User Manual Two-rotor Compression Tester - Rotary
Contents
1. EOF T 083 SEC DI 4 Figure 23 Expanded view at 2 display compression Normalizing the recorded data If the engine cranking speed at the time of the test was significantly higher or lower than 250 RPM you may want to normalize the readings in order to compare them to the Mazda engine specifications Mazda specifications for engine compression are generally specified at an engine cranking speed of 250 RPM If your engine cranking speed see below for how to calculate engine cranking speed is close to 250 RPM you can use the readings as recorded However if engine cranking speed deviates significantly from the Mazda criteria you may want to proceed with normalization of the recorded readings Mazda workshop manuals provide simple graphs that can be used for this purpose Essentially slower engine cranking speed during the test will result in readings lower than the Mazda standard and conversely a faster cranking speed will result in higher readings Be aware that our systems do not compensate for differences in atmospheric pressure due to elevation or weather conditions Mazda shop manuals for some models include a graph for elevation altitude correction Comparable graphs are available on various web sites including Wikipedia com The following instructions provide procedures for calculating engine cranking RPM from the recorded data to convert the readings for comparison to the Mazda specification This discus2. Select Edit gt Channels from the menu a GJ 01 145 Acquisition 4E662A 1L _ j File Edit View Scaling Options Help Copy Ctrl C Sample Rate F3 Channels F5 Channel Settings F10 Engineering Unit Settings Ctrl F Reset EU Ctrl Fl2 User Annotation Alt F11 Insert Mark Ctrl Space Insert Commented Mark Shift Space Compression F7 Compression x2 Page Up Compression 2 Page Down _ectlei ieee SMI T ee i epi EEEH TEE Preferences eoD 02A elatis SET UP Figure 4 Channels selection menu Make sure that the number of channels checked corresponds to the number of rotors you will be testing and that all other channels are unchecked Click on a check mark to activate or deactivate a channel Model ReCT TRTa is configured for 2 rotor testing Channel 1 R1 and Channel 2 R2 for simplicity The example below shows what the Channel Selection screen should look like for conducting a simultaneous 2 rotor test Note This setting is especially critical The number of channels activated i e checked determines the sampling rate for each channel If more channels than needed are checked the sampling rate per channel will be reduced See Appendix B for more information on sampling rates and the availability of high sampling rate trial and upgrade software When finished click OK Channel Selection Channels DI 1449 HUA A Click or press Space to select check or deselec
3. conduct a test or if you switch Acquisition Units inadvertently or otherwise we strongly advise that you run through the configuration procedure again when all tester components are connected and powered up as part of your preparation to conduct a test 14 Conducting the compression test Preparing the vehicle and recording program 2 rotor test example l Warm up the engine If the car battery 1s to be used as the power source it should be fully charged Remove spark plugs either the leading or trailing from both rotor housings Do not remove the other spark plugs Disable engine ignition and fuel delivery systems If you are not sure how to do this consult a workshop manual for your particular vehicle to determine the best method for disabling these systems For most modern fuel injected rotary engines this can be accomplished by removing the EGI fuse s from the engine compartment fuse box However in the case of the RX 8 Mazda recommends disconnecting the Eccentric Shaft Position Sensor located at the lower front left of the engine to disable these systems Screw a spark plug hole adapter into the open plug holes in both rotor housings Make sure the adapter is screwed in finger tight but snugly and that the O ring is sealing Do not over tighten You can lubricate the O rings with a little silicone based grease like dielectric grease to facilitate sealing but DO NOT use a petroleum based oil or grease on t
4. or replacement The example shown in Figure 26 was recorded from the same 3 generation RX 7 engine as the above example but as you can see compression readings for two of the rear rotor faces are significantly lower than the third face and well below the Mazda minimum This is definitely an indication of apex seal failure and the engine will need to be rebuilt or replaced Obviously if any of the recorded readings are at or near zero your engine is definitely sick and will need to be rebuilt or replaced For questionable compression readings it is advisable to run additional tests from the beginning to verify the numbers and to verify that you prepared the tester system correctly Consult the appropriate workshop manual for compression specifications for other rotary engines 24 w WINDAQ REAR 3 16 07 WDO File Edt Wiew Search Scaling Transhorm AY Op T0200 e ene 900 SEC TBF 31 396 SEC TM 4 Figure 26 Evidence of failed seal s rear rotor readings from 3 generation RX 7 Troubleshooting Problem When I connect the power cord to the battery the green power on indicator does not light and the system does not function Answer Double check the battery clip attachments and make sure the red clip is attached to the positive plus pole of the battery and the black clip is attached to the negative minus pole If the connections seem to be in order disconnect the battery clips and remove the 4 screws securing the enclosure cover C
