Kistler 5159A Series User manual

Instruction
Manual
5159A_002-890e-12.19
Charge and
thermocouple
amplifier
Type 5159A...

Page 1
5159A_002-890e-12.19
The information stated in this manual may be changed at
any time without prior notification. Kistler reserves the right
to improve and modify the product in keeping with tech-
nical advances, with no obligation to notify individuals or
organizations on account of such changes.
© 2019 Kistler Group. Products of the Kistler Group are pro-
tected by various intellectual property rights. For more infor-
mation, visit: www.kistler.com. The Kistler Group includes
Kistler Holding AG and its subsidiaries in Europe, Asia, the
Americas and Australia.
Kistler Group
Eulachstrasse 22
8408 Winterthur
Switzerland
Tel. [phone]
[e-mail]
www.kistler.com
Preface
Preface

Charge and thermocouple amplifier, Type 5159A...
5159A_002-890e-12.19
Page 2
Table of contents
1. Introduction.................................................................................................................................. 3
1.1 Safety information...............................................................................................................3
1.2 Electromagnetic compatibility (EMC)..................................................................................4
1.3 Warnings.............................................................................................................................4
1.4 Information on disposal of electronic equipment ................................................................5
1.5 Software upgrades and updates.........................................................................................5
2. Basic information........................................................................................................................6
2.1 Chargeamplier .................................................................................................................7
2.1.1 Analogchargeamplier.........................................................................................7
2.1.2 DigitalchargeamplierasperEUROMAP75(VARANorEtherCAT) ..................8
2.2 Thermocoupleamplier ......................................................................................................9
2.2.1 Importantrequirementforusewithanalogchargeamplier ...............................10
2.3 Switching based on cavity pressure .................................................................................10
2.3.1 Importantrequirementsforusewithchargeamplier .........................................10
2.3.1.1 Injection molding machine ...................................................................10
2.3.1.2 Injection mold.......................................................................................13
2.4 Switching based on cavity pressure
Self-optimizingswitch-overpointdetection(SLP) .......................................................................13
2.5 Block diagram...................................................................................................................14
2.6 Dimensions.......................................................................................................................15
2.6.1 Analogchargeamplier,Type5159A…1… ........................................................15
2.6.2 Digitalchargeamplier,Type5159A42…andType5159A43… ........................16
2.7 Connections......................................................................................................................17
2.8 Orderinginformation.........................................................................................................18
2.8.1 Orderingkey........................................................................................................18
2.8.2 Included accessories...........................................................................................18
2.8.3 Optionalaccessories...........................................................................................18
3. Commissioning .........................................................................................................................19
3.1 Installation information......................................................................................................19
3.2 Installation ........................................................................................................................20
3.2.1 Mains connection and power supply ...................................................................20
3.2.2 Connecting the sensors.......................................................................................20
3.3 Analogchargeamplier,Type5159A…1…......................................................................21
3.3.1 Measurement mode ............................................................................................21
3.3.2 Testmode............................................................................................................21
3.4 Type5159A…2…and5159A…3…digitalchargeampliers...........................................22
4. Maintenance and diagnostics..................................................................................................23
4.1 Service..............................................................................................................................23
Total pages: 23

Introduction
Page 3
5159A_002-890e-12.19
1. Introduction
Thank you for opting for a Kistler quality product. Please
read through this Instruction Manual carefully so that you
can make optimal use of your product's wide variety of fea-
tures.
Insofar as permitted by law, Kistler declines all liability in
case of actions contrary to this Instruction Manual, or if
products other than those listed under "Accessories" are
used.
Kistler offers an extensive portfolio of products and com-
plete solutions based on measurement technology:
Piezoelectric sensors to measure pressure, force, mo-
ment, strain, acceleration, shock and vibration
Strain gauge sensor systems to measure force and mo-
ment
Piezoresistive pressure sensors and transmitters, with
matching measurement amplifiers
Matching measurement amplifiers (charge amplifiers,
piezoresistive amplifiers, etc.), display units and charge
calibrators
Electronic control, monitoring and evaluation units as
well as application-specific software for measurement
technology
Data transmission modules (telemetry)
Kistler also designs complete special-purpose measuring
systems for use in the automotive industry, plastics process-
ing, biomechanics and many other application areas.
Our complete catalog provides an overview of our portfo-
lio. Detailed data sheets are available for virtually all Kistler
products.
If you have any specific questions that remain unanswered
after you have studied these instructions, you are welcome
to contact Kistler's worldwide Customer Service: our ex-
perts will also be glad to offer you professional advice on
any application-specific problems.
1.1 Safety information
The device was in absolutely safe condition when it left
the factory. In order to maintain this condition, and to en-
sure safe and reliable operation, follow the instructions and
warnings in this Instruction Manual and on the device itself.
Also comply with local safety regulations for handling elec-
trical and electronic equipment.

