Instruction
manual
Piezoelectric
Pressure Sensor
Type 6239A…
Tangential shot shell
pressure sensor
6239A_002-833e-06.21
Instruction
manual
Piezoelectric
Pressure Sensor
Type 6239A…
Tangential shot shell
pressure sensor
6239A_002-833e-03.19
ForewordIntroduction
Foreword
6239A_002-833e-03.19 Page 1
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.
© 2018 … 2021 Kistler Group. All rights reserved. Except
as expressly provided herein, no part of this manual may
be reproduced for any purpose without the express prior
written consent of 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
Eulachstrasse 22
8408 Winterthur
Switzerland
Tel. +41 52 224 11 11
info@kistler.com
www.kistler.com
Piezoelectric Pressure Sensor Type 6239A…
Page 2 6239A_002-833e-03.19
Content
1. Introduction .................................................................................................................................. 3
2. Important information ................................................................................................................. 4
2.1 Warranty .............................................................................................................................. 4
2.2 Disposal instructions for electrical and electronic equipment ............................................. 4
3. Sensor .......................................................................................................................................... 5
3.1 General functional description............................................................................................. 5
3.2 Measuring chain .................................................................................................................. 6
4. Installation and operation ........................................................................................................... 8
4.1 Mounting configurations ...................................................................................................... 8
4.1.1 Tangential mounting ............................................................................................... 8
4.1.2 Recessed mounting ................................................................................................ 8
4.2 Mounting bore preparation .................................................................................................. 9
4.2.1 Dimensions ............................................................................................................. 9
4.2.2 Machining ............................................................................................................. 10
4.2.3 Quality of mounting bore ...................................................................................... 12
4.2.3.1 Faulty sealing surface ........................................................................... 12
4.2.3.2 Reaming of sealing surface .................................................................. 12
4.3 Sensor installation and removal ........................................................................................ 15
4.3.1 Installation ............................................................................................................ 15
4.3.2 Tightening ............................................................................................................. 17
4.3.3 Cabling ................................................................................................................. 18
4.3.4 Removal ............................................................................................................... 18
5. Maintenance and calibration .................................................................................................... 19
5.1 Maintenance ...................................................................................................................... 19
5.1.1 Sensor .................................................................................................................. 19
5.1.2 Connectors ........................................................................................................... 19
5.2 Recalibration ..................................................................................................................... 21
6. Various measuring arrangements ........................................................................................... 22
6.1 Tangential pressure measurement on shot shells ............................................................ 22
6.1.1 Distance adjustment using dial gauge Type 1300A48A1 or Type 1300A48A2 ... 22
6.1.1.1 Measuring the distance between sensor membrane and cartridge ...... 22
6.1.1.2 Calculating the number of spacer rings ................................................ 25
6.2 General high pressure measurement ............................................................................... 26
6.3 Influence of long measuring bore ...................................................................................... 27
Total pages: 27
Introduction
6239A_002-833e-03.19 Page 3
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 gauge sensor systems for measuring force and
torque
Piezoresistive pressure sensors and transmitters
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,
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 on-line or in this manual, please contact Kistler's
extensive support organization.
Piezoelectric Pressure Sensor Type 6239A…
Page 4 6239A_002-833e-03.19
2. Important information
2.1 Warranty
The equipment supplied by Kistler Instrumente AG
Winterthur is covered by a warranty against faulty
material and workmanship.
This warranty extends 12 months from delivery date.
When submitting warranty claims, the items of equipment
concerned are to be delivered to the manufacturer's
works or to the regional distributor free of all charges, and
full details should be stated as to the nature of the claims.
Settlement of warranty claims may be effected, at the
manufacturer's discretion, either through reconditioning
or replacement of the faulty items, or through a credit
note to their value.
Items of equipment damaged as a result of improper use
are not covered by the warranty.
