hydraulic magnet generator hmg pro and valve user manual v1 6

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com 3

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You have just purchased DYNASET hydraulic equipment!

The equipment allows you to maximize the productivity and efficiency of your mobile machine. Read this User Manual before using your new equipment. It contains important information that will help you to take the full advance of the technical features avaible in your equipment.

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Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com

1. GENERAL 91.1. PRODUCT INFORMATION 91.2. PRODUCT IDENTIFICATION KEY 91.3. TYPE PLATE 101.4. HMG/CMG PRO’S LINE-UP 101.5. MAIN COMPONENTS OF HMG/CMG PRO 121.6. IP (Ingress Protection) CLASSIFICATION 14

2. SAFETY 152.1. SAFETY PRECAUTIONS 152.2. SAFETY EQUIPMENT 162.3. OPERATING SAFETY 172.4. MAINTENANCE SAFETY 182.5. WARNING LABELS 19

3. OPERATING PRINCIPLES 213.1. OPERATING DESCRIPTION 213.2. PERFORMANCE OF AUTOMATIC RPM-CONTROL 223.3. PRESSURE POWER RATIO 223.4. MAGNETIZATION AND DEMAGNETIZATION 233.5. THE DISPLAY OF THE MAGNET GENERATOR 23

4. INSTALLATION 254.1. BEFORE INSTALLATION 254.1.1. HYDRAULIC SYSTEM OF A BASE MACHINE 254.1.2. DYNASET VALVES 324.2. INSTALLING DYNASET HYDRAULIC PRODUCT 334.2.1. PLACING DYNASET HYDRAULIC PRODUCT 334.2.2. INSTALLING DYNASET VALVES 334.2.3. CONNECTING HYDRAULIC HOSES 334.2.4. HYDRAULIC FLUIDS 354.3. INSTALLATION OF THE HMG/CMG PRO 354.3.1. PLACEMENT 354.3.2. ATTACHMENT PLATE FOR CMG PRO 364.3.3. GROUNDING 374.3.4. IP CODE REQUIREMENTS 384.4. OUTPUT VOLTAGE INSPECTION AT START-UP 384.5. HGM/CMG PRO CONTROL CARD SETTINGS 404.5.1. DIP SWITCH SETTINGS FOR THE MASTER CONTROL CARD 40

HYDRAULIC MAGNET GENERATORS

TABLE OF CONTENTS


4.5.2. DIP SWITCH SETTINGS FOR SLAVE CARDS 404.6. WIRE SIZES AND WIRING FOR THE HMG/CMG CABLES 424.7. OPTIONAL ELECTRIC ACCESSORIES 444.8. MAGNET COMPATIBILITY TABLE 454.8.1. MEASURING MAGNET’S RESISTANCE 45

5. OPERATION 475.1. OPERATING THE HMG/CMG PRO 475.2. DISPLAY OF THE HMG/CMG PRO 485.3. HOW TO STOP THE HMG/CMG PRO 495.4. OVERHEAT, OVERLOAD AND OTHER ERROR SITUATION 495.5. AMBIENT TEMPERATURE 50

6. MAINTENANCE 516.1. MAINTENANCE INTERVALS 516.2. HYDRAULIC FLUIDS 516.3. CLEANING THE HMG/CMG PRO 526.4. REPLACING CONTROL CARD 546.5. OUTPUT VOLTAGE ADJUSTING 566.6. TROUBLESHOOTING 59

7. MANUFACTURER’S LIMITED WARRANTY 65

8. PRODUCT DISPOSAL 67

9. DECLARATION OF CONFORMITY 69

10. TECHNICAL SPECIFICATIONS 71


TABLE OF CONTENTS


Picture 1: HMG/CMG PRO Identification key. 9Picture 2: Type plate 10Picture 3: HMG PRO models line-up 11Picture 4: CMG PRO model 11Picture 5: Main components of HGM PRO 12Picture 6: Main components of CMG PRO 13Picture 7: HMG PRO 10 operating principle 21Picture 8: Automatic RPM-control 22Picture 9: Pressure/Power chart 22Picture 10: Open centre hydraulic system with load sensing variable displacement pump 26Picture 11: Connection figure for open centre hydraulic system with load sensing variable displacement pump 27Picture 12: Closed centre hydraulic system with load sensing variable displacement pump 28Picture 13: Connection figure for closed centre hydraulic system with load sensing variable displacement pump 29Picture 14: Open centre hydraulic system with constant displacement pump 30Picture 15: Connection figure for open centre hydraulic system with fixed displacement pump 31Picture 16: LSV Load sensing valve 32Picture 17: PV-SAE Priority valve 32Picture 18: Placing dynaset product 33Picture 19: Installing hydraulic hoses 33Picture 20: Hydraulic flow at nominal 34Picture 21: Base machine’s pumps 34Picture 22: Return line (T) pressure must be under 5 bars. 34Picture 23: Placement of the HMG/CMG PRO hydraulic magnet generator. 35Picture 24: Attachment plate for CMG PRO 36Picture 25: Grounding the HMG/CMG PRO hydraulic magnet generator 37Picture 26: IP classification requirements 38Picture 27: Starting HMG/CMG PRO 38Picture 28: Adjusting voltage 39Picture 29: Location of the DIP switches on the control card 40Picture 30: MASTER card DIP switches 40Picture 31: MASTER and SLAVE card order 41Picture 32: SLAVE card DIP switches 41Picture 33: Wiring for the cable from the generator to the magnet 42Picture 34: Control wire plugs 43Picture 35: HMG PRO Control wiring 43Picture 36: Protected booms socket and 20m cable to the magnet generator 44Picture 37: DYNASET MAG 45Picture 38: Measuring resistance from the magnet 45Picture 40: Hydraulic operation method 47Picture 41: Operating the magnetization by controlling magnet generator’s magnetizing voltage 48Picture 42: Generator’s voltage on the display 48Picture 43: O.HEA on the Display 49Picture 44: Power take off in higher temperatures 50Picture 45: Cleaning the HMG/CMG PRO 52Picture 46: Removing control card 54Picture 47: Apply the thermal paste 55


TABLE OF PICTURES


Kuva 48: Installation of control box cover. 55


TABLE OF PICTURES



GENERAL

1. GENERAL

This manual contains general information about the assembly, installation, operation and maintenance of the DYNASET HMG/CMG PRO hydraulic magnet generators.

ATTENTION!Read this operating manual before installation, use or maintenance of the HMG/CMG PRO hydraulic magnet generator, to ensure proper, installation, handling, operation and maintenance right from the beginning. Pay attention to the warning and safety instructions. Read more at “2. SAFETY” on page 15

1.1. PRODUCT INFORMATION

HMG/CMG PRO hydraulic magnet generators are compact and integrated all-in-one units, designed especially for mobile equipment. HMG/CMG PROs use hydraulic power source to operate and produce high quality electricity for magnetization.

1.2. PRODUCT IDENTIFICATION KEY

HMG/CMG PROs are identified by identification key. The key can be found from the products type plate which is attached on to HMG/CMG PRO side.

Picture 1: HMG/CMG PRO Identification key.

1. Product category HMG/CMG PRO Hydraulic magnet generators.

2. Generator’s theoretical power output in kW.

3. Generator’s output voltage for magnetizing is 220 VDC.

4. Nominal hydraulic flow. Theoretical hydraulic flow of the base machineneeded to operate the product.

5. Auxiliary power outputs are available for HMG PRO as an option by request.

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com10


GENERAL

1.3. TYPE PLATE

Picture 2: Type plate1. Product identification key

2. Product code

3. Serial number

4. Minimum hydraulic flow

5. Maximum hydraulic pressure

6. Production month / year

7. Output power / voltage

8. Manufacturer’s contactinformation

1.4. HMG/CMG PRO’S LINE-UP

DYNASET hydraulic magnet generator’s come in two main models HMG PRO and CMG PRO.

HMG PRO models are operated through an external control typically from the base machine’s cabin. There are two ways you can operate the HMG PRO.

1. Control the magnetization through the HMG PRO control box. In this modethe hydraulic flow is on at all the time and the operator switches magnetizationon and off separately.

2. Control the hydraulic flow. In this mode the magnetization starts when theoperator turns hydraulic flow ON to the magnet generator. Demagnetizationbegins when the hydraulic flow is stopped to the unit.

CMG PRO can only be operated by opening the hydraulic flow to the generator. As the hydraulic flow is opened to the CMG PRO the magnetization begins.



GENERAL

STANDARD MODELS

DYNASET HMG/CMG PROs come in eight standard models. They variate by their maximum generator power (3-40kW). The models can also be categorized through their looks and appearance into five different categories as shown in the picture 3.

Picture 3: HMG PRO models line-up

1. HMG/CMG PRO 3 kW 220 VDC

2. HMG/CMG PRO 6 kW 220 VDC HMG/CMG PRO 10 kW 220 VDC

3. HMG/CMG PRO 12 kW 220 VDC



CMG models are similar to the HMG PRO models but have cable power outlet instead of socket and no electrical control sockets as shown in the below. CMG PRO Generators are also equipped with hydraulic accumulator to withstand up to 50 bar pressure in the return line.

Picture 4: CMG PRO model



GENERAL

1.5. MAIN COMPONENTS OF HMG/CMG PRO

HMG PRO

Picture 5: Main components of HGM PRO

1. Type plate1

2. Serial number1

3. Hydraulic pressure line (P)

4. Hydraulic return line (T)

5. Hydraulic motor

6. Electric sockets in HMG PRO/Cable connection in CMG PRO

7. Solenoid valve plug

8. Control voltage plug

9. Digital display

1 Place may vary between models



GENERAL

CMG PRO

Picture 6: Main components of CMG PRO

1. Type plate1

2. Serial number1

3. Hydraulic pressure line (P)

4. Hydraulic return line (T)

5. Hydraulic motor

6. Hydraulic accumulator

7. Cable connection

8. Digital display

9. Attachment plate

1 Place may vary between models



GENERAL

1.6. IP (Ingress Protection) CLASSIFICATION

HMG/CMG PRO hydraulic generators are IP classified according to the IEC standard 60529 for the degrees of protection of electrical equipment. The protection class of standard HMG/CMG PRO hydraulic generators complies with the specifications of the IP23.

From the IP classification guide you can check your IP class information.



SAFETY

2. SAFETY

2.1. SAFETY PRECAUTIONS

ATTENTION!Operator and maintenance personnel must act in compliance with the laws, regulations and recommendations issued by the local electricity and work safety authorities.

ATTENTION!All installations and maintenance must be performed according to this manual. All electrical installations and maintenance that is not shown in this manual should only be performed by a qualified electrician.

WARNING

RISK OF ELECTRIC SHOCK!

Risk of electric shock. Do not remove any covers when operating. All the repairs must be done by a qualified electrician.

RISK OF ELECTRIC SHOCK.

Operating voltage of the HMG/CMG PRO hydraulic magnet generators is 220 VDC

WARNING

HIGH PRESSURE OIL!

Can cause severe injuries.Always wear appropriate clothing and safety equipment.



SAFETY

The hydraulic system is pressurized up to 420 bar. The pressure in hydraulic circuits of HMG/CMG PRO hydraulic magnet generator is considerably high. Therefore the technical condition of your equipment should be kept under constant observation.

All couplings, valves and hoses should be maintained tight and kept clean. Leaks in the hydraulic system must be fixed immediately to avoid injuries caused by high pressure and oil blowouts.

WARNING

MAGNETIC FIELD INTERFERENCE

Magnetic �eld may interfere and damage electronics nearby. Do not use near medical implants or electronics. Keep safe distance according the magnet manufacturer.

Magnet produces a strong magnetic field that interferes with electronic devices. Do not use electronic devices near the magnet.

NOTE!Technical condition of your machinery and equipment must be subjected to constant surveillance.

2.2. SAFETY EQUIPMENT

When operating in the immediate vicinity of the HMG/CMG PRO hydraulic magnet generator or its accessories, wear appropriate protective clothing, safety goggles, gloves, ear and eye protection.



SAFETY

2.3. OPERATING SAFETY

WARNING

RISK OF BURNS!

