Internet: http://www.dynaset.com 00 HGV VARIABLE HYDRAULIC GENERATOR SYSTEMS INSTRUCTIONS
Internet: http://www.dynaset.com 00 GENERAL NOTES DYNASET variable hydraulic generator system, especially designed for mobile installations, is comprised of an hydraulic generator and an hydraulic system, which actuates and keeps a generator running. DYNASET hydraulic generator, driven by an engine of a carrier machine by means of variable hydraulic system, produces electricity equivalent to the electric supply network power, when engine s rotation speed may vary broadly (ref. to the table on next page). DYNASET hydraulic generator comprises an alternator and an hydraulic motor, installed to an alternators s axle. The self-exited generator is equipped with an automatic rotation speed control valve as well as with an automatic voltage regulator. An automatic rotation speed control valve maintains constant rotation speed of an alternator as well as constant electric frequency, provided that at least a minimum oil flow is fed to a generator (refer to the MANUAL FOR HG- HYDRAULIC GENERATORS). A voltage regulator mantains voltage on a nominal level when generator s rotating speed is adequate to a nominal frequency. Monitoring of voltage level is quite sufficient to indicate whether the operation is correct or not. GENERAL DESING Together with an hydraulic generator the system comproses following main units:. Solenoid valve to start a system.. Variable displacement hydraulic pump. (An installation in engine compartment. Other installations applicable according to motor vehicle s brand, model and equipment). 3. Oil cooler guards a system against overheating. 3. Oil cooler as a component of generator assembly. 3. Oil cooler as a separate unit.
Internet: http://www.dynaset.com 00...GENERAL DESIGN 5. An optional electric board can be placed deliberately. 4. A hydraulic oil tank equipped with oil filter, sight glass and breather. System s control switches usually are placed on a vehicle s dashboard. 5. An oil filter in return line keeps system clean. STANDARD HGV-SYSTEMS MODEL ELECTRIC OUTPUT CHARACTERSITICS ROTATION SPEED RANGE POWER VOLTAGE FREQUENCY RPM kva, max V Hz min max HGV 3,5 kva 30 V - VE LS 3,5 30 50 (60) 500-4000 HGV 6,5 kva 400 V - VE LS 6,5 400 / 30 50 (60) 750-4000 HGV 0 kva 400 V - VE LS 0 400 / 30 50 (60) 00-4000 HGV 0 kva 400 V - VP 75 LS 0 400 / 30 50 (60) 700-3000 HGV kva 400 V - VP 75 LS 400 / 30 50 (60) 800-3000 HGV 5 kva 400 V - KV 07 LS 5 400 / 30 50 (60) 700-3000 HGV 0 kva 400 V - R40 LS 0 400 / 30 50 (60) 650-3000 3
AUTOMATIC ROTATION SPEED CONTROL T P HG H Y D R A U L IC GENERATOR A HYDRAULIC PUMP FLOW SENSOR SOLENOID VALVE PRESSURE LIMITING VALVE B OIL COOLER OIL FILTER HYDRAULIC OIL TANK, ASSEMBLY Automatic speed control adjusts hydraulic pump s swash plate according to the generators load, maintaining constant oil flow. When the generator is switched off, i.e. there is no load, pump s swash plate is at 0 angle and pump produces flow only for self-lubrication and self-flushing. In that case generator practically does not load the engine of carrier machine. After switching on, the solenoid valve guides the oil flow into the pressure line of the generator, when the hydraulic pump achieves the output, required for running the generator at adjusted speed (see below). Loading generator at engine s idle running turns the swash plate of hydraulic pump close to the maximum angle. Increasing engine s rpm angles the swash plate downwards when the oil flow is being kept on the adjusted level. Machine s engine is being loaded according to the electric power taken from the generator when the hydraulic pump maintains the constant oil flow. Pressure limiting valve is used to protect hydraulic system as well as vehicle s engine from overpressure and consequent damage. If the pressure exceeds maximum value, the device automatically by-passes the generator. The oil filter in return line keeps the hydraulic system clean and the oil cooler guards the system against the overheating. 4
SETTING THE MAXIMUM HYDRAULIC PRESSURE After having installed the variable hydraulic generator system to a carrier machine, set the maximum pressure in system to a demanded value. Variable displacement hydraulic pump is provided with a regulator, which allows to set the demanded maximum operation pressure and correct output frequency / voltage. Depending on pump model, regulator s appearance may vary, but functions remain the same. The setting is recommended to be made in following order:. Remove the protective cap (if provided) and loosen the lock nut of the corresponding adjusting screw.. Disconnect the pressure hose from generator s pressure port. 6 T P - 4 HG 3. Measurement unit*, which includes ball valve and pressure gauge, is to be installed into a pressure line. 4. Assemble the pressure line with a measurement unit. Ensure that the ball valve is open. 5. Start the engine and switch on the generator system. 6. While the system is running, cut off the oil flow to the generator by closing the ball valve. Generator stops but it s solenoid valve is kept activated. 