5. that the trial version of the higher sampling rate program will allow a given number of recordings before expiring A total of 20 recordings at total throughput rates up to 10 000 samples second are allowed before the trial version expires After 20 recordings at the higher rate have been conducted the maximum per channel sampling rate will be limited to 120 samples second Upgrades to WinDaq HS are available from RDS through our web site WinDag HS Acquisition i WinDag H has not been activated You are about to record at a rate over 240Hz Your trial version of WinDag H 5 will expire after recording 19 files over 240Hz Would you like to continue v Figure 15 WinDaq HS nag screen Complete Configuration Save this configuration by doing File gt Save default setup and you have completed configuration of the Hardware Manager see Note below You are now ready to conduct compression tests To conduct a test follow the instructions on the next few pages Note The settings just configured are associated only with the specific DATAQ unit installed in the enclosure Each Tester System has a unique serial number that is the same as the DATAQ unit serial number Note that the unit System serial number is listed along with the DATAQ unit description in the main hardware windows The configuration settings completed above will normally be retained in your computer for future use However if you are not planning to immediately
6. the recording portion of the test Reinstall spark plugs reconnect the spark plug wires and enable the ignition and fuel delivery systems The recorded data can now be viewed and analyzed using the WinDaq WaveForm Browser as described in the following sections 8 To pause the recording at any time during the test do File gt Stop To resume recording do File gt Record To completely stop recording do File gt Close or File gt Exit You may choose to have someone else do this part while you monitor the tester connections and computer display USB extension cables up to 10 feet in length total cable length of 16 feet also can be used to position the computer in the driver compartment or other remote location while conducting the test Extension cables are available from RDS and from many other sources See the RDS web site for pricing information and to place an order 1 Disconnecting tester hardware from the computer before closing the programs may cause your computer to freeze requiring a reboot 17 Extracting and interpreting the data Launch the WinDaq Waveform Browser from the Start gt Programs gt WINDAQ program group and open the wdq file created during the test Or alternatively find the file created during the test and double click on the file Using the slider at the bottom of the window to scan the record locate the recorded compression pulses Note A helpful hint is in order at this point The total recor
7. User Manual Model ReCT TRTa Two rotor Compression Tester Rotary Diagnostics Systems P O Box 524 Mont Alto PA 17237 USA http RotaryDiagnostics com Copyright 2014 by RDS Using the ReCT TRTa Rotary engine Compression Tester System Introduction The ReCT TRTa rotary engine compression tester is used to obtain accurate engine compression measurements in a rotary 1 e Wankel engine Model ReCT TRTa can be used to conduct compression tests on two rotors simultaneously The System combines the output from high precision AST pressure transducer s with the data conversion function of a DATAQ analog to digital device to acquire and record accurate compression readings for each face of each rotor in a rotary engine This system also allows the calculation of engine cranking RPM during the test that can be used for data normalization as desired Processing Unit 1 Enclosure housing A D Converter Power amp Data Connections 2 Power Cord 12VDC 3 USB Cable 4 WinDaq Programs amp Drivers Disk Acquisition Unit 5 DIN Connector Data Cable 6 Pressure Transducer Quick Coupler 7 Spark Plug Hole Adapter Figure 1 Rotary engine Compression Tester system Model ReCT TRTa components Model ReCT TRTa consists of a Processing Unit items 1 4 and two Acquisition Units items 5 7 The Processing Unit includes an enclosure that houses the analog to digital converter along with power USB and DIN data connections I
8. are Launch Hardware Manager from the Start gt Programs gt WINDAQ program group Highlight the DI 149 when it appears in the list and click Start WinDaq The R1 DIN socket on the enclosure is hard wired to Channel 1 of the data converter and the R2 DIN socket to Channel 2 15 Bi DATAQ Instruments Hardware Manager Allow 15 seconds for devices to appear Description Model Status Serial IP Address aercr1ee Available 477186 v1 52 Settings for AE FCEE ee Update List Start winds Help Figure 16 Hardware Manager hardware listing of DI 149 10 Verify that the upper and lower limits in the Hardware Manager display are 200 and 0 or 00 respectively If they are not you will need to run through the Hardware Manager configuration again before proceeding 11 Select File gt Record from the Hardware Manager menu to start data recording Select a folder for storing the data file and name the file something meaningful then click Open EJ Open J Ji Computer BOOT C gt DATAQ 4A379028 ii t Organize New folder 4g Downloads Name Date modified Type Recent Places ApS tN rants FR 44379028 Validation Test WDQ 6 26 2009 6 02 AM windaq Document jy Libraries E Documents a Music Pictures iT Videos wey Homegroup ji Computer Ma BOOT C ma BACKUP D 4 File name 44379028 Validation Test2 WDO Figure 17 Hardware Manager Record file name 16 12 When th
