Sensors for Combustion Analysis

PRODUCT CATALOG SENSORS FOR COMBUSTION ANALYSIS

Content

1 Introduction ...... 5 1 .1 Combustion measurement technology from AVL ...... 6 1 .2 Pressure sensors for combustion analysis from AVL ...... 8 1 .3 Setup of the measurement chain ...... 10

2 Pressure Sensors ...... 13 2 .1 Product selection guide ...... 14 2 .2 Cylinder pressure sensors for engine development ...... 26 2 .3 Low pressure sensors for engine development ...... 76 2 .4 Cylinder pressure sensors for engine monitoring ...... 80

3 Accessories for Pressure Sensors ...... 83 3.1 Racing amplifier ...... 84 3 .2 Adaptors and dummy plugs ...... 86 3 .3 Machining tools ...... 92 3 .4 Mounting tools ...... 94 3.5 Gaskets and flame arrestors ...... 98 3 .6 Cables and couplings ...... 100 3 .7 Cooling system ...... 106

4 Other Sensors ...... 109 4 .1 Crank angle encoder ...... 110 4 .2 TDC sensor 428 ...... 116 4 .3 Optical sensors for combustion measurement ...... 114 4 .4 Needle lift sensor ...... 118 4 .5 GCA ...... 120

5 Service & Calibration ...... 123 5 .1 Maintenance for piezoelectric sensors ...... 124 5 .2 Ramp calibration unit ...... 125 5 .3 Factory service ...... 126 5 .4 Spark plug sensors ...... 127 5 .5 Glow plug sensors ...... 128

Impressum ...... 134

1 Introduction

1 .1 Combustion measurement technology from AVL ...... 6 – Challenge – Complete toolbox for combustion analysis

1 .2 Pressure sensors for combustion analysis from AVL ...... 8 – Sensor portfolio for combustion analysis – Quality standards and production techniques – Research and development – Precision manufacturing and assembly

1 .3 Setup of the measurement chain ...... 10 1 INTRODUCTION

Combustion measurement technology from AVL

CHALLENGE These days legislation acts as a major driving force in the automotive industry and pushes current development trends . Effective drive systems with the lowest emissions possible at moderate costs will be in high demand for all engine sizes . At the same time the market is changing rapidly as a result of new manufacturers appearing on the market and intensifying the competitive pressure on all OEMs . All these circumstances lead to radically shortened development cycles in general . Due to peripheral conditions combustion analysis will increasingly become the central focus of tests because future engine maps for example will incorporate several combustion concepts . Therefore all test engineers, calibration engineers, development engineers as well as test-field managers are facing increasing complexity and need stronger interaction and correlation between combustion analysis results .

6 the enginevisibleandunderstandable. the AVL hascreated processes complexthermodynamic makethe toolsanddevicesthat practical in analysis ofcombustion methodology analysis .Basedondetailedknowledgeandexperienceinthe AVL beingabletooffer onlysupplier isworldwidethe completefieldofcombustion forthe solutions COMPLETE TOOLBOXFORCOMBUSTIONANALYSIS DATA ACQUISITIONANDANALYSIS SOFTWARE –AVL IndiCom™ pressureof cylinder signals. offers signalquality, outstanding ofinterest especially analysis forthermodynamic .Theuniquearchitecture signal conditioning converterwith analog-digital the different unitsundertestandenvironments combine .TheX-FEMsoptimally canbeeasilyadaptedto systemthat .X-ionisamodularacquisition platform AVL hasdevelopedAVL high-speeddataacquisition cutting-edge X-ion™–the Confronted growing the with andcomplexityofmodernpowertrains, diversity DATA ACQUISITION PLATFORM –AVL X-ion™ analysistasks. a widerangeofsensorsneededforcombustion pressure analysis.AVL combustion basisforhighquality sensoristhe provides A precise, pressure stable,andhighlyaccuratecylinder signaldelivered bythe AVL PRESSURESENSORS top workswhichoffer transparent chamber combustion accesstothe From carenginesuptocommercial small are enginesthey optical equippedwith under realistic before engineconditions production full tothe translating engine. AVL research singlecylinder enginesoffer significantadvantageoftesting the SINGLE CYLINDERRESEARCHENGINE is especially designed for use with large designed forusewith is especially engines. marineorstationary software systemdiagnostic intelligent system with implemented.Thesystem of robust andanacquisition signalamplifiers in-line monitoringsensorswith AVL provides monitoringconsisting acompletemeasuring chainforcondition MONITORING SOFTWARE –AVL EPOS™ robustness enginedevelopmentprocess ofthe andquality . and itsoffline counterpart –AVL –guarantee unparalleled CONCERTO™ objects.AVL tools,andpowerful display calculation versatile IndiCom™ offers advancedmeasurement interfaces, multiple setupandautomation, tomakingmodernengines cleanandefficient.which isessential Thesoftware AVL provides IndiCom™ process, combustion ofthe deepunderstanding

Introduction 1 INTRODUCTION

Pressure sensors for combustion analysis from AVL

SENSOR PORTFOLIO FOR COMBUSTION ANALYSIS AVL offers sensors for a wide range of combustion analysis applications . Sensors for measurement of the combustion pressure are available as well as sensors for absolute pressure measurements in injection lines and hydraulic systems . TDC (top dead center) sensors, sensors for needle lift and valve lift can also be found in the portfolio . The precise determination of the crankshaft position can be achieved with AVL crank angle encoders .

QUALITY STANDARDS AND PRODUCTION TECHNIQUES To control carefully the entire production process, AVL manufactures all of its critical sensor components in-house . Our own advanced processes were developed for temperature resistant coatings, clean room mounting, electron beam welding, state-of-the-art calibration and testing procedures . To guarantee the highest quality standards for the customer every single sensor is tested on a real engine and calibrated before it is delivered .

8 GaPO patentedcrystalmaterial use the one typecooledsensorsfrom AVL piezoelectric crystals.Uncooledand piezoelectricsensorsisasetof all for mechanicalwatches.Thecore of used those assembly techniqueslike partsand foroptical similar tothose This requires production tolerances insize. ofamillimeter a fewtenths areto 22parts.Someofthem just A piezoelectricsensorconsistsofup AND ASSEMBLY PRECISION MANUFACTURING AVL headquartersinAustria. 4 whichisproduced onlyat the

results . tectable levelandensures optimum signaltoanonde- ences onthe helps toreduce influ- anynegative sensorhousing.This design ofthe DoubleShell™ the with together useoftrimmedpiezoelements the AVLunique methods is practices .Oneexampleofthe ing algorithms computeraidedmodel- innovative velopment departmentalongwith high-tech know-howfrom de- the design ofeverysinglepartrequires To desired achievethe precision the DEVELOPMENT RESEARCH AND

Introduction 1 INTRODUCTION

Setup of the measurement chain

ENGINEENGINE SENSORS SENSORS SIGNAL CONDITIONING

Low pressure sensor – intake

Combustion pressure sensor

Combustion spark plug pressure sensor

Visio spark plug sensor

Low pressure sensor – exhaust

Crank angle encoder

10 Introduction

PARAMETERIZATIONPARAMETERIZATION / / OFFLINE PAST DATA ACQUISITIONDATA ACQUISITION OFFLINE PAST PROCESSING ONLINEONLINE EVALUATION EVALUATION PROCESSING

Data acquisition system Data acquisition software Data postprocessing AVL X-ion™ AVL IndiCom™ AVL Concerto™

2 Pressure Sensors

2.1 Product selection guide ...... 14

2.2 Cylinder pressure sensors for engine development ...... 26

2.3 Low pressure sensors for engine development ...... 76

2.4 Cylinder pressure sensors for engine monitoring ...... 80 2.1 PRODUCT SELECTION GUIDE

How to choose the right sensor and accessory

Each measurement task and application requires a specific The product selection guide starts with a list of common solution to achieve maximum precision and high quality questions and problems a customer typically faces in data. AVL offers a complete range of pressure sensors and the decision making process when selecting a sensor. accessories for combustion analysis. In order to make the Depending on how the question is answered a page choice of the right equipment more convenient AVL offers reference within the chapter is given which can act as a several tools. starting point in selecting the correct pressure sensor.

QUESTION ANSWER PAGE “How can sensors be quickly classified The use and interpretation of icons 14 according to their performance and usability?” “Which sensor type is necessary in which Table of mounting types 16 mounting situation?” “Which cylinder pressure sensor is typically Decision tree for cylinder pressure sensors 17 the best solution for a certain application?” “How does a specific sensor perform Comparison chart of sensor specifications 18 compared to others?” “Which datasheet terms are important and Explanation of datasheet terms 20 what do they mean?”

The use and interpretation of icons ‘strength’ indicates how well a sensor is suitable for a “How can sensors be quickly classified according to specific measurement task or application field. Further their performance and usability?” The icons used in the the icons for strength are rated from one to three stars datasheets and in the comparison chart help to classify a (standard, good, excellent suitability). The second type sensor quickly according to its strengths and key features. “key feature” gives information about the special There are two different types of icons. The first type technical components or design features.

ICONS OF STRENGTH / MEASUREMENT TASK

Toughness / knock applications Precision / thermodynamic analysis Durability / endurance testing Purpose: Specially designed to Purpose: Highly accurate measure- Purpose: Permanent, non-stop withstand under extreme and harsh ments for critical thermodynamic monitoring. conditions. analysis.

Examples: Analysis of knocking com- Examples: Measurements for heat Examples: Onboard monitoring of bustion, operation under high engine release and friction loss calculations large marine or stationary engines loads and supercharged engines

14 ICONS OF KEY FEATURES Pressure Sensors Pressure

Gallium Orthophosphate GaPO4 – Double Shell™ – Special sensor SDM Sensor Data Management – Patented unique high temperature design which decouples the crystals Increasing efficiency due to resistant crystal material for high mechanically from the housing for organized workflow durability and excellent linearity premium signal quality SDM guarantees end-to-end auto-

Today GaPO4 is by far the best The piezoelectric elements are sup- mated data transfer and thus ensures suitable piezoelectric material to posed to measure only the pressure error-free measurements. This solution be used in engine applications. It changes which are caused by the covers the complete measurement has a combination of several unique combustion process. Due to their chain running from the sensor to properties that make it the first high sensitivity these elements are the post-processing software. choice. It has unparalleled stability also susceptible to any other kind AVL Sensor Data Management™ up to a temperature of 970 °C with of applied pressure. For example SDM consists of several hardware twice the sensitivity of quartz and the mechanical stress which occurs and software components: performs better with respect to due to mounting the sensor into the sensitivity shifts if compared to mounting bore of the engine can • Automated sensor calibration Langasite crystals. The outstanding cause a misreading of the combus- system AVL RCU 601/300 stability of GaPO4 gives AVL the tion pressure. The Double Shell™ is • Sensor and testfield data base (SDB) ability to produce pressure sensors a special design feature which allows • Sensoridentification (SID, SIC, SDC) which show excellent measurement isolation of the piezoelectric measur- • Amplifier AVL X-ion™ and behavior, even at high temperatures ing elements from any of these neg- AVL IndiCom™ and pressures. The inherent physical ative influences and helps to ensure rigidity of GaPO4 allows the realiza- absolute measurement precision. For details see also page 24. tion of excellent signal qualities in very compact designs. For details see also page 22.

15 2.1 PRODUCT SELECTION GUIDE

Table of mounting types “Which sensor type is necessary in which mounting situation?”

Depending on the engine and measurement task for which a pressure sensor is required specific sensor types should be used. The choice of the sensor type typically defines the maximum achievable precision. In general two mounting families can be distinguished. One is the situation where a modification of the cylinder head of the engine e.g. drilling and milling of indicating passages is feasable and the other where modifications are not possible. If the available space is very limited or a modification is not possible a glow- or spark-plug adaptor solution is an option. On the other hand if a modification of the cylinder head is allowed it opens up the choices between several sizes of threaded, plug or probe type sensors.

CYLINDER PRESSURE

Mechanical modifications of cylinder head Use of existing standard bores

probe plug thread spark-plug glow-plug

• slim sensor design • less thermal deformation • best heat dissipation • no indicating passages necessary • also for glow-plug • less influence of • simple installation • custom tailored design adaptation mounting bore

16 Decision tree for cylinder pressure sensors “Which cylinder pressure sensor is typically the best solution for a certain application?”

With a certain application in mind this diagram allows the engineer to identify the recommended standard indicating solution. Depending on the detailed measurement task it is possible that other sensor types might be suitable as well.

Start small sized engines Usage of existing bore? yes gasoline spark plug ZI22 ZI33 diesel glow plug GH13G GH14P + AG0x no general purpose GH01D

GH15DK Sensors Pressure thermodynamic GH15D+PH08 knock analysis GP15DK

medium sized engines Usage of existing bore? yes gasoline spark plug ZI22 ZI33 ZI45 diesel glow plug GH13G GH14P + AG0x no general purpose GH01D GH15DK GU22CK GU24DK GC24DK thermodynamic GH15D+PH08 GU22C+PH04 GU24D GC24D knock analysis GP15DK GU22CK

large sized engines general purpose GH15DK GP15DK GU22CK thermodynamic GH15DK+PH08 GU22CK+PH04 GU24D QC34C QC34D GU31D GU41D

racing GP15DK GR15D GO15DK Gen2

17 2.1 PRODUCT SELECTION GUIDE

Comparison chart of sensor specifications “How does a specific sensor perform compared to others?”

To get an overview of the portfolio of pressure sensors, this chart can be used to compare a selected sensor with others. The most important features and parameters are listed for all pressure sensors.

Pressure Sensors Measurement task Mounting Thread / bore diameter Sealing Cable SDM Pressure Range Temp. Sensitivity Cyclic Natural frequency Page type type connection temperature drift

Toughness Precision Durability

4 Knock applications Thermodynamic analyis Endurance tests Plug type type Threaded Probe Spark-plug Glow-plug M3.5 × 0.35 M5 × 0.5 M7 × 0.75 M8 × 0.75 M8 × 1 M10 × 1 M12 × 1.25 M14 × 1.25 Ø 4.3 mm Ø 4.4 mm Ø 6.3 mm Ø 10 mm sealed Front Shoulder sealed M2 × 0.25 M3 × 0.35 M4 × 0.35 10-32 UNF Mirco-Dot Bürklin 70F 8251 Double Shell GaPO SID SIC SDC 5 bar 10 bar 30 bar 200 bar 250 bar 300 bar 350 bar 500 bar 1000 bar Maximum Temperature 1.5 pC/bar 5.3 pC/bar 10 pC/bar 11 pC/bar 15 pC/bar 16 pC/bar 19 pC/bar 20 pC/bar 34 pC/bar 35 pC/bar 45 pC/bar 68 pC/bar < ± 0.3 bar < ± 0.35 bar < ± 0.4 bar < ± 0.5 bar < ± 0.6 bar < ± 0.7 bar < ± 0.8 bar < ± 1.5 bar 50 kHz 69 kHz 85 kHz 90 kHz 92 kHz 96 kHz 100 kHz 115 kHz 130 kHz 150 kHz 160 kHz ≥ 170 kHz

Cylinder pressure sensors for engine development GH01D • • • • • • • 400 °C • • • 26 GH15D • • • • • • • • 400 °C • • • 28 GH15DK • • • • • • • • 400 °C • • • 30 GH15DKE • • • • • • • • 400 °C • • • 32 GP15DK • • • • • • • 400 °C • • • 34 GR15D • • • • • • • 400 °C • • • 36 GH14P – • • • • • • • • 400 °C • • • 38 GA16P – • • • • • • • 400 °C • • • 40 GH13G – • • • • • • 400 °C • • • 42 GU22C • • • • • • • 400 °C • • • 44 GU22CK • • • • • • • 400 °C • • • 46 GU21D • • • • • • • 400 °C • • • 48 GU24D • • • • • • • • 400 °C • • • 50 GU24DE • • • • • • • • 400 °C • • • 52 GU24DK • • • • • • • 400 °C • • • 54 GU31D • • • • • • • 350 °C • • • 56 GU41D • • • • • • • • 350 °C • • • 58 ZI22 • • • • • • 350 °C • • • 60 ZI33 • • • • • • 350 °C • • • 62 ZI45 • • • • • • 350 °C • • • 64 GC24D • • • • • • • 400 °C • • • 66 GC24DK • • • • • • • 400 °C • • • 68 QC34C • • • • • • 350 °C • • • 70 QC34D • • • • • • 350 °C • • • 72 QC43D • • • • • 80 °C • • • 74 Low pressure sensors for engine development LP12DA – • • • • • • • 200 °C 333, 1000, 2000 mV/bar 76 LP22DA – – – • • • • • 1100 °C 1000 mV/bar 78 Cylinder pressure sensors for engine monitoring

GO15DK • • • • • • • 350 °C • • • 80 Gen2

18 Pressure Sensors Gen2 GO15DK Cylinder pressure sensorsforenginemonitoring LP22DA LP12DA Low pressure sensorsforenginedevelopment QC43D QC34D QC34C GC24DK GC24D ZI45 ZI33 ZI22 GU41D GU31D GU24DK GU24DE GU24D GU21D GU22CK GU22C GH13G GA16P GH14P GR15D GP15DK GH15DKE GH15DK GH15D GH01D Cylinder pressure sensorsforenginedevelopment Measurement task Toughness

– – – – –

Knock

applications Precision

–

Thermodynamic analyis Durability

–

Endurance tests type Mounting • • • Plug type • • • • • • • • • • • • • • • • • • • Threaded type • • Probe • • • Spark-plug • Glow-plug Thread /bore diameter • M3.5 × 0.35 • • • • • • • M5 × 0.5 • M7 × 0.75 • • • • • • M8 × 0.75 M8 × 1 • • • M10 × 1 • M12 × 1.25 • • • M14 × 1.25 • Ø 4.3 mm • Ø 4.4 mm • • Ø 6.3 mm • Ø 10 mm type Sealing • • • • • • • • • • Front sealed • • • • • • • • • • • • • • • • • • • Shoulder sealed connection Cable • M2 × 0.25 • • • • • • • • • • • • • • • M3 × 0.35 • • • • • • • • • M4 × 0.35 • Mirco-Dot 10-32 UNF • • Bürklin 70F 8251 • • • • • • • • • • • • • Double Shell • • • • • • • • • • • • • • • • • • • • • • • GaPO4 SDM • • • • • • • • • • • • • • • SID SIC SDC Pressure Range • 5 bar • • 10 bar • 30 bar • • • • 200 bar • • • • • • • • • • • • • 250 bar • • • • • • 300 bar • 350 bar • 500 bar • 1000 bar Temp. 1100 °C 350 °C 350 °C 400 °C 350 °C 350 °C 400 °C 400 °C 400 °C 400 °C 400 °C 400 °C 400 °C 400 °C 400 °C 400 °C 400 °C 400 °C 400 °C 400 °C 200 °C 400 °C 400 °C 350 °C 350 °C 350 °C 350 °C 80 °C Maximum Temperature Sensitivity • 1.5 pC/bar • 5.3 pC/bar •

333, 1000,2000mV/bar 10 pC/bar • • • 11 pC/bar 1000 mV/bar • • 15 pC/bar • 16 pC/bar • • • • • • 19 pC/bar • • 20 pC/bar • • 34 pC/bar • • • 35 pC/bar • • • 45 pC/bar • 68 pC/bar temperature drift Cyclic • • • • • < ± 0.3 bar • < ± 0.35 bar • • < ± 0.4 bar • • • • • • • < ± 0.5 bar • < ± 0.6 bar • • • • • • < ± 0.7 bar • • < ± 0.8 bar • • < ± 1.5 bar Natural frequency • 50 kHz • • 69 kHz • 85 kHz • • • 90 kHz • • 92 kHz • 96 kHz • • • 100 kHz • 115 kHz • 130 kHz • • • 150 kHz • • • 160 kHz • • • • • ≥ 170 kHz Page 42 40 28 26 46 74 52 50 66 38 72 70 58 56 44 36 68 54 32 30 76 78 34 80 64 62 60 48 19

Pressure Sensors 2.1 PRODUCT SELECTION GUIDE

Datasheet information How to interpret datasheet parameters / Which specification is crucial for a certain application?

List of all specifications with their definition and how important they are in context with the specific application.