The unit parts and oil can be hotter than 80°C!

Wear personal safety equipment!

ATTENTION!Maximum load must never be exceeded.

WARNINGRISK OF ELECTRIC SHOCK!Do not unplug the magnet cable from the generator when the magnet is powered on! Unplugging the cable will cause an electric arc that can cause a severe or fatal injury. Always stop the generator and wait for the magnet to discharge before unpluggin it from the generator.


Never get under the magnet when operating. The collected metals might drop due to a failure in the base machine or in the HMG/CMG PRO system. Remember to keep the safe distance and stay outside of the base machines reach.

Ensure also that the magnetic field does not interfere and damage other electrical and electronic equipment and instrumentation. For the duration of using the magnet, switch off and unplug all sensitive electric and electronic units. Such units are e.g. AC-chargers, electronic sensors, control and measurement instruments.



SAFETY

2.4. MAINTENANCE SAFETY

NOTE!When carrying out any maintenance to HMG/CMG PRO hydraulic magnet generator keep the components of the system clean. This is to ensure safe, reliable and longlife operation of your equipment.

Hydraulic system of the base machine should be maintained according to the machine’s service program. READ CHAPTER “6.1. Maintenance Intervals” for more information.

WARNING

RISK OF ELECTRIC SHOCK!Wait until the charge of the electric parts is completely discharged before removing any covers.

Stop and wait at least 30 minutes for a proper discharge.


30min

Prior to the maintenance, detaching from the base machine or disassembling HMG/CMG PRO hydraulic magnet generator, the hydraulic system of the base machine have to be stopped and the hydraulic circuit depressurized.



SAFETY

2.5. WARNING LABELS

Warning labels are included with each main product.

Product recipient is obligated to place warning labels on the DYNASET product.Attach labels to visible and appropriate place on to or close to DYNASET product where it’s easily seen. Clean surface with solvent detergent before attaching labels.

USE EAR PROTECTIONAND SAFETY GOGGLES

READ OPERATINGINSTRUCTIONS

WEAR GLOVES WEAR SAFETY BOOTS

BEWARE THE HOTSURFACE

RISK OF ELECTRIC SHOCK

RISK OF MEDICAL EQUIPMENT FAILURE

BEWARE THE MAGNETIC FIELD

HIGH PRESSUREOIL



OPERATING PRINCIPLES

3. OPERATING PRINCIPLES

3.1. OPERATING DESCRIPTION

Picture 7: HMG PRO 10 operating principle

1. Starting the HMG/CMG PRO happens by opening the the hydraulic flow to the RPM-valve block. The RPM-valve keeps the flow constant and controls the speed of the hydraulic motor through the RPM-cartridge.

2. Hydraulic motor actuates the alternator’s rotor through a direct connection to the rotor. When the rotor spins it produces a changing magnetic flux that generates electricity.

3. From the stator windings the electricity is directed through the distribution box on to the generators control box.

4. When the magnetizing button is pressed on the generator produces 220 VDC to magnetize the magnet.




3.2. PERFORMANCE OF AUTOMATIC RPM-CONTROL

The RPM-cartridge maintains rotation speed of the hydraulic motor constant (±5 %). Even when incoming hydraulic flow (Q) can vary from minimal flow (Qmin) by exceeding it up to 20-30%, depending on the HMG/CMG PRO ‘s size, the hydraulic motors rpm is kept stable (±5 %).

Picture 8: Automatic RPM-control

3.3. PRESSURE POWER RATIO

Following chart in picture below describes the power to pressure ratio. The chart shows output powers relation to the pressure, when the hydraulic flow Q is kept constant. The best power to pressure ratio is achieved when the pressure is at nominal level, little under the maximum value. READ CHAPTER “10. TECHNICAL SPECIFICATIONS” for more information of each models nominal pressure.

Picture 9: Pressure/Power chart




3.4. MAGNETIZATION AND DEMAGNETIZATION

Magnetization and demagnetization are controlled electronicly by the HMG/CMG PRO control unit. The electronic control enables the magnet to demagnetize in 0,8s.

3.5. THE DISPLAY OF THE MAGNET GENERATOR

The display shows the steps of the magnetization, magnetizing voltage and error messages. Magnetization steps are described in READ CHAPTER “5.3. How to stop the HMG/CMG PRO” for more information. The error messages are described in READ CHAPTER “6.6. Troubleshooting” for more information.


INSTALLATION


4. INSTALLATION

4.1. BEFORE INSTALLATION

ATTENTION!Read these instructions before installation of the DYNASET product!

4.1.1. HYDRAULIC SYSTEM OF A BASE MACHINE

Base machines have different types of hydraulic systems. The most common hydraulic systems in mobile machinery are:

• Open centre hydraulic system with a Load Sensing variable displacement pump

• Closed centre hydraulic system with a Load Sensing variable displacement pump

• Hydraulic system with a fixed displacement pump

Before installing the DYNASET product, find out the type of the hydraulic system of your machine.

If you are unsure of the hydraulic system, please contact the manufacturer of your base machine.

Next three paragraphs describe the hydraulic systems in more detail.


INSTALLATION


OPEN CENTRE HYDRAULIC SYSTEM WITH LOAD SENSING VARIABLE DISPLACEMENT PUMP

Picture 10: Open centre hydraulic system with load sensing variable displacement pump

In open centre hydraulic system the flow is returned to tank through the control valves open centre; that is, when the control valve is centered. It provides an open return path to tank and the fluid is not pumped into a high pressure. In variable-displacement pump, the flow rate and output pressure adjusts automatically based on the load of the hydraulic system.


INSTALLATION


Picture 11: Connection figure for open centre hydraulic system with load sensing variable displacement pump

1. DYNASET hydraulic equipment

2. DYNASET Priority valve PV-SAE

2.1. DYNASET PC-SAE pressure compensator

2.2. DYNASET LSV Load Sensing valve

3. Base machine’s variable displacement pump

4. Open centre directional control valves

5. Oil cooler

6. Oil filter

7. Oil tank


INSTALLATION


CLOSED CENTRE HYDRAULIC SYSTEM WITH LOAD SENSING VARIABLE DISPLACEMENT PUMP

Picture 12: Closed centre hydraulic system with load sensing variable displacement pump

In a closed centre hydraulic system the oil flow is stopped from the pump when control valve is centered. The pump can rest when the oil is not required to operate a function. In variable-displacement pump, the flow rate and output pressure adjusts automatically based on the load of the hydraulic system.


INSTALLATION


Picture 13: Connection figure for closed centre hydraulic system with load sensing variable displacement pump


2. DYNASET LSV Load Sensing valve

3. DYNASET Shuttle valve

4. Base machine’s variable displacement pump

5. Closed centre directional control valves

6. Oil cooler

7. Oil filter

8. Oil tank


INSTALLATION


HYDRAULIC SYSTEM WITH FIXED DISPLACEMENT PUMP

Picture 14: Open centre hydraulic system with constant displacement pump

In hydraulic system which has the fixed displacement pump, the oil flow from the pump is fixed. Every stroke of the hydraulic motor moves the same amount of oil. The output flow is function of the motor’s rpm and pump’s displacement.


INSTALLATION


Picture 15: Connection figure for open centre hydraulic system with fixed displacement pump


2. DYNASET Priority valve PV-SAE

2.1. DYNASET PC-SAE pressure compensator

2.2. DYNASET LSV Load Sensing valve

3. Base machine’s fixed displacement pump

4. Open centre directional control valves

5. Oil cooler

6. Oil filter

7. Oil tank


INSTALLATION


4.1.2. DYNASET VALVES

DYNASET valves are designed to enable easy installation of your DYNASET hydraulic product.

DYNASET LSV LOAD SENSING VALVE

Picture 16: LSV Load sensing valve

DYNASET LSV load sensing valves are made for installations in a closed centre hydraulic systems.

DYNASET PV-SAE PRIORITY VALVE

Picture 17: PV-SAE Priority valve

DYNASET PV- SAE priority valve enables the installations of the DYNASET products into any hydraulic system.


INSTALLATION


4.2. INSTALLING DYNASET HYDRAULIC PRODUCT

4.2.1. PLACING DYNASET HYDRAULIC PRODUCT

Place the DYNASET hydraulic product where there is an easy access to the unit. Ensure proper ventilation.

Picture 18: Placing dynaset product

NOTE!When positioning the HMG/CMG PRO hydraulic magnet generator, ensure that the air venting is sufficient. READ CHAPTER “4.3.1. Placement” for more information.

4.2.2. INSTALLING DYNASET VALVES

Installation instructions can be found in the DYNASET LSV or DYNASET PV SAE installation manual.

4.2.3. CONNECTING HYDRAULIC HOSES

Pressure (P) and return (T) lines of a hydraulic system are connected to the DYNASET units corresponding hydraulic ports.

Picture 19: Installing hydraulic hoses


INSTALLATION


Ensure that the hydraulic flow of the base machine is sufficient to run the unit. At least the minimal flow must be available. READ CHAPTER “10. TECHNICAL SPECIFICATIONS” for more information.

Picture 20: Hydraulic flow at nominal

In case of the hydraulic flow being too high, it must be reduced. The flow can be reduced either by lowering the rotation speed of base machine’s hydraulic pump or using flow limiter valve. DYNASET priority valve is recommended.

Picture 21: Base machine’s pumps

Return line must be connected to a hydraulic oil tank directly in the shortest possible line in order to keep the return hydraulic pressure under 5 bar in the tank line. Generally DYNASET’s return line(T) is to be connected directly to the return line of a hydraulic system. CMG PRO Hydraulic Magnet Generators can withstand up to 50 bar of pressure in the return line.

ATTENTION!Ensure that the filtering degree and cooling capacity of the hydraulic system are sufficient. READ CHAPTER “10. TECHNICAL SPECIFICATIONS” for more information.


INSTALLATION


4.2.4. HYDRAULIC FLUIDS

To use proper hydraulic fluid READ CHAPTER “6.2. Hydraulic fluids” for more information.

4.3. INSTALLATION OF THE HMG/CMG PRO

4.3.1. PLACEMENT

DYNASET HMG/CMG PRO hydraulic magnet generator can be connected to the original hydraulic system of any base machine. It can be installed to a place where sufficient venting and easy access to the HMG/CMG PRO is ensured. The position of the generator must be horizontal.

Picture 22: Placement of the HMG/CMG PRO hydraulic magnet generator.

A. Minimum 25 mm B. Minimum 50 mm

NOTE!Sufficient venting is important. HMG/CMG PROs components heat up during the use. Maintain the generator accordingly and keep the vents open and clean.

An additional oil cooler is required when HMG/CMG PRO unit is installed to a truck with and a hydraulic hoist. Ensure that the cooling capacity of your hydraulic system is sufficient. READ CHAPTER “10. TECHNICAL SPECIFICATIONS” for more information.


INSTALLATION


4.3.2. ATTACHMENT PLATE FOR CMG PRO

For CMG PRO 3-12 kW models there are attachment plates available which helps to install the CMG PPRO on magnets.

Picture 23: Attachment plate for CMG PRO

MODEL DIMENSIONS, mm (in)

a b c d e f g h i

CMG PRO 3kW-220VDC-21 283(11.1)

454 (17.9)

198(7.8)

370(14.6)

196(7.7)

230 (9.1)

100(3.9)

10(0.4)

19(0.7)

CMG PRO 6kW-220VDC-34 240(9.4)

605(23.8)

130(5.1)

540(21.3)

170(6.7)

545(21.5)

163(6.4)

40(1.6)

5(0.2)

CMG PRO 10kW-220VDC-49

204(8.0)

695(27,4)

124(4.9)

610(24.0) - - 164

(6.5)25

(1.0) -

CMG PRO 12kW-220VDC-59

260(10.2)

665(26.2)

180(7.1)

585(23.0) - - 65

(2.6) - 40(1.6)


INSTALLATION


4.3.3. GROUNDING

ATTENTION!DYNASET HMG/CMG PRO must be grounded when the rubber cushions or plastic pads are installed to the HMG/CMG PRO’s framework. Grounding is also recommended when the generator is installed onto the base machine without rubber cushions or plastic pads.