Charge and thermocouple amplifier, Type 5159A...
5159A_002-890e-12.19
Page 4
If it must be assumed that the amplifier can no longer be
operated safely, switch it off and protect it against being
switched back on unintentionally.
Hazard-free operation is no longer possible if the device is
visibly damaged, does not function correctly,


was stored under unfavorable conditions for a lengthy
period,
was damaged during transportation.
If it is evident that hazard-free operation is no longer en-
sured, the device must immediately be sent to the appropri-
ate Kistler Sales Center or Kistler dealer for repair.
1.2 Electromagnetic compatibility (EMC)
The Type 5159A... charge amplifier is CE compliant as de-
fined in EU Directive 2004/108/EC and is also compliant
with the following product standard: EMC emissions: EN
61326-1 (class A), EMC immunity: EN 61326-1 (class A).
1.3 Warnings
Failure to comply with the precautions described here may
lead to malfunctions or damage to system components (see
the table below).
Symbol Non-compliance may cause:
Mechanical faults or unforeseeable consequences
(risks to property or people).
Refers to a hazard warning or other warning.

Introduction
Page 5
5159A_002-890e-12.19
Refers to important information or a recommendation.
1.4 Information on disposal of electronic equipment
Used electronic equipment must not be disposed of
with household waste. Please return disused or retired
equipment to the nearest electronic waste collection point
for disposal, or contact your Kistler Sales Center.
1.5 Software upgrades and updates
Kistler may develop upgrades or updates for the integrated
software.
This device does not allow firmware updates by the cus-
tomer. Please contact Kistler's Customer Service to check
out the options for updating your device to the latest firm-
ware.
Kistler declines all liability for direct or consequential dam-
age caused by products that operate with integrated soft-
ware and are not updated with the latest software supplied.

Charge and thermocouple amplifier, Type 5159A...
5159A_002-890e-12.19
Page 6
2. Basic information
The Type 5159A… multichannel-charge amplifier converts
the charge signal from piezoelectric cavity pressure sen-
sors and thermocouples into analog output signals or into
a digital output with an Ethernet real-time protocol as per
EUROMAP 75 with Varan or EtherCAT. This charge ampli-
fier was developed for industrial use with injection molding
machines and is available in differently equipped versions as
follows:
One or four inputs for piezoelectric cavity pressure sen-
sors
Two inputs for piezoelectric cavity pressure sensors and
two inputs for thermocouples of types K, J, L or N
In addition to the conventional single-channel inputs,
the Type 5159A4… version for four piezoelectric cav-
ity pressure sensors also features efficient multichan-
nel technology with only one cable (Type 1995A).
This can be used to connect up to four pressure sensors si-
multaneously.
The Type 5159A... amplifier features interfaces with the in-
jection molding machine or the data acquisition unit with
the following options:
Analog output 0 ... 10 V
Digital output as per EUROMAP 75 with Varan real-time
protocols
Digital output as per EUROMAP 75 with EtherCAT re-
al-time protocols
The versions with the digital interface as per EUROMAP
75 (Varan or EtherCAT real-time protocol) feature two bus
interfaces. Cascading on the bus is possible in order to in-
crease the number of channels.
For injection molding with thermoplastics, the SLP option
(Switch Level Process – self-optimizing switch-over point
detection) automatically detects the volumetric filling of the
mold and sends a switching signal to the injection molding
machine in each cycle. For this purpose, the mold must be
equipped with a cavity pressure sensor near the gate.
The functionalities of the analog and digital charge amplifi-
ers and the thermocouple amplifier are described in section
2.1 below.