A ment arrangement by the impact of connector. Our newest sensor, the the intake and exhaust valves on the GH01D, is equipped with a M2 × 0.25 Acceleration sensitivity [bar/g] valve seat which are transmitted by connector. structure-borne noise. AVL does not recommend the use of cables of other suppliers. Due to small incompatibilities the ceramic insulator inside the sensor gets B permanently damaged and proper signal transmission can not be Burn off resistance [ ] guaranteed. The burn off resistance of a spark- plug is limiting the electric current Figure 1 between the electrodes during the Capacitance [F] flashover. This value has no influence In principle, the capacitance is the on the measurement performance of ability of a device to hold electrical Inertial forces due to vibration or the pressure sensor. charge between electrodes. shock can cause an apparent change Old amplifier technologies require of the output signal. This parameter this value for accurate measure- has to be as small as possible. Burst pressure [bar] ments. In state of the art indicating The acceleration sensitivity of The burst pressure characterizes the measurement systems this value has water-cooled pressure sensors is maximum pressure before a sen- no practical relevance anymore and additionally influenced by the mass sor gets destroyed. The operating therefore no influence on the signal of the cooling water in the pres- pressure always has to be smaller to quality. sure sensor and tubes. It is usually guarantee safe operation. significantly higher than in uncooled pressure sensors. For pressure mea- Cooling rate [l/h] surements at positions with high ac- Quartz sensors require active water celeration load, such as close to the C cooling. The cooling rate is a con- intake or exhaust valves but also in stant flow rate of the water through racing engines at high speed, pres- Cable connection the sensor at a certain pressure. This sure sensors with low acceleration The cable connection specifies the rate has influence on the thermal sensitivity should be used. The sen- type and size of the electric connec- sensitivity change. That explains sor is rated on its axial acceleration tion of sensor and piezoelectric cable. also the reason why the value for the sensitivity. The sensor itself could Most of the piezoelectric pressure thermal sensitivity change of sensors also be effected in case of high sensors are equipped with either a with quartz material is stated in %/°C radial acceleration load. In this case M3 x 0.35 or a M4 x 0.35 connector. and not in %. a sensor with dedicated construction Older sensor types like, e.g. some like GR15D should be used. Figure 1 water cooled quartz piezoelectric shows an example of the influence of sensors, use so called microdot Cyclic temperature drift [bar] acceleration on the pressure sig- 10-32 UNF connectors. Line and low Due to the fact that the membrane nal. The high frequency oscillations pressure sensors have a Bürklin - 7 of the sensor is periodically heated superimposed on the pressure signal pin plug. Monitoring sensors require by the combustion in the cylinder the are caused in this specific measure- either an M4 x 0.35 or an M12-8 pin local temperature at the membrane

20 engine. and 1500 rpmonatypicalgasoline This valueismeasured at9 barIMEP sensors from manufacturers. other in order comparisonswith toallow AVL standard values Δp is also stated the to drift issignificant.Inaddition ofcyclic determination type forthe engine combustion choice ofthe 1300 rpmandanIMEPof7bar. The measured engineat onaDIdiesel catalogareThe valuesgiveninthis are they that aspossible. ascritical areconditions way choseninthat impossible. AtAVL measuring the of different manufacturers almost direct comparisonbetweenvalues has tobemeasured. Thismakesa drift cyclic the which conditions procedure whichdefinesunder moment there existsnostandard measurethe valueisdefined.At this procedureIt iscrucialhowthe to measurement.higher accuracyofthe temperaturecyclic driftresults ina asmaller significant. Consequently effective pressure IMEP)istherefore mean indicated one cycle(e.g.the areparameters that integratedover crank anglerange.Theinfluenceon itactsoveralarge factthat to the analysis.Thisisdue thermodynamic mostsignificantparametersfor the temperatureThe cyclic drift isoneof shock error. temperaturecyclic driftorthermal effect thermal due tothis iscalled maximum misreading onecycle within due tochangeoftemperature. The signal givesawrong pressure value output changethe sensitivity thermal changes periodically. Similartothe

original sparkplug. same gapasthe (45 kV) tousethe (ZI22, ZI33andZI45)ishigh enough ofsparkplugs newgeneration the The maximumelectricstrength of our website. sales supportordownloadedfrom be requested from yourtechnical documentAT4370Eto the whichcan pleasereferFor detailedinstructions demand required gap. tojumpthe roughly proportional voltage tothe This isaconvenientmetricwhich (FCP) from compression the stroke. finalcompressionto the pressure accordinggap mustbeadjusted surement sparkplug.Theelectrode possible electrode mea- gapofthe the maximum sparkplugdefines the The maximumelectricstrength of original sparkplug. gapofthe plug isdeterminedbythe electrodeThe optimal gapofaspark Electrode gap[mm] sparkplug. ofthe capability maximumelectricvoltage cates the electrode electricstrength the - indi center designofthe Based onthe Electric strength [V] availablespace. limited electrodecentricity ofthe duetothe pressure sensorrequire ec- asmall M10andintegrated diameter with sparkplug.Sparkplugs ofthe middle ter electrode axial inthe is exactly In astandard cen- sparkplugthe Eccentricity [mm] E oscillations. chanceforpipe the which eliminates also aflushmountedmembrane cal stress membrane.Itallows onthe which results inalmostnomechani - housing upperendofthe seal atthe precision. Shouldersealedsensors effectsthermal andimprove signal sealed sensorsandcanreduce shoulder headthan cylinder to the conductivity thermal cipal abetter front sealedsensorsshowinprin- measurement. hand other Onthe duringthe signalquality the limit can occur. Thisphysicaleffect can are chosen,pipeoscillations notwell channel indicating ofthis dimensions results channel.Ifthe inanindicating recessinghead the membrane ofthe mechanical strength cylinder ofthe onthe Depending mounting. requiresmounting alwaysarecessed Frontitoring installations. sealed mon- can beimportantforlongtime prevents thread depositsinthe and membrane. Thiskindofsealing sensor rimofthe ing surfaceatthe Front seal- sealedsensorshavethe Front sealed F 21

Pressure Sensors 2.1 PRODUCT SELECTION GUIDE

G The crystal structure of Gallium I Orthophosphate can be derived

Gallium Orthophosphate GaPO4 from α-quartz by replacing silicon Insulation resistance [ ] alternatively with gallium and phos- The insulation resistance is the phorus, see Figure 2. electrical (ohmic-) resistance mea- α-Gallium Orthophosphate is stable sured between the electrodes of up to a temperature of 933 °C. the sensor (electrical contacts of the Above that it changes into the high connector). Piezoelectric sensors cristobalite type. have to have a resistance in the The excellent thermal behaviour range of more than 1012 to ensure and the high sensitivity of Gallium proper operation. Figure 2 Orthophosphate have made great A higher resistance value allows full performance advantages over quartz sensor performance in quasi-static

The GaPO4 is the patented high and Langasite realized in AVL’s measurements. If liquids, moisture or temperature resistant piezoelectric uncooled pressure sensors. particles contaminate the connector material developed by AVL. It allows Langasite crystals tend to have higher or start to enter the interior of the high signal linearity and temperature longitudinal sensitivities than Gallium sensor the electrical resistance can stability like no other material on Orthophosphate. However, if mea- drop. This indicates that the sensor the market. The crystal material is surement accuracy and precision are needs to be serviced immediately grown and manufactured only in the of importantance terms like sensitivity by the manufacturer. headquarters of AVL. Even though change and linearity of a sensor are the hydrothermal growing process more relevant. These are the areas of GaPO4 takes several months AVL where GaPO4 shows its superior produces this piezoelectric material performance. The importance of the L in high quantities. In numbers this sensitivity change becomes clear means simultaneous growing up to in context with the sensor housing. Linearity [%] 300 crystals which corresponds to Designing a pressure sensor for almost 200 kg crystal material per automotive applications requires the year. Each crystal has a size larger piezoelectric crystal to be packed than a man’s palm giving thousands into a rigid sensor housing. The of thin slices and cubes in the cutting material of the sensor housing has process which can be used with to be chosen in a way that the ther- high yield for hundreds of pressure mal expansion of the sensor housing sensors. and crystal cancel out to zero. With Langasite crystals this process is much more difficult and results in higher design effort and costs. As the sensitivity defines how much Gallium Orthophosphate allows signal is generated per pressure unit a much better optimization of the it is furthermore expected that this design which results in sensors with sensitivity is the same for all applied higher measurement precision. pressures. A variation in this context is defined by the term called linearity. The maximum deviation (+A, -A) is expressed as a percentage of the maximum pressure of the measuring range which is called full scale output (FSO). This value should be as close to zero as possible.

22 tioned for the sakeofcompleteness. forthe tioned charge-amplifiers andisonlymen- modesofmodern drift compensating hasnorelevancedeviation dueto The resulting permanentzero-line dp/dt. gradient maximumzero-lineand iscalled pressureof the levelperunitoftime the maximumchange is definedby sudden loadchange).Thedriftitself effect pressure onthe sensor(bya heating ducing aquickchangeinthe offshutting pro fuelsupplythus the - changingtomotoredthen modeby engine ataspecificloadpointand the byfirstrunning engine operation, change driftisdeterminedinreal load valueforthe The characteristic of temperature levelandheatflux. change whichiscausedbya pressureof the signalafteraload The loadchangedriftisaslow Load changedrift[bar/s]

torque wrenches should beused. righttorque,the calibrated toolslike components. Tomance ofall apply andbestperfor safe operation aspecifictorque.with Thisensures connector needstobemounted Each sensor, adaptorandthreaded Mounting torque [Nm] diameter”). thread-typesfor the (see“thread thread mounting of the isonlylisted plug- and probe-types. The diameter bore indicating Diameter ofthe for Mounting bore [mm] required analysis. forthermodynamic hand other whichisonthe sensitivity decreasethe inresolution and maximum pressure isinmostcases The trade-off toimproved membrane. sensor materialofthe design andthe pressurethe ismainlydefinedby sensor fail.Themaximumallowed membraneandmakethe the fatigue an issue.Highpressure peakscan maximum pressure rangebecomes charged enginesandknockingthe Under severe super like conditions 0…200 bar. sure rangeshouldbeatleast this pres cylinder For analysisofthe - specifications. sensormeetsthe the pressureThis isthe rangeinwhich Measuring range[bar] plug seatofaspark-plugadaptor. temperatureimum allowed ofthe This temperaturethe max- defines Max. temperature ofplugseat[°C] M - -

natural frequency 1 nance frequency sameasthe isthe pressure basicreso sensors,the - caseforpiezoelectric the is generally Where there asit attenuation, islittle highestamplitude. the signal with pressurethe output sensorgivesthe measurementthe atwhich quantity frequencythe frequency defines of frequency, basicresonance the termnatural the In contrast,with least above100kHz. frequency sensorshouldbeat ofthe natural highenginespeedsthe with noise.Thereforeof this fortesting frequency frequency isinthe range measurement natural signalifthe become visibleasanartefactinthe high frequency noise.Thisnoisecan valvesgeneratemainly ofthe actions moving At highenginespeedsthe speeds atleast50kHz. This valueshouldbeatlowengine sure sensor. assembledpreselement ofafully - forced) measuring inthe oscillations possible frequency offree (non- The naturalfrequency lowest isthe Natural frequency [Hz] N mounting position. position. mounting maximumtemperatureis the at the temperature whichismeanthere should beatleast0…400 range analysisthis combustion datasheet.Fortypical ofthe tions pressure specifica- sensormeetsthe Temperature rangeinwhichthe Operating temperature range [°C] O st order. °C. The 23

Pressure Sensors 2.1 PRODUCT SELECTION GUIDE

Overload [bar] been shifted in level to provide a SDM clear overview. Acronym for Sensor Data Manage- ment. For an overview please refer to page 15.

R Sensitivity [pC/bar] Resistance of insulator (spark-plug) DIN1319 defines sensitivity in this [ ] context as the ratio of generated This is the ohmic resistance between electrical charge per pressure unit The overload is the maximum value the center electrode and the ceramic (bar). This value should be at least of pressure which the sensor can body of the insulator. 10 pC/bar for high accurate mea- withstand for short time periods. It is surement data (e.g. heat release above the maximum pressure of the analysis). measuring range. The electrical charge is measured in At high pressures within the over- S Coulomb (1 C = 1012 pC). load range it cannot be guaranteed The nominal sensitivity is the mea- that the sensor signal works accord- SDB sured sensitivity at 23 °C. ing to the specifications but the Acronym for Sensor Database that It might seem to be important to sensor is not permanently damaged. is part of the SDM Sensor Data choose a sensor with very high sensi- Management system. tivity. In fact sensitivities in the range The SDB is a central digital repos- of 10 to 20 pC/bar are by far suffi- itory for the management of the cient especially with modern charge P sensor specific data. This point can amplifiers. Practically, choosing sen- be either a local- or a network data- sors with very high sensitivities can Pipe oscillations [Hz] base. For each sensor all calibration lead to unwanted signal overloads data is stored, the total number of during measurements, especially performed cycles is monitored and under supercharged or knocking service intervals can be scheduled conditions. according to the testing needs.

Shock resistance [g] SDC The maximum acceleration a sensor Acronym for Sensor Data Connector can withstand without being per- that is part of the SDM Sensor Data manently damaged. The higher this Figure 3 Management system. value the more rigid the sensor is The sensor is connected to a piezo-in- against mechanical shocks. The indicating channel represents an put cable which has a special plug In application fields with extremely acoustic resonator which is excited with built-in electronics. The difference high engine speeds (racing) the by changes in pressure and produc- to SIC is that the SDC does not store valve closing noise can cause signif- es oscillations. This effect is illustrat- only the serial number but also all icant influence on the measurement ed in Figure 3 where the measured calibration data of the sensor. No con- signal. pressure curves relate to indicating nection to any database or calibration The shock resistance is measured in channels of different lengths. Five file is required. On the other hand the units of the gravitational acceleration pressure curves from single cycle data is only accessible locally and no which equals to 1 g = 9.81 m/s2 . measurements are shown for each additional information can be stored. indicating channel length. They have

24 data like total run-time, number of numberof totalrun-time, data like sensor. identified to the Additionally correspondsSensor Databasethat stored datafrom calibration SDB the requestThe systemcanautomatically system. sensor isconnectedtothe whichspecific systemtoidentify the is read andallows amplifier bythe number this identification amplifier number.tion Connectedto anAVL - serialoridentifica an uniquedigital electronicbuilt-in componentwith SIDelectronicsA sensorwith hasa Management system. SDMSensorData ispartofthe that Acronym forSensorIdentification SID from sensor. the SIC necessary nottoseparatethe onespecificsensoritis ciated with SIDisalwaysasso- number ofthe To ensure uniqueidentification the directly sensorhousing. insidethe anintegration design doesnotallow sensor SIDforSDMorifthe without is anidealwaytoupgradesensors system.AnSICsolution amplifier connectsasensortothe cable that piezoelectric is integratedintothe system.TheSID indicating ed tothe sensorcurrently the identify connect- fromamplifiers AVL to recognize and the numberwhichallows tification SIDitcarriesanuniqueiden- the the samepurposeasSID.Like fulfills Data Managementsystem.TheSIC SDMSensor ispartofthe Cable that Acronym forSensorIdentification SIC and illustrations. statedaboveforadefinition sealed” Please refer term“Front tothe Shoulder sealed Sensor Database. be monitored andstored SDB atthe load cyclesandpeakpressures can as small aspossible. as small changeshouldbe sensitivity thermal water.cooling Thevaluefor the the flowrateof onthe additionally cooled quartzsensorsdepends changeofwater sensitivity thermal nominalsensitivity.age ofthe The ture rangeisexpressed asapercent- acertaintempera - within sensitivity sensor.the Themaximum change of of the sensitivity isinfluencing tion temperature posi- mounting atthe the average This termclassifieshow Thermal sensitivitychange[%] atransducer.system tointerfacewith a measurement instrumentorcontrol neededby and containsinformation transducer tothe device attached The TEDS,inessence,isamemory systems-, andcontrol/field networks. ing transducerstoinstrumentation interfacesforconnect- munication a setofnetwork-independentcom- ThisstandardCommittee. describes standards developedbyanIEEE arethe IEEE1451 interface definedin related TEDSformats information. andmanufacturer calibration cation, - storing sensorandactuatoridentifi (TEDS) isastandardized of method A Transducer Electronic DataSheet for smarttransducers. Acronym IEEE1451standard forthe TEDS T sensors. threadmounting ofthread-type metricorUNF Diameter ofthe Thread diameter[metric] Temperature onpage20. Drift” of“Cyclic explanation Refer tothe Thermo shockerror W the connecting cable. connecting the sensorwithout Physical weightofthe Weight [g] 25

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GH01D TIGG2118A.01

The GH01D has the slimmest contour due to a M2 cable connector and is a miniaturized and robust M3.5 sensor. This sensor is suitable for mounting bores where access is a problem, a max. diameter of 3.5 mm makes it happen. It has thermally optimized piezoelectric crystal elements and the special Double Shell™ design. It decouples the piezoelectric elements from negative influences of mechanical stresses which can occur due to the mounting of the sensor into the engine. Additionally it has an improved membrane material and geometry.

SPECIFICATIONS Measuring range 0 … 300 bar Overload 350 bar Sensitivity 5.3 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 300 bar Natural frequency 170 kHz Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 3.5 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 2 % 0 ... 300 bar Thermal sensitivity change 250 ± 100 °C and ≤ ± 0.5 % 0 ... 300 bar typ. Load change drift ≤ 2.0 mbar/ms max. gradient typ. SCOPE OF SUPPLY Cyclic temperature drift 2) ≤ ± 0.7 bar Sensor GH01D Thermo shock error Δp 3) ≤ ± 0.4 bar typ. Piezo-input cable CI21-1 Thread diameter M3.5×0.35 front sealed Fitted coupling CC21 Cable connection M2×0.25 positive Calibration sheet Weight 0.8 grams without cable Documentation Mounting torque 0.5 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1300 rpm, diesel 3) at 9 bar IMEP and 1500 rpm, gasoline 26 Mounting paste Mounting Machining tool tool Mounting Dummy removal tool Dummy tool Cable mounting Cables &couplings ACCESSORIES SF01 Tap MT32 drill MD27 Step drill Torque wrench TT02 socketTT66 Mounting TD41 DG41 TC21 CI21, CC21 *) 1mmforsteel,3castiron andaluminiumalloys. Front sealeddirect installation.

TIHK0094A.01 TIWG0667A.01 TIWG0665A.01 TIWG0117A.01 TIWG0664A.01 TIWG0669A.01 TIWG0668A.01 TIWG0690A.01 See page96 See pages92to93 See pages94to97 See page96 See page91 See page95 See pages100to105 27

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GH15D TIGG1349B.01

The GH15D has the slimmest contour due to a M3 cable connector and allows very precise thermodynamic measurements with a sensor of size M5. This is realized by thermally optimized piezoelectric crystal elements and the special Double Shell™ design. It decouples the piezoelectric elements from negative influences of mechanical stresses which can occur due to the mounting of the sensor into the engine. Using a thermo protection like PH08 can improve the cyclic drift by 0.3 bar. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 250 bar Overload 300 bar Sensitivity 19 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 250 bar Natural frequency 160 kHz Acceleration sensitivity ≤ 0.0005 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 7.5 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 1 % 0 … 250 bar Thermal sensitivity change 250 ± 100 °C and ≤ ± 0.25 % 0 … 250 bar typ. SCOPE OF SUPPLY Load change drift 1.5 mbar/ms max. gradient typ. Sensor GH15D Cyclic temperature drift 2) ≤ ± 0.5 bar Piezo-input cable CI31-1 Thermo shock error Δp 3) ≤ ± 0.3 bar typ. Coupling CC31 Thread diameter M5×0.5 front sealed Accessory kit (protection cap + 2 spare o-rings) Cable Connection M3×0.35 negative Calibration sheet Weight 2.2 grams without cable Documentation Mounting torque 1.5 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 28 Flame arrestor paste Mounting Machining tool tool Mounting Adaptor sleeves Dummy removal tool Dummy tool Cable mounting Cables &couplings ACCESSORIES *) 1.5mmforsteel,4castiron andaluminiumalloys. Front sealeddirect installation.

PH01, PH08 SF01 Seat dressing toolMR01-160 Seat dressing toolMR01-85 Tap MT12 drill MD12 Step drill Toolset MS15(MD12,MT12) toolTT51 PH08 dismounting Torque wrench TT02 socketTT21 Mounting Toolset TS21(TT21,TT02) AH01, AH01A,AH91,MA01,MA02,MA03,MA07 TD13 DG24 TC02 CI31, CI32,CI3V, CC31,E124 *) Rigidadhesive,e.g.LOCTITE648orHenkelomniFIT. Installation withanAH91adaptorandthePH08. TIHK0094A.01 TIWG0632A.01 TIWG0616A.01 TIWG0346A.01 TIWG0335A.01 TIWG0337A.01 TIWG0532A.01 TIWG0117A.01 TIWG0214A.01 TIWG0213A.01 TIWG0224A.01 TIWG0334A.01 TIWG0613A.01 See page96 See pages92to93 See pages94to97 See page96 See page91 See page95 See page99 See page87 See pages100to105

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GH15DK TIGG1383B.01

The GH15DK has the slimmest contour due to a M3 cable connector and is an accurate and robust M5 sensor especially suited for supercharged engines with high specific output. It has thermally optimized piezoelectric crystal elements and the special Double Shell™ design. It decouples the piezoelectric elements from negative influences of mechanical stresses which can occur due to the mounting of the sensor into the engine. Additionally it has an improved membrane material and geometry. This makes the sensor more robust suitable as the standard solution for research and development work with perfect trade off between accuracy and robustness. Using a thermo protection like PH08 can improve the cyclic drift by 0.4 bar. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 300 bar Overload 350 bar Sensitivity 19 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 300 bar Natural frequency 170 kHz Acceleration sensitivity ≤ 0.0005 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 7.5 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 2 % 0 … 300 bar Thermal sensitivity change 250 ± 100 °C and ≤ ± 0.5 % 0 … 300 bar typ. SCOPE OF SUPPLY Load change drift 1.5 mbar/ms max. gradient typ. Sensor GH15DK Cyclic temperature drift 2) ≤ ± 0.7 bar Piezo-input cable CI31-1 Thermo shock error Δp 3) ≤ ± 0.4 bar typ. Coupling CC31 Thread diameter M5×0.5 front sealed Accessory kit (protection cap + 2 spare o-rings) Cable Connection M3×0.35 negative Calibration sheet Weight 2.2 grams without cable Documentation Mounting torque 1.5 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 30 Flame arrestor paste Mounting Machining tool tool Mounting Adaptor sleeves Dummy removal tool Dummy tool Cable mounting Cables &couplings ACCESSORIES *) 1.5mmforsteel,4castiron andaluminiumalloys. Front sealeddirect installation.

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GH15DKE TIGG1595A.01 (A-type) TIGG1597A.01 (B-type)

The GH15DKE is the elongated version of GH15DK and could be used within oil and water jackets without the need of an adaptor sleeve. It is an accurate and robust M5 sensor especially suited for supercharged engines with high specific output. It has thermally optimized piezoelectric crystal elements and the special Double Shell™ design. It decouples the piezoelectric elements from negative influences of mechanical stresses which can occur due to the mounting of the sensor into the engine. Additionally it has an improved membrane material and geometry. This makes the sensor more robust suitable as the standard solution for research and development work with perfect trade off between accuracy and robustness. Using a thermo protection like PH08 can improve the cyclic drift by 0.4 bar. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 300 bar Overload 350 bar Sensitivity 19 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 300 bar Natural frequency 170 kHz Acceleration sensitivity ≤ 0.0005 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 7.5 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 2 % 0 … 300 bar Thermal sensitivity change 250 ± 100 °C and ≤ ± 0.5 % 0 … 300 bar typ. SCOPE OF SUPPLY Load change drift 1.5 mbar/ms max. gradient typ. Sensor GH15DKE Cyclic temperature drift 2) ≤ ± 0.7 bar Piezo-input cable CI31-1 Thermo shock error Δp 3) ≤ ± 0.4 bar typ. Coupling CC31 Thread diameter M5×0.5 front sealed Accessory kit (protection cap + 2 spare o-rings) Cable Connection M3×0.35 negative Calibration sheet Weight 6.7 – 10.2 grams without cable Documentation Mounting torque 1.5 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 32 Flame arrestor paste Mounting Machining tool tool Mounting tool Cable mounting Cables &couplings ACCESSORIES PH01, PH08 SF01 Seat dressing toolMR01-160 Seat dressing toolMR01-85 toolTT51 PH08 dismounting Torque wrench TT02 socketTT21 Mounting Toolset TS21(TT21,TT02) TC02 CI31, CI32,CI3V, CC31,E124 *) 1.5mmforsteel,4castiron andaluminiumalloys. Front sealeddirect installation.

TIHK0094A.01 TIWG0632A.01 TIWG0616A.01 TIWG0532A.01 TIWG0117A.01 TIWG0214A.01 TIWG0213A.01 TIWG0613A.01 See page96 See pages92to93 See pages94to97 See page95 See page99 See pages100to105 33

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GP15DK TIGG1892A.01

The GP15DK has the slimmest contour due to a M3 cable connector and is a robust M5 sensor especially suited for supercharged engines with high knock events. The Double-Shell™ design decouples the piezoelectric elements from negative influences of mechanical stresses which can occur due to the mounting of the sensor into the engine. In addition to this, it has an improved membrane material and geometry. This makes the sensor to the standard solution for development work with heavy knock events and pre-ignition. The sensor could be equipped with SIC for SDM.

