Dynaset HG 1 User manual

HYDRAULIC GENERATORS
USER MANUAL
HG 1
HG 2 HG 3,5 HG 3,7
HG 4,1
HG 5
HG 6
HG 6,5
HG 6,6
HG 9
HG 10
HG 10,1
HG 12
HG 12,1
HG 15
HG15,1
HG 18
HG 20
HG 20,1
HG 25
HG 30
HG 30,1
HG 40
HG 50
HG 60
HG 70
Download PDF version from www.Dynaset.com/manuals Keycode: AGDB3F
06/18 rev 1.3

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com 3
Congratulations!
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.
Please contact us for any feedback you might have on our
products. Your feedback is important to us for improving our
products and customer service.
We are constantly developing and releasing new innovations.
Please visit on our website and social media channels for the
latest news and updates.
www.dynaset.com
[e-mail]
www.facebook.com/dynaset
www.youtube.com/dynasetoy
www.twitter.com/Dynaset_ofcl
www.instagram.com/dynaset_official
Subscribe to our newsletter. Follow the QR
code!

4Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
HYDRAULIC GENERATORS
TABLE OF CONTENTS
1. GENERAL 7
1.1. PRODUCT INFORMATION 7
1.2. PRODUCT IDENTIFICATION KEY 7
1.3. TYPE PLATE 8
1.4. HG’S LINE-UP 9
1.5. HG’S MAIN COMPONENTS 10
1.6. IP (Ingress Protection) CLASSIFICATION 10
1.7. VOLTAGE AND FREQUENCY 12
1.8. HYDRAULIC EQUIPMENT 13
1.9. ELECTRIC EQUIPMENT 14
1.9.1. SINGLE PHASE SOCKET PLUG TYPE 15
1.9.2. THREE PHASE SOCKET PLUG TYPE 17
2. SAFETY 19
2.1. SAFETY PRECAUTIONS 19
2.2. SAFETY EQUIPMENT 20
2.3. OPERATING SAFETY 20
2.4. MAINTENANCE SAFETY 21
2.5. WARNING LABELS 22
3. OPERATING PRINCIPLE 23
3.1. OPERATING DESCRIPTION 23
3.2. VOLTAGE CONTROL 23
3.3. PERFORMANCE OF AUTOMATIC FREQUENCY CONTROL 24
3.4. PRESSURE POWER RATIO 24
4. INSTALLATION 27
4.1. BEFORE INSTALLATION 27
4.1.1. HYDRAULIC SYSTEM OF A BASE MACHINE 27
4.1.2. DYNASET VALVES 34
4.2. INSTALLING A DYNASET HYDRAULIC PRODUCT 35
4.2.1. PLACING A DYNASET HYDRAULIC PRODUCT 35
4.2.2. INSTALLING DYNASET VALVES 35
4.2.3. CONNECTING HYDRAULIC HOSES 35
4.2.4. HYDRAULIC FLUIDS 37

5
Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
HYDRAULIC GENERATORS
TABLE OF CONTENTS
4.3. INSTALLING HG HYDRAULIC GENERATOR 37
4.4. GROUNDING 37
4.5. IP CODE REQUIREMENTS 39
4.6. OUTPUT FREQUENCY INSPECTION AT START-UP 39
4.7. K CABLE MODEL 40
4.7.1. CABLE CONNECTIONS 41
5. OPERATION 45
5.1. CONNECTING THE APPLIANCE 45
5.2. STOPPING THE HG HYDRAULIC GENERATOR 46
5.3. AMBIENT TEMPERATURE 46
6. MAINTENANCE 47
6.1. MAINTENANCE INTERVALS 47
6.2. HYDRAULIC FLUIDS 47
6.3. CLEANING THE HG 48
6.4. TEST SAFETY DEVICES 49
6.5. OUTPUT FREQUENCY ADJUSTING 50
6.6. TROUBLESHOOTING 54
7. MANUFACTURER’S LIMITED WARRANTY 57
8. PRODUCT DISPOSAL 59
9. DECLARATION OF CONFORMITY 61
10. TECHNICAL SPECIFICATIONS 63