Basic information
Page 7
5159A_002-890e-12.19
2.1 Charge amplifier
The term "charge amplifier" does not denote a device that
amplifies a charge Q1 to a value of Q2. Kistler uses this
term to denote a device that converts charge Q into a volt-
age Uaor into a digital signal. A "charge amplifier" is there-
fore a "charge-voltage converter". It uses the integrator
circuit principle.
The Type 5159A... multichannel charge amplifier is intend-
ed for use with piezoelectric cavity pressure sensors and
thermocouples of types K/J/L/N. It was developed for in-
stallation in injection molding machines.
The output signals can be used to monitor, control and opti-
mize the injection molding process. The SLP option (Switch
Level Process – self-optimizing switch-over point detection)
can easily be integrated into machine controls. In case of
a retrofit, the injection molding machine must be prepared
as appropriate by the machine manufacturer. The SLP op-
tion substantially reduces setup effort for the processes
because the switch-over point is specified automatically
by the charge amplifier, with no need for manual optimi-
zation. During production, this option automatically adjusts
the switching pressure, thus ensuring more consistent part
characteristics in case of process fluctuations.
2.1.1 Analog charge amplifier
The function of the Type 5159A…1… analog charge am-
plifier is to convert the electrical charge emitted by a piezo-
electric sensor into a proportional voltage.
Range switching, and also Reset/Operate, are electrically
isolated from the amplifier circuit by optocouplers.
Selection of measuring range
The measuring range (FSO: Full Scale Output) is dependent
on the maximum charge that occurs (Qmax). The maximum
charge that occurs is calculated from the maximum cavity
pressure (Pmax) and the sensor's sensitivity (E). The maxi-
mum charge that is expected to occur must correspond to
the charge amplifier's measuring range. Two measuring
ranges are available: measuring range I = ±20,000 pC and
measuring range II = ±5,000 pC. The maximum charge that
occurs is calculated as follows:
Qmax [pC] = Pmax [bar] • E [pC/bar]
Example:
Type 5159A…1… (see section 3.3 for an explanation of the
types)
Sensor sensitivity EP= 9.4 pC/bar
Pmax = 1,500 bar

Charge and thermocouple amplifier, Type 5159A...
5159A_002-890e-12.19
Page 8
Qmax = 14,100 pC ⇒Range I
Pmax = 300 bar
Qmax = 2,800 pC ⇒Range II
The charge amplifier is only suitable for cyclical measure-
ments and requires a Reset signal before every measuring
cycle. To perform measurements, the Reset/Operate signal
must be set to Operate.
An example of a suitable control signal for Operate (i.e.
"Measurement active" ) is a digital output on the injection
molding machine that signals the start of injection. Possi-
ble Operate signals could also include "Start closing mold",
"Start buildup of clamping force" and "Nozzle pressing
force reached", etc. Generally speaking, a signal that is as
close in time as possible to the start of the injection process
should be chosen. The digital output from the machine that
is used for the Operate signal must only be reset to "Inac-
tive" at the same time as "Start opening mold". The cavity
pressure measurement is stopped at this point in time be-
cause the part is no longer in contact with the sensor.
Section 3 includes important information about the integra-
tion of the charge amplifier into the injection molding ma-
chine control. This information is intended for the machine
manufacturer's developers.
2.1.2 Digital charge amplifier as per EUROMAP 75 (VARAN or EtherCAT)
The function of the Type 5159A…2… and Type 5159…3…
digital charge amplifiers is to convert the electrical charge
emitted by a piezoelectric sensor into a proportional volt-
age, and then into a digital signal as per the Varan or Eth-
erCAT Ethernet real-time protocols in accordance with the
EUROMAP 75 specification.
Range switching, and also Reset/Operate, are electrically
isolated from the amplifier circuit by optocouplers.
All communication, configuration and user data is trans-
mitted exclusively via Industrial Ethernet, making it easy
for machine and equipment manufacturers to use the de-
vice. No additional software is required; the programming
interface of the machine control (which is already familiar)
is used instead. Sound knowledge of setting up and pro-
gramming Ethernet real-time protocols, and of device inte-
gration, is required.
Integration into the control environment is implemented
with the help of the interface definition as per the EURO-
MAP 75 specification.
Selection of measuring range
The measuring range is selected in the same way as for
the analog charge amplifier, see section 2.1.1 "Selection of

