheated parts or particles in the
combustion chamber.
Pressure vs. Time (PT) - The dynamic pressure inside a cylinder referenced to crank-angle position.
Pressure vs. Volume (PV) - It is the pressure in pounds per square inch absolute times volume in cubic
feet. Pressure volume is used as an indication of work performed. It is sometimes referred to as "PV
Cards".
Pulsation - The pressure fluctuation in the nozzles, bottles, and piping 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.
Pyrometer - Used to indicate exhaust cylinder and manifold temperatures.

Rack - A type of gear that is flat. Usually associated with a pinion gear to convert rotational motion to
linear motion.
Reciprocating Weight - The combined mass (weight) of the piston nut, piston rod, and piston used in the
rod loading plot and calculation.
Rings - The sealing devices around the piston preventing gas from flowing around the piston and cylinder.
Riderband - The bands that support the mass of the piston and rod in a reciprocating compressor.
Rod Diameter - The diameter of the piston rod.
Rod Drop - The distance that the compressor piston rod moves over a long period of time as the rider
bands wear.
Rod Knock - A mechanical impact due to excessive clearance in the rod bearing or due to a lack of
proper lubrication of the rod bearing.
Rod Motion - The movement in the X or Y axis of the compressor rod.
Rod Runout - The dynamic movement of the piston rod of a compressor over a single stroke.
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 separable from the driver.
Sour Gas - A typical gas being compressed containing a high content of hydrogen-sulfide (H2S).
Stroke - The movement of the reciprocating machine during one rotation of the flywheel.
Suction Bottle - A container of large volume at the inlet of a compressor whose purpose is to reduce
pressure pulsations in the suction piping and increase the efficiency of the compressor.
Suction Pressure - The pressure of a gas entering the suction valve of a compressor.
Suction Temperature - The temperature of the gas entering the suction valve of a compressor. Typically
this is measured at or near the suction bottle or nozzle.
Supercharging - Pressurizing the inlet air above atmospheric pressure with a mechanically driven blower
or reciprocating cylinder.

Glossary 244
Theoretical PV - The ideal PV curve calculated from the suction and discharge conditions and the
equations of state of the gas mixture being used.
Top Dead Center (TDC) - A marking indicating that the lead cylinder is at its most extended position. A
mark is usually placed on the flywheel indicating this position.
Turbocharging - Induction of gas in a turbulent manner. Used with reference to pressurizing the inlet air
above atmospheric pressure with an exhaust driven blower.
Two-Stroke Engine - An engine requiring only one complete revolution (360 degrees) of the crankshaft to
complete a cycle of combustion events.
Ultrasonic - A sensor that detects sound above a frequency detectable by the human ear.
Unloader - A device used to cause gas to surge into and out of the compressor cylinder without going
through the discharge valve. An unloader has plungers that hold the valve plates or channels open.
Valve - A device to permit relatively unrestricted flow of gas in one direction but to all flow of gas in the
opposite direction.
Valve Dynamics - The mechanical movement of the valve as it responds to pressure differentials.
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 (VE) - The ratio of the volume of gas actually drawn into a cylinder to the total
cylinder volume. Also the percentage of the stroke where gas is drawn into or out of the cylinder.
Wrist Pin - The pin and bearing connecting a power piston to the power connecting rod.

Rod Length 27
Index Setup
Table
27
29
Auto Generate
Collection Points 84
-3- Sensor Points 65
Autoscale 160, 178
3-D Plot 187 Auxiliary Load 24
Averaged 152
-4-
-B-
4-20mA Sensor 49
Balance Report 202
-8- Balancer set up 144
Bale Angle 27
84-10 straight line method 220 Bank Angle 27
Bar Chart
-A- Group Plot 91
Setup 91
Adding Brake Specific Fuel Consumption (BSFC) 118, 120
Machines 15 BSFC 49, 118, 120
Stations 15 Curve 120
Address 3 Curve fit 120
Adjust Clearance 180 Data sources 120
Adjust toe point 161 Default Value 120
Adjust VE's 176 Fuel curve 120
Analyzer Setup 118
Notes 234 vs. Load 120
Angular Velocity 54 vs. Speed 120
Annotation Bypass valve 114
Add 189
Erase 189 -C-
Plot 189
API 670 140 Calculations 211
Archiving BHP 211
Data 231 BSFC Setup 118
Evport 231 BWR 211
Articulation 24, 27 Bypass Valve Leakage 114
Bale Angle 27 Compressor Temperature Setup 113
Bank Angle 27 Cost 131
Diagrams 34 IHP 211
Link Radius 27 Nozzle Trace Setup 114
Link Rod 27 Precent Load 211
RK 211