Our responsibility under the warranty is strictly restricted
to the above provisions and we specifically decline any
liability for damages incurred consequent upon the use or
operation of our equipment.
Especially for ballistic sensors:
As the service life of ballistic sensors strongly depends
on the application involved, warranty claims must be
clarified as the case may be.
2.2 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.
Sensor
6239A_002-833e-03.19 Page 5
3. Sensor
3.1 General functional description
Piezoelectric pressure sensor Type 6239A… is suitable
for tangential shot shell pressure measurements. Also
general high pressure measurements up to 1 500 bar can
be performed with this sensor. The shoulder sealing
design allows a flush or recessed mounting configuration.
Sensor Type 6239A… is characterized by:
Pressure range up to 1 500 bar
Excellent linearity <0.5%
High sensitivity of -5.6 pC/bar
Mounting thread options: 3/8-24 UNF or M10x1
Geometric compatibility with other sensors for this
application
Availability of tools for mounting bore preparation and
sensor installation
Optional dial gauge accessory for accurate distance
adjustment in tangential mounting
Fig. 1: Sensor dimensions of Types 6239AAA
(M10x1 thread) and 6239ABA (3/8-24 UNF
thread)
Piezoelectric Pressure Sensor Type 6239A…
Page 6 6239A_002-833e-03.19
3.2 Measuring chain
The measuring chain consists of:
1 Sensor Type 6239A…
2 High-insulation, low-noise cable (e.g. 1699AA0,5 and
1631C, 1603B)
3 Charge amplifier (e.g. 5015, 5018 or 5165A)
4 Data acquisition and processing unit (e.g. 5165A or
2519A, or from a third party)
Fig. 2: Measuring chain
Sensor Type 6239A…
Each sensor is calibrated in 100 % and 10 % of the
measuring range (FS: full scale). Depending on the
anticipated maximum pressure, the sensitivity must be
set to 0 ... 1500 bar or 0 ... 150 bar on the charge
amplifier.
High-insulation, low-noise cable
It is advisable to exclusively use Kistler cables. For
cables from other manufacturers, compatibility with the
sensor connector is not guaranteed and can result in
poor signal transmission.
Long cables between sensor and charge amplifier will
restrict the frequency range. The influence of cable
length is described in the operating instructions for the
charge amplifier.
In highly dynamic measurements, cable lengths of up to
50 m are usually acceptable.
Cable with single-part connector Type 1699AA0,5
This cable provides a reliable cable connection to the
sensor, even in the case of shock and / or vibration.
Compared with the standard cable Type 1631C... (with
knurled nut), this special cable features a single-part
connector which cannot work loose even with vibration,
since the entire cable must be rotated.
Fig. 3: Special cable Type 1699AA0,5
Sensor
6239A_002-833e-03.19 Page 7
Connector protection
Measuring charge is highly sensitive, and polluted
connectors can heavily impair the measurement quality. It
is therefore advisable to always keep the protective cap
on the sensor when it is not used. Connectors on the
cable and sensor can be cleaned with cleaning spray
Type 1003.
Charge amplifiers
Types 5015, 5018, 5165A and other Kistler laboratory
type charge amplifiers allow the required measuring
range to be freely adjusted.
Static measurements are not possible with the
piezoelectric system. The acceptable duration of the
measurement will depend on the insulation resistance of
the entire measuring chain and on the characteristics of
the charge amplifier.
Example:
With an insulation resistance of 1∙1013Ω and a drift of
0,03 pC/s (permissible drift of charge amplifier Type
5018), measurements with a sensor Type 6239A… will
results in an error of 1 bar/min.
Piezoelectric Pressure Sensor Type 6239A…
Page 8 6239A_002-833e-03.19
4. Installation and operation
4.1 Mounting configurations
4.1.1 Tangential mounting
The flush mounting configuration is intended for
tangential shot shell pressure measurement. There is
no dead space between the sensor diaphragm and
the test chamber. The sensor diaphragm is
tangentially aligned to the shot shell or the test
chamber.