SPECIFICATIONS Measuring range 0 … 500 bar Overload 600 bar Sensitivity 10 pC/bar nominal ≤ ± 0.3 % 0 ... 150 bar FSO Linearity ± 0.5 % 0 ... 300 bar FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 300 bar Natural frequency 170 kHz Acceleration sensitivity ≤ 0.0005 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 7.5 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 2 % 0 … 300 bar Thermal sensitivity change 250 ± 100 °C and ≤ ± 0.5 % SCOPE OF SUPPLY 0 … 300 bar typ. Sensor GP15DK Load change drift 7 mbar/ms max. gradient typ. Thermo protection PH08 Cyclic temperature drift 2) ≤ ± 1.5 bar Piezo-input cable CI35-1 Thermo shock error Δp 3) ≤ ± 0.8 bar typ. Coupling CC31 Thread diameter M5×0.5 front sealed Accessory kit (protection cap + 2 spare o-rings) Cable Connection M3×0.35 negative Calibration sheet Weight 1.6 grams without cable Documentation Mounting torque 1.5 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 34 Flame arrestor paste Mounting Machining tool tool Mounting Adaptor sleeves Dummy removal tool Dummy tool Cable mounting Cables &couplings ACCESSORIES PH01, PH08 SF01 Seat dressing toolMR01-160 Seat dressing toolMR01-85 Tap MT12 drill MD12 Step drill Toolset MS15(MD12,MT12) toolTT51 PH08 dismounting Torque wrench TT02 socketTT21 Mounting Toolset TS21(TT21,TT02) AH01, AH01A,AH91,MA01,MA02,MA03,MA07 TD13 DG39 TC02 CI35, CC31,E124 *) 1.5mmforsteel,4castiron andaluminiumalloys. Front sealeddirect installation.

TIHK0094A.01 TIWG0632A.01 TIWG0616A.01 TIWG0346A.01 TIWG0335A.01 TIWG0337A.01 TIWG0532A.01 TIWG0117A.01 TIWG0214A.01 TIWG0213A.01 TIWG0224A.01 TIWG0593A.01 TIWG0613A.01 See page96 See pages92to93 See pages94to97 See page96 See page91 See page95 See page99 See page87 See pages100to105 35

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GR15D TIGG1977A.01

The GR15D has the slimmest contour due to a M3 cable connector and is an accurate and robust M5 sensor especially suited for engines with high vibration. It has thermally optimized piezoelectric elements. In addition to this it has an improved internal design of the measurement cell and charge output. Using a thermo protection like PH08 can improve the cyclic drift by 0.4 bar. The sensor could be equipped with SIC for SDM.

SPECIFICATIONS Measuring range 0 … 300 bar Overload 350 bar Sensitivity 15 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 300 bar Natural frequency 160 kHz Acceleration sensitivity ≤ 0.0008 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 7 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 2 % 0 … 300 bar Thermal sensitivity change 250 ± 100 °C and ≤ ± 0.5 % 0 … 300 bar typ. SCOPE OF SUPPLY Load change drift 1.5 mbar/ms max. gradient typ. Sensor GR15D Cyclic temperature drift 2) ≤ ± 0.7 bar Piezo-input cable CI35-1 Thermo shock error Δp 3) ≤ ± 0.4 bar typ. Coupling CC31 Thread diameter M5×0.5 front sealed Accessory kit (protection cap + 2 spare o-rings) Cable Connection M3×0.35 negative Calibration sheet Weight 2.2 grams without cable Documentation Mounting torque 1.5 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 36 Flame arrestor paste Mounting Machining tool tool Mounting Adaptor sleeves Dummy removal tool Dummy tool Cable mounting Cables &couplings ACCESSORIES PH01, PH08 SF01 Seat dressing toolMR01-160 Seat dressing toolMR01-85 Tap MT12 drill MD12 Step drill Toolset MS15(MD12,MT12) toolTT51 PH08 dismounting Torque wrench TT02 socketTT21 Mounting Toolset TS21(TT21,TT02) AH01, AH01A,AH91,MA01,MA02,MA03,MA07 TD13 DG24 TC02 CI35, CC31,E124 *) 1.5mmforsteel,4castiron andaluminiumalloys. Front sealeddirect installation.

TIHK0094A.01 TIWG0632A.01 TIWG0616A.01 TIWG0346A.01 TIWG0335A.01 TIWG0337A.01 TIWG0532A.01 TIWG0117A.01 TIWG0214A.01 TIWG0213A.01 TIWG0224A.01 TIWG0334A.01 TIWG0613A.01 See page96 See pages92to93 See pages94to97 See page96 See page91 See page95 See page99 See page87 See pages100to105 37

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GH14P TIGG1323A.01

The GH14P is in combination with a glow-plug adaptor (direct mount) a nearly flush mounted solution for diesel engines. It allows measurements without pipe oscillations and pressures of up to 250 bar. The GH14P comes with an M3 connector which allows the smallest installation tool clearance diameters. The glow plug adaptor dimensions are custom tailored to the requirements of the customer. The Double-Shell™ design decouples the piezoelectric elements from negative influences of mechanical stresses which can occur due to the mounting of the sensor into the adaptor or engine. Using a thermo protection like PH08 can improve the cyclic drift by 0.3 bar. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 250 bar Overload 300 bar Sensitivity 15 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 250 bar Natural frequency 115 kHz Acceleration sensitivity ≤ 0.001 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 7 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 2 % 0 … 250 bar Thermal sensitivity change 250 ± 100 °C and ≤ ± 0.5 % 0 … 250 bar typ. SCOPE OF SUPPLY Load change drift 1 mbar/ms max. gradient typ. Sensor GH14P Cyclic temperature drift 2) ≤ ± 0.5 bar Piezo-input cable CI31-1 Thermo shock error Δp 3) ≤ ± 0.3 bar typ. Coupling CC31 Mounting bore 4.3 mm front sealed Accessory kit (protection cap + 2 o-rings) Cable Connection M3×0.35 negative Calibration sheet Weight 5.4 grams without cable Documentation Mounting torque 1.5 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 38 *) Direct installation. aluminium alloys. 1.5 mmforsteel,4castiron and Flame arrestor paste Mounting Machining tool tool Mounting Adaptors Dummy removal tool Dummy tool Cable mounting Cables &couplings ACCESSORIES

PH01 SF01 Seat dressing toolMR05 Tap MT11 drill MD26 Step drill Torque wrench TT02 socketTT21 Mounting Toolset TS21(TT21,TT02) AG03, AG04,AH13,AH45 TD13 DG13 TC02 CI31, CI32,CI3V, CC31,E124 Installation withglow-plugadaptorAG04. TIYF0592A.01 TIHK0094A.01 TIWG0575A.01 TIWG0154A.01 TIWG0574A.01 TIWG0117A.01 TIWG0214A.01 TIWG0213A.01 TIWG0224A.01 TIWG0219A.01 TIWG0613A.01 Installation withanAH45adaptor See page99 See page96 See pages92to93 See pages94to97 See page96 See page91 See page95 See page87 See pages100to105 39

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GA16P TIGG1924A.01

The GA16P is a derivate of the GH14P sensor. It can be used in combination with glow-plug adaptors with sensor bores of 4.4 mm in diesel engines. The GA16P comes with an M3 connector which allows the smallest installation tool clearance diameters. The Double-Shell™ design decouples the piezoelectric elements from negative influences of mechanical stresses which can occur due to the mounting of the sensor into the adaptor or engine. The sensor could be equipped with SIC for SDM.

SPECIFICATIONS Measuring range 0 … 250 bar Overload 300 bar Sensitivity 19 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 250 bar Natural frequency 160 kHz Acceleration sensitivity ≤ 0.0005 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 8.2 pF Sensor operating temperature - 40 … 400 °C range 1) 20 ... 400 °C and ≤ 1 % 0 ... 250 bar Thermal sensitivity change 200 ± 100 °C and ≤ ± 0.25 % 0 ... 250 bar typ. SCOPE OF SUPPLY Load change drift 1.5 mbar/ms max. gradient typ. Sensor GA16P Cyclic temperature drift 2) ≤ ± 0.5 bar Piezo-input cable CI31-1 Thermo shock error Δp 3) ≤ ± 0.3 bar typ. Coupling CC31 Mounting bore 4.4 mm front sealed Accessory kit (protection cap + 2 o-rings) Cable Connection M3×0.35 negative Calibration sheet Weight 4.0 grams without cable Documentation Mounting torque 1.5 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 40 Mounting paste Mounting tool Mounting tool Cable mounting Cables &couplings ACCESSORIES SF01 Torque wrench TT02 socketTT21 Mounting Toolset TS21(TT21,TT02) TC02 CI31, CI32,CI3V, CC31,E124 Direct installation. TIHK0094A.01 TIWG0117A.01 TIWG0214A.01 TIWG0213A.01 TIWG0613A.01 See page96 See pages94to97 See page95 See pages100to105 41

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GH13G TIGH13GPA.01

The GH13G is a glow-plug sensor for diesel applications where the cylinder head design requires glow-plug diameters down to 4.3 mm. The membrane of this glow-plug sensor is nearly flush mounted which leads to high signal quality without pipe oscillations. The shape of the glow-plug sensor is custom tailored to the requirements of the customer. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 250 bar Overload 300 bar Sensitivity 16 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 250 bar Natural frequency 130 kHz Acceleration sensitivity ≤ 0.001 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 8 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 2 % 0 … 250 bar Thermal sensitivity change 250 ± 100 °C and SCOPE OF SUPPLY ≤ ± 0.5 % 0 … 250 bar typ. Sensor GH13G Load change drift 1.5 mbar/ms max. gradient typ. Piezo-input cable CI31-1 Cyclic temperature drift 2) ≤ ± 0.5 bar Coupling CC31 Cable Connection M3×0.35 negative Accessory kit (protection cap + 2 o-rings) without sleeve Weight 12.6 grams Calibration sheet and cable Documentation Mounting torque 4 Nm using SF01

1) surface temperature around the cable connection < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel

42 Mounting paste Mounting tool Mounting Design costs tool Cable mounting Cables &couplings ACCESSORIES Example ofdirect installation. SF01 Torque wrench TT18 socketTA16Mounting (forM10 versions) socketTT09(forM8versions) Mounting TC02 CI31, CI32,CI3V, CC31,E124 Dimensions oftheglow-plug. TIHK0094A.01 TIWG0209A.01 TIWG0200A.01 TIWG0140A.01 TIWG0613A.01 TIAGDESA.01 See page96 See pages94to97 See page95 See page90 See pages100to105 43

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GU22C TIGG1073A.01

The GU22C is a 6.2 mm plug-type sensor for precise thermodynamic analysis which fulfills reference class requirements when used in combination with the PH04 flame arrestor. It is based on a well established design concept that allows high accuracy. It has thermally optimized piezoelectric elements and no influence from the mounting bore on the pressure signal due to minimized mechanical contact between the mounting bore and the sensor housing. A thermo protection can improve the cyclic drift down below ± 0.4 bar. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 250 bar Overload 300 bar Sensitivity 34 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 250 bar Natural frequency 100 kHz Acceleration sensitivity ≤ 0.001 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 8 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 1 % 0 … 250 bar Thermal sensitivity change 250 ± 100 °C and ≤ ± 0.25 % SCOPE OF SUPPLY 0 … 250 bar typ. Sensor GU22C Load change drift 1.5 mbar/ms max. gradient typ. Piezo-input cable CI41-1 Cyclic temperature drift 2) ≤ ± 0.4 bar Coupling CC41 Thermo shock error Δp 3) ≤ ± 0.2 bar typ. Gasket SG02 Mounting bore 6.3 mm shoulder sealed Accessory kit (protection cap + 2 o-rings) Cable Connection M4×0.35 negative Spare gasket SG02 Calibration sheet Weight 12.5 grams without cable Documentation Mounting torque 10 Nm using SF01

1) surface temperature around the cable connection < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 44 AM04 (AM05). Direct installationwiththemountingnipple Flame arrestor paste Mounting Machining tool tool Mounting adaptors Mounting Dummy removal tool Dummy sleeves Mounting nipples Safety ringformounting nipples Mounting Gasket tool Cable mounting Cables &couplings ACCESSORIES PH04 SF01 Tap MT13(3/8×24UNF) drill Tap MT31(M10×1) drill thread MD16 (with Step drill M10×1) thread MD10 (with Step drill 3/8``x24UNF) Torque wrench TT18 socketTT07 (forAH26,27,28) Mounting socketTA13Mounting (forAM04,05) socketshort TT09(forAM04,05) Mounting Toolset TS02(TT09,TT18)(forAM04,05) MA05 (GU22C+PH04),MA06(GU22C) TD01 DG10 (GU22C),DG14(GU22C+PH04) AH26, AH27,AH28 AM06 AM04 (M10×1),AM05(3/8×24UNF) SG02 TC01 CI41, CI42,CI4V, CC41,CC42,E124 AM04 (AM05)andthermoprotection PH04. Direct installationwiththemountingnipple TIYF0760A.01 TIHK0094A.01 TIWG0369A.01 TIWG0156A.01 TIWG0418A.01 TIWG0257A.01 TIWG0209A.01 TIWG0133A.01 TIWG0136A.01 TIWG0140A.01 TIWG0128A.01 TIWG0122A.01 TIWG0417A.01 TIWG0240A.01 TIBQ0227A.01 TIWG0131A.01 AH26 (AH27). Direct installationwiththemountingsleeve See page99 See page96 See pages92to93 See pages94to97 See page96 See page88 See page88 See page98 See page95 See page86 See page91 See page87 See pages100to105

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GU22CK TIGG1355A.01

The GU22CK is an accurate and robust 6.2 mm plug-type sensor. It is based on a well established design concept that allows high accuracy. It has thermally optimized piezoelectric elements and no influence from the mounting bore on the pressure signal due to minimized mechanical contact between mounting bore and the sensor housing. A thermo protection can improve the cyclic drift down below ± 0.3 bar. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 350 bar Overload 400 bar Sensitivity 34 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 300 bar Natural frequency 96 kHz Acceleration sensitivity ≤ 0.001 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 8 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 1 % 0 … 300 bar Thermal sensitivity change 250 ± 100 °C and ≤ ± 0.25 % SCOPE OF SUPPLY 0 … 300 bar typ. Sensor GU22CK Load change drift 1.5 mbar/ms max. gradient typ. Piezo-input cable CI41-1 Cyclic temperature drift 2) ≤ ± 0.6 bar Coupling CC41 Thermo shock error Δp 3) ≤ ± 0.3 bar typ. Gasket SG02 Mounting bore 6.3 mm shoulder sealed Accessory kit (protection cap + 2 o-rings) Cable Connection M4×0.35 negative Spare gasket SG02 Calibration sheet Weight 12.5 grams without cable Documentation Mounting torque 10 Nm using SF01

1) surface temperature around the cable connection < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 46 AM04 (AM05). Direct installationwiththemountingnipple Flame arrestor paste Mounting Machining tool tool Mounting adaptors Mounting Dummy removal tool Dummy sleeves Mounting nipples Safety ringformounting nipples Mounting Gasket tool Cable mounting Cables &couplings ACCESSORIES PH04 SF01 Tap MT13(3/8×24UNF) drill Tap MT31(M10×1) drill thread MD16 (with Step drill M10×1) thread MD10 (with Step drill 3/8``×24UNF) Torque wrench TT18 socketTT07 (forAH26,27,28) Mounting socketTA13Mounting (forAM04,05) socketshort TT09(forAM04,05) Mounting Toolset TS02(TT09,TT18)(forAM04,05) MA05 (GU22C+PH04),MA06(GU22C) TD01 DG10 (GU22C),DG14(GU22C+PH04) AH26, AH27,AH28 AM06 AM04 (M10×1),AM05(3/8×24UNF) SG02 TC01 CI41, CI42,CI4V, CC41,CC42,E124 AM04 (AM05)andthermoprotection PH04. Direct installationwiththemountingnipple TIYF0760A.01 TIHK0094A.01 TIWG0156A.01 TIWG0156A.01 TIWG0418A.01 TIWG0257A.01 TIWG0209A.01 TIWG0133A.01 TIWG0136A.01 TIWG0140A.01 TIWG0128A.01 TIWG0122A.01 TIWG0417A.01 TIWG0240A.01 TIBQ0227A.01 TIWG0131A.01 Installation withadaptorAH28. See page99 See page96 See pages92to93 See pages94to97 See page96 See page88 See page88 See page98 See page95 See page86 See page91 See page87 See pages100to105 47

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GU21D TIGG0558A.01

The GU21D is an M7 solution for precise thermodynamic analysis especially when a smaller thread diameter than M8 is preferred. An integrated heat conducting element ensures excellent thermal coupling of the piezo elements to the cylinder head and therefore minimizes any negative thermal effects. The split mounting thread reduces negative influences like mechanical stresses from the mounting bore. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 250 bar Overload 300 bar Sensitivity 35 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 250 bar Natural frequency 85 kHz Acceleration sensitivity ≤ 0.002 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 8 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 2 % 0 … 250 bar Thermal sensitivity change 250 ± 100 °C and ≤ ± 0.5 % SCOPE OF SUPPLY 0 … 250 bar typ. Sensor GU21D Load change drift 1.5 mbar/ms max. gradient typ. Piezo-input cable CI41-1 Cyclic temperature drift 2) ≤ ± 0.4 bar Coupling CC41 Thermo shock error Δp 3) ≤ ± 0.3 bar typ. Gasket SG03 Thread diameter M7×0.75 shoulder sealed Accessory kit (protection cap + 2 o-rings) Cable Connection M4×0.35 negative Spare gasket SG03 Calibration sheet Weight 6 grams without cable Documentation Mounting torque 3 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 48 Mounting paste Mounting Machining toolforAH06 Machining tool tool Mounting Adaptor sleeves Dummy removal tool Dummy tool Gasket dismounting Gasket tool Cable mounting Cables &couplings ACCESSORIES Direct installation. SF01 Tap MT31 drill MD24 Step drill Toolset MS24(MD24,MT31) Tap MT21 drill MD22 Step drill Toolset MS22(MD22,MT21,MG22) Torque wrench TT02 socketTT11 Mounting Toolset TS03(TT11,TT02) AH06 TD01 DG04 TT17 SG03 TC01 CI41, CI42,CI4V, CC41,CC42,E124 Installation withadaptorsleeveAH06. TIHK0094A.01 TIWG0156A.01 TIWG0153A.01 TIWG0167A.01 TIWG0155A.01 TIWG0151A.01 TIWG0165A.01 TIWG0117A.01 TIWG0180A.01 TIWG0181A.01 TIWG0175A.01 TIWG0122A.01 TIWG0170A.01 TIWG0185A.01 TIBQ0228A.01 TIWG0131A.01 See page96 See pages92to93 See pages92to93 See pages94to97 See page87 See page96 See page91 See page96 See page98 See page95 See pages100to105 49

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GU24D TIGG1329A.01

The GU24D is a sensor which combines the convenient installation of M8 thread-type sensors with high accuracy that is required for precise thermodynamic analysis. The Double-Shell™ design decouples the piezoelectric elements from negative influences of mechanical stresses which can occur due to the mounting of the sensor into the engine. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 250 bar Overload 300 bar Sensitivity 45 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 250 bar Natural frequency 92 kHz Acceleration sensitivity ≤ 0.002 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 8 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 1 % 0 … 250 bar Thermal sensitivity change 250 ± 100 °C and ≤ ± 0.25 % SCOPE OF SUPPLY 0 … 250 bar typ. Sensor GU24D Load change drift 4 mbar/ms max. gradient typ. Piezo-input cable CI41-1 Cyclic temperature drift 2) ≤ ± 0.3 bar Coupling CC41 Thermo shock error Δp 3) ≤ ± 0.2 bar typ. Gasket SG21 Thread diameter M8×0.75 shoulder sealed Accessory kit (protection cap + 2 o-rings) Cable Connection M4×0.35 negative Spare gasket SG21 Calibration sheet Weight 14 grams without cable Documentation Mounting torque 6 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 50 Mounting paste Mounting tool Mounting Adaptor sleeves Dummy removal tool Dummy tool Gasket dismounting Gasket tool Cable mounting Cables &couplings ACCESSORIES Direct installation. SF01 Torque wrench TT32 socketTT11 Mounting AH35, MA04 TD01 DG09 TT33 SG21 TC01 CI41, CI42,CI4V, CC41,CC42,E124 *) Installation withanAH35adaptor. Rigid adhesive,e.g.LOCTITE648orHenkelomniFIT. TIHK0094A.01 TIWG0236A.01 TIWG0180A.01 TIWG0122A.01 TIWG0278A.01 TIWG0281A.01 TIYF0718A.01 TIWG0131A.01

See page96 See pages94to97 See page96 See page91 See page96 See page98 See page95 See page87 See pages100to105 51

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GU24DE TIGG1478A.01

The GU24DE is a sensor which combines the convenient installation of M8 thread-type sensors with the high accuracy that is required for precise thermodynamic analysis. The sensor has also a special extension tube which allows it to cross water and oil jackets of the engine without the need of an adaptor sleeve. The Double-Shell™ design decouples the piezoelectric elements from negative influences of mechanical stresses which can occur due to the mounting of the sensor into the engine. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 250 bar Overload 300 bar Sensitivity 45 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 250 bar Natural frequency 92 kHz Acceleration sensitivity ≤ 0.002 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 8 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 1.5 % 0 … 250 bar Thermal sensitivity change 250 ± 100 °C and ≤ ± 0.25 % SCOPE OF SUPPLY 0 … 250 bar typ. Sensor GU24DE Load change drift 4 mbar/ms max. gradient typ. Piezo-input cable CI41-1 Cyclic temperature drift 2) ≤ ± 0.3 bar Coupling CC41 Thermo shock error Δp 3) ≤ ± 0.2 bar typ. Gasket SG21 Thread diameter M8×0.75 shoulder sealed Accessory kit (protection cap + 2 o-rings) Cable Connection M4×0.35 negative Spare gasket SG21 Calibration sheet Weight 22.5 grams without cable Documentation Mounting torque 6 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 52 Mounting paste Mounting tool Mounting Dummy removal tool Dummy tool Gasket dismounting Gasket tool Cable mounting Cables &couplings ACCESSORIES SF01 Torque wrench TT32 socketTT11 Mounting TD01 DG25 TT33 SG21 TC01 CI41, CI42,CI4V, CC41,CC42,E124 Direct installation. TIHK0094A.01 TIWG0236A.01 TIWG0180A.01 TIWG0122A.01 TIWG0405A.01 TIWG0281A.01 TIYF0718A.01 TIWG0131A.01 See page96 See pages94to97 See page96 See page91 See page96 See page98 See page95 See pages100to105 53

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GU24DK TIGG1887.01

The GU24DK is a sensor which combines the convenient installation of M8 thread-type sensors with high accuracy and robustness that is required for typical research and development work. It has thermally optimized piezoelectric elements. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 300 bar Overload 350 bar Sensitivity 35 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 300 bar Natural frequency 100 kHz Acceleration sensitivity ≤ 0.0013 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 12 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 1.5 % 0 … 300 bar Thermal sensitivity change SCOPE OF SUPPLY 250 ± 100 °C and ≤ ± 0.25 % Sensor GU24DK 0 … 300 bar typ. Piezo-input cable CI31-1 Cyclic temperature drift 2) ≤ ± 0.7 bar Coupling CC31 Thermo shock error Δp 3) ≤ ± 0.3 bar typ. Gasket SG21 Thread diameter M8×0.75 shoulder sealed Accessory kit (protection cap + 2 o-rings) Cable Connection M3×0.35 negative Spare gasket SG21 Calibration sheet Weight 14 grams without cable Documentation Mounting torque 6 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 54 Mounting paste Mounting tool Mounting Adaptor sleeves Dummy removal tool Dummy tool Gasket dismounting Gasket tool Cable mounting Cables &couplings ACCESSORIES SF01 Torque wrench TT32 socketTT11 Mounting AH35, MA04 TD01 DG09 TT33 SG21 TC02 CI31, CI32,CI3V, CC31,E124 Direct installation. TIHK0094A.01 TIWG0236A.01 TIWG0180A.01 TIWG0122A.01 TIWG0278A.01 TIWG0281A.01 TIYF0718A.01 TIWG0613A.01 See page96 See pages94to97 See page96 See page91 See page96 See page98 See page95 See page87 See pages100to105 55

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GU31D TIGG2057A.01

GU31D is a durable M10 cylinder pressure sensor for large-bore engines. The sensor can be used with various fuels such as diesel, heavy fuel oil or natural gas. It is equipped with a central preload element that makes this sensor suitable for permanent non-stop operation. The Double-Shell™ design decouples the piezoelectric elements from negative influences of mechanical stresses which can occur due to the mounting of the sensor into the engine. The sensor could be equipped with SIC for SDM.

