Kistler 6041B Owner's manual

Instruction

Manual

7061_002-027e-09.23

Water cooled

piezoelectric

pressure sensors

Types

6041...,

6043...,

6061...,

6067...,

7061...

Page 17061_002-027e-09.23

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.

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

Eulachstraße 22

8408 Winterthur

Switzerland

Tel. +41 52 224 11 11

info@kistler.com

www.kistler.com

Foreword

Water cooled piezoelectric sensors

7061_002-027e-09.23Page 2

Content

1. Introduction ...................................................................................................................................3

1.1 Disposal instructions for electronic equipment ...................................................................4

1.2 Software upgrades and updates .........................................................................................4

2. Preface ..........................................................................................................................................5

2.1 Techical data and documentation .......................................................................................5

2.2 Principle of operation ..........................................................................................................6

2.3 Requirements to water cooling ...........................................................................................7

2.4 Precautions for water cooling .............................................................................................7

3. Installation of the piezoelectric sensor ..........................................................................................9

3.1 General information ............................................................................................................9

3.2 Direct installation ................................................................................................................9

3.3 Installation with sleeve ........................................................................................................9

3.4 Installation examples ........................................................................................................10

3.5 Machining the mounting bore ...........................................................................................11

3.6 Mounting the water hose on the cooling pipe ...................................................................11

3.7 Check points before installation ........................................................................................12

4. Installing the sensor into the bore ...............................................................................................13

5. Piezoelectric sensor cable routing ..............................................................................................14

6. Setting up the measuring chain ..................................................................................................15

6.1 Connectingthepiezoelectriccabletochargeamplier ....................................................15

6.2 Selecting the sensor sensitivity ........................................................................................15

7. Dismounting and maintenance ...................................................................................................16

7.1 Dismounting ......................................................................................................................16

7.2 Maintenance .....................................................................................................................16

Kistler Technical Center services ...........................................................................................................19

Total pages 19

Introduction

Page 37061_002-027e-09.23

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oers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.

Water cooled piezoelectric sensors

7061_002-027e-09.23Page 4

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 o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

Page 57061_002-027e-09.23

2. Preface

Water cooled piezoelectric sensors are the most precise

cylinder pressure sensors. They are essential for per-

forming high-precision thermodynamic studies such as

assessment of the combustion curve, determination of the

friction loss and analysis of the gas exchange. The built-

in water cooling keeps the sensing element at constant

temperature (most stable sensor sensitivity regardless

of the engine operating condition) and reduces the load-

changedrift(zeroosetofthepressuresignal)duringthe

measurement.

Types 6041 6061 6067 7061 6043

Fig. 1: Water-cooled cylinder pressure sensors

2.1 Techical data and documentation

Data sheets are available on www.kistler.com.

Water cooled piezoelectric sensors

7061_002-027e-09.23Page 6

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 most suited for measure-

ments of fast, dynamic and quasi-static pressure changes

and thus plays a key role in engine pressure measure-

ments.

Fig. 2: Cross section of a piezoelectric water cooled

sensor

Preface

Page 77061_002-027e-09.23

2.3 Requirements to water cooling

The use of cooling system Kistler Type 2621 is highly

recommended. It can supply up to ten water cooled

piezoelectric sensors (depending on the heat load created

by the application) with the optimum quantity of water,

at the right pressure and constant temperature. This

facilitates measurements with absolute reproducibility and

best lifetime of the piezoelectric sensors.

Cooling system specication

Coolant temperature: 50 °C

Coolantowrate: 0.3to0.5l/min

Coolant pressure: 1.7 ±0.2 bar

Cooling uid specication

Demineralized water according to norm VDE-Norm 0510

CoolinguidadditiveGlysantinG30orG40(donotmix

with each other)

Mixing ratio: 1 part additive with 4 parts demineralized

water (Frostproof down to -9°C)

For more information, please refer to instruction manu-

al of cooling unit Type 2621

Never connect the piezoelectric sensor to an open coo-

ling system with water from the mains supply. This water

source contains calcium and lime deposits and will ac-

cumulate inside the piezoelectric sensor – impacting the

sensitivity and even in the worst case, block the cooling

channel inside the piezoelectric sensor.