Fig. 4: Tangential / flush mounting configuration
4.1.2 Recessed mounting
The recessed mounting configuration cannot be used
for tangential shot shell pressure measurement, but
for universal high pressure applications. Due to the
passage hole, the sensor membrane is better
protected against the effect of high flash temperature
and particle hit. This method can extend sensor life
and increase data quality by reducing thermal error.
Fig. 5: Recessed mounting configuration
Installation and operation
6239A_002-833e-03.19 Page 9
4.2 Mounting bore preparation
4.2.1 Dimensions
The bore depth must be sufficiently long to allow thread
engagement over the full length of the sensor.
Installing the sensor for tangential pressure measurement
(flush mounting) requires a depth (barrel wall thickness)
of max. 20mm (see Fig. 6). For the recessed mounting
setting, the wall thickness depends on the length of the
desired passage bore. It is recommended to avoid long
passage lengths, as pipe oscillations can occur (see
section 6.3).
L
Flush
mounting
Recessed
mounting
Thread engagement
12 mm
12 mm
Wall thickness
20 mm
Passage hole
0 mm
0 - 22 mm
For thicker walls, the top part of the bore must be drilled
to at least ø12,5 mm, so that the sensor can be mounted
using a tubular socket wrench Type 1373A1.
Fig. 6: Flush mounting situation for Type
6239ABA (UNF 3/8-24 thread)
Fig. 7: Flush mounting situation for Type
6239AAA (M10x1 thread)
Piezoelectric Pressure Sensor Type 6239A…
Page 10 6239A_002-833e-03.19
Fig. 8: Recess mounted situation for Type
6239ABA (UNF 3/8-24 thread)
Fig. 9: Recess mounted situation for Type
6239AAA (M10 thread)
4.2.2 Machining
Most important bore parameters:
Perpendicularity of M10x1 or 3/8-24 UNF to sealing
surface
The thread must be positioned exactly concentrically
to the bore.
Flatness of sealing surface
When preparing the mounting bore it is important to
ensure concentricity of the thread with respect to the
bore. This can be achieved without difficulty by cutting
the thread in the same workholding fixture on the drilling
machine or by using a locating center.
1. Rough drilling
with max. ø6.25 mm
(ideal ø2,5 ... 5 mm)
Installation and operation
6239A_002-833e-03.19 Page 11
2. Counterboring
Flush mounting
Recessed mounting
3. Countersinking
1x45°
4. Flat drilling
Flush mounting
Recessed mounting
5. Tapping
Thread Type
Depth
M10x1
12mm
3/8-24 UNF
12mm
The thread must be positioned exactly concentrically to
the bore.
6. Reaming
In order to ensure the best possible measuring accuracy,
the sealing surface must be finish reamed with the
surface finishing tool Type 1300A25A1 for the 3/8-24
UNF thread or 1300A46A1 for the M10x1 thread. A
planarity of 0.01 on the sealing surface needs to be
achieved. This step is described in more detail in section
4.2.3.2.
Tool Type
Depth
Ø 9 / 8.5 mm drill for M10 / UNF
12 mm
Ø 6.25 mm drill
18 mm
(through wall
thickness)
Tool Type
Depth
Ø 9 / 8.5 mm drill for M10 / UNF
12 mm
Ø 6.25 mm drill
18 mm
Tool Type
Depth
Ø 9 / 8.5 mm flat drill for M10 / UNF
14 mm
Ø 6.4 mm flat drill
Not required
(flush mount)
Tool Type
Depth
Ø 9 / 8.5 mm flat drill for M10 / UNF
14 mm
Ø 6.4 mm flat drill
Min 20.2 mm
Piezoelectric Pressure Sensor Type 6239A…
Page 12 6239A_002-833e-03.19
4.2.3 Quality of mounting bore
4.2.3.1 Faulty sealing surface
An uneven or concave sealing surface (Fig. 10) will
impede a proper sealing function. If an excessive
tightening torque is applied repeatedly, the sensor may
also dig into the sealing surface preventing uniform
pressure distribution over that surface.