Do not ground the HMG/CMG PRO hydraulic magnet generator through hydraulic connections. Make the grounding only to the base machines frame. Use external galvanized wire to gain proper grounding as shown in the picture below. The ground wire size/gauge is to be selected according to the following table.

The ground wire is recommended to be according to the following table. Generator size S (kW) Ground wire cross-section area (mm2)

S < 10 kW 2.5 mm2 (13AWG)

10 < S < 20 kW 4 mm2 (11AWG)

20 < S < 40 kW 6 mm2 (9AWG)

S ≥40 kW 10 mm2 (7AWG)

Ground the generator from the marked grounding spot in generators frame. Grounding spot of the HMG PRO 10 is shown in the picture below. The grounding spot varies between different generator models.

Picture 24: Grounding the HMG/CMG PRO hydraulic magnet generator

4.3.4. IP CODE REQUIREMENTS

Dynaset products with the IP class IP23 must be installed into a place where water can’t enter the generator from below or from the sides according to the IP23 classification


INSTALLATION


Picture 25: IP classification requirements

4.4. OUTPUT VOLTAGE INSPECTION AT START-UP

HMG/CMG PROs are tested and adjusted at the factory but it is recommended to check the DC voltage before taking the HMG/CMG PRO into operation.

1. Ensure that the generator is properly connected to the hydraulic system ofyour base machine and there are no oil leakages in the system.

2. Start the engine of your base machine. Adjust the engine speed to demanded level if necessary.

3. Start the generator by opening the hydraulic flow to the generator.

4. Turn on the magnet:

Picture 26: Starting HMG/CMG PRO

A. HMG PRO: Turn the magnet ON with ON/OFF switch.

B. CMG PRO: magnetization starts immediately when the the hydraulic flow isopened to the generator.


INSTALLATION


5. Check the voltage from generator’s display. The voltage should be 220VDC±5%.

Picture 27: Adjusting voltage

6. Adjust the voltage if necessary. READ CHAPTER “6.5. Output voltage adjusting” for more information.

NOTE!DYNASET HMG/CMG PRO hydraulic magnet generators are tested and adjusted at the factory! Do not adjust the voltage without real need.


INSTALLATION


4.5. HGM/CMG PRO CONTROL CARD SETTINGS

Control mode settings for control cards are made with the following instructions with DIP-switches located on a control card as shown in the picture below.

Picture 28: Location of the DIP switches on the control card

4.5.1. DIP SWITCH SETTINGS FOR THE MASTER CONTROL CARD

Picture 29: MASTER card DIP switches

Switch 1 select the master function.Switch 2 selects generator type HMG PRO or CMG PRO.Switch 3 Do not touch. internal function.Switch 4 Do not touch. internal function.

4.5.2. DIP SWITCH SETTINGS FOR SLAVE CARDS

Depending on the size of the HMG/CMG PRO generator, control units can be equipped with more than one control card. The following instructions are for the models where two or more control cards are used.

HMG PRO 12 - 20kW has two (2) cards. HMG PRO 30kW has three (3) and HMG PRO 40kW has four (4) cards.


INSTALLATION


NOTE!The MASTER card is installed on the right side and SLAVE card to the left side of the control unit as shown in the picture below.

Picture 30: MASTER and SLAVE card order

1. MASTER card 2. SLAVE card

Picture 31: SLAVE card DIP switches

Switch 1 select the slave function.Switch 2 selects generator type HMG PRO or CMG PRO.Switch 3 Do not touch. internal function.Switch 4 Do not touch. internal function.


INSTALLATION


4.6. WIRE SIZES AND WIRING FOR THE HMG/CMG CABLES

MAGNET CABLE

Following table contains the recommended sizes for the output cables and sockets when using the HMG/CMG PRO.

MODEL CABLE SIZE SOCKET SIZE

HMG/CMG PRO 3 kW 5 x 2,5mm2 (3 x 6mm2) 13AWG5 (9AWG3) 5 x 16 A

HMG/CMG PRO 6 kW 5 x 2,5mm2 (3 x 6mm2) 13AWG5 (9AWG3) 5 x 16 A

HMG/CMG PRO 10 kW 5 x 6mm2 (3 x 10mm2) 9AWG5 (7AWG3) 5 x 16 A

HMG/CMG PRO 12 kW 5 x 6mm2 (3 x 10mm2) 9AWG5 (7AWG3) 5 x 32A





If you are using an another kind of cable, ensure the proper cable size.

Picture 32: Wiring for the cable from the generator to the magnet


INSTALLATION


HMG PRO CONTROL CABLES

HMG PRO has two control cables. Control voltage cable to opearate the magnetizing and solenoid voltage cable to start the Hydraulic flow to the HMG PRO generator.

Picture 33: Control wire plugs

A. Control voltage plug B. Solenoid voltage plug

Wire the control cables by the following wiring schema:

Picture 34: HMG PRO Control wiring

Solenoid cables “Potential free NO contact” can be used for e.g. excavators hydraulic system to detect and inform the rest of the system that the generator needs hydraulic flow.

Recommended cable size:CABLE SIZE

0,75mm2 18AWG

DYNASET also offers an optional HMG PRO Control wiring kit for control cables. More information about the Control wiring kit can be found from chapter “4.7 Optional electric accessories”.


INSTALLATION


4.7. OPTIONAL ELECTRIC ACCESSORIES

Optional DYNASET magnet cable kit can be purchased for connecting DYNASET HMG PRO to the magnet. Also optional HMG PRO control wiring kit is available to enable the external control connections.

HMG PRO MAGNET CABLE KIT

Magnet’s wiring kits is suitable for all of the HMG PRO units the kit includes

1. Socket with a protective cover, to be fitted to a boom

2. 20 m cable from the booms socket to the generator’s socket, with a plug.

Picture 35: Protected booms socket and 20m cable to the magnet generator

HMG PRO CONTROL WIRING KIT

HMG PRO control wiring kit is available for all externally controlled HMG PRO units. The kit includes:

• control switch for the magnet,

• generator’s starting switch,

• plugs for generator and solenoid valve,

• magnetization signal light and

• cables (5m)

Switches can be placed on a dashboard or to any other suitable place.

Wiring kit contains signal light to show the magnetizing phase.

• When the magnet is magnetized the indicator light will turn on

• When the demagnetization is on the indicator light will turn off


INSTALLATION


4.8. MAGNET COMPATIBILITY TABLE

The following table shows an appropriate lifting magnet for different HMG/CMG PRO models. Suitable DYNASET MAG lifting magnets are also listed. Coil resistance values are measured at +20oC temperature.

GENERATOR MODEL

MAGNET RESISTANCE

RECOMMENDED LIFT MAGNET TYPE

General DYNASETMin MaxHMG/CMG PRO 3 kW 15 100 2,5 kW MAG 700

HMG/CMG PRO 6 kW 8,8 100 5,1 kW MAG 900







Picture 36: DYNASET MAG

4.8.1. MEASURING MAGNET’S RESISTANCE

Magnet’s resistance can usually be measured between the magnets + and - poles as shown in the picture. Check the correct way to measure resistance from the magnet’s manual or take contact to the magnet’s manufacturer.

Picture 37: Measuring resistance from the magnet



OPERATION

5. OPERATION

ATTENTION!Check the HMG/CMG PRO hydraulic magnet generator and its hoses condition before use to ensure there are no leaks or damages.

After having ensured the proper mechanical and hydraulic installation of the HMG/CMG PRO unit, plug the magnet into the generator’s socket with a suitable cable (Dynaset cable kit recommended).

5.1. OPERATING THE HMG/CMG PRO

WITH HYDRAULIC CONTROL

1. Start base machines engine and move the magnet to the working area.

2. Open the hydraulic flow to the unit and the HMG/CMG PRO begin the magnetization.

Picture 40: Hydraulic operation method

NOTE!The switch has to be pressed on at all the time between the collection and the dropping of metals to enable magnetization.

3. Release the control switch to demagnetize and drop the collected metals.



OPERATION

WITH EXTERNAL CONTROL

1. Start machine’s engine and move the magnet to the working area.

2. Open the solenoid valve of the HMG PRO with the assigned switch.

HMG PRO generator is ready for the use when the hydraulic flow and the pressure achieve the minimum level. Generator is running constantly in this installation when the pressure line is open.

3. Activate the magnet by pressing the assigned switch once.

4. To drop the collected material, press the same switch again to demagnetize the magnet.

Picture 41: Operating the magnetization by controlling magnet generator’s magnetizing voltage

5.2. DISPLAY OF THE HMG/CMG PRO

The display shows the magnetizing voltage and error messages. READ CHAPTER “6.6. Troubleshooting” for more information about the error messages.

When the magnetizing is started the magnetizing voltage is shown on the dispaly.

Picture 42: Generator’s voltage on the display



OPERATION

5.3. HOW TO STOP THE HMG/CMG PRO

Stop the HMG PRO by switching off the hydraulic flow to the generator.

CMG PRO shuts off when the button enabling the hydraulic flow to the generator is released.

5.4. OVERHEAT, OVERLOAD AND OTHER ERROR SITUATION

HMG/CMG PRO’s alternator and control card are equipped with a temperature measuring circuit. In overheat situations the error message O.HEA shown on the display.

In control unit’s overheating situations, control electronics prevent the HMG/CMG PRO to magnetize the magnet until the temperature in control unit drops.

When alternator’s temperature switch trips, the magnetization should be switched off in order to cool HMG/CMG PRO generator as fast as possible.

After few minutes, when the HGM/CMG PRO generator has cooled down, the unit automatically switches the overheat alarm off and is operable again

Other error messages are described in the chapter “6.6. Troubleshooting” on page 59.

NOTE! Check and obey the magnet manufactures load duty value (ED). Exceeding of the ED-value causes HMG/CMG PRO to overheat ! in need of more information about the ED-value take contact to magnet’s manufacturer.

Picture 43: O.HEA on the Display



OPERATION

5.5. AMBIENT TEMPERATURE

To avoid the power loss, it is not recommended to use the HMG/CMG PRO when the ambient temperature exceeds +40 ºC. When the ambient temperature exceeds +40 ºC power takeoff should be limited in accordance with the attached diagram in picture below, e.g. for instance, at the ambient temperature of +50 ºC the power takeoff should not be more that 80 % of the maximum.

If the ambient temperature reaches +40 ºC, the HMG/CMG PRO’s full output power can be maintained by adding an additional air ventilation.

Picture 44: Power take off in higher temperatures



MAINTENANCE

6. MAINTENANCEDYNASET HMG/CMG PRO hydraulic magnet generators are low-maintenance units. Only normally wearing parts such as sealings in hydraulics, brush collector and bearings are needed to be replaced when necessary.

ATTENTION!Before beginning any maintenance or repair, ensure that the system is stopped and depressurized. Make sure that the system can not start accidentally.

6.1. MAINTENANCE INTERVALS

All maintenance must be complied as they are scheduled in this manual. The following table provides maintenance schedule for the HMG/CMG PRO.

CHECK POINTS NEW DEVICE AFTER INSTALLATION

AFTER DAILY USE

Perform the needed actions after each HMG/CMG PRO hydraulic magnet generator installation accord-ing to the chapter 4. Installation.

x

Check if the HMG/CMG PRO hydraulic magnet gen-erator need cleaning and clean it according to the chapter 6.3.

x

6.2. HYDRAULIC FLUIDS

Wide range of standard hydraulic fluids can be used with the DYNASET hydraulic equipment. Depending on the operating temperature, following mineral hydraulic oils are recommended:

MINERAL HYDRAULIC OIL OPERATION TEMPERATURE UP TO

ISO VG 32S 60 °C

ISO VG 46S 70 °C

ISO VG 68S 80 °C

NOTE!Recommended oil viscosity is between 10 to 35 cSt when operating at normal operating temperature.

Synthetic and bio oils can also be used if their viscosity characteristics and lubricating efficiency are corresponding to the mineral oils.



MAINTENANCE

Automatic transmission fluids and even engine oils can be used, provided that they are allowed to be used in the hydraulic system of your base machine.