9. d time for the test will be a few seconds long so a 5 second burst of compression pulses may be difficult to locate or keep track of in the relatively long data record Before concluding that no data was recorded scan the entire record for the compression pulses It actually may be there essentially hiding in the long data record A cursory examination of the recorded data will quickly reveal any significant problems with engine compression The absence of pulse peaks where expected or very low compression peaks are indications of seal failure and one need go no further with data extraction and analysis The engine will likely require rebuilding or replacement However additional compression tests starting from the beginning should be conducted to verify any questionable numbers See the section Meaning of the compression readings for additional information Significant differences between the peak pulse amplitudes 1s also an indication of failing seals and depending on the extent of the differences this may also be an indication of the need to rebuild or replace an engine In this case continue with data extraction and analysis to determine the relative health of the engine Proceed with the following instructions to extract the recorded values and to normalize the data for comparison to the engine manufacturers specifications Only then can the recorded readings be used to determine the exact status of engine health Referring to th
10. e File Size window appears set the recording time or file size desired and when you are ready and only when ready to conduct the test and to start the recording click OK The program will begin recording as soon as OK is clicked Continue with Conducting the test File Size wana Lust File Size in Kilobytes Ata sample rate of 240 Ss Recording Time in hours min sec 0 1 2 46 cancel Figure 18 Hardware Manager recording time and file size selection Conducting the test Now that your car has been prepared for the test your System hardware has been connected to the car the power supply and to the computer and the Hardware Manager program has been set up and ready to record you are ready to conduct the test 1 Check all your connections before proceeding and make sure that the ignition and fuel delivery systems have been disabled Make sure all wires and cables are well clear of engine moving parts 2 Start the recording function in Hardware Manager That is click OK as instructed above 3 Get in the car depress the gas pedal to the floor important and activate the starter for about 5 seconds 4 Stop recording File gt Stop This portion of the test is complete so you can save the recording File gt Close or File gt Exit Exit the Hardware Manager program disconnect all cables and remove the adapters If the Hardware Manager device selection window is still open close it 5 You are finished with
11. e example record in Figure 19 below note that compression pulses are represented by the peaks in the recording each peak representing a compression pulse of a single rotor face In the example the top display is for the front rotor and the bottom is for the rear rotor of a Mazda 13b naturally aspirated engine A compression reading for the same rotor face is repeated every third pulse The maximum compression of each face is represented by the peak value at that point in the test Compression readings for each rotor face are viewed by moving the line cursor in the display to the peak of each pulse and noting the compression number displayed at the left side of the window In the example the cursor 1s positioned at a compression peak of one rotor face of the front rotor and the compression number is displayed at the left margin of the display 126 74 PSI in the example To move the line cursor place the mouse cursor on the DATA bar at the bottom of the display directly below the line cursor hold down the left mouse button and drag the line cursor to the desired position in the display Move the line cursor left and right slightly until the maximum reading for the peak of interest is shown at the left After you have read and made note of a meaningful series of peak pulses you can easily calculate the differences between the compression readings of rotor faces and between rotors in order to compare the readings with the engine manufacturers s
12. e the fuse if necessary No other servicing of or modifications to the System by the customer are authorized Beyond the stated warranty Rotary Diagnostics Systems is not liable for any System failures due to improper or abusive use of the system For example reversing battery connections resulting in component damage constitutes an improper use of the System Nor is RDS responsible for resultant damage to an engine or engine component due to misuse of the System Parts and service are available from RDS after this warranty has expired CAUTIONS Do not attempt to disassemble the spark plug hole adapter item 7 Figure 1 The threads are sealed with an epoxy and any attempt to separate the components will render this component inoperable requiring replacement at the owners expense In addition the pressure transducer Item 6 Figure 1 in this system is a precision instrument and should be handled accordingly While the unit is not fragile extreme mishandling especially involving high lateral G forces or excessive stress on the cable may damage the internal elements and render it inoperable The pressure transducer is not user serviceable and 27 attempts to disassemble or modify it in any way will likely result in an inoperable system and will definitely void the warranty NOTICE Customer service requests particularly those that potentially involve individual component warranty claims must be handled through Rotary Diagnostics Syste
