3. Hole
3.1 Unmachined Sensor
For use in flat cavity wall with sensor fitted at right angles
to cavity.
• Hole and thread must be free of debris and shavings
• Use checking tool Art. No. 55155779 also to lapp
hole
Quick Start Installation
2 mm Cavity Pressure Sensor
Type 6185AA... (–2,2 pC/bar, 2 000 bar, 200 °C)
Type 6185AC... (–2,2 pC/bar, 2 000 bar, 200 °C)
6185A_002-787e-11.16
Content
Front Page: Machining the Mold
1. General Notes
2. Important Areas of Sensor Hole
3. Hole
3.1 Unmachined Sensor
3.2
Cavity-Matched Sensor
4. Cable Channeling and Connector
Rear Page: Sensor Installation, Service and Repair
5. Installing Sensor
6. Installing Cable and Connector
7. Installing Identification Plate
8. Functional Test
9. Service and Repair
Foreword
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.
To the extent permitted by law Kistler does not accept any
liability if this Quick Start Installation is not followed or prod-
ucts other than those listed under Accessories are used.
© 2016, Kistler Group. All rights reserved.
1. General Notes
• Sensor ø2 mm may not be machined
• Front of sensor must be clean and without notches
• Only use recommended installation accessories
• Do not use cable to pull sensor out of hole
1. Sensor contact surface must be flat and perpendicular
2. Hole with H7 tolerance to center sensor
3. Chamfer protects O-ring during installation
4. No centering mounting bore
5. Sharp edges reduce witness mark on part
2. Important Areas of Sensor Hole
Note the following critical installation criteria:
• Use cleaning spray Type 1003
• Use extraction tool Type 1358A
4.1 Cable Technology
The single-wire technology uses the tool steel to ensure elec-
trical shielding of the sensor signal. Thus the wiring is routed
through drilled holes or channels.
• Single-wire cable must be completely enclosed in mold
• Single-wire cable must not be routed with power
cables
4.1.1 Single Channel Connector: Single Wire Type 1839
Machine cable channel and recess for mounting plate.
Example shown: Drilled hole.
3.2 Cavity-Matched Sensor
For use in cavity with sloped, textured or free-form surface
install sensor with keyway pin Type 65001430 and mounting
nut Type 6460A1.
3.2.1 Sensor with Mounting Nut Type 6460A1
Electrical discharge machine (EDM), mill or precision grind H7
hole in hardened tool steel. Check centering and alignment.
3.1.1 Sensor with Spacer Sleeve Type 6464A1
Electrical discharge machine (EDM), mill or precision grind H7
hole in hardened tool steel. Check centering and alignment.
4.1.2 Multi Channel Connectors: Single Wire or Coaxial
Recess for 4-channel connector Type 1722A…
• Observe radii
• Cover open channels to prevent cable damage
Recess for 8-channel connector Type 1722A…
Example shown: Channel
3.2.2 Machining Sensor Front
Grind sensor front or install sensor in hole and then machine
complete cavity profile. Then remove sensor with extraction
tool Type 1358A. Clean hole and sensor.
• Only uncoated variants Type 6185AA ... permitted
2,5 anpassen
M8x0,75
4
4,2
5,2
+
0,05
0
4,5
+
0,05
0
min 21,8
0,02 ... 0,04
60°
2 H7
+
0,010
0
0,2 ... 0,3
2,5 anpassen
min. 21,8
4,5
+
0,05
0
60°
0,2 ... 0,3
2 H7
+
0,010
0
Einbaubohrung
4,2
5,2
+
0,05
0
M8x0,75
4
Mounting bore
2,5 anpassen
min. 21,8
4,5
+
0,05
0
60°
0,2 ... 0,3
2 H7
+
0,010
0
5,2
+
0,05
0
4,2
M8x0,75
min. 21.8
4
2,5
2
4
1720A1
40
M3x0,35
3,1
2,5 anpassen
min.
8,2
M8x0,75
5,5
15,5 5,5
4,5
0,02 ... 0,04
60°
2 H7
+
0,010
0
0,2 - 0,3
Einbau mit Montagenippel
2 H7
+
0,010
0
2,5 anpassen
0,2 ... 0,3
60°
0,02 ... 0,04
min. 25,5
4,5
Einbau mit Distanzhülse
2 H7
+
0,010
0
15,5
min.
8,2
M8x0,75
5,5
5
2,5
0,2 ... 0,3
60°
5,5
2,8
2,5 anpassen
M8x0,75
4
4,2
5,2
+
0,05
0
4,5
+
0,05
0
0,02 ... 0,04
60°
2 H7
+
0,010
0
0,2 ... 0,3
Einbaubeispiele 6185
A4
0
1 / 1
3:2
measure. analyze. innovate.
Erstmals verwendet
Erste Proj.-Nr.
Werkstoff
Änderung
Datum
Massstab
Ersatz für
Kopie Datum
gez.
gepr.
ges.
16.09.2016
Mfl
100.263.512
Zeichnungs-Nr.
Material-Nr.
KIWAG-SWX_A4h
Ver.
Bl.
öffentlich
Das Urheberrecht an dieser Zeichnung, die dem Empfänger
persönlich anvertraut wird, verbleibt unserer Firma.