7. Set the pressure to the required level by turning the adjusting screw (screw No. ) of the pump s regulator with allen key. Follow the pressure readings from the gauge. After having made the setting, lock the adjusting screw and replace protective cap (if provided). Pump models VP 75 ja VP 45: To enable pump flushing and protect it from damage, needle valve MUST be kept open for / 3/4 revolutions, when the generator rotates slowly producing current of 5 0 Hz. 8. Switch off the generator and stop the truck s engine. Depressurise the hydraulic circuit by opening the ball valve. Generator s rotor may rotate a few revolutions. Pump model VP 75 (VP 45) Dismount the measuring unit and re-assemble generator s pressure line. Ensure that all fittings are tightened properly. *) MAXIMUM PRESSURE VALUE MAY VARY DEPENDING ON CHOSEN COMPONENTS AND OPTIONAL EQUIPMENT ACTUATED FROM HYDRAULIC CIRCUIT. If the measurement unit is not available, pump s pressure line can be plugged with pressure gauge, accomplished with appropriate fitting. 5
Internet: http://www.dynaset.com 00 SETTING OUTPUT FREQUENCY AND VOLTAGE After having adjusted the maximum pressure in the hydraulic circuit, set generator s output characteristics (voltage and frequency) to the demanded level. Adjustments should be made at suitable engine rpm, which ensures sufficient oil flow as well as sufficient torque through the entire load range of the generator system. Frequency setting is done by adjusting differential LS pressure p (LShydraulic pump. p) by a regulator, incorporated in the. Start an engine and adjust the required rpm. Hydraulic flow should exceed the minimum demand by 0-30%. Please consider as well above reasons and transmission ratio of PTO.. Turn on the generator. 3. Switch the multimeter to Hz-position and plug it into a generator s socket. 4. Adjust the frequency with an accuracy of +5 Hz ( + 0%), turning the p adjusting screw (screw No ). Follow the frequency readings from the multimeter. After having adjusted the frequency, lock the adjusting screw. If better accuracy is required, the adjustment should be made by an expert. Pump model VP 75 (VP 45) NOTE. Frequency setting affects directly the voltage, therefore if only a voltagemeter is in your disposal, frequency setting of generator with a compound voltage regulator can be accomplished by adjusting the output voltage to the demanded level. If a generator is provided with an electronic voltage regulator, voltage is to be set by generator s voltage control potentiometer, but frequency should be adjusted by LS- p adjusting screw as described above. 6
DYNASET STANDARD PUMPS FOR VARIABLE HYDRAULIC GENERATOR SYSTEMS DYNASET Oy supply a range of standard hydraulic pumps for variable hydraulic generator systems. Although the pump size and appearance may vary depending on system s power output as well as on vehicle design features, all DYNASET hydraulic pumps are equipped with a regulator, which provides following controls: ADJUSTING SCREW :Hz / V - setting ADJUSTING SCREW :SYSTEM S MAXIMUM PRESSURE ADJUSTMENT. MODELS VP 75 and VP 45: To make setting, loosen the check nut first, make an adjustment with an appropriate allen key and secure adjusting screw with check nut. Models VP 75 and VP 45: To enable pump flushing and protect it from damage, needle valve MUST be kept open for / 3/4 revolutions, when the generator rotates slowly producing current of 5 0 Hz.. MODELS VE and VE 8 A A 7
... DYNASET STANDARD PUMPS 3. RV-MODELS A series: 8 cc, 45 cc, 7 cc, 00 cc, 40 cc B series: 60 cc To make setting, remove the protective cap, loosen the check nut and make an adjustment with an appropriate allen key. Then lock adjusting screw with check nut and replace protective cap. B 4. MODELS KV 80 and KV 07 B 5. MODELS VH 74 and VH 3 8
... DYNASET STANDARD PUMPS 6. V60N-MODELS POWER SETTING MODEL Vg pnom pmax cm3/rev bar bar V60N 60 350 400 V90N 90 350 400 V0N 0 350 400 OPERATION Depending on a system s customisation level, vehicle s equipment or other features, generator is started by activating a solenoid valve or PTO with hydraulic pump attached to it. Appropriate switches are placed either on a machine s dashboard or on a separate electric board (option). In normal use, a generator can be switched on whenever it is necessary. The performance of the entire system and the generator particularly must be tested and adjusted prior to connecting any electric tools or appliances. Provided that the system works properly, load can be plugged in prior to starting the generator. At least minimum rotation speed (= speed, maintaining the minimum oil flow) of engine should be kept to ensure proper operation of hydraulic generator. Further, automatic speed control keeps the hydraulic flow constant maintaining steady output characteristics of generator (frequency and voltage) throughout the allowed rotation speed range. When the ambient temperature is below 0 C, the generator SHOULD NOT be started immediately after starting the engine (refer to the specifications of your hydraulic oil supplier). Allow the hydraulic oil to circulate in system until it achieves the temperature, which enables the safe start. Otherwise, after starting the generator from a cold, the output voltage will remain low down to the moment, when the oil will be warm enough. When using the normally recommended oils, temperature should be at or above 50 F/0 C before use. In hot conditions ensure the proper operation of the oil cooler by checking the oil temperature regularly from the thermometer attached to the oil tank. If the oil temperature exceeds 75 C, check the oil filter and clean when necessary. Refer to the hydraulic oil recommendation below. 9
