Kistler 601C Series User manual

Instruction
Manual
Piezoelectric
Pressure Sensors
Type 601C…
Type 603C…
60xC_002-741e-08.18

Instruction
Manual
Piezoelectric
Pressure Sensors
Type 601C…
Type 603C…
60xC_002-741e-08.18

Foreword
60xC_002-741e-08.18 Page 1
Foreword
Thank you for choosing a Kistler quality product charac-
terized by technical innovation, precision and long life.
Information in this document is subject to change without
notice. Kistler reserves the right to change or improve its
products and make changes in the content without obli-
gation to notify any person or organization of such
changes or improvements.
© 2015 … 2018 Kistler Group. All rights reserved. Except
as expressly provided herein, no part of this manual may
be reproduced for any purpose without the express
prior written consent of Kistler Group. The Kistler
Group in-cludes Kistler Holding AG and all its
subsidiaries in Europe, Asia, the Americas and
Australia.

Piezoelectric Pressure Sensor Type 601C/603C
Page 2 60xC_002-741e-08.18
Content
1. Introduction.................................................................................................................................. 3
2. General functional description .................................................................................................. 4
2.1 PE Pressure sensors .......................................................................................................... 5
2.1.1 Measuring chain (PE)............................................................................................. 5
2.1.2 Characteristics of PE sensors and measuring chains............................................ 6
2.2 IEPE pressure sensors ....................................................................................................... 7
2.2.1 Measuring chain (IEPE) ......................................................................................... 7
2.2.2 Characteristics of IEPE sensors and measuring chains ........................................ 8
3. Equipment .................................................................................................................................... 9
3.1 Sensor housing ................................................................................................................... 9
3.2 Sensor dummy .................................................................................................................. 10
3.3 Seal (Sensor) .................................................................................................................... 10
3.4 Floating clamp nut............................................................................................................. 10
3.5 Adapter.............................................................................................................................. 11
3.6 Seal (adapter) ................................................................................................................... 11
4. Mounting & installation............................................................................................................. 12
4.1 Mounting options............................................................................................................... 12
4.1.1 Direct mounting .................................................................................................... 12
4.1.2 Passage mounting................................................................................................ 13
4.1.3 Adapter mounting ................................................................................................. 14
4.2 Installation ......................................................................................................................... 15
4.2.1 Tightening torque ................................................................................................. 15
4.2.2 Cabling ................................................................................................................. 15
4.3 Manufacturing of mounting hole........................................................................................ 16
4.3.1 Direct mounting (ISO)........................................................................................... 16
4.3.2 Direct mounting (ANSI) ........................................................................................ 18
4.3.3 Adapter Mounting (ISO) ....................................................................................... 20
4.3.4 Adapter Mounting (ANSI) ..................................................................................... 20
5. Maintenance and calibration .................................................................................................... 21
5.1 Maintenance...................................................................................................................... 21
5.1.1 Sensors ................................................................................................................ 21
5.1.2 Connectors ........................................................................................................... 21
5.2 Calibration ......................................................................................................................... 23
5.3 Warranty............................................................................................................................ 23
5.4 Disposal instructions for electrical and electronic equipment ........................................... 23
6. Conformity declaration ............................................................................................................. 24
Total pages 24

Introduction
60xC_002-741e-08.18 Page 3
1. Introduction
First of all we would like to thank you for trusting Kistler
and using one of our sensors for your measurements.
Please take the time to thoroughly read this instruction
manual. It will help you with the installation, maintenance
and use of this product.
To the extent permitted by law Kistler does not accept
any liability if this instruction manual is not followed or
products other than those listed under Accessories are
used.
This manual covers several general purpose piezoelec-
tric pressure sensors that are suited for a variety of appli-
cations. Please see below list for an overview of sensors
covered by this manual:
601CAA
601CAB
601CBA00001.5
601CBA00003.5
601CBA00014.0
601CBA00035.0
601CBA00070.0
601CBA00250.0
603CAA
603CAB
603CBA00014.0
603CBA00035.0
603CBA00070.0
603CBA00350.0
603CBA00690.0
603CBA01000.0
This manual might have changed since last downloaded,
please check the Kistler webpage for the newest version.
For full sensor specifications please refer to the data
sheet. If you need any additional help beyond what can
be found either on-line or in this manual, please don’t
hesitate to contact your local Kistler sales offices.

