Dynaset GENSCO HMAG PRO 700-21 User manual

Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [e-mail] | www.dynaset.com
1. GENERAL 7
1.1. PRODUCT INFORMATION 7
1.2. PRODUCT IDENTIFICATION KEY 7
1.3. TYPE PLATE 8
1.4. HMAG PRO’S LINE-UP 8
1.5. MAIN COMPONENTS OF THE HMAG PRO 9
1.6. IP(Ingress Protection) CLASSIFICATION 9
1.7. ATTACHMENTS 11
1.8. OTHER OPTIONS 12
2. SAFETY 13
2.1. SAFETY PRECAUTIONS 13
2.2. SAFETY EQUIPMENT 15
2.3. OPERATING SAFETY 15
2.4. MAINTENANCE SAFETY 16
2.5. WARNING LABELS 17
3. OPERATING PRINCIPLES 19
3.1. OPERATING DESCRIPTION 19
3.2. MAGNETIZATION AND DEMAGNETIZATION 20
4. INSTALLATION OF THE HMAG PRO 21
4.1. INSTALLATION TO A HYDRAULIC TOOL LINE 21
4.2. INSTALLATION TO A HYDRAULIC PRESSURE LINE 23
4.3. HYDRAULIC FLUIDS 24
4.4. ATTACHING THE HMAG TO THE BOOM 24
5. OPERATION 25
5.1. OPERATING THE HMAG PRO 25
5.2. OVERHEATING AND OVERLOAD SITUATION 26
5.3. AMBIENT TEMPERATURE 26
6. MAINTENANCE 29
6.1. MAINTENANCE INTERVALS 29
6.2. HYDRAULIC FLUIDS 29
6.3. ACCESSING THE GENERATOR 30
6.4. CLEANING HMAG PRO’S GENERATOR 31
6.5. TROUBLESHOOTING 32
HYDRAULIC MAGNET GENERATORS
TABLE OF CONTENTS

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7. MANUFACTURER’S LIMITED WARRANTY 37
8. PRODUCT DISPOSAL 39
9. DECLARATION OF CONFORMITY 41
10. TECHNICAL SPECIFICATIONS 43
HYDRAULIC MAGNET GENERATORS
TABLE OF CONTENTS

Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [e-mail] | www.dynaset.com
Picture 1: HMAG PRO Identication key 7
Picture 2: Type plate 8
Picture 3: HMAG hydraulic magnet’s lineup 8
Picture 4: HMAG’PROs main components 9
Picture 5: Quick attach plate (Q) for excavator mount 11
Picture 6: Lifting adapter (G) for grapper 11
Picture 7: HMAG PRO with claw 12
Picture 8: Operating principle of HMAG PRO 19
Picture 9: Couplers of the HMAG PRO 21
Picture 10: Exaple of existing tool line installation 22
Picture 11: Example of installing the HMAG PRO to a open centre hydraulic system with needed valves. 23
Picture 12: HMAG PRO’s chains attach point example 24
Pictures 13: Operating HMAG PRO 25
Pictures 14: O.HEA on the Display 26
Pictures 15: Power take oin higher temperatures 27
Picture 16: Removing the cover of the HMAG PRO 30
HYDRAULIC MAGNET
TABLE OF PICTURES