SPECIFICATIONS Measuring range 0 … 250 bar Overload 300 bar Sensitivity 20 pC/bar nominal Linearity ≤ ± 0.5 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 250 bar Natural frequency 90 kHz Acceleration sensitivity ≤ 0.001 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 7 pF Sensor operating temperature - 40 … 350 °C range 1) 20 … 350 °C and ≤ 0.5 % 0 … 250 bar Thermal sensitivity change 250 ± 100 °C and ≤ ± 0.2 % SCOPE OF SUPPLY 0 … 250 bar typ. Sensor GU31D Load change drift 1.5 mbar/ms max. gradient typ. Piezo-input cable CI41-1 Cyclic temperature drift 2) ≤ ± 0.8 bar Coupling CC41 Thermo shock error Δp 3) ≤ ± 0.4 bar typ. Gasket SG20 Thread diameter M10×1 shoulder sealed Accessory kit (protection cap + 2 o-rings) Cable Connection M4×0.35 negative Spare gasket SG20 Calibration sheet Weight 22 grams without cable Documentation Mounting torque 15 … 20 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 56 Mounting paste Mounting Machining tool tool Mounting Dummy removal tool Dummy tool Gasket dismounting Gasket tool Cable mounting Cables &couplings ACCESSORIES Shoulder sealeddirect installation. SF01 Torque wrench TT18 Tap MT31 drill socketTA16Mounting TD01 DG11 TT15 SG20 TC01 CI41, CI42,CI4V, CC41,CC42,E124 *) recommended Recessed shouldersealeddirect installation. TIHK0094A.01 TIWG0209A.01 TIWG0156A.01 TIWG0200A.01 TIWG0122A.01 TIWG0339A.01 TIWG0179A.01 TIBQ0231A.01 TIWG0131A.01

See page96 See pages92to93 See pages94to97 See page96 See page91 See page96 See page98 See page95 See pages100to105 57

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GU41D TIGG2292A.01

GU41D is a durable M14 cylinder pressure sensor for engine development. The sensor can be used with various fuels such as diesel, heavy fuel oil or natural gas. It is equipped with a central preload element that makes this sensor suitable for permanent non-stop operation. The Double-Shell™ design decouples the piezoelectric elements from negative influences of mechanical stresses which can occur due to the mounting of the sensor into the engine. The sensor could be equipped with SIC for SDM.

SPECIFICATIONS Measuring range 0 … 250 bar Overload 300 bar Sensitivity 20 pC/bar nominal Linearity ≤ ± 0.5 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 250 bar Natural frequency 90 kHz Acceleration sensitivity ≤ 0.001 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 7 pF Sensor operating temperature - 40 … 350 °C range 1) 20 … 350 °C and ≤ 0.5 % 0 … 250 bar Thermal sensitivity change 250 ± 100 °C and ≤ ± 0.2 % 0 … 250 bar typ. SCOPE OF SUPPLY Load change drift 1.5 mbar/ms max. gradient typ. Sensor GU41D Cyclic temperature drift 2) ≤ ± 0.8 bar Piezo-input cable CI41-1 Thermo shock error Δp 3) ≤ ± 0.4 bar typ. Coupling CC41 shoulder or front Gasket SG05 Thread diameter M14×1.25 sealed Accessory kit (protection cap + 2 o-rings) Cable Connection M4×0.35 negative Spare gasket SG05 Calibration sheet Weight 34 grams without cable Documentation Mounting torque 20 … 25 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 58 Mounting paste Mounting tool Mounting Dummy removal tool Dummy tool Gasket dismounting Gasket tool Cable mounting Cables &couplings ACCESSORIES *) recommended Shoulder sealeddirect installation.

SF01 Torque wrench TT18 socketTT07 Mounting TD01 DG12 TT14 SG05 TC01 CI41, CI42,CI4V, CC41,CC42,E124 Front sealeddirect installation. TIHK0094A.01 TIWG0209A.01 TIWG0133A.01 TIWG0122A.01 TIWG0340A.01 TIWG0178A.01 TIBQ0230A.01 TIWG0131A.01 See page96 See pages94to97 See page96 See page91 See page96 See page98 See page95 See pages100to105 59

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

ZI22

The ZI22 is a spark-plug with integrated pressure sensor. The new M10 design has a small eccentricity of the center electrode which allows the ignition to behave in nearly the same manner as the original spark plug. In order to maximize the electric strength of the insulator, an increased ceramic diameter and a complete new design of the sensor membrane is used. All this results in an impressive measurement performance and highest reliability. The insulator of the spark-plug is manufactured by Bosch. The sensor could be equipped with SIC for SDM.

SPECIFICATIONS Measuring range 0 … 200 bar Overload 250 bar Sensitivity 11 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 140 bar 0 … 200 bar Natural frequency ~ 150 kHz Acceleration sensitivity ≤ 0.0001 bar/g axial/radial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 3.5 pF Sensor operating temperature - 40 … 350 °C range 1) 200 ± 50 °C and Thermal sensitivity change ≤ ± 0.3 % 0 … 200 bar typ. Load change drift 2 mbar/ms max. gradient typ. Cyclic temperature drift 2) ≤ ± 0.5 bar Thermo shock error Δp 3) ≤ ± 0.4 bar typ. Temperature of plug-seat ≤ 230 °C permanent Spark-plug insulator resistivity ≥ 108 Ω at 20 °C, 1 kV Burn-off resistance 6 kΩ at 20 °C, 1 kV SCOPE OF SUPPLY Electric strength 45 kV Sensor ZI22 (ISO 11565, 3.7.2) Piezo-input cable CI33-1 Eccentricity of insulator 1.25 mm Coupling CC41 Thread diameter M10×1 Gasket SG32 Cable Connection M3×0.35 negative Accessory kit (protection cap + 2 o-rings) Weight 33 grams without cable Calibration sheet Mounting torque 10 … 15 Nm using SF01 Documentation (into spark plug bore)

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 60 * Spare insulator*: PURCHASE NUMBER ) Position-order-sequence asforspark plugsshownabove Spare parts paste Mounting Spark-plug insulatorgrease Special toolsforsparkplugs tool Mounting Gasket (forinsulator) Gaskets (forsparkplug) tool Cable mounting extensioncable voltage Ignition Cables &couplings ACCESSORIES M S N Connector type/insulator Thread length Z mm X …28 mm L …26.5 mm M …19 mm S …12.7 … … … … SAE /9mm specific NAPF /9mm M4 /9mm NAPF TI SP Sealing /wrench size Z F … … SAE specific Flat /HEX12 R Φ Z 4 E A … … … … IN A. M4 /10.5mm specific SAE /10.5mm NAPF /10.5mm M4 TI 22 Insulator dummy(forcalibration) Spare insulator Napf-connector SF01 ZFK01 tool TA32Gap adjustment Torque wrench forinsulatorexchangeTT50 socketTT48 (forinsulatorexchange) Mounting Torque wrench forsparkplugsensorTT18 socketTT34 (Ø=19.9mm) Mounting socketTT30 (Ø=17.0mm) Mounting SG30 SG32 (1.5mm)andcustomizedsolutions TT39 CE09 CI33, CI37,CC41,CC42,CC43,E124 Dummy –insulator*: Z…specific B D P …Pin-Pin (Pt) T …Top Electrode type/indexmounting … … Heat range(Bosch) 4 … 3 … 1 …07 A) Pin-Pin +Indexmounting Top +Indexmounting notstandard model A Top A. TI DY 9 7 … 6 … 5 … … specific A R see above see above TIYG2453A.01 TIHK0094A.01 TIHS0060A.01 TIWG0387A.01 TIWG0473A.01 TIWG0469A.01 TIWG0209A.01 TIWG0606A.01 TIWG0598A.01 TIYG2513A.01 TIYG2767A.01 TIWG0510A.01 TIBY0679A.01 Pin-Pin IN A. mm 3 … mm 2 … mm 1 … Spark protrusion See page96 See page96 See page97 See pages94to97 See page98 See page98 See page95 See pages100to105 Z mm G …1.0 mm F …0.9 mm E …0.8 mm D …0.7 mm C …0.6 mm B …0.5 mm A …0.4 Electrode-gap … 9 mm 6 … mm 5 … mm 4 … specific … specific 61

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

ZI33

The ZI33 is a spark-plug with integrated pressure sensor. The new M12 design has 0.0 mm eccentricity of the center electrode which allows the ignition to behave in the same manner as the original spark plug. In order to maximize the electric strength of the insulator, an increased ceramic diameter and a completely new design of the sensor membrane is used. All this results in impressive measurement performance and highest reliability. The insulator of the spark-plug is manufactured by Bosch. The sensor could be equipped with SIC for SDM.

SPECIFICATIONS Measuring range 0 … 200 bar Overload 250 bar Sensitivity 11 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 140 bar 0 … 200 bar Natural frequency ~ 150 kHz Acceleration sensitivity ≤ 0.0001 bar/g axial/radial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 3.5 pF Sensor operating temperature - 40 … 350 °C range 1) 200 ± 50 °C and Thermal sensitivity change ≤ ± 0.3 % 0 … 200 bar typ. Load change drift 2 mbar/ms max. gradient typ. Cyclic temperature drift 2) ≤ ± 0.5 bar Thermo shock error Δp 3) ≤ ± 0.4 bar typ. Temperature of plug-seat ≤ 230 °C permanent Spark-plug insulator resistivity ≥ 108 Ω at 20 °C, 1 kV Burn-off resistance 6 kΩ at 20 °C, 1 kV SCOPE OF SUPPLY Electric strength 45 kV Sensor ZI33 (ISO 11565, 3.7.2) Piezo-input cable CI33-1 Eccentricity of insulator 0.0 mm Coupling CC41 Thread diameter M12×1.25 Gasket SG08 Cable Connection M3×0.35 negative Accessory kit (protection cap + 2 o-rings) Weight 44 grams without cable Calibration sheet Mounting torque 15 … 25 Nm using SF01 Documentation (into spark plug bore)

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 62 * Spare insulator*: PURCHASE NUMBER ) Position-order-sequence asforspark plugsshownabove Spare parts paste Mounting Spark-plug insulatorgrease Special toolsforsparkplugs tool Mounting Gasket (forinsulator) Gaskets (forsparkplug) tool Cable mounting extensioncable voltage Ignition Cables &couplings ACCESSORIES M S N Connector type/insulator Thread length Z mm X …28 mm L …26.5 mm M …19 mm S …12.7 … … … … SAE /9mm specific NAPF /9mm M4 /9mm NAPF TI SP D… Conical G… Flat/HEX12 Sealing /wrench size C… Conical F… Flat/BI-HEX16 1) conical:thread lengthisreduced by1.5mm SAE R Φ Z 4 E A … … … … IN A. 1 1 M4 /10.5mm specific SAE /10.5mm NAPF /10.5mm /BI-HEX16 /HEX12 M4 TI 33 Insulator dummy(forcalibration) Spare insulator Napf-connector SF01 ZFK01 tool TA32Gap adjustment Torque wrench forinsulatorexchangeTT50 socketTT48 (forinsulatorexchange) Mounting T-handle TT44 Extension TT43 Torque wrench forsparkplugsensorTT18 socketTT22 (Ø=19.0mm) Mounting socketTT57 (Ø=19.9mm) Mounting socketTT24 (Ø=20.2mm) Mounting SG30 SG08 (1.5mm)andcustomizedsolutions TT39 CE09 CI33, CI37,CC41,CC42,CC43,E124 Dummy –insulator*: Z…specific B D P …Pin-Pin (Pt) T …Top Electrode type/indexmounting … … 4 … 3 … 1 …07 Heat range(Bosch) A) Pin-Pin +Indexmounting Top +Indexmounting notstandard model A Top A. TI DY 9 7 … 6 … 5 … … specific A R see above see above TIYG2453A.01 TIHK0094A.01 TIHS0060A.01 TIWG0387A.01 TIWG0473A.01 TIWG0469A.01 TIYG1027A.01 TIYG1026A.01 TIWG0209A.01 TIWG0233A.01 TIWG0585A.01 TIWG0234A.01 TIYG2513A.01 TIYF0640A.01 TIWG0510A.01 TIBY0679A.01 Pin-Pin IN A. mm 3 … mm 2 … mm 1 … Spark protrusion See page96 See page96 See page97 See pages94to97 See page98 See page98 See page95 See pages100to105 Z mm G …1.0 mm F …0.9 mm E …0.8 mm D …0.7 mm C …0.6 mm B …0.5 mm A …0.4 Electrode-gap … 9 mm 6 … mm 5 … mm 4 … specific … specific 63

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

ZI45

The ZI45 is a spark-plug with integrated pressure sensor. The new M14 design has 0.0 mm eccentricity of the center electrode which allows the ignition to behave in the same manner as the original spark plug. In order to maximize the electric strength of the insulator, an increased ceramic diameter and a completely new design of the sensor membrane is used. All this results in impressive measurement performance and highest reliability. The insulator of the spark-plug is manufactured by Bosch. The sensor could be equipped with SIC for SDM.

SPECIFICATIONS Measuring range 0 … 200 bar Overload 250 bar Sensitivity 11 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 140 bar 0 … 200 bar Natural frequency ~ 150 kHz Acceleration sensitivity ≤ 0.0001 bar/g axial/radial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 3.5 pF Sensor operating temperature - 40 … 350 °C range 1) 200 ± 50 °C and Thermal sensitivity change ≤ ± 0.3 % 0 … 200 bar typ. Load change drift 2 mbar/ms max. gradient typ. Cyclic temperature drift 2) ≤ ± 0.5 bar Thermo shock error Δp 3) ≤ ± 0.4 bar typ. Temperature of plug-seat ≤ 230 °C permanent Spark-plug insulator resistivity ≥ 108 Ω at 20 °C, 1 kV Burn-off resistance 6 kΩ at 20 °C, 1 kV SCOPE OF SUPPLY Electric strength 45 kV Sensor ZI45 (ISO 11565, 3.7.2) Piezo-input cable CI33-1 Eccentricity of insulator 0.0 mm Coupling CC41 Thread diameter M14×1.25 Gasket SG06 Cable Connection M3×0.35 negative Accessory kit (protection cap + 2 o-rings) Weight 53 grams without cable Calibration sheet Mounting torque 15 … 25 Nm using SF01 Documentation (into spark plug bore)

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 64 * Spare insulator*: PURCHASE NUMBER ) Position-order-sequence asforspark plugsshownabove Spare parts paste Mounting Spark-plug insulatorgrease Special toolsforsparkplugs tool Mounting Gasket (forinsulator) Gaskets (forsparkplug) tool Cable mounting extensioncable voltage Ignition Cables &couplings ACCESSORIES M S N Connector type/insulator Thread length Z mm X …28 mm L …26.5 mm M …19 mm S …12.7 … … … … SAE /9mm specific NAPF /9mm M4 /9mm NAPF TI SP Sealing /wrench size C… Conical BI-HEX17 / F …Flat 1) conical:thread lengthisreduced by1.5mm SAE R Φ Z 4 E A … … … … IN A. 1 M4 /10.5mm specific SAE /10.5mm NAPF /10.5mm /BI-HEX17 M4 TI 45 Insulator dummy(forcalibration) Spare insulator Napf-connector SF01 ZFK01 tool TA32Gap adjustment Torque wrench forinsulatorexchangeTT50 socketTT48 (forinsulatorexchange) Mounting T-handle TT44 Extension TT43 Torque wrench forsparkplugsensorTT18 socketTT42 Mounting SG30 SG06 (1.5mm)andcustomizedsolutions TT39 CE09 CI33, CI37,CC41,CC42,CC43,E124 Dummy –insulator*: Z…specific B D P …Pin-Pin (Pt) T …Top Electrode type/indexmounting … … 4 … 3 … 5 … Heat range(Bosch) A) Pin-Pin +Indexmounting Top +Indexmounting notstandard model A Top A. TI DY 9 7 … 6 … … specific A R see above see above TIYG2453A.01 TIHK0094A.01 TIHS0060A.01 TIWG0387A.01 TIWG0473A.01 TIWG0469A.01 TIYG1027A.01 TIYG1026A.01 TIWG0209A.01 TIYG1024A.01 TIYG2513A.01 TIYF0629A.01 TIWG0510A.01 TIBY0679A.01 Pin-Pin IN A. mm 3 … mm 2 … mm 1 … Spark protrusion See page96 See page96 See page97 See pages94to97 See page98 See page98 See page95 See pages100to105 Z mm G …1.0 mm F …0.9 mm E …0.8 mm D …0.7 mm C …0.6 mm B …0.5 mm A …0.4 Electrode-gap … 9 mm 6 … mm 5 … mm 4 … specific … specific 65

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GC24D TIGG1785A.01

The GC24D is a watercooled GaPO4 sensor with a convenient installation by M8 threads and allows very precise thermodynamic measurements. It has thermally optimized piezoelectric elements. An active water cooling system is required to ensure long lifetimes and excellent thermodynamic behavior. In case of a failure in the cooling system the GC24D is designed so that the sensor can survive temperatures up to 400 °C. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 250 bar Overload 300 bar Sensitivity 45 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 250 bar Natural frequency 90 kHz ≤ 0.01 bar/g axial, water Acceleration sensitivity cooled ≤ 0.001 bar/g axial, uncooled Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 12 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and ≤ 1.5 % 0 … 250 bar Thermal sensitivity change 50 ± 30 °C and ≤ ± 0.25 % SCOPE OF SUPPLY 0 … 250 bar typ. Sensor GC24D Load change drift 3.0 mbar/ms max. gradient typ. Piezo-input cable CI31-1 Cyclic temperature drift 2) ≤ ± 0.3 bar Coupling CC31 Thermo shock error Δp 3) ≤ ± 0.2 bar typ. Gasket SG21 Thread diameter M8×0.75 shoulder sealed Accessory kit (protection cap + 2 o-rings) Cable Connection M3×0.35 negative Spare gasket SG21 Calibration sheet Weight 14 grams without cable Documentation Mounting torque 6 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 66 Cooling system Cooling paste Mounting tool Mounting Dummy removal tool Dummy tool Gasket dismounting Gasket tool Cable mounting Cables &couplings ACCESSORIES ZP91.00 (230Vversion) ZP91.00 (115Vversion) SF01 Torque wrench TT32 socketTT11 (fordummy) Mounting socketTT23 (forsensor) Mounting TD01 DG09 TT54 SG21 TC02 CI31, CI32,CI3V, CC31,E124 Direct installation. TIZP91A.04 TIZP91A.14 TIHK0094A.01 TIWG0236A.01 TIWG0180A.01 TIWG0548A.01 TIWG0122A.01 TIWG0278A.01 TIWG0560A.01 TIYF0718A.01 TIWG0613A.01 See pages106to107 See page96 See pages94to97 See page96 See page91 See page96 See page98 See page95 See pages100to105 67

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

GC24DK TIGG1792A.01

The GC24DK is a watercooled GaPO4 sensor with a convenient installation by M8 threads and suitable for accurate and robust measurements in supercharged engines with very high specific output. It has thermally optimized piezoelectric elements. An active water cooling system is required to ensure long lifetimes and excellent thermodynamic behavior. In case of a failure in the cooling system the GC24DK is designed so that the sensor can survive temperatures up to 400 °C. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 300 bar Overload 350 bar Sensitivity 35 pC/bar nominal Linearity ≤ ± 0.3 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 300 bar Natural frequency 100 kHz ≤ 0.13 bar/g axial, water Acceleration sensitivity cooled ≤ 0.0013 bar/g axial, uncooled Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 12 pF Sensor operating temperature - 40 … 400 °C range 1) 20 … 400 °C and 2 % ≤ 0 … 300 bar Thermal sensitivity change SCOPE OF SUPPLY 50 ± 30 °C and ≤ ± 0.25 % Sensor GC24DK 0 … 300 bar typ. Piezo-input cable CI31-1 Cyclic temperature drift 2) ≤ ± 0.7 bar Coupling CC31 Thermo shock error Δp 3) ≤ ± 0.4 bar typ. Gasket SG21 Thread diameter M8×0.75 shoulder sealed Accessory kit (protection cap + 2 o-rings) Cable Connection M3×0.35 negative Spare gasket SG21 Calibration sheet Weight 14 grams without cable Documentation Mounting torque 6 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 68 Cooling system Cooling paste Mounting tool Mounting Dummy removal tool Dummy tool Gasket dismounting Gasket tool Cable mounting Cables &couplings ACCESSORIES ZP91.00 (230Vversion) ZP91.00 (115Vversion) SF01 Torque wrench TT32 socketTT11 (fordummy) Mounting socketTT23 (forsensor) Mounting TD01 DG09 TT54 SG21 TC02 CI31, CI32,CI3V, CC31,E124 Direct installation. TIZP91A.04 TIZP91A.14 TIHK0094A.01 TIWG0236A.01 TIWG0180A.01 TIWG0548A.01 TIWG0122A.01 TIWG0278A.01 TIWG0560A.01 TIYF0718A.01 TIWG0613A.01 See pages106to107 See pages96 See pages94to97 See page96 See page91 See page96 See page98 See page95 See pages100to105 69

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

QC34C TIGG1364A.01

The QC34C is a cooled quartz sensor with a mounting diameter of 9.9 mm designed especially for midrange engines. An active water cooling system is required to ensure long lifetimes and excellent thermodynamic behavior. In case of a failure in the cooling system the QC34C is designed so that the sensor can survive temperatures up to 350 °C. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 250 bar Overload 300 bar Sensitivity 19 pC/bar nominal Linearity ≤ ± 0.2 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 250 bar Natural frequency 69 kHz ≤ 0.013 bar/g axial, water Acceleration sensitivity cooled ≤ 0.003 bar/g axial, uncooled Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 10 pF Sensor operating temperature - 40 … 350 °C range 1) Thermal sensitivity change 20…80 °C and ≤ 0.003 %/ °C (cooled) 0 … 250 bar Load change drift 5.5 mbar/ms max. gradient typ. SCOPE OF SUPPLY Cyclic temperature drift 2) ≤ ± 0.3 bar Sensor GC24D Thermo shock error Δp 3) ≤ ± 0.2 bar typ. Piezo-input cable CI31-1 Mounting bore 10 mm shoulder sealed Coupling CC31 Cable Connection M4×0.35 negative Gasket SG20 Accessory kit (protection cap + 2 o-rings) Cooling rate ≥ 20 l/h Spare gasket SG20 Weight 15 grams without cable Calibration sheet using AH05 and Mounting torque 15 Nm Documentation SF01

1) surface temperature around the cable connection < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 70 Cooling system Cooling paste Mounting tool Mounting Adaptor sleeves Dummy removal tool Dummy tool Gasket dismounting Gasket tool Cable mounting Cables &couplings ACCESSORIES ZP91.00 (230Vversion) ZP91.00 (115Vversion) SF01 Torque wrench TT18 socketTT08 (forAH05) Mounting AS02, AH05,AH08 TD01 DG05 TT15 SG20 TC01 CI41, CI42,CI4V, CC41,CC42,E124 *) Installation withanAS02adaptorset. Rigid adhesive,e.g.LOCTITE648orHenkelomniFIT. TIZP91A.04 TIZP91A.14 TIHK0094A.01 TIWG0209A.01 TIWG0132A.01 TIWG0122A.01 TIWG0187A.01 TIWG0179A.01 TIBQ0231A.01 TIWG0131A.01

See pages106to107 See pages96 See pages94to97 See page96 See page91 See page96 See page98 See page95 See page87 71

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

QC34D TIGG1367A.01

The QC34D is a cooled quartz sensor with a mounting thread of M10 designed especially for midrange engines. An active water cooling system is required to ensure long lifetimes and excellent thermo dynamic behavior. In case of a failure in the cooling system the QC34D is designed so that the sensor can survive temperatures up to 350 °C. The sensor is equipped with built in SID for SDM.

