Document 110401-2093

INSTRUCTION MANUAL

DATA ACQUISITION AND ALARM SYSTEM

SERIES 533

MODEL 533-100-031

SERIAL NUMBER 2093

These drawings and specifications and information contained herein are the property of Kahn & Company, Inc., Kahn Industries, Inc., or Kahn Instruments, Inc. and may only be
used in connection with the product provided by Kahn & Company, Inc., Kahn Industries, Inc., or Kahn Instruments, Inc. In no event may this drawing be copied, reproduced or
used in part or in full as a basis of design, manufacture or sale without the prior permission of Kahn & Company, Inc., Kahn Industries, Inc., or Kahn Instruments, Inc. Any
reproduction of technical data or portions thereof marked with this legend must also reproduce the markings. Any person, other than the receiving party, who has been provided
access to such data must promptly notify one of the above named companies.

Government Contracts and Subcontracts

LIMITED RIGHTS: All data and information set forth on this page are proprietary to Kahn & Company, Inc., Kahn Industries, Inc., or Kahn Instruments, Inc. and is subject to
section (b)(2)(ii) of 48 C.F.R. 252.227-7013 Rights in Technical Data and the terms of the contract between the parties. Any reproduction of technical data or portions thereof
marked with this legend must also reproduce the markings. Any person, other than the Government, who has been provided access to such data must promptly notify the above
named contractor.

The information on this document and any attachments is proprietary to Kahn & Company, Inc., Kahn Industries, Inc., or Kahn Instruments, Inc., and contains valuable trade and
proprietary or financial or commercial information which is not customarily released to the public, and may not be disclosed to third parties, copied or disclosed in any form, in
whole or in part, or used in any other manner other than for this solicitation. UNDER NO CIRCUMSTANCES IS THIS INFORMATION TO BE RELEASED BY THE
GOVERNMENT IN RESPONSE TO ANY REQUEST UNDER THE FREEDOM OF INFORMATION ACT.

KAHN INDUSTRIES, INC.

885 Wells Road, Wethersfield, CT 06109 Phone (860) 529-8643 Fax (860) 529-1895 E-mail info@kahn.com
TABLE OF CONTENTS

1. SPECIFICATIONS ...................................................................................................... 4
2. INTRODUCTION......................................................................................................... 6
2.1 INTRODUCTION ................................................................................................... 6
2.2 APPLICATION ....................................................................................................... 6
2.3 DESCRIPTION ...................................................................................................... 6
2.4 DATA ACQUISITION SYSTEM ............................................................................. 6
2.4.1 COMPUTER.................................................................................................... 7
2.4.2 MONITOR ....................................................................................................... 7
2.4.3 PRINTER ........................................................................................................ 7
2.4.4 OPERATING SYSTEM SOFTWARE .............................................................. 8
2.4.5 BASIC DATA ACQUISITION AND ALARM SOFTWARE ............................... 8
2.4.6 JUNCTION BOX ............................................................................................. 8
2.4.8 PROCESSOR MODULE ................................................................................. 8
2.4.9 ANALOG INPUT MODULES........................................................................... 9
2.4.10 THERMOCOUPLE INPUT MODULE .......................................................... 10
2.5.1 DIGITAL INPUT MODULE ............................................................................ 10
2.5.2 DIGITAL OUTPUT MODULE ........................................................................ 10
2.6 OPTIONAL SENSORS AND TRANSDUCERS ................................................... 10
2.6.1 TEMPERATURE MEASUREMENT .............................................................. 11
2.6.2 4-20 mADC CURRENT MEASUREMENT .................................................... 11
2.6.3 PRESSURE MEASUREMENT...................................................................... 11
2.6.4 VIBRATION MEASUREMENT ...................................................................... 12
2.6.5 FLOW MEASUREMENT ............................................................................... 12
2.6.6 SENSORS WITH DISCRETE OUTPUTS ..................................................... 13
2.6.7 INTERFACING WITH THE DYNAMOMETER CONTROL SYSTEM ............ 13
2.7 CONNECTING CABLES .................................................................................... 13
3. INSTALLATION......................................................................................................... 15
3.1 INSPECTION....................................................................................................... 15
3.2 COMPUTER ........................................................................................................ 15
3.3 JUNCTION BOX .................................................................................................. 15
3.4 CONNECTING CABLES ..................................................................................... 15
3.5 SENSORS AND TRANSDUCERS ...................................................................... 16
3.6 SOFTWARE ........................................................................................................ 16
4. SYSTEM SETUP....................................................................................................... 17
4.1 GENERAL ........................................................................................................... 17
4.2 SETTING UP SYSTEM PREFERENCES............................................................ 17
4.3 STARTING THE DATA ACQUISITION AND ALARM SOFTWARE..................... 18
4.4 SETTING UP SCREEN PREFERNCES.............................................................. 19
4.5 CONFIGURING ANALOG INPUTS ..................................................................... 19

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 4.6 CONFIGURING DIGITAL INPUTS ..................................................................... 21
4.7 CONFIGURING DIGITAL OUTPUTS .................................................................. 22
4.8 CONFIGURING THE REPORT LAYOUT........................................................... 24
4.9 SAVING CONFIGURATION FILES ................................................................... 24
4.10 DOWNLOADING CONFIGURATION FILES ................................................... 24
4.11 RETRIEVING CONFIGURATION FILES .......................................................... 26
5. OPERATION ............................................................................................................. 27
5.1 GENERAL .......................................................................................................... 27
5.2 “MASTER” COMPUTER OPERATION................................................................ 27
5.2.1 MAIN DATA SCREEN.................................................................................. 27
5.2.3 STRIP CHART SCREEN ............................................................................. 28
5.2.4 ALARM MONITORING ................................................................................. 28
5.2.5 DATA LOGGING.......................................................................................... 29
5.2.6 REPORT GENERATION............................................................................... 30
5.2.7 POST TEST DATA ANALYSIS ..................................................................... 30
5.2.8 TIME AND DATE SYNCHRONIZATION....................................................... 31
5.3 “SLAVE” COMPUTER OPERATION ................................................................... 31
6. MAINTENANCE ....................................................................................................... 32
6.1 PERIODIC INSPECTION .................................................................................... 32
6.3 SOFTWARE UPDATES ...................................................................................... 32
6.3.1 SOFTWARE UPDATE OF THE “MASTER” COMPUTER............................. 32
6.3.2 SOFTWARE UPDATE ON THE “SLAVE” COMPUTER ............................... 32
6.3.4 NI CRIO SYSTEM SOFTWARE UPDATE .................................................... 33
7. TROUBLESHOOTING ............................................................................................. 34
8. ATTACHEMENTS ..................................................................................................... 35