Fig. 10: Wrong: Concave sealing surface
If the sealing surface is regularly checked and reamed,
these errors are effectively prevented (Fig. 11).
Fig. 11: Correct: Sealing surface adjacent to the
sensor shoulder
4.2.3.2 Reaming of sealing surface
Use surface finishing tool Type 1300A46A1 (M10x1
thread) or 1300A25A1 (3/8-24 UNF thread) to regularly
maintain the quality of the mounting bore.
Incorrect use of the surface finishing tools Type
1300A46A1 or 1300A25A1 can damage the sealing
surface. Practice sessions on a disused bore or a
practice piece are therefore recommended. This
experience will ensure that excellent sealing surfaces
are produced on the test barrel or vessel.
Installation and operation
6239A_002-833e-03.19 Page 13
Fig. 12: Surface finishing tool Type 1300A46A1
(M10x1 thread) or 1300A25A1 (3/8-24 UNF
thread)
Fill the grooves of the cutting surfaces with special
lubricating grease Type 1063 (supplied). The grease
picks up the chips, preventing them from becoming
jammed between cutter and sealing surface. The
lubricating effect also prevents scoring.
Fig. 13: Apply grease Type 1063 to the front
surface and thread of the reamer
Fig. 14: Hand screw the reamer into the mounting
bore
Piezoelectric Pressure Sensor Type 6239A…
Page 14 6239A_002-833e-03.19
Adjust the friction force by tightening or loosening with
the tubular socket wrench, so that the reamer can be
easily turned by hand.
Ream sealing surface:
Rotate the red handle in counter-clockwise direction
for 5 revolutions.
Tighten the reamer to keep up sufficient friction. Avoid
excessive friction in order to prevent scoring.
Rotate the red handle in counter-clockwise direction
for 5 revolutions.
Frequently remove the reamer to clean and inspect
the mounting bore.
Fig. 15: Reamer handling
During the lifetime of the test barrel, the depth of the
mounting bore will increase slightly by repetitive reaming
of the sealing surface. To ensure a proper flush mounting
situation of the sensor, regularly check the distance to the
cartridge using dial gauge Type 1300A48A1 (M10x1
thread) or 1300A48A2 (3/8-24 UNF thread). Follow the
instructions in section 4.3.
Rotate handle
in counter
-
clockwise
direction
Tighten
reamer
Installation and operation
6239A_002-833e-03.19 Page 15
4.3 Sensor installation and removal
4.3.1 Installation
During the installation of sensor Type 6239A... the
sealing ring 1100A105 has two functions. First, it seals
and avoids gas evasion and pressure loss through the
thread. Second, for tangential shot shell pressure
measurements the rings are used to adjust the distance
of the sensor from the cartridge (see section 6.1.1).
Fig. 16: Dimensions of sealing ring 1100A105
The soft steel of the sealing ring is subject to plastic
deformation when the sensor is tightened. Thus, it is
recommended to replace the sealing ring for every
sensor installation.
Fig. 17: Apply two dots of special lubricating grease
Type 1063 to hold the sealing ring in place.
Then spread the grease with your finger
around the sealing surface. This small amount
of grease will hold the seal ring in place, while
the sensor is being inserted.
0,5 mm
Piezoelectric Pressure Sensor Type 6239A…
Page 16 6239A_002-833e-03.19
Fig. 18: Insert the sealing ring.
For every additional sealing ring, two additional dots of
grease must be applied.
Fig. 19: Apply grease to the sensor thread to facilitate
insertion.
Check the mounting bore for any remaining sealing rings
from the previous installation. If the sealing surface is
uneven, follow the reaming instructions in section
4.2.3.2 Reaming of sealing surface.
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