PowerNet 2.0

© Copyright 2006, PowerTest, Inc.PNWS0612

PowerNet 2.0PowerNet 2.0PowerNet 2.0PowerNet 2.0PowerNet 2.0

Engine DynamometerEngine DynamometerEngine DynamometerEngine DynamometerEngine Dynamometer

Data Acquisition and ControlData Acquisition and ControlData Acquisition and ControlData Acquisition and ControlData Acquisition and Control

Operator's and Administrator's ManualOperator's and Administrator's ManualOperator's and Administrator's ManualOperator's and Administrator's ManualOperator's and Administrator's Manual

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PowerNet CD Operator’s Manual CD Operator’sManual

ContentsContentsContentsContentsContents

ContentsTable of Contents ........................................................................................................................... iii-iv

Chapter 1 - System Overview ........................................................................................................... 1Data Acquisition and Control System Components ...................................................................................... 3Software Overview........................................................................................................................................ 4The PowerNet File System .......................................................................................................................... 6

Chapter 2 - Basic Operation .............................................................................................................. 7Starting the Commander Computer .............................................................................................................. 9Connections .............................................................................................................................................. 10Test Procedure .......................................................................................................................................... 12

Chapter 3 - Main Display .................................................................................................................. 13The Main Display Window ......................................................................................................................... 15Floating Pull-Down Menus ......................................................................................................................... 16 The File Menu ...................................................................................................................................... 16 The View Menu .................................................................................................................................... 18 Configuring Sensors ........................................................................................................................ 20 Alarms ............................................................................................................................................ 21 The Data Menu .................................................................................................................................... 23 The Window Menu ............................................................................................................................... 24 The Add-Ins Menu ................................................................................................................................ 25 The Help Menu ..................................................................................................................................... 25

Chapter 4 - Controller Interface ....................................................................................................... 27Controller Interface Window ....................................................................................................................... 29Controlling the Dynamometer .................................................................................................................... 30 Throttle Control Modes ......................................................................................................................... 30 Dynamometer Control Modes ............................................................................................................... 30Controller Interface Window Pull-Down Menus ........................................................................................... 31 The View Menu .................................................................................................................................... 32 Control Mode .................................................................................................................................. 32 Tuning Parameters.......................................................................................................................... 33 Settings .......................................................................................................................................... 36 Ramping ......................................................................................................................................... 37 Statistics ........................................................................................................................................ 37

Chapter 5 - Pattern Runner .............................................................................................................. 39The Pattern Runner Interface Window ........................................................................................................ 41Pattern Runner Pull-Down Menus .............................................................................................................. 42 The File Menu ...................................................................................................................................... 42 The Edit Menu...................................................................................................................................... 42 Creating a New PowerNet Pattern ................................................................................................... 43 Saving a PowerNet Pattern ............................................................................................................. 45 Running a PowerNet Pattern ........................................................................................................... 45 The Tools Menu .............................................................................................................................. 45

Chapter 6 - Report Generator .......................................................................................................... 47The Report Generator Program .................................................................................................................. 49The Report Generator Window Pull-Down Menus ....................................................................................... 49 The File Menu ...................................................................................................................................... 49

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ContentsContentsContentsContentsContents

Copyright © 2006 by Power Test, Inc. All rights reserved. This manual may not be copied, photographed, reproduced, translated orconverted to any electronic media or machine-readable format in whole or in part without prior written approval of Power Test, Inc.

Chapter 6 - Report Generator The Edit Menu...................................................................................................................................... 50

Using the Edit Report Window .......................................................................................................... 51 Creating a New User Table ................................................................................................................ 52 Editing User Tables ........................................................................................................................... 53 Creating a New Data Table ................................................................................................................ 54 Reference Sensors .................................................................................................................... 54 Editing Data Tables ................................................................................................................... 55 Phases ...................................................................................................................................... 55 Function List ............................................................................................................................. 55 Creating a New Graph ....................................................................................................................... 56 Editing Graphs .................................................................................................................................. 57 Creating a New Spreadsheet ............................................................................................................. 58 Editing Spreadsheets ........................................................................................................................ 59 Creating a New Paragraph ................................................................................................................ 60 Editing Paragraphs ........................................................................................................................... 61 The View Menu .................................................................................................................................... 62 New Graph View ............................................................................................................................... 62 New Graph View Properties .............................................................................................................. 62 Creating a New Graph View .............................................................................................................. 63 Editing a New Graph View ................................................................................................................ 64 The Import Menu .................................................................................................................................. 64 The Export Menu.................................................................................................................................. 64 Ignore List ............................................................................................................................................ 64

Chapter 7 - Workstation ................................................................................................................... 65The PowerNet Workstation ........................................................................................................................ 67Using the Workstation Touch Screen ......................................................................................................... 68Connections .............................................................................................................................................. 68Workstation Main Menu ............................................................................................................................ 69Run Mode .................................................................................................................................................. 70 Run Mode Function Buttons ................................................................................................................. 70Calibration ................................................................................................................................................. 71 Methods of Calibrations ........................................................................................................................ 71 Valve/Throttle Calibration ...................................................................................................................... 72 Smart Throttle Calibration ............................................................................................................... 73 Pressure Calibration ............................................................................................................................. 74 Temperature Calibration ........................................................................................................................ 75 Primaries Calibration ............................................................................................................................ 76Dynamometer Setup.................................................................................................................................. 77 Advanced Dynamometer Setup ............................................................................................................ 78

Chapter 8 - Add-In Programs ........................................................................................................... 79The Add-in Programs ................................................................................................................................. 81Security Editor .......................................................................................................................................... 81ECM Communicator .................................................................................................................................. 82Gas Analyzer ............................................................................................................................................. 85Calculated Sensors ................................................................................................................................... 85Fuel Controller ........................................................................................................................................... 87Correction Factors ..................................................................................................................................... 89Reference Data Builder .............................................................................................................................. 91

System Overview

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- CHAPTER 1 -

System Overview

PowerNet 2.0

Data Acquisition and Control

System Overview

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System Overview

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Data Acquisition and Control System ComponentsThe system is divided into three groups: the Commander Computer, the PowerNet Workstation and optional components.

Commander ComputerThis terminal interfaces with the Workstation and the dynamometer and performs all of theembedded control functions. It is also the location where new tests and reports are generated,manipulated, stored, run, and printed.

The PowerNet WorkstationThe Workstation contains the system’s pressure and temperature sensors. The sensors are housed in anindustrial cabinet and supplied with quick disconnect connections. Information is collected from the sensorsand ECM (Optional), and combined with torque, speed and power measurements from the dynamometerand sent to the Commander Computer.

Optional ComponentsPower Test offers a wide range of optional components and accessories for the PowerNet Data Acquisition and SoftwareSystem, including:

ECM Communicator Smoke Opacity Meters Auxiliary Outputs

Fuel Measurement System Five Gas Analyzer Alarms

Additional Sensors Electronic Throttle Interfaces PC Upgrades- Temperature- Pressure- Vibration- Speed- Crankcase Blow By

Our in-house manufacturing and electronics department guarantees that we will be able to provide a data acquisition andcontrol system for nearly any application. For more information, contact your Power Test representative, or visit us on theweb at www.pwrtst.com.

System Overview

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Software OverviewThe PowerNet Software Package is a complete data acquisition and control program for dynamometers and engines. PowerNettransforms a standard computer and specially designed electronic components into a highly efficient engine development andqualification tool.

The software is comprised of several programs running at the same time, the Main Display, Controller Interface, PatternRunner and Report Generator. There may be other programs running minimized in the background (operational, but hidden)according to what is listed under the add-ins menu of the Main Display, such as Correction Factors, ECM Communicator,etc.

Main Display Controller Interface

Pattern Runner Report Generator

System Overview

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Main DisplayThe Main Display contains the readings for all of the availablevisible sensors. All of the sensor parameters and configurationscan be modified from this window by right-clicking on the indi-vidual sensor readings. Additionally, this window is used to openand save PowerNet Templates and DataSpaces, as well as exitthe Commander program. The details of the functions and fea-tures of the Main Display are discussed in Chapter 3.

Controller InterfaceThe Controller Interface provides essential control functions for the dynamometer. This windowidentifies the dynamometer’s active load control mode and the current setpoint. It is possiblefor a user at the Commander Computer to control the dynamometer and engine using the modebuttons and the input box directly from the Controller Interface. The details of the functions andfeatures of the Controller Interface are discussed in Chapter 4.

The Pattern Runner Interface WindowThe Pattern Runner program allows the user to create, load, save and executePowerNet Patterns. PowerNet Patterns are pre-configured tests that are de-signed to run in a specific order. The details of the functions and features of thePattern Runner are discussed in Chapter 5.

The Report Generator Interface WindowThe PowerNet Report Generator allows the operator to arrange the data into ameaningful visual format. The data can be arranged as spreadsheets and/orgraphs, while any customer and vehicle information can be put into paragraphsand/or tables. The details of the functions and features of the Report Generatorare discussed in Chapter 6.

System Overview

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The PowerNet File SystemThe PowerNet File System consists of the following components: PowerNet Templates, PowerNet DataSpaces, and Pow-erNet Patterns. It is important to understand the function of each of these file types.

PowerNet Template (.tds)A Template is a file containing pre-configured, basic test information. All Templates can be customized with informationapplicable to the kind of test you wish to perform. This may include sensor configurations and report formats and patterns.Templates are created by the administrator. Templates do not contain any data. Once a test is performed, data can then becollected and saved in the form of a DataSpace.

PowerNet DataSpace (.pds)After a Template has been used to acquire data, it is then saved as a DataSpace. A DataSpace contains the same informationas the Template with the addition of specific test data. A DataSpace is utilized whenever an operator wishes to save new testdata, or recall data from a previously saved test and is the area where live data is stored.

PowerNet Pattern (.pcp)Patterns are pre-configured tests that are designed to run in a specific order. Patterns are created by the administrator andthey can be saved within a Template or as individual files to be loaded into existing Templates.

PowerNet Tuning Files (.pct)Tuning Files are individual files storing dynamometer tuning parameters. The tuning parameters should not be modified unlessotherwise instructed to do so by Power Test.

PowerNet ECM Information (.pei)Specific vehicle ECM Communication configurations can be saved and loaded as individual files.

NOTE: All file types should be stored in the C:\Program Files\PowerNet\Commander 2.0 directory.

- CHAPTER 2 -

Basic Operation

PowerNet 2.0


Basic Operation

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Basic Operation

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Starting the Commander ComputerOnce the Commander Computer and all related components have beeninstalled and set up by your PTI representative, you are ready to turn onthe Commander Computer. At this time, make sure the monitor andprinter are also on.

Note: Each program on the computer utilizes a system of commandchoices, called Menus. If you click on a Menu, and it drops down withmultiple choices for you, it is called a pull-down menu. To make thecomputer follow instructions, simply point the mouse and click on themenu selections you wish to have performed.

PowerNet Commander Splash Screen

The computer should automatically execute the PowerNet 2.0 w/Workstation program, and the splash screen will becomevisible during the time the program is loading. Once closed, the program may be restarted by clicking on the “P” icon on yourscreen. Double click that icon to launch the software. For administrative functions, a log-in name and password are required.

Note: If the program does not automatically start, or the icon does not appear, contact your Power Test representative.

Once you have powered up (for operators) or logged-in (as anadministrator), the default PowerNet Template should be loadedand visible (right).

The program will automatically open the “default” template uponstart-up. Typically, the operator will open one of several tem-plates created by the administrator and select a template basedon the type of engine or test being performed.

Note: Depending on the operating system used, the software may have a slightly different appearance than the examples in thismanual. This does not affect the performance of the program in any manner.

Basic Operation

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Pressure Connectionat Engine

Pressure Connection atthe Workstation

ConnectionsNote: Before performing a test, the following connections may need to be made.

ThermocouplesTo connect a temperature probe, first set the depth of the probe into the compression fitting. The depth of the probe into thecompression fitting will be determined by the location of the fluid being measured. Once a compression fitting has been crimpedon a probe, it cannot be relocated. The probe can be used over and over again, but the depth will be fixed. After the compressionfitting is assembled on the probe, NPT adapters will need to be provided to match the probe connection to its final location. Withthe probe in place, simply plug the female end of the yellow extension cord into the probe and the male end into the control box.

Pressure ConnectionsTo connect to a pressure port, first set the length of the pressure tube. A pressure tube consists of ¼" flexible tube withcompression fittings on each end, one end terminating in a male NPT fitting (engine) and the other terminating with a quick-disconnect (control box). Simply, route the tube to the pressure (or vacuum) source and adapt accordingly.

Temperature Connection atthe Workstation

Temperature Connectionat Engine

Basic Operation

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Engine ConnectionsIn most circumstances, an engine start relay (not required if using air starting) and a fuel stop solenoid will have to be connectedprior to testing an engine.

The start wires (white/red/black) are connected to the Engine Start Relay on the base of the Workstation for the engine beingtested, as shown in the diagram above.

The stop wires (blue/brown/green) are connected to the ECM power connection or the Fuel Stop Relay for the engine beingtested, as shown above.

ECM Connection (Optional)To connect to the vehicle’s ECM, plug the ECM cable (provided by Power Test) into the Workstation (labeled ECM) on one end,and to the appropriate diagnostic adapter (available separately from Power Test) on the other end.

Other Connections Please refer to a specific component’s installation manual for other connections.

Fuel Stop Solenoid LT Relay Connection Diagram

Engine Start Relay

Basic Operation

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Test ProcedureOnce the engine has been prepared for testing, including mounting the engine to the engine cart/stand and installation of allcomponents (flywheel, engine adaptors, drive shafts, engine cooling system, etc.), the next step of the process is to perform theactual engine test. Once the safety and integrity of all of the systems, connections, supplies and the engine are verified, you areready to begin. The following information outlines a typical test sequence.

Prepare for TestingConnect Throttle Cable to EngineIf a throttle actuator is used, set the throttle actuator to the “low idle” position (slack removed from cable).