LIST OF FIGURES

Figure 1. Main Data Screen ........................................................................................ 35

Figure 2. All Channels Screen.................................................................................... 36
Figure 3. Strip Chart Screen....................................................................................... 37
Figure 4. 4-20 mA Inputs Configuration Screen ....................................................... 38
Figure 5. Thermocouple Input Configuration Screen............................................... 39
Figure 6. Digital Inputs Configuration Screen .......................................................... 40
Figure 7. Digital Outputs Configuration Screen ....................................................... 41
Figure 8. Report Layout Configuration Screen......................................................... 42
Figure 9. Analysis Mode Screen ................................................................................ 43

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 1. SPECIFICATIONS
DATA ACQUISITION SYSTEM SERIES 533 SN 2093
Data Channels

K-type Thermocouple Input Channel 16

Temperature Measurement Range -370 °C to 1372 °C
4-20 mA Input Channels 32
0-10VDC Input Channels 8

Performance and Accuracy

Data Acquisition Rate Per Channel 20 Hz

Resolution 12 bit
Accuracy, 4-20 mA and 0-10 VDC Channels ±0.05%
Accuracy, Thermocouple Channels ±0.1%
Data Logging Interval 0.05–60 sec
Data Logging Format CSV
Alarm Configuration 4 Limits per Channel

Computer Configuration

Operating System Windows 7 Pro. 32 bit

Computer Configuration Desktop Computer
CPU Intel Dual Core,3.4 GHz
Memory 4 GB RAM
Hard Drive 500 GB
Color Monitor 20 inch
Printer Type Monochrome Laser
Printer Resolution 2400x600 dpi
IP Address 192.168.0.100
Subnet Mask 255.255.255.0

Data Screens
Main Data Screen Speed, Torque, Power,
(8) user selectable
All Channels Screen All I/O Channels
Strip Chart Up to 16 channels

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Software Configuration

Operating System MS Windows 7

Number of Configuration Files
Report Generation
Alarm Management
Professional (32 bit)
Unlimited
Print Screen, Data
Snapshot
Alarm Annunciation,
Alarm Logging, Alarm
Acknowledgement

Electric Power Supply 85-265 VAC, 50/60 Hz,

Single Phase

Environmental Conditions

Computer, Temperature 5 to 40 °C
Computer, Humidity Max. to 95% RH, non
condensing
Junction Box, Temperature 5 to 50 °C
Junction Box, Humidity Max. to 95% RH, non
condensing

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 2. INTRODUCTION
2.1 INTRODUCTION

This manual contains descriptive material, installation and operating instructions,

maintenance procedures for a Kahn Series 533 Data Acquisition System and optional
Alarm System. The contents of this manual should be fully understood before an
attempt is made to install or operate this equipment.

Refer to the enclosed documentation for more information on system components.

2.2 APPLICATION

The Kahn Series 533 Data Acquisition and Alarm Systems are designed for use in gas
turbine and diesel engine test cells.

2.3 DESCRIPTION

The Kahn Series 533 Data Acquisition and Alarm System consists of the following major
components:

• Data Acquisition System;

• Optional Alarm System;
• Optional Sensors and Transducers with Interconnecting Cables.

Refer to the enclosed data acquisition and alarm system schematic and the associated
bill of materials for detailed information on the system components.

2.4 DATA ACQUISITION SYSTEM

The Kahn Series 533 Data Acquisition System offers the following features:

• 32 Analog input channels

• 16 Thermocouple input channels
• 16 Digital input channels (contact closure inputs)
• 8 Digital output channels for alarm monitoring
• Graphical and tabular data presentation on the computer screen;
• Central location point for sensors and transducers connection (junction box);
• Alarm annunciation and logging;
• Data logging with programmable time interval;
• Report setup and printing;
• Save and retrieve multiple system configurations;
• Post test data retrieval and analysis.

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The Kahn Series 533 Data Acquisition System includes the following components:

• Computer with keyboard and mouse;

• Monitor;
• Printer;
• Operating System Software;
• Data Acquisition and Alarm Software;
• Junction Box;
• Sensors and Interconnecting Cables

2.4.1 COMPUTER

The desktop computer meets or exceeds the following specifications:

• Intel Pentium Dual Core, 3.6 GHz CPU;

• 4 GB RAM;
• 500 GB hard drive;
• CD/DVD-RW drive;
• Ethernet port;
• Keyboard;
• Mouse;
• (9) USB ports;

Refer to the enclosed documentation for additional information.

2.4.2 MONITOR

The color monitor meets the following specifications:

• 20 inch flat screen;

• 1280X1024 dpi screen resolution.

Refer to the enclosed documentation for additional information.

2.4.3 PRINTER

The printer meets the following specifications:

• Monochrome laser type;

• 2400 x 600 dpi resolution;
• USB interface with computer.

Refer to the enclosed documentation for additional information.

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2.4.4 OPERATING SYSTEM SOFTWARE

The computer comes preloaded with Microsoft Windows operating system. Refer to the
enclosed documentation for additional information.

2.4.5 BASIC DATA ACQUISITION AND ALARM SOFTWARE

The data acquisition system is provided with a preinstalled software package, which
offers the following features:

• Monitoring of all input and output channels;

• Alarm management;
• Graphical / tabular data presentation;
• Strip Chart recorder mode;
• Data Logging;
• Post test data retrieval and analysis;
• Saving and retrieval of multiple system configurations;
• Report setup and generation.
• Supporting complex digital output control logic.

The Data Acquisition and Alarm System software is also supplied on CDROM.

2.4.6 JUNCTION BOX

The junction box provides the central location point for measurement channels, data
acquisition and connection. The junction box is equipped with PLC-type microprocessor
based distributed I/O system (NI cRIO). The NI cRIO system includes an independent
processor module running preinstalled real-time embedded software and is equipped
with a fast Ethernet network interface for connection to a host computer. The NI cRIO
system is comprised of several I/O modules to handle every type of input or output
signal monitored by the system. In addition to the PLC functionality, the processor
module can perform complex signal conversion, data acquisition and networking.