Piezoelectric Pressure Sensor Type 601C/603C
Page 4 60xC_002-741e-08.18
2. General functional description
Due to their high natural frequencies, piezoelectric pres-
sure sensors can be used for a variety of applications
where dynamic pressures need to be measured. Another
unique characteristic of piezoelectric pressure sensors is
their ability to measure small pressure fluctuations that
are superimposed on top of high static pressures with
highest resolution.
Please notice that as with any piezoelectric sensor, true
static measurements are impossible. Piezoresistive pres-
sure sensors are the right choice when measuring static
pressures.
At the core of a piezoelectric pressure sensor there’s a
synthetic crystal, with quartz being the most used materi-
al by sensor manufacturers. Kistler additionally grows
own high performance crystals called PiezoStar. Sensors
based on PiezoStar crystals show several advantages
over quartz based sensors as for example higher operat-
ing temperatures, higher sensitivities, etc.
The pressure to be measured acts on the sensor’s dia-
phragm and coverts it into a proportional force which then
acts on the crystal. The compressed crystal produces a
charge which is proportional to the pressure. The charge
itself is being picked-up by the sensors electrode and
taken to the plug. Finally the charge signal needs to be
converted, by a charge amplifier, into a voltage to be
read.
Two variants of piezoelectric sensors are available,
charge output (PE) and voltage output (IEPE). The fol-
lowing chapters will give you an overview on the charac-
teristics of both variants, with their corresponding ad-
vantages and disadvantages compared to each other
and with that give you the chance to select the best op-
tion for your corresponding measurement task.

General functional description
60xC_002-741e-08.18 Page 5
2.1 PE Pressure sensors
Piezoelectric pressure sensors with charge output are re-
ferred to as PE throughout this document.
2.1.1 Measuring chain (PE)
PE sensors deliver a charge signal; hence the sensitivity
is given as pico-coulombs per unit of pressure (e.g.
pC/bar or pC/psi). Pressure applied to a PE sensor pro-
duces a negative going charge signal (hence the nega-
tive sensitivity of PE sensors), which then is turned into a
positive voltage signal by the external charge amplifier.
Contrary to IEPE sensors, PE sensors don’t need to be
powered as a charge signal is produced as soon as
pressure is applied to the piezoelectric material. However
a special high impedance cable supplied by Kistler is es-
sential to transport the incredibly small charges.
Kistler offers dual-mode (PE and IEPE) multi-channel
charge amplifiers with integrate DAQ (digital and analog
outputs) which can be connected directly to a PC through
an Ethernet cable or through its analog outputs to an ex-
ternal DAQ system. Alternatively Kistler offers single-
mode charge amplifiers with analog outputs which can
then be connected to an external DAQ system.

Piezoelectric Pressure Sensor Type 601C/603C
Page 6 60xC_002-741e-08.18
2.1.2 Characteristics of PE sensors and measuring chains
Here’s an overview on the main characteristics of PE
sensors and measuring chains:
Dynamic and quasi-static pressure measurements
As already mentioned true static measurements are
impossible with any piezoelectric sensor. However
with PE sensors quasi-static measurements can be
performed. The duration over which so-called quasi-
static measurements can be performed depends on
the insulation resistance of the sensor and its con-
necting cable (the higher the better), and the time
constant adjusted on the external charge amplifier.
Extreme wide operating temperature range
Since no electronics are built into the sensor it’s pos-
sible to operate and measure within an extreme tem-
perature range. The operating temperature range is
shown on the data sheet and is wider for sensors
based on PiezoStar than quartz crystals.
Adjustable FSO pressure range
The Full Scale Output (usually ±10 V) pressure range
can be adjusted by the external charge amplifier. This
means that the same sensor can be used to measure
a few mbar or, by changing the measuring range on
the charge amplifier, a few hundred bars. This makes
the measurement chain very flexible so that it can be
used for different measurement tasks and be adjusted
to whatever scale is needed.
Need for special high impedance cables
The charge signal of the PE sensor needs to be
transmitted through a special high insulation re-
sistance cable that can be purchased at Kistler. The
use of cheaper standard cables leads to drift and is
therefore not recommended. Also, high impedance
cables should be protected against humidity.
Connectors need to be kept clean
The connectors (of the sensor, high insulation re-
sistance cable and charge amplifier), must be protect-
ed against contamination and humidity in order to
keep the high insulation. All plugs must be kept as
clean and dry as possible and should therefore always
be capped in order to keep contamination out when
not connected.