Hydraulic fluid change interval is according to the base machine’s maintenance instructions. To use special hydraulic fluid with DYNASET equipment, please contact nearest DYNASET presentative for an advice.

6.3. CLEANING THE HMG/CMG PRO

ATTENTION!Before beginning any maintenance or repair, ensure that the system is stopped and depressurized. Make sure that the system can not start accidentally.

ATTENTION!Maintain the generator accordingly and keep the vents open and clean. Check your equipment after every work shift.

Picture 45: Cleaning the HMG/CMG PRO



MAINTENANCE

Depending on the operational environment, clean the HMG/CMG PRO as frequently as necessary to maintain it in perfect working condition.

1. Remove the generator’s cover, side screens and the air diffuser.

2. Clean fan, rotor, stator compartments and alternator’s electric components by using compressed air. Ensure that the electric enclosures drain holes are dirt free.

3. After cleaning the generator, place the screens/covers back on and secure them with appropriate screws.

NOTE!Use compressed air to clean your equipment.

Remove all unnecessary grease and oil deposits from the HMG/CMG PRO. Accumulated grease and oil can cause overheating and a potential fire hazard.

ATTENTION! Do not leave anything inside the generator case or control box which does not belong to the assembly.

Check the lids and the covers as well as the screw joints on regular basis, at least once in a week, and tighten them if they are loose. When HMG/CMG PRO is exposed to a noticeable vibration, checking should be done more frequently.

NOTE!Ensure clean venting of the HMG/CMG PRO. Components wearing increases in dusty conditions.



MAINTENANCE

6.4. REPLACING CONTROL CARD

Replace the control card with the following instructions.

NOTE!When replacing control card to multiple card control unit, all control cards must be thesame type version (e.g. EM-xxx) to ensure HMG/CMG PRO stable and correct function.

1. Open the control box cover by unscrewing the screws.

2. Disconnect the wires and plugs from the faulty card. If needed mark the wires and the plugs for the installation to secure them back on to their correct places for the new card.

3. Unscrew all the control card’s screws (5 pcs) and remove the faulty card.

Picture 46: Removing control card

4. Apply the thermal paste provided with the card or quality termal paste to the bottom of the new card



MAINTENANCE

Picture 47: Apply the thermal paste5. Install the new card to its place. Plug on all wires, plugs and screws(5). Tighten

the screws into the 4 Nm torque.

NOTE!Remember to check that the dip switches on the new control card are in correct position. READ CHAPTER “4.5. HGM/CMG PRO control card settings” for more information.

Kuva 48: Installation of control box cover.

6. After installing the new card HMG/CMG PRO, screw the control box cover back on.



MAINTENANCE

6.5. OUTPUT VOLTAGE ADJUSTING

WHEN HMG/CMG PRO IS INSTALLED INTO THE HYDRAULIC SYSTEM WITH A DYNASET INSTALLATION VALVE

ATTENTION!The HMG/CMG PROs are tested and adjusted at the factory. Do not adjust them without real need. Adjust first the base machine’s hydraulic flow at least to the minimum level.

ATTENTION!When measuring the output frequency, act in compliance with the laws, regulations and recommendations issued by the local electricity, work safety authorities and universal multimeter manufacturer.

ATTENTION! Do not adjust the generator when a magnet is connected to it.

NOTE!When doing adjustment, the hydraulic fluid should be at normal operation temperature! READ CHAPTER “6.2. Hydraulic fluids” for more information.

Turn the generator on and ensure that the hydraulic flow is atleast at the minumum level. When the hydraulic flow is at the proper level, set the voltage by adjusting the RPM-cartridge with following instructions.

1. Loose the locknut A.

2. Adjust the adjusting screw B according to the voltage shown on thegenerator’s display. Due to the response time make only a small adjustment ata time and wait for the generator to level its speed before turning the screw Bmore. Do not make more than quarter revolution turns at the time!

3. When the voltage has reached the required 220 VDC - tighten the locknut Ato 10 Nm.



MAINTENANCE

During the adjustment U.CUR will blink on the display. This is normal. Do not attach magnet on to the generator while measuring the voltage.

If voltage measurement option is not available, adjustments can be made by measuring the output frequency (50Hz).

WHEN HMG/CMG PRO IS INSTALLED TO THE HYDRAULIC SYSTEM WITHOUT DYNASET INSTALLATION VALVE

ATTENTION!Adjust only with the following instructions when the HMG/CMG PRO is installed to the hydraulic system without a DYNASET installation valve. Otherwise you may damage your HMG/CMG PRO doing the procedure.

Primarely adjust the base machine’s hydraulic flow to the required, atleast minimum level before making any adjustment to the RPM-cartridge. If the voltage is still out of the range, adjust the RPM-cartridge with the following instructions.

1. Adjust the hydraulic flow until the output voltage will achieve the value of 220 VDC. Follow the readings of generator’s display.

If the adjusting does not effect on the output voltage, there is a feed problem



MAINTENANCE

in the base machines hydraulic system that has be fixed before continuing the adjustments.

If the output voltage does change when the adjustments are made to the hydraulic flow, continue with the following instructions.

2. Loose the locknut A.

3. Turn the adjusting screw B counter-clockwise until it starts to control the flow.

4. Then turn the screw B counter-clockwise for a another quarter of revolution.

5. Lock the setting with locknut A tightening it to 10 Nm.



MAINTENANCE

6.6. TROUBLESHOOTING

Performing these maintenance tasks requires a qualified hydraulic mechanic or/and an electrician. Please, contact a DYNASET authorized workshop or a dealer in case of a need for more information.

FAILURE REASON CORRECTIVE ACTION

HMG/CMG PRO GENERATOR IS OILY.

The pressure line is connected while the return line is disconnected and the pressure relief valve leaks the oil.

Check the connection and connect the hoses to their correct places.

MAGNET DOES NOT WORK

Readout is displayed when magnet current is under 2A.

Magnet unplugged or magnet cable is damaged.

Switch off the generator.Check the plug to the magnet. Change the cable if it is damaged.

Magnet is damaged.

Check the coil’s resistance and compare the result to the value indicated in the magnet’s manual. Check also coil’s inductance if possible.

Generator won’t produce 220 VDC.

Turn off the generator.Check whether there is a DC voltage between the control card’s terminals 6 and 7.

If control unit is provided with multiple control cards check the connection between different cards. Check the connection between different card terminals 6 and 7 e.g check if there is a connection between card 1 terminal 6 and card 2 terminal 6 etc. If connection is lost it has to be set back up to clear the problem.

If the connection is in order the control card is broken. Defective card(s) should be replaced.



MAINTENANCE


MAGNET MALFUNCTIONS

O.CUR blinks in turn with time indication countdown from 30 sec to 0 sec.

!WARNING!O.CUR stops the magnet immediately from magnetization. Watch out the dropping collected metals.

O.HEA indicated on a digital display.

SNUB indicated on a digital display.

Magnet shuts down by itself after magnetization is started.

Magnet’s power demand exceeds HMG PROs output. Generator gets overloaded and stopped.

Generator’s output voltage is too high causing overloading.

In single card use: Choose magnet according to HMG PRO’s power output.

With multiple cards: Check first the connection between terminals 6 and 7 between different cards. e.g check if there is a connection between card 1 terminal 6 and card 2 terminal 6 etc. if connection is lost it has to be repaired.

If the connection is in order the control card is broken. Defective card(s) should be replaced.

Magnet’s cable shortcircuits.

Connections in control card short circuit.

Problem outside the generator.

To test the cable shut down the generator, unplug the cable and turn on the generator.

If the generator’s display shows O.CUR, problem is in the control unit’s connections.

If the generator’s display blinks U.CUR/220, the problem is outside the control unit. Then check the frequency (50Hz±5%). Frequency can be measured between terminal 1 and 3 in the control box. If the frequency is ok, then the generator’s hydraulics are in order.

After this measure the AC voltage between all the phases from terminals 1-2,2-3,1-3. If the Voltage is under 170 VAC the problem is in the voltage regulator system and it needs a repair.

The generator is overheating

Ensure proper ventilation and clean the generator. READ CHAPTER “6.3. Cleaning the HMG/CMG PRO” for more information.. Check if the fans are working in the multiple card use.

The generator will turn back on automatically after it has cooled enough.

Failure on the control unit or in the internal wirings.

Measure resistance between control card terminal 8 and 9.

If it is 12 Ohms, the problem is in the control card and it needs to be replaced.

If it is not 12 Ohms the problem is in the resistors. If it is 24 Ohms, one resistor is broken. If it is something else both resistors are broken and need replacing.



MAINTENANCE


There is a shortout in the cable or wiring

Check the cable condition and wiring and rectify.

The ambient temperature is too high.

Increase cooling to the magnet generator.

Faulty current

The control card is in SLAVE mode

Check and setup the control card according to the capter “4.5. HGM/CMG PRO control card settings” on page 40 instructions.

Acceleration alert

The magnet generator has been moved in a pace that sets up the alarm. Do not use the MAgnet as a wrecking ball or in such manner. It will damage the magnet.

Low magnet power.

Check VDC-voltage on the display. If ok, check magnet’s resistance.

If VDC is not ok check the frequency and AC voltage (170VAC) between all phases to the control unit between terminals 1-3. If the frequency is out of range, the problem is in hydraulic system. If the frequency is ok and the AC voltage is not, the prolem is in the generator (not in the control box).

If the frequency is ok, the problem is in the control card.

DEMAGNETIZATION DOES NOT WORK

Control cable or push button malfunction.

Lay magnet down, switch off generator. Check control cable and push button.



MAINTENANCE


LOW OUTPUT VOLT-AGE AT NO LOAD

Poor contact in electric system.

Check all internal contacts and wirings of the generator. Check and clean brushes and slip ring.

OUTPUT VOLTAGE < 20Vac

Excitation rectifiers failure.

Trace the failure and replace the rectifier (with compound or Capasitor voltage regulator).

Voltage regulators failure.

Replace the capacitor.

Check and adjust the air gap of the compound regulator. Replace if broken.

Check and adjust or replace the electronic regulator (HMG/CMG PRO with AVR).

Insufficient residual magnetizm.

Use external 12 V DC battery for 1 - 2 sec. to magnetize the rotor. Warning! Be sure of the polarity of the connected battery. Wrongly con-nected battery can damage the coil. If unsure contact Dynaset After Sales.

LOW OUTPUT VOLT-AGE AND FREQUENCY AT LOAD

The generator is being overloaded.

Reduce the load and check the current I (A) to ensure that the proper load is being applied.

LOW FREQUENCY AT NO LOAD

Too low rotation speed

If frequency is out of range, hydraulic system failure is concerned.

Check whether the hydraulic flow and pressure are sufficient. Adjust RPM-cartridge if neces-sary.

Check the hydraulic motor for possible leakage. Replace motor if necessary.

HIGH FREQUENCY AT LOAD

Too high rotation speed

If frequency is out of range, hydraulic system failure is concerned.

Check whether the hydraulic flow and pressure are sufficient. Adjust RPM-cartridge if neces-sary.

OUTPUT VOLTAGE INSTABILITY

Instable rotation speed of generator

Check generator’s hydraulics, including auto-matic frequency control valve. Make an adjust-ment if necessary.

Check that the hydraulic oil Flow is constant.

Check whether the hydraulic fluid flow and pressure are not excessive. Adjust when neces-sary.

Check the hydraulic motor for possible leakage. Replace motor if necessary.

LOW OUTPUT VOLT-AGE AT LOAD

The generator is being overloaded.

Reduce the load and check the current I (A) to ensure that the proper load is being applied.



MAINTENANCE


GENERATOR CON-SUMES ABNORMAL AMOUNT OF HYDRAU-LIC FLUID

Failure of axial seal-ing in generator’s hydraulic motor.

External indication: hydraulic oil out-flow from ventila-tion grids.

Axial sealing of hydraulic motor broken by reason of excessive pressure in return line (T). Rebuild the return line (T). Maximum allowed pressure in return line is 5 bar. Replace axial sealing of generator’s motor.

