Kistler 6239AAA Owner's manual

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.

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

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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