SPECIFICATIONS Measuring range 0 … 250 bar Overload 300 bar Sensitivity 19 pC/bar nominal Linearity ≤ ± 0.2 % FSO 0 … 80 bar Calibrated ranges 0 … 150 bar 0 … 250 bar Natural frequency 69 kHz ≤ 0.013 bar/g axial, water Acceleration sensitivity cooled ≤ 0.003 bar/g axial, uncooled Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 10 pF Sensor operating temperature - 40 … 350 °C range 1) Thermal sensitivity change 20…80 °C and ≤ 0.003 %/ °C (cooled) 0 … 250 bar SCOPE OF SUPPLY Load change drift 4.5 mbar/ms max. gradient typ. Sensor QC34D Cyclic temperature drift 2) ≤ ± 0.3 bar Piezo-input cable CI41-1 Thermo shock error Δp 3) ≤ ± 0.2 bar typ. Coupling CC41 Thread diameter M10×1 shoulder sealed Gasket SG20 Cable Connection M4×0.35 negative Accessory kit (protection cap + 2 o-rings) Cooling rate ≥ 20 l/h Spare gasket SG20 Calibration sheet Weight 15 grams without cable Documentation Mounting torque 10 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 72 Direct installation. Cooling system Cooling paste Mounting Machining tool tool Mounting Adaptor sleeves Dummy removal tool Dummy tool Gasket dismounting Gasket tool Cable mounting Cables &couplings ACCESSORIES ZP91.00 (230Vversion) ZP91.00 (115Vversion) SF01 Tap MT31 drill Torque wrench TT18 toolZ314(ø=13.8 mm) Mounting socketTT07 (ø=15.8mm) Mounting AH14, AH18 TD01 DG06 TT15 SG20 TC01 CI41, CI42,CI4V, CC41,CC42,E124 *) Installation withtheadaptorAH14andPin-Tool Z314. Rigid adhesive,e.g.LOCTITE648.

TIZP91A.04 TIZP91A.14 TIHK0094A.01 TIWG0156A.01 TIWG0209A.01 TIWG0103A.01 TIWG0133A.01 TIWG0122A.01 TIWG0188A.01 TIWG0179A.01 TIBQ0231A.01 TIWG0131A.01 *) Installation withadaptorAH18andboxspannerTT07. Rigid adhesive,e.g.LOCTITE648. See pages106to107 See page96 See pages92to93 See pages94to97 See page96 See page91 See page96 See page98 See page95 See page87 See pages100to105 73

Pressure Sensors 2.2 CYLINDER PRESSURE SENSORS FOR ENGINE DEVELOPMENT

QC43D TIGG0538A.01

The QC43D has a mounting thread of M14 and is especially suited for large diesel engines. It is designed for cylinder bores above 100 mm and if quartz sensors are preferred. An active water cooling system is required to protect the quartz in order to ensure long lifetimes and excellent data reproducibility.

SPECIFICATIONS Measuring range 0 … 200 bar Overload 250 bar Sensitivity 68 pC/bar nominal Linearity ≤ ± 0.2 % FSO 0 … 80 bar Calibrated ranges 0 … 140 bar 0 … 200 bar Natural frequency 50 kHz ≤ 0.002 bar/g axial, water Acceleration sensitivity cooled ≤ 0.003 bar/g axial, uncooled Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 18 pF Sensor operating temperature 20 … 80 °C range 1) Thermal sensitivity change 20 … 80 °C and ≤ 0.02 %/ °C (cooled) 0 … 200 bar SCOPE OF SUPPLY Load change drift 4 mbar/ms max. gradient typ. Sensor QC43D Cyclic temperature drift 2) ≤ ± 0.35 bar Piezo-input cable CI04-1 Thermo shock error Δp 3) ≤ ± 0.2 bar typ. Coupling E127M Thread diameter M14×1.25 shoulder sealed Gasket SG05 Cable Connection 10-32 UNF Micro-Dot Accessory kit (protection cap + 2 o-rings) Cooling rate ≥ 20 l/h Spare gasket SG05 Calibration sheet Weight 34 grams without cable Documentation Mounting torque 20 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 74 Cooling system Cooling paste Mounting tool Mounting Adaptor sleeves Dummy removal tool Dummy tool Gasket dismounting Gasket tool Cable mounting Cables &couplings ACCESSORIES Direct installation. ZP91.00 (230Vversion) ZP91.00 (115Vversion) SF01 Torque wrench TT18 socketTT08 Mounting AH15 TD01 DG07 TT14 SG05 TC01 CI04, E127M,E124 *) Installation withanAH15adaptor. Rigid adhesive,e.g.LOCTITE648orHenkelonmiFIT. TIZP91A.04 TIZP91A.14 TIHK0094A.01 TIWG0209A.01 TIWG0132A.01 TIWG0194A.01 TIWG0122A.01 TIWG0189A.01 TIWG0178A.01 TIBQ0230A.01 TIWG0131A.01

See pages106to107 See pages96 See pages94to97 See pages87 See page96 See page91 See page96 See page98 See page95 See pages100to105 75

Pressure Sensors 2.3 LOW PRESSURE SENSORS FOR ENGINE DEVELOPMENT

LP12DA

The M5 low pressure indicating sensor LP12DA measures the absolute pressure in the intake or exhaust manifold of combustion engines. The sensor is available in different versions with the pressure ranges of 5, 10 and 30 bar. This piezoresistive sensor is used for precise measurement of static and dynamic pressure variations. Typical applications are gas-exchange analysis, precise friction analysis or turbo charger development. For measurements in the exhaust manifold a cooling adapter is necessary. The sensor is equipped with an integrated amplifier featuring thermal compensation.

Type Art. No. Pressure range LP12DA05 TIEZ1719A.01 0 … 5 bar LP12DA10 TIEZ1720A.01 0 … 10 bar LP12DA30 TIEZ1721A.01 0 … 30 bar

SPECIFICATIONS Measuring range 0 … 5, 10, 30 bar Overload 50, 50, 90 bar Sensitivity • LP12DA05 ≤ 2,000 mV/bar • LP12DA10 ≤ 1,000 mV/bar • LP12DA30 ≤ 333 mV/bar Linearity ≤ ± 0.1 % FSO Frequency response > 50 kHz Total error band (accuracy < 1 % FSO and temperature error) Operating temperature range - 50 … 200 °C Compensated temperature - 40 … 180 °C range SCOPE OF SUPPLY Thread diameter M5×0.5 Sensor LP12DA with cable and integrated Weight 4 grams Sensor only amplifier Mounting torque 2 Nm using SF01 Gasket SG44 Amplifier output 0 … 10 V Empty 7-pin connector Power supply 12 … 32 V DC Protection cap oil, fuel (diesel, Calibration sheet Media compatibility gasoline, hfo,...), Documentation gases, coolant

76 Pin assignment. Direct installationofLP12DA. 2 Cooling system Cooling paste Mounting tool Mounting Welding bung Adaptor sleeves Dummy Gasket Power supplyandcables Measurement cableextension ACCESSORIES 3 1 7 6 5 4 3 2 1 PIN + - + Function RS485B RS485A OUT OUT n.c GND Vcc 7 6 4 5 2 connected Internally 3 1 7 6 5 4 3 2 1 PIN + + - Function Vcc RS485B RS485A OUT OUT n.c GND 7 6 4 LP12DA mountedintocoolingadaptorAE04. ZP91.00 (230Vversion) ZP91.00 (115Vversion) SF01 boxnut) TT64 (slotted TT29 (flatwrench) WS01 (forAI01andAE04) AI01, AE04 DL01 SG44 PS10 (powersupply24V) supply) PY10 (y-cableformultiple toy-cable) CY10 (connection toAVLCX10 (connection X-ion) CS11 (10m) CS10 (5m) 5 connected Internally TIZP91A.04 TIZP91A.14 TIHK0094A.01 TIWG0631A.01 TIWG0371A.01 TIYF0821A.01 TIDL01A.01 TIYG3136A.01 TILPPS10A.01 TILPYS10A.01 TILPYS10A.01 TIBU0244A.01 TILPCS11A.01 TILPCS10A.01 LP12DA withSG44andWS01. See pages106to107 See pages96 See pages94to97 See page89 See page91 See page98 See pages104to105 See page104 See pages87 77

Pressure Sensors 2.3 LOW PRESSURE SENSORS FOR ENGINE DEVELOPMENT

LP22DA TIEZ1821A.01

The M5 low pressure indicating sensor LP22DA measures the absolute pressure in the intake or exhaust manifold of combustion engines. The sensor is available in different versions with the pressure ranges of 2, 5, 10 and 30 bar. This piezoresistive sensor is used for precise measurement of static and dynamic pressure variations. Typical appli cations are gas-exchange analysis, precise friction analysis or turbo charger development. For measurements in the exhaust manifold a cooling adapter is necessary. The sensor is equipped with an integrated amplifier featuring thermal compensation.

SPECIFICATIONS Measuring range 0 … 10 bar Overload 50 bar Sensitivity ≤ 1,000 mV/bar Total error band (accuracy < 1% FSO and temperature error) Linearity ≤ ± 0.1 % FSO Frequency response > 50 kHz Operating temperature range • Sensor front end -40 … 1100 °C • Amplifier -40 … 125 °C SCOPE OF SUPPLY Thread diameter M8×0.75 Sensor LP22DA with cable and integrated Weight 12 grams Sensor only amplifier Mounting torque max. 6 Nm using SF01 Gasket SG45 Amplifier output 0 … 10 V Empty 7-pin connector Power supply 12 … 32 V DC Protection cap oil, fuel (diesel, Calibration sheet Media compatibility gasoline, hfo, ...), Documentation gases, coolant

78 Pin assignment 2 Cooling system Cooling paste Mounting adaptor Mounting Welding bung Dummy Gasket Power supplyandcables Measurement cableextension ACCESSORIES 3 1 7 6 5 4 3 2 1 PIN + + - Function Vcc RS485B RS485A OUT OUT n.c GND 7 6 4 5 connected Internally Direct installationofLP22DA ZP91.00 (230Vversion) ZP91.00 (115Vversion) SF01 MA10 WS02 DG09 SG45 PS10 (powersupply24V) supply) PY10 (y-cableformultiple toy-cable) CY10 (connection toAVLCX10 (connection X-ion) CS11 (10m) CS10 (5m) TIZP91A.04 TIZP91A.14 TIHK0094A.01 TIWG0677A.01 TIYS0914A.01 TIWG0278A.01 TIYS0892A.01 TILPPS10A.01 TILPPY10A.01 TLPYS10A.01 TIBU0244A.01 TILPCS11A.01 TILPCS10A.01 Installation usingweldingbungWS02 See pages106to107 See page96 See page89 See page89 See page91 See page98 See pages104to105 See page104 79

Pressure Sensors 2.4 CYLINDER PRESSURE SENSORS FOR ENGINE MONITORING

GO15DK Gen2 TIGG2121A.01

The GO15DK Gen2 has the slimmest contour due to an M3 cable connector and is an M5 monitoring sensor especially suited for pmax monitoring with maximum amount of knock. The Double-Shell™ design decouples the piezoelectric elements from negative influences of mechanical stresses which can occur due to the mounting of the sensor into the engine. In addition to this it has an improved membrane material and geometry. This makes the sensor to the standard solution for monitoring with maximum levels of knock. The sensor could be equipped with SIC for SDM.

SPECIFICATIONS Measuring range 0 … 1,000 bar Overload 1,000 bar Sensitivity 1.5 pC/bar nominal Linearity ≤ ± 0.5 % 200 °C 0 … 150 bar FSO 0 … 150 bar Calibrated ranges 0 … 300 bar Natural frequency > 400 kHz Acceleration sensitivity ≤ 0.0005 bar/g axial Shock resistance ≥ 2,000 g Insulation resistance ≥ 1*1013 Ω Capacitance 7 pF Sensor operating temperature - 40 … 350 °C range 1) 20 … 250 °C and Thermal sensitivity change ≤ 4 % 0 … 300 bar SCOPE OF SUPPLY Load change drift 4 mbar/ms max. gradient typ. Sensor GO15DK Gen2 Cyclic temperature drift 2) ≤ ± 1.5 bar Piezo-input cable CI35-1 Thermo shock error Δp 3) ≤ ± 0.8 bar typ. Coupling CC31 Thread diameter M5×0.5 front sealed Accessory kit (protection cap + 2 o-rings) Cable Connection M3×0.35 negative Calibration sheet Weight 1.6 grams without cable Documentation Mounting torque 1.5 Nm using SF01

1) surface temperature around the HEX < 200 °C 2) at 7 bar IMEP and 1,300 rpm, diesel 3) at 9 bar IMEP and 1,500 rpm, gasoline 80 Racing Amplifier paste Mounting Machining tool tool Mounting Adaptor sleeves Dummy removal tool tool Cable mounting Cables &couplings ACCESSORIES MiniAmp R4–1.5 MiniAmp R3–1.5 SF01 Seat dressing toolMR01-160 Seat dressing toolMR01-85 Tap MT12 drill MD12 Step drill Toolset MS15(MD12,MT12) Torque wrench TT02 socketTT21 Mounting Toolset TS21(TT21,TT02) AH01, AH01A,AH91,MA01,MA02,MA03,MA07 TD13 TC02 CI35, CC31,E124 *) Front sealeddirect installation. 1.5 mmforsteel,4castiron andaluminiumalloys. TIGG2086A.01 TIGG2200A.01 TIHK0094A.01 TIWG0616A.01 TIWG0346A.01 TIWG0346A.01 TIWG0335A.01 TIWG0337A.01 TIWG0117A.01 TIWG0214A.01 TIWG0213A.01 TIWG0224A.01 TIWG0613A.01

See pages84to85 See pages96 See pages92to93 See pages94to97 See page96 See page95 See pages87 See pages100to105 81

Pressure Sensors

3 Accessories for Pressure Sensors

3.1 Racing amplifier ...... 84

3.2 Adaptors and dummy plugs ...... 86

3.3 Machining tools ...... 92

3.4 Mounting tools ...... 94

3.5 Gaskets and flame arrestors ...... 98

3.6 Cables and couplings ...... 100

3.7 Cooling system ...... 106 3.1 RACING AMPLIFIER

Racing amplifier

AMPLIFIER – FOR ON-BOARD COMBUSTION ANALYSIS

The AVL MiniAmp is a miniaturized charge amplifier for combustion monitoring and control tasks in racing applications.Benefiting from the well known experience with amplifiers for research and development tasks, the MiniAmp R4 has a tailored design, especially compact dimension and low weight in racing environments.

AVL MiniAmp without: with AVL MiniAmp:

GAIN MAXIMUM POWER by going 220 02 220

810

02 to the limit – without going into 610 410

810

210

extreme knocking! 01 610

410 PCYL1 [bar]

• Miniature design 210 0 0 120

20 0 45 90 01 • Precise onboard measurement CAD MiniAmp R4_freigestellt.pdf 1 18.12.18 10:33 220 02

810

• Continuous drift compensation 610

410

60 • Galvanic isolated signal and 210

power lines PCYL1 [bar] 60

20 40 PCYL1 [bar]

0 0 0 0 0 45 90 – 40 – 20 0 20 40 60 80 Crank Angle [deg] Crank Angle [deg]

84 typically Output signal temperature) and room (@ 0RPM Zero level range complete Output signal Time constant Time sation Drift compen- range Frequency per channel Input range Charge Amplifier tion Parametriza- protection Degree of resistance Shock range Temperature @ 12VDC Input Current Power supply Documentation –MiniAmpR3orR4 Amplifier SCOPE OFSUPPLY Weight W ×HD Dimension Input channels General TECHNICAL DATA the sensors the Piezo cableto tion) parametriza- power supply, ECU (signals, Connectors ~ < < ~ Δ1 bar 0.5 V 0 1 sec(10pC/bar) 1,6 sec(1,5pC/bar) Continuous compensation Continuous 50 kHz 6,000 pC(10pC/bartype) 900 pC(1.5pC/bartype) PCinterface Via IP67 (according toIEC60068-2-27) 500 g/1 ms 80… – °C – 20…115 50mA) (typically temperature range complete 150 mAoverthe 8 80 g (without plugs) (without mm 40 ×2050 3 or4 10/32 UNF ASDD006-09-PN-HE DEUTSCH 20 … … 4.97 V 60 VDC … 115 °Creduced accuracy 80 °Cbestaccuracy ≙ Δ 6.5 mV

MiniAmp R4 TIGG2087A .01MiniAmpR4–10 TIGG2086A .01MiniAmpR4–15 MiniAmp R3 TIGG2201A .01MiniAmpR3–10 TIGG2200A .01MiniAmpR3–15 Dimensions ofaMiniAmpR4 Dimensions ofMiniAmpR3 4 3 5 2 6 9 8 7 6 5 4 3 2 1 Pin PIN ASSIGNMENT 9 8 7 6 5 4 3 2 1 Pin PIN ASSIGNMENT 1 7 Signal GND SDA Configuration SCL Configuration Signal 1 Signal 2 Signal 3 – Power GND– Power supplypos.+ Function Signal GND SDA Configuration SCL Configuration Signal 1 Signal 2 Signal 3 Signal 4 Power GND– Power supplypos.+ Function 9 8 85

Accessories for Pressure Sensors 3.2 ADAPTORS AND DUMMY PLUGS

Adaptors and dummy plugs

MOUNTING ADAPTOR

Mounting adaptors are used to install a smaller sensor into a larger mounting bore. The mounting adapter should be chosen with the inner dimensions of the new sensor and the outer dimensions of the bore.

Type Art. No. Recommended Sensor type Mounting bore mounting torque type M5×0 .5: M8×0 .75: GH15D, GH15DK, MA01 TIWG0364A .01 6 Nm GU24D, GU24DK, GR15D, GP15DK, GC24D, GC24DK GO15DK Gen2 M5×0 .5: GH15D, GH15DK, M10×1: MA02 TIWG0427A .01 10 Nm GR15D, GP15DK, QC34D, GU31D GO15DK Gen2 M5×0 .5: GH15D, GH15DK, M14×1 .25: MA03 TIWG0399A .01 20 Nm GR15D, GP15DK, GU41D, QC43D GO15DK Gen2 M8×0 .75: M14×1 .25: MA04 TIWG0356A .01 20 Nm GU24D, GU24DK GU41D, QC43D Ø 6,3 mm: M14×1 .25: MA05 TIWG0413A .01 20 Nm GU22C + PH04, GU41D, QC43D GU22CK + PH04 Ø 6,3 mm: M14×1 .25: MA06 TIWG0428A .01 20 Nm GU22C, GU22CK GU41D, QC43D M5×0 .5: GH15D, GH15DK, Ø 10 mm: MA07 TIWG0535A .01 15 Nm GR15D, GP15DK, QC34C GO15DK Gen2

Principle section of a standard mounting adapter

86 Dimensions ofastandard adaptorsleeve to mounttheadaptorsleeveintocylinderhead. Standard socketmounting toolissufficientandnospecial required AH91 AH45 AH35 AH28 AH27 AH26 AH18 AH15 AH14 AH13 AH08 AH06 AH05 AH01A AH01 Type Art. No TIWG0691A .01 TIWG0397A .01 TIWG0333A .01 TIWG0255A .01 TIYG1521A .01 TIYG1520A .01 TIWG0197A .01 TIWG0194A .01 TIWG0193A .01 TIWG0218A .01 TIWG0183A .01 TIWG0175A .01 TIWG0174A .01 TIWG0252A .01 TIWG0115A .01 torque Rec. mounting 3 5 15 10 10 10 20 20 20 5 20 10 10 8 3 D1 M7×0 .75 M6×0 .5 M12×1 .25 M14×1 .25 3/8”×24 UNF M10×1 M14×1 .25 M18×1 M14×1 .25 M5×0 .5 M14×1 .25 M10×1 – M7×0 .75 M7×0 .75 for further information. information. for further tools are adaptors,refer ofthese availableforinstallation topages92 interference developedmachiningandmounting head.Specially cylinder tothe aspossibleinordersmall the measurement tofulfill aminimumof taskwith shouldbechosenas channel.Theadaptor(typeanddimensions) indicating possible andwherever hastobecrossed jacketoroilgallery acooling bythe Adaptor sleevesare usedwhere adirect sensorisnot ofthe installation ADAPTOR SLEEVES D2 9 .5 7 .5 14 16 11 11 19 23 16 6 16 12 – 9 .5 9 .5 D3 10 10 14 19 – – 22 26 19 7 19 15 – 12 12 D4 HEX10 HEX10 HEX17 HEX19 HEX12 HEX12 HEX22 HEX27 HEX19 HEX10 HEX19 HEX14 HEX14 HEX12 HEX12 L1 12 12 22 18 1 to133 1 to133 18 25 18 10 18 17 .5 – 12 12 L2 15 to205 max. 205 max. 186 132 – – 15 to223 15 to240 to 140 max. 15 max. 98 140 15 to200 – 15 to205 15 to205 Installation withthemountingsleeveAH26 (AH27). L3 5 5 8 8 – – 8 8 8 4 11 5 – 5 5 For sensors GP15DK, GO15DKGen2 GH15D, GH15DK,GR15D, GH14P GU24D, GU24DK GU22C, GU22CK GU22C, GU22CK GU22C, GU22CK QC34D QC43D QC34D GH14P QC34C GU21D QC34C GO15DK Gen2 GH15DK, GR15D,GP15DK, GH14D, GH14DK,GH15D, GO15DK Gen2 GH15DK, GR15D,GP15DK, GH14D, GH14DK,GH15D, – 97

Accessories for Pressure Sensors 3.2 ADAPTORS AND DUMMY PLUGS

Adaptors and dummy plugs

ADAPTOR SET

An adaptor set is available if more than one adapter is typically needed for the mounting of a sensor.

