Kistler 5064E11 Owner's manual

Instruction

Manual

5064E_002-967e-12.20

Charge Amplier

Type 5064E...

Page 1

5064E_002-967e-12.20

The information in this document is subject to change

without notice. Kistler reserves the right to change or im-

prove its products and make changes in the content without

obligation to notify any person or organization of such

changes or improvements.

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

Eulachstrasse 22

8408 Winterthur

Switzerland

Tel. +41 52 224 11 11

info@kistler.com

www.kistler.com

Foreword

Charge Amplifier Type 5064E...

5064E_002-967e-12.20Page 2

Contents

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

1.1 Disposal instructions for electronic devices ........................................................................4

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

2. Safety notes .................................................................................................................................5

2.1 For your safety ....................................................................................................................5

2.2 Notes concerning the product .............................................................................................6

2.3 Electromagnetically compatibility ........................................................................................7

3. Charge amplier Type 5064E1..., 5064E2... ...............................................................................8

3.1 Description Type 5064E1... for SCP Slim & KiBox .............................................................9

3.2 Description Type 5064E2... for SCP ...................................................................................9

3.3 Driftcompensationofthepiezoelectricamplier ..............................................................10

3.3.1 DriftcompensationwithamplierType5064E... .................................................13

3.4 AutomaticsensoridenticationPiezoSmart .....................................................................14

3.4.1 Automatic operating data acquisition ..................................................................16

3.5 pMax value acquisition .....................................................................................................17

3.5.1 ClassicationofpMaxvaluesinTEDS ................................................................19

3.5.2 Analog pMax output ............................................................................................20

3.5.2.1 Analog interface pMax output ..............................................................21

3.5.3 Digital pMax output..............................................................................................22

4. Integration of the SCP/CAN-2 interface for pMax acquisition ..............................................23

4.1 CAN bus network structure ...............................................................................................23

4.2 Connection assignment CAN-2 interface for SCP/SCP Slim............................................24

4.3 Data transmission rate ......................................................................................................25

4.4 CANmessage/CANidentier ...........................................................................................25

4.5 Dataeld ..........................................................................................................................26

4.5.1 DataeldpMaxoutput5064E... ..........................................................................26

4.5.2 Sending test pMax...............................................................................................27

4.5.3 Activation of the CAN-2 output ............................................................................27

4.6 CANdecriptionle(*.dbc) ................................................................................................27

4.7 SCPSoftwaresettingsforparameterizationoftheamplier ............................................28

4.8 ParameterizationforthechargeamplierType5064E ....................................................30

4.9 DigitalI/O(digitalinputsoroutputs) .................................................................................34

4.9.1 Remote function Measure/Reset .........................................................................36

4.9.2 Remotefunctiondriftcompensation(Drco)on/o ...............................................37

5. TEDS conguration...................................................................................................................38

6. Technical data ...........................................................................................................................39

6.1 ChargeamplierType5064E... ........................................................................................39

6.2 BlockdiagramchargeamplierType5064E... .................................................................41

7. Appendix ....................................................................................................................................42

Total pages 43

Introduction

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5064E_002-967e-12.20

1. Introduction

Thank you for choosing a Kistler quality product. Read

this instruction manual carefully so that you can make full

use of your product's many features.

Where permitted by law, Kistler accepts no liability if this

instruction manual is disregarded or if products other than

those listed under accessories are used.

Kistleroersawiderangeofmeasuringtechnologypro-

ducts and complete solutions:

Piezoelectric sensors for measuring pressure, force,

torque, strain, acceleration, shock and vibration

Strain gauge sensor systems for measuring force and

torque

Piezoresistive pressure sensors and transmitters with

thecorrespondingampliers

Corresponding ampliers (charge ampliers, piezore-

sistive ampliers, etc.), indicators and charge calibra-

tors

Electronic control, monitoring and evaluation units as

wellas application-specicsoftware formeasurement

technology

Datatransmissionmodules(telemetry)

Kistler also designs entire measurement systems for spe-

cicpurposes,forexample,intheautomotiveindustry,in

plastics processing and in biomechanics.

Our complete catalog provides an overview of our product

range. Detailed data sheets are available for nearly all of

our products.