Oil leakage from hydraulic motor.

Hydraulic motor worn out and should be replaced.

GENERATOR CON-SUMES ABNORMAL HYDRAULIC PRESSURE AT NO LOAD

Winding failure. One ore more stator winding is in short circuit. Replace generator.

A MILD ELECTRIC SHOCK FROM HY-DRAULIC GENERATOR

Poor hydraulic gen-erator grounding.

Ensure proper grounding cable installation. READ CAPTER “4.3.2 Grounding” for more information.

ABNORMAL NOISE FROM GENERATOR

Bearing failure. Replace broken/worn bearing.

Broken fan. Replace broken/worn fan.



WARRANTY

7. MANUFACTURER’S LIMITED WARRANTY

1. Warranty coverageAll hydraulic accessories manufactured by DYNASET OY are subject to the terms and conditions of this limited warranty. Products are warranted to the original purchaser to be free from defects in materials or workmanship. Exclusions from warranty are explained in item Exclusions from warranty.

2. Beginning of warranty periodWarranty period begins from the delivery date of the product. Delivery is considered to be done on the date when installation has been accomplished or purchaser has taken the product in use. Product is considered as taken in use at the date when DYNASET OY has delivered the product to purchaser, unless separately agreed otherwise by written agreement.

3. Warranty periodWarranty period is twenty four (24) months based on maximum of 2000 hours usage during this time period. In cases where the system is provided complete with certain special components (e.g. drive unit), those components are considered as a subject to their manufacturer’s warranty.

4. Warranty proceduresImmediately upon identifying a problem which purchaser believes to be a failure subject to the product’s limited warranty, purchaser must contact primary to the seller of the product. Contact must be made as soon as possible, latest thirty (30) days after the problem was identified. Seller and/or manufacturer technical staff determines the nature of the problem primarily by phone or e-mail. Purchaser commits to give necessary information and to perform routine diagnostic procedures in order to determine the nature of the problem and necessary procedures.

5. Warranty repairsIf the product is found to be defective during the warranty period, DYNASET OY will, at its option, either repair the product, author it to be repaired at its authorized workshop or exchange the defective product. If the product must be repaired elsewhere than premises of DYNASET OY or authorized workshop, all costs excluded from this warranty (traveling and waiting hours, daily allowance, traveling expenses and uninstallation/reinstallation costs) will be charged from the purchaser.If the problem is not covered by this limited warranty, DYNASET OY has the right to charge purchaser of troubleshooting and repairing.

6. Delivery terms of warranty repairIf the product is found possible to be defective under this limited warranty and it needs to be repaired, DYNASET OY gives Warranty Return Number (WRN). Items being returned must be shipped, at the purchaser’s cost, adequately packed for shipment, to the DYNASET OY or to other location authored by DYNASET OY.Shipment documents must contain:

• Purchaser’s name and contact information

• Receipt of original purchase

• WRN code

• Problem description



WARRANTY

7. Warranty of repaired productWarranty period of the product repaired under this limited warranty continues to the end of original warranty period.

8. Exclusions from warrantyThis warranty shall not apply to:

• Failures due to normal wear and tear, improper installation, misuse, abuse, negligence, purchaser selection of improper product to intended use, accident, improper filtration of hydraulic oil or intake water or lack of maintenance.

• Cost of maintenance, adjustments, installation or startup.

• Coating, hydraulic oil, quick couplings and interconnection hoses (internal or external to system assemblies).

• Products altered or modified in a manner not authorized by DYNASET OY in writing.

• Products which have been repaired during warranty period by others than DYNASET OY or its authorized workshop.

• Costs of any other damage or loss, whether direct, indirect, incidental, special or consequential, arising out of the use of, or the inability to use, the product.

• Telephone or other communications expense.

• Product that is used in exceptional conditions, considered to cause excessive wear and tear.

• Faults caused by nature phenomenon’s like flood, thunder, etc.

© DYNASET OY, all rights reserved



PRODUCT DISPOSAL

8. PRODUCT DISPOSALDispose and recycle all DYNASET products and their packaging environmentally responsible way.

Do not dispose used oils, electrical components, batteries or any other hazardous waste with normal waste. They are harmful to the environment and can be recycled for re-use.

Contact your local waste recycling facility for more information about recycling hazardous waste.

NOTE!Always act according to the waste legislation, regulations and recommendations in waste disposal and waste recycling issued by your local authorities.



DECLARATION OF CONFORMITY

9. DECLARATION OF CONFORMITY

We hereby declare that the design and manufacture of the product stated below are in conformity with the provisions of the European Parliament and Councils on the harmonization of the laws of Member States on the safety of machines.

Machine directive 2006/42/EC

LVD directive 2014/35/EU

EMC directive 2014/30/EU

RoHS directive 2015/863

Applied conformity standards:

CEN EN ISO 4413: EN ISO 4413:2010 Hydraulic fluid power - General rules and safety requirements for systems and their components.

EN60204-1 Safety of machinery – Electrical equipment of machines.

Manufacturer: DYNASET Oy Menotie 3, FI-33470 Ylöjärvi, Finland

Product group: HYDRAULIC MAGNET GENERATORS

Product: HMG PRO hydraulic magnet generator CMG PRO hydraulic magnet generator

If the device has been modified by someone other than the manufacturer or without the manufacturer’s permission, this declaration is not valid.

Timo NieminenR&D ManagerMenotie 3, 33470Ylöjärvi, Finland 01.07.2019



TECHNICAL SPECIFICATIONS

10. TECHNICAL SPECIFICATIONS

STANDARD MODELS

HMG/CMG PRO 3kW

21

HMG/CMG PRO 6kW

34

HMG/CMG PRO

10kW49

HMG/CMG PRO

12kW59

OUTPUT CHARACTERISTICS

Generator power max. kW 3 6 10 12

Magnet coil power max. KW 0,5 - 3 0,5 - 5,5 1,0 - 9,1 1,0 - 11

Operating voltage VDC 220±5%

Auxiliary electricity Optional

Operating control voltage* VDC 6 - 32

HYDRAULIC CONNECTION

Pressure line P P BSP 1/2” BSP 3/4”

Return line T T BSP 1/2” BSP 1”

Drain line D D 06L - (M12x1,5 Male) BSP 1/4”

HYDRAULIC POWER REQUIREMENTS

Flow min. l / min(gpm) 23 (6.1) 37 (9.8) 53 (14.0) 63 (16.6)

Flow max. l / min(gpm) 37 (9.77) 53 (13.99) 68 (17.95) 77 (20.33)

Pressure at nominal power output bar (psi) 190 (2800) 140 (2000) 170 (2500) 190 (2800)

Pressure max. bar (psi) 210 (3000) 210 (3000) 210 (3000) 210 (3000)

Pressure when unloaded bar (psi) 30 (450) 30 (450) 30 (450) 25 (350)

HYDRAULIC FLUID REQUIREMENTS

Viscosity cSt 10-200 / optimum 25-35

Temperature ° C(°F) max. 70 (158)**

Filter ratio um 25 or better

Cooling capacity requirements *** kW 1,4 2,4 3,1 3,5

OVERALL DIMENSIONS

Length mm (in) 431 (17.0) 526 (20.7) 582 (23.0) 580 (22.8)

Width mm (in) 337 (13.3) 326 (12.9) 325 (12.8) 460 (18.1)

Height mm (in) 317 (12.5) 351 (13.8) 355 (14.0) 375 (14.8)

Weight kg (lb) 34 (75) 58 (128) 60 (132) 100 (220)

Gallons are U.S. liquid gallons.

* Only with HMG PRO** Ref. to hydraulic fluids in chapter 6.2*** Minimum cooling capacity for the HMG/CMG PRO on the base machine.



TECHNICAL SPECIFICATIONS

STANDARD MODELS

HMG/CMG PRO

15kW65

HMG/CMG PRO

20kW92

HMG/CMG PRO

30kW120

HMG/CMG PRO

40kW165

OUTPUT CHARACTERISTICS

Generator power max. kW 15 20 30 40

Magnet coil power max. KW 14,5 19,5 29,5 39,5

Operating voltage VDC 220±5%

Auxiliary electricity Optional

Operating control voltage* VDC 6 - 32

HYDRAULIC CONNECTION

Pressure line P P BSP 3/4” BSP 3/4” BSP 3/4” BSP 3/4”

Return line T T BSP 1” BSP 1” BSP 3/4” BSP 3/4”

Drain line D D BSP 1/4" BSP 1/4" M22x1,5 M22x1,5

HYDRAULIC POWER REQUIREMENTS

Flow min. l / min(gpm) 68 (18.0) 94 (24.9) 122 (32.2) 167 (44.1)

Flow max. l / min(gpm) 102 (27.0) 141 (37.3) 140 (36.96) 185 (48.84)

Pressure at nominal power output bar (psi) 190 (2750) 180 (2600) 190 (2750) 190 (2750)

Pressure max. bar (psi) 210 (3000) 210 (3000) 210 (3000) 210 (3000)

Pressure when unloaded bar(psi) 25 (350) 30 (440) 40 (580) 30 (440)

HYDRAULIC FLUID REQUIREMENTS

Viscosity cSt 10-200 / optimum 25-35

Temperature °C (°F) max. 70 (158) **

Filter ratio um 25 or better

Cooling capacity requirements *** kW 3,9 4,5 7,8 8,5

OVERALL DIMENSIONS

Length mm (in) 828 (32.6) 878 (34.6) 993 (36.7) 1003(39.5)

Width mm (in) 501 (19.7) 511 (20.1) 515 (20.3) 600 (23.6)

Height mm (in) 416 (16.4) 416 (16.4) 450 (17.7) 600 (23.6)

Weight kg (lb) 145 (320) 163 (359) 175 (386) 198 (437)

Gallons are U.S. liquid gallons.

* Only with HMG PRO** Ref. to hydraulic fluids in chapter 6.2*** Minimum cooling capacity for the HMG/CMG PRO on the base machine.

GEN CO

DYNASET PRIORITY VALVE

PV SAE 3fl” -1 1/4~~

GENSCO EQUIPMENT (1990) Inc. GENSCO AMERICA INC.53 Carlaw Avenue 5307 Dividend DriveToronto, Canada Decatur, Georgia 30035M4M 2R6 Phone: 770-808-8711Phone: 416-465-7521 Fax: 770-808-8739Fax: 416-465-4489

Across USA Call 1-800-268-6797E Mail: info~penscoeguio cornInternet: www.genscoepuip.com

Serving indust,y world wide since 1919

WARRANTYALL ORDERS FOR PRODUCT ARE SUBJECT TO THE FOLLOWING:

Gensco Equipment (1990) Inc. warrants each product to be free from defects inmaterial and workmanship under normal use and service. Gensco Equipment’sobligation under this warranty is limited to repairing or supplying, at our option, apart or parts to replace any defective part or parts which fail, within one (1) yearfrom date of original sale. No product shall be returned without prior authorizedapproval, and if authorized, the transportation charges shall be prepaid to GenscoEquipment, Toronto, Canada, or Gensco America, Decatur, GA. Unauthorizedreturns will not be accepted.

The provisions of this warranty shall not apply to any part or parts which have beensubject to misuse, negligence or accident, or which have been repaired or alteredoutside of Gensco Equipment’s service department in any way, so, as in thejudgment of Gensco Equipment to affect adversely its performance, stability orreliability.

Gensco Equipment neither assumes nor authorizes anyone to assume for it anyother obligation or liability for any loss or damage, either direct, incidental orconsequential, resulting from or arising out of, or in connection with, any of itsdefective part or parts.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESSEDOR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANT ABILITY OR FITNESSFOR A PARTICULAR PURPOSE, AND OF ANY OTHER OBLIGATION OR LIABILITY ON THE

PART OF GENSCO EQUIPMENT OF ANY NATURE WHATSOEVER.

RETURN POLICY

A Returned Goods Authorization must be obtained from Gensco Equipment priorto the return of any product. All shipments to us must be sent freight prepaid.Upon inspection, should the Quality Control Department determine the product tobe defective, credit will be issued accordingly.