Turn on the PowerNet WorkstationTo turn on the Workstation, press the black button on the outside of the box, below the emergency stop button.

Turn on the Commander ComputerTurn on the computer, monitor and printer. The PowerNet Data Acquisition and Control Software will load automatically.

Enter in Your User PasswordLogin to the systems from the Main Display menu. Enter your assigned user name and password.

Load a PowerNet TemplateLoad an appropriate template by selecting File > Open > Template from the Main Display. This Template is normally identifiedby engine model. If an appropriate Template does not exist, one must be created by the System Administrator.

Calibrate the ThrottlePrior to starting the engine, the throttle must be calibrated with each new type being tested. This is to ensure proper operationduring testing that could possibly be affected by the distance between each new engine and the actuator. Calibration proce-dures are outlined in Chapter Four, Controller Interface.

Turn on the Support SystemsTurn on the water recirculation system (if applicable), including cooling towers, pumps, etc. Additionally, ensure that allventilation equipment is operable. Turn on the Fuel System. Once the throttle has been calibrated and the support systemshave been turned on, start the engine.

Begin TestingIf a closed loop test is being run, click the Play button in the Pattern Runner program. If the appropriate Pattern is not visible,select a Pattern from the file or consult the administrator. If a manual test is being run, test the engine as specified by yoursupervisor.

After Testing is CompletedShut off the EngineOnce the cool down period has completed, shut down the engine

Turn off the Support SystemsTurn off the water supply to the dyno. If the cooling tower fans or pump are running, leave that part of the system on.

Edit DataEnter any test specific data using the Report Generator program. Use the Print Preview function to view the edited report.

Save Test DataFrom the Main Display, click File > Save As > Data Space. Assign a file name, typically determined by work order #, etc. Ifdesired, print a hard copy of the report by selecting File > Print from the Report Generator program.

Shut down the Commander ComputerShut down the computer by clicking File > Shut Down System in the Main Display window.

Turn off the PowerNet WorkstationTo turn off the Workstation, touch the Shut Down Workstation button on the Main Menu Screen.

Main Display

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- CHAPTER 3 -

Main Display

PowerNet 2.0


Main Display

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Main Display

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The Main Display WindowThe Main Display Window contains all of the sensors that are connected to the system. The Sensors can be displayed in twoformats. The Single Main Form format displays all of the individual gauges in fixed format. The Floating Form formatallows the user to customize the size and location of the individual gauges on the screen. Each of these sensors can bedisplayed in one of four available gauge types as explained on page 20, Sensor Properties.

Example of the Single Main Form Format

Example of the Floating Form Format

NOTE: The illustrations throughout the rest of this manual will display sensors in the floating form format. This may or maynot represent how your system is configured.

Main Display

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Main Display Window - Pull-down MenusThe pull-down menus are located in the header of the Main Display when the Single Main Form format is applied, or in afloating window if the Floating Forms format is applied (as illustrated throughout this manual). If the floating window isselected, the full pull-down menus will appear by putting your cursor on the "P" icon. The pull down menus consist of: File,View, Data, Window, Add-Ins and Help.

Single Main Form Pull Down Menu Floating Form Pull Down Menu and Icon

The File MenuFile Menu: From the File Menu, many of the file management tools needed to operate Commander can be accessed. TheFile Menu consists of Log in, New, Open Template, Open DataSpace, Save, Save As Template, Save As DataSpace,Revert to Saved, Shut Down System and Exit.

File > Login: Opens the Login screen so an administra-tor can login to perform administrative functions.

* Note: Without logging in, many menu items will begrayed out and the corresponding administrative func-tions can not be performed. All functions requiring loginwill be noted with an * throughout the rest of this chap-ter.

File > New: Creates a new blank Template.

* File > Open > Template: Loads an existing Templatefrom which to use for running a pre-configured test. Ifnot logged in, the user will only have the option of open-ing a Template within the program directory. If loggedin, the user will have the ability to search the CommanderComputer and all removable drives for a Template.

File > Open > DataSpace: Loads an existing DataSpacethat contains previously saved test data.

Open DataSpace ScreenOpen Template Screen Open Template Screen (logged in)

Main Display

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The File Menu - (continued)* File > Save: Saves the current active DataSpace orTemplate, overwriting the current file.

Note: Use caution when using the Save function. Oncechanges have been saved and the original file has beenoverwritten, the original file can not be retrieved.

File > Save As >Template or DataSpace: Saves theactive Template or DataSpace as a new Template orDataSpace. The user will be prompted to name the newfile before saving. In addition to the new file being savedto the system, the original file will still exist.

File > Revert to Saved: Ignores recent changes in theactive Template or DataSpace and reverts back to thepreviously saved version.

File > Shut Down System: Closes the software pro-gram and powers down the Commander Computer.

File > Exit: Closes the program and returns the user tothe Windows Desktop. If changes have been made tothe current open DataSpace, the user will be given theoption of saving the changes before closing the program.

Main Display

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The View MenuView Menu: From the View Menu, hidden sensors can be made visible and the sensor layout can be changed. The ViewMenu consists of More Sensors, Display Layout, Chart, Find Overlapped Sensor(s) and Lock Sensors Positions.

View > More Sensors: Produces a pop-up window(shown below) that allows the user to make hidden sen-sors visible. Check the boxes of the sensors you wish toshow and click OK.

Note: A sensor does nothave to be visible for itsdata to be shown in theReport.

View > Display Layout: Clicking Display Layout willautomatically open the Sensor Order window (shownbelow). There are two options in the Sensor Order win-dow, Sensor Order and Sensor Configuration.

The Single Main FormThere are two formats to display the sensors: SingleMain Form and Floating Forms. In the Single MainForm format, all of the available sensors are groupedtogether in the Main Display window. To display all sen-sors in a Single Main Form, click on the Sensor Con-figuration tab and click on the All Sensors check box.

To change the order in which sensors appear in a Main Form, click on the Sensor Order tab. To change the order, highlighta sensor by clicking on it, then use the navigational buttons at the right of the window. Click OK when finished to save thenew sensor order, or click cancel to disregard changes.

Note: The Sensor Order function will not work if all sensors are displayed in a Floating Form format.

Sensor List

Move Sensor Position Up

Move Sensor Position Down

Main Display

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The Single Main Form (continued)From the Sensor Configuration tab, the user can select how many sensors appear in each row of the Single Main Form inthe Main Display.

If the 3 on top row (stationary) 5 on remaining rows option is selected,a Single Main Form will display three sensors in the top row, and fivesensors in each row thereafter until all sensors are displayed. ex. Ifthere are 13 sensors in the Main Form, three sensors will be displayed inthe first row, five sensors will be displayed in the second row, and fivesensors will be displayed in the third row. If selected, the sensors in thefirst row will all be square in size.

If the 4 on top row (stationary) 5 on remaining rows option is selected,a Single Main Form will display four sensors in the top row, and five sen-sors in each row thereafter until all sensors are displayed. ex. If thereare 13 sensors in the Main Form, four sensors will be displayed in thefirst row, five sensors will be displayed in the second row, and four sen-sors will be displayed in the third row. If selected, the sensors in the firstrow will all be square in size.

If the 5 on top row (stationary) 5 on remaining rows option is selected,a Single Main Form will display five sensors in the top row, and five sen-sors in each row thereafter until all sensors are displayed. ex. If thereare 13 sensors in the Main Form, five sensors will be displayed in the firstrow, five sensors will be displayed in the second row, and three sensorswill be displayed in the third row. If selected, the sensors in the first rowwill all be square in size.

If the 5 on all rows (non-stationary) option is selected, a Single Main Form will display five sensors in each row . ex. Ifthere are 13 sensors in the Main Form, five sensors will be displayed in the first row, five sensors will be displayed in thesecond row, and three sensors will be displayed in the third row. If selected, each sensor will be equal in size, regardless ofnumber selected.

Floating FormsFloating Forms can exist anywhere on screen and can be sized individually. The use of the Floating Form format allows ahighly customizable appearance to the Main Display. A Single Main Form display and Floating Forms display can existtogether.

The Sensor Display frame of the Sensor Configuration tab is used to determine how many sensors will be displayed onthe Single Main Form display and how many Floating Forms exist. If the All Sensors check box is selected, all sensorswill be displayed in a Single Main Form mode. To display sensors in both a Single Main Form and Floating Forms format,enter the number of sensors that should remain in the Single Main Form in the Number of Sensors on Main Form text box.ex. If there are 13 sensors available, and a number of six is entered into the Number of Sensors on Main Form text box,then six sensors will be displayed in the Single Main Form, and the remaining seven sensors will exist as Floating Forms.To change which sensors appear in the Single Main Form, click on the Sensor Order tab and rearrange the sensors.

To have all sensors display as Floating Forms, un check the All Sensors check box and enter the number zero (0) into theNumber of Sensors on Main Form text box.

To move a sensor's position in the Floating Form format, confirm that the Lock Sensor Positions option in the View Menuis unchecked. Clicking on Lock Sensor Positions will check or un check that option. If it is not unchecked, click on LockSensor Positions to unlock the sensors. This will allow the sensors to be placed anywhere on the screen. Next, click on thesensor and drag it to its new location. To change the size of a sensor, click on an edge or corner of the sensor window, anddrag it to the desired size. Once all sensors have been placed, click on Lock Sensors Positions from the View Menu. Thiswill lock the sensors in their current position, and help to avoid the possibility of accidentally moving, re-sizing, or hiding asensor.

Main Display

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Sensor PropertiesRight-clicking on any of the sensors allows the user to modify the sensor’s properties. Right-clicking brings up the option boxshown below right.

Properties: Selecting Properties will open the Sensor Properties window.

Hide: Selecting Hide will remove that sensor from the Main Display window and return it to the list of sensors under MoreSensors on the Main Display window’s View Menu. Select View > More Sensors to undo the hide sensor command.

Sensors displaying readings with an Optimal (an administrator defined "normal") range will display in GREY. Sensors in aLow alarm range will display BLUE. Sensors in a High alarm range will display RED.

Sensor Properties Window: The Sensor Properties window contains five tabs that allow the user to customize thesensor. The tabs are Gauge, Display, Units, Low Alarm and High Alarm. In addition, the name of the sensor can bechanged by entering the new name into the Sensor Name input box.

Display: This is where the operator can select which type of gauge should be displayed for asensor. The operator can select from a Digital, Sweep Dial, Round Dial or Bar gauge.Note: Bar gauges are only available as Floating Forms.

Gauge: This tab provides the operator options to define the displayed range and multiplier forthe gauge. Maximum Reading: Establishes the top, or highest number displayed in a dial orbar gauge. Minimum Reading: Establishes the bottom, or lowest number displayed in a dialor bar gauge. Display Multiplier: The number by which the numbers in a display are dividedby, ex. A multiplier of ten will display 1000 RPM as 100 RPM. This will also change the displayunit to RPM x 10 (or whichever multiplier is chosen). Decimal Places without Display Multi-plier: The number of decimal places to which is displayed as determined by the number en-tered in the input box. ex. If a value of three (3) is entered in the input box, data will bedisplayed to .000, or thousandths.

Units: This is where the user defines the units displayed for the gauge display. Common stan-dard units can be chosen by selecting Use List and picking from the menu. To define a customunit, select Custom and enter a unit name, description and display symbol. Enter the valuesthat the sensor’s standard unit must be multiplied by and/or added to achieve the custom unit.Once all information is entered, the custom unit can be added to the list of standard units. Tofind the base unit, select units from the Use List until you find one with adder of zero and amultiplier of one (usually, the first listing).

Digital Sweep Dial Round Dial Bar

Main Display

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Sensor Properties (continued)

Low Alarm/High Alarm: These tabs are where the user defines whatactions (explained below) will be taken during a Low Alarm/HighAlarm state.

When finished, select OK to keep changes or Cancel to disregardany changes.

AlarmsAs soon as the sensor travels out of its operational range, it will change color. Blue indicates it has fallen below its opera-tional range (Low Alarm) while red indicates it has exceeded its operational range (High Alarm). There will be two optionsavailable to the operator, Hold (suspend) or Reset the alarm. If the Hold button is clicked during alarm state, the softwarewill suspend the alarm Action for the period of time indicated in the “Suspend Time”. Reset clears the alarm condition.Shown below are examples of alarm conditions and the resulting alarm buttons that may be displayed on screen. To removethe condition, simply click on one of the function buttons, either Hold or Reset.

The user has the option of setting a high and low alarm to activate during an engine test. As previously discussed, they arelocated by right clicking on a sensor in the Main Display Window. The user may then choose from the following options:Trigger Point, Wait Secs Before Action, Suspend Time, a variety of Actions to perform, Grab Data Point if Triggered,and Auto Reset. In both the Low Alarm and High Alarm state, the administrator has the following options available.

Trigger Point: The value at which the software will indicate that the sensor is out of the operational range. The units of thevalue entered are selected from the Units tab. For example, if the sensor is configured in RPM, then the value entered willreflect RPM.

Wait Secs Before Action: Indicates how many seconds the software should wait before performing the alarm Action.

Suspend Time: Indicates how long the alarm action will be delayed if the Hold button is clicked.

Action: The Action state of the alarm allows the administrator to set the following actions to be performed by the softwareafter the number of “Wait Secs Before Action” has completed.

None: Indicates no action is to be performed and only a color change is indicated on the screen.

Soft Stop: When the alarm is triggered, the software will first apply the "Wait Secs Before Action" value, then perform a softstop. Both the speed control and the dyno control return to zero and the Stop relays fire automatically. These actions stopthe engine as if it were shut down normally, as no load is applied during a soft stop. If selected, an alarm will sound.

E Stop: The throttle returns to zero and the valve is fully opened, applying a preset load to the engine, the stop relays arefired, and the engine is brought to an abrupt stop. If selected, an alarm will sound.

Warning Only: In this condition, only an alarm warning is displayed on screen, no actions are performed.