Type Art. No. For sensor Consists of

AS02 TIWG0184A .01 QC34C AH05 + AH08

MOUNTING NIPPLES

Plug type sensors require specific mounting screws or so called mounting nipples. To fix an AM04 or AM05 with the sensor the AM06 safety ring (Art. No. TIWG0417A.01) is required.

Type Art. No. For sensor Mounting tool Mounting thread

GU22C AM04 TIWG0240A .01 TT09 M10×1 GU22CK GU22C AM05 TIWG0253A .01 TT09 3/8“×24 UNF GU22CK

88 sensor. refer alsotopage76formore aboutthis information piezoresistiveing adapterforthe sensorLP12DA.Please AI01isamount- adaptorandthe The AE04isacooling ADAPTORS FORLOW-PRESSUREINDICATING AI01 type Adaptor AE04 WS01 WS02 MA10 Art. No. TILPIA01A.01 TILPEA01A.01 TIYF0821A .01 TIYS0914A .01 TIWG0677A .01 Description the intakemanifold the adaptorfor Mounting the exhaustmanifold the adaptorfor Cooling AI01 orAE04 Used formounting M8×0.75 sensors Welding bungfor M14×1.25 bore M8×0.75 sensorinto Used formounting sensor For pressure LP12DA LP12DA LP12DA LP22DA LP22DA Mounting thread M14 M14 M14 M8 M14 89

Accessories for Pressure Sensors 3.2 ADAPTORS AND DUMMY PLUGS

Adaptors and dummy plugs

GLOW-PLUG ADAPTORS

AVL glow-plug adaptors allow the use of probe-type sensors in standard and custom tailored glow-plug bores. AG03 and AG04 can be customized down to 5 mm tip diameters. The selection of the adaptor type depends on the thread diameter of the glow-plug bore of the engine: For threads down to M10 AG03 adaptor is recommended. For threads of sizes between M10 and M8 AG04 is the right choice. For smaller diameters down to 4.3 mm please

refer to the integrated glow-plug solution GH13G on pages 58 – 59 .

Adaptor type Art. No. Thread diameter D4 1) Tip bore For sensor Mounting torque 2) diameter DB [Nm]

AG03 TIAG03A .01 ≥ M10 ≥ 5 mm GH14P 4 .0

AG04 TIAG04A .01 ≥ M8 ≥ 5 mm GH14P 4 .0

1) Drawing available on page 131 2) Higher mounting torque could be calculated depending on type

A new design of a glow plug adaptor must be ordered separately with the article TIAGDESA.01.

Glow-plug adaptor order form To customize the adaptor to your specific application a detailed description of the glow-plug bore is required. To ensure the best performance and durability of the delivered sensor especially the bore dimensions and length are important for optimum design. AVL requires a full description of the custom tailored adaptor. The glow-plug order form allows a clear specification of all required dimensions. Based on this data AVL can design the adaptor to the customer needs. The data is stored in the AVL database for further orders. The input as well as forwarding the form can be carried out electronically. Please see page 130 for drawings with the required dimensions. The order form is also available as download at www.avl.com/sensors .

90 1) For shouldersealedinstallationwithminimumthread lengthof14mmandminimumdistancebetweencombustionchambersealing17 DL01 DG41 DG39 DG25 DG24 DG14 DG13 DG12 DG11 DG10 DG09 DG07 DG06 DG05 DG04 Dummy Art. No. TIDL01A.01 TIWG0668A .01 TIWG0593A .01 TIWG0405A .01 TIWG0334A .01 TIWG0367A .01 TIWG0219A .01 TIWG0340A .01 TIWG0339A .01 TIWG0336A .01 TIWG0278A .01 TIWG0189A .01 TIWG0188A .01 TIWG0187A .01 TIWG0170A .01 Fits intosensor LP12DA GH01D GP15DK, GO15DKGen2 GU24DE GH15D, GH15DK,GR15D GU22C +PH04,GU22CKPH04 GH14P GU41D GU31D GU22C, GU22CK GU24D, GU24DK,GC24D,GC24DK QC43D QC34D QC34C GU21D dummy removal toolisavailable. sensors. Foreasyandconvenientremoval dummyfrom ofthe enginea the for measurements. Thisreplacement ofthe usagetime helpstoextendthe It isrecommended toreplace adummyplugifitisnotused sensorwith the bore indicating A sensordummyplugsealsthe engineinasaveway. ofthe DUMMY PLUGS Mounting tool TT29 TT66 TT21 TT11 TT21 TT09 TT21 TT07 TA16 TT09 TT11 TT08 TT07 TT08 TT11 Removal tool – TD41 TD13 TD01 TD13 TD01 TD13 TD01 TD01 TD01 TD01 TD01 TD01 TD01 TD01 91

Accessories for Pressure Sensors 3.3 MACHINING TOOLS

Machining tools

For appropriate preparation and machining of the indicating bore an assorted collection of machining tools is available. These tools are designed to machine the bores and threads of AVL sensors for several sizes. Especially for the M5 sensors it is very important to machine the seat for the sensor (front-sealing) in high quality to guarantee correct operation up to maximum pressure and the exact mounting torque. A set of machining tools consists of one step drill, one tap drill and if needed one guiding tool to keep the tap drill aligned inside long bores.

SET OF MACHINING TOOLS

Type Art. No. To machine bore for The set consists of GH15D, GH15DK, GR15D, MS15 TIWG0337A .01 GP15DK, GO15DK Gen2, MD12 + MT12 GH15DKE MS22 TIWG0165A .01 AH01, AH01A, AH91, GU21D MD22 + MT21 + MG22 MS24 TIWG0167A .01 AH06, GU21D MD24 + MT31 + MG24 MS25 TIWG0394A .01 AH45 MD25 + MT25

Sensors or adaptors which are not listed do not require any machining or any special AVL tools to machine the indicating bore. Machining of adapter bores might need an additional standard tool (see table standard tools). In this case please refer to your standard tool supplier.

SEAT DRESSING TOOLS

Type Art. No. To machine bore for GH15D, GH15DK, GR15D, GH15DKE, GP15DK, MR01-85 TIWG0616A .01 GO15DK Gen2 GH15D, GR15D, GH15DK, GH15DKE, GP15DK, MR01-180 TIWG0632A .01 GO15DK Gen2 MR05 TIWG0575A .01 GH14P

STANDARD TOOLS Additional standard drills are needed in order to finalize the bore for adapter sleeves. These tools could be taken from a standard tool supplier.

D1 To machine bore for 10 mm AH91, AH45 12 mm AH01, AH01A 15 mm AH06

92 an additionalstandard tool (seetablestandard tools). Inthiscasepleaserefer toyourstandard toolsupplier. Sensors oradaptorswhichare notlisteddorequire anymachiningorspecialAVL toolstomachinetheindicatingbore. Machiningofadapterbores mightneed an additionalstandard tool(seetablestandard tools).Inthiscasepleaserefer toyourstandard toolsupplier. Sensors oradaptorswhichare notlisteddorequire anymachiningorspecialAVL tools tomachinetheindicatingbore. Machiningofadapterbores mightneed STEP DRILLS TAP DRILLS MD27 MD26 MT32 MD25 MT31 MD24 MT25 MD22 MT21 MD16 MT13 MD12 MT12 MD10 MT11 Type Type Art. No. TIWG0665A .01 TIWG0574A .01 TIWG0667A .01 TIWG0391A .01 TIWG0156A .01 TIWG0153A .01 TIWG0392A .01 TIWG0151A .01 TIWG0155A .01 TIWG0418A .01 TIWG0369A .01 TIWG0335A .01 TIWG0346A .01 TIWG0257A .01 TIWG0154A .01 Art. No. For sensororadaptor GH01D GH14P GH01D AH45 GU22CK, AH06,GU21D QC34D, GU31D,GU22C, AH06, GU21D AH45 GU21D AH01, AH01A,AH91, GU21D, AH01,AH01A,AH91 with threadwith M10×1 GU22C, GU22CK GU22C, GU22CK GH15DKE GP15DK, GO15DKGen2, GH15D, GH15DK,GR15D, GH15DKE GP15DK, GO15DKGen2, GH15D, GH15DK,GR15D, with threadwith 3/8“×24UNF GU22C, GU22CK GH14P For sensororadaptor D1 2 3 M3 .5×035 5 . M10×1 9 M6×0 .5 6 .2 M7×0 .75 6 .3 3/8“×24 UNF 3 M5×0 .5 6 .3 M5×0 .5 D1 3 .13 4 .2 – – – 8 .5 4 .5 – D2 D2 4 .5 4 .5 7 .5 12 10 8 .9 5 .7 8 .5 D3 4 .5 10 7 8 10 5 .7 6 – 5 .7 – – – – – – D4 10 10 20 20 20 20 10 20 L1 L1 15 20 20 19 20 14 14 16 35 – – – 34 19 – L2 134 47 225 215 215 215 134 215 L3 L2 200 250 250 250 250 200 200 190 134 270 270 270 270 190 270 L4 – 190 – – – – – – L5 93

Accessories for Pressure Sensors 3.4 MOUNTING TOOLS

Mounting tools

The limited space that is given inside the mounting bores requires special tools to allow convenient and correct installation of sensors and adaptors into the engine. To ensure appropriate installation of sensors and adaptors a collection of mounting tools is available. These tools are matched to the different dimensions and applications of the sensors and adaptors. Sensors and adaptors which are not listed here do not require any special AVL mounting tools. In this case please refer to your standard tool supplier.

SOCKETS AND WRENCHES

Type Art. No. D1 D2 D3 L to mount into QC34D indicating bore, AH18 GU41D indicating bore TT07 TIWG0133A 01. HEX12 15 .8 HEX16 250 GU22C, GU22CK indicating bore with AH26, AH27, AH28 AH05 AH08 TT08 TIWG0132A 01. HEX14 18 .2 HEX19 250 QC43D indicating bore, AH15 GH13G, AG04 M8 glow-plug bore TT09 TIWG0140A 01. HEX8 11 .5 HEX12 70 GU22C, GU22CK indicating bore with AM04 or AM05 GU21D indicating bore, AH06 TT11 TIWG0180A 01. HEX7 9 .5 HEX8 250 GU24D, GU24DK indicating bore, AH35 GU24DE indicating bore GH15D, GH15DK, indicating bore, AH01, GR15D, GP15DK, AH01A, AH91 TT21 TIWG0214A 01. HEX4 5 .6 HEX8 220 GO15DK Gen2 indicating bore GH15DKE i.b., AG03, AG04, AH13, AH45 GH14P glow plug adaptor TT22 1) TIWG0233A .01 HEX16 19 SQR 3/8“ 73 ZI33 spark-plug bore GU24DK, GC24D, TT23 TIWG0548A 01. HEX9 12 HEX14 250 indicating bore GC24DK TT24 TIWG0234A 01. HEX16 20 .2 SQR 3/8“ 60 ZI33 spark-plug bore GH15D, GH15DK, GR15D, GP15DK, TT26 TIWG0247A 01. HEX4 7 .4 HEX8 215 GO15DK Gen2, indicating bore GH15DKE, GH14P, GA16P TT29 2) TIWG0371A .01 HEX5.5 – – – LP12DA direct installation, AI01, AE04 TT30 TIWG0598A 01. HEX12 17 SQR 1/4“ 65 ZI22, (ZI33) spark plug bore TT34 TIWG0606A 01. HEX12 19 .9 SQR 1/4“ 65 ZI22, (ZI33) spark plug bore TT42 TIYG1024A .01 HEX17 21 .8 SQR 3/8“ 70 ZI45 spark-plug bore TT571) TIWG0585A .01 HEX16 19 .9 SQR 3/8“ 73 ZI33 spark-plug bore TT64 TIWG0631A 01. HEX5.5 8 .5 SQR 1/4“ 50 LP12DA direct installation, AI01, AE04 TT66 TIWG0664A 01. HEX3 4 .5 HEX8 220 GH01D indicating bore indicating bore with AM04 TA13 TIWG0136A 01. HEX8 11 .5 HEX12 200 GU22C, GU22CK or AM05 GH13G, AG03 M10 glow-plug bore TA16 TIWG0200A 01. HEX10 13 .8 HEX14 139 GU31D indicating bore

1) narrow spark-plug bore 94 2) flat wrench Specifications ofsocketmountingtools SET OFMOUNTINGTOOLS PIN TOOLS/POLYGON-HEAD SPANNERS TS43 TS21 TS03 TS02 Type Type Z314 Art. No. Art. No. TIWG0211A .01 TIWG0213A .01 TIWG0181A .01 TIWG0128A .01 TIWG0103A .01 to mount to mount ZI45 GO15DK Gen2 GH14P, GA16P, GR15D, GP15DK GH15DKE, GU21D GU22C, GU22CK GH15D, GH15DK, QC34D for whichsensor. Usabilitydepends on sensortypeandmountingbore. Please refer totheaccessorieslistofaspecificsensorinorder whichspecifictoolisneeded togetinformation CABLE MOUNTINGTOOLS TT39 TC31 TC21 TC03 TC02 TC01 Type

into into spark-plug bore AG03, AG04,AH13,AH45,AH91 bore,indicating AH01,AH01A, indicating bore,indicating AH06 boreindicating AM04,AM05 with indicating bore,indicating AH14 Art. No. TIWG0510A .01 TIWG0215A .01 TIWG0690A .01 TIWG0653A .01 TIWG0613A .01 TIWG0131A .01 For cableconnectortype M3×0.35 with HEX3.5 M3×0.35 with HEX3.5 M3×0.35 with HEX M2×0.25 without HEX3.5 M3×0.35 with HEX3.5 M3×0.35 with HEX4 M4×0.35 with Scope ofsupply D1 t-handle TT44 t-handle TT43, socket TT42,elongation socket TT21,torque wrench TT02 socket TT11,torque wrench TT02 socket TT09,torque wrench TT18 pins D2 13 .8 D3 HEX12 L 140

Accessories for Pressure Sensors 3.4 MOUNTING TOOLS

Mounting tools

MOUNTING PASTE

Type Art. No. Purpose

Ensures easy removal of the sensor SF01 TIHK0094A.01 after long engine operation

ADAPTOR MOUNTING ADHESIVE SET

Type Art. No. Purpose

For secure fixing and waterproof sealing of adaptors in cylinder heads. Consists of one thin and one thick AMA01 TI0600ZB.01 high temperature resistant component cement Loctite 648 and Loctite 290

SPARK-PLUG ISOLATION GREASE

Type Art. No. Purpose

To ensure best isolation this highly resistive grease needs to be applied between the insulator and the ZKF01 TIHS0060A .01 spark-plug socket. For further information refer to the instruction manuals of your spark plug pressure sensor.

GASKET AND DUMMY REMOVAL TOOL

Type Art. No. Purpose

TT14 TIWG0178A .01 to remove gasket SG05 from QC43D/GU41D TT15 TIWG0179A .01 to remove gasket SG20 from QC34C/QC34D/GU31D TT17 TIWG0185A .01 to remove gasket SG03 from GU21D TT33 TIWG0281A .01 to remove gasket SG21 from GU24D/GU24DE/GU24DK TT54 TIWG0560A .01 to remove gasket SG21 from GC24D/GC24DK TD01 TIWG0122A .01 to take a dummy plug out of the mounting bore which has a M4×0.35 connector TD13 TIWG0224A .01 to take a dummy plug out of the mounting bore which has a M3×0.35 connector TD41 TIWG0669A .01 to take a dummy plug out of the mounting bore which has a M2×0.25 connector

96 This can be done with ourtorqueThis canbedonewith wrenches. torque. acertainmounting and accessorieshavetobefixedwith To ensure accuratemeasurements sensors andsafeoperation STANDARD TOOLS SPECIAL TOOLSFORSPARK-PLUG SENSORS TT02 TT25A TT50 TT47 TT44 TT43 TT35 TT32 TT18 TA32 TT48 Type Type Art. No. Art. No. TIWG0117A .01 TIYM5782A .01 TIWG0473A .01 TIWG0395A .01 TIYG1027A .01 TIYG1026A .01 TIWH0093A .01 TIWG0236A .01 TIWG0209A .01 TIWG0387A .01 TIWG0469A .01 Remarks Purpose incl. 1/4”SQRdriveTT36(DIN3120),Torque range:0.5 …4.5Nm 1/4” socket tool cable mounting torque wrench 1/4”drive forinsulatorexchangewith plug insert,3/8”SQRdrive(DIN3120)9×12mmforTT18 spark-plugboreinto the T-handle ofsparkplugs toeasemounting socket and mounting torque betweenthe elongation wrench orT-handle for TT18 insert-reversible ratchet,3/8”SQRdrive(DIN3120)9×12mm incl. 1/4”SQRdriveTT36(DIN3120),Torque range:1…6Nm 1/4” socket incl. 3/8”SQRdriveTT35(DIN3120),Torque range: 4 …40Nm 9x12 mmsocket toolsetforelectrodeadjustment gap 9×12mmdrive for insulatorexchangewith 97

Accessories for Pressure Sensors 3.5 GASKETS AND FLAME ARRESTORS

Gaskets and flame arrestors

GASKETS & GASKET DISMOUNTING TOOLS

Gaskets are used as sealing between the sensor and the cylinder head or adaptor. Due to usage of optimized gasket material there is no additional temperature stress to be expected during operation. All sensors with shoulder sealing (all types except the M5 types) need an appropriate gasket for correct installation. For exchange of the gasket a dismounting tool has to be used.

Gasket Art. No. For sensor / adaptor Quantity Dismounting tool

SG02 TIBQ0227A.01 GU22C, GU22CK 5 pcs. – SG03 TIBQ0228A.01 GU21D 5 pcs. incl. TT17 TT17 SG05 TIBQ0230A.01 QC43D, GU41D 5 pcs. incl. TT14 TT14 SG06 TIYF0629A 01. ZI45 5 pcs. – SG08 TIYF0640A 01. ZI33 5 pcs. – SG20 TIBQ0231A.01 QC34C, QC34D, GU31D 5 pcs. incl. TT15 TT15 GU24D, GU24DE, GU24DK, TT33 (GU24D, GU24DE, GU24DK) SG21 TIYF0718A 01. 1 pc . GC24D, GC24DK TT54 (GC24D, GC24DK) SG30 TIYG2513A .01 spark plug insulator 10 pcs. – SG32 TIYG2767A .01 ZI22 5 pcs. – SG44 TIYG3136A .01 LP12DA 10 pcs. – SG45 TIYS0892A 01. LP22DA 10 pcs. –

98 Installation ofthePH01togetherwithGH15D. 1) DismountingtoolTT51(TIWG0532A.01) is neededformaintenance PH04 PH08 PH01 Thermo protection 1) Art. No. TIYF0760A .01 TIBY3882A.01 TIYF0592A .01 for Recommended GU22CK GU22C GP15DK GR15D GH15DKE GH15DK GH15D GH14P GP15DK GR15D GH15DKE GH15DK GH15D not recommended ahighdensityofsootparticles. useinenginewith forthe front holesatthe can beachieved.Duetosmall flamearrestors are inprincipal protection atextremely sensorincaseofoperation ofthe hightemperatures protection. thermo or asocalled Asignificant driftand the cyclic of reduction For highlyaccuratemeasurements werecommend useofaflamearrestor the FLAME ARRESTORS Installation ofthePH08togetherwithGH15D. without flamearrestor Cyclic temperature drift 0.5 bar 0.4 bar – 0.7 bar 0.7 bar 0.7 bar 0.5 bar 0.5 bar – 0.7 bar 0.7 bar 0.7 bar 0.5 bar Installation ofthePH04togetherwithGU22C. with flamearrestor Typical cyclictemperature drift 0.3 bar 0.3 bar 1.5 bar 0.4 bar 0.4 bar 0.4 bar 0.3 bar 0.3 bar 1.5 bar 0.4 bar 0.4 bar 0.4 bar 0.3 bar 99

Accessories for Pressure Sensors 3.6 CABLES AND COUPLINGS

Cables and couplings

PIEZO-INPUT CABLES SPECIFICATIONS CI21-1 Art. No. TICI21/1A.02 Connection M2×0.25 neg. – M2×0.25 neg. CI21-2 Art. No. TICI21/2A.02 Cable material Teflon™ coated Maximum temperature 200 ° C Cable diameter 2 mm Mounting torque 0.35 Nm HEX at sensor friction-type connection Cable mounting tool TC21 1 m … CI21-1 Length 2 m … CI21-2

Note: To connect a sensor to the amplifiere with this cable the BNC Coupling CC21 is additionally necessary. Minimum bending radius 20 mm.

CI31-1 Art. No. TICI31/1A.02 Connection M3×0.35 pos. – M3×0.35 pos. Art. No. TICI31/2A.02 CI31-2 Cable material Teflon™ coated CI31-3 Art. No. TICI31/3A.02 Maximum temperature 200 ° C CI31-5 Art. No. TICI31/5A.01 Cable diameter 2 mm Mounting torque 0.5 Nm HEX at sensor side 3 .5 Cable mounting tool TC02, TC31, TT39 1 m … CI31-1 2 m … CI31-2 Length 3 m … CI31-3 5 m … CI31-5

Note: To connect a sensor to the amplifier with this cable the BNC Coupling CC31 is additionally necessary. Minimum bending radius 20 mm.