General functional description
60xC_002-741e-08.18 Page 7
2.2 IEPE pressure sensors
Piezoelectric pressure sensors with voltage output are re-
ferred to as IEPE or Piezotron sensors throughout this
document. IEPE stands for Integrated Electronics Piezo
Electric and refers to an industry standard for piezoelec-
tric sensors with integrated electronic circuits that convert
a charge into a voltage signal. Piezotron is the registered
trademark of Kistler for IEPE sensors.
2.2.1 Measuring chain (IEPE)
IEPE sensors deliver a voltage signal; hence the sensitiv-
ity is given as Millivolt per unit of pressure (e.g. mV/bar or
mV/psi). Pressure applied to an IEPE sensor produces a
positive voltage signal (hence the positive sensitivity of
IEPE sensors).
Contrary to PE sensors, IEPE sensors need to be pow-
ered due to the built-in electronics. However a standard
two-wire cable suffices to power the sensor and transmit
the voltage signal to an IEPE-coupler. An IEPE-Coupler
is an electronic circuit that supplies constant current exci-
tation to IEPE sensors and decouples the subsequent
voltage signal. So you just see the pressure signal.
Kistler offers dual-mode (PE and IEPE) multi-channel
charge amplifiers with integrated IEPE-Coupler and DAQ
(digital and analog outputs) which can be connected di-
rectly away to a PC through an Ethernet cable or through
its analog outputs to an external DAQ system. Alterna-
tively Kistler offers single or multi-channel IEPE-Couplers
that can then be connected to an external DAQ system
and of course IEPE sensors can directly be connected to
any IEPE compatible DAQ.

Piezoelectric Pressure Sensor Type 601C/603C
Page 8 60xC_002-741e-08.18
2.2.2 Characteristics of IEPE sensors and measuring chains
Only dynamic pressure measurements
Whilst quasi-static measurements are possible with
PE sensors, this is not the case for IEPE due to the
fixed time constant in the built-in charge amp. Never-
theless IEPE sensors are well suited to measure dy-
namic pressures and pressure pulsations.
Limited operating temperature range
The operating temperature range of IEPE sensors is
limited due to the integrated electronics and is shown
in the data sheet.
Fixed FSO pressure range
The Full Scale Output (usually nominal ±5 V) pressure
range of IEPE sensors is fixed by the settings of the
integrated electronics and can’t be adjusted.
Use of standard cables
IEPE sensors can be operated with standard two-wire
cables. Standard cables can be used in harsh envi-
ronments and are less sensitive to dirty and humid
environments. IEPE sensors are also the preferred
choice when very long cables are needed.
Compatible with IEPE systems
IEPE sensors can be connected directly to
IEPE-DAQ’s or to a DAQ, through an external IEPE-
coupler, if already available, without the need to pur-
chase an external charge amplifier. Sometimes an ex-
ternal IEPE-coupler might offer some technical ad-
vantages, as for example a higher power supply to
drive longer cables or power supplies with lower noise
for a better signal quality.

Equipment
60xC_002-741e-08.18 Page 9
3. Equipment
3.1 Sensor housing
PE pressure sensors come with a standard or short
housing, whereas IEPE sensors are only available with a
standard housing. Please notice that the connector for
the short housing is different than for the standard hous-
ings.
Type Output signal Housing Connector
60xCAA Charge (PE) Standard 10-32
60xCAB Charge (PE) Short M4
60xCBA… Voltage (IEPE) Standard 10-32
Whenever possible it’s recommended to use a piezoelec-
tric sensor with a standard housing.
The sensor version with short housing was primarily de-
veloped for customers that want to replace their current
Kistler PE pressure sensor (e.g. 601A, 6001, 6031, etc.)
but still keep using the older accessories (e.g. connecting
nipples, adapters).
Fig. 1: Standard housing vs. short housing

Piezoelectric Pressure Sensor Type 601C/603C
Page 10 60xC_002-741e-08.18
3.2 Sensor dummy
It’s recommended to replace the sensor by a sensor
dummy when not being used for measurements or tests
where pressures may exceed the maximum overload
pressure indicated in the datasheet. Using a dummy sen-
sor allows prolonging the life time of the sensor resp.
prevents the sensor being damaged by a too high pres-
sure.
Type Housing Connector
6487AA Standard 10-32
6487AB Short M4
3.3 Seal (Sensor)
Five replaceable copper seals of Kistler Type 1131 are
part of each sensor delivery. Replacement seals as well
as nickel seals of Kistler type 1131A can be ordered sep-
arately. It’s recommended to replace the sensor seal
each time the sensor get demounted and mounted again.
3.4 Floating clamp nut
All of the piezoelectric pressure sensors listed in the in-
troduction of this instruction manual utilize a floating
clamp nut to secure the sensor either into a mounting
adapter or into an appropriately dimensioned mounting
bore (direct mounting). The next chapters will provide
some more details on direct and adapter mounting of the
sensors.
The floating clamp nut needs to be ordered separately as
there are different options to choose from. The table be-
low lists all available types.
Type Hex Thread
6423B00 8 mm M7x0.75
6423B11 9/32” 5/16-24 UNF
Fig 1: Floating clamp nut