Grab Data Point if Triggered: If checked, the software will immediately grab data if the Trigger Point is reached. Grabbingdata once a trigger point has been reached will help in identifying the problem area, and cause of the alarm. If Grab DataPoint if Triggered is not checked, the data will be gathered normally.

Auto Reset: If checked, the software will automatically reset the alarm after the sensor limit has returned to normal.

Main Display

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The View Menu (continued)View > Chart:By selecting Chart under the View Menu, the Real-TimeChart (shown below) will be displayed. This chart dis-plays the real-time data change. Additionally, ReferenceData Can be viewed on the Real Time Chart.

To customize the Real-Time Chart, right click the chart andchoose Properties. The user has the option to choose whatinformation will appear on the X (horizontal) axis and Y (ver-tical) axis of the Chart.

From the Points frame, the user is able to select how many Points appear in theReal Time Chart. The number of Points (30, 60 or 90) will determine the actualwidth of the Chart. From the Speed frame, the user can select the speed (Me-dium or Fast) at which the system updates and displays data. The actual rangesof the Chart are determined by the minimum and maximum values of the sensoras established in the Sensor Properties Window.

To display the information from the Current Active Data Space as it is being re-corded, select Rolling Time Chart from the X Axis list. If Rolling Time Chart isselected, the chart will scroll to the left as data selected as the Y Axis is beingdisplayed.Note: Real-Time graphing consumes a greater amount of processor speed as the number of sensors and the update rateare increased.

Selecting Chart Reference Data will display Reference Data on the chart in addition to Data from the Current Active DataSpace. More information on Reference Data can be found on page 24 and in Chapter 7, Add-In Programs

To hide the real-time chart, right click the chart and choose Hide.

View > Find Overlapped Sensor(s): This menu itemwill be active only if there are some sensors displayedas Floating Forms. In this case, some visible sensorsmay be overlapped by other sensors. This selection willpoint out the positions of overlapped sensors. As shownin the figure far right, the positions of the overlappedsensors are marked by the Overlap symbol. Clickingthe Overlap symbol will cause the overlapped sensorto appear.

View > Lock Sensors Positions: This menu item willbe active only if there are some sensors displayed asFloating Forms. Normally, the positions of sensors shownas Floating Forms can be any size or anywhere on thescreen. Checking this menu item will disable the abilityto size or move floating sensors.

Main Display

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The Data MenuData Menu: Test data from the sensors can be cleared and recorded from the Data Menu . The Data Menu consists ofClear Data, Grab Data , AutoGrab, Delete Data Point(s), Load Reference Data and Assign Sensors to Reference Data.This data is later used in reports and graphs.

Data > Clear Data: Erases any stored data in the cur-rent open DataSpace. This change will not be saveduntil the current DataSpace is saved.

WARNING: Once data has been erased, it can not berecovered.

Data > Grab Data: Instantly records the current datareadings. The Grab Data function can be performed byclicking on this menu item or by using the Windows key-board shortcut keys Ctrl + G.

Data > AutoGrab: Allows you to turn AutoGrab offor select an interval in which data will be recorded.The user is able to choose one of several presetintervals or custom configure time intervals.AutoGrab only records data when the engine is run-ning.

Note: The data you grab is saved into the currentactive DataSpace and can be printed using the Re-port Generator program, as described in Chapter 6.

Data > Delete Data Points: Deletes data points or dataphases. If this function is selected, a pop-up window(shown below) will appear. The user can choose to de-lete individual data points or delete entire phases.

Note: Phases are only available with the Advanced Pat-tern Runner.

To delete Data Points, enter the Data Point number andclick the Delete button. A confirmation window will ap-pear. If the information in the window is correct, clickOK. The selected point will be deleted. Data Points arenumbered consecutively.

To delete a Data Phase, select the Delete Phase op-tion. A window (shown right) will list the available phasesto delete. Highlight the phase to delete and click theDelete button. Confirm the selection by clicking “OK” inthe confirmation window. .

Main Display

24

The Data Menu (continued)* Data > Load Reference Data: This menu item allowsthe user to load Reference Data into the report from anexternal data source.

Reference Data is data that is typically used for com-paring results of a test to accepted standards when view-ing a graph. This data can be imported from aDataSpace, a text file created in Excel, or created bythe administrator using the Reference Data Builder fea-ture found in the Add Ins Menu. Further details can befound in Chapter 7, The Add Ins Menu.

Once reference data has been loaded to the DataSpace, the Assign Sensors to Reference Data window will automaticallyopen. The user is given the choice of available sensors to assign reference data to.

* Data > Assign Sensors to Reference Data: Tochange sensors assigned to the reference data after ithas been loaded, select Assign Sensors to ReferenceData... from the Data menu. After the reference data isloaded, this menu item will become active. It is used toassociate the reference data to existing sensors.

Note: Once Reference Data has been assigned to a specific sensor, it will appear in any Graph in which that sensor isassigned if the Use Reference Data check box is checked in the Graph Properties window found in the Report Generator.

The Window MenuWindow Menu: From the Window Menu, the arrangement of the Main Display Window can be modified. The WindowMenu consists of Default Positions and Show Main Form (which toggles to Hide Main Form) and AutoHide.

Window > Default Positions: If the active windows havebeen modified or moved by the user, selecting the De-fault Positions will return them to their default displaypositions.

Main Display

25

The Window Menu (continued)Window > Show Main Form: If the sensors are onlydisplayed in a Floating Form format, the Main Form willremain empty. To display the Main Form, select theShow Main Form option. To hide the Main Form, se-lect the Hide Main Form function.

After the main form appears, the Show Main Form menuitem will change to Hide Main Form. By selecting HideMain Form, the Main Form will be hidden again.

Window > Auto Hide: Checking Auto Hide will reducethe floating menu to an icon (shown below) after a shortperiod of time. To reactivate it, simply place your cursorover the icon.

The Add-Ins MenuAdd-Ins Menu: The selections in the Add-Ins menumay vary with different embedded programs. Any op-tional component programs that do not come standardwill be listed under the Add-Ins Menu. Programs foundin the Add-Ins Menu are explained in Chapter 7, Add-In Programs.

Note: For instructions and specifications for specifichardware included with your system, please consultthe information provided with the equipment.

The Help MenuHelp: The Help menu of the Main User Interface Window shows the Versions of the programs and the Release Notes.

Help > Show Versions: Displays the current ver-sion specifications of the software (shown below).

Help > Release Notes: Opens a .txt file that con-tains the historical changes to the software pro-gram. This is used as a reference file by PTI em-ployees.

Main Display

26

Controller Interface

27

- CHAPTER 4 -


PowerNet 2.0



28


29

Controller Interface WindowThe Controller Interface window provides essential control functions for the dynamometer. This window identifies thedynamometer’s active load control mode and the current setpoint.

It is possible for a user at the Commander computer to control the dynamometer using the mode buttons and the input boxdirectly from the Controller Interface window. Additionally, the dynamometer tuning parameters can be accessed from thiswindow.


30

Controlling the DynamometerThere are two methods for manually controlling the dynamometer and/or engine directly from the Controller Interface. The firstmethod is by entering a number in the Setpoint Entry Box directly above the Start, Home and Soft Stop buttons. Entering avalue in this window and pressing enter on the keyboard will move the yellow Slide Bar to the desired set point. Additionally,a blue bar will display the progress of the change being made. The second method for controlling the dynamometer and/orengine is by clicking on the Slide Bar and dragging it to the desired set point. As the Slide Bar is moved, its position will bedisplayed in the Setpoint Entry Box. A blue bar will display the progress of the change being made. Additionally, clicking on thearrows at the top and bottom of the Slide will move the Slide Bar 5% for each click.Note: The system can only be controlled using the Slide Bar in the Throttle Position and Dynamometer Valve Position modesas described below.

Throttle Control ModesThere are two standard and two optional methods by which the engine operating speed may be controlled during testing:

1) Position: A method of controlling the engine in which the throttle is set at a percentage of the pre-calibrated throttle range andis maintained at this position during testing. Speed adjustment may be made by using the Slide Bar or entering the percentagevalue.

2) Speed: A method of controlling the engine in which an actual speed in RPM is entered and the system will move the throttlein an effort to maintain the entered value during testing.

3) Torque Mode (Optional): A method of controlling the engine in which a torque set point is entered and the throttle tries tomaintain that amount of load, regardless of the engine’s speed or its ability to achieve that load (may overload engine if set pointis too large).

4) Horse Power Mode (Optional): A method of controlling the engine in which a horsepower set point is entered and thethrottle tries to maintain that amount of load, regardless of the dynamometer’s speed or the engines ability to achieve that load.

Dynamometer Control ModesWhether performing automated or manual setpoint operation, the dynamometer will ultimately be controlled by one of thefollowing four modes:

1) Position (Valve Mode): A method of controlling the dynamometer in which the dynamometer water valve position is directlycontrolled by valve percentage (manual load method). Load adjustment may be adjusted by using the Slide Bar or entering thepercentage value.

2) Torque Mode: A method of controlling the dynamometer in which a torque set point is entered and the dynamometer triesto maintain that amount of load, regardless of the engine’s speed or its ability to achieve that load (may overload engine if setpoint is too large).

3) Horse Power Mode: A method of controlling the dynamometer in which a horsepower set point is entered and the dyna-mometer tries to maintain that amount of load, regardless of the engine’s speed or its ability to achieve that load. This istypically used for endurance testing or warm up and may overload the engine if the set point is too large.

4) Engine Speed Mode: A method of controlling the dynamometer in which an engine speed is entered and the dynamometertries to maintain the engine speed (dynamometer must be reading engine speed either through the engine’s ECM or thedynamometer’s speed pickup). If the engine speed is higher than the set point, the dynamometer will load the engine until theengine speed set point is achieved. If the engine speed is lower than the set point, the dynamometer will unload the engine untilthe engine speed is achieved. This mode is typically used for maximum power pulls.


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Controller Interface Window Pull-Down MenusThe Controller Interface Window consists of the File and View menus.

The File MenuFile Menu: The File pull-down menu allows the operator to load and save sets of tuning parameter values. The File pull-downmenu consists of Open Tuning, Save Tuning, Save Tuning As, Import 1.2 Tuning, Request Auxiliary Names FromWorkStation and Send Auxiliary Names To WorkStation. Tuning is explained on page .

File > Open Tuning: Will open a previously saved set of tuning param-eters.

File > Save Tuning: Saves over the currently active set of tuning param-eters as a file with the same name.

Note: Use caution when using the Save function. Once changes havebeen saved and the original file has been overwritten, the original file cannot be retrieved.

File > Save As Tuning: Saves the active set of Tuning Parameters as anew set of Tuning Parameters. The user will be prompted to name thenew file before saving.

File > Import 1.2 Tuning: Imports an older version of the tuning file (fromPowerNet 1.2). After importing the file, the 1.2 tuning file can be used withthe PowerNet 2.0 software.


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The File Menu (cont’d)File > Request Auxiliary Names from WorkStation: Requests sensornames from the WorkStation and assigns them to sensors displayed inthe Main Display window.

File > Send Auxiliary Names to WorkStation: Sends sensor namesfrom the Main Display window to the WorkStation to update the sensor tohave the same name.

The View MenuView Menu: From the View menu, the user can switch between viewing the Control, Tuning and Setting modes. This modescan be also be accessed by using the three tabs below the pull-down menu bar (bottom left). The View pull-down menuconsists of Control, Tuning, Settings, Ramp and Status.

View > Control: Displays the control mode of the Controller Interface.After viewing the Tuning or Settings modes, the Controller Interface mustbe returned to the Control Mode (shown below) in order to perform test.


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The View Menu (cont’d)View > Tuning: Displays the dynamometer tuning parameters. ThePowerNet Data Acquisition and Control software utilizes a ProportionalIntegral Derivative controller. The PID controller compares a measuredvalue from a process with a reference setpoint value. The difference or“error” signal is then used to calculate a new value for the throttle or valve.The PID loop occurs many times/second.

Note: Tuning parameters should not be modified or shown, unless in-structed to do so, AND THEN DONE SO BY THE ADMINISTRATORONLY.

The Proportional, or gain, positions the throttle or valve at a percentageproportional to the error.

The Integral is the rate at which the dynamometer will reach that setpoint.

Derivative controls the rate of change.

I2 has the same properties as Integral, but has a greater effect the further it is from the setpoint.

The Lim%/Sec is the actual rate at which the valve moves.

Determining the appropriate settings for P and I can be a difficult task. Asimple method for tuning is to first set the I and D values to zero. Increasethe P until the system begins to oscillate, and then divide by 2. Thenincrease I until oscillation starts, and divide by 2. A fast PID loop tuningusually overshoots slightly to reach the setpoint more quickly; however,some systems cannot accept overshoot. If this is the case, the tuning willneed to be slower.


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The View Menu (cont’d)View > Tuning (cont’d):

The tuning display contains nine separate sec-tions: Positive, Negative, Engine, Throttle,Span, Constants, Dynamometer Properties,Valve and Misc.

Positive: Represents the positive error, or the dis-tance beyond the setpoint.

Negative: Represents the negative error, or thedistance away from the setpoint.

Note: In most circumstances, the Positive andNegative tuning ratios should be identical.

The Positive and Negative tuning parametersdirectly affect the control of the dynamometerwhen in torque or power mode.

Engine: The P, I and D settings for the Enginetuning section produce a torque setpoint, appliedto the Positive and Negative tuning parameters.

The Engine tuning parameters affect the controlof the dynamometer when in Dyno Speed Con-trol mode.

Span: The Span Speed setting determines themaximum speed at which the system will allowthe dynamometer to operate. The Span Torquesetting determines the maximum torque that eachrotor in the dynamometer will absorb. This num-ber is multiplied by the value entered in the RtrNum box.

ex. If the system is controlling a 50X02 (two ro-tor) dynamometer, a value of two would be en-tered in the Rtr Num box. If a value of 2000 isentered into the Torque Span box, the total torquethat the system could control would be 4000. Ifthe dynamometer exceeds 4000 ft-lbs of torque,the system will use the P tuning parameter foundunder the Valve section with a setpoint of 4000.