The junction box also includes vibration transmitters and power supplies and is
equipped with connectors and terminal blocks for connecting to the sensors and
transducers as well as for connecting to the user supplied test cell safety system.

Refer to the enclosed junction box assembly drawing and associated bill of material for
components identification.

2.4.8 PROCESSOR MODULE

The NI cRIO distributed I/O system installed in the junction box includes a dedicated
processor module which offers the following features:

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 • Up to 2M gate reconfigurable FPGA;
• Up to 256 MB DRAM memory;
• 266 MHz real-time processor;
• Stand-alone operation with real-time operating system;
• 10/100BASE-TX Ethernet ports with built-in FTP/HTTP servers and LabView
remote panel Web server;
• RS232 serial port and available USB port for peripheral devices;

Refer to the enclosed documentation for additional information.

2.4.9 ANALOG INPUT MODULES

The NI cRIO distributed I/O system installed in the junction box includes three analog
input modules. These modules offer the following features:

• (8) 0-10VDC input channels;

• (32) 4-20mADC input channels;
• 12 bit resolution (voltage), 24 bit resolution (current);
• Up to 500 kilo-samples per second (kS/s) sampling rate;

Note: The input channels dedicated to interface with the dynamometer controller are
configured for 0-10 VDC inputs (channels U1-U4).

Note: The input channels dedicated to vibration measurement are configured to

interface directly with vibration accelerometers (channels V1-V3).

Refer to the enclosed documentation for additional information.

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2.4.10 THERMOCOUPLE INPUT MODULE

The NI cRIO distributed I/O system installed in the junction box includes one
thermocouple input module. This thermocouple input module offers the following
features:

• (16) input channels;

• 24 bit resolution;
• Up to 1088 samples per second (S/s) sampling rate;
• All channels configured for K-type thermocouples;
• Isothermal terminal block for high accuracy measurements;
• Temperature measurement range is –270 °C to 1372 °C.

Refer to the enclosed documentation for additional information.

2.5.1 DIGITAL INPUT MODULE

The NI cRIO distributed I/O system installed in the junction box includes two digital input
modules. These modules offer the following features:

• (16) input channels;

• Input type: 24VDC logic sinking;
• 100 µs response speed;
• Extreme industrial certifications / ratings;

Refer to the enclosed documentation for additional information.

2.5.2 DIGITAL OUTPUT MODULE

The NI cRIO distributed I/O system installed in the junction box includes one digital
output module. The digital output module offers the following features:

• (8) output channels;

• 6 to 30 VDC range;
• Output type: sourcing;
• 100 µs response speed;

Refer to the enclosed documentation for additional information.

2.6 OPTIONAL SENSORS AND TRANSDUCERS

The Kahn Series 533 Data Acquisition and Alarm System can be supplied with the
following sensors and transducers:

• K-type thermocouples;

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 • Strain gage pressure transducer;
• Variable area flow transmitters;
• Vibration accelerometers.

Refer to the enclosed Bills of Material for quantity and type of sensors and transducers
supplied.

2.6.1 TEMPERATURE MEASUREMENT

The Kahn Series 533 Data Acquisition System is supplied with K-type (Nickel-
Chromium vs. Nickel-Aluminum) ungrounded thermocouples. Each thermocouple is
supplied with a stainless steel compression fitting (1/8” NPT pipe thread) for installation
in the appropriate ports. The temperature measurement channels are marked Tn at the
junction box, where “n” denotes a channel number.

Refer to the enclosed Bills of Material for details on quantity and type of thermocouples
supplied.

2.6.2 4-20 mADC CURRENT MEASUREMENT

The Kahn Series 533 Data Acquisition System is equipped with 32 analog input
channels. Most of the analog input channels are configured to accept 4-20 mADC
signals from any 2-wire or 3-wire process transducers or transmitters, such as pressure
transducers or flow transmitters. See the Data Acquisition System Wiring Diagram for
channel designations and connection information.

Note: Several analog input channels are dedicated for vibration measurement and are
marked as Vn, where “n” denotes the channel number. Additionally several analog
input channels are configured to accept 0-10 VDC signals from the dynamometer
control console as well as from the valve interface unit. See the Data Acquisition
System Wiring Diagram for channel designations and connection information.

Refer to the enclosed Bills of Material for details on the quantity and type of analog
inputs supplied.

2.6.3 PRESSURE MEASUREMENT

The Kahn Series 533 Data Acquisition System is optionally supplied with precision
strain gage pressure transmitters. The pressure transmitters are housed in a stainless
steel body and configured as 2-wire 4-20 mADC transmitters. Pressure transmitter can
be connected to any analog input of the junction box which is configured to accept a 4-
20 mADC signal. See the Data Acquisition System Wiring Diagram for channel
designations and connection information.

Refer to the enclosed Bills of Material for the quantity of pressure transmitters supplied
under this purchase contract.

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Refer to the enclosed documentation for additional information on pressure transmitters.

2.6.4 VIBRATION MEASUREMENT

The Kahn Series 533 Data Acquisition System is optionally supplied with vibration
measurement channels. Each vibration measurement channel includes the following
components:

• Piezoelectric accelerometer with built-in amplifier, housed in a stainless steel

enclosure;
• Vibration transmitters are installed in the junction box.

The accelerometers provide a 100 mV/g output signal. They are powered by the
vibration transmitters. Each accelerometer has a frequency range of 3 Hz to 11 kHz (3
dB level).

The vibration transmitter accepts a signal from the accelerometer, converts this signal
into velocity, amplifies and filters the signal and converts it to a 4-20 mADC output. The
vibration transmitter is equipped with high pass filter to reduce low frequency vibration
signal components. The vibration accelerometers can be wired to any connector at the
junction box marked as Vn, where “n” denotes the channel number.

Refer to the enclosed Bills of Material for the quantity and types of vibration
instrumentation.

Refer to the enclosed documentation for additional information on vibration

instrumentation.

2.6.5 FLOW MEASUREMENT

The Kahn Series 533 Data Acquisition System is optionally supplied with flow
transmitters calibrated for oil flow measurement and utilizing the variable annular orifice
principle of operation. The flow transmitters are equipped with direct reading scales and
configured as 2-wire 4-20 mADC transmitters. The flow transmitters can be connected
to any analog input of the junction box, configured to accept a 4-20 mADC signal.

See the Data Acquisition System Wiring Diagram for channel designations and
connection information.

Refer to the enclosed Bills of Material for the quantity of flow transmitters provided
under this purchase contract.