Equipment
60xC_002-741e-08.18 Page 11
3.5 Adapter
Fitting sensors into a mounting adapter greatly simplifies
the installation process (for more information see “Mount-
ing Options” chapter). Please find below an overview of
available adapters and floating clamp nuts that fit the cor-
responding adapter:
Type Adapter
Thread Hex Floating Clamp Nut
6503C0A M10x1 11 mm 6423B00
6503C1A 3/8-24 UNF 7/16” 6423B11
6507B0A M3x0.5 8 mm 6423B00
6503B1A 5-40 UNC 11/32” 6423B11
Adapters include one tube of lubrication grease Type
1063. It’s strongly recommended to apply a thin film of
lubricating grease of Kistler Type 1063 to the external
thread of the adapter before mounting. The lubrication
prevents seizing of the threads and surfaces when de-
mounting the adapter as well as sealing against high
pressures.
Below list gives an overview on the approximate pres-
sures up to which the adapters are tight (check tightening
torque chapter for right torques).
6503C 1 000 bar / 14 500 psi
6507B 300 bar / 4 350 psi
3.6 Seal (adapter)
One replaceable seal is part of the adapter delivery. Be-
low table lists all seal types in case replacement is need-
ed.
Type Material Adapter
1113C0B Stainless Steel
1-4301 / 304 6503C0A
1113C1B Stainless Steel
1-4301 / 304 6503C1A
1117B0C Cu 6507B0A
6507B1A
Fig. 2: Kistler lubrication grease, Type 1063

Piezoelectric Pressure Sensor Type 601C/603C
Page 12 60xC_002-741e-08.18
4. Mounting & installation
4.1 Mounting options
4.1.1 Direct mounting
When the mounting location space is restricted, the sen-
sor can be located in an appropriately dimensioned
mounting bore, and then held in place with a floating
clamp nut. Please note that for a reliable and accurate
pressure measurement a precise machining of the
mounting hole is required (for details on mounting hole
fabrication please see corresponding chapter).
Below drawings show the direct mounting of a piezoelec-
tric sensor with standard housing (left) and with short
housing (right). It’s clearly visible that with the standard
housing a cable can be connected and disconnected
without having to dismount the sensor. With the short
housing version the clamping nut and sensor need to be
taken out of the bore. Please take care not to bend the
cables too much, even when space is tight (check cable
datasheet for information on max. bending radius).
Fig 3: Direct mounting

Mounting & installation
60xC_002-741e-08.18 Page 13
4.1.2 Passage mounting
Ideally for best accuracy, a pressure sensor should be
flush-mounted. However sometimes, due to access re-
strictions to the pressure chamber or due to established
engineering practices, this is not possible and so the
sensor needs to be installed recessed.
In these cases, acoustic oscillations may occur in the
cavity if the gas to be measured is stimulated by a fast
pressure change at the entrance of the passage. This ef-
fect is commonly referred to as the ‘organ-pipe effect’.
The pressure oscillation in the cavity is superimposed to
the regular pressure and may affect the signal quality by
making important information like maximum pressures
difficult to extract.
When a sensor installation requires a passage mounting,
it’s recommended to model (e.g. Bergh & Tijdeman,
Helmholtz, organ-pipe acoustical models) the natural fre-
quency of the passage accurately and to design the size
and shape of the passage to optimize the signal quality.
Nominally, the suggested passage diameter would be
equal or greater than 20% of the passage length. For
more information on this please contact Kistler.
Fig. 4: Passage mounting

Piezoelectric Pressure Sensor Type 601C/603C
Page 14 60xC_002-741e-08.18
4.1.3 Adapter mounting
Fitting sensors into a mounting adapter greatly simplifies
the installation process (when space and wall thickness
are not a premium). Use of a mounting adapter will elimi-
nate the need to provide a precise mounting configura-
tion and allow the installer to provide only a threaded
hole of the size and depth required for the adapter se-
lected. Special reamers or taps are not required when us-
ing an adapter.
Fig 5: Mounting adapter (left: 6503C… / right: 6507B…)

