Hydrotechnik HySense QL 326 User manual

HySense® QL 326
Load valve
Manual
Version 1.0 ENG
ENG

Table of contents
1 SECURITY....................................................................................4
General safety instructions and warnings ...............................................4
Notes on handling the load valve............................................................4
2Introduction .................................................................................4
Scope ......................................................................................................4
Copyright .................................................................................................4
Disclaimer................................................................................................5
Intended use............................................................................................5
Guarantee ...............................................................................................6
Obligations of the customer ....................................................................6
Authorized personnel ..............................................................................6
3Description of the device ...........................................................7
Components ............................................................................................7
Intended use of the QL 326.....................................................................8
Commissioning........................................................................................8
Technical data .........................................................................................9
Connect ...................................................................................................11
Venting ....................................................................................................11
4Operation with MS5060 plus......................................................12
Activating the CAN-BUS .........................................................................12
Starting the application Load valve .........................................................12
Programming the load valve ...................................................................14
Programming the operating mode MANUAL ..........................................14
Programming the operating mode Ramp................................................15
Programming the sine wave operating mode .........................................16
Programming channels ...........................................................................17
End programming....................................................................................17
operate a load line...................................................................................18
Saving measurement results...................................................................19
5Operation with MS5070 ..............................................................20
Activating the CAN-BUS .........................................................................20
Starting the application Load valve .........................................................20
Setting Load profile .................................................................................21
Programming the operating mode MANUAL ..........................................22
Programming the operating mode Ramp................................................22
Programming the sine wave operating mode .........................................23
Setting QL326 Sensors ...........................................................................24
Scan CAN bus.........................................................................................24
Detection of multiple sensors on the CAN bus .......................................25
Activation QL326 .....................................................................................26
ONLINE / OFFLINE - Mode ....................................................................26
Storing measured values ........................................................................26
Measured value display ..........................................................................27
Start test cycle Manual............................................................................28
Start test cycle Ramp or sine ..................................................................29
Display of the storage .............................................................................30
6Control with Can commands .....................................................31
CAN - Setup ............................................................................................31
Heartbeat.................................................................................................31
CAN commands in SDO and QL326 protocol.........................................32
SDO protocol...........................................................................................32
QL326 Protocol .......................................................................................32
Query of the control box..........................................................................33
Example for control via CAN ...................................................................34
Operating mode Ramp / Sine..................................................................34
Manual operating mode ..........................................................................34
End test cycle..........................................................................................34
Example for programming and starting with CAN commands ................35
Calibration ...............................................................................................35
Setting a ramp load .................................................................................37

Setting a sinusoidal load .........................................................................39
Starting and stopping the control box .....................................................41
Status of the heartbeat............................................................................41
7Accessories.................................................................................41
8Cleaning and maintenance ........................................................42
Cleaning ..................................................................................................42
Calibration and maintenance ..................................................................42
Repair......................................................................................................42

1 SAFETY
Warning
Danger of bursting due to contaminated nozzles!
The pressure on the load valve is relieved via pilot control and nozzles, which can be
clogged by impurities in the fluid. This can lead to overload, which can cause compo-
nents to blow off or fluid to leak. Install an effective pressure relief valve upstream of
the load valve!
General safety instructions and warnings
-Do not cut, damage or modify the connection cables or place any objects on them.
-Never touch the control box with wet or clammy hands.
-Connect the device only to power supplies for which it is suitable (see technical data).
-Disconnect the power cord from the load outlet during a thunderstorm.
-Unplug the power cord from the outlet if you notice an odor or smoke, or if the cord is damaged.
-Make sure your system is properly grounded. Incorrect grounding may result in incorrect measurements.
Notes on handling the load valve
-Do not expose the control box to excessive heat or moisture, respect the technical data.
-Do not store the unit in damp and dusty places or in temperatures below freezing.
-Do not immerse the unit in water or other liquids. Never allow liquids to get inside the unit.
-Never open the device
-Do not use the unit after it has been dropped or the housing is damaged.
-Avoid strong magnetic fields. Keep the device away from electric motors or other devices that
generate electromagnetic fields. Strong magnetic fields can cause malfunction and affect readings.
Note
The information and notes in this section are important.
Failure to do so may invalidate any claims under warranty
and guarantee.
Scope
These operating instructions apply to load sections designated "QL 326". It is intended for operator who
are working with the unit. This is not a technical manual. For questions that go beyond the contents of
this manual, please contact our customer service.
Copyright
The device and this manual are protected by copyright. Reproduction without permission will be followed up in a
judicial process. We reserve all rights to this manual, including the rights of reproduction and/or duplication in
any conceivable form e.g. by photocopying, printing, on any data carriers or in translated form. This manual may
only be reproduced with the written permission of Hydrotechnik GmbH.
2
INTRODUCTION