Ifyoustillhaveanyspecicquestionsafterreadingthese

instructions, Kistler's customer service is ready to assist

you anywhere in the world and can also provide advice on

application-specicproblems.

Charge Amplifier Type 5064E...

5064E_002-967e-12.20Page 4

1.1 Disposal instructions for electronic devices

Waste electronic equipment must not be disposed of with

household waste. At the end of its service life, return the

device to the nearest electronic disposal location or con-

tact your Kistler sales outlet.

1.2 Software upgrades and updates

If Kistler supplies upgrades or updates for embedded soft-

ware, they must be installed.

Kistler assumes no liability for direct or consequential da-

mages caused by products whose embedded software is

not up-to-date.

Failure to observe the precautions described here may

result in malfunctions or damage to system components.

Safety notes

Page 5

5064E_002-967e-12.20

2. Safety notes

Please note the following instructions; they are impor-

tant for your personal safety when working with the Sig-

nalConditioningPlatform(SCP)andtoensurelongterm,

fault-free operation of this unit.

2.1 For your safety

This product has been manufactured in compliance with

the currently valid safety regulations. It meets all relevant

regulations according to the attached conformity declara-

tion. It has left the factory in a perfectly safe condition. In

order to maintain this condition and ensure safe operati-

on, compliance is required with the instructions and war-

ning notes contained in this instruction manual or imprin-

ted on the product.

Please also comply with the local safety regulations con-

cerning the handling of electrical and electronic equip-

ment.

If it is to be assumed that safe operation is no longer pos-

sible, the equipment must be shut down and made safe

against being accidentally started up.

Safe operation is no longer possible when the product

shows visible signs of damage,

has been in lengthy storage under unsuitable condi-

tions,

has been subjected to rough transport conditions.

If safe operation can no longer be guaranteed, the pro-

duct must be returned immediately to the manufacturers

or to the authorized distributor for repair. Whenever the

product is connected to the power supply, live parts can

be exposed if covers are opened or if parts are removed –

except when this is possible by hand.

Adjustment, maintenance and repair work on exposed,

live parts must be avoided as far as possible. If, however,

such work is unavoidable, it must be undertaken only by

a skilled person who is familiar with the dangers involved.

Charge Amplifier Type 5064E...

5064E_002-967e-12.20Page 6

2.2 Notes concerning the product

Check all packaging for visible transport damage. Report

any such damage to the transporters and to the autho-

rized Kistler distributor/sales outlet.

Pleasecheckthescopeofdeliverybeforerstuseofthe

equipment. Report any missing parts to the authorized

Kistler distributor/Sales Center.

Carry out the following safety precautions if the product

is to be transported or stored for a lengthy period of time.

Cover all BNC, Fischer and triax connections with the

dust caps supplied

Make sure that no dirt can enter the product.

The environment should be as dry and free from vibra-

tions as possible. If possible, store the product in its origi-

nal packaging.

Comply with the requirements for ambient temperature for

storage and operation as stated in the technical data. If,

for example, the ambient temperature is exceeded to a

signicantextent,thiscanpermanentlydamagethepro-

duct.

Comply with the requirements for ambient temperature for

storage and operation as stated in the technical data. If,

for example, the ambient temperature is exceeded to a

signicantextent,thiscanpermanentlydamagethepro-

duct.

Protect the inputs and outputs of the product against con-

tamination. Keep the plug-and-socket connections clean

and dry. When a connector is not being used, cover it with

the cap provided.

Carryoutworkwiththeproductonlyunderthespecied

operating conditions. Protect the SCP against dust and

mechanical stress such as shock and vibration. Avoid

high atmospheric humidity and changes in temperature

which could lead to condensation.

Safety notes

Page 7

5064E_002-967e-12.20

2.3 Electromagnetically compatibility

To ensure that electromagnetic compatibility (EMC) is

maintained for the entire measuring chain, particular care

must be given to connection of the inputs and outputs of

the cable screen and to the cable installation:

Do not install the cable in parallel with interfering con-

ductors – particularly those where strong magnetic

eldsmayoccur

Use only shielded cables

Ensure good connection between screen, connector

case and equipment case

Comply with EMC standards also on the machine side

Signal output

Channel A, channel B

Signal input

Channel A, channel B

Fig. 1: FrontviewamplierType5064E...