CI32-1 Art. No. TICI32/1A.02 Connection M3×0.35 pos. – M3×0.35 pos. Art. No. TICI32/2A.02 CI32-2 Cable material Metal shielded – Viton™ coated CI32-3 Art. No. TICI32/3A.02 Maximum temperature 200 °C Cable diameter 2 .4 mm Mounting torque 0.5 Nm HEX at sensor 3 .5 Cable mounting tool TT39 1 m … CI32-1 Length 2 m … CI32-2 3 m … CI32-3

Note: To connect a sensor to the amplifier with this cable the BNC Coupling CC31 is additionally necessary. Minimum bending radius 20 mm.

100 CI35-3 90° CI35-3 CI35-3 CI35-2 CI35-1 PIEZO-INPUT CABLES CI33-2 CI33-1 CI37-3 CI37-2 CI37-1 Art. No.TICI33/2A.02 Art. No.TICI33/1A.02 Art. No.TICI37/3A.02 Art. No.TICI37/2A.02 Art. No.TICI37/1A.02 Art. No.TICI35/3A.04 Art. No.TICI35/3A.03 Art. No.TICI35/3A.02 Art. No.TICI35/2A.02 Art. No.TICI35/1A.02 the BNCCouplingCC41isadditionallynecessary. Minimumbendingradius20mm. Note: Metalshieldedcable.To connectasensortotheamplifierwiththis cable is additionallynecessary. Minimumbendingradius20mm. Note: To connectasensortotheamplifierwiththiscableBNCCouplingCC41 BNC CouplingCC31isadditionallynecessary. Minimumbendingradius20mm. strucural vibration.To connectasensor totheamplifierwiththiscable Note: Thiscablehasadifferent cableconnectionto bemore resistent against Connection SPECIFICATIONS Length tool Cable mounting HEX atsensor torqueMounting Cable diameter Maximum temperature Cable material Length tool Cable mounting HEX atsensor torqueMounting Cable diameter Maximum temperature Cable material Connection Connection Length tool Cable mounting HEX atsensor torqueMounting Cable diameter Maximum temperature Cable material M3×0.35 pos.–M4 2 m...CI33-2 1 m...CI33-1 TC02, TC31,TT39 3 .5 0.5 Nm 2 mm ° C 200 Teflon™ coated 3 m…CI37-3 2 m…CI37-2 1 m…CI37-1 TT39 3 .5 0.5 Nm 2 .4mm ° C 200 coated Metal shielded–Viton™ M3×0.35 pos.–M4×0.35 M3×0.35 pos.–M3 3m ...CI35-390° 3m ...CI35-3 3m ...CI35-3 2m ...CI35-2 1m ...CI35-1 TC02, TC31,TT39 3 .5 0.5 Nm 2 mm ° C 200 Teflon™ coated ×0.35 pos. ×0.35 pos.

101

Accessories for Pressure Sensors 3.6 CABLES AND COUPLINGS

Cables and couplings

PIEZO-INPUT CABLES SPECIFICATIONS CI38-1 Art. No. TICI38/1A.02 Connection M3×0.35 pos. – Microdot pos.* CI38-2 Art. No. TICI38/2A.02 Cable material Metal shielded – Viton™ coated Art. No. TICI38/3A.02 CI38-3 Maximum temperature 200 ° C Cable diameter 2 .4 mm Mounting torque 0.5 Nm HEX at sensor 3 .5 Cable mounting tool TT39 1 m … CI38-1 Length 2 m … CI38-2 3 m … CI38-3

Note: Metal shielded cable. To connect a sensor to the amplifier with this cable the BNC Coupling CC41 is additionally necessary. Minimum bending radius 20 mm. *) 10-32UNF.

CI3V-1 Art. No. TICI3V/1A.01 Connection M3×0.35 pos. – M3×0.35 pos. Art. No. TICI3V/2A.01 CI3V-2 Cable material Viton™ oil proof CI3V-3 Art. No. TICI3V/3A.01 Maximum temperature 200 ° C Cable diameter 2 mm Mounting torque 0.5 Nm HEX at sensor 3 .5 Cable mounting tool TT39 1 m … CI3V-1 Length 2 m … CI3V-2 3 m … CI3V-3

Note: Metal shielded cable. To connect a sensor to the amplifier with this cable the BNC Coupling CC31 is additionally necessary. Minimum bending radius 20 mm.

CI41-1 Art. No. TICI41/1A.02 Connection M4×0.35 pos. – M4×0.35 pos. Art. No. TICI41/2A.02 CI41-2 Cable material Teflon™ coated CI41-3 Art. No. TICI41/3A.02 Maximum temperature 200 ° C Cable diameter 2 mm Mounting torque 0.5 Nm HEX at sensor 4 Cable mounting tool TC01 1 m … CI41-1 Length 2 m … CI41-2 3 m … CI41-3

Note: To connect a sensor to the amplifier with this cable the BNC Coupling CC41 is additionally necessary. This cable has a very good signal to noise ratio. Minimum bending radius 20 mm.

102 CI04-2 CI04-1 CI52-3 CI52-2 CI52-1 CI4V-3 CI4V-2 CI4V-1 CI42-3 CI42-2 CI42-1 PIEZO-INPUT CABLES Art. No.TICI04/2A.02 Art. No.TICI04/1A.02 Art. No.TICI52/3A.02 Art. No.TICI52/2A.02 Art. No.TICI52/1A.02 Art. No.TICI4V/3A.01 Art. No.TICI4V/2A.01 Art. No.TICI4V/1A.01 Art. No.TICI42/3A.02 Art. No.TICI42/2A.02 Art. No.TICI42/1A.02 the BNCCouplingCC41isadditionallynecessary. Minimumbendingradius 20 mm. Note: Metalshieldedcable.To connectasensortotheamplifierwiththiscable is additionallynecessary. Minimumbendingradius20mm. Note: To connect asensortotheamplifierwiththiscable theBNCCouplingE127M *) is additionallynecessary. Metalshieldcable.Minimumbendingradius20mm. Note: To connectasensortotheamplifier withthiscabletheBNCCouplingE127M Coupling CC41isadditionallynecessary. Minimumbendingradius20mm. Note: Oilproof cable.To connectasensortotheamplifierwiththiscableBNC 10-32UNF Length HEX atsensor torqueMounting Cable diameter Maximum temperature Cable material Connection Length tool Cable mounting HEX atsensor torqueMounting Cable diameter Maximum temperature Cable material Connection SPECIFICATIONS Length tool Cable mounting HEX atsensor torqueMounting Cable diameter Maximum temperature Cable material Connection Length tool Cable mounting HEX atsensor torqueMounting Cable diameter Maximum temperature Cable material Connection 3 m…CI4V-3 2 m…CI4V-2 1 m…CI4V-1 4 0.5 Nm 2 mm ° C 200 oilproofViton™ M4×0.35 pos.– 3 m…CI42-3 2 m…CI42-2 1 m…CI42-1 TC01 4 0.5 Nm 2 .4mm ° C 200 Metal shielded–Teflon™ coated M4×0.35 pos.– 2 m…CI04-2 1 m…CI04-1 TC01 4 0.5 Nm 2 mm ° C 200 Teflon™ coated Microdot pos.–Microdot pos.* 3 m…CI52-3 2 m…CI52-2 1 m…CI52-1 TC01 4 0.5 Nm 2 .4mm 200 °C Metal covered – Teflon™ coated Microdot pos.–Microdot pos.* *) 10-32UNF

103

Accessories for Pressure Sensors 3.6 CABLES AND COUPLINGS

Cables and couplings

MEASURING CABLES SPECIFICATIONS CX10 Art. No. TIBU0244A.01 Connection DIN 7-pin neg. – LEMO 6-pin Cable material PVC Maximum temperature 80 ° C Cable diameter 5 mm Length 1 m

Note: Measuring cable for connecting low pressure sensors to AVL X-ion™.

CY10 Art. No. TILPYS10A.01 DIN 7-pin neg. – Connection D-SUB 9-pin pos. / BNC pos. Cable material PVC Maximum temperature 80 ° C Cable diameter 5.8 + 2.8 mm Length 1 m

Note: Measurement Y-cable which seperates signal path and power supply.

E124-1.5 Art. No. TIBV2480A.01 Connection BNC pos. – BNC neg. Art. No. TIBV0055A.01 E124-5 Cable material PVC E124-10 Art. No. TIBV0056A.01 Maximum temperature 70 ° C E124-25 Art. No. TIBV4995A.01 Cable diameter 5 mm 1 .5 m … E124-1.5 5 m … E124-5 Length 10 m … E124-10 25 m … E124-25

Note: Extension cable for the connection of the piezo-input cable to the amplifier.

Connection DIN 7-pin neg. – DIN 7-pin pos. Cable material PVC CS10 Art. No. TILPCS10A.01 Maximum temperature 70 ° C CS11 Art. No. TILPCS11A.01 Cable diameter 5 mm 5 m … CS10 Length 10 m … CS11

Note: Extension cable for low pressure sensors and line pressure sensors.

104 PY10 POWER SUPPLY ANDCABLES COUPLINGS PS10 TIEU4137A.01 Art. No. CC42 TIEU2077A.01 Art. No. CC41 TIEG0908A.01 Art. No. CC21 Art. No.TILPPS10A.01 Art. No.TILPPY10A.01 sensor andCC41. size M4.Thisallowstoextendthedistancebetween Note: Couplingtoconnecttwopiezo-inputcablesof the measuringcable. cables CI33,CI37,CI41,CI42,CI4Vtotheamplifieror Note: Couplingfortheconnectionofpiezo–input cable CI21totheamplifierofmeasuringcable. Note: Couplingfortheconnectionofpiezo-input Connection SPECIFICATIONS Connection SPECIFICATIONS Connection SPECIFICATIONS M4×0.35 neg.– M4×0.35 neg.–BNCpos. pos. BNC – pos. M2×0.25 Note: Low-pressure sensorpowersupplyfornonAVL X-ion™units. Note: Y-cable formultiplepowersupply. TIEU0861A.01 Art. No. E127M TIEU2085A.01 Art. No. CC31 TIEU3385A.01 Art. No. CC43 Length Cable diameter Maximum temperature Cable material Connection Length Cable diameter Maximum temperature Cable material Connection SPECIFICATIONS cable CI04totheamplifierormeasuringcable. Note: Couplingfortheconnectionofpiezo–input measuring cable. cables CI31,CI32,CI35,CI3Vtotheamplifieror Note: Couplingfortheconnectionofpiezo–input Management. the automated usage of sensor within AVL Sensor Data Note: CouplingincludesanSIDelementandenables Connection SPECIFICATIONS Connection SPECIFICATIONS Connection SPECIFICATIONS 2 .5m 5 mm ° C 80 PVC power plugCEE7-16A D-SUB 9-pinneg.– 0 .3m 5 mm ° C 80 PVC D-SUB9-pinneg. 2 times D-SUB 9-pinpos.– M4×0.35 neg.–pos. Micro Dot neg. – BNC pos. BNC – neg. Dot Micro M3×0.35 neg.–BNCpos. 105

Accessories for Pressure Sensors 3.7 COOLING SYSTEM

Cooling system

This cooling system provides direct water cooling of the sensor dia- phragm and the measurement cell for sensors which require active cooling. This is only necessary for sensors with piezoelectric quartz material or piezoresistive sensors.

The advantages can be summarized to: • Prevention of overheating of quartz measuring elements and piezoresistive measurement cells • Reduction of load change drift • Minimum change of sensitivity due to almost constant temperature of quartz measuring elements

SCOPE OF SUPPLY 1 Cooling water tank incl. immersion pump 1 Distributor 1(2) Inspection glass(es) (depending on type) 1 Set of hoses Documentation

106 GENERAL PROPERTIES 2) 1) sensor.the through coolantflow monitoring ofthe the enginetoprevent of overheating of constantpressure (preventing pressure/signal Thisunitallows fluctuations). systemprovidesThe Cooling sensorbymeans watertothe supplyofcooling Tank re-filling possible duringoperation. minimumquantity10m Weight Dimensions Electric pump Immersion pump Tank capacity SPECIFICATIONS Level switchZP93 2.4) tube(Viton-hose Cooling PVC-tube 12.0(12mminnerradius) PVC-tube 4.0(4mminnerradius) Y- Distributor Reducing nipple glass Inspection Distributor Tank ZP93 Tank ZP91 Pump unit115V Pump 230V–50/60Hz Pump unit230V Cooling systemZP93/1-8 Cooling systemZP91.00/1-8 Cooling systemZP91.00/1–4 Cooling systemZP91.00/5–8 Cooling Cooling systemZP91.00/1–4 Cooling AVAILABLE VERSIONS ACCESSORIES 2) 1) 1) Art. No. approx. 12kg ZP93: Ø360×805mm ZP91: 275×235×600mm 230 V, 50/60Hz(115V, 50/60Hz),0.25kW, powercable3m 6 l/minat0.6barpressure difference ZP93: approx. 50l ZP91: approx. 20l 230 V, ports for1to8cooling TIEZ1815A.01 TIZP9140A .01 TIZP9142A .01 TIZP9145A .01 TIBO0188A.01 TIBO0187A.01 TIBO3364A.01 TIBO0183A.01 TIHY0316A .01 TIBO0196A.01 TIGH0116A .01 TIMV0076A.01 TIGH0086A .01 120 V, ports for1to8cooling 115 V, ports for1to4cooling 230 V, ports for1to8cooling 230 V, ports for1to4cooling Art. No. TIZP93A .08 TIZP91A .28 TIZP91A .14 TIZP91A .08 TIZP91A .04 107

Accessories for Pressure Sensors

4 Other Sensors

4.1 Crank angle encoder ...... 110 4.1.1 366C 4.1.2 365X

4.2 TDC sensor 428 ...... 116

4.3 Optical sensors for combustion measurement ...... 114

4.4 Needle lift sensor ...... 118

4.5 GCA ...... 120 4.1 CRANK ANGLE ENCODER

366C angle encoder TI366C.01

Know exactely where you are Your benefits at a glance Angle Encoder Unit suitable for mounting to a free shaft end for • 720 crank degree marks (CDM) plus 1 flange mounting. The angle encoder is hardly sensitive against high trigger information (TRG) per revolution temperature, electrical interference and vibration of the engine. as LVDS-signal • Precise measurement from n = 0 rpm to The integrated marker disc is equipped with 720 marks therefore the n = 20,000 rpm encoder provides a live resolution of ½ deg Crank angle. Additionally • Additional information about direction to CDM and Trigger the electronics provide the information about of rotation: revolving right – left, evaluation rotation direction – right – left. In combination with AVL X-ion™ for via AVL X‑ion™ example when Stop-Start-operation is performed, the actual angle • small height of the body, less volume and position is available. less mass and therefore less inertia, fits perfectly for in vehicle operation • Additional signal-out-plug integrated in electronics for CDM transfer e.g. to the test cell (PUMA)

110 stop application. engineisshutdown,usefule.g.forstart- the atanydesiredpositioned crankanglewhen shaftcanbe X-ion™the with in combination and crankshaftisknownatanytime of the reasonor right.Forthis absoluteposition the ofrotationinformation direction left –either newencoderprovides the Beyond this the vehicle. the andoperatedin Itcanbeinstalled inertia. little with andlight isverysmall 366C that AVL encoder hasdevelopedanewoptical road onthe to eveninvehicletesting (RDE). rise.Enginetestsexpand But expectations Application highly resolved andreliable dataacquisition. surement ofmanydifferent valuesinparallel, encoderandpreciseof the andsavemea- is“plugandplay”:Easyinstallation tation standard Today application. customerexpec- isa testcell Usage ofangleencoderatthe Customer requirements Life time Temperature range(mechanics) Short termload resistanceVibration Speed range rotationDetection direction Preferred acquisition Type TECHNICAL DATA Article numbertoorderArticle Compatibility Signal type Shaft positon,knownatanytime Crank AngleEncoder366C Light [V] 10 11 0 1 2 3 4 5 6 7 8 9 13750 1380013850139001395014000 10 – 1000 g 500 ×9.81m/s²(500g) 0 rpmto20,000 Yes, absoluteangle available AVL X-ion™(Gigabitpossible) encoder366C Optical TI366C.01 situation 365C mounting LVDS, RS422 40 °Cto120 Time [ms] 7 revs at500gload Engine shutdown 111

Other Sensors 4.1 CRANK ANGLE ENCODER

365X angle encoder set TI0365XC.08

365X: SUITABLE FOR ANY SHAFT POSITION

365X Angle Encoder Set is a high precision sensor for angle-related Your benefits at a glance measurements mainly for indicating purposes. The encoder can • High precision be mounted between the engine and the dynamometer. The high • High resolution tensile steel disk is manufactured to customer’s specification. • High mechanical resistance • Output: LVDS, TTL, RS422

112 electrical interference electronics. tothe temperature influenceofvibration, the and crankshafttominimize sensor headatthe ponents are mountedseparatelyoff the technology.indicating Theelectronic com - mostcommonlyusedsysteminengine the and 720CDM-signalsperrevolution. Itis principleandprovideslight oneTrigger reflection the utilizes on aslotmarkdisk, encoderisbased ofthe function The optical Technical insight Crank AngleEncoder365X Article numbertoorderArticle Temperature range max.load Short time Vibration durability Vibration Speed Range Type TECHNICAL DATA TI0365XC.08 – – 1,000 g 500 ×9.81m/s 50 min AngleEncoder 365X Optical 40 °Cto+70°C,electronics 40 °Cto120°C,mechanics –1 to28,000min 2 (500g) –1 113

Other Sensors 4.2 TDC SENSOR 428

TDC sensor 428 TI0428SETA.01

THE MOST IMPORTANT CRANK ANGLE: TDC – WE MEASURE IT!

When performing thermodynamic calculations on pressure curves Your benefits at a glance measured in internal combustion engines, the exact determination • Dynamic determination of the angular TDC of the TDC position is of great importance (e.g. IMEP calculation). position under motored or non-fired oper- Due to the not ideally rigid construction of the engine, the static ating conditions better than ± 0.1 deg. CA determination of the TDC can lead to uncertainties at calculation. • AVL Indicating Software IndiCom recognizes The capacitive TDC Sensor 428 is a precise measuring instrument the compression TDC and calculates the for determination of the TDC of a motored or non-fired cylinder TDC symmetry angle. of internal combustion engines. • Simple installation of the sensor via the pressure sensor bore, spark bore plug A specially developed electronic circuit delivers an analogue signal, or injector bore. it’s maximum value corresponds to the engine’s TDC position. The • Comparison of the TDC-sensor and the AVL Indicating Systems are able to process this signal in conjunction cylinder pressure signals with an angle encoder directly. The necessary power for the TDC- sensor is supplied by means of AVL’s angle encoder.

114 (M10, M12,M14). consists ofthree suitableadaptors „TDC-Sensor-Set= 260mmthe 428“ standardapplying the probe Length be manufactured user. bythe For usually necessaryadapterwill the spark plugsandenginetypesinuse, highvarietyofinjectorsor to the bores usingsuitableadapters. Due headviaalreadycylinder existing inthe The TDC-Sensorisinstalled Technical information Sensor mountedincylinderhead Gas-ex.-TDC 1.5 mmat Minimum Distance Adaptor Clamping Set Probe Electronics TDC-Sensor-Set 428 Article numbertoorderArticle Weight Analogue OutputSignal Power Supply Speed Range TemperatureOperating Range SENSOR Measurement set-up Analog signal Evaluation Service, PUMA X2 CDM,out TRIG Supply in, X1 TI0428SETA.01 TDC-Sensor 428:780g ±10 V AVL angleencoder 600 rpmto2000rpm,non-fired Sensor Electronic: 0°Cto80 Sensor Probe: 0°Cto250(Cycleaverage) AVL Angle encoder366C AVL X-ion™ 115

Other Sensors 4.3 OPTICAL SPARK PLUG SENSORS FOR COMBUSTION MEASUREMENTS TASKS

Optical sensors TI366C.01

THE CHALLENGE

Stringent emissions targets force our industry into ever more complex combustion technologies. The combination of electrification and advanced combustion solutions provides key ingredients for clean and efficient propulsion. As this results in increased efforts in powertrain development, robust and thorough analysis methods become mandatory.

Beside the classic pressure sensors for combustion analysis AVL offers optical spark plug sensors based on fiber optic technology for advanced combustion analysis. This solution in combination with the X-FEM Visio data acquisition module represents the perfect completion to the data acquition platform X-ion for the detailed analysis of combustion phenomena.

116 THE SOLUTION SPECIFICATIONS Mounting thread M10×1 M10 VisioKnock SPARK PLUG SENSOR Thread length 26.5 mm Due to the increasing complexity of today’s combustion engines the available space for Heat value (BOSCH) HV3 spark plugs is reduced already. The mounting Spark position 3 mm size M10×1 becomes more and more popular. Electrode gap 0.7 mm Temperature of the plug seat 230 °C permanent AVL covers this demand already with the brand Spark plug insulator resistivity 108 Ω at 20 °C, 1 kV new M10 VisioKnock Spark Plug Sensor for optical investigation of knocking combustion Burn-off resistence 6 kΩ at 20 °C, 1 kV Electric strength for performance optimization. Five optical ele- 40 kV ments provide the functionality of VisioKnock (ISO11565, 3.7.2) measurements with fifteen cones of view. One Eccentricity of the insulator 1.15 mm optical element provides one further cone of view towards the piston to identify the diffusion flame radiation from the piston surface.

M12 VISIO SPARK PLUG SOLUTIONS Mounting thread M12×1.25 Most of the engine designs today use a spark Thread length 26.5 mm plug of size M12×1.25. In order to perform advanced combustion analysis based on opti- Heat value (BOSCH) HV3, HV5 cal investigation the AVL product spectrum of Available spark position 3 mm, 5 mm optical spark plug solutions of size M12×1.25 Electrode gap 0.7 mm covers a broad range of crank angle based Temperature of the plug seat 230 °C permanent flame measurement applications from in IC Spark plug insulator resistivity 108 Ω at 20 °C, 1 kV engine cylinders to enable the identification of premixed flames versus versus diffusion Burn-off resistence 6 kΩ at 20 °C, 1 kV flames for the root cause analysis of partic- Electric strength 40 kV ulate formation in stationary and transient (ISO11565, 3.7.2) operation, flame kernal propagation, knock Eccentricity of the insulator 0 mm starting locations analysis and the identification of irregular combustion. Beside the available standard solutions customized solutions Other Sensors can be built up on request.