The technical status at the time of delivery of the device and instructions is decisive, unless other infor-
mation is provided. We reserve the right to make technical changes without special notice. Earlier in-
structions lose their validity. The General Conditions of Sale and Delivery of Hydrotechnik GmbH apply.
Disclaimer
We guarantee the fault-free functioning of our product in accordance with our advertising, the product
information published by us and this manual. Further product characteristics are not promised. We ac-
cept no liability for economic efficiency and faultless function, if the product is used for a purpose other
than that described in the section "Intended use".
Compensation for damages is generally excluded, except in cases of intent or gross negligence on the
part of Hydrotechnik GmbH or if promised product properties are not available. If this product is used in
environments for which it is not suitable or which do not meet the technical standard, we are not respon-
sible for the consequences.
We accept no liability for damage to equipment and systems in the vicinity of the product caused by a
fault in the product or in this manual.
We are not responsible for the infringement of patents and/or other rights of third parties outside the
Federal Republic of Germany.
We are not liable for damage caused by improper operation and not following the instructions in this
manual. We are not liable for loss of profit and consequential damage due to non-observance of safety
and warning instructions. We accept no liability for damage caused by the use of accessories and/or
wearing parts that were not supplied or certified by Hydrotechnik GmbH.
The products of Hydrotechnik GmbH are designed for a long service life. They correspond to the state
of science and technology and were individually tested in all functions before delivery. The electrical and
mechanical construction complies with the applicable standards and guidelines. Hydrotechnik GmbH
conducts ongoing product and market research in order to promote the continuous development and
improvement of its products.
In case of malfunctions and/or technical problems, please contact the Hydrotechnik GmbH customer
service. We assure you, that suitable measures will be taken immediately. The warranty conditions of
Hydrotechnik GmbH apply, which we will be pleased to send you on request.
Intended use
The device "QL 326" is a load line controlled via a bus system, which is equipped with a proportional
pressure relief valve with preamplifier. It is used to measure pressure, volume flow and temperature.
The integrated proportional valve can be used to simulate a load in order to measure the behaviour of,
for example, a hydraulic pump under load. A pre-programmed pressure curve (setpoint 0...100% corre-
sponding to 0...10V) of the load curve is run to obtain reliably reproducible test sequences. No set-
point/process value comparison is carried out and no control is performed.
Any other use of this device is considered improper. If you have any questions or wish to use the unit for
any other purpose, please contact our customer service. We will be happy to help you with any neces-
sary configurations.