2.4 Precautions for water cooling

The water cooling system must be turned on before the

engine is started. The reason is that if the water cooling

system is turned on after the engine has been running for

a period of time, the piezoelectric sensor may be dama-

ged due to the low temperature coolant encountering the

hotpiezoelectricsensor(thermalshockeect).

Do not start the water cooling system if the temperature

of the piezoelectric sensor is high.

Water cooled piezoelectric sensors

7061_002-027e-09.23Page 8

If the water cooling system fails and cannot work normally,

the engine and water cooling system should be shut down

immediately to prevent the water cooling system from

working intermittently, thus damaging the sensor. To con-

tinue using the water cooling system, stop the engine until

the temperature of the piezoelectric sensor drops to ap-

proximately the same temperature as the coolant.

During the operation of the water cooling system, it must

be ensured that the water hoses and tubes are not con-

stricted–freeowofthecoolantisessential.

Before using the sensor without water cooling, empty the

water from the sensor, ush it with demineralized water

and blow it out very carefully with compressed air. The

same procedure should be applied before storing the

sensor when not in use.

Installation of the piezoelectric sensor

Page 97061_002-027e-09.23

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.

3.2 Direct installation

Direct installation requires the least installation space. Of

course, a direct installation is only possible if it is not ne-

cessary to cross any water or oil galleries in the cylinder

head casting.

In the case of repeated mounting and dismounting of

the sensor, there is the risk of damaging the sealing me-

chanism and thread of the mounting bore. Typically, the

cylinder head material is softer than that of the sensor.

Before mounting the sensor in the bore, also to facilitate

dismounting it at the end of the test, it is recommended

to coat thread and sealing part of the piezoelectric sen-

sor with high temperature resistant grease (for example

MOLYKOTE HSC plus or Metaux 70-81). Do not apply

any grease on the membrane.

3.3 Installation with sleeve

In the case where the cylinder can only be accessed via

an oil or cooling water gallery, a mounting sleeve is ne-

cessary to provide adequate sealing for the installation. At

the front, the sleeve is screwed and sealed with a sealing

ringattherear,sealingisachievedusingO-ringsand/or

Loctite compound (Loctite 648 for shaft-hub, Loctite 290

for thread).

Water cooled piezoelectric sensors

7061_002-027e-09.23Page 10

Benetsofusingamountingsleeve:

Precise sensor bore inside the sleeve

Machining of the bore for the mounting sleeve is

simplied

The mounting sleeve has the required strength to en-

sure that the sealing part can resist wear. This allows

the sensor to be mounted and dismounted repeatedly

without restrictions

When removing the sensor, the mounting sleeve pre-

ventscoolinguidfrompassingfromleakingintocom-

bustion chamber

Disadvantages of using a mounting sleeve:

Can inuence on the cylinder head cooling perfor-

mance (depending on size and position of the sleeve

with respect to the water cooling channels)

3.4 Installation examples

Fig. 3: Left:sleevemountingwithmembraneush;

right: direct mounting with small gas channel

Installation of the piezoelectric sensor

Page 117061_002-027e-09.23

3.5 Machining the mounting bore

When preparing the sensor bore, ensure that the thread

is concentric in relation to its individual steps. The sealing

part must be completely at. Refer to the specications

and tolerances stated on the datasheet of the sensor.

All machining steps with the drill, milling cutter, reamer

and screw tap must be performed with the work held se-

curely in the same position.

3.6 Mounting the water hose on the cooling pipe

Soak the end of the rubber hose in boiling water for seve-

ral seconds – this allows expansion via heating to assist

tting,thenttherubberhoseonthecoolingpipeofthe

sensor. With this procedure it is not necessary to rotate

therubberwaterhosebackandforthwhilstttingasthis

creates a risk of loosening the cooling pipe. If a cooling

pipe becomes loose, it must be unscrewed completely

– then follow the procedure as mentioned in the chapter

"maintenance".