Throttle: The P, I and D settings for the Throttle tuning parameters affect the control of the dynamometer when in ThrottleSpeed Control mode.

Constants: The PD LSM (Lower Speed Multipliers) and I LSM (Lower Speed Multipliers) determine a gain or reduction on thePID before it reaches the Tune Speed as specified by Tune Spd in the Misc. section. During a sweep, up until the time the TuneSpeed is reached, the P, I and D is multiplied by the LSM.


35

The View Menu (cont’d)View > Tuning (cont’d):

Misc: The Misc. tuning section contains the Thr.Rate, V. Rate, Bal. Rate and Tune Spd tuningparameters. The Thr. Rate and V. Rate param-eters determine the percentage rate at which thethrottle and valve increase per second.

ex. If a value of 10 in entered in the Thr. Ratebox, and the throttle is changed from 0% to 100%from the control window, the system will take tenseconds to reach full throttle.

The Bal. Rate function does not apply to the Pow-erNet 2.0 software.

The Tune Spd. is the speed at which the PIDsettings take effect. Up until the time that theTune Speed is reached, the PID is multiplied bythe PD LSM (Lower Speed Multipliers) and I LSM(Lower Speed Multipliers) found in the Constantssection.

Dynamometer Properties: The DynamometerProperties section contains the Hp/Rtr, Lb-Ft/Rtr,and Rtr Num tuning parameters.

The Hp/Rtr and Lb-Ft/Rtr tuning parameters donot apply to the PowerNet 2.0 software.

The number of rotors of the dynamometer beingused is entered into the Rtr Num box. This valueis entered and multiplied by the value entered inthe Torque box found in the Span section.

ex. If the system is controlling a 50X02 (two ro-tor) dynamometer, a value of two would be en-tered in the Rtr Num box.

Valve: The Valve tuning section contains the Pro-portional tuning parameter for the valve. If thesystem exceeds the torque specified by the val-ues entered in the Span and Rtr Num tuning pa-rameters, the value entered into the Valve P boxwill be applied to the system.


36

The View Menu (cont’d)View > Settings: Shows the currently active Interface Settings. Allowsthe operator to precisely refine the Inertia compensation, MaximumSpeed, Overspeed Reset, and Minumum Run Speed.

Inertia: A value is entered in this box to compensate for theInertia of the spinning components of the engine.

If possible, obtain the rotational inertia of each component fromthe manufacturer. Some simple rules for calculating the systeminertia:

• Add up the inertia values of all rotating components, including:dynamometer, flywheel or flexplate, engine adapter, crankshaft,vibration dampener, pulleys, etc.

• The inertia of any belt or gear driven components must bemultiplied by the square of their respective drive ratio.

If the inertia information is not available for a component, almostall rotating components on an engine/dynamometer system havegeometry similar to, or can be approximated by, a ring or rings.To calculate the rotational inertia, the mass (Lbs) and the dimen-sions (Inches) must be known.

Maximum Speed: The value enetered in the Maxmum Run Speed window sets the maximum speed (in RPM) that thesystem will allow the engine to run. If the speed of the engine exceeds the determined value, the system will fire the Engine Stoprelay until the engine speed falls below the operated speed as determined by the Overspeed Reset.

Overspeed Reset: If the engine accelerates beyond the Maximum Speed, the sytem will not return to normal operation untilthe engine speed falls below that as determined by the value entered in the Overspeed Reset box.

ex. If a value of 4000 is entered in the Maximum Speed box and a value of 100 is entered in the Overspeed Reset box, theengine spped must fall below 3900 RPM before the system will return to normal operation.

Minumum Run Speed: Once the engine being tested achieves the RPM entered in the Minumum Run Speed box, thesystem’s starting rel


37

The View Menu (cont’d)View > Ramp: Clicking on Ramp displays the Ramping (shown below),or percentage of change per second, of the value being changed.

ex. Entering a throttle value of 50 in the Setpoint Entry Box and a value of10 in the %/sec Entry Box will increase the throttle percentage by 10percent every second, acheiving the set value of 50% throttle in five sec-onds.

View > Statistics: This menu item is used to display a form that showsthe status of the controller (shown below).


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Pattern Runner

39

PowerNet 2.0


- CHAPTER 5 -

Pattern Runner

Pattern Runner

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Pattern Runner

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The Pattern Runner Interface WindowThe Pattern Runner program allows the user to create, load, save and execute PowerNet Patterns. Patterns are pre-configured load and speed set-points that are designed to automatically run in order. Each of these set-points is represents anaction executed by the Controller Interface. Once a Pattern has been created, that Pattern is used to run individual commandsof the Controller Interface.

NOTE: A thorough understanding of the dynamometer load and throttle controls, modes of operation, and effects on the engineare required before creating new Patterns. When creating new Patterns, it is recommended to insert many small steps betweenchanges in RPM and load. It is also recommended that the time interval (Point Duration) is set long is set long enough to allowfor each step to stabilize before advancing to the next.

Example of a PowerNet Test Pattern

Each row represents one point in the Pattern. Each row is divided into as many as five columns.

The first column represents the Point, or step of the pattern. ex. 1), 3), etc....

The second column represents the Throttle mode. In the above example, Th:, represents the Throttle position during the test.The throttle value can be set by either the percentage of the throttle that is desired (%), or by a set speed (RPM).

The third column, represents the Unit of measure for each Control Mode. ex. HP, RPM and %. In the example above, V:,represents position of the load control valve. There are four settings for determining the valve position: Valve position, Torque,Power, and Speed.Note: The units for each of these settings are selected from the Sensor properties menu of the Main Display. To access aSensor’s properties, right click on the sensor and select the appropriate unit from the Units tab.

The fourth column represents the Duration, or the elapsed time during each step of the pattern. ex. 30, 01:00, etc... In theexapmle above, Wait, represents the Duration, or the elapsed time during each step of the pattern.

Column five indicates whether or not data will be recorded, including activation of the AutoGrab feature.

Pattern Runner

42

Pattern Runner Window Pull-Down MenusThe Pattern Runner Window consists of three (3) pull down menus, the File, Edit, and Tools.

The File MenuFile Menu: There are four options within the File Menu, New, Open, Save, and Save As.

File > New: Clears the current Pattern to allow the user to create a new Pattern, asexplained on the following page.

File > Open: Allows the operator to open an existing PowerNet Pattern.

File > Save: Overwrites the active PowerNet Pattern with a file having the same name.

Note: Use caution when using the Save function. Once changes have been saved andthe original file has been overwritten, the original file can not be retrieved.

File > Save As: Saves a copy of the current PowerNet Pattern as a new Pattern. Theuser will be prompted to name the new file before saving.

The Edit MenuEdit Menu: There is one option available for the Edit menu, Edit Full Pattern.

Edit > Edit Full Pattern: This allows the operator to edit the active Pattern. SelectingEdit > Edit Full Pattern brings up the Edit Pattern Window as shown on the followingpage. The procedure for editing an existing Pattern is similar to creating a new Pat-tern.

Pattern Runner

43

Creating a New PowerNet PatternA new PowerNet Pattern can be created from scratch or by modifying an existing Pattern and saving it as a new file name. Tocreate a new Pattern from scratch, click on New under Pattern Runner’s File pull-down menu. To modify an existing Pattern,select Open from the File pull-down menu and open the Pattern to be modified. In any case, the Pattern must be edited. (SeeEdit > Edit Full Pattern on the previous page).

Each Pattern Point must indicate the control mode, the setpoint, and how long to hold the setpoint before proceeding to the nextsetpoint. The Pattern Point also must indicate if data is to be recorded during the point (Auto Grab or Grab) and it should includeinstructions for the Operator (Operator Prompt) and designate the Phase.

The first line of the Edit Pattern Window displays the Current Point. ex. Current Point 1 in the example above. The FunctionButtons on the bottom of the Edit Report window are used to Add, Delete and toggle (Previous/Next) between Pattern Points.When the current point has been modified, click on the OK button.

The options for controlling the engine operating speed are located directly below the Current Point heading. There are twooptions for controlling the engine operating speed: Throttle (%), and Speed (RPM). By using different variations of load controlmethods (Valve (%), Torque (ft-lbs), Power (Hp), or Speed (RPM)) in combination with these settings, the operator can runa variety of tests. To the right of the Control Modes there is a box to enter the appropriate Unit of value for the current Point. Formore information about control modes, see Chapter 4, The Controller Interface.

The center of the Edit Pattern window displays the options for the Duration of the current Point. The administrator has theoption to chose from a variety of factors affecting the start of the current Point, including Stability, Operator Prompt, and PointDuration. Details for each of these sections are described in detail on the following page.

Below the Duration sections are the AutoGrab, Point Duration, “Go to” info, and Digital Outs sections. The AutoGrabfunction allows the administrator to determine if Data is to be grabbed at the end of each Point (No Change if Grab Data at theend of this point is checked beneath the Point Duration box), throughout the duration of the Point (At the start of point grabdata every ___ secs), or not at all (Off).

The elapsed time of each Point is entered in the Point Duration (secs) box. The determines the amount of time required beforethe next Point begins.

“Go to” Info allows the administrator to create a new Point that makes the Pattern return to a previous point. This allows theadministrator to duplicate stages of a Pattern without having to create them again. How many times a section of the Patternrepeats is determined by the number entered in the Go to count box.

The Digital Outs section allows the administrator to automatically turn relays on/off as part of a Point.

C CC

Pattern Runner

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Duration SettingsIn order to provide the administrator with greater flexibility, there are three setting that define how long the setpoint should be heldbefore proceeding to the next Point: Stability, Operator Prompt, and Phase.

Stability: The settings entered in the Stability section cause the system to wait to perform the functions specified in the currentpoint until the requirements specified by the administrator are met. The Stability section includes the Wait for Sensor, Waitfor Setpoint, and None check boxes.

If the Wait for Sensor box is checked, the setpoint will be held until a selected sensor has reached a predetermined value(Goal), within a certain tolerance (Tolerance), for a certain duration (Wait stability Secs). When using “Wait for Sensor”, the“Wait Stability Secs” won’t begin counting down until the sensor value is within the range defined by the Goal and the Tolerance.If the sensor value drifts outside the range during the wait time, the wait time will start over once the setpoint is back within therange.

If the Wait for Setpoint box is checked, the setpoint will be held until its value is reached within a certain Tolerance (Tolerance),for a certain duration (Wait Stability Secs). When using “Wait for Setpoint”, the “Wait Stability Secs” won’t begin counting downuntil the indicated control mode value is within the range determined by the setpoint and the tolerance. If the control mode value driftsoutside the tolerance during the wait time, the wait time will start over once the control mode value is back within the range.

Note: If a Pattern is suspended or restarted after a particular sensor or setpoint has been reached, the system may not be ableto resume if the sensor or SetPoint value has traveled outside of its specified Goal and Tolerance. ex. If a point was set tobegin when the engine temperature has reached 180° with a setpoint of 180 and a tolerance of five, and the Pattern has beensuspended after the engine temperature has reached 205°, the Point will not Proceed to the next Point if the test is restartedwithout allowing sufficient time for the engine to cool.

Operator Prompt: The settings entered in the Operator Prompt section allow the administrator to display instructions for theoperator and to pause the current pattern until the operator responds. The Operator Prompt section includes the OperatorPrompt text box and the Show Status on Handheld, Wait for Continue, and Allow skip of ___ points check boxes.

If the Wait for Continue box is checked, the Pattern will not proceed to the next point until the Operator touches the “Continue”button that will be displayed on the Handheld Controller.

If the Allow Skip of Points box is checked, a skip button will appear on the Handheld Controller. If the Operator touches theSkip button, the Pattern will skip the indicated number of Pattern points.

Pattern Runner

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Duration Settings (continued)Point Duration: In this method, the administrator simply enters how many seconds the current setpoint is to be held beforecontinuing to the next pattern point. The number of seconds is entered at the Point Duration input box.

Note: It is possible to use any of the above methods for determining setpoint duration simultaneously. The dynamometer willfirst try to satisfy the Stability settings, then the Operator Prompt settings, and finally the Point Duration settings as they appearin the Edit Report window, from left to right.

Grabbing Data PointsThe AutoGrab function allows the administrator to determine if Data is to be grabbed at the end of each Point (No Change ifGrab Data at the end of this point is checked beneath the Point Duration box), throughout the duration of the Point (At the startof point grab data every ___ secs), or not at all (Off).

Selecting No Change keeps the AutoGrab setting the same as in the preceding Pattern point.

Selecting At the start of point grab data every ___ secs and entering a value defines the time interval that data will becaptured during the current Pattern point.

Selecting Off disables the AutoGrab feature.

PhasesPhases allow acquired data to be grouped for reporting purposes. To assign the data collected during the current setpoint to aparticular Phase, simply select the desired Phase from the pull-down. To create a new Phase, type the name of the new phasein the pull-down menu. Phases are explained in detail in Chapter 6, Report Generator.

Function ButtonsPrevious: Makes the preceding Pattern point active (if one exists) to allow it to be edited. Click once to restart the current point.To activate the previous point, click twice.

Next: Advances to the next Pattern point (if one exists) to allow it to be edited.

Add: Inserts a copy of the current Pattern point and makes it active for editing.

Delete: Deletes the current Pattern point.

OK: Exits the Edit Pattern window.

Saving a PowerNet PatternWhen finished editing the Pattern, it will be saved with the active DataSpace or Tem-plate. The Pattern can also be saved as its own file by selecting Save As from PatternRunner’s File pull-down menu.

Running a PowerNet PatternWhen all of the Pattern Points have been edited and saved, the Pattern is now ready to run. To run a Pattern, click on the Playtab. This will display the time remaining for the current Pattern Point. Clicking the Pause tab pauses the current Pattern andchanges the function of the Play tab to Stop. To resume the Pattern, click the Pause tab again. To stop the Pattern, click onthe Stop tab. The <<Previous and Next>> tabs are used to navigate to different points in the Pattern.