Guarantee
For this device, we guarantee perfect condition for a period of six months within the scope of our warranty con-
ditions. Wearing parts are excluded from this guarantee. The warranty claim expires if repairs or interventions
are carried out by persons who are not authorized by us.
Within the warranty period, we will remedy free of charge any damage or defects that are demonstrably based
on a factory defect, provided that we are notified of such defects immediately upon their discovery, but no later
than within six months of delivery. The guarantee is provided at our discretion by repairing defective parts free
of charge or replacing them with faultless parts.
Send devices for which a warranty claim is made to the Hydrotechnik GmbH customer service centre carriage
paid and with a copy of the invoice or delivery note. You will find the address at the end of this manual.
Obligations of the customer
The operator of this device must ensure that only persons who
• know the rules of work safety and accident prevention
• were instructed in the operation of this measuring instrument
• have read and understood this manual completely
be able to use and operate this device.
Persons who operate this measuring instrument are obliged
• to observe all rules of work safety and accident prevention
• to read this manual completely, especially the safety instructions in the first chapter.
Authorized personnel
Persons are regarded as authorized who have completed professional training, have technical experience and
knowledge of the relevant standards and guidelines and who are able to assess the tasks assigned to them and
recognize possible dangers at an early stage.
Operator of the device
Persons are considered authorized who have been instructed in the operation of the device and have read and
understood this manual completely.
Personnel for installation and maintenance
Persons are considered authorized who have been instructed in all aspects of the device and have read and
understood this manual completely.

3DES CRIP TION OF THE DEVICE
Components
1
Control box
receives the device settings from the measuring device and controls
the proportional valve (pilot circuit)
2
Proportional valve with
amplifier
Controls the flow rate according to the programmed characteristic
curve (set point)
3
Amplifier
Proportional valve amplifier
4
CAN Pressure Sensor
Pressure measurement
5
CAN inductive trans-
ducer
Volume flow measurement
6
CAN temperature sen-
sor
Temperature measurement
7
Minimess® test point
Venting and measuring point for pilot pressure
8
Venting screw
Venting screw of the proportional valve under screw cap
9
Power supply
Power supply for control box, CAN sensors and proportional valve
amplifier
10
CAN port
Connection for measuring instrument or CAN bus
11
Inlet port
ISO226-G1 1/4
12
Outlet port
ISO226-G1 1/4
4
5
6
7
8
11
10
9
1
2
6
3
12

Intended use of the QL 326
The QL 326 load valve is a further development of the proven QL 2xx load valve. The manually operated throttle
valve was replaced by a proportional pressure relief valve with preamplifier. The excellent technical properties of
the previous version (nominal pressure, maximum volume flow, error limits, etc.) were completely retained.
The programming of the load valve is carried out either by the Hydrotechnik measuring device or by means of
the available CAN commands when connected to an existing CAN bus.
During operation of the load line, previously defined test parameters are transmitted to the control box via CAN
bus. The control box controls the proportional valve. The load valve is capable of processing a defined load pro-
file (ramp or sine) as a single action or in several cycles. Identical loads can be run several times in succession.
The load valve considerably simplifies the adjustment of pressure relief valves and the testing of pumps, e.g. the
recording of the characteristic curve as a function of pressure, as a non-existent load can be simulated exactly
and reproducibly.
The components volume flow sensor (turbine) and proportional valve as well as measuring points for pressure
and temperature are combined in one unit. The mechanical connection (inlet/outlet) is designed as a female
thread ISO 150 228-G 1¼".
For safe operation of the load line, we recommend the installation of an external pressure protection.
This must be installed by the customer, e.g. by installing a pressure relief valve upstream of the load
valve, or via the upstream hydraulic system.
The device must not be used for control purposes.
Commissioning
Wear eye protection!
Wear hand protec-
tion!
Attention
Damage to the turbine wheel possible!
Commissioning and venting may only be carried out at a flow rate of max. 30
l/min and a pressure of 30 bar. Otherwise, the turbine wheel can be dam-
aged by the air contained in the system.
Warning
Hydraulic oil can blind you!
Immediately after connecting the Minimess® measuring hose, the hydraulic
oil contained in the system escapes from the hose. Take care not to get the
oil in your eyes or on your skin. This can cause serious injuries such as
blindness or skin irritation. Wear safety glasses and protective gloves! Have
suitable collecting containers for the hydraulic oil ready!