Water cooled piezoelectric sensors

7061_002-027e-09.23Page 12

3.7 Check points before installation

Water leakage - After connecting the rubber hoses to

the cooling pipes of the sensor, operate the cooling

system and check that there is no leakage

Piezoelectric cable - If the piezoelectric cable connec-

ted to the sensor is loose it must be retightened. Note

that the piezoelectric cable of sensor type 6041B is ac-

cessible only after removing one of the water cooling

pipes (see chapter "maintenance")

Carefully check the piezoelectric cable for damage

over its full length, and if necessary replace it comple-

tely. The insulation resistance of sensor and piezoelec-

tric cable should be checked by connecting the insu-

lation tester at the end of the piezoelectric cable. The

minimumrequirementatroomtemperatureis10E13Ω

Sensor seal ring - The sensor seal ring must al-

ways be applied to the sensor as shown in Figure

4. If the seal ring is damaged, it should be replaced

Fig. 4: Seal ring of a shoulder sealing sensor

Mounting bore - Check the condition of the mounting

bore;itmustbemachinedtothespecieddimensions

and tolerances as described in the datasheet, and also

clean and dry prior to installation

Installing the sensor into the bore

Page 137061_002-027e-09.23

4. Installing the sensor into the bore

Feed the piezoelectric cable and both rubber hoses

through the mounting wrench, and then t the mounting

wrench on the hex of the sensor. If you are using the slot-

ted mounting wrench Type 1300A73 for sensor Type 6041,

pay attention to proper positioning of the piezoelectric

cable and rubber water hoses in the slot (otherwise

danger of compression damage). Make sure the pins

are properly engaged into the small bores of the sensor.

Before installing the sensor in the bore, the thread and

sealing part should be lubricated with high-temperature

resistant grease (for example MOLYKOTE HSC plus or

Metaux70-81).Thiswillfacilitatedismountingthesensor

from the bore post-testing.

During installation and disassembly, the piezoelectric

cable and rubber water hoses should be rotated with the

mounting wrench to avoid damage of the piezoelectric

cable and the possibility of inadvertently loosening the

cooling pipes. During use, pay attention to protect the

sensor piezoelectric cable. Do not squash, twist or pull the

piezoelectric cable.

Screw the sensor hand-tight and then use the torque

wrenchfortighteningtotherequiredvalueasspeciedin

the datasheet of the sensor.

When the sensor installation is completed, connect the

water hoses to feed and return manifolds of the water

cooling system.

Fig. 5: Assembly with water cooled sensor and moun-

ting wrench for installation

Water cooled piezoelectric sensors

7061_002-027e-09.23Page 14

5. Piezoelectric sensor cable routing

The piezoelectric cable of the sensor must be routed to

avoid other high-frequency, or power cables, as much

as possible, e.g. ignition or fuel injection system cabling,

dynamometer or motor power cables. If this cannot be

avoided, the piezoelectric cables should be kept perpen-

dicular to the high-frequency signal lines to reduce signal

interference.

There must be no mechanical tension on the piezoelec-

tric cable. It is absolutely essential to avoid deformation

caused by sharp bends. During use, pay attention to pro-

tect the piezoelectric cable: do not squash, twist or pull

it. Ensure the cleanliness of the piezoelectric cable con-

nector. Do not allow water, oil, dust, or other dirt in the

vicinity of the cable interfaces. If the piezoelectric con-

nector becomes contaminated during use, use an elec-

tronic cleaning spray to clean it. Use the cap to cover and

protect the piezoelectric connector when the piezoelectric

sensor is not in use.

Setting up the measuring chain

Page 157061_002-027e-09.23

6. Setting up the measuring chain

6.1 Connecting the piezo electric cable to charge amplier

Fig. 6: Basic arrangement of a measuring chain

Piezoelectric sensor cable, adapter, and piezoelectric ex-

tension cable should be connected before connecting its

endtotheinputsocketofthechargeamplier.

Makesurethechargeamplierisnotinmeasuringmode

when connecting the piezoelectric sensor cable to the

charge amplier input. This avoids potential damage to

sensitive electronic input circuitry.