7
Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [e-mail] | www.dynaset.com
HYDRAULIC MAGNETS
GENERAL
1. GENERAL
This manual contains general information about assembly, installation, operation
and maintenance of the DYNASET HMAG PRO hydraulic magnet.
Regarding information about HMAG PRO’s magnet generator, please refer to the
DYNASET HMG/CMG PRO hydraulic magnet generator user manual provided with
HMAG PRO user manual.
ATTENTION!
Read this user manual before installation, use or maintenance of the
HMAG PRO hydraulic magnet to ensure proper handling, operation and
maintenance right from the beginning. Pay attention to warnings and
safety instructions. READ CHAPTER ”2. SAFETY” for more information.
1.1. PRODUCT INFORMATION
HMAG PRO hydraulic magnet transforms the hydraulic power of the base machine
into a high quality electricity (DC) to power the magnet. HMAG PROs are compact
and integrated all-in-one attachment units for gathering and sorting scrap and
metals.The HMAG hydraulic magnet is designed as an attachment for the material
handling machines (hydraulic excavators, heavy trucks with hydraulic cranes etc.).
1.2. PRODUCT IDENTIFICATION KEY
All the HMAG PRO are identified by an identification key. The key can be found
from the products type plate which is attached onto the HMAG PRO.
Picture 1: HMAG PRO Identification key
1. Product Group HMAG PRO Hydraulic Magnets.
2. Magnet model
3. Nominal hydraulic flow. Theoretical hydraulic flow required for the HMAG PRO
to work.
4. Attachment method to the base machine’s boom. More information on the
attatchments on chapter 1.7.
5. Quick coupler options. Describes the quick coupler model if they are used as
an attachment.
6. Describes other options if included to the HMAG PRO.

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HYDRAULIC MAGNETS
GENERAL
1.3. TYPE PLATE
Picture 2: Type plate
Type plate is found above and on the backside of the service hatch.
1. Product identification key
2. Product code
3. Serial number
4. Minimum hydraulic flow
5. Maximum hydraulic pressure
6. Production month / year
7. Magnetizing power/
magnetizing voltage
8. Maximum continuous power
load to the magnet
9. Manufacturer’s contact
information
1.4. HMAG PRO’S LINE-UP
HMAG PRO comes in four standard models. Models are shown in the picture 3.
Picture 3: HMAG hydraulic magnet’s lineup
1. HMAG PRO 700 - 21
2. HMAG PRO 900 - 34
3. HMAG PRO 1200 - 49
4. HMAG PRO 1400 - 57

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HYDRAULIC MAGNETS
GENERAL
1.5. MAIN COMPONENTS OF THE HMAG PRO
Picture 4: HMAG’PROs main components
1. Type plate (also behind
the service hatch)
2. Serial number
3. Hydraulic pressure line (P)
4. Hydraulic return line (T)
5. Service hatch
6. Lifting hooks
7. Magnet generator’s cover
8. Magnet coil assembly
9. Magnet socket’s cover
10. DYNASET CMG PRO
magnet generator
1.6. IP(Ingress Protection) CLASSIFICATION
HMAG PRO hydraulic magnets are IP classified according to the IEC standard 60529
for the degrees of the protection of the electrical equipment. The protection class
of a standard HMAG PRO hydraulic magnet complies with the specifications of the
IP23.
From the IP classification guide you can check your IP class information.

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HYDRAULIC MAGNETS
GENERAL
1
2
3
4
5
6
1
2
3
5
6
7
8
2
2
3
4
SOLIDS WATER
30 min
15°
Ingress
Protection
Protected against a
solid object greater
than 50 mm3 such as a
hand.
Protected against a solid
object with greater than
12.5 mm diameter, such
as a nger.
Protected against
a solid object with
greater than 2.5 mm
diameter such as a
screwdriver.
Protected against a solid
object with greater than
1 mm diameter such as
a wire.
Dust protected.
Limited ingress of
dust permited i.e. no
harmful deposit.
Totally dust protected.
No ingress of dust.
Protected against
vertically falling drops
of water.
Protected against
direct sprays of water
with up to 15 degrees
from vertical.
Protected against
direct sprays of water
up to 60 degrees from
vertical.
Protected against
water sprayed from
all directions. Limited
ingress permitted.
Protected against low
pressure jets of water
from all directions.
Limited ingress
permitted.
Protected against
strong jets of water
from all directions.
Limited ingress
permitted
Protected against the
eects of immersion in
water between 15 cm
and 1 m for 30 min.
Protection against the
eects of immersion in
water under pressure
for long periods.
IP Classication guide
Rating
example:
IP 23
9
Protection against
high pressure, high
temperature jets of
water from multiple
directions.