13. ers Make sure that the spark plug hole adapters are firmly hand tight screwed into the hole and sealing Also it is possible that the compression in the engine is so low that the display will not show an obvious reading Check the very bottom of the display to see if there are small squiggles at some point in the recording If so it may be that your engine has essentially no compression This is not likely but it is possible If possible try testing the system on another engine Otherwise contact RDS for further instructions Problem The test seems to run OK but the data shows widely or irregularly spaced compression pulses Answer Compare your recording to the example records in this manual As you can see in the examples the compression pulses are very regularly spaced and similar in amplitude for a healthy engine If your recorded data shows what appear to be gaps in the data or great differences in pulse amplitudes the engine likely has one or more failed seals If you like you can e mail a copy of the wdq file to RDS for evaluation Problem My recorded readings show compression pulses with small differences in amplitude What does that indicate Answer In order to answer that question you must first extract and compare the readings from all rotor faces Then consult the appropriate workshop manual to determine the engine compression specifications for your particular engine to see if the readings fall within the manufac
14. es are adequate for acquiring accurate compression readings However if this system is to be used to conduct detailed analysis of compression pulses we recommend an upgrade to the high sampling rate program WinDaq HS The maximum total sampling rate for WinDaq HS is 10 000 samples second which is more than adequate for detailed analysis of the pulses A trial version of the higher sampling rate WinDaq HS program is integrated with the WinDaq Lite software that ships with this System A total of 20 recording sessions is allowed at higher rates before the trial expires If the sampling rate is set Edit gt Sample Rate higher than 240 during Hardware Manager setup a nag screen warning about the expiration of the trial will appear when the Record function is activated To use this trial version continue with the test Each time you use the WinDaq HS trial software the nag screen will appear providing the number of high sampling rate recording sessions remaining until the trial expire Upgrades to WinDag HS are available through RDS The upgrades are linked to the specific serial number of the DATAQ hardware and are licensed for use with that specific DATAQ unit only Visit the RDS web site for pricing and to order an upgrade 29
15. he O rings Connect an Acquisition Unit AU quick coupler to each adapter and to the appropriate enclosure DIN socket For example connect the front rotor cable to the R1 DIN socket and the rear rotor cable to the R2 socket NOTICE The pressure transducers used in this system are precision instruments and should be handled accordingly While the unit is not fragile extreme mishandling especially involving high lateral G forces or excess stress on the cable may damage the internal sensor elements in the pressure transducer rendering it inoperable Plug the power cord into the connector on the side of the enclosure and connect the battery clips to the appropriate battery terminals Red Pos Black Neg Any 12VDC battery can be used if your car battery has been remotely located and is not convenient Be very careful when making battery connections Reversing the connections will likely damage System components Connect red clip to positive battery post then black clip to negative battery post Remove in reverse order when the test 1s completed Verify that the green power indicator is lit If it is not see Troubleshooting section Boot up your computer 1f it is not already powered up and connect the USB cable to the System enclosure and to the computers USB port Allow the computer to fully boot up before connecting to the enclosure in order to allow for the operating system to automatically initialize the System hardw
16. heck to see if the fuse is blown If it is replace it with a comparable fuse and see if the system will power up If the fuse is not blown or if you replaced it and the system still does not power up try connecting the system to another known good 12VDC battery If none of that solves the problem contact RDS for assistance Problem When I run the test nothing is recorded by the Hardware Manager Answer First carefully scan through the entire data record using the WinDaq Waveform Browser to verify that nothing was recorded Remember if the recording ran for say 60 seconds a 5 second burst of compression pulses may be difficult to locate in the data stream So scan the data to verify that the compression data is in fact not there If it is definitely not there then go through a full test setup as follows Shut down the Hardware Manager program disconnect all cables and basically start over Plug the USB cable into the DATAQ port on the side of the enclosure and to a USB port on the computer Then launch the Hardware Manager program Run through the instructions in the section entitled Hardware Manager Configuration to verify that the program is configured correctly Note the USB cable must be connected to the DATAQ port and to the computer 25 before launching the Hardware Manager program After connecting the cable allow sufficient time for the computer operating system to recognize the DATAQ device and to load the hardware driv