Mounting & installation
60xC_002-741e-08.18 Page 15
4.2 Installation
4.2.1 Tightening torque
It’s mandatory to use a torque wrench for tightening the
floating clamp nut and adapter in order to ensure tight-
ness at the max. specified pressures. Following table
gives on overview on the corresponding torques to be
applied:
The adapter should whenever possible be mounted and
tightened first (without sensor) and then in a second step
the sensor with the floating clamp nut. For demounting
start first with the floating clamp nut, then the sensor and
finally the adapter.
It’s strongly recommended to apply a thin film of lubricat-
ing grease of Kistler Type 1063 to the external thread of
the adapter before mounting. The lubrication prevents
seizing of the threads and surfaces when demounting the
adapter as well sealing against high pressures. Adapters
include one tube of lubrication grease Type 1063.
4.2.2 Cabling
Cables should be routed to avoid tension, kinking, and
sharp bends, particularly at the connectors. Restrain ca-
bles by tying, taping or clamping in high vibrations envi-
ronments so as to avoid mechanical damage. For high
impedance cables this also removes triboelectric noise.
Care should be taken to avoid routing wires near hot
pipes or where cable damage could occur from moving
parts of the installation.
Floating clamp nut N·m in·lbf
6423B00 2 17.7
6423B11 2 17.7
Adapter N·m in·lbf
6503C0A 10 88.51
6503C1A 10 88.51
6507B0A 1 8.85
6507B1A 1 8.85
Fig. 6: Kistler lubrication grease, Type 1063

Piezoelectric Pressure Sensor Type 601C/603C
Page 16 60xC_002-741e-08.18
4.3 Manufacturing of mounting hole
4.3.1 Direct mounting (ISO)
The following procedure is recommended for the manu-
facturing of the direct mounting bore with Kistler step drill
type 1331 and for use with ISO floating clamp nut
6423B00 with a M7x0.75 thread.
Fig. 7: Flush mounting bore Fig. 8: Kistler step drill, Type 1331
1. Centering hole, use a center drill with 3.0 mm diameter
and 90° chamfer angle.
2. Ø5.5 mm through-hole, use a spiral drill with 5.5 mm
diameter.
Ø7.35 mm countersink at the entrance of the Ø5.5 mm
blind hole, use a countersink cutter with a 90° chamfer
angle.
3. Ø6.3 mm blind hole, use a spiral drill with 6.3 mm
diameter. Select the bore depth accordingly, so that
the front cutting lips of the spiral drill do not undercut
the residual wall thickness of 6.1 mm at the diameter
of 5.5 mm.
A too deep blind hole will damage the contact surface
to the sensor (shoulder) and thus the sealing surface.
This could result in leakage at low pressure.

Mounting & installation
60xC_002-741e-08.18 Page 17
4. Stepped bore, use the Kistler step drill type 1331 to
obtain the final dimensions of the direct mounting
bore. The residual wall thickness is 5.9 mm.
The sealing surface (shoulder) created by the step drill
must meet following requirements: A surface flatness
of 30 μm or less, no radial chatter marks and a
maximum roughness of 0.4 μm.
5. Chamfer, chamfer the inner edge of the sealing sur-
face to a maximum size of 0.05 mm x 45°.
Keep the chamfer as small as possible in order to
obtain a large sealing surface.
6. Thread, use a M7x0.75 tap. The thread must be fully
functional up to a maximum distance of 5 mm from the
sealing surface.
Pay attention to the thread run-out length to prevent
damage to the sealing surface.
7. Rework direct mounting bore to meet specifications if
required.

Piezoelectric Pressure Sensor Type 601C/603C
Page 18 60xC_002-741e-08.18
4.3.2 Direct mounting (ANSI)
The following procedure is recommended for the manu-
facturing of the direct mounting bore with Kistler step drill
type 1331 and for use with ANSI floating clamp nut
6423B11 with a 5/16-24 UNF thread.
Fig. 9: Flush mounting bore Fig. 10: Kistler step drill, Type 1331
1. Centering hole, use a center drill with 0.125″diameter
and 90° chamfer angle.
2. Ø0.2165″through-hole, use a spiral drill with 0.2165″
diameter.
Ø0.328″countersink at the entrance of the 0.2165″
blind hole, use a countersink cutter with a 90° chamfer
angle.
3. Ø0.248″blind hole, use a spiral drill with 0.248″
diameter. Select the bore depth accordingly, so that
the front cutting lips of the spiral drill do not undercut
the residual wall thickness of 0.24″at the diameter of
0.2165″.
A too deep blind hole will damage the contact surface
to the sensor (shoulder) and thus the sealing surface.
This could result in leakage at low pressure.