For product returned in an “as new” condition, the restocking charges are asfollows:

RETURNED FROM DATE STOCK ITEMS SPECIAL ORDER ITEMSOF ORIGINAL SHIPMENT

120 Days 20% 50%

,17-~1(P1 111;~— &~LI 0

DYNASET PRIORITY VALVES OF PV SAE SERIES ARE ESPECIALLY DESIGNED TO ENABLE EASYAND RELIABLE INSTALLATION OF DEYNASET HYDRAULIC GENERATOR TO A HYDRAULIC SYSTEMOF ANY TYPE.

DYNASET PRIORITY VALVE ENABLES TO OPERATE YOUR DYNASET-UNIT SIMULTANEOUSLYWITH OTHER HYDRAULIC EXECUTORS.

DYNASET PRIORITY VALVE ENSURES THE PRIORISED AND NON-FLUCTUATING HYDRAULICFLUID FLOW TO YOUR DYNASET-UNIT.

DYNASET PRIORITY VALVE IS DESIGNED TO OPERATE TOGETHER WITH HYDRAULICPUMP’S CONTROL IN HYDRAULIC SYSTEM OF ANY TYPE.

I DYNASET OY, Menotie 3 I DYNASET PRIORITY VALVE I~ FIN-33470 Ylojarvi, FINLAND I PV SAE 3/4” - 1 1/4” , II Tel.: +358 3 3488200 I I I DYNA5ET ‘PAGES’

~ 1 I 12

I Fax +358 3 3488222 I INSTALLATION AND USE , I~ E-mail: info @dynaset.com 050224 I KL

I

DYNASET PRIORITY VALVEPV SAE 3/4” - 1 1/4”

-.

r~

DYNASET OY, Menotie 3FIN-33470 YLöjärvi, FINLANDTeL.: +358 3 3488200Fax +358 3 3488222E-mail: info @dynaset.com

DYNASET PV SAE priority valve includes folLowing components:

Sandwich-mounted PRESSURE COMPENSATOR with SAE-fLange specification;Pressure compensator incLudes one seaL fLange (1.20) as standard.

LS-VALVE2.2SoLenoid vaLve 12/24V;2.3FLow limiting vaLve.2.4Pressure relief valve.3.AN OPTIONAL height adjustment kit.

5-6.HYDRAULIC HOSES.

CONSTRUCTION

VALVE MODEL PV SAEsize

LSVmodel

PV SAE 3/4-40 Ipm-1 2/24 VPV SAE 3/4-60 lpm-12/24 VPV SAE 1-40 lpm-12/24 VPV SAE 1-60 1pm - 12/24 VPV SAE 1 1/4 -40 1pm -12/24 VPVSAE 11/4-60 1pm -12/24V

p maxbar

3/4”3/4”1”1”I

Q CF, max *

I/mm

LSV 40ISV 60ISV 40LSV 60LSV 40LSV 60

1/4”1/4”

350350350350350350

* CF-rate is adjusted at factory to the value specified by a customer

355535553555

4°ERC

4

Jii~AWPVSAEv~ve

BSP 3/4”BSP 1/2”


INSTALLATION AND USE

I PAGES]

~DYI1A5ET~ 2/ 12~

I

____iPV5AE~lV~

DYNASET OY, Menotie 3 DYNASET PRIORITY VALVEFIN-33470 YLöjarvi, FINLAND PV SAE 314” - 1 1/4”TeL.: +358 3 3488200Fax +358 3 3488222 INSTALLATION AND USEE-mail: info @dynaset.com

CONSTRUCTION II

VALVE MODEL PV SAE LSV P max Q CF, max *

size modeL bar L/min

PV SAE 3/4-95 lpm-12124 V 3/4” LSV 95 350 85

PVSAEI-951pm-12/24V 1” LSV95 350 85

PV SAE 1 1/4 -95 1pm -12/24 V 1 1/4” LSV 95 350 85

* CF-rate is adjusted at factory to the vaLue specified by a customer

I!!,

(~~) 2.3

CF - BSP 3/4”T- BSP3/4”

1DYNA5ET3/ 12~

I

/~D


CONSTRUCTION III

PV SAEsize

LSVmodeL

P maxbar

VALVE MODEL

PV SAE 3/4-150 Ipm-1 2/24 V 3/4” LSV 150

PV SAE 1-150 1pm - 12/24 V I “ LSV 150

PV SAE 1 1/4 -150 1pm -12/24 V 1 1/4” LSV 150


Q CF, max *

L/min

350

350

350

140

140

140

—0

1’~~

\

I

CF - BSP 3/4”T- BSP3/4”

~Sn1PVSAEVaIVe-—-1 —~

CF

L~_~Th~Z~DYNASET OY, Menotie 3FIN-33470 Ylojarvi, FINLANDTel.: +358 33488200Fax +358 3 3488222E-mail: info @dynaset.com INSTALLATION AND USE

I PAGE I

~DYI1A5ET~ 4/12~

d ~ ~ d

°

DYNASET OY, Menotie 3FIN.33470 Ytöjärvi, FINLANDTeL.: +358 3 3488200Fax +358 3 3488222E-mail: info @dynaset.com

0®—. IiI—~—.

DYNASET PRIORITY VALVEPVSAE3I4” - 1114”


PV SAE priority valve is designed forthe instalLation to main pressure Line(ref to pages 5 - 7).Pre-adjusted, independent from otherfunctions and priorised hydraulic flowfor DYNASET-unit comes from thesolenoid vaLve.

I PAGE

DYIIASET / 12

I1. OPEN CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP

INSTALLATION

F— I.’

0 L~-o

1__j_®I ~

0 HG

I

HYDRAULIC SYSTEM WITH CONSTANT DISPLACEMENT PUMP

®—~ ii~

INSTALLATION

I~• 1\ ____- 1

.r rj ‘.~ , — s .(c~~~o

L~.o


DYNASET PRIORITY VALVEPVSAE3/4” - 1114”


I PAGE

1 DYIIASET 6I12~

0111

050224 I KL

II - 2 OPTIONS FOR AN INSTALLATION OF PRESSURE COMPENSATOR

INSTALLATION

DYNASET OY, Menotie 3FIN-33470 Y[öjärvi, FINLANDTeL: ÷358 3 3488200Fax +358 3 3488222E-mai I: info @dynaset.com



I PAGE I

DYI1A5ET~ 7/12~

LS

II

III’HG

ID~1ACETI HMG

It is recommended to install DYNASET hydraulic generator to a closed centre hydraulic system of anexcavator (see diagram above) without pressure compensator, using only a LS-vaLve of required capacity.InstalLed to a closed centre hydraulic system of a modern excavator, pressure compensator may causecertain deceleration of machine’s movements and functions when the prionsed flow to the generator ison - pls. consuLt DYNASET’s experts!

For all other carriers with closed centre hydraulics (fire trucks etc.) an installation of DYNASET hydraulicgenerator can be made using a complete PV SAE valve

-—I

I PAGE~ DYNASET OY, Menotie 3 DYNASET PRIORITY VALVEI FIN-33470 Ylöjärvi, FINLAND I PV SAE 3/4” - 1 1/4” I II TeL.: +358 3 3488200 I I I DYNASET~ 8/12~I Fax +358 3 3488222 INSTALLATION AND USE I I~ E-mail: info @dynaset.com 050224 I KL

I3. CLOSED CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP

.

INSTALLATION

7,

0

DYNASET OY, Menotie 3FIN-33470 YLöjarvi, FINLANDTeL.: +358 3 3488200Fax ÷358 3 3488222E-mail: info @dynaset.com

b. .

- r r ___~,~—~- ~ ~ 2’

~ H— 11’ H’

-

- H

~• .~

ADYNASET hydraulic generator is — _____

started by activating a solenoidvaLve of LS-valve, when hydrauLicfLuid flows in circuit A - P - P - CF through pressure compensator and LS-vaLve.FLow Limiting valve permits only the pre-adjusted throughflow when an excessive fluidgoes to the main pressure line (A-B). Pressure compensator changes it’s throughputcapacity being controLled by LS-signal. Hydraulic pump adjusts it’s output capacity inaccordance with the mentioned LS-signat as weLl as with the LS-signaL of the machine’shydraulic system.

Pressure reLief vaLve of LS-vaLve protects the hydraulic generator against damaging by dicecting the hydrauLicfluid to the tank (T) if pressure rises over the Limit.

When any other hydraulic operating unit (cylinder, motor, PTO etc.) is being actuated, PV SAE, having ensureddemanded and PRIORISED hydrauLic fLow to the DYNASET unit (CF), opens main suppLy line directing requestedhydraulic flow for the corresponding function. Operation of a pressure compensator is controlLed by a LSsignal according to a current capacity request.

If controlled flow (CF) for DYNASET-unit is not requested, soLenoid vaLve cLoses correspondingcircuit and aLl the hydrauLic fLow is at system’s disposal.

a —4~,. o~

~I___~J_ ~

E~F~~

P

Q When the compressive force of hydrauLic fLow in main supply Line exceeds the spring

force of PV SAE, the incorporated vaLve of pressure compensator cLoses tightLy excludingLeakage flow.

When an excavator’s engine is on without any executor being used, a hydraulic pump OPERATIONLevels to the idLe mode producing the flow conditioned by the hydrauLic system of amachine.

B

-i~

~Jx~

BLS

AP

T = 0 1/mm

CF = 0 1/mm


INSTALLATION AND USE050224/ KL

I

P

L

B

OEm.

SE AD

PRESSURE COMPENSATOR DYNASET PV SAE

C mm 23 27,2 31,5D mm 49 55,6 63,5

L mm 64 73 89W mm 67,5 82 95H mm 60 65 72

P BSP 1/2” BSP 3/4” BSP 3/4”LS BSP 1/8” BSP 1/8” BSP 1/8”MP BSP 1/8” BSP 1/8” BSP 1/8”

OPTIONS:1 HEIGHT ADJUSTMENT KIT

SEALING PLATE (SE);ADAPTER PLATE (AD).

2 BOLTS (4-8 pcs), metric or imperial.



W H

C

aS.

PV SAE 3/4” PV SAE 1” PV SAE 1 1/4”

SEAD

mmmm

36

36

36

OPENING PRESSURE

PV SAE 3/4” PV SAE 1”

BAR

PVSAEI 1/4”

MAX. PRESSURE

MAX.FLOW A-B

MAX.FLOW A-P

PRESSURE DROP AT MAX. FLOWA - B completely openA- P

BAR

L/MIN

L/MIN

13,5

350

200

70

14

350

350

17,5

350

450

SAE - FLANGE

PRESSURE HOSE

BARBAR

100

3000 - 6000 Psi

LENGTHSIZE

145

CONTROL HOSE

mm

LENGTHSIZE

2,93,0

SAE 3/4”

800R 1/2

1000R 1/4

mm

2,83,0

SAE 1”

800R 5/8

1000R 1/4

3,03,5

SAE 1 1/4”

800R 3/4

1000R 1/4


HOWTO ORDER:

PRESSURE COMPENSATOR is to be chosen according to the main pump’s flange size.2LS-VALVE is to be chosen according to the required oil flow (CF).

NOTE! Flow limiting valve is adjusted at factory to the requested value and can not be re-adjusted

3.SOLENOID VALVE’s COIL is to be chosen according to the on-board voltage of a vehicle (12 or 24 VDC).

PV SAE j - 1/mm - j V

3/4,,I1 1/4”

0- 140

1224

PRESSURE COMPENSATOR IS AVAILABLE SEPARATELY:

PVSAE I3/4,,I”1 1/4”

HYDRAULIC FLUIDS

Wide range of standard hydrauLic fluids can be used with the DYNASET hydraulic equipment.Depending on the operating temperature, following mineral hydraulic oils are recommended:

ISO VG 32S for oil’s operation temperature up to 70 °C;ISO VG 46S for oil’s operation temperature up to 80 ~C;ISO VG 68S for oil’s operation temperature up to 90 ~C.