Technical data
Mechanical data
Material housing
3.4365
... turbine wheel
1.0718
... Seals
FKM
Mechanical connection
ISO 228 - G 1¼"
Mounting position
any
Weight
approx. 6,5 kg
Medium temperature
max. 120 °C
Ambient / storage temperature
-20...+65 °C
Hydraulic data
Permissible operating pressure
420 bar
Measuring range
16...600 l/min
Calibration viscosity
30 mm²/s (cSt)
Viscosity range
1...100 mm²/s (cSt)
Recommended filter
10 µm
Electrical data of the sensors
Output signal
CAN 2.0A
Electrical measuring connection
M12x1 5-pin plug
Protection class
IP 40 (EN 60529 / IEC 529)
Supply voltage Ub
12...24 VDC
Power consumption
max. 1 A
Overvoltage protection
36 VDC
Response time
≤ 50 ms
Electrical data of the control box
Input signal
CAN 2.0A
Control signal to proportional
valve
0...10V (1)
Connection Input/Output
M12x1 5-pin socket and plug
Connection Supply voltage
M16x0,75 3-pin connector
Supply voltage Ub
12...24 VDC
Power consumption
max. 1 A
Measurement accuracy
Flow rate
±0.5% of MW @ 30mm²/s (cSt)
Pressure
typ. ±0.5% of MW (
2
)
Temperature
typ. ±2°K (2)
(1) When used in the CAN bus, this range corresponds to the default value 0...100% (0…10V).
(2) Detailed information on the measuring accuracy of the individual sensors can be found in the corresponding
product data sheets.

Connections control box
CAN socket
M12 x 1 with screw lock A-coding, 5-pin, socket IEC / DIN EN 61076-2-101
M12 A 5p f
1
CAN SHLD
CAN shield
2
CAN Ub
CAN supply
3
CAN GND
CAN ground
4
CAN H
CAN high
5
CAN L
CAN low
CAN connector
M12 x 1 with screw lock A-coding, 5-pin, connector IEC / DIN EN 61076-2-101
M12 A 5p m
1
CAN SHLD
CAN shield
2
CAN Ub
CAN supply
3
CAN GND
CAN ground
4
CAN H
CAN high
5
CAN L
CAN low
Supply connector
M16 x 0.75 3-pin, connector
M16 3p m
1
PWR+
Power supply control box
24VDC (+)
2
NC
unassociated
3
PWR-
Power supply control box
Ground (GND)

Connect
Connecting to a Hydrotechnik measuring instrument with CAN functionality
1. Connect the control box of the QL 326 with the CAN data cable to the measuring instrument.
2. Connect the power supply unit to the supply plug of the control box.
3. Please refer to the operating manual of the measuring instrument for further information.
Connecting to an existing CAN bus
1. Connect the control box of the QL 326 with the CAN data cable to the existing CAN bus.
2. Connect the power supply unit to the supply plug of the control box.
Venting
After the load valve has been installed in a measuring point, it must be vented during the first two minutes
of operation.
1. Remove the protective cap (pos.8, page 3) on the proportional valve to gain access to the venting screw
underneath.
2. Connect a Minimess® measuring hose to the Minimess® test point (pos.7, page 3).
Caution: Oil-air mixture of the system immediately escape at the hose end.
3. Let the oil-air mixture contained in the load valve escape and simultaneously open the vent screw in the
proportional valve by one to two turns with a Phillips screwdriver.
4. Wait until the oil flows out evenly without interruptions or bubbles.
5. Close the bleed screw in the proportional valve.
6. Remove the Minimess® measuring hose from the test point.
7. Mount the protective cap on the proportional valve