Available solutions • VisioFlame Spark Plug Sensor (7 channels) • VisioKnock Spark Plug Sensor (8 channels) • VisioVolume Spark Plug Sensor (8 channels, for soot investigations) • VisioKnock Advanced Spark Plug Sensor (35 channels, for knock studies) • VisioHighRes Spark Plug Sensor (70 channels, for pre-ignition and high M10 VisioKnock M12 HighRes Spark Plug Sensor resolution soot investigations) Spark Plug Sensor as an example

117 4.3 OPTICAL SPARK PLUG SENSORS FOR COMBUSTION MEASUREMENTS TASKS

VISIO SPARK PLUG SOLUTIONS Many of the engine designs today use a spark SPECIFICATIONS plug of size M14×1.25. In order to perform Mounting thread M14×1.25 advanced combustion analysis based on opti- Thread length 26.5 mm cal investigation the AVL product spectrum of Heat value (BOSCH) HV3, HV5 optical spark plug solutions of size M14×1.25 covers a broad range of crank angle based Available spark position 3 mm, 5 mm flame measurement applications in IC engine Electrode gap 0.7 mm cylinders to enable the identification of pre- Temperature of the plug seat 230 °C permanent mixed flames versus versus diffusion flames for Spark plug insulator resistivity 108 Ω at 20 °C, 1 kV the root cause analysis of particulate formation in stationary and transient operation, flame Burn-off resistence 6 kΩ at 20 °C, 1 kV Electric strength kernal propagation, knock starting locations 40 kV analysis and the identification of irregular (ISO11565, 3.7.2) combustion. Beside the available standard Eccentricity of the insulator 0 mm solutions customized solutions can be built up on request.

Available solutions • VisioFlame Spark Plug Sensor (8 channels) • VisioKnock Spark Plug Sensor (8 channels) • VisioVolume Spark Plug Sensor (8 channels, for soot investigations) • VisioKnock Advanced Spark Plug Sensor (40 channels, for knock studies) • VisioHighRes Spark Plug Sensor (80 channels, for pre-ignition and high-res soot studies)

M14 VisioFlame Spark Plug Sensor with 8 Channel as an example

118 4.4 NEEDLELIFTSENSOR data acquisition channelisrequired.data acquisition field.Moreover magnetic ofthe and phaseposition oneavailable amplitude changeofthe box 3077)bylookingatthe (incl. Oscillator AVL impedance iscalculatedbythe of the 3010 BridgeAmplifier ofenergy extraction on the from circuit. anoscillating Thechange The eddycurrent nozzleneedle. movement ofthe principleisbased eddycurrent sensorusesthe lift The needle principletomeasure the heavy dutyormarineengines. dutyengines.Itisalsoavailablefor largecars orlight injectorsin sizeinjectorsusedin and medium isavailableforsmall adaptation customer’s the within sensor isinstalled originalR&D injector. The developed pulse.Thisspecially injection ofthe duration end andthe apreciseinjectors. Thisallows beginning,the ofthe determination measure fuel indiesel injectornozzleneedle movement ofthe the customerto sensorenablesthe indicating lift The nozzleneedle TI0600DNA.02 sensor lift Needle • • Your benefitsataglance Design ofcustomtailored solutions ofinjection and duration for precise ofbeginning determination Direct measurement lift ofneedle

119

Other Sensors 4.5 GCA

Gas exchange and combustion analysis (GCA) TI0GCAADDB.01

THE VIRTUAL SENSOR

Accurate combustion analysis can help with engine design, efficiency Your benefits at a glance improvements or pollutants reduction by providing instantaneous • Deep insight into the phenomena feedback on the combustion process. It can also convey detailed com- connected with the combustion chamber bustion information to help speed up the engine calibration process. provides understanding of the combustion process AVL GCA is a thermodynamic analysis tool based on measured data. • Acquisition of values that cannot be mea- The engine’s intake, cylinder and exhaust are considered in detail. sured. Verified results by plausibility checks GCA calculates the complete cycle in an iterative matter, firstly “ • Full integration of AVL indicating software combustion” then “gas exchange”. By using the measured pressure and post-processing software leads to traces, values can be determined that otherwise can only be acquired reduction of interfaces with a lot of effort, or even not at all e.g. residual gas content or volumetric efficiency.

Therefor GCA is called “The Virtual Sensor” Calibration of a simulation model by measurement is mandatory in case high accuracy is required. The calibration process requires data exchange between BOOST and GCA, therefore the consistency of these two calculation programs is necessary. Both use the same calculation core, therefore consistency is guaranteed.

120 main columns. by adevelopmentteaminvolvingAVL’s three AVL result GCAisthe effort ofcontinuous natural charging. gas masspropagation, butalsoeffects like consideringnotonly dynamics evaluation exhaust. GCAprovides acompletegas inthe intakemanifoldandanother in the alowpressure issetupwith cells sensor The measurement equipmentatmanytest it iscrucialforreducing fuelconsumption. heatlossas andwall stability combustion tween mixture preparation, charge motion, regardingespecially relationship the be- chamber– combustion in the processes thermodynamic knowledge ofthe ible valve-trainsystem.Thisrequires detailed different technologies such as the highly flex- enginesuseabroadGasoline rangeof Mastering complexity–ratingplausibility in thermodynamic analysis: in thermodynamic AVL offers services consulting following the Article numbertoorder:Article TI0GCAADDB.01 Technical AVL GCA Support Measurement support application execution, Performance improvement Troubleshooting ofprocess anomalies relevant comparison with including AVL pattern proficiency ofcurrent systemdesign combustion assessmentofthermodynamic Quantitative SERVICES Calculation ofnon-measureable parameters AVL GCA–consistentwithAVL BOOST Auslass Zylinder Einlass MESSUNG SIMULATION 121

Other Sensors

5.1 5 5.4 5.3 5.2 5.5 Maintenance forpiezoelectricsensors Spark plugsensors Factory service unit Ramp calibration Glow plugsensors Service &Calibration . . . . . 126 125 124 128 127

Service & Calibration 5.1 PRESSURE SENSORS

Maintenance for piezoelectric sensors

COMPONENTS OF SENSOR MAINTENANCE The maintenance of sensors contains typically a visual Additionally a dynamic test on the engine might be inspection, a cleaning, once again a visual inspection after performed in order to control the dynamic behaviour cleaning, an insulation check and a calibration. In some of the sensor. Spark plug sensor maintenance contains cases it might be necessary to exchange single components as well a verification of the spark function. as piezoelectric cables or cooling nipples.

ABOUT THE IMPORTANCE OF SENSOR CALIBRATION Calibration means the process of checking precisely the 2) A further minor improvement occurs during operation status of the sensor. Piezoelectric sensors are stable over in the field. Now the sensor operates with highest their lifetime if used under regular combustion conditions. performance. It lasts for a certain number of cycles of All piezoelectric sensors go through a lifetime cycle, see operation depending on the intensity of use. Figure (a). 3) Calibration in regular time intervals is recommended 1) It starts with an improvement of linearity. The perfor- to ensure that the measurements are always performed mance improvement based on linearity happens already with the correct sensitivity of the sensor. during the run-in procedure on the test engine at the 4) At the end a sensor falls below the required accuracy AVL headquarter. level. Calibration is absolutely essential.

Figure a) Figure b) 1 2 3 4 1

2 total costs performance

number of load cycles number of maintenances

OPTIONS OF SENSOR MAINTENANCE Pressure sensors can be maintained upon request directly Regarding costs, Figure (b) shows the total costs over at AVL (factory service). Another possibility is the in-house the number of maintenances. (1) For every single mainte- maintenance based on above-mentioned steps with an nance a fixed price will be charged (excluded exchange own calibration device. The main criterion for an internal parts) in case of factory service. (2) The inertial costs or external maintenance is the expected number of main- are high due to the investment for maintenance devices tenances per year. A maintenance directly at AVL offers (incl. calibration unit). After this the costs per mainte- the advantage that the customer does not have to spend nance are much less. The point where these two lines any manpower and investment for equipment. On the cross each other represents an orientation when an other hand the in-house solution allows the customer in-house maintenance becomes more economical than ndependent maintenance at any time, instantly. a factory service.

THREE MAIN QUESTIONS FOR THE DECISION OF A MAINTENANCE PROCESS: • How long is the maintenance allowed to take? • How much does it cost per year to calibrate all sensors on a scheduled basis externally? • How accurate is the system and how reliable are the resulting data?

124 Ramp calibration unit Ramp calibration BENEFITS AT AGLANCE • • • These factorsdefinethedemandforacalibrationunit IN-HOUSE MAINTENANCE • • • • The most important part of in-house maintenance is the calibration of the cylinder pressure cylinder ofthe calibration The mostimportantpartofin-housemaintenanceisthe sensor. Commissioning installation Notebook with Use of optimum performance based on continuous calibration performancebasedoncontinuous Use ofoptimum The charge annualcostsforin-housemaintenance neededinsideoneyearexceedsthe calibrations forthe ashorttime within Request forinstantcalibration sensor ensures reproducible andaccuratecalibrations Temperature isolatedabsolutereference pressure areCold andhotcalibrations onesystem possiblewith reduces procedure calibration ofthe time the atoncewhich Up to6sensorscanbecalibrated pressure isneededtoapplythe operation –nomanualspindle automatedoperation Fully MicroIfem Piezo4 NI-USB 6210 adapters(per piece) Mounting (alternative) RCU 601/300hot(120V) (alternative) RCU 601/300hot(230V) RCU 601/300cold MINIMUM CONFIGURATION th Generation TI0SDMCOMA.01 TI0620PCB.01 TI04PIEZA.04 TI0SDMDATA.01 TI0SDMADAP.01 TI0SDMABSA.04 TI0SDMABSA.03 TI0SDMABSA.01 to 4barup030bar. verify measurement andlowpressure chains(sensor+amplifier) sensorsfrom0 corresponding SDBSensorDatabase.Itisalsopossibleto inthe information the link itwith systemand SIDSensorIdentification viathe test automatically By usingAVL chargethe sensorsunder the systemisabletoidentify amplifiers which enablescentralmanagementandcoordination schedules. ofcalibration SDBSensorDatabase tothe connection andthe customized documentation responseto the buildinreference ofthe sensor. software Thecalibration allows increasing pressure hydraulic sensorsundertest.Thesignalsare tothe related UnitRCU601/300acomputercontrolled Calibration generatesan spindle fortemperaturestions upto250 To requirements coverthese AVL- developedanautomatedsystemforcalibra RCU 601/300 OPTIONS ANDACCESSORIES Hardware forlowpressure verification + lowpressure verification Software formeasurement chain Mobile cabinetforRCU Absolute reference sensor GU21C) device with (for existing Retrofit kittoabsolutepressure reference sensor device) (for existing 120V Upgrade tohotcalibration device) (for existing 230V Upgrade tohotcalibration adapter(per piece) Mounting • • • software interface userfriendly Clear stepbyguidanceduetothe performance sensor Sensor Databasetotrackandmonitorthe A sensorhistoryisbuildupandstored SDB inthe softwareby the Standardized sheetscanbegenerated calibration °C andpressures upto300bar. Ramp Inthe TI0SDMCHLA.01 TI0SDMCHAA.01 TI0600TROB.01 TIEZ1155A.01 TI0SDMABSA.05 TI0SDMOHCA.02 TI0SDMOHCA.01 TI0SDMADAP.01 125

Service & Calibration 5.1 PRESSURE SENSORS

Factory service

AVL is offering a factory service for cylinder pressure sensors on request which is an important part of the service of the complete indicating equipment. AVL recommends to service the piezoelectric sensors latest every 400 hours or annually including a calibration which checks the sensitivity and linearity values for room temperature and 250 °C. The service contains inspection, cleaning, calibration and repair of cylinder pressure sensors. Repairs are performed only on demand.

THE CONTENT OF THE FACTORY SERVICE IS (DEPENDING ON TYPE):

• Optical inspection of the pressure sensor • Insulation check for pressure sensor and piezo input cable • Cleaning of the pressure sensor • Cleaning and heating of electrical connection on demand • Cold and hot calibration with a ramp calibration system • Exchange of a defective piezo input cable on demand • Check of spark functionality with a pressurized ignition system • Exchange of a defect insulator (or all insulator components) on demand • Exchange of a defect mass electrode on demand • Exchange of cooling water nipples on demand

FACTORY SERVICE DEPENDING ON TYPE Service for uncooled cylinder pressure sensor TI0SERVICU.01 Service for cooled cylinder pressure sensor TI0SERVICC.01 Service for spark plug sensor TI0SERVICS.01 Service for sensor and spark plug adapter TI0SERVICE.01 Service for spark plug adapter TI0SERVICA.01 Service for reference sensor GU21C TI0SERVICR.01 Service for low pressure sensor TI0SERVICL.01

126 FAQ forsparkplugsensors position? existing sparkpluginanoriented How couldyoumountanalready sensor aswellwithoutsealingring? Is itpossibletouseAVL sparkplug how couldthisbedone? as wellduringoperationand electrode gapbefore everyusage Does itmakesensetocheckthe without limits? Could theelectrode gapbeadjusted compared to the original spark plug? there isnomatchingAVL solution Which valuesshouldbetakenif heat rangesandsparkprotrusions. AVL are onlyavailableindedicated The measurement sparkplugsfrom or manufacturer code? engine type,OEMpartnumber spark plugwithinformationlike determine asuitablemeasurement Why isn’t italwayspossibleto frequently askedquestions. originalsparkplugs.ThisFAQ the with shouldhelptofindanswers list sparketc.AVLof the offers ofsparkplugsinline artgeneration astateofthe the sparkenergy,like onmanyinfluences chamberisdepending the position gas mixture chamber. combustion inthe in combustion Theexpansionofthe plug sensormeasures pressure combustion the ignitesthe andinaddition The sparkplugsensorsfrom AVL Thespark inparallel. havetwofunctions to reach sparkpotrusion. aminimum impacttothe with orientedposition the AVL offers different rings(usedas indexingwashers)with sealing thicknesses specification. ringifneeded duetothe sealing AVLBased onthis measurement sparkplugsensorscouldbe usedwithout high accuracyandlessroughness originalsparkplug. incomparisontothe AVL surfaceofthe The sealing sparkplugsensorismanufactured a with toolTA32 the done with from AVL. onfuel).Thecheckshouldbe (every50to100hdepending during operation AVL recommends electrode tocheckthe gapbefore everyusageandalso delivered standard agapof0.8mm. wisewith electrical strength. Themeasurement are newgeneration spark plugsofthe for measurement ZI22,ZI33andZI45dueto the sparkplugsofgeneration The electrode originalsparkplug valueofthe tothe gapcouldbeadjusted means ahighuncertainty. of AVL heatrange conversionofthe istochooseacolderheatrangeifthe are ofstandard possiblebasedoncustomization types.Recommendation sparkprotrusions 4and6(Bosch)adjusted heatrangeslike Additionally the correctdefine type. or ahighuncertainty. InworstcaseAVL wouldneedanoriginalsparkplug to orheatrangeconversionaren’tadaptions clearduetomissinginformation totally sparkprotrusion, like butinformation to getmostinformation customized define sparkplug.Themanufacturer conversion tables with helpstogether OEMpartnumber.for everyenginetypeandthe doesn’t Theenginetypeitself AVL doesn’t recommended aboutthe haveinformation originalsparkplug

127

Service & Calibration 5.1 PRESSURE SENSORS

Design specification – spark plug sensor

TO CUSTOMIZE THE SPARK PLUG SENSOR TO YOUR SPECIFIC APPLICATION A DETAILED DESCRIPTION OF THE ORIGINAL SPARK PLUG AND BORE IS REQUIRED.

A proper analysis of the original spark plug is needed in order to ensure the best performance and durability of the sensor solution and a comparable spark initiation in the cylinder. Based on these data AVL can design the sensor according to the customer needs. The data is stored for further orders. The input as well as forwarding the form can be carried out electronically. The order form is also available as download at www.avl.com/sensors.

BASE INFORMATION:

Customer name / contact Affiliate name / contact Date

ENGINE INFORMATION:

Engine manufacturer / code Spark plug manufacturer / part number

SPARK PLUG SENSOR SOLUTIONS: (Type selection via checkbox)

Sensor Thread diameter [I] Selection

ZI22 M10 × 1

ZI33 M12 × 1.25

ZI45 M14 × 1.25

128 Outer diameter mounting tool= mounting Outer diameter Dimension INSTALLATION SOCKETINFORMATION Surface gap Ground electrodes specification hexagon=HEX Mounting Mounting hexagon SPECIFICATION OFSHAPEANDDIMENSIONTHEORIGINAL SPARK PLUG: Dimension Connector SAE NAPF Side M4 ______Top ______Pin-Pin mm (necessary for conical sealing andHEX<16): (necessary forconicalsealing Diameter spark plugbore = Connector ofinsulator[L]= Length [E]= Insulator diameter Dimension Top Surface gap Electrode type Number ofelectrodes Indexed mounting Ground electrode specification Heat range Scale type Heat range Flat Sealing SAE Spark protrusion [C]= Maximum depth [K]= Maximum depth Shaft diameter [F]= Shaft diameter Electrode gap[D]= Thread return [J]= Total [B]= length (type selection viacheckbox) (type selection Conical NAPFM4thread Length [G]= Length Length [H]= Length ______(type selection viacheckbox) (type selection Reach [A]= ______(type selection viacheckbox) (type selection ______Pin-Pin ______Side mm mm mm mm mm mm mm mm mm mm mm mm 129

Service & Calibration 5.1 PRESSURE SENSORS

Design specification – glow plug sensor /adaptor

A DETAILED DESCRIPTION OF THE ORIGINAL GLOW PLUG AND BORE IS REQUIRED IN ORDER TO CUSTOMIZE THE GLOW PLUG SENSOR / ADAPTOR ACCORDING TO YOUR SPECIFIC APPLICATION.

To ensure the best performance and durability of the sensor / adaptor solution the bore dimensions in the flame deck are particularly critical. Based on this data AVL can design the adaptor according to the customer’s needs. The data is stored in the AVL database for further orders. The input as well as forwarding of the form can be carried out electronically. The order form is also available as download at www.avl.com/sensors.

BASE INFORMATION:

Customer name / contact Affiliate name / contact Date

ENGINE INFORMATION:

Engine manufacturer / code Spark plug manufacturer / part number

SELECTION OF GLOW PLUG SENSOR / ADAPTOR: (Type selection via checkbox)

Sensor Sensor / adapter Thread diameter D4 Tip bore diameter DB Selection

TIGH13GPA.01 GH13G ≥ M8 4.3 mm ≤ DB ≤ 5.0 mm

TIGG1323A.01 GH14P ≥ M8 ≥ 5.0 mm TIAG04A.01 AG04

TIGG1323A.01 GH14P ≥ M10 ≥ 5.0 mm TIAG03A.01 AG03

NEW GLOW PLUG DESIGN (Definition by AVL): A new design needs to be done, if the glow plug of interest isn’t available in the AVL adapter data base. Customer understands the need for this article.

Article number Article Selection

TIAGDESA.01 Glow plug sensor / adaptor design

130 SPECIFY TYPE,SHAPEANDDIMENSIONOFTHEGLOWPLUGBORE: SPECIFY SHAPEANDDIMENSIONOFTHEORIGINALGLOWPLUG: Final check (with boreFinal check(with typeB): LA –LD≥15mm LA +L3≥57mm

HEX = W1 = W3 = W2 = W2 = DC = DB = DB = DK = DK = D4 = D3 = D2 = D1 = LD = LC = LC = LA = LA = LB = LB = L7 = L6 = L5 = L4 = L3 = L2 = L1 = ______° ______M ______° ______° ______° ______± ± ± ± ± ± x mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm ______mm mm mm mm mm mm 131

Service & Calibration 5.1 PRESSURE SENSORS

FAQ for glow plug sensors

AVL has made a list of frequently asked questions and tricks in order to avoid typical problems occurring while defining a glow plug adapter.

What is the difference between The original glow plug is supporting the engine start especially with low ambient an original glow plug and a measure- temperatures (cold start). Due to this the tip of the glow plug is designed to ment glow plug? bring as much heat as possible into the fuel / air mixture in the combustion chamber. One factor that influences the heat contribution is the gap between the glow plug and the glow plug bore in the cylinder head.

The glow plug adaptors and sensors are used for the pressure measurement in the combustion chamber without the glow function. It is necessary to have a minimum gap between the glow plug adaptor / sensor and the bore in the cylinder head in order to ensure the best possible lifetime of the sensor. With this design, the heat transfer from combustion to the adaptor and sensor is reduced to a minimum. Based on this, the diameter and shape of the tip has to be aligned with the glow plug bore in the cylinder head. The diameter DB, DK and DC (if applicable) have to be determined with the best possible precision in order to allow the design department the smallest tolerances.

Beside the lifetime the measurement accuracy is most important. The adapter construction allows a positioning of the pressure sensor membrane close to the combustion chamber with a minimum of pipe oscillation.

To ensure a safe and damage-free dismounting a minimum wall thickness is needed. The pressure sensor GH14P has an outer diameter of 4.3 mm, therefore the minimum diameter for the usage of a sensor with glow plug adaptor (modular approach) is a DB of 5 mm. For bore diameters smaller than 5 mm, AVL can provide a glow plug sensor GH13G. This glow plug sensor will then be supplication specific and can’t be used in engines with different bore dimensions.

Which dimensions are needed It is possible to make a design proposal, if: minimum in order to make a proper design proposal? a) the dimension of the original glow plug is available (but this is a recessed solution with pipe oszillation) b) the dimension of the original glow plug and the diameter DB, DK and DC (if applicable) and the length LA respectively LD are available c) all dimension / the construction drawing of the glow plug bore and the tip geometry of the original glow plug (D1 and L2) are available

132 facturer code notenough? type, originalpartnumberormanu- Why istheinformationofengine even with known engine type information in the database. inthe knownenginetypeinformation even with mustbechecked dimension the Based onthis aswell. to bechangedslightly required duetosomeofthe it ispossiblethat headhas cylinder changes,the manufactured more 500different than typesofglowplugadapters.Inaddition, For mostrequests AVL noenginecodeorpartnumberisgiven,although has bore ortoream bore the toadefinedvalue. glow plugboredifferent itcouldbenecessarytodefine adaptersforeach borejudge the tolerancesofthe onthe DBandDC.Depending diameter itisimpossibleto time headcannotbejudged.Mostofthe cylinder in the bore ofthe dimensions notavailableandthe glowplugisnormally of the spare this partnumber(ormanufacturerWith dimension partnumber)the spare onlyleadstoapartnumberofthe The enginetypenormally part. 133

Service & Calibration PEFC certified This product is from sustainably managed forests and controlled sources. www.pefc.org Published in 01/2019 by AVL List GmbH, Hans-List-Platz 1, 8020 Graz, Austria Responsible for the contents: AVL List GmbH, Graz, Email: [email protected], www.avl.com Layout: SCOOP & SPOON GmbH, Vienna PA4044E, Subject to modifications and amendments. Printed in Austria by AVL www.avl.com