17. ll program should start automatically If it does not navigate to your CD DVD drive and double click on the exe file These instructions apply specifically to the DATAQ device the associated WinDaq Lite programs and the AST pressure transducer The software that ships with this tester is a lite version of the Windaq programs It has a maximum total throughput sampling rate of 240 samples second that is adequate for determining accurate compression readings However the higher sampling rate version Windaq HS is recommended for detailed analysis of the compression pulses See Appendix B for more information on sampling rates and on the Windaq HS software This task does not require access to a vehicle It can be completed anywhere as long as the system enclosure is connected to the computer using the supplied USB cable to a 12 VDC power source and to the Acquisition Units 1 e pressure transducers Follow the instructions on each succeeding install window When asked if you want to install WinDaq XL select No Thanks WinDaq XL is an add on program which requires an additional purchase and it is not required for this application The installation of hardware drivers and programs is a one time exercise All settings in the Hardware Manager are specific to the System hardware and are usually retained for future tests See note on page 14 for more information If you have successfully completed the software installation you can
18. ms Do not contact component manufacturers directly for assistance Support services and warranties on individual system components fall to the original component purchaser namely RDS For further guidance contact the RDS Appendix A Tester System software installation The following instructions are for installing the hardware drivers and programs on computers running Windows operating systems Power up your computer and allow it to fully boot up Insert the WinDaq Resource Disk into your CD DVD drive Do not connect the main enclosure to the computer at this time The WinDaq install program should launch automatically and bring up the first install process window Follow the instruction in each succeeding window When asked if you want to install WinDaq XL select No Thanks WinDaq XL is an add on program that requires an additional purchase and it is not required for this application If the program does not load automatically navigate to your CD DVD drive and double click on the exe file to launch the program The exe file should be named dataq_starterkits exe or something similar Your Resource Disk may contain a more recent install file that is named slightly differently When instructed connect the enclosure to your computer using the supplied USB cable Make sure the cable connects securely into the enclosure port and the USB port on your computer You should hear the USB connect tone when the cable is plugged in You a
19. ncluded with the Processing Unit enclosure is a power cable USB cable and the WinDaq Resource Disk The Acquisition Unit includes high precision pressure transducers with attached 30 inch cables quick couplers and A computer with an available USB port is required for use with this system A computer is not included with the tester This user manual is also included with the system spark plug hole adapters with swivel air plugs This user manual details the procedures for configuring and using the software for simultaneous 2 rotor testing It should be clearly understood that this system requires installation and configuration of software and manual extraction of the compression readings from the recorded data The readings are not automatically presented to the user as is the case with some more expensive rotary engine compression testers This user manual contains all the information needed to install and configure the associated software and to operate the system to conduct compression tests on rotary engines It is not an exhaustive treatment of all the capabilities of the WinDaq programs so we encourage you to read the user manuals that are provided with the WinDaq software for more information The WinDaq manuals are installed on your computer with the programs and are available via the WINDAQ program group under the Programs menu You can also go to the DATAQ web site for more information Links to that site as well as to
20. nit Settings Yolts Upper Level Fa 5 oo Lower Level Al Moo o OK Next Set Offset Cancel Set Channel 1 Offset psi Change Current Sampled Value to any desired reading within the engineering units range The difference is applied as an offset across the entire measurement range Click Cancel to revert without changes Current Sampled Yalue 020 psi Desired Reading io psi Figure 10 Hardware Manager Engineering Unit Settings Set Offset 11 Set scaling limits Highlight 1 1 in the left area of the display and select Scaling gt Limits z DI 149 Acquisition 4E7C718 File Edit View Scaling Options Help Te i Limits Altera 451 29 Division Ctrl Shift V Show Dynamic Range Alt R Grow Up Shrink Down Invert Ctrl I AA any e rc E EREE CO M e E e TE Waveform Down 1 Pixel Gray Waveform Down 10 Pixels Ctrl Gray Waveform Up 1 Pixel Gray Waveform Up 10 Pixels Ctrl Gray Analog Plot Alt Shift N Digital Plot Alt Shift T eee DE a i Etat ie SET UP Figure 11 Scaling Limits settings menu Top Limit 200 Bottom Limit 0 may show as 00 Click OK Channel 1 Display Limits Top Limit 200 Bottom Limit lol Next Previous Cancel Figure 12 Channel 1 display limit setting Complete the system setup by configuring the settings for Channel 2 1 e 2 2 Highlight 2 2 and proceed with Channel 2 setup in the same manner as Channel