The length of piezoelectric cables between sensor and

charge amplier should not exceed 10 m. Interference

from extraneous voltages and ground loop issues at the

test cell can be avoided, or reduced, by using a short pie-

zoelectriccableandpositioningthechargeamplierclose

to the piezoelectric sensor.

6.2 Selecting the sensor sensitivity

Since Kistler water cooled sensors can be used with wa-

ter cooling or uncooled, the sensitivity at 50 °C should be

used if water cooling is used, and the sensitivity at 250 °C

should be used in the case of uncooled operation.

Operation with water cooling is recommended to achieve

the highest accuracy of the pressure measurement (most

stable sensor sensitivity regardless of the engine opera-

ting condition, no load change drift).

Water cooled piezoelectric sensors

7061_002-027e-09.23Page 16

7. Dismounting and maintenance

7.1 Dismounting

Allow the cylinder head to cool down before removing the

sensor from the mounting bore. Dismount in reverse order

than installation:

Switchothewatercoolingsystem

Disconnect the water hoses of the sensor from feed

and return manifold

Disconnect the piezoelectric sensor cable from the

chargeamplier/fromtheextensioncable

Feed the piezoelectric sensor cable and both rubber

hoses through the mounting wrench, carefully slide

it to the sensor, and then t the mounting wrench

on the hex of the sensor. If you are using the slotted

mounting wrench Type 1300A73 for sensor Type 6041,

pay attention to properly position piezoelectric cable

and both rubber water hoses in the slot (otherwise

danger of squeezing). Make sure the pins are properly

engaged into the small bores of the sensor

Unscrew the sensor from the bore

7.2 Maintenance

Piezoelectric pressure sensors are precision instruments;

theywilldelivermeasurementsinthespeciedaccuracy

range only if they are handled with care. Special attention

is required for the front part of the sensor – the membrane

and sealing area must always be protected against me-

chanical damage.

Do not tap impact or shock the front surface of the sensor

with metal or any other objects – this will help to avoid

damage to the membrane.

Visual inspection - Sensor, piezoelectric cable and

cooling pipes should be carefully inspected for anoma-

lies (damage, soot deposits, overheating due to com-

bustion gas leakage)

Dismounting and maintenance

Page 177061_002-027e-09.23

Cleaning - After the sensor is disassembled from the

engine, combustion deposits may be cleaned with a soft

brush and Isopropyl alcohol (CAS Number 67-63-0).

The front part of the sensor (membrane) cannot be

cleaned using mechanical means such as brushing,

sand blasting, grinding, etc. as this will irreparably da-

mage the membrane and thus the sensor

Visual inspection - After cleaning, see above

Insulation check - The insulation resistance of the

sensor with piezoelectric cable should be checked by

connecting the insulation tester Type 5493 at the end

of the piezoelectric cable. The requirement at room

temperature is 10E13 Ω. If the value is too low, all

piezoelectric connectors should be disconnected and

the insulators cleaned with electronic cleaning spray

Kistler Type 1003 or a similar product. Do not touch the

connectorinsulatorwithbarengersanddonotblowit

out with shop compressed air

Pressure calibration - Recalibration is recommended

every 200 hours of operation or after each disassembly

of the sensor from the cylinder head

Exchange of components - It is possible to replace

the sealing ring, the piezoelectric cable, and the coo-

ling pipes. Material numbers are listed in the datas-

heet of the sensor. The replacement of the sealing ring

should be done by Kistler

Removing the cooling pipes Types 1225,

1225A1/A2/A5

Necessary material

-Hot-air blower with variable temperature

-Open ended wrench 3 mm AF

-Solvent iso-propanol or a similar product

Procedure:

-Remove the rubber hose from the cooling pipe

-Locally heat by hot-air blower the contact area of the

cooling pipe with the sensor body (max. air temp.

200 °C). Do not expose the piezoelectric cable to

the hot air (risk of overheating)

-Simultaneously unscrew the cooling pipe with the

open ended wrench 3 mm AF

-With the means of a small brush, clean the thread

M3x0.35 of the cooling pipe with iso-propanol or a

Kistler 6041B, 6041C, 6061C, 6067D, 7061C Owner's manual

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