Kistler 6613CG2 Owner's manual

Instruction

Manual

Cylinder Pressure

Sensor

Type 6613CG1/CG2

ä

6613CG_002-664e-07.22

Page 2 6613CG_002-664e-07.22

Foreword

Thank you for choosing a Kistler quality product

characterized 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

obligation 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

Content

6613CG_002-664e-07.22 Page 3

Content

1.

Introduction ........................................................................................................................................ 4

1.1

Disposal instructions for electrical and electronic equipment .................................................. 5

2.

Description .......................................................................................................................................... 6

2.1

Introduction ...................................................................................................................................... 6

2.2

Dimensions Type 6613CG1/CG2 ................................................................................................ 7

2.3

Working principle ............................................................................................................................ 8

3.

Installation ......................................................................................................................................... 10

3.1

General .......................................................................................................................................... 10

3.2

Recommended mounting ............................................................................................................... 11

3.2.1

Sealing ............................................................................................................................. 11

3.2.2

Installing the sensor ....................................................................................................... 11

3.2.3

Installing the charge amplifier ....................................................................................... 12

3.2.4

Cable between charge amplifier and data acquisition unit ...................................... 12

3.2.5

Electric block diagram ................................................................................................... 13

3.2.6

Pin connections .............................................................................................................. 13

3.2.7

Mounting tools ................................................................................................................ 13

5.2.8

Accessories ..................................................................................................................... 13

4.

Operation ........................................................................................................................................... 14

5.

Maintenance ...................................................................................................................................... 15

6.

Trouble shooting .............................................................................................................................. 16

6.1

Repair ............................................................................................................................................. 16

Total pages 16

Cylinder Pressure Sensor, Type 6613CG1/CG2

Page 4 6613CG_002-664e-07.22

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

products other than those listed under Accessories are

used.

Kistler offers a wide range of products for use in

measuring technology:

 Piezoelectric sensors for measuring force, torque,

strain, pressure, acceleration, shock, vibration and

acoustic-emission

 Strain gage sensor systems for measuring force and

torque

 Piezoresistive pressure sensors and sensors

 Signal conditioners, indicators and calibrators

 Electronic control and monitoring systems as well as

software for specific measurement applications

 Data transmission modules (telemetry)

Kistler also develops and produces measuring solutions

for the application fields engines, vehicles, manufac-

turing, 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 on-line or in this manual, please contact Kistler's

extensive support organization.

Introduction

6613CG_002-664e-07.22 Page 5

1.1 Disposal instructions for electrical and electronic equipment

Do not discard old electronic instruments 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

Instrument sales office for return instructions.

Cylinder Pressure Sensor, Type 6613CG1/CG2

Page 6 6613CG_002-664e-07.22

2. Description

2.1 Introduction

Measuring chain consisting of a life time optimized

piezoelectric pressure sensor linked by a robust

fluoropolymer cable to a charge amplifier with MIL

connector. The rugged design and high temperature

resistance allows for flush mounting and enables reliable

knock detection. The sensor can be installed either by

using shoulder sealing or front sealing. The good linearity

and stability of the sensors ensures reliable and

repeatable measurements over a long period of time. The

charge amplifier provides a galvanic isolated three wire

type current output.

The integrated charge amplifier provides a current output

signal in a range of 4 … 20 mA. The sensor has a zero

line of about 6.5 mA (at dynamic pressure 0 bar). The

output is ac-coupled, so static pressure measurements

are not possible.

 Type 6613CG1 has a time constant >10 s

and is recommended for medium speed engines.

 Type 6613CG2 has a time constant >110 s and is

recommended for low speed engines.

All other technical data are identical.

Description

6613CG_002-664e-07.22 Page 7

2.2 Dimensions Type 6613CG1/CG2

Fig 1: Dimensions of Type 6613CG1/CG2

Cylinder Pressure Sensor, Type 6613CG1/CG2

Page 8 6613CG_002-664e-07.22

2.3 Working principle

The cylinder pressure is acting on the diaphragm. The

diaphragm converts the pressure in proportional force on

the sensor element. The piezoelectric sensor element

converts the force into a charge. The charge is converted

by a charge amplifier into a current.

The complete measuring chain is designed for easy

operation and very long life time.

The advantage piezoelectric principle is:

 Operates safe up to high temperatures and therefore

ideally suited for accurate measurements in harsh

conditions

 Very small sensitivity change over temperature range

 High stiffness, results in small diaphragm stress

 High reproducibility since the piezoelectric constant

of the measuring element is a constant of the

material and does not change over time

Fig 2: Schematic cross section of sensor element

Description

6613CG_002-664e-07.22 Page 9

2

4

6

8

10

12

14

16

18

20

22

time

output signal [mA]

upper border

bias current

low er border

signal 4-stroke

signal 2-stroke

Example of output signal from

2- and 4-stroke engine with signal span 12.5 mA

Fig. 3: Example of sensor output signal for 2- and 4-stroke engine

Cylinder Pressure Sensor, Type 6613CG1/CG2

Page 10 6613CG_002-664e-07.22

3. Installation

3.1 General

The quality of the measurement and the life time

depends very much of a correct mounting.