21. pecification 18 To switch from separate rotor display to a superimposed display select View gt Format Screen and select the display desired In this example 2 Waveforms overlapped has been selected WINDAQ 4E7C718B Val Test120 2 WDQ File Edit Search Scaling Transform XY Options Help 200 Assign Channel Assign Range Forward Range Backward Range Format Screen Statistics DAC Playback Channel Settings Event Markers Next Palette Previous Palette User Palette Split Exit Enter Split More Eottom Y Less Bottom Y Left Limit Right Limit Toggle Pane Refresh Ctrl Down Ctri Up Ctrl T Ctrl Shift D F10 Fa Alt P Alt Shift P Ctrl U Ctrl Alt Alt FL Ctri FL FG Shift F5 WINDAQ 4E7C7186 Val Test120 2 WDOQ 1 Waveform 2 Waveforms overlapped 2 Waveforms 4 Waveforms overlapped 4 Waveforms a Waveforms overlapped 6 Waveforms 16 Waveforms overlappe 16 Waveforms 34 Waveforms overlappe User specified format Figure 20 Format Screen Waveform selection menu Shift 1 Shift 2 Shift 3 Shift 4 Shift 5 Shift 6 Shift 7 d Shift 8 Shift 9 d Shift 0 Shift f File Edit View Search Scaling Transform XY Options 200 0 0 3 13 858 SEC TEF 4 15 133 SEC TM 47 8 ROP T le SEC DIY Figure 21 Superimposed compression recording of both rotors 20 In Figure 21 above the recordings for the front ro
22. proceed with configuring the Hardware Manager Hardware Manager Configuration To begin the Hardware Manager configuration connect the main enclosure to the computer using the USB cable provided Then connect the Acquisition Units 1 e pressure transducers to the enclosure and connect the power cord to the enclosure and to a 12VDC power source usually the car battery If the DI 149 drivers were installed successfully the operating system will automatically activate the drivers for the DI 149 when the cable is plugged into the USB port Launch the Hardware Manager program from the Start gt Programs gt WINDAQ program group menu When the devices list appears highlight the DI 149 device and press the Start WinDaq button Continue with the following settings when the Hardware manager program has launched Eyi DATAQ Instruments Hardware Manager Allow 15 seconds tor devices to appear Description _ Model _ Status Serial IP Address 4EFCFIGB DI 143 Available 4E VC F18B a Settings for AE FCF 188 Update List Start Windag Help Figure 2 Hardware Manager initializing Example of initial default screen display after clicking on Start WinDaq Your display may look slightly different from the graphic EJ DI 149 Acquisition 4E7C7188 File Edit View Scaling Options Help gt Oscill Channels sec DIV Ee a Status SET UP Figure 3 Default Hardware Manager display Continue with the following configuration settings
23. re now ready to configure the Hardware Manager program Return to page 4 to complete the software installation and configuration If problems are encountered with the above procedure try the Alternate Tester System instructions below Alternate Tester System software installation Go to the latest DATAQ software download page http www dataq com support installation instructions html Follow the instructions on that page which includes an imbedded link to download the WinDagq software Congratulations You have successfully installed all the software required by the System You can remove the Resource Disk from the computer drive but if you plan to complete the Hardware Manager configuration at this time you can leave the System enclosure connected to your computer Return to page 4 when ready to configure the Hardware Manager program and complete the software installation and configuration process Appendix B Sampling rates and WinDag programs The total throughput sampling rate in the WinDaq Lite software that ships with this tester is limited to 240 samples second When more than one channel is activated during a test the total 28 throughput rate is divided among the channels For example for a 2 channel 2 rotor test the sampling rate for each channel would be 120 samples second The display of the compression pulses recorded at the default rate may appear to be a bit notchy but testing has shown that these sampling rat
24. reasonable pricing schedule so your comments constructive criticisms and your suggestions will be greatly appreciated Do not hesitate to contact RDS if you have problems with the system or if you would like to pass on any comments Contact Information For assistance or questions contact Larry at Rotary Diagnostics Systems P O Box 524 Mont Alto PA 17237 USA 717 352 7096 In case no one answers leave a message and you will be contacted ASAP 717 360 3633 cell Rotary13b RotaryDiagnostics com http RotaryDiagnostics com Warranty The Rotary Diagnostics Systems RDS testers are warranted for a period of one year from the date of purchase This warranty is limited to repair or replacement of any components necessary to restore the system to full functionality RDS will restore the system to full functionality during the warranty period at no cost to the customer unless the malfunction 1s the result of improper use or abuse of the System In rare cases the System may be replaced with a new system at the discretion of RDS Contact RDS for instructions on returning a system for service or for a warranty claim Safe and effective operation of each unit is verified prior to sale when using the configuration and testing procedures specified in this manual Any modifications to this system or the testing procedure by the user voids the stated warranty The customer is authorized to remove the enclosure cover to check and or replac