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
6
HYDRAULIC GENERATORS
TABLE OF PICTURES
Picture 1: Identication key for HG hydraulic generators.................................................................................................7
Picture 2: Type plate........................................................................................................................................................8
Picture 3: HG hydraulic generator line-up .......................................................................................................................9
Picture 4: Main assembly of the HG hydraulic generators..............................................................................................10
Picture 5: Single phase voltage and frequency map......................................................................................................12
Picture 6: Three phase voltage and frequency world map .............................................................................................13
Picture 7: Single phase sockets and plugs .....................................................................................................................16
Picture 8: Single phase plug and socket map ................................................................................................................17
Picture 9: IEC60309 three phase sockets and plugs .......................................................................................................17
Picture 10: NEMA three phase sockets and plugs...........................................................................................................18
Picture 11: HG hydraulic generators operating principle ...............................................................................................23
Picture 12: Automatic frequency control .......................................................................................................................24
Picture 13: Pressure/Power chart ..................................................................................................................................25
Picture 14: Open centre hydraulic system with load sensing variable displacement pump...........................................28
Picture 15: Connection gure for open centre hydraulic system with Load Sensing variable displacement pump........29
Picture 16: Closed centre hydraulic system with Load Sensing variable displacement pump........................................30
Picture 17: Connection gure for closed centre hydraulic system with Load Sensing variable displacement pump......31
Picture 18: Hydraulic system with xed displacement pump ........................................................................................32
Picture 19: Connection gure for hydraulic system with xed displacement pump.......................................................33
Picture 20: Load sensing valve LSV................................................................................................................................34
Picture 21: Priority valve PV-SAE...................................................................................................................................34
Picture 22: Location of the HG hydraulic generator .......................................................................................................35
Picture 23: Installing hydraulic hoses............................................................................................................................35
Picture 24: P-line operational hydraulic ow.................................................................................................................36
Picture 25: Base machine’s pumps................................................................................................................................36
Picture 26: Return line (T) pressure must be under 5 bars. ...........................................................................................36
Picture 27: Placement of the HG hydraulic generator with sucient room and ventilation...........................................37
Picture 28: HG hydraulic generator grounging, in picture HG 6,5 ..................................................................................38
Picture 29: IP23 and IP54 positioning ...........................................................................................................................39
Picture 30: Starting the HG hydraulic generator............................................................................................................39
Picture 31: Metering frequency from the socket............................................................................................................40
Picture 32: HG 40 cable model ......................................................................................................................................40
Picture 33: Connecting load to the HG hydraulic generator...........................................................................................45
Picture 34: Stopping the HG hydraulic generator ..........................................................................................................46
Picture 35: Power take o in higher temperatures ........................................................................................................46
Picture 36: Cleaning the HG hydraulic generator...........................................................................................................48
Picture 37: Testing the residual current device ..............................................................................................................50
Picture 38: Adjusting the RMP-cartridge.......................................................................................................................51
Picture 39: Adjusting the RPM-cartridge without installation valve 1...........................................................................52
Picture 40: Adjusting the RPM-cartridge without installation valve 2...........................................................................53

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com 7
HYDRAULIC GENERATORS
GENERAL
1. GENERAL
This manual contains general information about assembly, installation, operation
and maintenance of DYNASET HG hydraulic generators.
ATTENTION!
Read this user manual before installation, use or maintenance of the
HG hydraulic generator to ensure proper handling, operation and
maintenance right from the beginning. Pay attention to warnings and
safety instructions. READ CHAPTER„2. SAFETY“.
1.1. PRODUCT INFORMATION
HG hydraulic generators are compact and integrated all-in-one units, especially
designed for mobile installations. The generators use hydraulic power source to
operate and produce high quality electricity.The generators can be used to power
a wide variety of tools, appliances and electric machinery.
1.2. PRODUCT IDENTIFICATION KEY
The product identification key describes the characteristics of the DYNASET
product. The product identification key is on the product type plate which is
attached on to every DYNASET product.
Picture 1: Identification key for HG hydraulic generators
1. Product category, HG hydraulic generators.
2. Nominal power output. Generator’s theoretical power output in kVA.
3. The product series that the generator model belongs to.
4. AC frequency, 50/60 Hz, which the generator is build for.
5. Main output voltage of the generator.
6. Generator’s wiring model.
7. Products ingress protection (IP) class.
8. Nominal hydraulic flow. Theoretical hydraulic flow of the base machine
needed to operate the product.