Refer to the enclosed documentation for additional information on the flow transmitters.

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2.6.6 SENSORS WITH DISCRETE OUTPUTS

The optional Kahn Series 533 Alarm System is equipped with 16 digital inputs. Each
input can be connected to a sensor with a discrete output, such as a temperature limit
switch, pressure limit switch or flow limit switch.

2.6.7 INTERFACING WITH THE DYNAMOMETER CONTROL SYSTEM

The Kahn Series 533 Data Acquisition System is equipped with several analog input
channels dedicated to receiving 0-10 VDC signals from the Series 545 Dynamometer
Control System:

No. Measured Signal Signal Source Connection Port at

Parameter Type the Junction Box
1 Speed 0-10 VDC Dynamometer U1
controller
2 Torque 0-10 VDC Dynamometer U2
controller
3 Inlet Valve 0-10 VDC Valve Interface Unit U3
Position
4 Outlet Valve 0-10 VDC Valve Interface Unit U4
Position

When the dynamometer speed and torque signals are connected with ports U1 and U2
on the junction box, the data acquisition system provides calculated dynamometer
power data.

Refer to the enclosed schematic and wiring diagram for details on the interface with the
Series 545 Dynamometer Control System.

2.7 CONNECTING CABLES

The data acquisition system computer is supplied with the following cables:

• USB printer cable long;

• Ethernet network cable.
• Power cords for computer, monitor and printer.
• Cables for connecting the Series 545 Dynamometer Controller to the junction box
(speed, torque signals, valves position signals).

The optional sensors and transducers can be supplied with the following shielded
cables:

• Thermocouple extension cables;

• Pressure transmitter cables;
• Flow transmitter cables;

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 • Vibration Accelerometer cables.

All unused ports of the junction box are equipped with appropriate mating connectors.

Refer to the enclosed Bills of Material for the quantity and type of cables provided.

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 3. INSTALLATION
3.1 INSPECTION

Remove all components from the shipping crates. Inspect immediately for any indication
of damage, which may have occurred during shipment. Any damage claims should be
made to the shipping agent before installing or operating the system.

3.1.1 Verify that all components of the data acquisition and alarm system (if applicable)
have been received. Refer to the enclosed system schematic, wiring diagram, and the
associated bills of material for component identification.

3.2 COMPUTER

Place the computer and the monitor on a desk with a flat surface. Place the keyboard
on a sliding keyboard rack (not provided) or a flat surface in front of the monitor. Place
the computer mouse near the keyboard and use the mouse pad provided. Place the
printer on a flat surface near the computer. Connect the computer, the monitor and the
printer to a power source, using the surge protector (not provided). Connect the monitor,
keyboard, mouse and the printer to the computer.

3.3 JUNCTION BOX

Install the junction box in an easily accessible location in the test cell. Position the
junction box at least 6 feet away from the fuel supply components or exhaust system
components, and at least 4 feet above the floor. Do not install the junction box in a
location which may be inadvertently be sprayed with water, oil or other liquids. Locate
the junction box at least 6 feet away from any hot surfaces.

3.4 CONNECTING CABLES

Connect the Ethernet port on the junction box to the Ethernet port on the data
acquisition system computer. Using the appropriate cables provided with the data
acquisition system,

a. Connect the thermocouples to the junction box.

b. Connect the pressure transmitters to the junction box.
c. Connect the oil flow transmitters to the junction box.
d. Connect the vibration accelerometers to the junction box.
e. Connect the Series 545 dynamometer control console to the junction box.

3.4.1 To reduce electromagnetic interference, place the cables away from high power
lines, contactors, electric motors, electric heaters, variable frequency drives and similar
equipment. Do not run the cables in parallel with power lines.

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3.4.2 Refer to the enclosed schematic, wiring diagram and associated bill of material
for cables identification.

3.5 SENSORS AND TRANSDUCERS

3.5.1 Install the thermocouples in the appropriate ports on the dynamometer, the
flywheel and the water discharge line, using the compression fittings provided.

3.5.2 Install the pressure transmitter in the water supply line upstream from the
dynamometer inlet control valve.

3.5.3 Install the flow transmitters in the appropriate oil supply lines with the flow
direction corresponding to the arrow on the flow transmitter scale. Orient the flow
transmitters to permit easy reading of the flow rate. Use Teflon tape on the pipe treads.

3.5.4 Rigidly install the vibration accelerometers on the appropriate mounting pads on
the dynamometer and the flywheel (if applicable). CAUTION: Tighten the
accelerometer by using the hex on the transducer. Never tighten by twisting the body of
the transducer.

3.6 SOFTWARE

The data acquisition system computer is provided with the operating system software,
data acquisition and alarm software, and printer driver software installed. No additional
software installation by the user is required.

3.6.1 The NI cRIO distributed I/O system (located in the junction box) comes with the
embedded software loaded. No additional software installation by the user is required.

3.6.2 Refer to Section 6 for instructions regarding installation of the software updates.

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 4. SYSTEM SETUP
4.1 GENERAL

Setting up the Kahn Series 533 Data Acquisition and Alarm System includes the
following steps:

• Setting up system preferences;

• Setting up screen preferences;
• Configuring analog channels;
• Configuring digital input channels (if the alarm system is provided)
• Configuring digital output channels (if the alarm system is provided);
• Configuring report layout;
• Saving configuration;
• Downloading configuration to the NI cRIO distributed I/O system.

4.1.1 The Kahn Series 533 Data Acquisition and Alarm System permits connecting up
to two computers to a single junction box via the Ethernet interface. When two
computers are provided, they have to be connected to the Ethernet port of the junction
box via Ethernet switch. If one computer is provided, it must be configured as the
“master”. If two computers are provided, one computer must be configured as the
“master” and the other computer must be configured as the “slave. Only the “master”
computer can be used to change the system configuration, perform data logging or
provide post test data analysis, in addition to data monitoring functions. The “slave”
computer provides only data monitoring functions.

WARNING: Changing the system configuration requires knowledge of the computer

and its operating system. Attempts by untrained personnel to change the system
configuration may compromise the system operation.

4.1.2 Changing the system preferences requires that the data acquisition and alarm
software is not running. All other system configuration modes require that the data
acquisition and alarm software is running.

4.2 SETTING UP SYSTEM PREFERENCES

The following system preferences are available for setup:

• IP address of the “master” computer;

• IP address of the “slave” computer, if applicable;
• Password for accessing channel configuration screen;
• Password for accessing post test analysis screen.