Piezoelectric sensors are designed in such a way that the

potential of an electrode is at the ground potential. When

installed, the sensor is grounded through the metal struc-

ture(safety).Theamplierhasseparatedinputgroundsof

channel A and channel B in order to prevent signal interfe-

rence.Adierentialamplierstagepreventgroundloops

between any input ground and the output ground.

Charge Amplifier Type 5064E...

5064E_002-967e-12.20Page 8

3. Charge amplier Type 5064E1..., 5064E2...

The amplier modules are microprocessor-controlled, 2-

channel charge ampliers for signal conditioning of the

measurement signals from piezoelectric pressure sen-

sors. The Types 5064E12, 5064E13, suitable for SCP Slim

as well as the Types 5064E22, 5064E23, are equipped

with automatic sensor identication (PiezoSmart). When

piezoelectric PiezoSmart pressure sensors are used, the

operating time and the number of cycles are automatically

recordedandstoredontheTEDSchip(TransducerElec-

tronic Data Sheet), which is situated in the connector of

the sensor. The determined pMax values / cycle are clas-

sied into 6 dierent pressure ranges (<100 bar / <150

bar/<200bar/<250bar/<300bar/≥300bar)inorderto

be able to assess the sensor load.

An additional feature is the cyclic acquisition of pMax

values, which are output as digital signals via the CAN

bus interface (CAN2) of the SCP. In addition, the pMax

values are output as analog signals via the analog outputs

(CandD).

TherederrorLEDsashiftheoverloadthreshold(±11V)

for the analog output signal is exceeded. The LEDs are

reset via the SCP software or during reset.

The yellow LEDs light up when drift compensation is swit-

ched on. If drift compensation is not possible, or if a cyc-

le is not detected, the module automatically switches the

chargeamplierstageto"Short"or"Long".Thisisindica-

tedthroughthefast andslow ashingyellow LEDs.The

twogreenLEDsindicatethe"Measure"operatingmode.

Fig. 2: Type 5064E22 for SCP

Parameterization is carried out as described above via the

SCP software.This is where the sensor-specic data is

entered, such as the sensor sensitivity and the measuring

range. When sensor identication (PiezoSmart) is used,

this data is recorded automatically.

Fig. 3: Type 5064E12 for SCP Slim and KiBox

ChargeamplierType5064E1...,5064E2...

Page 9

5064E_002-967e-12.20

3.1 Description Type 5064E1... for SCP Slim & KiBox

Signal input: 2 x BNC

Fig. 4: Type5064E11chargeamplierforpiezoelectricsensorswithoutsensoridentication

Signal input: 2 x Triax

Fig. 5: Type5064E12chargeamplierforpiezoelectricsensorswithsensoridentication

(PiezoSmart)

Signalinput:2xFischerTriax(push/pull)

Fig. 6: Type5064E13chargeamplierforpiezoelectricsensorswithsensoridentication

(PiezoSmart)

3.2 Description Type 5064E2... for SCP

Signal input

2 x BNC

Signal input

2 x Triax

Signal input

2 x Fischer Triax

(push/pull)

Charge Amplifier Type 5064E...

5064E_002-967e-12.20Page 10

Fig. 7: Type 5064E21

chargeamplierfor

piezoelectric sensors

without sensor

identication

Fig. 8: Type 5064E22

chargeamplierfor

piezoelectric sensors

withsensoridentica-

tion(PiezoSmart)

Fig. 9: Type 5064E23

chargeamplierfor

piezoelectric sensors

withsensoridentication

(PiezoSmart)

3.3 Drift compensation of the piezoelectric amplier

Thermal charge transfers in the measuring element and

leakage current in the supply lines and in the amplier

lead to a gradual change in the measured value. This

change in the measured value is referred to as drift and

has a signicant inuence on the measuring accuracy,

especially when the load on the engine changes or if un-

cooled sensors are being used. During prolonged measu-

rement, this drift can lead to the measured signal excee-

dingthechargeamplier'soutputrangeof±10V.