With the MultiSystem 5060 Plus, you can program the electronically controlled load valve HySense QL 326 and
operate it in various operating modes.
Activating the CAN-BUS
Start the MultiSystem 5060 Plus and activate the CAN bus in the "DEVICE" menu. Set the baud rate to
125kBit/s. With F5 (OK) you leave the menu.
1 Press to open the menu.
2 Use to highlight Device and press .
3 Use to highlight Can and press .
4 Use to highlight the Baud rate and press .
5 Use to select select 125kBit/s and press .
6 Exit the settings with F5 (OK).
Starting the application Load valve
Select the "Special Applications" menu and open the menu with . Select the "Load valve" menu.
1 Press to open the menu.
2 Use to highlight Special Applications and press .
3 Use to highlight Load valve and press .
4 Via F3 (CONFIG) the connected sensors are recognized. Select "YES",
to add the sensors to the display.
5 Confirm with the menu "Load valve" - CAN-BUS is scanned again
and you reach the programming level.
6 Use to highlight Parameter and press .
You are now at the programming level of the load valve.
In the "Parameter" menu you can set the operating mode "MANUAL", "RAMP", "SINUS" or "INACTIVE".
4OPERATION WITH MS5060 P LUS

Parameters Shows the current configuration of the load valve
Use to highlight Parameter and press .
Note: You can only program the load valve if it is INACTIVE
Device or QL-326 If no load valve is connected to the measuring instrument device is displayed.
If a load valve is connected to the measuring instrument, the short designation QL-326
is displayed.
QL326 is INACTIVE,
- then you can configure the parameters of the load valve
- the load valve cannot be operated in this state
QL326 is CONNECTED,
- the load valve can be operated in this state
- a configuration is not possible
Heartbeat The measuring instrument communicates with the load valve when ACTIVE
is displayed. The code before ACTIVE indicates the state of communication.
Software Shows the software version of the load valve.

Programming the load valve
Note: You can only program the load distance if it is INACTIVE.
You can define the operating modes in the Load valve (1/2) dialog.
1 Press to open the menu.
2 Use to highlight Special Applications and press .
3 Use to highlight Load distance and press .
4 Use to highlight Parameter and press .
You can define the behaviour of the load valve in the dialog:
Operating mode Press to select the desired operating mode:
Ramp The valve follows the curve of a defined ramp
see programming operating mode ramp
Sine The valve follows a sinusoidal curve.
see programming operating mode sine
Inactive The load valve is switched off.
Manual The proportional valve of the load valve is operated manually via
the function keys
Mode Press and select between the following options.
CYCLICAL Ramp/sine is repeatedly run down. The number of repetitions is
defined as Nbr. of cycles.
SINGLE VAL Ramp/sine is run exactly once.
Nbr. of cycles If the load is repeated cyclically, enter the number of the repetitions.
Programming the operating mode manual
In this operating mode it is not necessary to program additional parameters.
In manual mode, the position of the proportional valve is set by pressing the function keys while the
load valve is in operation.
Save and exit the setting with F5 .

Programming the operating mode ramp
In this operating mode a ramp, devided in four stages, can be defined.
The values shown in above dialog results in this ramp:
Range A: Rising edge from start value Ato end value Ain time duration A.
Range B: Level B with value Band the dwell time duration B
Range C: Falling edge from start value C to end value C in time duration C
Range D: Level D with value Dand the dwell time duration D
Range
Starting value
Final value
Duration
A
10%...100%
10%...100%
0,01…10s
B
10%...100%
10%...100%
0,01…99,99s
C
10%...100%
10%...100%
0…99,99s
D
10%...100%
10%...100%
0…99,99s
After range "D" has expired, the proportional valve is set to 0V or 0%.
In cyclic mode, the system jumps to the start value "A" after range D. A maximum of 9999 cycles can be run.
Highlight the setting values of the curve, press and enter the desired value and confirm with .
Save and exit the setting with F5 .

Programming operating mode sine wave
In this operating mode a sinusoidal curve, devided in three stages, can be defined.
The values in the shown dialog result in this sine wave:
A amplitude of the oscillation and corresponds to the Volt value as a percentage of the maximum output
voltage.
O Offset between zero and the baseline of the oscillation and corresponds to the Volt value as a percentage
of the maximum output voltage.
F Frequency of the oscillation - is given as a multiple of 10 mHz
Range
Value range
A
10%...100%
O
10%...100%
A+O
max. 100
F
0.01Hz... 2Hz...
A minimum offset of 10% is specified in this operating mode. The amplitude of the sine is added to the offset.
The value of 100% is not exceeded, nor is the value falling below 0%.
Make sure that the sum of amplitude and offset is less than 100%. A negative amplitude cannot be displayed.
Highlight the setting values of the curve, press and enter the desired value and confirm with .
Save and exit the setting with F5 .