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HYDRAULIC MAGNETS
GENERAL
1.7. ATTACHMENTS
CHAINS (K)
Chains come as standard attachment with the HMAG PRO. Chains are not provided
if other lifting adapter is chosen instead.
LIFTING ADAPTERS(Q/G)
DYNASET offers two optional lifting adapters for the HMAG PRO, a quick attach
plate (Q) for an excavator mount and a lifting adapter for a grapper (G). The
adapters are optional and available by request.
Picture 5: Quick attach plate (Q) for excavator mount
Picture 6: Lifting adapter (G) for grapper
ATTENTION!
Always secure HMAG PRO with the grapper lifting adapter to the grapper
tool with chains. Secure spot for attaching the chains to the HMAG PRO is
shown in the picture 6 spot A.

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HYDRAULIC MAGNETS
GENERAL
QUICK ATTACHMENT PLATE OPTIONS
Quick attachment plate (Q) is available for the excavators accordind to the standard
S. The standard S specifications are described in the following table.
HMAG PRO
MODEL
QUICK
ATTACHMENT
WIDTH
(mm)
SHAFT
C-C
(mm)
700 S40 200 300
700 S40/240 240 300
700/ 900 S45 290 430
700/ 900 S50 270 430
700/ 900/1200 S60 340 480
900/1200 S70 450 600
1200 S80 590 670
1.8. OTHER OPTIONS
CLAW (C)
HMAG PRO can also be ordered with claw.
ED100%
HMAG PRO are also available as an ED100% model. This model can work on full
power all the time without overheating in the constant use.
ED100% is recomended when the metal collecting is made in longer seqments
and the magnetizations is on all the time, e.g. cleaning the railtracks.
Picture 7: HMAG PRO with claw

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HYDRAULIC MAGNETS
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 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 HMAG PRO hydraulic magnet is 220 VDC .
WARNING
HIGH PRESSURE OIL!
Can cause severe injuries.
Always wear appropriate clothing
and safety equipment.
The hydraulic system is pressurized up to 350 bar.

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HYDRAULIC MAGNETS
SAFETY
The pressure in the hydraulic circuits of the HMAG PRO hydraulic magnet is
considerably high. Therefore the technical condition of your equipment must 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 near by. Do not use near medical
implants or electronics. Keep the safe
distance of the base machine or at least 5m
to the HMAG magnet.
HMAG PRO hydraulic magnet produces a strong magnetic field that might
interfere with electronic devices. Ensure also that the magnetic field does not
interfere and damage other electrical and electronic equipment or any other
sensitive equipment such as credit cards or watches.
When using the magnet, switch off and unplug all sensitive electric and electronic
devices nearby. Such units are e.g. AC-chargers, electronic sensors, control and
measurement instruments.
After shutting the HMAG PRO system the magnet holds magnetization before it
complately discharges.
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.

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HYDRAULIC MAGNETS
SAFETY
2.2. SAFETY EQUIPMENT
When operating in the immediate vicinity of the HMAG PRO hydraulic magnet or
accessories, wear the appropriate protective clothing, safety goggles, gloves and
ear protection.
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.
WARNING
DO NOT GET UNDER THE LOAD!
Danger of getting crushed. Stay
clear from the magnet and the base
machine’s reach. Check base
machine’s manual for safety area
details.
Never get under the magnet. The collected metals might drop due to a failure
in the base machine or in the HMAG PRO system. Remember to keep the safe
distance of the base machine and stay outside of its reach.