The Tools MenuThe Tools Menuis currently grayed oiut, as there are no options available at this time.

Pattern Runner

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47

Report Generator

- CHAPTER 6 -

Report Generator

PowerNet 2.0


Report Generator

48

49

Report Generator

The Report Generator ProgramA copy of the data recorded during a dynamometer test should be saved following each test session. The Report Generatorallows the operator to arrange the data into a meaningful visual format. Customer, engine, and set up information can be put intoUser Tables and Paragraphs. The information gathered during a test can then be arranged in a Data Table, Spreadsheet,and/or Graph. Report formats can be created and edited before or after a DataSpace has been created.

There are two types of information tables, a User Table and a Data Table. A User Table provides blanks for the operator toenter specific information about the test being performed. This can include, but is not limited to: Customer Information, EngineInformation, Test Specific Information, etc. A Data Table contains information gathered from the attached sensors during atest, and displays only that information that is specified for that particular Data Table, such as maximum and minimum values.

The data gathered during a test can also be arranged in a Spreadsheet and/or Graph. A Spreadsheet is a computergenerated arrangement of the test data into rows and columns. A Graph is a drawing representing the relationship between twosets of data. One set, such as gathered information, is represented on a vertical scale or axis, the other, such as time or otherdata, is represented on a horizontal scale or axis.

In addition to tables, graphs, and spreadsheets, information can also be entered into a Paragraph. A Paragraph is typicallyused to enter notes, disclaimers, descriptions, etc. relating to a specific test or stage of testing.

Report Generator Window Pull-Down MenusThe Report Generator Window consists of the File, Edit, View, Import, Export, and Ignore List menus.

The File MenuFile Menu: The File Menu allows the user to access the Reporter printfeatures. The menu consists of Print Preview, Print, and Print Screen.

File > Print Preview: This selection allows the user to view the printedreport on screen. Once selected, a report preview appears (below right).From the preview, the user can print a hard copy of the report by clickingon Print in the upper left-hand corner.

The operator may print out reports that can be configured to display yourcompany’s logo and contact information. Contact your Power Test repre-sentative for assistance in creating a custom header.

Report Generator Window

Report Generator

50

File > Print: Displays a preview of the report and opens up the printproperties screen.

The Edit MenuEdit Menu: The Edit Menu consists of one selection, Edit Report.

*Edit > Edit Report: This function allows the administrator to modify theactive data report.

* Note: Without logging in, many menu items will be grayed out and thecorresponding administrative functions can not be performed. All func-tions requiring login will be noted with an * throughout the rest of thischapter.

Click on Edit Report and a new window will appear. The Edit Reportwindow (shown right) allows the user to configure the printed reports andthe entry fields of User Tables, Data Tables, Graphs, Spreadsheets andParagraphs.

File > Print Screen: Sends a snapshot of the entire Commander screento the printer. It makes no difference which interface windows are open,some may be minimized. It simply takes a screen capture of whatever ison the screen at the time.

51

Report Generator

Using the Edit Report WindowFrom the Edit Report Window, the user can move, add, delete, copy and edit sections. The information displayed on thereport will display as it appears in the list. Clicking on a section highlights that section, and enables the function buttons on theleft side of the window.

Report Sections

Move Section Up

Move Section Down

Delete Section

Add Section

Copy Section

Edit Section

Edit Report WindowEdit Report Function ButtonsMove Section Up: Clicking this button will move the highlighted section up, changing the order in which information appears onthe final report.

Move Section Down: Clicking this button will move the highlighted section down, changing the order in which informationappears on the final report.

Delete Section: Clicking this button will delete the highlighted section.

Add Section: Clicking this button will bring up the Add Section window (above left), allowing the user the option of adding oneof five section types: User Table, Data Table, Graph/Spreadsheet, Paragraph, and Page Break, all of which are explainedthroughout this chapter.

Copy Section: Clicking this button makes a copy of the highlighted section and all of its properties. This is useful for creatinga similar section without having to create it from new.

Edit Section: Clicking this button allows the user to edit the particular section of the report that is highlighted. Additionally, theedit report window can also be accessed by double clicking on any highlighted section.

Creating and Editing Report Section TypesDetails for creating and editing User Tables, Data Tables, Graphs, Spreadsheets and Paragraphs are explained in detail onthe following pages.

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Creating a New User TableTo create a new User Table, select User Table from the list of section types under the Add Section (+) function of the mainEdit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the new User Tableto edit the new User Table.

Table Name

Field Name

Number of Columns Assigned to the Table

Report Fields

Navigational Buttons

Begin by assigning a name to the new User Table by entering a name in the Table Name text box. This will name the newUser Table. To change the name of a Report Field, click on the field name in the Report Field box. Entering a name in theField Name text box will change the name of the Report Field.

To add a Report Field, click on the Add Section (+) button. Report Fields can be also be moved up/down and deleted from theUser Table using the navigational buttons. The navigational buttons perform the same function as previously described inUsing The Edit Report Window section, found on page 49.

The user also has the option to choose how many columns are assigned to the table.

Note: It is recommended to keep the number of columns in a User Table a multiple of the number of fields. i.e. 3 fields - 1 or3 columns; 4 fields - 1,2 or 4 columns. This will help to ensure that the data is presented in an organized manner.

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Editing User TablesTo edit a User Table, highlight the desired table, and either click on the Edit Section button, or double click on the highlightedselection itself. The Edit Report window (shown below) will appear. The navigational buttons perform the same function aspreviously described in Using The Edit Report Window section, found on page 49.

To change the name of the User Table, highlightthe current name in the Table Name text box andeither press the delete key, or overwrite the cur-rent name with the new name.

To change the name of a Report Field, click onthe field name in the Report Field box. Next,either press the delete key, or overwrite the cur-rent name with the new name.

To add a new Report Field to the User Table, clickon the Add Section (+) button. Report Fields canbe also be moved up/down and deleted from theUser Table using the navigational buttons.

Note: A User Table is limited to 12 Report Fields.

The user also has the option to choose how manycolumns are assigned to the table.

Note: It is recommended to keep the number ofcolumns in a User Table a multiple of the numberof fields. i.e. 3 fields - 1 or 3 columns; 4 fields -1,2 or 4 columns. This will help to ensure that thedata is presented in an organized manner. Sample User Table

Examples of User Tables - As Printed (left) and On Screen (right)

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Creating a New Data TableTo create a new Data Table, select Data Table from the list of section types under the Add Section (+) function of the mainEdit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the new Data Tableto edit the table.

Table NameNumber of Columns Assigned to Table

FunctionAvailable Sensors

Reference SensorAdd Sensors to the Data Table Sensors List

Available PhasesData Table Sensors

Navigational ButtonsRemove Sensors from the list of Sensors

*Plot Individual Phases

*Requires Advanced Pattern Runner

Assign a name to the new Data Table by entering a name in the Table Name text box. This will name the new Data Table.

Report data is gathered from the sensors displayed in the Available Sensors list. This list displays all of the sensorsconnected to the system at the time of the report’s creation (available sensors may vary depending on version of software). TheData Table Sensors list displays all of the sensors whose data will be displayed on the final report. To add a sensor to the DataTable Sensors list, first click on a sensor from the Available Sensors list. The Available Sensors list displays all of thesensors currently connected to the system. Next, select a function to be performed on the sensor from the Function list(explained on the following page). Then click the Add button to add the selected sensor and function to be performed to the listof Data Table Sensors. To change the order in which the Data Table Sensor information appears on the printed report,highlight a sensor in the list, and click on the Navigational Buttons to the left of the Data Table Sensors list.

The user also has the option to choose how many columns are assigned to the table.

Note: It is recommended to keep the number of columns in a User Table a multiple of the number of fields. i.e. 3 fields - 1 or3 columns; 4 fields - 1,2 or 4 columns. This will help to ensure that the data is presented in an organized manner.

Reference SensorsSelecting the Reference Sensor function will display a particular sensor values and it’s correlation to another sensor’s greateror lower value. i.e. Speed at Peak Torque.

To display Reference Sensor data in the final report, choose a Reference Sensor from the drop-down menu. The list of sensorsavailable as Reference Sensors is the same as the list of sensors available in the Available Sensors list. When the desiredreference sensor has been selected, click on Hi Ref to display the peak value, or Lo Ref to display the low value.

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Editing Data TablesTo edit a Data Table, highlight the desired table, and either click on the Edit Highlighted Section button, or double click on thehighlighted selection itself. The Edit Report window (shown below) will appear. The navigational buttons perform the samefunction as previously described in Using The Edit Report Window section, found on page 49.

To add a sensor to the Data Table Sensors list,first click on a sensor from the Available Sen-sors list. Next, select a function to be performedon the sensor from the Function list (explainedbelow). Then click the Add button to add theselected sensor and function to be performed tothe list of Data Table Sensors. To change theorder in which the Data Table Sensor informa-tion appears on the printed report, highlight a sen-sor in the list, and click on the Navigational But-tons to the left of the Data Table Sensors list.

Phases (Optional)A Phase represents a segment of the data gath-ered during a test. The Phases section displaysthe list of stored phases from the currentDataSpace. Selecting a phase will include it inthe generated report. If the Individual Phasesbox is left unchecked, all function values for theincluded Data Table Sensors will be calculatedby grouping data from the selected phases. If theIndividual Phases box is checked, the functionvalues will be calculated on a per phase basis.i.e. If there were six phases selected, and threesensors in the Data Table Sensors list, the reportwould yield a total of 18 values. Sample Data Table

The Function ListThe Function List defines which data points will be displayed in the Data Table.

First: This will display the first value of the sensor selected. If “Individual Phases” is also selected, it will display the firstvalue of the sensor selected for each selected phase.Last: This will display the last value of the sensor selected. If “Individual Phases” is also selected, it will display the lastvalue of the sensor selected for each selected phase.Delta: This will display the difference between the first and last value of the sensor selected. If “Individual Phases” isalso selected, it will display the difference between the first and last value of the sensor selected for each selectedphase.Average: This will display the average value of the sensor selected. If “Individual Phases” is also selected, it willdisplay the average value of the sensor selected for each selected phase.Peak: This will display the largest value of the sensor selected. If “Individual Phases” is also selected, it will display thelargest value of the sensor selected for each selected phase.Low: This will display the lowest value of the sensor selected. If “Individual Phases” is also selected, it will display thelowest value of the sensor selected for each selected phase.

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Creating a New GraphTo create a new Graph, select Graph/Spreadsheet from the list of section types under the Add Section (+) function of themain Edit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the new Graphto edit the graph.

Graph NameSection Type (Graph/Spreadsheet)

X-AxisAvailable Sensors

Use Reference DataHide Symbols

Plot Individual Phases

Available PhasesY2

Included Sensors

Size (Height/Width)Copy to Graph View

Begin by selecting Graph under Section Type. Next, create a name for the new Graph by entering a name in the Headingtext box.

Choose which sensors to display on the X Axis and Y Axis of the Graph. The X Axis menu contains the sensors available fordisplay on the X (horizontal) axis of the Graph. The graph can only display 1 (one) sensor on the X axis per graph. Select asensor from the X Axis pull-down menu. Clicking on the Hide Symbols box will create lines on the graph without showing asymbol at the individual points. If the Plot Individual Phases box is left unchecked, the graph will show each IncludedSensor as a continuous line throughout all of the phases selected. If the Plot Individual Phases box is checked, eachIncluded Sensor will be graphed with multiple lines corresponding to each phase selected.

A Phase represents a segment of the data gathered during a test. The Phases section displays the list of stored phasesfrom the current DataSpace. Selecting a phase will include the selected phase in the generated report.Note: Phases are only available with the Advanced Pattern Runner software.

The Available Sensors list displays the sensors available for display on the Y (vertical) Axis. The sensor displayed on the YAxis is displayed on the left side of the graph. To add a sensor to the Included Sensors list, click on a sensor from theAvailable Sensors list, then click on the Add button. To remove a sensor from the Included Sensors list, click on the sensorto be removed, and click the Remove button.

Clicking the Use Reference Data check box will plot Reference Data on the Graph in addition to the data being recordedduring the test. Reference Data is data that is typically used for monitoring and comparing the results of the test. Instructionsfor creating and loading Reference Data can be found in Chapter 3, Main Display and is further discussed in Chapter 7, Add-In Programs.

The Y2 feature allows the user to display a second sensor’s data on the Y2 (vertical, right) axis of the Graph. To assign a sensorto the Y2 Axis, click on that sensor in the Included Sensors box, then check the Y2 box.

The user has the option of setting the Height and Width of the Graph, determining the size of the Graph on the generated report.

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Editing GraphsTo edit a Graph, highlight the desired graph, and either click on the Edit Highlighted Section button, or double click on thehighlighted selection itself. The Edit Report window (shown below) will appear. The navigational buttons perform the samefunction as previously described in Using The Edit Report Window section, found on page 49.

If a Graph is selected the user has the ability todecide which sensors they wish to display on theX Axis and Y Axis of the Graph. The X Axismenu contains the sensors available for displayon the X (horizontal) axis of the Graph. The graphcan only display 1 (one) sensor on the X axis pergraph. Clicking on the Hide Symbols box willcreate lines on the graph without showing a sym-bol at the individual points. If the Plot IndividualPhases box is left unchecked, the graph will showeach Included Sensor as a continuous linethroughout all of the phases selected. If the PlotIndividual Phases box is checked, each In-cluded Sensor will be graphed with multiple linescorresponding to each phase selected.

The Available Sensors list displays the sensorsavailable for display on the Y (vertical) Axis. Toadd a sensor to the Included Sensors list, clickon a sensor from the Available Sensors list, thenclick on the Add button. To remove a sensor fromthe Included Sensors list, click on the sensor tobe removed, and click the Remove button.