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
8
HYDRAULIC GENERATORS
GENERAL
9. Hydraulic output equipment attached to the product. READ CHAPTER„1.8.
Hydraulic equipment“.
10.Electric output equipment attached to the product. READ CHAPTER „1.9.
Electric equipment“.
11.Single phase power output socket type on the HG hydraulic generator.
READ CHAPTER„1.9.1. Single phase socket plug type“.
1.3. TYPE PLATE
Picture 2: Type plate
1. Product identification key
2. Product code
3. Serial number
4. Minimum hydraulic flow
5. Maximum hydraulic pressure
6. Production month / year
7. Three Phase: Main voltage
/ current, frequency,
IP classification.
8. Single Phase: Main
voltage/ current.
9. Manufacturer’s contact
information

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com 9
HYDRAULIC GENERATORS
GENERAL
1.4. HG’S LINEUP
Standard DYNASET HG hydraulic generators are divided into six groups. All groups
are divided based on their basic structure and IP classification.
1. HG 1 kW - 2 kW
2. HG 3,5 kVA - 5,0 kVA
3. HG 6,5 kVA - 12 kVA
4. HG 15 kVA - 20 kVA
5. HG 30 kVA - 70 kVA
6. HG P54 generators
Models are presented in picture 3 below.
Picture 3: HG hydraulic generator line-up

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
10
HYDRAULIC GENERATORS
GENERAL
1.5. HG’S MAIN COMPONENTS
Picture 4: Main assembly of the HG hydraulic generators
1. Type plate1
2. Serial number1
3. Electric sockets1
4. Hydraulic return line (T)
5. Hydraulic pressure line (P)
6. Hydraulic motor
7. Residual current device
8. Voltage meter 1,2
9. Fuses 1
1Place may vary between models
2 Optional
1.6. IP Ingress Protection) CLASSIFICATION
HG hydraulic generators are IP classified according to the IEC standard 60529 for
the degrees of protection of electrical equipment.The protection class of standard
HG hydraulic generator complies the specifications IP23 or IP54. Also other IP
class generators are available by request.
HG hydraulic generator’s IP class is marked into the products identification key.
From the following chart you can check your IP class information.

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com 11
HYDRAULIC GENERATORS
GENERAL

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
12
HYDRAULIC GENERATORS
GENERAL
1.7. VOLTAGE AND FREQUENCY
HG hydraulic generators are manufactured to output 110V-690V voltage and
50 or 60 Hz frequecy. Exeption to this are HG 1 and HG 2 models that are VDC
generators. Their output voltage is 14 - 28 VDC.
Picture 5 represents different single phase and picture 6 represents different three
phase voltage and frequency areas in the world.
NOTE!
Always check that the HG hydraulic generators output frequency, voltage
and socket are suitable for your work location.
More information about different countries single and three phase electric
power usage can be found e.g. from the website http://www.worldstandards.eu/
electricity/
The pictures are based on information on the internet page: http://www.
worldstandards.eu/electricity/plugs-and-sockets.
Picture 5: Single phase voltage and frequency map

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com 13
HYDRAULIC GENERATORS
GENERAL
Picture 6: Three phase voltage and frequency world map
1.8. HYDRAULIC EQUIPMENT
This product identification key describes which hydraulic options are included to
the HG hydraulic generator’s structure.
Drain line (L)
An additional drain line can be installed on the HG hydraulic generator if the
pressure in tank line is too high.
NOTE!
The maximum pressure in tank line is 5 bar.
Pressure relief valve (P)
An additional pressure releaf valve can be installed on the generators RPM-block.
Pressure release valve prevents oil pressure raising too high.