 The mounting hole must be manufactured within the

tolerances

 Avoid mounting at the end of long tubes, it creates

pipe ringing and overheating of the sensor

 Ideal is a mounting hole in the cylinder head with

about 10 … 15 mm distance from the combustion

chamber

 Sensor must be tightened according the mounting

torque of 15 N·m

 The cable must not be twisted during installation/

removal of the sensor

If there are any question regarding installation please

contact Kistler.

Installation

6613CG_002-664e-07.22 Page 11

3.2 Recommended mounting

Fig. 4a: Mounting bore Fig. 4b: Mounting bore (4-stroke application)

(4-stroke application) for flush mounting for recessed mounting with additional gas

Mounting torque: 15 ± 1 N·m channel. Admissible bore length depends on

the application. Too long bore may interfere

the quality of the measuring results

Mounting torque: 15 ± 1 N·m

3.2.1 Sealing

A leak proof mounting of the sensor is essential to

prevent overheating of the sensor by leaking hot gases.

Good sealing is obtained by

 fine-machined sealing surface on the engine (for

surface roughness, flatness and squareness)

 all sealing surfaces (on engine and on sensor) must

be clean and free of any burrs (e.g. combustion

residuals, sooth, etc.)

3.2.2 Installing the sensor

Clean all parts and apply a light film of grease to the thread

and the sealing surface. Use high-temperature paste

MoS2 (e.g. Molycote P74 or 1 000) or copper grease.

Insert the sensor into mounting bore with a torque of 15

N·m.

Use a torque wrench for sensor mounting. After installing

the sensor, check if there is no leaking when engine runs

on idle speed.

Cylinder Pressure Sensor, Type 6613CG1/CG2

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3.2.3 Installing the charge amplifier

Charge amplifier should be fixed with two vibrations

damping clamps as shown in the picture below. Select a

location where the temperature does certainly not exceed

110 °C. Route and fix the integrated cable between

sensor and charge amplifier so it is protected against

mechanical damage. Keep it away from any source of

heat such as the exhaust or hot fuel lines.

Picture shows an example of Charge Amplifier installation

with Stauff’s damping clamps fixed with clamp body with

rubber insert with film hinge. Clamp Assembly order code

is 419 PAR.

Clamp body, order code 4 PAR:

 Standard type

 Basic Material – Polyamide

 Temperature Resistance -40 °C ... +120 °C /

-40 °F ... +248 °F

Rubber insert with film hinge, order code RI 19 (4+4S):

 Exact outside diameter D = 19 mm:

 Basic Material – Thermoplastic Elastomer (73 Shore-A)

 Temperature Resistance -40 °C ... +125 °C /

-40 °F ... +257 °F

Recommended is to use a product that is intended for the

extra vibration/noise reducing installation of pipes and

tubes or the extra gentle installation of hoses and cables.

3.2.4 Cable between charge amplifier and data acquisition unit

We recommend using cable Type 1700B69A…, which is

available in different lengths (for more detailed

information, see datasheet of Type 6613CG1/CG2, doc.

no. 003-043).

This cable can be made by the user. Use a shielded

cable; otherwise the sensor is not conform with CE rules.

The wiring must be done according to the electric block

diagram shown in chapter 5.2.5

Installation

6613CG_002-664e-07.22 Page 13

3.2.5 Electric block diagram

3.2.6 Pin connections

Connector

1 Exct GND

2 don’t connect

3 don’t connect

4 don’t connect

5 Signal output

6 don’t connect

7 don’t connect

8 +Exct (18 … 32V)

Fig 5: View on M12 connector of amplifier

3.2.7 Mounting tools

Torque wrench Type 1300A11

Fork wrench Hex 12 for Type 1300A11 Type 1300A13

Tubular socket Hex 12 / Hex 16, 24, l = 350 mm Type 1300B6

Fork wrench Hex 16 for Type 1300A11 Type 1300A33

5.2.8 Accessories

Dummy plug shoulder sealed Type 6442

Cylinder Pressure Sensor, Type 6613CG1/CG2

Page 14 6613CG_002-664e-07.22

4. Operation

After the starting up the engine check for any gas

leakage at once. If there is any gas leaking out, stop the

engine and correct the mounting to achieve a complete

sealing (see chapter 5).

Warning:

If the sensor is mounted in an indicator valve:

When the engine is operating do not open the

indicator valve for more than one working circle as

otherwise the sensor may be overheated.

Maintenance

6613CG_002-664e-07.22 Page 15

5. Maintenance

After installation, the sensor needs no maintenance. Do

not use a steam or high-pressure cleaner for cleaning

purposes.

Never use wire brushes, screw drivers or any other sharp

pointed instrument for cleaning the diaphragm.

Cylinder Pressure Sensor, Type 6613CG1/CG2

Page 16 6613CG_002-664e-07.22

6. Trouble shooting

In case the sensor does not give a proper output signal,

please disconnect the cable for a couple of seconds and

connect it again.

The amplifier works with a so-called time constant to

ensure a reliable signal without drift, because of this time

constant it can happen that the sensor is out of range for

a short while. To overcome this cable should be

disconnected. Otherwise it may take 1 … 2 minutes until

the signal is within the specified signal range.

6.1 Repair

The sensor cannot be repaired on site. In case of

incorrect functions or broken parts the sensor must be

sent to factory.

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