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4.2.1 To set up system preferences, locate the KAHN.INI file in the C:\KAHN directory
on the “master” computer. Open the file with the NOTEPAD text editor.

WARNING: When editing the KAHN.INI file, keep the existing file format as well as the
formats of all data fields as provided by Kahn. Altering the data fields other than as
listed below or modifying the data format will compromise the operation of the system.

4.2.2 Verify that the IP address of the “master” computer matches the IP address in the
“master” group of the KAHN.INI file.

4.2.3 Verify, that the IP address of the “slave” computer (if applicable) matches the IP
address in the “slave” group of the KAHN.INI file.

4.2.4 The password for accessing the channels configuration is located in the
USERIFO group. Enter the required password (limited to 6 alphanumeric characters)
between quotes in the CONFIG PASSWORD data field.

4.2.5 The password for accessing the post test analysis mode is located in the
USERIFO group. Enter the required password (limited to 6 alphanumeric characters)
between quotes in the ANALYSIS PASSWORD data field.

4.2.7 Save the KAHN.INI file.

4.3 STARTING THE DATA ACQUISITION AND ALARM SOFTWARE

To start the data acquisition and alarm software, locate and execute on the “master”
computer the file START.EXE in the KAHN program group. On the “master” computer
the software starts with the MAIN DATA screen. Locate on the top of the screen the
following software controls: EXIT, VIEW, PRINT, ANALYZE, CONFIGURE and ABOUT.

4.3.1 Selecting EXIT stops running of the software.

4.3.2 Selecting VIEW permits switching between the following screens: MAIN DATA,
STRIP CHART and ALL CHANNELS.

4.3.3 Selecting PRINT permits print screen or print report with a snapshot of data and
user defined fields.

4.3.4 Selecting ANALYZE permits retrieval of previously logged data files in the post
test analysis mode.

4.3.5 Selecting CONFIGURE permits configuring of data channels or loading previously

saved channels configurations.

4.3.6 Selecting ABOUT displays the software version number and information about
Kahn Industries.

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NOTE: The CONFIGURE and ANALYZE controls are not available while data logging
is in process. Additionally, selecting CONFIGURE and ANALYZE stops alarm
annunciation and alarm logging.

4.4 SETTING UP SCREEN PREFERNCES

The following screen preferences are available for setup:

• Selecting channels to be displayed on the MAIN DATA screen;

• Selecting channels to be displayed on the STRIP CHART screen.

To select channels to be displayed on the MAIN DATA screen, go to MAIN DATA

screen, then click on menu bar located above the horizontal bargraphs and select
desired channel.

To select channels to be displayed on the STRIP CHART screen, go to STRIP CHART

screen, then click on menu bars located on the right to select desired channel.

4.5 CONFIGURING ANALOG INPUTS

Configuring the analog inputs consists of the following steps:

• Selecting channels to be configured;

• Selecting if channel is enabled;
• Entering description of the channels;
• Scaling the input signal to engineering units;
• Entering units;
• Selecting format of the data;
• Normalizing the data;
• Selecting open sensor action;
• Selecting if alarms are enabled;
• Entering alarm setpoints;
• Entering alarm delay.

4.5.1 Select the channel to be configured on the left of the screen. Note that the
channel tag corresponds to the connector markings on the junction box.

4.5.2 Check the ENABLED? checkbox for the channel to be configured. If the channel
is disabled, the data for this channel will not be displayed or logged. The system will not
check alarms for disabled channels. Note: For optimal system performance always
disable the channels which are not used.

4.5.3 Enter the description of the channel (not longer than 12 alphanumeric
characters).

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4.5.4 Scale the raw input signal (4-20 mADC or 0-10 VDC) to the engineering units by
entering the calibration data into the following fields:

SCALE LOW – value in engineering units corresponding to the INPUT LOW value of the
raw input signal;
SCALE HIGH – value in engineering units corresponding to the INPUT HIGH value of
the raw input signal.

For example, the pressure transmitter is provided with the following calibration data: 0
bar at 3.9 mADC, 7.5 bar at 19.7 mADC. To scale the 4-20 mADC signal generated by
the pressure transducer into engineering units, enter SCALE LOW = 0, INPUT LOW =
0.0039, SCALE HIGH = 7.5, INPUT HIGH = 0.0197. Note that the INPUT LOW and
INPUT HIGH fields require data to be entered in Ampers DC.

4.5.5 Enter the required engineering units (not longer than 4 characters). Note that
channel U2 is dedicated for the dynamometer torque measurement. The following units
are available for torque measurement: lb-ft, lb-in and Nm, Selecting lb-ft or Nm
determines the units for the calculated channel POWER. If lb-ft or lb-in is selected, the
power will be displayed in hp. If Nm is selected, the power will be displayed in kW.
Temperature measurement channels permit selection of °C, °F or °K.

4.5.6 Enter the required number of digits after the decimal point by clicking on the
PRECISION selection bar.

4.5.7 Normalize the data by entering 0% F.S. and 100% F.S. data. This feature
determines the range of graphic bargraphs on the MAIN DATA screen and scaling of
the Y-axis on the STRIP CHART screen. Note that the 0% F.S. value should be equal
or greater than the SCALE LOW value and that 100% F.S. should be equal or less than
the SCALE HIGH value.

4.5.8 The 4-20 mA measurement channels offer the selection of open sensor action. If
the OPEN SENSOR ACTION checkbox is not checked, the channel data will be set to 0
in case of an open sensor condition. If the OPEN SENSOR ACTION checkbox is
checked, the channel data will be set equal to the SCALE HIGH value in case of an
open sensor condition.

The thermocouple input channels are configured to display SCALE HIGH value in case
of the open sensor condition.

4.5.9 If it is required to check the measured value against one of several alarm
setpoints, check the checkbox ALARM ENABLE and enter the desired setpoint values
into the ALARM HIGH HIGH, ALARM HIGH, ALARM LOW or ALARM LOW LOW fields.
If the alarm is enabled and the alarm setpoint is entered, the system will continuously
check the measured value against the setpoint and update the color of the data field
background according to the following rules:

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 • Background stays green if there is no alarm condition;
• Background turns red if the alarm condition is present;
• Background turns yellow if the alarm condition returns to normal;
• Background turns green after the alarm condition returns to normal and after this
is acknowledged by the user.