25. sion assumes that the System is being used with a Mazda rotary engine For other rotary engines consult the appropriate workshop manual for engine compression specifications 22 Engine RPM calculation As stated above to normalize the measured compression readings the engine cranking RPM at the time of the test must be determined Using the WinDaq Waveform Browser the engine cranking RPM during the test can be determined by measuring elapsed time between a number of compression peaks and converting that to the equivalent revolutions of the eccentric shaft per minute Note For the highest accuracy use a series of compression peaks near the middle of recorded data to eliminate any start up lag at the beginning of the test and possible minor battery voltage drop off near the end of the test Using the example in Figure 24 for reference calculate the engine RPM as follows First place your cursor in the DATA bar at the bottom of the display directly below the line cursor on the screen Holding the left mouse button down move the cursor to one of the compression peaks and record the time displayed at the lower left corner of the window In the example the elapsed time at peak 0 is 127 19 rounded from 127 188 seconds Move the line cursor 9 peaks further along the data record 1 e peak 9 recording the time 129 03 Subtracting 127 19 from 129 03 gives an elapsed time of 1 84 seconds Since this span of pulses equates to 9 compre
26. ssion cycles or 9 eccentric shaft revolutions 1 e 3 eccentric shaft revolution per rotor revolution x 3 the elapsed time of 1 84 seconds equates to the elapsed time for 9 eccentric shaft revolutions In the example engine RPM calculation is determined by solving for in the simple ratio of 9 1 84 x 60 where x equals engine cranking RPM at the time of the test That is 1 84x 9 60 therefore x 540 1 84 or 293 sey 99 amp WINDAO 20060612 wdq File Edit view Search Scaling Transform Y Options Help 200 00 127 19 sec 129 03 sec Figure 24 Example of engine cranking RPM calculation 23 Meaning of the compression readings The recorded compression readings will indicate the state of your engines health and whether of not it requires rebuilding or replacement A healthy engine will exhibit readings that are at or above the Mazda minimum standard In the example below the compression pulses are well above the minimum Mazda compression specifications This is what you hope to see 2 WINDAQ FRONT 3 16 07 WDO File Edit View Search Sc Transform XY Options Help ra ree send sae pos Cr a ec nie bose eT fa n On cr ee aage ee Pepe ao i a pi z a4 F oar an DATA 27 542 SEC TBF 10 754 SEC TH 71 9 EOF T 083 SEC DI Figure 25 Indication of healthy engine front rotor readings from 3 generation RX 7 If any rotor faces are well below the Mazda minimum standard your engine probably requires rebuilding
27. starting with the Calibrate all Channels section beginning on page 10 Then continue with the instructions below 12 Set the sampling rate desired Click on Edit gt Sample Rate B DI 145 Acquisition 4E6GZA1D Ca aa a DENEI a en File Edit View Scaling Options Help Undo Ctrl Z Copy Ctrl C Sample Rate Fa Channels F5 Channel Settings F10 Engineering Unit Settings Ctrl F Reset EU Ctrl Fl2 User Annotation Alt F11 Insert Mark Ctrl Space Insert Commented Mark Shift Space Compression Fi Compression x2 Page Up Compression 2 Page Down Preferences Figure 1 3 Sample Rate menu Set the Sample Rate Channel at 120 The default maximum throughput sampling rate allowed in this program WinDaq Lite is 240 samples second The total sampling rate will be split between the number of channels selected Channels enabled 2 Total Sample Rate 240 Set Maximum ratefchannel 5000 Set ini 1525925 sample Rate Channel 120 Cancel Figure 14 Sample Rate setting See Appendix B for more information on sampling rates 13 Higher sampling rates are possible with the upgrade program WinDaq HS A trial version of WinDaq HS is integrated with this program If a sampling rate higher than 120 samples per second per channel 1 e 240 total throughput is set a nag screen will inform the user when activating the Record function during test setup The nag screen will indicate
28. t Click or press I in channel 9 to select digital input Click or press E in channel 10 to select rate counter Click or press C in channel 11 to select reset counter OK Cancel Figure 5 Hardware Manager channel selection Select View gt Format Screen from the menu For a two rotor test click on the 2 Waveforms setting It is best to conduct the test with a Waveforms setting vs a Waveforms overlapped setting The waveforms can be viewed later in overlapped mode if desired after the test is completed using the WinDaq Waveform Browser program EJ DI 149 Acquisition 4E7C718B san Nn a a a Assign Channel Assign Range Forward Range Ctrl Down Backward Range Ctri Up A Format Screen 1 Waveform Shift 1 2 Waveforms overlapped Shift 2 2 Waveforms shift s 4 Waveforms overlapped Shift 4 4 Waveforms Shift 5 Next Palette Alt P Previous Palette Alt Shift P User Palette Ctrl U Add ons 6 Waveforms overlapped Shift 6 Channel Properties Ctrl F10 Waveforms Shift 7 EE TE E ITN AN EET E TENT 16 Waveforms overlapped Shift 8 16 Waveforms Shift 9 32 Waveforms overlapped Shift 0 User specified format Shift S s CHAN 20 sec DIV 1 Status SET UP Figure 6 Hardware Manager screen format setting gt The Waveform Browser allows 2 channels per display section to be viewed in overlap mode See example later in the manual Resul