Programming channels
If further CAN sensors are integrated into the CAN bus and it becomes necessary to reassign the channels of
the load valve, then proceed as follows
Press to display the second dialog box Load valve (2/2).
Seven channels are required to operate the load line.
1 Highlight the desired channel,
2 Press and change the channel number.
3 Confirm the entry with .
Save and exit the setting with F5
Exit programming
Press F5 to exit the programming of the load valve and to save your entries.
If the channels of the load valve are not shown in the measurement display, the measuring instrument offers to
add the channels to the display.
YES The measured values of the load valve are inserted into the measurement
display.
NO The measurement display is not adjusted.

Operate the load line
The following requirements must be met before you can operate a load valve with the measuring instrument:
• The load valve is connected to the measuring instrument and ready for operation.
• Active communication between the measuring instrument and the load valve.
A heartbeat is displayed.
• The load distance is programmed.
Activate load valve
1 Press to open the menu.
2 Use to highlight Special Applications and press .
3 Use to highlight QL-326 (device) and press .
Connected is displayed next to the QL-326 entry.
4 Press repeatedly until the measurement display appears
The function bar at the bottom of the measurement display, has a double assignment - this can be recognized by
two arrows on the right-hand side of the screen.
Press to switch between the assignments:
In the operating mode ramp and sine the commands START and STOP appear on the function bar
In the operating mode manual, the commands START and STOP and a status display appear on the function
bar

The special function bars contain the following functions:
START Starts the load valve.
Yellow: The loading section can be started.
Green: The load valve has started and is running.
STOP Stops the load valve. The valve of the load valve is opened and the full flow rate
flows through the load valve.
Yellow: The load valve has started and can be stopped.
Red: The load section has not started. The key has no function.
Set the position of the proportional valve – decrease the flow restriction
(only in operating mode manual)
Set the position of the proportional valve – increase the flow restriction
(only in operating mode manual)
STOP Freezes the measurement display.
When you have finished your measuring, you can deactivate the load valve again.
Saving measurement results
To save measured data, use the submenu Memory in the MultiSystem 5060 Plus.
1
Select the used CAN channels for storage.
2
Define additional channels for storage, if necessary.
3
Define the storage time and the sampling rate.
4
When using the load valve, the use of Trigger 1 with the corresponding trigger
value is useful and helpful.
Further information on the topic of storing, formatting and displaying measurement data and series can be found
in the operating manual of the MultiSystem 5060 Plus.

With the MultiSystem 5070, you can program the electronically controlled load valve HySense QL 326 and
operate it in various operating modes.
Activating the CAN-BUS
Start the MultiSystem 5070 and activate the CAN #1 bus in the menu "Connections". Set the baud rate
to 125kBit/s. With F5 (OK) you leave the menu.
1 Press to open the menu.
2 Use to highlight Setting and press .
3 Use to highlight Device and press .
4 Use to highlight Connections and press .
5 Use to highlight CAN #1 and press .
6 Use to highlight Interface and press tACTIVE.
7 Use to highlight Power Supply and use and to switch to OFF.
8 Use to highlight Bus termination and press and switch to YES.
9 Use to highlight Baudrate and press and switch to 125kBit/s.
10 The Start CANopen entry is not relevant for the operation of the load valve.
11 Exit folder using F5 .
Starting the application Load valve
Select the menus "Extras", "Special applications" always open the menus by selecting . Select the
menu "Load valve".
1 Press to open the menu.
2 Use to highlight Extras and press .
3 Use to highlight Special Applications and press .
4 Use to highlight Load valve and press .
You are now in the "Load valve" application.
5OP ERATION WITH MS 5070