Withaspeciallydevelopeddriftcompensation,thiseect

is largely eliminated electronically. This allows measure-

ments of any length of time, even during engine transi-

ents.

In the eect, the drift compensation is comparable to a

high-passlter. However, switchingonthe driftcompen-

sation does not result in pMax or PMI errors at low speed

aswiththehigh-passlterbecauseonlythedriftandnot

the actual cylinder pressure signals are compensated.

Keine Drift mit

Driftkompensation

Drift ohne

Driftkompensation

No drift with drift

compensation

Drift without drift

compensation

Fig. 10: Cylinder pressure signals with and without drift

compensation

Fig. 10 shows that the reference line remains zero for the

ChargeamplierType5064E1...,5064E2...

Page 11

5064E_002-967e-12.20

drift compensated engine pressure signal, whilst for the

uncompensated signal, it drifts in the negative direction.

Charge Amplifier Type 5064E...

5064E_002-967e-12.20Page 12

Example: Drift with a change in load during measure-

ment with uncooled sensor

When there is a change of load in the engine between

red and unred mode, the combustion temperature

changes. Fig. 11 shows a measured curve with no drift

compensation applied. The signal drifts considerably.

Fig. 11: Measured curve without drift compensation

Whenthedriftcompensationisswitchedon(Fig.12),the

measurement signal does not drift. The rapid rise at the

beginningoftheengineinunredmodeisrecognizedas

an erroneous signal and compensated for after a slight

delay.

Fig. 12: Measured curve with drift compensation

ChargeamplierType5064E1...,5064E2...

Page 13

5064E_002-967e-12.20

3.3.1 Drift compensation with amplier Type 5064E...

TheamplierType5064E...eliminatesthedriftofacylin-

der pressure signal with a digital drift compensation func-

tion.

Fig. 13: Schematic diagram of the drift compensation

Thesignalfrom thechargeamplieris acquireddigitally

for this purpose. The microprocessor calculates the drift

over recent cycles and extrapolates its trend. This anti-

cipated drift is then fed back into the input of the charge

amplier as reverse current. This avoids falsifying either

the phasing or the amplitude curve of the cylinder pres-

sure signal. Correct combustion analysis values can be

calculatedfromthesignalsofthechargeamplier.

The drift compensation works in the speed range from

100 … 20 000 rpm as well as from a minimum amplitude

of 5 % of the set measuring range.

If no drift compensation is possible or no combustion cy-

cles are detected, the module automatically switches the

charge amplier stage to "Short" or "Long" mode (user

congurable). This is indicated by a fast ashing yellow

LEDfor"DrcoShort"andbyaslowashing yellowLED

for"DrcoLong".Theamplierautomaticallyswitchesback

to drift compensation when a combustion cycle is detec-

ted.

For measuring cylinder pressure signals, the amplier

can always be operated with drift compensation switched

on. However, the drift compensation cannot be applied to

other signals.

Charge Amplifier Type 5064E...

5064E_002-967e-12.20Page 14

3.4 Automatic sensor identication PiezoSmart

TheautomaticsensoridenticationPiezoSmartisanac-

tivesystemfortheidenticationofindividualpiezoelectric

and piezoresistive pressure and accelerometers. The sys-

tem is based on the IEEE 1451.4 standard and is used

for automatic parametrization of measuring chains (plug

&measure).

Fig. 14: Measuring chain consisting of a PiezoSmart sen-

sorwithchargeamplierType5064E12andSCP

Slim

The core element of PiezoSmart is an electronic data

carrier, the so-called TEDS (Transducer Electronic Data

Sheet) which is integrated in the amplier-side plug of

the sensor cable. This connector is designed as a TRIAX

connector and forms a physical unit together with the

pressure sensor. The size and geometry of the TRIAX

connector are designed so that standard tools can still

be used for installation and assembly of the sensor

measuring chain. This means that the connector with

the TEDS need not be separated from the sensor and

thus reliable assignment of the sensor data is always

guaranteed in daily test bench operation.

ChargeamplierType5064E1...,5064E2...

Page 15

5064E_002-967e-12.20

The type and serial numbers, initial and recalibration va-

luesofthesensorandtheoperatingdata(operatingtime,

cycle number and pMax classication) are stored in the

TEDS.