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
14
HYDRAULIC GENERATORS
GENERAL
Rubber cushions (R)
Rubber cushions are attachments between HG hydraulic generator and its base
machine. If HG hydraulic generator comes with rubber cushions, grounding of the
generator have to be ensured.
NOTE!
READ CHAPTER„4.4. Grounding“ to see proper grounding for the HG
hydraulic generators.
Without automatic frequency regulation (S)
Without automatic frequency regulation generator does not have any automatic
rotation or frequency control.
NOTE!
Customer is responsible of controling the suitable oil flow and rotation
speed of the hydraulic motor, if an automatic frequency regulation isn´t
provided.
Silence-Motor (E)
An additional hydraulic motor option which noise level is reduced. Silence-motors
are used when low noise level is required.
1.9. ELECTRIC EQUIPMENT
The product identification key describes which electric equipments are included
in HG hydraulic generator’s structure.
All DYNASET HG hydraulic generators except the cable model (K), include fuses
and either a residual current device (V) or a residual current circuit breaker device
(Y). Other electric equipment are optional.
Cable connection (K)
Generators with cable connection come only with cable output. These models
don´t have any electrical safety devices such as fuses and residual current device
circuit breakers on them.
Residual current device (V)
A residual current device (RCD) responds to current leakages by switching the
current off if the current difference between phase and neutral is more than 30
mA.
RCD has a test button to test its proper operation in fault condition. When the
test button is pressed it safely creates a small leakage condition which releases
the switch. RCD is to be tested monthly. READ CHAPTER„6.4. Test Safety devices“.
The RCD (V) includes a residual current circuit breaker device (RCCBD) which
functions are presented in the equipment (Y).

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com 15
HYDRAULIC GENERATORS
GENERAL
Residual current device circuit breaker (Y)
The Residual current device circuit breaker (RCCBD) is installed in the distribution
box. Each socket in distribution box has its own RCCBD with a reset switch.
Automatic circuit breakers protects the unit from a current overload.
RCCBD also includes a test button. When the button is pressed, it safely creates a
small leakage condition and releases the switch. RCCBD (Y) is integrated into the
RCD which functions are presented in the equipment (V).
Insulation monitoring device (I)
An insulation monitoring device is located in the distribution box. The insulation
monitoring device monitors the ungrounded system between an active phase
conductor and earth. It is intended to give an alert (light) or disconnect the power
supply when the resistance drops below the limit value. The first limit value
switches on the red light. The second limit value disconnects the power supply.
Rotation speed sensor (S)
An additional rotation speed sensor can be included on the HG hydraulic generator
when purchasing the generator. The rotation speed sensor is a Hall sensor with
NPN and it is located in the rotors rear axle. Ordering the HG hydraulic generator
with the rotation speed sensor is agreed separately.
Centre grounding transformer (T)
A centre grounding transformer is located in the distribution box. Grounding
transformers allow three wire (delta) polyphase system supplies to accommodate
phase to neutral loads by providing a return path for current to a neutral.
Other Electric Equipment
If you have a need for other electrical equipment for your generator please contact
us for more information about the possibilities of upgrading your product.
1.9.1. SINGLE PHASE SOCKET PLUG TYPE
Picture 7 below shows all the single-phase electricity socket types. In the following
chart are their specification. The pictures are without lids to demonstrate the type
of socket. All delivered sockets come with lids. IP54 models have lockable lids.
NOTE!
Ungrounded plugs and sockets A,C and I are not available.
The pictures are from: http://www.worldstandards.eu/electricity/plugs-and-
sockets.