Basic information
Page 9
5159A_002-890e-12.19
measuring range".
Four measuring ranges/span lists are available as per EURO-
MAP 75:
- Measuring range I = ±2,000 pC
- Measuring range II = ±5,000 pC.
- Measuring range III = ±10,000 pC.
- Measuring range IV = ±20,000 pC.
In the same way as for the analog charge amplifiers, the
maximum charge that occurs is calculated as follows:
Qmax [pC] = Pmax [bar] • E [pC/bar]
Example:
Type 5159A…2… (see section 3.3 for an explanation of the
types)
Sensor sensitivity EP = 9.4 pC/bar
Pmax = 150 bar
Qmax = 1,410 pC ⇒Range I = ±2,000 pC
Pmax = 600 bar
Qmax = 5,600 pC ⇒Range III = ±10,000 pC
The charge amplifier is only suitable for cyclical measure-
ments and requires a Reset signal before every measuring
cycle. To perform measurements, the Reset/Operate signal
must be set to Operate.
The digital charge amplifier (slave) receives the Operate sig-
nal (i.e. "Measurement active") from the master (the injec-
tion molding machine).
Section 3 includes important information about the integra-
tion of the charge amplifier into the injection molding ma-
chine control. This information is intended for the machine
manufacturer's developers.
2.2 Thermocouple amplifier
The amplifiers (analog and digital versions) are available
with a combined 2-channel pressure and 2-channel ther-
mocouple amplifier (Type 5159A3…). Thermocouples of
types K, J, N and L (e.g. Types 619…) and the temperature
sensors of combined pressure/temperature sensors (p-T
sensors: Type 6188A, Type 6189A..., Type 6190A…) can
be connected.
The temperature amplifier is available for a melt tempera-
ture measuring range from 0°C to 300°C.
For the analog amplifier (Type 5159A31...), 300°C corre-
sponds to an analog voltage of 10 V at the output.
For digital amplifiers, the output signal is defined in EURO-
MAP 75.

Charge and thermocouple amplifier, Type 5159A...
5159A_002-890e-12.19
Page 10
2.2.1 Important requirement for use with analog charge amplier
Function of the digital machine signal inputs
The digital input can be connected internally either with po-
tential of 18 ... 30 VDC or with GND.
Test, Operate, Range II and Sensitivity are therefore activat-
ed with the opposite potential or (on a customized basis) in
response to any desired potential.
Control level:
TeSel2 TeSel1
bits 2 1
Thermocouple K Low Low
Thermocouple J Low High
Thermocouple N High Low
Thermocouple L High High
Test signal (8 V) On logic High
Test signal Off logic Low
(Test signal of 8 V on all available analog output chan-
nels when Range II is active)
2.3 Switching based on cavity pressure
2.3.1 Important requirements for use with charge amplifier
2.3.1.1 Injection molding machine
For switching based on cavity pressure, the injection mold-
ing machine must be designed with a selectable "Switching
based on cavity pressure" option.
This machine-side option must essentially have the follow-
ing characteristics:
Hardware for analog Type 5159A…1…
i. Analog machine inputs:
One analog voltage input 0 ... 10 V into the machine
control for Type 5159A…1… for the cavity pressure sig-
nal, for one channel in each case.