4.5.10 An alarm condition is acknowledged by clicking on the ACKNOWLEDGE

ALARM button on the “master” computer or the “slave” computer (if applicable). The
GLOBAL ALARM annunciator changes the background color according to the following
rules:

• Background stays green if none of the channels is in alarm condition;

• Background turns red if any channel is in alarm condition;
• Background turns yellow after all channels have returned to normal condition;
• Background turns green after all channels have returned to normal condition and
after this is acknowledged by the user.

4.5.11 The ALARM DELAY feature is provided to prevent false alarms if the measured
value fluctuates around the alarm setpoint. For example, if the alarm delay is set to
1000 msec, the alarm annunciator will be set only if the condition is present
continuously for a minimum of 1000 msec. The same rule applies to resetting the alarm.
The system will reset the alarm annunciator only if the alarm condition is not present
continuously for a minimum of 1000 msec.

4.6 CONFIGURING DIGITAL INPUTS

The following applies only if an alarm system is provided. Configuring digital inputs
requires the following steps:

• Select the channel to be configured;

• Select if the channel is to be enabled;
• Enter the description of the channel;
• Select if the alarms are to be enabled;
• Select the alarm state;
• Enter alarm delay.

4.6.1 Select the digital input to be configured on the left of the screen. Note that the
channel tags (DI1-DI16) displayed correspond to the connector markings on the junction
box.

4.6.2 Check the ENABLED? checkbox for the channel to be configured. If the channel
is disabled, the data for this channel will not be displayed or logged. The system will not
check alarms for disabled channels. Note: For optimal system performance always
disable the channels which are not used.

4.6.3 Enter the description of the channel (not longer than 12 alphanumeric characters).

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4.6.4 If it is required to set an alarm if the digital input changes its state, check the
checkbox ALARM ENABLE.

4.6.5 Select which state of the digital input sets the alarm: open or closed by clicking on
the DI ALARM STATE button.

4.6.6 If alarm is enabled, the system will continuously check the state of the digital input
and update the color of the data field background according to the following rule:

• Background stays green if there is no alarm condition;

• Background turns red if the alarm condition is present;
• Background turns yellow if the alarm condition returns to normal;
• Background turns green after the alarm condition returns to normal and after this
is acknowledged by the user.

4.6.7 An alarm condition is acknowledged by clicking on the ACKNOWLEDGE ALARM

button on the “master” computer or “slave” computer (if applicable). The GLOBAL
ALARM annunciator changes the background color according to the following rules:

• Background stays green if none of the channels are in alarm condition;

• Background turns red if any channel is in alarm condition;
• Background turns yellow after all channels have returned to normal condition;
• Background turns green after all channels have returned to a normal condition
and after this is acknowledged by the user.

4.6.8 The ALARM DELAY feature is provided to avoid false alarms when the digital
input bounces.

4.7 CONFIGURING DIGITAL OUTPUTS

4.7.1 The Kahn Series 533 Data Acquisition System includes 8 user-programmable
digital output channels. These channels output a DC voltage when a parameter is in an
alarm state. This allows the Data Acquisition System to trigger external events or relay
alarms in response to the status of incoming data.

Each of the digital output channels can be controlled by up to 8 separate rules. Setting
these rules allows the user to pick which alarm states will trigger the digital output to
toggle to its ON state. When configured, a digital output will be ON whenever any of its
rules are true. When a digital output is ON, the voltage output is +24 VDC. When a
digital output is OFF, the voltage output is 0 VDC. The status of a digital output
channels is displayed as Closed when that channel is ON, and Open when that channel
is OFF. As per the wiring diagram, connections to the digital output channels should be
made at terminal block TB3 within the Data Acquisition System junction box. (Note that
the even numbered terminals of TB3 are Negative and that the odd numbered terminals
are Positive.)

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* A 1.5 Amp fast acting fuse should be installed between the positive terminal of the
digital output and the load when using these channels. Digital output channels are
sourcing outputs and can supply up to 1 Amp per channel.

4.7.2 To configure a digital output channel, perform the following:

1. In the Kahn Data Acquisition System program, choose Configure from the menu
bar at the top of the screen, and click Channels.

2. A prompt will inform you that you will be leaving the acquisition screen, click
Proceed.

3. You will also be prompted to enter your password. If you have set a password,
enter it and click OK. If you have not set a password simply leave the text field
blank and click OK.

4. You will now have the channel configuration screen open. On the left hand side
of the screen you will see a list of channels. The Digital Output Channels are
located at the end of this list.

5. Click on one of the Digital Output Channels (DO1-DO8) in the channels list. This
will select the channel to be configured.

6. On the right hand side of the screen, you can edit the channel’s description, as
well as set the logical rules that determine the channel’s operation.

7. Click on one of the 8 logical rules in the center of the right hand side of the
screen. A menu will drop down listing all the data acquisition system channels.

8. Click on a channel in this list to set that channel as a trigger parameter for the
digital output being configured. Setting these trigger parameters will determine
what channel(s) will control the digital output.

9. You will now need to set which alarm state of the trigger parameter will cause the
digital output to be ON. To do this, click on the drop down button to the right of
the trigger parameter and click the desired alarm state (Low-Low, Low, High, or
High-High).

10. Repeat steps 5-9 for each digital output channel you wish to configure.
Remember that you can have up to 8 logical rules for each digital output channel.
When you have multiple rules, the digital output will be ON if ANY of the trigger
parameters are in their defined alarm states (i.e. if any of the logical rules are
true).

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4.7.3 Additional Notes on Alarm States:

1. In order to use alarm states to cause the digital output channels to be ON, these
states need to be defined as part of their corresponding channel’s configuration (see
section 4.5.9 of the data acquisition system manual). In the channel configuration
screen (see 4.7.2 steps 1-4) the alarm states can be defined and enabled for each of
the system’s input channels.

2. Digital output channels are setup so that they can be configured based off of priority
of alarms. Selecting only high priority alarm states (High-High and Low-Low) for
critical trigger parameters allows a digital output to be used for a higher priority task.
This way one high priority digital output channel can be used to stop an engine or
activate a remote emergency shutdown, ect. A lower priority digital output or outputs
can be used to turn on a test cell annunciator or additional cooling system, ect. This
advanced control of alarm logic makes it possible for the data acquisition system to
be customized to a wide variety of applications.