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
16
HYDRAULIC GENERATORS
GENERAL
Picture 7: Single phase sockets and plugs
Type Grounding Current (A) Voltage (V) Socket compatibility with
plug(s)
ANot grounded 15 100-127 A
BGrounded 15 100-127 A&B
CNot grounded 2,5 220-240 C
DGrounded 5 220-240 C & D, (Unsafe with E & F)
EGrounded 16 220-240 C, E & F
FGrounded 16 220-240 C, E & F
GGrounded 13 220-240 G
HGrounded 16 220-240 C & H (Unsafe with E & F)
I2 pins: not grounded
3pins:grounded 10 220-240 I
JGrounded 10 220-240 C & J
KGrounded 16 220-240 C & K (Unsafe with E & F)
LGrounded 10
16 220-240 10 A socket: C & L. 16 A socket: L
MGrounded 15 220-240 M
NGrounded 10
20 220-240 C & N
OGrounded 16 220-240 C & O (Unsafe with E & F)
The single-phase plugs are also presented in the following map in picture 8 by
their usage in different parts of the world. Note that the map is for general use
only and the plug & socket types might vary from it.

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com 17
HYDRAULIC GENERATORS
GENERAL
Picture 8: Single phase plug and socket map
The pictures are from: http://www.worldstandards.eu/electricity/plugs-and-
sockets.
1.9.2. THREE PHASE SOCKET PLUG TYPE
Three-phase socket plugs are delivered according to the IEC60309 and NEMA
standards. Few common models are presented in the pictures 9 and 10.
Picture 9: IEC60309 three phase sockets and plugs

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
18
HYDRAULIC GENERATORS
GENERAL
Picture 10: NEMA three phase sockets and plugs
Pictures are from: http://www.abb.com/, http://www.mennekes.com/ and http://
www.hubbellcatalog.com/.
Delivered sockets or plugs might have different color or exterior than in the
pictures 9 and 10. Ask for suitable three-phase plug, socket, IP class configuration
when ordering HG hydraulic generator.
Nr. Voltage Rated
current IP class HZ Number of poles
Earthing
sleeve
position
1380 - 415 V 16 A 44 50-60 3p + n + e 6h
2380 - 415 V 16 A 44 50-60 3p + n + e 6h
3346- 415 V 32 A 44 50-60 3p + n + e 6h
4346 - 415 V 32 A 44 50-60 3p + n + e 6h
5346 - 415 V 63 A 44 50-60 3p + n + e 6h
6346 - 415 V 63 A 44 50-60 3p + n + e 6h
7400 V 16 A 67 50-60 3p + n + e 6h
8400 V 32 A 67 50-60 3p + n + e 6h
9125/250V 30 A 66 50-60 3p+e 6h
10 120/208V 30 A 66 50-60 4p+e 6h

19
Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
HYDRAULIC GENERATORS
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 HG hydraulic generator varies 110 - 690V depending on the
generator type.
WARNING
HIGH PRESSURE OIL!
Can cause severe injuries.
Always wear appropriate clothing
and safety equipment.
The hydraulic system is pressurized up to 420bar.

20 Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | [email protected] | www.dynaset.com
HYDRAULIC GENERATORS
SAFETY
The pressure in hydraulic circuits is considerably high. Therefore the condition of
your equipment are to be kept under constant observation. All couplings, valves
and hoses are to be kept tight and clean. Leaks in the hydraulic system must be
repaired immediately to avoid injuries caused by high pressure and oil blowouts.
ATTENTION!
All installations and maintenance must be performed according to this
manual. All electrical installations and maintenance that is not mentioned
in this manual should only be performed by qualified electrician.
NOTE!
Technical condition of your machinery and equipment must be subjected
to constant surveillance.
The base machine must be stopped and the hydraulic circuit be depressurized
prior to maintenance, detaching or disassembling the HG hydraulic generator.
2.2. SAFETY EQUIPMENT
When working with HG hydraulic generator or accessories, wear appropriate
protective clothing, safety goggles, gloves, ear protection.
2.3. OPERATING SAFETY
ATTENTION!
Do not exceed the maximum load.