Basic information
Page 11
5159A_002-890e-12.19
ii. Digital machine outputs (active = 10 ... 30 V,
inactive <5 V):
The digital input can be connected internally either with po-
tential of 18 ... 30 VDC or with GND.
Test, Operate, Range II and Sensitivity are therefore activat-
ed with the opposite potential or (on a customized basis) in
response to any desired potential.
Control level:
Operate logic High
Reset logic Low
Range II ( 5,000 pC) logic High
Range I ( 20,000 pC) logic Low
Hardware for digital Types 5159A…2… and 5159A…3…
The machine must have an Ethernet hardware interface, in-
cluding power supply, as specified in EUROMAP 75.
Software:
A screen page must be created in the machine control
where the following values have to be entered by the oper-
ator / setup technician / tester, depending on the hardware
configuration:
Input / select measuring range: Range I and Range II of the
charge amplifier
On the analog charge amplifier (Type 5159…1…), users
can choose between Range I = ±20,000 pC and Range
II=±5,000 pC. This involves data specific to the charge am-
plifier and the amplifier usually stays on the machine; for
this reason, it is advisable to allow only one administrator
to access the values and to store them in the machine con-
figuration.
Digital charge amplifiers of Type 5159…2… and Type
5159…3… select the measuring range automatically (see
EUROMAP 75). Four measuring ranges are available with
the following values: ±2,000 pC, ±5,000 pC, ±10,000 pC
and ±20,000 pC.
Selecting the type and input for the sensor's sensitivity
1. Direct-measuring sensor: enter the sensitivity Ep in [pC/
bar]
2. Indirect-measuring sensor: enter the sensitivity EN in
[pC/N] and add the ejector diameter D [mm] or the
ejector area [mm2].

Charge and thermocouple amplifier, Type 5159A...
5159A_002-890e-12.19
Page 12
The sensitivity in [pC/bar] is calculated as follows:
Possible values for the sensitivity are 1 ... 50 pC/bar. Two
decimal places should be available for the input.
The most frequently used Kistler cavity pressure sensors
have –2.5 pC/bar or –9.4 pC/bar. The minus sign (–) is not
relevant to the calculation and can be disregarded.
The sensor data is generally mold specific; the data should
be stored and called up again together with the mold-relat-
ed data.
Activation: Reset/Operate
The injection molding machine's Reset/Operate signal
starts and ends the charge amplifier's measurement. The
machine's Operate output should be set to "Active" as
promptly as possible before injection starts. Other usable
triggers could include: "Start closing mold", "Start build-
up of clamping force", "Nozzle pressing force reached",
"Needle valve nozzle opened", etc. The Operate signal
must remain on "Active" throughout the entire cycle and
must only be reset to "Inactive" on "Start opening mold".
v. Using the cavity pressure signal (Signal Out) for switching
On the screen, it must be possible to enter the screw po-
sition SUm [mm] or [cm3] or [in] or the hydraulic pressure
PHydum [bar] at which the switch to holding pressure is per-
formed by the machine. It must also be possible to enter a
threshold or limit value for the cavity pressure.
In addition, it must be possible to enter a release position
for the screw (SFreigabe) at which the switch in response to
the cavity pressure signal first becomes possible or is per-
mitted.
As soon as the position falls short of release position SFreiga-
be, the current cavity pressure must be compared with the
threshold value that was entered. If the cavity pressure ex-
ceeds the threshold value, the machine must switch from
injection (speed controlled) to holding pressure (pressure
controlled). If either of these conditions: current screw po-
sition S< = switching position SUm or hydraulic pressure P>
= switching pressure PHydum are met before the threshold
value is reached, a switch to holding pressure must be per-
formed by the injection molding machine as a mandatory
requirement.