Sample Graph

Clicking on the Copy To Graph View tab takes the data created from the report and displays it in a new window. The NewGraph View will have all of the same properties of the graph it was created from. A Graph View displays recorded data from atest and is refreshed every time a data point is recorded. This is different from the real-time chart, which displays dataregardless if data points are recorded or not.

Note: Clicking Copy To Graph View opens a Graph in a new window. Any changes made to the New Graph View will not besaved as part of the report. Consequently, any changes made to the Graph from the Edit Graph window will not appear on theNew Graph View unless the Copy To Graph View tab is clicked again, opening a New Graph View in a new window.All functions and properties of the graph created by clicking the Copy To Graph View button are the same as those for a NewGraph View, as described on page 60.

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Creating a New SpreadsheetTo create a new Spreadsheet, select Graph/Spreadsheet from the list of section types under the Add Section (+) functionof the main Edit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the newSpreadsheet to edit the spreadsheet.

Spreadsheet Name

Section Type (Graph/Spreadsheet)Enable Grouping

Available SensorsKey Sensor

Group By Sensor*Group By Phase

*Available PhasesIncluded Sensors

Remove from the List of Sensors


Begin by selecting Spreadsheet under Section Type. Next, create a name for the new Spreadsheet by entering a name inthe Heading text box.

The Available Sensors list displays the sensors available for display on the Spreadsheet. To add a sensor to the IncludedSensors list, click on a sensor from the Available Sensors list, then click on the Add button. To remove a sensor from theIncluded Sensors list, click on the sensor to be removed, and click the Remove button.

If a Spreadsheet is selected from the Section Type, the user has the option of clicking on the Enable Grouping check box. Ifthe Enable Grouping check box is not selected, the Included Sensors will display as a continuous column throughout thewhole Spreadsheet. If the Enable Grouping check box is selected, the user will have option to the select a Key Sensor (thesensor that data is matched to, typically speed), and whether the data will be grouped by Sensor or Phase in the final report.By selecting Sensor, the data is paired by sensors and displayed under each phase. By selecting Phase, the data is groupedby phase under each sensor.

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Editing SpreadsheetsTo edit a Spreadsheet, highlight the desired spreadsheet, and either click on the Edit Highlighted Section button, or doubleclick on the highlighted selection itself. The Edit Report window (shown below) will appear. The navigational buttonsperform the same function as previously described in Using The Edit Report Window section, found on page 49.

The Available Sensors list displays the sensorsavailable for display on the Spreadsheet. To adda sensor to the Included Sensors list, click on asensor from the Available Sensors list, then clickon the Add button. To remove a sensor from theIncluded Sensors list, click on the sensor to beremoved, and click the Remove button.

If a Spreadsheet is selected from the SectionType, the user has the option of clicking on theEnable Grouping check box. If the Enable Group-ing check box is not selected, the Included Sen-sors will display as a continuous column through-out the whole Spreadsheet. If the Enable Group-ing check box is selected, the user will have op-tion to the select a Key Sensor (the sensor thatdata is matched to, typically speed), and whetherthe data will be grouped by Sensor or Phase inthe final report. By selecting Sensor, the data ispaired by sensors and displayed under eachphase. By selecting Phase, the data is groupedby phase under each sensor.

Example of a Spreadsheet (Grouped by Sensor)

Example of a Spreadsheet (Grouped by Phase)

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Creating a New ParagraphTo create a new Paragraph, select Paragraph from the list of section types under the Add Section (+) function of the mainEdit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the new Paragraphto edit the Paragraph.

Paragraph Name

Text Input Box

Browse for Text File

Make Paragraph Importable

Assign a name to the new Paragraph by entering the name in the first box. This will name the new Paragraph. To create anew Paragraph, click anywhere in the Text Input Box and enter the information you wish to appear on the report.

Clicking the Browse for text file opens a window (shown below) which displays available text files. Opening the .txt file willimport the text into the box.

Selecting the Importable option displays the paragraph input box on the main form of the Report Generator, as explained onpage 58. From this window, the user can import text without having to go into the edit feature.

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Editing ParagraphsTo edit a Paragraph, highlight the desired table, and either click on the Edit Highlighted Section button, or double click onthe highlighted selection itself. The following Edit Report window (shown below) will appear.

The name of the paragraph can be changed byentering a new name into the Paragraph Nametest box. The paragraph text can be entered intothe Text Input Box.

Clicking the Browse for text file opens a win-dow which displays available text files. Openingthe .txt file will import the text into the box.

Selecting the Importable option displays theparagraph input box on the main form of the Re-port Generator, as explained on page 62. Fromthis window, the user can import text without hav-ing to go into the edit feature.

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The View MenuThe View Menu: The View menu item lists only one option - New Graph View.

View > New Graph View: Automatically creates a new Live Graph andopens the Properties window of that graph (described below). In addition,right-clicking the New Graph View will display the Options window.

New Graph ViewNew Graph View displays recorded data from a test and is refreshed every time a data point is recorded. This is different fromthe real-time chart, which displays data regardless if data points are recorded or not.

Example of a New Graph View New Graph View Options

New Graph View PropertiesThe Properties window opens automatically when a new graph is created. In addition, right-clicking the New Graph View willdisplay the Properties window. The users has the following options for modifying the New Graph View.

Print: Prints the current New Graph ViewSymbols: Displays the symbols indicating each point where data has been recorded.Legend & Title: Displays the Legend (displayed at the bottom of the graph) and the Title (displayed at the top) of the graph.Grid Lines: Displays the grid lines of the New Graph View.Undo All Changes: Resets any changes made using the Zoom, Move and Scale functions.Zoom: Allows the user to zoom-in on a specific point on the graph while retaining the X axis and Y axis.Move: Allows the New Graph View to be repositioned within the window.Scale: Allows the New Graph View to be re-sized, enlarging and reducing the actual size of the graph.Properties: Opens the Properties window.

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Creating a New Graph ViewTo create a New Graph View, select New Graph View from the View Menu in the Report Generator. This will automaticallyopen the Properties window for the New Graph. Begin by creating a name for the New Graph View by entering a name in theGraph Name text box.

Graph Name

X-AxisUse Reference DataPlot Individual PhasesAvailable Sensors

Add Sensor to the List of Included Sensors

Y2

Included Sensors

*PhasesRemove Sensors from the List of Included Sensors


Choose which sensors to display on the X Axis and Y Axis of the New Graph. The X Axis menu contains the sensorsavailable for display on the X (horizontal) axis of the New Graph. The graph can only display 1 (one) sensor on the X axis pergraph. The Available Sensors list displays the sensors available for display on the Y (vertical) axis. The sensor displayed onthe Y Axis is displayed on the left side of the graph. To add an additional sensor to the list of Included Sensors, click on a sensorfrom the Available Sensors list, then click on the Add button. The Y2 feature allows the user to display a sensor’s data on theY2 (vertical, right) axis of the New Graph. To assign a sensor to the Y2 Axis, click on that sensor in the Included Sensors box,then check the Y2 box.

Below the X Axis pull down menu are two options: Use Reference Data and Plot Individual Phases. Clicking the UseReference Data check box will plot Reference Data on the Graph in addition to the data being recorded during the test.Reference Data is data that is typically used for monitoring and comparing the results of the test. Instructions for creating andloading Reference Data can be found in Chapter 3, Main Display and further discussed in Chapter 7, Add-In Programs. If thePlot Individual Phases box is left unchecked, the graph will show each Included Sensor as a continuous line throughout allof the phases selected. If the Plot Individual Phases box is checked, each Included Sensor will be graphed with multiplelines corresponding to each phase selected.

Editing a New Graph ViewTo change the name of the New Graph, enter the new name in the Graph Name text box. Choose which sensors to display onthe X Axis and Y Axis of the New Graph. To add an additional sensor to the list of Included Sensors, click on a sensor fromthe Available Sensors list, then click on the Add button. The Y2 feature allows the user to display a sensor’s data on the Y2(vertical, right) axis of the New Graph. To assign a sensor to the Y2 Axis, click on that sensor in the Included Sensors box,then check the Y2 box.

Clicking the Use Reference Data check box will plot Reference Data on the Graph in addition to the data being recordedduring the test. If the Plot Individual Phases box is left unchecked, the graph will show each Included Sensor as acontinuous line throughout all of the phases selected. If the Plot Individual Phases box is checked, each Included Sensorwill be graphed with multiple lines corresponding to each phase selected.

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The Import MenuImport Menu: The Import Menu contains one option, Text File.

Import > Text File: If a Paragraph has been made importable (asintroduced on page 59), this menu item will become active and thename of the paragraph will be listed in this menu. If there is text withinthe saved paragraph, a check mark will appear next to its name. If noimportable paragraphs are available, the tab will display the text “NoImportable Paragraphs”.

The Export MenuExport Menu: There are three options available for the Export Menu: As .chm file, Excel and Text File. By selecting thoseoptions, the user can export the report to the desired file type.

Export > As .chm file: This menu item gives the user the option to exporta report as a .chm file. A .chm file is a compressed html page. This typeof file normally used by Microsoft to create help files is perfect for creatingsmall files easily e-mailed. By compressing the html page, not only is thefile size made significantly smaller, it also includes all of the support files.To create a .chm file simply click on the menu item and choose a file name.The Reporter program will then recreate the html page, compress it andsave it to the location specified. A .chm file may be requested by yourPower Test representative when providing technical assistance.

Export > Excel: This allows the user toexport data directly into Microsoft Ex-cel. The administrator must choosewhich Excel template will be availableto the operator to export the data into.All available Excel templates (.xlt files)will be listed under the arrow of the “Se-lect Template” menu.Note: All available templates must havea sheet labeled “Data”.

Export > Text File: This allows the operator to export all the data from aDataSpace to a tab delimited text file (.txt). By exporting data to this typeof file, the data may be imported into virtually any spreadsheet program.Simply click on the “Text File...” menu item, select a file name and clickon “Save”. The default path is C:\Program\PowerNet\Commander 2.0.

The Ignore List*Ignore List: The Ignore List lists all of the phases in the DataSpace. Ifa phase is added to the Ignore List, the data from that particular phasewill not be displayed in the entire report. To eliminate (but not delete) anyparticular phase from the entire report, simply check the phase nameunder this menu item.

*Requires Advanced Pattern Runner software.

PowerNet 2.0


- CHAPTER 7 -

Workstation

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Workstation

The PowerNet WorkstationThe PowerNet Workstation is a pedestal mounted unit that is placed inside the test cell next to the dynamometer. TheWorkstation performs all sensor calibration, dynamometer control, and data acquisition. It sends data and receives commandsvia an ethernet link with the PowerNet Commander PC.

The Workstation is engineered to stand up to the harsh environments inside of the testcell. The unit houses a 10.4" color touch screen and front-mounted temperature andpressure input jacks. The pedestal mount allows its display to rotate 350° for viewing atany angle.

The Emergency Stop Button is used to activate PowerNet’s emergency shut down se-quence in the event of an emergency. The Button will remain locked, preventing thesystem from operating until it is physically pulled out to the run position.

The System Power Switch, located below the Emergency Stop Button, is used to activatethe Work Station. Pressing the button will apply power to all of the Work Station’s compo-nents and begin the start-up cycle.

The Work Station is equipped with a color LCD Touch Screen for displaying data andaccepting user input. The Touch Screen has been designed to provide a simple, easy-to-use interface between the operator and the PowerNet system. Buttons are pressed bylightly touching the touch screen in the desired area. The Touch Screen is a highly accuratedevice that must be kept clean to ensure proper operation.

Workstation Welcome Screen

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Using the Workstation Touch ScreenThe PowerNet Workstation uses a color flat-panel LCD touch screen to display important information and accept operatorinput. The touch screen has a sealed gasket to prevent damage from liquids entering the cabinet. Proper operating andmaintenance procedures should be observed to keep the touch screen in peak operating condition.

The touch screen accepts user input by sensing the electrical resistance generated by an object touching the screen. Thisresistance generates values on an x and y axis, allowing the Work Station to compute where the screen is being touched.

Note: The touch screen works by sensing electrical resistance and not by sensing pressure. There is no need to applypressure to the screen.

Touch screen maintenance is a simple yet important procedure. The build up of foreign matter on the screen’s surface isinevitable in an industrial environment. This buildup inhibits the screen’s function. If the buildup is large enough, the touchscreen will see this as a resistance and mistake it for an operator’s finger. Use nonabrasive glass cleaner and a soft, lint-freecloth to remove any smudges or fingerprints from the screen’s surface. Do not use a petroleum based cleaner on the touchscreen. Always shut down the Workstation before cleaning the screen.

ConnectionsThe various input jacks and wiring connectors on the Workstation allow the unit to send and receive data with its varioussensors and controls:

T/C Inputs: Accepts Type K thermocouple probes

Pressure Inputs: Accepts male pressure couple

Ethernet Jack: Accepts coax Ethernet cable

Load Valve and Throttle Actuator Jacks: Accepts threaded connector

Speed and Load Sensor Jacks: Accepts sensor input from magnetic speed pickups and strain gauge load cell

Relayed Power Binding Posts:Accepts stripped wire or banana plugs.

The System Power Switch is used to activate the Work Station. Pressing the button will apply power to all of the Work Station’scomponents and begin the start-up cycle.

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Workstation Main MenuAfter activating the PowerNet Workstation, the Welcome Screen (shown below) will be displayed. From the WelcomeScreen, the user has can select from the following options: Run Mode, Valve/Throttle calibration, Pressures calibration,Temperature calibration, and Primaries calibration.

In addition to the options displayed on the left hand of the screen, the operator is provided with a Help function. The Helpscreen provides the user with information regarding the function of each of the touch screen menu options. To use the Helpscreen, touch a button at the bottom of the screen, then touch an area where assisted is needed. A Help window will appear.

