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Kistler 6152AA Series Instruction Manual

Direct measuring mold cavity pressure sensors with ø6 mm sensor front
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Instruction
Manual
Direct Measuring
Mold Cavity Pressure
Sensors with ø6 mm
Sensor Front
with Machinable Front
Type 6152AA...
with Chrome-Plated
Front or Diaphragm
Type 6152AC...
6152A_002-459e-02.12

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Summary of Contents for Kistler 6152AA Series

  • Page 1 Instruction Manual Direct Measuring Mold Cavity Pressure Sensors with ø6 mm Sensor Front with Machinable Front Type 6152AA... with Chrome-Plated Front or Diaphragm Type 6152AC... 6152A_002-459e-02.12...
  • Page 2 Instruction Manual Direct Measuring Direct Measuring Mold Cavity Pressure Mold Cavity Pressure Sensors with ø4 mm Sensors with ø6 mm Sensor Front Sensor Front Type 6157BA..., 6157BB..., with Machinable Front Type 6152AA... 6177AA..., 6157BC..., 6157BD..., with Chrome-Plated Front 6177AC..., 6167A... or Diaphragm Type 6152AC...
  • Page 4 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.

  • Page 5: Table Of Contents

    Direct Measuring Cavity Pressure Sensors, Type 6152AA… and Type 6152AC… Content General Information ........................4 Important Hole Conditions ......................5 Holes for Sensors ........................... 6 Hole for Unmachined Sensors .................... 6 3.1.1 Hole for Sensor with Mounting Nut Type 6453 ..............7 3.1.2 Hole for Sensor with Spacer Sleeve Type 6462 ..............
  • Page 6 Repairs at Kistler ....................... 25 Disposal Instructions for Electrical and Electronic Equipment ..........25 Measuring Chains ......................... 26 10.1 Machine-Integrated Mold-Cavity Pressure Monitoring ............. 26 10.2 Mold Cavity Pressure Monitoring with External Kistler Instruments ........27 Total Pages 27 6152A_002-459e-02.12 Page 3...

  • Page 7: General Information

    Direct Measuring Cavity Pressure Sensors, Type 6152AA… and Type 6152AC… 1. General Information  Sensor diameter ø6 mm must not be machined  Sensor front must be clean and without notches  Use only recommended mounting tool  Do not pull the sensor out of the hole by pulling on the cable.

  • Page 8: Important Hole Conditions

    Important Hole Conditions 2. Important Hole Conditions The measuring hole can influence the function and life of the sensor. Inaccurate holes can lead to measuring errors due to the inclusion of transverse forces acting on the sensor. Thus attention must be given to the following criteria: Fig.

  • Page 9: Holes For Sensors

    Direct Measuring Cavity Pressure Sensors, Type 6152AA… and Type 6152AC… 3. Holes for Sensors The sensor is mounted front flush in the measuring hole in the cavity wall. The pressure in the cavity is transferred via the sensor front directly onto the piezoelectric measuring element, which produces a proportional charge.

  • Page 10: Hole For Sensor With Mounting Nut Type 6453

    Holes for Sensors 3.1.1 Hole for Sensor with Mounting Nut Type 6453 Use EDM (Electrical discharge machining), mill or grind H7 hole in hardened tool steel. Check centering and positional alignment. Clean thread free of metal particles and debris. Fig. 4: Sensor hole for fitting mounting nut; mounting nut 3.1.2 Hole for Sensor with Spacer Sleeve Type 6462 Use EDM, mill or grind H7 hole in hardened tool steel.

  • Page 11: Hole Seat With Rotation Protection

    Direct Measuring Cavity Pressure Sensors, Type 6152AA… and Type 6152AC… With an oblique cavity wall or one with a oblique structure or in free-form surfaces, the sensor can be adapted to the contour. The sensor front can be machined within certain limits. For this purpose and in every case, the sensor must be secured against rotation before machining by machining the sensor shoulder on one side.

  • Page 12: Machining The Sensor Shoulder

    Holes for Sensors 3.2.2 Machining the sensor shoulder Sensor diameter ø10 mm has 2 flats (SW8) for positioning.  No further machining required. 3.2.3 Adapting the Sensor Front to Cavity Contour This applies to sensor Type 6152AA..The front of the sensor can be machined with a radius or slanted surface, also when mounted in the mold.

  • Page 13: Sensors With Chrome-Plated Front

    Direct Measuring Cavity Pressure Sensors, Type 6152AA… and Type 6152AC… Sensors with Chrome-Plated Front This applies sensor Type 6152AC… .  Chrome-plated sensors must not be machined. Machining the sensor front will damage the chrome layer and ruin the sensor. All liability and claims under warranty become void in the case of a sensor whose front has been machined.

  • Page 14: Cable Installation And Connectors

    Cable Installation and Connectors 4. Cable Installation and Connectors The cables for piezoelectric sensors must be well insulated. Cables and connectors must be installed with good protection to prevent cable damage during installation and in operation. Moisture and dirt in the area of the connector must be prevented in order to ensure optimum function.