Index 246
Calculations 211 Crankshaft Offset 44

Volume 211 CSV 195
Capacity 207 Cylinder Layout 24
Cascade 225
Channel Resonance 185 -D-
Clearance
84-10a 122 Data entry
Adjust 180 Tips 22
Calculation 122 Data Export
Defined 207 Raw 156
GPSA 122 SWR 156
Collection Point Data Structures 216
Add 77, 78 Database 9
Allow Re-use 84 Delete 156
Auto Generate 84 Derivative
Compatibility 78 Frst 166
Copy 78 Second 166
Delete 77, 78 Directory 9
Editor 78
Drivers 227
Modify 77, 78
Print 77
Re-arrange order 77, 78
-E-
Reorder 78
Economic
View 77
Report 212
Colors 3
Setup 131
Communications 227
Editor
Compress Files 19
Collection Point 78
Compressibility 207
Sensor Points 52
Compressor
Email
Cylinders 24
Receiving Data 21
Diagnostics 3
Sending Data 19
Report Setup 198
Engine Rotation 24
Reports 207
Engineering Units 138
Rod Load 122
Evport
Rod Reversal 122
Additional 9
Rod runout 171
First time 9
Temperature Setup 113
New 9
Configuration 122
Export
Contents 1
Data fields 216
Copy
Data to file 190
Collection Point 78
Settings | Modify Data 156
Gas files 107
Sensor Point 52
Cost Calculations 131

-F- -I-
Fields 216 Ignition
File Specs 227 Primary 54
Fixed Scaling 160, 178 Report 203
Formulas Report Setup 197
Trend Points 149 System 24
Fuel curve 120 Timing 23
Inertial Load Plot 170
-G- Infrared Temperature 57
Gas -L-
Composition 107
Copy Files 107 Leak Index 3
Load Plot 170 Line Fill 173
Names 107 Line Intensity 173
Temperatures 114 Link Radius 27
Geometry 23 Link Rod 27
Print 23 Load step 24, 207
View 23 Locating an Existing Database 18
GPSA 220 Logo 3
Grid Style 172 LogP-LogV Plot 168
Group Name 154 Low Vibration 54, 57
Group Plot 154
Auto generate
Bar charts 91
99 -M-
Multiplot 91 Machine 9
Printing set up 98 Add 13, 15
Reordering 95 Buttons 13
Setup 91 Copy Machine 13
Trend plots 91 Directory 13
Type 91 Edit 13
Viewing set up 98 Import 15
Manager 13
-H- Names 13
Selection 13
Help 231 Zip 13
High Vibration 54, 57 Main Bearing 84
History manage 226
Edit 222 Manual
Print 222 Report 214
To PDF 222 Scaling 160, 178

Index 248
Manual Group 154

Temperature Point 49 Historical 152
Mechanical Efficiency 24 Settings 154
Metric Type 154
New 138 Plot Annotation 189
Send to Analyzer 138 Plotting Data 150
Migrating 231 Clear Plot 150
Modify Settings 150
Curve TDC Offset 156 Toggles 150
Data Day TDC Offset 156 Point 152
Date & Time 156 Selection 154
Export Data 156 Polytropic 207
Load step 156 Power
Run Number 156 Cylinder Mass 44
Speed 156 Cylinders 24
SWR Export 156 Pin Pressure Trace 122
Temperature Points 156 Report Setup 197
Mole Fractions 107 Reports 200
Multi-plot Stat Box 165
Setup 91 Preferences
Analyst 3
-N- Company Address
Company Logo 3
3
New Product Key 231 Graph Colors 3

Notes 190, 222 Leak Index 3
On Analyzer 234 Sound 3
Nozzle 207 Pressure-Time Plot 169
Trace Setup 114 Pressure-Volume Plot 168
Primary Ignition 54
-O- Print
Auto Printing 222
Offset 24 Collection Point List 77
Overall Efficiency 24 Geometry 23
Sensor Point List 45
Overlay
Mode 162 Pulses per Rev 24
-P- -Q-
Panel Readings 49 Quick Report 195
Peak Frequency Tool
Phase Angles 23
185
-R-
Phasing 163
Rated
Plot
Load 24

Rated Rod Load 122

Speed 24 Rod Load Plot 170
Ratio limit 122 Rod Motion 49
Raw Data Export 156 Rod Reversal 122
Raw Vibration Rod runout 171
Density 122 Run Number 156
Sensor Point 49
Recip Mass 41
Reinstalling Windrock Program 231
-S-
Reordering Scale
Data Base Files - Analyzer 18 Add copy 106
Data Base Files - PC 18 Add New 106
Machine 18 Copy / Paste 106
Station 18 Creating new 106
Report Delete 106
New Format Setup 200 Editor 106
Report Export Fixed data scales 100
Report Export 195 Imported /Exported 106
Report Export Format 216 Scaling 160, 178
Reports Autoscale 160, 178
Balance 202 Fixed 160, 178
Common Questions 220 Manual 160, 178
Compressor 207 Secondary Ignition 54
Compressor (calculations) 211 Send 19
Compressor Report Panel Points 112 Sensor Point
Economic 212 Auto Generate 65
Engine Compression Model 190 Copy 52
Exhaust Temperatures 118 Delete 52
Export 216 Editor 52
Exporting Data 190 Maximum Number 46
Graphics 190 Name 47
Ignition 203 Reorder 52
Manual Data 214 Setup 46
Missing data 190 Sensor point types 47
New Format 190 Sensor pont dislay
Power 200 Overlaying 179
Run number 190 Setup 131
Show Details 190 Articulation Diagrams 34
Spark Survey 204 Articulation Table 29
Rod Balancer 144
Load 122 Bar Chart Group Plot 90
Reversal 122 BSFC 118
Rod Drop 49 Bypass Valve 114
Rod Length 27 Comp Valve Order 84