29. the AST web site are in the References section of this manual All support for the System is provided by RDS The user should not contact the component manufacturers directly for support See the Warranty section for instructions on how to obtain support for this system Installing the DATAQ software The software installation and configuration task involves the following steps 1 Installation of the hardware drivers and the WinDaq programs associated with the DI 149 data converter unit 2 Configuration of the DATAQ Instruments Hardware Manager The main programs associated with the DI 149 data converter are the DATAQ Instruments Hardware Manager hereinafter referred to as the Hardware Manager and the WinDaq Waveform Browser The Hardware Manager is used to record the compression data during the test and the WinDaq Waveform Browser is used to view extract and analyze the recorded data The hardware drivers and both programs are provided on The WinDaq Resource Disk and must be installed on your computer If you have basic computer skills you can probably work through the install process with little or no assistance Otherwise refer to Appendix A for step by step instructions Do not connect the main enclosure to your computer at this time During the install process you will be instructed when to connect the main enclosure To begin software installation insert the WinDaq Resource Disk into your CD DVD drive The insta
30. tor blue trace 1 1 Channel 1 are superimposed on those for the rear rotor red trace 2 2 Channel 2 To extract compression readings move the line cursor to a peak of interest and make note of the reading at the appropriate side of the display That is the readings for the front rotor will be displayed on the left 1 1 side and readings for the rear rotor will appear at the right 2 2 side To change the colors assigned to each trace select View gt User Palette and select colors for the traces and other aspects of the display To add simple annotations to each trace select Edit gt User Annotation and type in an annotation for the recorded channels To expand the display for easier viewing select Edit gt Compression Set Compression to 2 and click OK Higher negative numbers will expand the display even further FJ WINDAQ 4E7C7188 Val Test120 2 WDQ LS ees File Edit View Search Scaling Transform AY Options Help Compression Compression 2 SEC IDIV 1e7 Compressed Data Display MID C MIN C MAX C MsMn 1 hKdaximum Cancel Ef by ie IE s 3 D a Figure 22 Expanded view menu Compression in this instance refers to the compression of the displayed data not the compression of the engine 21 WINDAQ 4E7C 7156 Val Test120 2 WDQ lo el eS i File Edit View Search Scaling Transform AY Options Help fe a a a ee ee ee ee ee ee 13 858 SEC TEF 15 1233 SEC TM 47 8
31. ts of 2 Waveforms display setting 1 1 Channel 1 will display and record the data from rotor 1 2 2 Channel 2 will display and record the data from rotor 2 EA DI 149 Acquisition 4E7C 7188 File Edit View Scaling Options Help Mode Oscill Channels 5y a ee E e a i i Figure 7 Two waveform display Calibrate all channels Highlight 1 1 in left border area of the display and select Edit gt Engineering Unit Settings EJ DI 145 Acquisition 4E662A1D File View Scaling Options Help Mode Ss Undo Copy sample Rate Channels Channel Settings Engineering Unit Settings Reset EU User Annotation Insert Mark Insert Commented Mark Compression Compression x2 Compression 2 Preferences S s CHAN 60 Ctrl 7 Ctrl C F3 F5 FLO Ctrl F Ctrl Fl2 Alt FLL Ctrl Space Shift Space F7 Page Up Page Down SET Figure 8 Hardware Manager Engineering Unit Settings Upper Level Volts 5 Upper Level EU 200 Lower Level Volts 1 Lower Level EU 0 EU Tag PSI Click OK Channel 1 Engineering Unit Settings Volts Upper Level Pl 5 200 ee gt psi Lower Lewel Al f zi ol Set Offset Cancel Figure 9 Hardware Manager Engineering Unit Settings 10 Edit gt Engineering Unit Settings yes again Verify settings Click on Set Offset Enter 0 in the Desired Reading box Click OK then OK again to complete this setting Channel 1 Engineering U
32. turers limits for a healthy engine In general however if the differences in the compression readings between rotor faces and or between rotors are significant your engine 1s less than healthy And depending on the specific compression numbers your engine may require rebuilding or replacement Problem When I launch the Hardware Manager program the DATAQ device is recognized but when I click on Start WinDagq I get an error message Answer Occasionally internal program or operating system component linkages are lost or the installation of a program or security fix after installation of the DATAQ software will modify a required component of the program Try rebooting the computer and if that doesn t eliminate the error uninstall the WinDaq programs reboot the computer and reinstall the latest version of the software A link to the latest software can be found at the bottom of the Purchasing Info page on our web site http www rotarydiagnostics com pricing 20combined htm Also if you disconnected the USB cable after starting the Hardware Manager program the program will almost certainly freeze or show an error message If this is the problem reboot the computer and restart Hardware Manager Note The System Developer has made a good faith effort to build and deliver a working test device that will provide accurate compression measurements for many years We constantly 26 strive to improve our systems while maintaining a
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