Wide range of standard hydraulic fluids can be used with DYNASET hydraulic equipment. Depending on the operating temperature, following mineral hydraulic oils are recommended: ISO VG 3S operation temperature up to 70 C ISO VG 46S operation temperature up to 80 C ISO VG 68S operation temperature up to 90 C HYDRAULIC FLUIDS Synthetic and bio-oils can be used as well, if their viscosity characteristics and lubricating efficiency are corresponding 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. Special hydraulic fluids are allowed to be used with DYNASET equipment as well, provided that the DYNASET representative will be asked for an advice. MAINTENANCE AN EXTERME CLEANLINESS MUST BE MAINTAINED WHEN CARRYING OUT ANY DISSASSEMBLING, SERVICE OR REPAIR OF HYDRAULIC SYSTEM. THIS IS CRUCIAL TO ENSURE SAFE, RELIABLE AND LONG-LIFE OPERATION OF YOUR EQUIPMENT. ONCE A DAY CHECK ENSURE oil level in the oil tank. When the oil is cold, level should be app. at middle of the sight glass, and at top when the oil is hot. that there are no oil leakages in system. Repair the failure immediately and refill the system if necessary. AFTER VERY FIRST 50 HOURS OF OPERATION (OR AT THE MILEAGE OF 000 KM OR AFTER FIRST WEEK OF REPLACE the oil filter cartridge, type MF-XXX-X-XXX-X-X. To replace the filter cartridge, open the filter cover at the top of the oil tank. Clean the filter bowl as well. AFTER SEQUENT 500 HOURS OF OPERATION (OR 0,000 KM OR 6 MONTHS) REPLACE CHECK GAGE CHECK oil filter cartridge. Clean the filter bowl. condition of the hydraulic fluid and change if necessary. the output voltage (if possible - frequency too) of generator. Adjust the output parameters by turning LS - p adjusting screw of the hydraulic pump. condition of mechanical transmission. Replace worn components, such as timing belt, grease lubrications points, etc. AFTER SEQUENT 000 HOURS OF OPERATION (OR 40,000 KM OR MONTHS) CARRY OUT CHANGE all above jobs. hydraulic oil. (Refer to the hydraulic oil recommendation) 0
SAFETY PRECAUTIONS The generator s output voltage is as high as 30/400 V. Operators and maintenance personnel must always comply with local safety regulations and precautions in order to close out the possibility of damages and accidents. The hydraulic system is pressurised up to 0 (40) bar. Keep strictly to 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. All couplings, valves and hoses of the system should be kept clean in order to follow their technical condition. Hydraulic leakages must be rectified immediately to avoid injuries caused by hot oil blowouts. Prior to service or disassembling the hydraulic system must be stopped and depressurised. Never wear loose clothing that can get entangled in the working equipment. All installation and service of both hydraulic and electric equipment must be performed by qualified and experienced personnel only.
MANUFACTURER S LIMITED WARRANTY. Warranty coverage All 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 8.. Beginning of warranty period Warranty 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 period Warranty period is twelve () months based on maximum of 000 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 procedures Immediately 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 repairs If 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 repair If 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 7. Warranty of repaired product Warranty period of the product repaired under this limited warranty continues to the end of original warranty period. 8. Exclusions from warranty This warranty shall not apply to: a. 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 b. Cost of maintenance, adjustments, installation or startup c. Coating, hydraulic oil, quick couplings and interconnection hoses (internal or external to system assemblies) d. Products altered or modified in a manner not authorized by DYNASET OY in writing e. Products which have been repaired during warranty period by others than DYNASET OY or its authorized workshop f. 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 g. Telephone or other communications expense h. Product that is used in exceptional conditions, considered to cause excessive wear and tear i. Faults caused by nature phenomenon s like flood, thunder, etc. DYNASET OY, all rights reserved