4.8 CONFIGURING THE REPORT LAYOUT

When PRINT INSTANT REPORT is selected from the PRINT menu, the system prints a
snapshot of the enabled channels, including channel tag, description, value and unit.
The report layout offers several user configurable fields which can be used to customize
the report: Left header, right header, intro text, additional text, left footer and right
footer. Any of the fields can be used to enter the company name, operator name, test
description, equipment description, etc.

4.8.1 To permit the quick entry of an operator’s comment into a report, the MAIN DATA,
STRIP CHART and ALL CHANNELS screens are equipped with a REPORT MESSAGE
field. The REPORT MESSAGE field gets automatically appended to the report. This
feature permits the entering of comments into a report without modifying the report
layout.

4.9 SAVING CONFIGURATION FILES

After the screen preferences are selected and the channel configuration is completed,
save the configuration files under a user defined name by clicking on the CONFIGURE
menu and selecting SAVE CONFIGURATION. The system configuration is saved in the
CONFIG FILES subdirectory on the hard drive of the “master” computer. Do not enter
the file extension, the system automatically assigns the file extension CFG.

4.9.1 The Kahn Series 533 Data Acquisition and Alarm System permits an unlimited
number of configuration files to be created and saved.

4.10 DOWNLOADING CONFIGURATION FILES

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After the configuration file is saved, it can be downloaded into the NI cRIO distributed
I/O system by selecting DOWNLOAD from the CONFIGURE menu. During the
downloading process, the configuration file is saved in the NI cRIO system as an
FP.CFG file. When a new configuration is downloaded, the NI cRIO system sends a
request to the “slave” computer (if applicable) to update its configuration.

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4.11 RETRIEVING CONFIGURATION FILES

Previously saved configuration files can be retrieved from the “master” computer hard
drive by selecting LOAD CONFIGURATION from the CONFIGURE menu. The retrieved
configuration files can be loaded into the NI cRIO system by selecting DOWNLOAD
CONFIGURATION from the CONFIGURE menu.

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 5. OPERATION
5.1 GENERAL

The “master” computer can work in one of the following operating modes:

• System Configuration;
• Data Acquisition and Alarm Monitoring;
• Post Test Data Analysis.

Regardless of the operating mode of the “master” computer, or even when the “master”
computer is off, the NI cRIO distributed I/O system continuously scans the inputs,
updates the outputs (if an alarm system is provided) and broadcasts data over the
Ethernet network to the “master” and “slave” computers (if applicable). The NI cRIO
system briefly interrupts scanning the inputs and updating the outputs only when a new
configuration file is downloaded.

5.1.1 The “master” and “slave” computers (if applicable) provide the user with real time
data values and alarm status only in the data acquisition and alarm monitoring mode.
When the user returns to the data acquisition and alarm monitoring mode, after being in
another mode, or when the data acquisition and alarm software starts, the “master”
computer sends a request to the NI cRIO system to update the status of the alarms.
The alarm status also gets updated on the “slave” computer (if applicable). The request
to update an alarm status is logged into an alarm log file.

5.1.2 The “slave” computer can only work in the data acquisition and alarm monitoring
mode.

5.2 “MASTER” COMPUTER OPERATION

Refer to Section 4 for “master” computer operation in the system configuration mode.
The “master” computer is in the data acquisition and alarm monitoring mode if one of
the following screens is selected from the VIEW menu:

• Main Data;
• All Channels;
• Strip Chart.

The “master” computer is in post test data analysis mode if the ANALYZE screen is
selected from the VIEW menu.

5.2.1 MAIN DATA SCREEN

The MAIN DATA screen is designed to provide the most important data to the user,
such as speed, torque and power, as well as data from eight user selectable channels.

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The MAIN SCREEN offers digital as well as graphical presentation of the data. The
color of the data field background represents the alarm status of the channel.

5.2.2 ALL CHANNEL SCREEN. The ALL CHANNEL SCREEN provides data from all
enabled channels. The data is displayed in digital format only. The color of the data field
background represents the alarm status of the channel.

5.2.3 STRIP CHART SCREEN

The STRIP CHART SCREEN offers presentation of the data in the form of an XY plot.
Up to 16 variables can be displayed simultaneously. The Y axis is scaled from 0 to
100% of full scale according to the channel setup. The X axis represents time. The
following XY plot controls are available:

• Line color;
• Line type;
• Line thickness;
• Y axis zoom,
• X axis zoom.
• Manual control of the XY plot area;
• Auto-scaling of the Y and X axis.

The STRIP CHART screen also provides digital indication of the channel value in
engineering units, normalized values in 0 to 100 % F.S. and units. The color of the data
field background represents the alarm status of the channel.

5.2.4 ALARM MONITORING

The NI cRIO distributed I/O system, located in the junction box, continuously broadcasts
the alarm status of the inputs (for which alarm is enabled during the input configuration)
to the “master” and “slave” computers (if applicable).

The background color of the digital indicators on the computer screen reflects the alarm
status of the channel. If the color is green, no alarm condition was registered. If the
color is red, the channel is in alarm condition. If the color is yellow, the channel was in
alarm condition, but is no longer in it.

The background color of the GLOBAL ALARM annunciator reflects the alarm condition
of the system. If the color is green, none of the input channels is in alarm condition. If
color is red, at least one of the channels is in alarm condition. If the color is yellow, none
of the inputs are in alarm condition, but at least one was in alarm condition and is no
longer in it.

At the bottom of any view screen there is an alarm sub window which continuously
provides the following information to the user:

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 • Message specifying the alarm condition occurred;
• Message confirming that alarm condition is no longer present;
• Message informing that the alarm status is being refreshed;
• Message confirming that alarm condition was acknowledged by the user.

All messages generated by the system are logged into an alarm log file. The alarm log
files are stored in the subdirectory C:\KAHN\ALARM LOGS\ of the “master” computer.
Whenever the user starts the system or returns to a view mode from the configuration
mode or from the post test analysis mode, the system starts a new alarm log file. The
name of the alarm log file has the following structure: alarmxxxxxx_yyy, where xxxxxx
represents the current date, yyy represents the sequential number of the alarm log file
within the current date. If number of records in alarm log file exceeds 32,000, the
system closes current alarm log file and opens new alarm log file with sequential
number. The alarm log files are stored in text form and can be viewed by Microsoft
Word or Excel programs.

