Kistler 6052 Series User manual

Instruction
Manual
6052_002-839-12.20
Uncooled
piezoelectric
pressure sensors
Types
6052...,
6054...,
6056...,
6058…,
6124...,
6125...,
6044…,
6045...

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6052_002-839-12.20
We thank you for choosing a Kistler quality product distin-
guished 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 obliga-
tion to notify any person or organization of such changes
or improvements.
© 2018 ... 2020 Kistler Group. Kistler Group products are
protected by various intellectual property rights. For more
details visit www.kistler.com. The Kistler Group includes
Kistler Holding AG and all its subsidiaries in Europe,
Asia, the Americas and Australia.
Kistler Group
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Switzerland
Tel. [phone]
[e-mail]
www.kistler.com
Foreword
Foreword

Uncooled piezoelectric pressure sensors
6052_002-839-12.20
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Content
1. Introduction ...................................................................................................................................3
1.1 Disposal instructions for electronic equipment ...................................................................4
1.2 Software upgrades and updates.........................................................................................4
2. Preface..........................................................................................................................................5
2.1 Technical data and documentation .....................................................................................5
2.2 Principle of operation..........................................................................................................6
3. Installation of the piezoelectric sensor ..........................................................................................7
3.1 General information ............................................................................................................7
3.2 Direct installation ................................................................................................................9
3.3 Installation with sleeve........................................................................................................9
3.4 Installation examples ........................................................................................................10
3.5 Machining the mounting bore ...........................................................................................10
3.6 Check points before installation........................................................................................12
3.7 Flameguard for M5 sensors .............................................................................................13
4. Installing the sensor into the bore ...............................................................................................14
5. Piezoelectric sensor cable routing ..............................................................................................15
6. Setting up the measuring chain ..................................................................................................16
6.1 Connectingthepiezoelectriccabletochargeamplier ....................................................16
6.2 Selecting the sensor sensitivity ........................................................................................16
7. Dismounting and maintenance ...................................................................................................18
7.1 Dismounting......................................................................................................................18
7.2 Maintenance .....................................................................................................................18
Kistler Technical Center services...........................................................................................................23
Total pages 23

Introduction
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6052_002-839-12.20
1. Introduction
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 pro-
ducts other than those listed under Accessories are used.
Kistler offers a wide range of products for use in measu-
ring technology:
Piezoelectric sensors for measuring force, torque,
strain, pressure, acceleration, shock, vibration and
acoustic-emission
Strain gage sensor systems for measuring force and
moment
Piezoresistive pressure sensors and transmitters
Signal conditioners, indicators and calibrators
Electronic control and monitoring systems as well as
softwareforspecicmeasurementapplications
Data transmission modules (telemetry)
Kistler also develops and produces measuring solutions
fortheapplicationeldsengines,vehicles,manufacturing,
plastics and biomechanics sectors.
Our product and application brochures will provide you
with an overview of our product range. Detailed data
sheets are available for almost all products.
If you need additional help beyond what can be found
either online or in this manual, please contact Kistler‘s
extensive support organization.

Uncooled piezoelectric pressure sensors
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1.1 Disposal instructions for electronic equipment
Do not discard old electronic devices in municipal trash.
For disposal at end of life, please return this product to
an authorized local electronic waste disposal service
or contact the nearest Kistler sales ofce for return
instructions.
1.2 Software upgrades and updates
Kistler may from time to time supply upgrades or updates
for embedded software. Such upgrades or updates must
always be installed.
Kistler declines any liability whatsoever for any direct or
consequential damage caused by products running on
embedded software which has not been upgraded or up-
dated with the latest software supplied.

Preface
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6052_002-839-12.20
2. Preface
Uncooled piezoelectric sensors are a highly efcient
design of sensor. This allows easy access to the
combustion chamber with minimal installation and in-
service effort. They provide highly precise measurements
and data quality, with a level of performance comparable to
water cooled sensors (depending upon the application and
installation). They are easily capable of performing high-
precision thermodynamic studies such as assessment of
the combustion curve and analysis of the gas exchange
process. The design of the sensor body allows reliable
measurements irrespective of engine operation mode and
boundary conditions.
Types 6052 6054 6056 6058 6124 6125 6044 6045
Fig. 1: Uncooled cylinder pressure sensors
2.1 Technical data and documentation
Data sheets are available on www.kistler.com.

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2.2 Principle of operation
The sensor membrane converts the measured pressure
into a force which is applied to the piezoelectric measu-
ring element. In the piezoelectric crystal package this
force generates an electrostatic charge proportional to the
load. An electrode collects this charge and supplies it to
the sensor connector, then via the piezoelectric cable; the
chargeamplierconvertsthischargeintoanelectricvol-
tage for measurement and processing.
The piezoelectric principle is suitable for measurements
of fast, dynamic and quasi-static pressure changes and
thus plays a key role in engine pressure measurements.
Fig. 2: Structure of a front sealing sensor Type 6052

Installation of the piezoelectric sensor
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6052_002-839-12.20
3. Installation of the piezoelectric sensor
3.1 General information
The accuracy of a measurement and quality of the data
are highly dependent on careful installation of the piezo-
electric pressure sensor.
Thesensorboremustbemachinedtothespeciedtole-
rances.
Thespeciedtighteningtorqueofthepiezoelectricsensor
must be observed.
The sensor installation plays a critical part in contributing
to the overall accuracy and performance of the measu-
rement chain itself. So a good understanding of the ins-
tallation types and their strengths and weaknesses is es-
sential information for the measurement and development
engineer.
Sensors can be classied in several ways. In this do-
cument, relating to uncooled sensors, we shall look at
sealing and installation securing technologies as the main
differentiators. This means whether the sensor is front
sealed or shoulder sealed. In combination with threaded
or plug-in securing methods.
When planning the installation, it is possible with certain
types, to consider the amount of recession of the sensor
membrane itself relative to the inner cylinder head surface.
Thiscanhaveconsiderablebenetswithrespecttosensor
temperature management - but must be traded off with the
potential that the additional volume in front of the mem-
brane can act as a resonator at certain conditions - thus
adding undesirable high frequencies to the measured data
atspecicspeedsorloadoperatingpointsattheengine.
Fig. 3: Volume in front of sensor membrane

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As a general rule 8mm, threaded (Type 6044/6045) and 1/4
inch plug-in sensor (Type 6124/6125) from Kistler can be
completelyushmountedifdesired.However,aslightre-
cess of up to 2 mm can help considerably with sensor du-
rability, without creating a resonance in a frequency range
which is problematic for engine measurement applications.
Plug-in sensors (Type 6124/6125) are particularly sensi-
tive to machining bore tolerances. This is due to the fact
that the smooth, larger bore is used to correctly position
the sensor concentrically, before the clamping device is
applied. Any mis-alignment will create potential of incor-
rect sealing, excessive localised heat build-up and prema-
ture failure of the sensor itself.
Fig. 4: Sensor Type 6124/6125 bore machining requi-
rements
Front sealed sensors will always require some structural
material at the front of the sensor in order to provide and
support the sealing surface itself. This fact inevitably me-
ans that a front sealed sensor cannot be mounted ush
with the cylinder head surface - there must always be vo-
lume in front of the membrane. The size of this volume
depends upon the material surrounding the sensor instal-
lation - as higher strength material can provide the requi-
red support with less material and thus a smaller volume
in front of the membrane.
Fig. 5: Front seal sensor, dead volume in front of
membrane