Synthetic and bio-oils can be used as well if their viscosity characteristics and Lubricating efficiency arecorresponding to above mineral oils. Automatic transmission fluids and even engine oils can be used,provided that they are allowed to be used in hydraulic system of your carrier machine.To use special hydraulic fluids a with DYNASET equipment, please be kindly requested to contact nearestDYNASET representative for an advice.

DYNASET OY, Menotie 3 DYNASET PRIORITY VALVE II FIN-33470 Ylöjärvi, FINLAND I PV SAE 3/4” - 1 1/4” I I DY~A5ET I PAGEI Tel.: ÷358 3 3488200 I I I

~ Il/ 12~

I Fax ÷358 3 3488222 INSTALLATION AND USE Ij E-mail: info @dynaset.com 050224 I KL

SAFETY PRECAUTIONSThe pressure in hydraulic fluid circuit is considerably high. Thereat the technical condition of yourequipment should be under constant scrutiny. Especially couplings, valves and hoses should be maintainedtight and clean as welt as kept under constant observation.Hydraulic leakages must be rectified immediately to avoid injuries caused by pressure and hot oil blowouts.Follow all your local safety instructions related to the high pressure hydraulics.Hydraulic system of a carrier machine should be maintained according to the service program.In order to exclude possible accidents, it is not allowed to clean or inspect PV SAE valve when hydraulicfluid circuit is pressurised. Prior to any cleaning, inspection and service hydraulic system of your carriermachine must be stopped and all hydraulic fluid circuits dissipated.Always wear appropriate clothing and safety equipment such as goggles, ear protection and safety shoesat all times when maintaining the PV SAE valve. Beware of machinery parts warmed by hot hydraulic oil.

AN EXTERME CLEANLINESS MUST BE MAINTAINED WHEN CARRYING OUT ANY SERVICE DISSASSEMBLINGOR REPAIR OF HRN-TOOL AND HYDRAULIC SYSTEM. THIS IS CRUCIAL TO ENSURE SAFE, RELIABLE ANDLONG-LIFE OPERATION OF YOUR EQUIPMENT.

Operators and maintenance personnel must always comply with local safety regulations and precautionsin order to close out the possibility of damages and accidents.All installation and service of both hydraulic and electric equipment must be performed by qualified andexperienced personnel only.

WARRANTY

DYNASET products are warranted against defects in materials and workmanship for a period of 6 (six)months from the date of purchase. Exceptions are parts subject to normal wear and tear, such as sealsand other parts that become worn through normal use of the unit.Warranty covers detective parts solely. Expenditure incidental to shipping and replacement are notcovered by present warranty.The warranty is void if product has been modified, provided with parts other than original or misused.

DYNASET OY, Menotie 3 DYNASET PRIORITY VALVE PAGEFIN-33470 Ytöjärvi, FINLAND PV SAE 3/4” - 1 1/4” 12/12Tel.: +358 3 3488200Fax ÷358 3 3488222 INSTALLATION AND USE ________________________

E-mail, info @dynaset.com 050224 I KL

DENECO

DYNASET LOAD SENSING VALVE

LSV 40LSV 60LSV 90LSV 150


Across USA Call 1-800-268-6797E Mail: info(d~cienscoepui~.comInternet: www penscoeciuio.com

Serving industry world wide since 1919

DYNASET LOAD SENSING VALVELSV 40

LSVI5O

DYNASET LSV LOAD SENSING VALVES ARE ESPECIALLY DESIGNED TORELIABLE INSTALLATION OF DYNASET HYDRAULIC GENERATOR TO AHYDRAULIC SYSTEM.

,,~ ~

Al ~ir

DYNASET LSV-VALVE ENABLES TO OPERATE YOUR DYNASET-UNIT SIMULTANEOUSLYWITH OTHER HYDRAULIC EXECUTORS.

DYNASET LSV-VALVE ENSURES THE NON-FLUCTUATING HYDRAULIC FLUID FLOW TOYOUR DYNASET-UNIT.

DYNASET LSV-VALVE IS DESIGNED TO OPERATE TOGETHER WITH HYDRAULIC PUMP’SCONTROL.

I DYNASET OY, Menotie 3 DYNASET LOAD SENSING VALVEI FIN-33470 Ytöjärvi, FINLAND I LSV 40 xx (pm - 12/24 V - LSV 150 xx (pm - 12/24 II TeL.: +358 3 3488200 I I ~ DY~ASET

1/7

I Fax +358 3 3488222 INSTALLATION AND USE I~ E-mail: info @dynaset.com 050530 I KL

LSV 60LSV 90

I

ENABLE EASY ANDCLOSED CENTRE

DYNASET LSV valve includes foLlowing components:1.2Solenoid valve 12/24V;1.3FLow Limiting valve.1.4Pressure relief valve

CONSTRUCTION I

VALVE MODEL p max Q CF, max * HYDRAULIC PORTS

bar 1/mm

LSV4O- xx Lpm-1 2/24 V 350 40LSV6O- xx lpm-12/24 V 350 60

~ CF-rate is adjusted at factory to the value specified by a customer

I

*4%

I DYhjASET LS VALVE

PAGES’~ DYNASET OY, Menotie 3 I DYNASET LOAD SENSING VALVE II FIN-33470 YLöjärvi, FINLAND I LSV 40 xx 1pm - 12/24 V - LSV 150 xx (pm - 12/24 I II Tel.: +358 3 3488200 I I I DYNASET~ 2f7~I Fax +358 3 3488222 INSTALLATION AND USE I I~ E-mail: info @dynaset.com 050530 I KL

00

DYNASET OY, Menotie 3 DYNASET LOAD SENSING VALVEI FIN-33470 YLöjarvi FINLAND I LSV 40 xx 1pm - 12/24 V - LSV 150 xx (pm - 12/24 I I DY~A5ET~ IPAGE~I TeL.: +358 3 3488200 I I I

V?7I Fax +358 3 3488222 INSTALLATION AND USE I I~ E-mail: info @dynaset.com 050530/ KL

I CONSTRUCTION II

VALVE MODEL p max

bar

LSV95 - xx Ipm-12/24 V 350


HYDRAULIC PORTS

Se~:iø

0

IDYh~ASETI LS VALVE

LS

IP CF

II

L____

mi

0

DYNASET OY, Menotie 3FIN-33470 Ylojarvi, FINLANDTel.: +3583 3488200Fax +358 3 3488222E-mail: info @dynaset.com

DYNASET LOAD SENSING VALVELSV4Oxx 1pm- 12/24V LSV 150 xx (pm- 12/24

INSTALLATION AND USE050530 I KL

PAGE

DYI1A5ET~ h/i

I CONSTRUCTION III

HYDRAULIC PORTSVALVE MODEL p max Q CF, max *

bar 1/mm

LSVI5O-xxlpm-12/24V 350 150

* CF-rate is adjusted at factory to the value specified by a customer

e

INSTALLATION

BASIC INSTALLATION WITH SHUTTLE VALVE IN LS-LINE

The shuttLe vaLve to LS-Line is availabLefrom DYNASET Oy as an optionaL accessory.

AN INSTALLATION TO A SYSTEM WITH PARALLEL LS-CONNECTION (for reference only)


-=~- J:~-—~4f~~

______ HG

DVhIA CIT HMG~ HWG1


I DYNASET LOAD SENSING VALVE I PAGELSV 40 xx 1pm - 12/24 V - LSV 150 xx (pm - 12/24 I DY~~A5ET ~ “7

050530/KL

INSTALLATION /OPERATION

The complete controL is achieved by proper positioningthe hydrauLic pump’s swash plate to meet current fLowand pressure requirements. This is achieved by a pump’sregulator, hydraulic system’s controL valves and DYNASETLS-VALVE.

PRESSURE CUT-OFF SPRING

PRESSURE CUT-OFF SPOOL

THE DYNASET GENERATOR IS INOPERATION ALL OTHER EXECUTORS BEINGDISCONNECTED:The setting of the incorporated flow limitingvaLve (VR) , which operates in givenconditions as a flow sensor, rates thedischarge produced by a hydraULic pump,ensuring the constant Level of the pressuredifference L~p between pump’s outletpressure and pressure in LS-Line as well asconstant hydrauLic flow for the DYNASETgenerator.

III~9~!JJ—!’~~~ I••-4~

MAIN VALVE BLOCK

F~] ; ~ IL~ ___

LOAD SENSING SPOOL

CONTROL PISTON

SHUTILE VALVE(OPTIONAL)

1

I~5E7I

Li

INLETPRESSURE PISTON

L.J CASE DRAIN

I

OIL FLOW LIMITINGVALVE (VR),pressure compensated

S

Li

j~ LS-VALVE

~DY~ASET j~

HGHMGHWG

AUTOMATICFREQUENCY / ROTATION SPEED

CONTROL VALVE

__~___~1DY~ASET1]

WHEN THE DYNASET GENERATOR IS OPERATED ALONG WITH OTHER HYDRAULIC EXECUTORS:The pressure in LS control Line is defined by system’s maximum functional pressure, when the pump outletpressure LeveLs correspondingly. Flow limiting vaLve’s pressure compensation constraints the fLow increase,sequentiaL to the mentioned ~p rise, through the LS-vaLve, ensuring constant hydraulic fLow to the DYNASETgenerator.

I DYNASET OY, Menotie 3 DYNASET PRIORITY VALVEI FIN-33470 YLöjärvi, FINLAND I PV SAE 3/4” - 1 1/4” I II Tel.: +358 3 3488200 I I I DY~A5ET I PAGE

6/7

I Fax +358 3 3488222 INSTALLATION AND USE I I~ E-mail: info @dynaset.com 050530 I KL

HOWTO ORDER:0 i

LS-VALVE is to be chosen according to the required oil flow (CF).

NOTE Flow limiting valve is adjusted at factory to the requested value and can not be re-adjusted

2.SOLENOID VALVE’s COIL is to be chosen according to the on-board voltage of a vehicle (12 or 24 VDC).

LSVI I j V

406095

150 0-150

HYDRAULIC FLUIDS

Wide range of standard hydraulic fluids can be used with the DYNASET hydraulic equipment.Depending on the operating temperature, following mineral hydraulic oils are recommended:

ISO VG 32S for oil’s operation temperature up to 70 °C;ISO VG 46S for oil’s operation temperature up to 80 °C;ISO VG 68S for oil’s operation temperature up to 90 °C.

Synthetic and bio-oils can be used as well if their viscosity characteristics and lubricating efficiency arecorresponding to above mineral oils. Automatic transmission fluids and even engine oils can be used,provided that they are allowed to be used in hydraulic system of your carrier machine.To use special hydraulic fluids a with DYNASET equipment, please be kindly requested to contact nearestDYNASET representative for an advice.

SAFETY PRECAUTIONSThe pressure in hydraulic fluid circuit is considerably high. Thereat the technical condition of yourequipment should be under constant scrutiny. Especially couplings, valves and hoses should be maintainedtight and clean as well as kept under constant observation.Hydraulic leakages must be rectified immediately to avoid injuries caused by pressure and hot oil blowouts.Follow all your local safety instructions related to the high pressure hydraulics.Hydraulic system of a carrier machine should be maintained according to the service program.In order to exclude possible accidents, it is not altowed to clean or inspect LSV-vatve when hydraulic fluidcircuit is pressurised. Prior to any cleaning, inspection and service hydraulic system of your carrier machinemust be stopped and all hydraulic fluid circuits dissipated.Always wear appropriate clothing and safety equipment such as goggles, ear protection and safety shoesat alt times when maintaining the LSV-valve. Beware of machinery parts warmed by hot hydraulic oil.

AN EXTERME CLEANLINESS MUST BE MAINTAINED WHEN CARRYING OUT ANY SERVICE DISSASSEMBLINGOR REPAIR OF LSV-VALVE AND HYDRAULIC SYSTEM. THIS IS CRUCIAL TO ENSURE SAFE, RELIABLE ANDLONG-LIFE OPERATION OF YOUR EQUIPMENT.

Operators and maintenance personnel must always comply with local safety regulations and precautionsin order to close out the possibility of damages and accidents.All installation and service of both hydraulic and electric equipment must be performed by qualified andexperienced personnel only.