At any time the user can acknowledge alarm condition by clicking on ACKNOWLEDGE
ALARM button on the “master” computer or on the “salve” computer (if applicable).
Acknowledgement of the alarm condition on the “master” computer is transmitted over
the Ethernet network to the “slave” computer. Acknowledgement of the alarm condition
on the “slave” computer is transmitted over the Ethernet network to the “master”
computer.

5.2.5 DATA LOGGING

The “master” computer is equipped with the data logging capability. At the lower left
corner of any view screen there is a data logging ON/OFF button. Pressing on that
button brings up the data logging interval selection from 0.05 to 60 seconds. After the
interval selection, the system displays the data log file name entry screen. The data log
files are stored on the “master” computer's hard drive in the C:\KAHN\DATA LOGS\
subdirectory. The system limits the size of the data log file to 32,000 records. With the
fastest data logging rate of 50 msec, the duration of the data logging time period is
approximately 27 minutes. With a data logging interval of 1 second, the duration of the
data logging time period is approximately 8.8 hours. Select the data logging time
interval accordingly.

Note: Do not assign the file extension to the data log file. The system automatically
assigns the extension LOG to the data file log files.

The data log files are stored in CSV format and can be viewed by Microsoft Word or
Excel programs.

The data log file can be viewed in the form of an XY plot in the ANALYZE mode for post
test data analysis.

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5.2.6 REPORT GENERATION

The system is equipped with two report generation features: printing window, and
printing instant report.

Printing window is available form any screen of the “master” computer. To print window,
select PRINT WINDOW from the print menu. This feature permits printing full size color
images of the current screen.

Printing an instant report is available from any view screen of the “master” computer.
The instant report consists of the snapshot of data for all enabled channels along with a
channel description and engineering units. The instant report also includes user defined
fields (refer to paragraph 4.8 for details) as well as report messages entered by the user
from any view screen.

5.2.7 POST TEST DATA ANALYSIS

The Kahn Series 533 Data Acquisition and Alarm System permits the user to retrieve
previously saved data log files and view the data in the form of an XY plot. To access
the post test data analysis mode select VIEW DATA LOG FILE from the ANALYZE
menu and then select the file to be retrieved.

Warning: The system will not permit to go to the analysis mode if data logging is in
process. In the post test analysis mode the system does not update the status of
alarms.

In the analysis mode the system permits the selection of one or more channels from the
list of channels logged. The median filter with variable rank is provided to reduce the
noise of a user selectable channel. The following XY plot controls are offered:

• Cursor position control;

• Line color;
• Line type;
• Line thickness;
• Y axis zoom,
• X axis zoom.
• Manual control of the XY plot area;
• Auto-scaling of the Y and X axis.

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5.2.8 TIME AND DATE SYNCHRONIZATION

The NI cRIO hardware is equipped with a real time clock, and assigns time stamps for
data log and alarm log files. To synchronize the NI cRIO clock with the clock of the
Master computer, perform the following procedure:

• Set required time and date on the Master computer using the operating system
features;
• Select CONFIGURE screen;
• Select OTHER INFO tab on the CONFIGURE screen;
• Press on SYNCHRONIZE button once;
• Reboot the NI cRIO system.

5.3 “SLAVE” COMPUTER OPERATION

The “slave” computer permits the user to monitor the channels in the VIEW mode only.
The “slave” computer offers the same view screens as “master” computer.

Note: The slave computer does not permit data logging and does not log alarms. The
default screen for the “slave” computer is the ALL CHANNELS screen.

The “slave” computer permits the user to acknowledge alarm by selecting the
ACKNOWLEDGE ALARM button.

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 6. MAINTENANCE
6.1 PERIODIC INSPECTION

To maintain optimum performance and to insure long life, the data acquisition and alarm
system should be inspected regularly. A preventive maintenance program will lead to
the detection of most trouble spots before they can cause serious damage to the
equipment.

6.1.1 Every month or every 100 operating hours, inspect the electrical cables and the
wiring, Tighten all connections, repair or replace as necessary.

6.1.2 Every month or every 100 operating hours, check the installation of all sensors
and transducers.

6.2 SPARE PARTS. As set of recommended spare part is provided with the data
acquisition system. Additional spare parts may be directly obtained from Kahn
Industries. To order a spare part, provide the serial number, the name of the part and
assembly drawing number followed by the detail number.

6.3 SOFTWARE UPDATES

Kahn Industries continuously works on the improvement of its products to provide best
performance of the equipment. Check periodically with Kahn Industries for the latest
software updates.

6.3.1 SOFTWARE UPDATE OF THE “MASTER” COMPUTER

To perform the software update of the “master” computer perform the following
procedure:

• Obtain the software update from Kahn Industries;

• Save all configuration files, data log files and alarm log files, if applicable;
• Uninstall the software using the REMOVE SOFTWARE feature of operating
system;
• Install new software by selecting SETUP.EXE file located in the subdirectory
INSTALLER of the CDROM provided;
• Start the software. Create the new or open the existing configuration file, then
download it to the NI cRIO distributed I/O system.

6.3.2 SOFTWARE UPDATE ON THE “SLAVE” COMPUTER

To perform the software update on the “slave” computer perform the following
procedure:

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 • Obtain the software update from Kahn Industries;
• Uninstall the software using the REMOVE SOFTWARE feature of operating
system;
• Install new software by selecting the SETUP.EXE file located in the subdirectory
INSTALLER of the CDROM provided;
• Start the software. The “slave” computer will update its configuration
automatically from the NI cRIO distributed I/O system.

6.3.4 NI CRIO SYSTEM SOFTWARE UPDATE

If a software update is available, Kahn Industries will provide specific instructions

detailing the update process.

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 7. TROUBLESHOOTING
Follow the instructions below on how to resolve the following possible problems.

Problem Possible Cause Recommended Solution

Computer displays Bad connection of the Tighten the Ethernet
message OFF-LINE Ethernet cable between cable connection
computer and junction
box
The junction box power is Turn ON the junction box
OFF

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 8. ATTACHEMENTS

Figure 1. Main Data Screen

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 Figure 2. All Channels Screen

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 Figure 3. Strip Chart Screen

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 Figure 4. 4-20 mA Inputs Configuration Screen

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 Figure 5. Thermocouple Input Configuration Screen

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 Figure 6. Digital Inputs Configuration Screen

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 Figure 7. Digital Outputs Configuration Screen

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 Figure 8. Report Layout Configuration Screen

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 Figure 9. Analysis Mode Screen

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