  • Page 15: Single-Wire Clamping Connector Type 1839 And Mounting Plate

    Direct Measuring Cavity Pressure Sensors, Type 6152AA… and Type 6152AC… 4.1.1 Single-Wire Clamping Connector Type 1839 and Mounting Plate Mill a recess for the mounting plate. Contact surfaces and threads must be clean and free of grease. Provide radii at transitions and corners in the cable channel or hole, so as to prevent cable damage during assembly and in operation.

  • Page 16: Recess For 8-Channel Connector Type 1710A

    Cable Installation and Connectors 4.1.2.2 Recess for 8-Channel Connector Type 1710A... Wherever possible, position the cable channel or cable hole in the middle of the recess to simplify connection of the sensors. When space is limited, the cable entry can be located as required, in which a side entry at the level of the base may be used.

  • Page 17: Sensor Installation

    Direct Measuring Cavity Pressure Sensors, Type 6152AA… and Type 6152AC… 5. Sensor Installation First install the sensor, then the cable and finally the connector. This sequence is particularly important when installing single-wire sensors, in which the cable in the mold is cut to the required length. ...

  • Page 18: Sensor Installation With Spacer Sleeve Type 6462

    Sensor Installation Sensor Installation with Spacer Sleeve Type 6462 Insert the sensor into the hole with a slight rotary movement. Tool Type 1315A is suitable for deep holes and is screwed onto the M5 thread at the back of the sensor. Allow a clearance of 0,01 ...

  • Page 19: Cable And Connector

    Direct Measuring Cavity Pressure Sensors, Type 6152AA… and Type 6152AC… 6. Cable and Connector The most frequent sensor failures are caused by damage to the cable during installation. It is essential to allow suffi- cient slack when installing the cable and the connector. Edges and transitions should thereby be provided with radii and a sufficient length of cable installed to ensure that it is not under strain.

  • Page 20: Cut And Grip Technique

    Cable and Connector 6.1.1 Cut and Grip Technique Cut the sensor cable to the required length but do not strip off the insulation. To simplify mold servicing, cut the cable to an adequate length. Slacken the connector at the knurled nut but do not separate it. Ensure that the insulation is not stripped from the cable and the first 10 mm are not kinked.

  • Page 21: Installation For Multichannel Connector Types 1708A0 And 1710A0

    Direct Measuring Cavity Pressure Sensors, Type 6152AA… and Type 6152AC… Fig. 16: Installing connector Type 1839 and mounting plate  Tapped holes must be clean and free of grease.  Secure and install the cap. 6.1.2.2 Installation for Multichannel Connector Types 1708A0 and 1710A0 The recess for the multichannel connector must be clean.

  • Page 22: Coaxial Technique

    Cable and Connector Coaxial Technique The traditional coaxial cable technique uses a shielded cable, which is permanently connected to a connector. The cable length cannot be shortened and the cable must normally be installed in a channel. To prevent damage to the cable during assembly of the mold or during mold servicing, open channels should be covered with a plate.

  • Page 23: Identification Plate

    Direct Measuring Cavity Pressure Sensors, Type 6152AA… and Type 6152AC… 7. Identification Plate The identification plate contains the type number and serial number of the sensor or the assembly number in the case of the systems and sets for molds with several sensors. Also shown is the sensitivity measured and the average sensitivity in the case of the Unisens ®...

  • Page 24: Function Test

    Then check the sensor once more with the cable connected. Any sensor with a too low insulation value should be sent in to the Kistler factory. The local Kistler distributor will provide further information. Contact information is available at www.kistler.com.

  • Page 25: Testing The Sensor Function

     The sensor selector on the sensitivity meter Type 5993A is incorrectly set  Sensor with particularly high sensitivity A sensor with too low sensitivity should be sent to Kistler for testing and calibration. The local Kistler distributor will provide further information.

  • Page 26: Servicing And Repairs

    Servicing and Repairs 9. Servicing and Repairs Quartz crystal pressure sensors are very low maintenance and do not need to be removed for a mold service or cleaning. Nevertheless, it is advisable to test the insulation and sensitivity of the sensor in its measuring position. The connector part must be dry and clean before connection to an external meter.

  • Page 27: Testing The Sensor Function

     The sensor selector on the sensitivity meter Type 5993A is incorrectly set  Sensor with particularly high sensitivity A sensor with too low sensitivity should be sent to Kistler for testing and calibration. The local Kistler distributor will provide further information.

  • Page 28: Single-Wire Repairs

    Repairs at Kistler Sensors can be tested and a recalibration performed at Kistler. Repairs and testing at Kistler are arranged through the local distributor. Contact information is available at www.kistler.com. 9.6 Disposal Instructions for Electrical and Electronic Equipment Do not discard old electronic instruments in municipal trash.

  • Page 29: Measuring Chains

    To assess the cavity pressure, the amplified signal can be processed either via the machine or with an external Kistler monitor. Pressure monitoring allows automated assessment of the molding during production and can be used for good/bad grading.

  • Page 30: Mold Cavity Pressure Monitoring With External Kistler Instruments

    Measuring Chains 10.2 Mold Cavity Pressure Monitoring with External Kistler Instruments Kistler sensors can be used together with external instru- ments for recording and subsequent optimization and monitoring of the pressure signals. The Signal Conditioning Platform Type 2865A... is the equipment of choice for the optimization.

This manual is also suitable for:

6152ac series

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