Basic information
Page 13
5159A_002-890e-12.19
2.3.1.2 Injection mold
For switching based on the cavity pressure threshold, the
mold must be equipped with a cavity pressure sensor near
the gate. It should be located in the first third of the flow
path.
2.4 Switching based on cavity pressure
Self-optimizing switch-over point detection (SLP)
The SLP option (Switch Level Process – self-optimizing
switch-over point detection) can be selected when ordering
the charge amplifier. An algorithm determines the optimal
switch-over point and sends a switching signal to the in-
jection molding machine. Cavity pressure sensors near the
gate are required for switching in response to cavity pres-
sure.
The fixed pressure threshold and the maximum pressure
threshold are dependent on the range that is set and the
sensor's sensitivity. With the fixed pressure threshold,
switching takes place during the first cycle. The switch-
ing takes place at the latest when the maximum pressure
threshold is reached.
The algorithm adapts itself continuously and does not re-
quire a learning phase. The switch-over points for the last
three cycles are continuously averaged to increase the sta-
bility of the switch-over point. To prevent the triggering of
a switching by mistake due to disturbances when the cycle
starts, the switching takes place at the earliest after a mini-
mum period.
If the algorithm detects a pressure drop, the switching
threshold is increased automatically for the next cycle. This
takes place until the pressure drop can no longer be detect-
ed.
On the Type 5159A…1… charge amplifier, a switching sig-
nal is sent to the machine as soon as the first channel reach-
es the switch-over point.
On Types 5159A…2… and 5159A…3…, it is possible to
select the channel that triggers the switching signal. Al-
ternatively, in exactly the same way, the first channel that
reaches the switch-over point can trigger the switching sig-
nal.

Charge and thermocouple amplifier, Type 5159A...
5159A_002-890e-12.19
Page 14
2.5 Block diagram

Basic information
Page 15
5159A_002-890e-12.19
2.6 Dimensions
2.6.1 Analog charge amplifier, Type 5159A…1…
Abb. 1: Dimensions of the Type 5159A11…, Type 5159A41… charge amplifier
Abb. 2: Dimensions of the Type 5159A31… charge amplifier

Charge and thermocouple amplifier, Type 5159A...
5159A_002-890e-12.19
Page 16
2.6.2 Digital charge amplifier, Type 5159A42… and Type 5159A43…
Abb. 3: Dimensions of the Type 5159A42… and 5159A43… charge amplifier
Abb. 4: Dimensions of the Type 5159A32… and Type 5159A33… charge amplifier

Basic information
Page 17
5159A_002-890e-12.19
2.7 Connections
Connections
Sensor charge input
1 Channel 1
2 Channel 2
3 Channel 3
4 Channel 4
5 SensorGND
6 NC
Sensor thermocouple input
Reddot
Type BNCneg./TNCneg.and,
 ifnumberofchannels>1,
Fischer A103A056 male
(connected in parallel)
Type Fischer
 DBPU102A051
female
Powersupply,signaloutputs,controlinputs
a) for1-channelversion:NC
b) for1-and2-channelversion:NC
Type DSub25polmale
*SF1 ...4 = melt front 1 ... 4
Varaneldbusinput Type M12chassisplug
 8-polemale,
binder connector
09-3481-116-08
Varan-FeldbusAusgang(Slave) Type M12chassissocket
 8-polefemale,
binder connector
09-3482-116-08

Charge and thermocouple amplifier, Type 5159A...
5159A_002-890e-12.19
Page 18
2.8 Ordering information
Various versions of the Type 5159A... charge amplifier are
available. They differ as regards the type and number of
inputs, the interface and the logic functions. The full type
designation of the multichannel charge amplifier consists of
the basic type identifier (Type 5159A) plus three additional
digits. The following key shows the available versions of the
device:
2.8.1 Ordering key
Charge amplifier Type 5159A
Inputs
1 channel charge 1
2 channels charge + 2 channels temperature 3
4 channel charge 4
Outputs
Analog 1
Varan 2
EtherCAT 3
Logic functions
Standard 0
SLP 1
2.8.2 Included accessories
None
2.8.3 Optional accessories
Type/Mat. No.
BNC-TNC adapter 1719
D-Sub socket/plug connector, 25-pole 65009205
female
D-Sub plastic cover (hood), waterproof, 65008375
shielded, for 25-pole D-Sub
(Conec art. no.: 165X15039X)
D-Sub connector, 25-pole, female, IP67 1557A10
with cable bushing M20x1.5, for cable
diameters of 6 …12 mm
Compensation lead, type K 2295A…