WARRANTY

DYNASET products are warranted against defects in materials and workmanship for a period of 6 (six)months from the date of purchase. Exceptions are parts subject to normal wear and tear, such as sealsand other parts that become worn through normal use of the unit.Warranty covers detective parts solely. Expenditure incidental to shipping and replacement are not coveredby present warranty.The warranty is void if product has been modified, provided with parts other than original or misused.

DYNASET OY, Menotie 3 DYNASET PRIORITY VALVEI FIN-33470 Ytöjärvi, FINLAND I PV SAE 314” - 1 1/4” I I DY~A5ET I PAGE]I TeL: +358 3 3488200 I I I

~7I7

I Fax +358 3 3488222 INSTALLATION AND USE I I~ E-mail: info @dynaset.com 050530 I KL

GENECO

DYNASET FLOW LIMITERS

VR 50VR 95VRD 180


Across USA Call 1-800-268-6797E Mail: info~kienscoeciuip.comInternet: www.penscoepuic.com

Serving industiy world wide since 1919

I

DYNASET FLOW LIMITERSVR5OVR95VRD 180

DYNASET VR FLOW LIMITERS ARE ESPECIALLY DESIGNED TO ACHIEVE RELIABLE HYDRAULICFLUID FLOW CONTROL IN ORDER TO KEEP FLOW CONSTANT, ENSURING PROPER OPERATIONOF DYNASET HYDRAULIC GENERATOR.

DYNASET PRESSURE COMPENSATED OIL FLOW LIMITER FOR IN-LINE INSTALLATIONprovides extra fast control of hydraulic fLuid fLow.

DYNASET OIL FLOW LIMITER is especially designed for use in LS-hydrautic systems withseveral simuLtaneously running executors.

DYNASET OIL FLOW LIMITER is an essential part of a DYNASET PRIORITY VALVE whichenables the trouble-free operation of a DYNASET generator in open centre hydraulicsystems.

Outlet flow rate is independent of the pressure and viscosity.The flow rate is determined by a fixed measuring sensor. DYNASET FLOW LIMITER ispre-adjusted at factory.

DYNASET OY, Menotie 3 DYNASET FLOW LIMITERS PAGESFIN-33470 Ylöjärvi, FINLAND VR I VRD 1 I 6TeL.: +358 3 3488200Fax +358 3 3488222 INSTALLATION AND USE _________________________E~maiI. info @dynaset.com 050610/ KL

200

100

90

I I I

I I I

I I I

I: ~ ••_~.~~~:; .‘:~

I 1~~ct270

60

0 100 200 300 350

DYNASET pressure compensated flow Limiters are fixedorifice vaLves with back-up differential pressurecompensator for hydraulic systems.The differentiaL pressure compensator consists of acontrol spool, spring, controL opening and the adjustmentscrew to adjust the control pressure differentiaL. Theoil flow sensor determines the flow adjustment range.The fLow from 1 to 2 in the valve is specified by apressure drop in the oiL flow sensor. The compensatingspool moves into a controL position which correspondsto the equiLibrium between the force reLated to thepressure drop via the oil flow sensor on the other handand the spring force on the other.As the fLow rate increases, e. g. increasing pressuredrop, the diameter of the controL opening is reducedin accordance with the increased pressure drop, untila force equLibrium exists once more.Due to the continuous adjustment of the compensatingspool in accordance with the prevailing pressure drop,a constant fLow in control direction 1-2 is ensured.

LOCKING NUT

ADJUSTMENT SCREW

CONTROL OPENING

I1~ ~lI~[c

CONTROL SPOOL

OIL FLOW SENSOR

BASIC CONSTRUCTION AND FUNCTION

The basic DYNASET FLOW LIMITER corresponds to the glow limiting cartridge valve, which can be fitted intodifferent controL bLocks and housings. Depending on a flow Limiter’s capacity, the compLete valve includesan appropriate housing.

I = FREE FLOW.

2 = CONTROLLED FLOW.

FLOW RATE (Q) DEPENDENCY ON PRESSURE

SIMPLIFIED SYMBOL DETAILED SYMBOL

iF 2.o ~ ~

___L/~\~.

COIL FLOW SENSOR) (PRESSURE COMPENS~~D

-~ Qmax/VRD 180

C

E

0’

-ø~Qmax/VR95CIn

>

MEASURED AT:x•0EdA

50

40

30

20

10

;‘....

- ~

• U,

• >

I°• C

- _...Ec

\? =72mm2/sec.

toil=30 °C.

- .* Qmin/VR95

p [bar]

I DYNASET OY, Menotie 3 I DYNASET FLOW LIMITERS I~ FIN-33470 YLöjärvi, FINLAND VR I VRD I I~ TeL.: +358 3 3488200 I I I DYNASET ‘PAGES’

2/6

I Fax +358 3 3488222 INSTALLATION AND USE I I~ E-mail: info @dynaset.com 050610/ KL

I

DYNASET OY, Menotie 3FIN-33470 Ytöjärvi, FINLANDTeL.: +358 3 3488200Fax +358 3 3488222E-mail: info @dynaset.com

BASIC CARTRIDGE INSTALLATION DIMENSIONS

VALVE CARTRIDGEFOR:

STOCKNUMBER

p max

bar

VR5OPK-1/2-xx 1pm 13004280 350VR95PK-3/4-xx 1pm 13004430 350

* CF-rate is adjusted at factory to the value specified by a customer.

Q CF. max *

L/min

5095

DIMENSIONS

H,mm G

37 BSP 1/2”51 BSP 3/4”

WEIGHT

g

49112

T)

TORQUET, Nm

VR 5OPK-1/2- xx 1pm 8 - 12VR 95PK- 3/4-xx 1pm 12- 18

e mm

VALVE CARTRIDGEFOR:

G

DIMENSIONS, mm

a mm b mm C mm d mm e mm h max

VR 5OPK-1/2- xx 1pm BSP 1/2” 40 15 37 18 10 2,5

VR 95PK-3/4- xx 1pm BSP 3/4” 51 24 51 24 12 2,5

The instalLation dimensions listed above are minimum values for pipe threads and male threadsto DIN 3852.

AVAILABLE HOUSINGS

p

BSP 1/2”

BSP 3/4”

Housing for VRDSTOCK NUMBER:

I8OPK-1”-xx 1pm07030797

DYNASET OY, Menotie 3FIN-33470 Ylojarvi, FINLANDTel.: +3583 3488200Fax +358 3 3488222E-mail: info @dynaset.com

I PAGE

UDYNASET~ 14/61050610 /KL

HOUSING FOR: STOCKNUMBER

VR 95PK- 3/4-xx 1pm

VR 5OPK-1/2- xx 1pm

CF

13004400

mm

13004460

Lmm

BSP 1/2” 82

BSP 3/4” 98

SWmm

WEIGHTkg

14 27 0,2

16 36 0,43

IDY~A5ETI VRp CF

I~

(yR 95PK

0pCF

0

BSP IBSP I”

11

r1~1i7WEIGHT 3,3 kg

p

The flow tuning can onLy be made when thevalve is taken out from its housing. In orderto change the fLow rate setting the Lockingnut has to be Loosened. By turning theadjustment screw in the appropriate direction(+ increase flow; - reduce flow), the fLow rateis tuned.SubsequentLy, the adjustment screw is securedby means of the Locking nut.

NOTE!The edging on both sides of the vaLve bodyLimits the adjustment range. Do not force theLocking nut past the adjustment Limit.

cb4

I—T - TUNING RANGE: +For VR 50: T = approx. 3 mmFor VR 95 T = approx. 3 mm

FACTORY SETTING:

The adjustment screw is set at factoryapproximiteLy to the middle of the tuning range,which is about 2- 10 % of the pre-adjustednominaL rate of the flow limiter.

HYDRAULIC DETAILS

NOMINAL PRESSURE: p~ 350 bar on aLL ports;

WORKING PRESSURE RANGE:~ p = the required controL pressure differentiaLp1 - p~. If the differentiaL pressure is lower, the valveoperates as a speed control vaLve. p1 max = 350 bar;

HYDRAULIC FLUID TEMPERATURE RANGE:tmin= —20CC;tmax= +80C;

VISCOSITY RANGEVmin = 2,8 mm2/sec;‘Vmax= 380 mm2/sec.

.1 ON-SITE TUNING

I

~r-1

~ F, ‘VIII, __________

1L’ __

•. —L~ r~

-~+

FLOW RATE

I DYNASET OY, Menotie 3 DYNASET FLOW LIMITERS II FIN-33470 YLöjärvi, FINLAND I VR I VRD I DY~A5ET I PAGE~ TeL.: +358 3 3488200 I I I

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~ Fax +358 3 3488222 INSTALLATION AND USE I I~ E-mail: info @dynaset.com 050610 I KL

HYDRAULIC FLUIDS:

Wide range of standard hydrauLic fLuids can be used with the DYNASET hydrauLic equipment.Depending on the operating temperature, folLowing mineral hydraulic oiLs are recommended:

ISO VG 325 for oiL’s operation temperature up to 70 ‘C;ISO VG 46S for oiL’s operation temperature up to 80 ‘C;ISO VG 685 for oft’s operation temperature up to 90 ‘C.

Synthetic and bio-oiLs can be used as well if their viscosity characteristics and Lubricating efficiency arecorresponding to above mineraL oiLs. Automatic transmission fluids and even engine oils can be used, providedthat they are aLLowed to be used in hydrauLic system of your carrier machine.To use speciaL hydrauLic fluids a with DYNASET equipment, please be kindLy requested to contact nearestDYNASET representative for an advice.

HOW TO ORDER:

VR / VRD FLOW LIMITER is to be chosen according to the required oil flow (CF).

VR I - I - 1/mm VRD I8OPK-1- I - I/mm

5OPK- 1/2-95PK-3/4- 5-95 97-180

SAFETY PRECAUTIONS

The pressure in hydraulic fluid circuit is considerabLy high. Thereat the technical condition of yourequipment should be under constant scrutiny. EspecialLy coupLings, valves and hoses should be maintainedtight and clean as welL as kept under constant observation.Hydraulic Leakages must be rectified immediately to avoid injuries caused by pressure and hot oil blowouts.FoLLow all your LocaL safety instructions related to the high pressure hydrauLics.HydrauLic system of a carrier machine should be maintained according to the service program.In order to excLude possibLe accidents, it is not aLLowed to cLean or inspect VR/VRD-VALVE when hydraulicfLuid circuit is pressurised. Prior to any cLeaning, inspection and service hydrauLic system of your carriermachine must be stopped and aLl hydrauLic fluid circuits dissipated.Always wear appropriate cLothing and safety equipment such as goggles, ear protection and safety shoesat aLL times when maintaining the VR/VRD-VALVE. Beware of machinery parts warmed by hot hydraulicoil.

AN EXTER~ME CLEANLINESS MUST BE MAINTAINED WHEN CARRYING OUT ANY SERVICE DISSASSEMBLINGOR REPAIR OF LSV-VALVE AND HYDRAULIC SYSTEM. THIS IS CRUCIAL TO ENSURE SAFE, RELIABLE ANDLONG-LIFE OPERATION OF YOUR EQUIPMENT.

Operators and maintenance personnel must aLways comply with local safety regulations and precautionsin order to close out the possibility of damages and accidents.ALL instaLLation and service of both hydraulic and electric equipment must be performed by quaLified andexperienced personnel only.

WARRANTY

DYNASET products are warranted against defects in materials and workmanship for a period of 6 (six)months from the date of purchase. Exceptions are parts subject to normal wear and tear, such as sealsand other parts that become worn through normal use of the unit.Warranty covers detective parts soleLy. Expenditure incidentaL to shipping and replacement are notcovered by present warranty.The warranty is void if product has been modified, provided with parts other than original or misused.

DYNASET OY, Menotie 3 I DYNASET FLOW LIMITERS I~ FIN-33470 Ylöjärvi, FINLAND I VR I VRD I I DY~ASET I PAGEi TeL.: +358 3 3488200 I I I

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I Fax +358 3 3488222 INSTALLATION AND USE I~ E-mail: info @dynaset.com 050610/ KL

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