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Run ModeTouching the Run Mode button will open the run mode screen, activating a series of events that begin testing. The screen’sbackground color indicates the status of the Work Station. Red indicates that Emergency Stop has been activated, greenindicates that a test is underway (engine speed >25rpm) and yellow (as shown below) indicates that PowerNet is ready tobegin testing. Speed Display Torque Display Power Display

Engine Start Button

Torque Tare Button

Engine Stop Button

Emergency Stop Button

Return to Main Menu Button

Temp Display Valve Indicators Pressure Display

Run Mode Function ButtonsEngine Start Button: Touching this button activates the engine’s starting system if equipped.

Engine Stop Button: Touching this button stops the engine if equipped.

Emergency Stop Button: Touching this button activates the Emergency Stop procedure.

Return to Main Menu Button: Touching this button returns the Workstation to the Main Menu but does not stop thecurrent test.

Speed Display: Displays engine speed in RPM.

Torque Display: Displays engine torque in foot pounds (ft-lbs).

Power (Hp) Display: Displays engine power in horsepower (HP).

Temp Display: Displays available temperatures in degrees Fahrenheit (°F). To display alternate temperatures, presseither side of the box to advance or return to an alternate temperature reading.

Manual/Automatic Throttle and Valve Indicators: Indicates throttle/valve position and if PowerNet is in manual orautomatic throttle control/valve mode.

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Workstation

Run Mode Function Buttons (continued)Pressure Display: Displays available pressures in pounds per square inch (psi). To display alternate pressures, presseither side of the box to advance or return to an alternate pressure reading.

Torque Tare Button: Touching this button sets the current torque reading to zero.

CalibrationCalibration procedures have been provided for each of sensor. Proper calibration is necessary for accurate operation. Eachtype of sensor has its own specific calibration procedure. The Primary, Pressure and Temperature calibration screensinclude on-screen instructions that guide you through the calibrate procedure.

Methods of CalibrationSimple Offset Procedure: Using the Simple Offset Procedure, a sensor’s offset is calculated using one point. The properreading for the sensor being offset is entered in the actual display. The Workstation then calculates the offset and applies itto the sensor.

Two Point Procedure: Using the Two Point Procedure is a more accurate method of calibration. It uses the sameprocedure for calculating offset as the simple offset method but adds a second point to the calibration and calculates thesensor’s rise over the run between the two points (multiplier). This second point is usually set with a known input (regulatedpressure for pressures, hand tach reading for speed, etc.). The points entered should be within the range intended for useduring a typical engine test.

Multiplier Procedure: The sensors supplied with PowerNet are factory calibrated for a high level of accuracy. The SensorMultiplier Table (shown below) displays the correct multiplier values for each of your sensors. Enter this value in themultiplier box and set the sensor offset using the simple offset method.

Touching any of the input boxes will open the numeric keypad (shown right). Enter the desiredvalue using the keypad and click Clear to clear the current value, Accept to accept the currentvalue and return to the Calibrations screen, or Cancel to return to the Calibrations screen withoutentering a value.

SENSOR MULTIPLIER VALUESTANDARD SPEED 4005K LOAD CELL (TORQUE) 291,6674K LOAD CELL (TORQUE) 233,333500 PSI 100250 PSI 50200 PSI 4050 PSI 105 PSI 12 PSI .4BAROMETRIC PRESSURE (ATM) .8702+/- 15 PSI 6

Sensor Multiplier Table

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Valve/Throttle CalibrationTouching the Valve/Throttle button in the Main Menu calls up the Valve and Throttle Calibration Screen. This screen allowsthe operator to calibrate PowerNet’s throttle control motor and high speed load control valve. The slider bars to the rightdisplay the current position of throttle and valve. Touching on either of the sections allows the operator to manually controlthe throttle and valve positions. Zero Valve Cycle Valve

Analog Throttle Adjustment

Non-Analog Throttle Adjustment

Return to Main Menu

Valve CalibrationZero Valve: Touching this button cuts the power to the load valve, allowing the operator to set the zero point of the servo valve.The zero point is manually set by matching the alignment marks on the load controller’s gear faces.

Cycle Valve: Touching this button cycles the high speed load control valve.

Note: During periods of low usage, it is recommended to cycle the valve at regular intervals to prevent binding.

Throttle AdjustmentIf “There is No Analog Throttle Controller” is selected from the Dynamometer Setup section of the Primaries Calibration Screen, thethrottle will need to be manually adjusted using the span and zero sliders shown in the example above. Instructions are providedon the following page for calibrating the Analog Smart Throttle.

With each new engine being tested, the Throttle Actuator span and zero position will need to be adjusted. This is to ensure properoperation during testing that could possibly be affected by the distance between each new engine and the actuator.

Before making any adjustments to the Throttle, the throttle position must be set at zero percent (0%) at the Workstation inorder to avoid any confusion of throttle placement.

Make a visual inspection of the actuator. There should be little-to-no slack in the cable between the two connection points. Inmost cases, a value of “0” will be entered in the first three boxes. If your engine is shut down using the throttle, or requires aslight increase to start the engine, these values will vary according to application.

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Throttle CalibrationThe 1st box, Zero Throttle Pos, represents the position of the actuator when set at 0% throttle, or low idle. This value must begreater than or equal to the value entered in the 2nd box.

The 2nd box, Start Throttle Pos, represents the position of the actuator required to start the engine. In some circumstances, anincrease in throttle is required to start the engine. This value should be greater than or equal to the value entered in the 1st box.

The 3rd box, Stop Throttle Pos, represents the position of the actuator required to stop the engine. In some circumstances, thethrottle will return beyond the low idle position, resulting in stopping the engine.

The 4th box, Full Throttle Pos, represents the position of the actuator that is full throttle. This number will always be 100%.

Note: On most engines, the first 3 settings shown at the left will be at zero. The lastsetting, Actuator % that is 100% Throttle, will be directly dependent upon youradjustment of the throttle control actuator and your engine being tested. You willwant to visually inspect the throttle control actuator before each engine test andreadjust before the performance testing of each NEW engine.

Smart Throttle Calibration (if equipped with Smart Throttle)With each new engine being tested, the Smart Throttle will need to be adjusted. This is toensure proper operation during testing that could possibly be affected by the distancebetween each new engine and the actuator.

Before making any adjustments to the Smart Throttle, the throttle position must be setat zero percent (0%) at the Controller Interface in order to avoid any confusion ofthrottle placement.

Make a visual inspection of the actuator. There should be little-to-no slack in the cablebetween the two connection points. In most cases, a value of “0” will be entered inthe first three boxes. If your engine is shut down using the throttle, or requires a slightincrease to start the engine, these values will vary according to application. The throttle span and zero position can be adjusteddirectly from the back of the throttle control actuator as described below.

Note: Before adjusting to 100% throttle from the actuator, begin by pressing the decrease span button for 10 seconds. This willdecrease the span, and reduce the risk of damaging the engines throttle as a result of over travel.

Depress the Throttle Override switch to the 0% position. When depressed, the shaftwill release, allowing the operator to adjust the zero position by hand. When released,the throttle actuator will return to the position specified at the Controller Interface,which should be 0%.

To set the maximum throttle, depress the Throttle Override switch to the 100% posi-tion. This will move the throttle position to 100 percent. Keeping the Override switchat 100%, depress the throttle span switch in either direction to obtain the correct span.When the Throttle Override switch is released, the throttle actuator will return to theposition specified at the Controller Interface, which should be 0%.

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Pressure CalibrationPressure calibration can be achieved with three methods. A Simple Offset Procedure can be exercised by simply entering thecorrect pressure and selecting adjust offset only. A Two Point calibration procedure allows you to enter two calibration pointswith a known pressure input. The Multiplier based calibration uses the factory specified multiplier value to determine propersensor reading. The multiplier method is recommended. Touching the Pressures button in the Main Menu calls up thePressure Calibration Screen. This screen allows the operator to calibrate each of PowerNet’s pressure transducers.

Current Value Previous Current Next

Offset Only Button

Slope/Offset Button

Enter Actual Value Here

Accept Button

Enter Known Value Here

Accept Button

Multiplier Display

Return to Main Menu

Sensor Voltage Undo Change Return to Default

Current Value: Displays the current pressure value for the selected sensor

Previous/Next Buttons: Touching this button toggles between the available pressures.

Current: Displays the current pressure sensor number

Offset Only Button: Touching this button activates single point offset calculation, allowing the user to set the sensor’s offsetwith one input value instead of using the two point calibration method.

Slope/Offset Button: Touching this button activates the two point slop calibration method. Enter a value in the window to theright and click the Accept button to accept the entered value.

Multiplier Display: Factory calibrated gauges have specific multiplier values based on the senor’s operating range. A sensorcan be calibrated by touching this box and entering the proper value. Once entered, press the Accept button to accept theentered value.

Sensor Voltage Display: Displays the selected sensor’s voltage.

Undo Change: Touching this button reverses the most recent calibration change.

Return to Default: Touching this button all settings to their factory calibrated values.

Return to Main Menu: Touching this button returns to the Main Menu screen.

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Temperature CalibrationTemperature calibration is a simple offset calculation procedure. The thermocouples supplied with PowerNet are factorycalibrated for proper operation. If a thermocouple is reporting an incorrect temperature, it can be corrected with a simple, onepoint offset calculation procedure. Touching the Temperatures button in the Main Menu calls up the Temperature CalibrationScreen. This screen allows the operator to calibrate the offset for each of PowerNet’s thermocouple probes.

Current Temp Previous Current Next

Enter Offset Value Here

Adjust Button

Reset Button

Return to Main Menu

Sensor Voltage Undo Change Return to Default

Current Value: Displays the current temperature value for the selected sensor

Previous/Next Buttons: Touching this button toggles between the available pressures.

Current: Displays the current temperature sensor number

Enter Offset Value Here: Touching this button activates the keypad, allowing the user to enter the determined temperature.

Adjust Button: Touching this button sets the current sensor to display the temperature entered in the Enter Offset ValueHere box.

Reset Button: Touching this button resets the current sensor to its factory calibrated values.

Sensor Voltage Display: Displays the selected sensor’s voltage.

Undo Change: Touching this button reverses the most recent calibration change.



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Primaries CalibrationThe Primaries Calibration screen contains the calibration sections for all other sensors connected to the system, including,but not limited to: Speed, Torque, and Auxiliary sensors. Touching any of the Sensor Selection Buttons will open thecalibrations screen for that particular sensor. If more than six (6) sensors are connected, the toggle buttons (as previouslyexplained) will appear.

In addition to sensor calibrations, the operator can view the Calibration Log, reset the system to Factory Defaults, and enterthe Dynamometer Setup screens.

Sensor Selection Buttons

View Calibration Log

Return to Main Menu

Return to Default Dyno Setup

Sensor Selection Buttons: Touching any of the Sensor Selection Buttons will open the calibrations screen for that particularsensor.

View Calibration Log: Touching this button opens the calibration log (shown below), allowing the operator to view whatcalibration changes have been made.

Dyno Setup: Touching this button opens the Dyno Setup screen, as explained on the following page.



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Dynamometer SetupTouching the Dynamometer Setup button on the Primaries Calibration screen opens the Dynamometer Setup screen. Fromthis screen, the operator can choose the settings the valve position during an E-Stop, Remote Start, and OverSpeed Reset.

Additionally, the operator can choose how many dynamometers are part of the system, what type of throttle controller isbeing used (analog or non-analog), and whether or not the Stop Relay is to be used with OverSpeed.

Touching the Advanced Dynamometer Setup button opens the Advanced Dynamometer Setup screen.

E-Stop Valve Open: This setting determineshow much the valve opens during an EmergencyStop. ex. A setting of 100% opens the valvecompletely during an E-Stop, flooding the waterbrake and abruptly stopping rotation of theengine.

Remote Start Max On Time: This settingdetermines how long the remote start will engagewhen depressed. If the engine does not startwithin the time allowed, the starting circuit willreset and the start button will need to be pressedagain.

Remote Start Arm Time: This settingdetermines the amount of time the operator hasto return to the Commander PC and start theengine before having to reset the startingsequence from the Workstation.

Throttle Controller Button: Touching this button sets whether or not there is an analog or non-analog starter throttle in use.If a non-analog throttle is being used, the throttle will have to be calibrated from the Throttle Calibrations screen.

Stop Relay w/OverSpeed: Touching this button selects whether or not the Stop relay will engage is an OverSpeed isdetected.

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Advanced Dynamometer SetupTouching the Advanced Dyno Setup button on the Dynamometer Setup screen opens the Advanced Dynamometer Setupscreen (shown below). From the Advanced Dynamometer Setup screen, the operator can set the values for the Fast and SlowAcquisition Rates, Manage IP Connections, and name and assign averaging values to available sensors.

Additionally, the operator can choose which servo is being used, customize E-Stop functions, and choose to display the RealTime Graph in Run Mode.

Fast Acquisition Rate: This setting determinesthe fast rate at which data is being acquired bythe system. Fast acquisition is used in the RunScreen only. In most cases, this setting shouldnot be changed from the factory default setting.

Slow Acquisition Rate: This setting determinesthe slow rate at which data is being acquired bythe system. Slow acquisition is used in all otherscreens. In most cases, this setting should notbe changed from the factory default setting.

Managing Connections by Number: Touchingthis button opens a keypad, allowing the operatorto enter the IP address from which theWorkstation is to communicate with. In mostcases, this setting should not be changed fromthe factory default setting.

Previous/Next: Touching this button togglesbetween the available sensors.

Standard Sensors: Touching the sensor list opens a keypad, allowing the operator to assign a name and number to thecurrent available sensor.

Number to Average: Touching this section opens a keypad, allowing the operator to enter the averaging value.]

The buttons on the left side of the screen perform the following functions.

First Button - Servo Selection: Touching this button sets whether or not the system is using a Silver or Gold servo.

Second Button - Emergency Stop will/will Not be triggered when there is no connection: Touching this button selectswhether or not the E-Stop relay will engage if connection to the system is lost.

Third Button - Emergency Stop will/will NOT be triggered when exiting Run Mode: Touching this button selectswhether or not the E-Stop relay will engage when exiting Run Mode.

Fourth Button - Emergency Stop will/will Not be triggered when there is no connection: Touching this button selectswhether or not the E-Stop relay will engage if connection to the system is lost.