Ohne unsere schriftliche Genehmigung darf die Zeichnung
weder kopiert noch vervielfältigt, noch an Drittpersonen
mitgeteilt oder zugänglich gemacht werden.
4. Cable Channeling and Connector
• Fixed cable reduces mounting
• Do not run cables next to hot runner cartridge
• Chamfer all sharp edges
• Cover open channels/slots
Outline
Outline
Kistler Group
Eulachstrasse 22
8408 Winterthur, Switzerland
Tel. +41 52 224 11 11
Fax +41 52 224 14 14
info@kistler.com www.kistler.com
6185A_002-787e-11.16 ©2016, Kistler Group
5. Installing Sensor
• Ensure all sensor hole and threads are clean
• Use checking tool Art. No. 55155779
• A chamfered cable channel or cable hole prevents
damaged cables
8. Functional Test
On completion of mold assembly, test sensor insulation and
sensitivity.
• Ensure that connector is dry
• Use cleaning spray Type 1003
8.1 Insulation Test
Use insulation tester Type 5495 to check sensor insulation.
Resistance >1013 Ω.
8.2 Sensor Functional Check
Test the sensitivity of the installed sensor using Test Set Type
5495.
Approximate measured sensitivity value: –2,1 … –2,6 pC.
9. Service and Repair
Piezoelectric pressure sensors are maintenance-free. Insulation
and sensitivity of the installed sensor should, however, be
checked after each molding run.
• Ensure that connector is dry
• Cover sensor hole during cleaning
• Use cleaning spray Type 1003
9.1 Insulation Test
See chapter 8.1.
9.2 Sensor Functional Check
See chapter 8.2.
9.3 Removing Sensor
Remove sensor with extraction tool Type 1358A or use a flat
ejector pin to press on the sensor front.
• Do not use a hammer on the sensor front
• Do not use a sharp center punch
9.4 Dismounting of cables
Fixe Sensor with auxilary tool Type 1300A30 and detach
cable with fork wrench AF 3,5 Type 5.210.445.
9.5 Single-Wire Repair
Slightly damaged cables can be repaired using the Repair Kit
Type 1207. If single-wire cables have been severed, solder
ends, slide over Teflon tube and cover with shrink tubing.
• Do not overheat sensor and cable when using hot
air blower
9.6 Repairs at Kistler
Factory repairs at Kistler are arranged by the local sales office
Information: www.kistler.com
9.7 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 autho-
rized local electronic waste disposal service
or contact the nearest Kistler Instrument
sales office for return instructions.
5.1 Sensor Installation with Spacer Sleeve Type
6464A1
Install sensor into hole with extraction tool Type 1358A or
directly with spacer sleeve.
5.1.1 Machining Spacer Sleeve
Cut spacer sleeve so that it has an overlength of 2 … 3 mm.
Place sensor and sleeve into hole and determine exact length,
ensuring a clearance of 0,01 … 0,03 mm. Sleeve must be
ground so the end is square and planar. Remove any burrs.
For multi-cavity applications each spacer sleeve should be
numbered and allocated to a sensor.
5.1.2 Spacer Sleeve and Retaining Plate
Install sensor and spacer sleeve. Ensure a clearance of 0,01 …
0,03 mm.
Sensor may not be preloaded when assembling the mold.
• Do not preload sensor
• Use extraction tool Type 1358A to install sensor
• For multi-cavity applications each spacer sleeve
should be numbered
6. Installing Cable and Connector
• Check again that edges of cable duct and hole are
chamfered
• Use a metal plate to cover open ducts/slots
• Attach cap and place on connector
6.1 Single-Wire Technology
• Single-wire cable must be completely enclosed in
the mold
• Single-wire cable may not be routed with power
cables
• Ensure that all contact surfaces and threads are clean
and dry
6.1.1 Cut & Grip Connection
Cut the single-wire cable to length and do not strip the insu-
lation. Open connector by hand, insert the single-wire cable
and close it again.
6.1.2 Installing Single-Wire Connector
Install connector and mounting plate in recess. Attach cap
using one of the screws. Place cap on open connector.
Installation of Connector Type 1839 and Mounting Plate
7. Installing Identification Plate
Rivet plate to side of mold or fit with four M2,5 screws.
Installation of Multichannel Connector
Example: Type 1722A4...
5.2 Sensor Installation with Mounting Nut Type
6460A1
Install sensor into hole with extraction tool Type 1358A.
Tighten mounting nut Type 6460A1 with socket wrench Type
1300A131. Hand tighten with 3 ... 5 N∙m torque.
• Do not preload sensor
• Hand tighten with 3 ... 5 N∙m torque
• Take care not to wrap single-wire cable around
socket wrench
• Use extraction tool Type 1358A
• Use Installation tool Type 1300A131
6.2 Coaxial Cable
6.2.1 Installation of Coaxial Connector
Install connector and mounting plate in recess. Attach cap
using one of the screws. Place cap on open connector.
4.1.3 Single Channel Connector: Coaxial
Machine cable channel and recess for mounting plate.
• Cover open channel to prevent cable damage
-
1
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2
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