Index 250
Setup 131 Buttons 13

Compressor Nozzle 114 Cost Performance 13
Compressor Report Panel Points 112 Delete 13
Compressor Temperatures 113 Economic Report 212
Compressor vave numbering 65 Edit 13
Compressors 41 Import 13, 15
Cost Calculations 131 Manager 13
Diagnostic 140 Names 13
Economic Factors 131 Selection 13
Engines 38 Zip 13
Engines without Articulation 37 Stripcharting 179
Exhaust Temperatures 118 Strokes per Cyl 24
Fuel Curve 120 SWR 220
Gas Composition 107 SWR Data Export 156
Gas Names 107
General
Group Plots
24
90
-T-
Main Bearings 84 Tandem 24
Miscellaneous 44
TDC Shift 165
Point Types 47
Theoretical 207
Sensor Point Names 47
Tile 226
Sensor Points 46
Tips
Software Configuration 122
Data entry 22
Spark Survey 144
Toe point adjust 161
Trend Group Plot 90
Valve Survey 84 Toggle
B&W / Color 172
Shortcut 233
Nozzle traces on / off 176
Single 152
Overlay on / off 173
Smoothing 173
Phasing on / off 173
Peak Frequency Tool 185
Power stats box on / off 176
Smoothing Factor 207
Show TDC positions on / off 175
Smoothing Factors 177
Show toe points on / off 176
Software Configuration 122 Smoothing on / off 173
Spark Plug 54 TDC Shift 173
Spark Survey Thertical on / off 176
Report 204 Valve Events on / off 175
Spark Survey Setup 144 Toolbar
Spark Timing 41, 44 Customize 8
Speed 156 Torque 207
Spreadsheet Data 156, 190 Tracking Angles 23
Spreadsheet export 156 Transfer
spreadsheet style editing 22 Files 227
Station 9 Trend
Add 13, 15 Editor 148

Trend Zip file

Formulas 149 Copy 19
Group Plot 90 Email 19
Group Plot setup 91
Limits, Hi-Low 148
Plot 148
Sensor Points 148
-U-
Ultrasonic 54, 57
Units 138
Metric 138
New 138
Other 138
Send to Analyzer 138
Standard 138
Upgrade
6310 to 6320 232
Computer 231
Operating system 231
PC 231
USB 3
-V-
Valve Events 164
-W-
Waterfall
Plot 187
View 187
Whats New 231
Windows shortcut 233
Write raw data to file 156
wrom file type 19
wrpm file type 19
wrps file type 19
-Z-
Zip 13

Windrock MD Manual PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Windrock MD Manual PDF

Uploaded by

Copyright:

Available Formats

Windrock MD

© Windrock, Inc. 2017

1997-2016 by Windrock Incorporated, All rights reserved.

Software and Firmware License Notice

Windrock MD Application Manual

Part II Machine Database 9

Part III Setting up your machine 22

Part IV Plot 150

© Windrock, Inc. 2017

Plot Data ......................................................................................................................................................... 152

Part V Format 172

Part VI Tools 181

Part VII Reports 190

Part VIII History 222

© Windrock, Inc. 2017

Part IX Window 224

Part X Utility 227

Part XI Help 231

Part XII Appendix 231

Part XIII Glossary 237

The File Menu

© Windrock, Inc. 2017

Utility (Connect to the Analyzer)

1.2 File Menu

© Windrock, Inc. 2017

1.3 Edit Preferences

© Windrock, Inc. 2017

Company Info Tab - (Address & Logo)

Use the browse button to select the file

Select Thumbnails to view the the

Select the image you want to use, then

MultiMedia Tab - (Options)

Plotting Tab - (Graph Colors)

© Windrock, Inc. 2017

Show Station and Machine names on plots:

Defaults Tab - (Optional Operational Parameters)

© Windrock, Inc. 2017

Show Leak Index for Compressor Pressure Curves:

When the Show Leak Index check box is

Show “Explore To” in Station / Machine Manager:

© Windrock, Inc. 2017

If you have disabled any messages, pressing the

© Windrock, Inc. 2017

View allows the user to turn the tool bar on

1.4.1 Customizing the Toolbar

© Windrock, Inc. 2017

The Commands section of

Creating first database;

© Windrock, Inc. 2017

Then continue on to "Locating an existing database".

Creating an additional database;

© Windrock, Inc. 2017

© Windrock, Inc. 2017

© Windrock, Inc. 2017

2.2 Station / Machine Manager

Station Level Commands

© Windrock, Inc. 2017

Station Cost Performance

Machine Level Commands

© Windrock, Inc. 2017

Right clicking on the machine with

2.3 Adding Stations and Machines

© Windrock, Inc. 2017