Fifth Button - The E-Stop Relay will be triggered whenever E-Stop is triggered/only when engine is running: Touchingthis button selects whether or not the E-Stop relay will engage at any time, or only if the engine is running.

Sixth Button - The Real Time Graph will/will NOT be shown in Run Mode: Touching this button selects whether or notthe Real Time Graph will be displayed during Run Mode.

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PowerNet 2.0


- CHAPTER 8 -

Add-in Programs

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The Add-In ProgramsIn this chapter, some add-in programs will be introduced. For some systems, Security Editor and ECM Communicator arestandard components. All other add-in programs are optional, such as the Smoke Check Transfer program, Fuel Controllerand Gas Analyzer. All existing add-in programs are listed in the Add-Ins menu in the Main Display Window.

NOTE: The following are some examples of add-in options available for Power Test data acquisition systems. For instructionsand specifications for specified equipment, please consult the information provided with the option.

Security EditorSecurity Editor: The Security Editor is an administrative tool used to assign rights to operators.

To access the Security Editor program, the user must have full administra-tive rights. The administrator has to log in, even if they have logged in to theprogram.

Edit Users: The administrator can add, delete, or edit usernames, passwords, and security levels. To add a new user,click Add, and a New User will be added to the list of currentusers. To delete a user, highlight the user name and clickDelete.

NOTE: If there is only one user with full administrative rights inthe list, the program will not allow you to delete their securitylevel. If an attempt is made to do so, the following warning willappear (shown below).

To edit a user’s security levels, highlight the user whose levels you want to edit and click Proper-ties. The Edit Security Levels window (shown right) will appear, in which the user’s name, pass-word and security can be assigned. Edit the user name and password and check the appropriateboxes to grant those individual security rights to the user. When finished editing, click OK to keepthe changes or Cancel to ignore them

NOTE: If there is only one user with full administrative rights in the list, the program will not allowyou to edit their security level. If an attempt is made to do so, the following warning will appear(shown below).

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ECM Communicator (if included)ECM Communicator: This program is designed to communicate with the engine’s ECM system using the SAE 1708 or SAE1939 protocol. The program has four pull-down menus: File, Edit, View and Protocol.

The File MenuFile Menu: The File Menu allows the user to open or save an ECM communication file. The menu consists of Open, Saveand Save As.

File > Open: opens a previously saved ECM communication sensor listfile

File > Save: Overwrites the current ECM communication sensor list as afile having the same name.

File > Save As: Saves a copy of the current ECM communication sensorlist as a new file. The user will be prompted to name the new file beforesaving.

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ECM Communicator (continued)The Edit MenuEdit Menu: The Edit Menu consists of the following options : Add Sensors, ECM Connections, and Local MID.

Edit > Add Sensors: Adds sensors from the ECM to the data acquisitionsystem. To add a sensor to the system, click the Add Sensors menuitem. The Add Sensor window will appear. The left drop-down box con-tains the possible modules connecting to the communication bus to thesystem. If you are connecting to the engine module, choose “128: Engine#1”. The right drop-down box contains a list of parameters or sensors.Choose the sensor you wish to monitor through the data acquisition sys-tem and click the Apply button. Continue this process to add all desiredsensors, and click OK to make the additions permanent.

Edit > ECM Connections: When the ECM Connection is selected, theConnections window will appear. If the ECM Communicator is connectedthrough an ethernet connection, use 123.123.123.129:10004 as the ECMAddress. If connected to a serial port, enter the serial port number. If anECM communicator is not connected, click on the Reset Connectionbutton to disconnect and reconnect to the ECM. Status lines below theECM Address input box will indicate the current state of the ECM Con-nection.

Edit > Local MID: In order for the ECM Communicator to enter into theECM communication bus, the Local MID must be 180.

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ECM Communicator (continued)The View MenuView Menu: There are three options under the View menu. The menu consists of the Summary, All Info, and ShowReserved PID Fault Codes menus.

View > Summary: If Summary is selected, only the sensors added tothe system will be displayed in the communicator.

View > All Info: If All Info is selected, all sensors (or parameters) beingread by the ECM will be displayed.

View > Show Reserved PID Fault Codes: Fault codes can also bedisplayed if Show Reserved PID Fault Codes is checked. (PID 194under MID 128 must be added to display fault codes.

The Protocol MenuProtocol: Allows the operator to choose the proper communication proto-col for the system. Available protocols are: 1708, 1708 Intelligent and1939. When communicating in SAE 1708 protocol, either 1708 or 1708Intelligent will work. 1708 intelligent uses additional hardware to speed upand simplify communication between the ECM and computer. If the con-nection is lost while changing from one protocol to another, it maybe nec-essary to cycle the power on Controller Box.

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Gas Analyzer (if included):This program is designed to communicate with the Gas Analyzer.Once this program is started, the system will begin to communicatewith the Gas Analyzer and show the real time gas analysis result(shown right).

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Calculated SensorsCalculated Sensors: This program has the ability to take two sensors or typed values and add, subtract, multiply, divide orpower the two values. The user must choose a sensor type, determining what type of units to use on the new calculated sensor.When a Calculated Sensor is created, it is permanently added to the list of available sensors.

A user must be logged in to access the Calculated Sensors program. To begin calculating sensors, click View > Edit.Clicking the Add Sensor button will allow the user to configure the sensors. By selecting the Sensor Input or Typed Input,either a sensor value or a literal value can be used in the calculation. Select the calculation function by clicking on the variousoption buttons in the Operator section. Clicking the Add Sensor button saves the new Calculated Sensor.

To add additional sensors, click on the Add Sensor button. The name of the new sensor is assigned ex. CALC0, CALC1, etc.The name of the sensor, as well as its variables and calculations used to determine the value of the calculated sensor can beedited from the Sensor Properties function in the Main Display. Additionally, a custom unit can be assigned to a CalculatedSensor from the Sensor Properties function in the Main Display. Any custom unit can be assigned by choosing the Customoption button on the Units tab. If the Sensor name has been changed, it will not be renamed until the DataSpace has beenreopened.

If more than one sensor is added, the Previous and Next buttons allow navigation from one Calculated Sensor to the next.

If two like sensors are selected and either add or subtract is selected as an operator, all calculations are performed on the baseunit. ex. if two volume flow sensors are added or subtracted, the units selected for each individual sensor would have no effecton the outcome of the calculated sensor. If the two like sensors are divided, a ratio will be assigned.

Example: 20 degrees C = 68 degrees FSubtracting two sensors with a value of 20 degrees C would be 68 - 68 = 0 0 Degrees F = -18 Degrees C

If the program has determined that it will use a generic sensor type, all operations are performed based on the displayed value.For instance, if 10 is added to a temperature sensor with units of degrees F displaying 68 degrees, the calculated sensor wouldread 78. Changing the temperature sensors units to degrees C would change the value of the display to 20. The added 10 wouldstill have the same effect, causing the calculated sensor to read 30.

Note: There is no way to remove a sensor. Sensors can only be added. If a calculated sensor is no longer needed, a newtemplate must be created from an existing template not containing the calculated sensor.

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Fuel Controller (if included)Fuel Controller: This program is designed to communicate with PTI fuel system. When the fuel system is operating, thefollowing data can be measured and shown in the Main Display as sensors:

Volume Burn Rate Volume Burn Rate is defined as the total volume of fuel being burned by the engine during testing.The default unit is measured in gallons/hour.

Mass Burn Rate Mass Burn Rate is defined as the total weight of fuel being burned by the engine during testing.The default unit is measured in pounds/hour.

Fuel Density Fuel Density is defined as the total density of fuel being used by the engine during the test.The default unit is measured in pounds/gallon.

Total Volume Total Volume is defined as the total volume of fuel being used by the engine during the entire test run.The default unit is measured in cubic gallons.

Fuel API Fuel API is a standard method established by the American Petroleum Institute to measure fuelquality.The default unit is a standard number measured in API degrees.

BSFC BSFC is defined as Brake Specific Fuel Consumption. This number represents the overall efficiency ofthe engine at the time of the test. The unit is measured in Pounds/Horsepower Hour.

DPV Distance Per Volume is the distance that the vehicle travels on the chassis dynamometer “virtualroad” and is measured in miles/gallon. (Chassis dynos only)

Fuel Controller Interface ButtonsThere are three buttons located on the Fuel Controller Interface window. They are as follows: Empty Fuel System - purges thefuel in the system. Fill Fuel System -readies the system to run. Shut Down System - empties the fuel system, then shutsdown the power to the fuel system only.

The Setup MenuSetup: The Fuel Controller program only has a Setup menu. The Setup Menu contains the following options: Power Sensor,Speed Sensor, Average Rates, and Calibration Density.

Power Sensor: This allows the operator to select the source ofpower for the fuel controller. If there is only one source of power,there will be only one calculating BSFC selection in the menu.

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Fuel Controller (continued)The Setup Menu (continued)Speed Sensor: This selection allows the operator to set the sourceof the speed sensor. For use in calculating DPV.

Average Rates: This menu selection allows the operator to choosethe average time period that the sensors sample the readings formass and volume burn rate. The time periods are either none, 5, 10or 30 seconds, and there is a custom option to allow the operator toenter a custom time period.

Calibration Density: The calibrate density choice initiates the pro-cedure for calibrating fuel density. The measurement is manuallyentered. The operator indicates the temperature in degrees Fahren-heit and the fuel specific gravity from a sample of the fuel to be usedin the testing.

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Correction Factors (If included)The Correction Factors option allows the user to ap-ply SAE or custom corrections to torque and horse-power readings, and creates a five new sensors: Cor-rected Gross Torque, Corrected Gross Horse-power, Corrected Net Torque, Corrected Net Horse-power and the Correction Factor itself.

Note: Corrected Net Torque and Corrected Net Horse-power are only used in some custom corrections, andare normally not available.

The Configuration Menu: The ConfigurationMenu contains the following options: SAE, CustomCorrection, Search for Custom Correction andRebuild All.

Configuration > SAE: Allows the user to select correction formulas as specified in SAE documents J607 and J1995/J1394.SAE J607 is intended for spark ignition engines only. SAE J1995/J1394 allows for both spark and compression ignitionsystems.

To apply the correction factor settings to a particular engine type, select the appropriate options from the sub-menus asillustrated below.

Configuration > Custom Correction: Allows the user to select a Cor-rection file containing a custom formula for determining Corrected Powerand Corrected Torque. These files can been created by your Power Testrepresentative to your administrator’s specifications.

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Correction Factors (continued)Configuration > Search for Custom Correction: Searches all remov-able drives for any Custom Correction files.

Configuration > Rebuild All: Refreshes the sensor names in the Sen-sor Input drop down lists.

NOTE: If changes are made in the Main Display to sensors names thatcorrespond to those listed in the Sensor Input drop down boxes, the usermust click on the Rebuild All menu item to reflect the changes made.

Correction Factor InputsAfter applying all necessary SAE correction settings, all Correction Factor formula inputs will be listed on the main form of theCorrection Factors program. The first button, Sensor Input, allows the user to select a sensor to obtain information needed forthe correction formula. The second button, Typed Input, allows the user to enter a fixed value and the unit of measurementapplied to the correction formula.

Sensor Input

Typed Input

NOTE: A simple method for configuring Correction Factors is to select J1995/J1394 - Spark Ignition, regardless of ignition type(illustrated below). This configuration allows for atmospheric correction only, yet is an effective method of establishing correc-tions for atmospheric corrections only.

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Reference Data BuilderReference Data is data that is typically usedfor comparing the results of a test.

The Reference Data Builder creates a filecontaining reference data that can be dis-played in Charts, Report Graphs, and GraphViews. Reference Data can be obtained froman existing DataSpace, a tab delimited filecreated in a spreadsheet program such asMicrosoft Excel, or manually entered by theuser.

The File MenuThe File Menu contains the following options: New, Open, Save, Save As, Import From DataSpace, Import Tab DelimitedFile and Exit.

File > New: Clears the current Reference Data file to allow the user to create anew Reference Data file.

File > Open: Prompts the user to open an existing Reference Data file.

File > Save: Overwrites the current Reference Data file as a file having the samename.

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Reference Data Builder (continued)File > Save As: Saves a copy of the current Reference Data file as a new file. Theuser will be prompted to name the new file before saving.

File > Import from DataSpace: This menu item allows the user to import Refer-ence Data into the report from an existing DataSpace by opening the ChooseTraces and Phases window, as described on page 62.

File > Import Tab Delimited File: This menu item allows the user to importReference Data into the report from a program such as Excel.

File > Exit: Provides the user with the option to save their data (shown below),and closes the Reference Data Builder program.

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Reference Data Builder (continued)Importing Reference Data from a DataSpaceTo import data from an existing DataSpace,click on File > Import from DataSpace. TheChoose Traces and Phases window (shownright) will appear.

Select the Sensors and Phases to be includedin the Reference Data File. Assign a prefaceto the sensor name ex. Ref. in the Trace Pref-ace input box. When finished, click OK.

TracesA Trace is a line on a graph representing a specific sensor’s values.To add a trace to a Reference Data File, click on the Add Tracebutton. This will open the Add Trace window (shown right). From theAdd Trace window, the user will be able to assign a name to the newTrace, and select the Sensor type.

To edit an existing trace, highlight the Trace and click the Edit Tracebutton. This will open the Edit Trace window (shown right). From theEdit Trace window, the user can edit the Trace Name and SensorType of the selected Trace.

To delete a Trace, highlight the Trace and click the Delete Tracebutton.

Individual Data Points can be edited by manu-ally entering values directly into the text box.To add Data Points, the user can click on theInsert Data Point at End button.

Clicking on the numeral to the left of the DataPoint will highlight that particular line andchange the button to Insert Data Point Be-fore Selection.

NOTE: To load Reference Data into a DataSpace or Template, refer to the Data Menu section of Chapter Three, The MainDisplay.

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Documents

PowerNet 2.0