The initial values and recalibration values for piezoelectric

sensors are recorded in tabular form. Depending on the

reference temperature selected and nominal pressure

range entered, the relevant sensitivity values of the

sensors are automatically read out from the table with

the recalibration values, used for parameterization of the

measuring amplier. When the sensor is new, its initial

values and recalibration values are identical.

Monitoring the sensor-specic calibration data can allow

the early detection of sensor anomalies and helps to

avoid test stand and data failures. The user can dene

graded hierarchy and password levels which are secure

and provide requirement-orientated allocation of read/

write access. Thus, the user – depending on the degree

of authorization – is able to edit recalibration values or

exchange defective sensors and cables.

Due to the decentralized storage of the sensor data, a

completely autonomous operation of the sensor and the

measuring chain is possible. This means that measure-

ments can also be carried out without any upstream da-

tabase. The system is ready for use at any time with the

relevant data being available.

A sophisticated in-built functionality ensures that the

actual measuring signals are not disturbed or impaired by

thesensoridenticationsignalsduringthemeasurement.

Type 5064E… is equipped with a cycle detection. As

a result, in the "Measure" operating state, TEDS data

can be accessed if no cycle is detected. This function

is activated in the basic settings in the setup menu

"TEDS conguration". The modular system allows the

simultaneous use of sensors with and without sensor

identication.Existingsensorscanalsoberetrottedwith

sensoridenticationatanytime.

Charge Amplifier Type 5064E...

5064E_002-967e-12.20Page 16

3.4.1 Automatic operating data acquisition

The operating hours and operating cycles are automati-

callydetectedbythechargeamplierType5064E...and

storedontheconnectedPiezoSmart(TEDS)sensor.

The integrated cycle detection is used as the basis for ac-

quiringtheworkingtime.Assoonastheamplierdetects

an engine cycle, the cycles are counted and the corres-

ponding working time is calculated.

Fig. 15: Schematic diagram of the cycle detection

WhenthechargeamplierissettoRESETor2seconds

after the last detected cycle, the operating hours and ope-

rating cycles are calculated and the measured data are

classiedandwrittentotheTEDS.

Operating hours and operating cycles of a measurement

cannot be updated if a TEDS sensor is removed during

MEASURE with a pending engine cycle.

Cycle detection uses a dynamic threshold and is active in

the speed range from 100 … 20 000 rpm. Depending on

the engine pressure signal and speed, the cycle is detec-

ted based on a trigger of an amplitude of 5 % of the set

measuring range.

Cycle detection is activated as soon as the charge ampli-

erisswitchedtoMEASURE.

ChargeamplierType5064E1...,5064E2...

Page 17

5064E_002-967e-12.20

3.5 pMax value acquisition

The pMax value corresponds to the dierence between

the maximum and minimum of a cycle. The pMax value is

calculated at the beginning of the next high-pressure pha-

se.ThefollowinggureshowsthepMaxrecordingusing

an example with two combustion cycles.

Fig. 16: Explanation of pMax calculation

After detection, the pMax value is immediately available

ontheanalogchannelsC(forinputA)andD(forinputB)

and optionally on the digital output on the CAN interface.

A maximum output voltage of 10V corresponds to two

times or four times of the range, which corresponds to a

maximumoutputlevelof-10Vto+10Vofanalogchannels

A and B.

The scaling of the detection range is adjustable between

±1FSand±2FS.

(Type5064Dhasaxscalingof±1FS).

Followingdiagramshowsthedierentscalingfactors.

Charge Amplifier Type 5064E...

5064E_002-967e-12.20Page 18

Diagram1:Type5064Dwithxscalingfactor±1FS

Diagram2:Type5064Ewithadjustedscalingfactor±2FS

The charge amplier Type 5064E… provides 3 dierent

output options of the detected pMax values.

ClassicationofpMaxvaluesinTEDS

Digital pMax value output

Analog pMax value output

Fig. 17: Block diagram of the possible pMax signal output

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Kistler 5064E11, 5064E12, 5064E13, 5064E21, 5064E22, 5064E23 Owner's manual

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