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HYDRAULIC MAGNETS
SAFETY
HMAG PRO magnet has two temperature switches that cut off the magnetization
if the temperature raises too high. In this case the collected metals will eventually
drop unexpectantly.
WARNING
DANGER OF GETTING CRUSHED!
Magnet will draw ferrous material around it
to itself when magnetized. Do not put
yourself between magnet and object that it
can draw to itself. Stay clear from the
magnet and the base machine’s reach.
Do not lift people with the HMAG PRO magnet.
Do not hang or grap the chains while lifting.
Do not let any person or animal get closer than 5 m when operating the HMAG
PRO magnet.
Do not drag HMAG PRO along the ground. Draging it might damage the magnet.
Do not release the scrap from HMAG PRO by swinging the unit.
When picking and moving scrap, twitches, sudden moves and reversals must be
avoided. Prior to starting to operate the HMAG PRO ensure clear visibility to the
magnet and its surroundings.
Do not cool the HMAG PRO magnet with water.
Do not use HMAG PRO magnet under water.
2.4. MAINTENANCE SAFETY
NOTE!
Keep the components of the system clean when carrying out any
maintenance to the HMAG PRO. This is to ensure safe, reliable and longlife
operation of your equipment.
Hydraulic system of the base machine must be maintained according to the
machines service program. READ CHAPTER ”6.1. Maintenance Intervals” for more
information

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HYDRAULIC MAGNETS
SAFETY
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.
RISK OF ELECTRIC
SHOCK.
30min
Base machine has to be stopped and hydraulic circuit depressurized prior to
maintenance, detaching HMAG PRO from a base machine or disassembling HMAG
PRO.
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 or close to DYNASET product
where its easily seen. Clean surface with solvent detergent before attaching labels.
USE EAR PROTECTION
AND SAFETY GOGGLES
READ OPERATING
INSTRUCTIONS
WEAR GLOVES WEAR
SAFETY BOOTS
BEWARE THE HOT
SURFACE
RISK OF ELECTRIC
SHOCK
RISK OF MEDICAL
EQUIPMENT FAILURE
BEWARE THE
MAGNETIC FIELD
HIGH PRESSURE
OIL

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HYDRAULIC MAGNETS
SAFETY

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HYDRAULIC MAGNETS
OPERATING PRINCIPLES
3. OPERATING PRINCIPLES
3.1. OPERATING DESCRIPTION
Picture 8: Operating principle of HMAG PRO
1. When the hydraulic flow is swithced on and is directed to the HMAG PRO’s
generator, the base machine’s hydraulic flow is automatically leveled to the
correct level. Generator’s RPM-valve block keeps the flow constant and controls
the speed of the hydraulic motor through a RPM-cartridge.
2. Hydraulic motor connects directly to the alternator’s rotor. When the rotor spins
it produces a changing magnetic flux that generates electricity.
3. The generator produces 220 VDC voltage that activates the magnet’s coils and
produces magnetic field that lifts ferrosious metals.

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HYDRAULIC MAGNETS
OPERATING PRINCIPLES
3.2. MAGNETIZATION AND DEMAGNETIZATION
Magnetization and demagnetization of the HMAG PRO is controlled electronically
by CMG PRO control unit. The electronic control enables the magnet to
demagnetize in 0,8s. Delay for the demagnetization is adjustable for occations
when slower demagnetizing time is required.
Please take contact to DYNASET if in need for more information about adjusting
demagnetisation delay.

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HYDRAULIC MAGNETS
INSTALLATION
4. INSTALLATION OF THE HMAG PRO
4.1. INSTALLATION TO A HYDRAULIC TOOL LINE
The HMAG PRO is recommended to be installed into the base machine’s existing
hydraulic tool line. Usually other installations are not required and the HMAG PRO
can be operated from the existing controls.
Install the hydraulic tool lines pressure (P) and return (T) to their correct places
on the HMAG PRO.
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 9: Couplers of the HMAG PRO
ATTENTION!
Ensure that the filtering degree and cooling capacity of the hydraulic
system are sufficient. READ CHAPTER ”10. TECHNICAL SPECIFICATIONS” for
more information.