Dynaset HGV Power Box Series User manual

HGV Basic 3,5
HGV Basic 6,5
HGV Basic 10
HGV Basic 12
HGV Basic 15
HGV Basic 20
HGV Power Box 3,5
HGV Power Box 6,5
HGV Power Box 10
HGV Power Box 15
HGV Power Box 20
06/18 rev 1.2
HGV POWER BOX / HGV BASIC
VARIABLE HYDRAULIC GENERATOR SYSTEMS
USER MANUAL
Download PDF version from www.Dynaset.com/manuals Keycode: B36FKP

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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.
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VARIABLE HYDRAULIC GENERATOR SYSTEM
TABLE OF CONTENTS
1. GENERAL 9
1.1. PRODUCT INFORMATION 9
1.2. PRODUCT IDENTIFICATION 9
1.2.1. HGV POWERBOX 9
1.2.2. HGV BASIC 10
1.3. TYPE PLATES 11
1.4. DYNASET HGV POWER BOX SYSTEMS LINE-UP 12
1.5. DYNASET HGV BASIC SYSTEMS LINE-UP 12
1.6. MAIN ASSEMBLY COMPONENTS OF HGV POWER BOX SYSTEM 13
1.7. MAIN ASSEMBLY COMPONENTS OF HGV BASIC SYSTEMS 14
1.7.1. MAIN ASSEMBLY COMPONENTS OF HGV PUMP 14
1.7.2. MAIN ASSEMBLY COMPONENTS OF HGV GENERATOR 15
1.7.3. MAIN ASSEMBLY COMPONENTS OF HGV COOLER 16
1.7.4. MAIN ASSEMBLY COMPONENTS OF HGV TANK 16
1.8. MAIN ASSEBLY OF THE ELECTRIC CENTRAL 17
1.9. IP(Ingress Protection) CLASSIFICATION 17
1.10. VOLTAGE AND FREQUENCY 18
1.11. HYDRAULIC EQUIPMENT 20
1.12. ELECTRIC EQUIPMENT 20
1.12.1. SINGLE-PHASE SOCKET PLUG TYPE 21
2. SAFETY 25
2.1. SAFETY PRECAUTIONS 25
2.2. SAFETY EQUIPMENT 26
2.3. OPERATING SAFETY 26
2.4. MAINTENANCE SAFETY 27
2.5. WARNING LABELS 28
3. OPERATING PRINCIPLES 29
3.1. OPERATING DESCRIPTION 29
3.2. AUTOMATIC HYDRAULIC FLOW CONTROL 30
4. INSTALLATION 31
4.1. BEFORE INSTALLATION 31
4.1.1. BASE MACHINE 31
4.1.2. HYDRAULIC FLUIDS 32
4.1.3. IP CODE REQUIREMENTS 32

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VARIABLE HYDRAULIC GENERATOR SYSTEM
TABLE OF CONTENTS
4.2. INSTALLING DYNASET HGV POWERBOX SYSTEM 32
4.2.1. HYDRAULIC PUMP & HPTO 32
4.2.2. POWER BOX PLACEMENT AND INSTALLATION MEASUREMENTS 33
4.3. INSTALLING HGV BASIC SYSTEM 35
4.3.1. HYDRAULIC PUMP & DYNASET HPTO 35
4.3.2. HYDRAULIC GENERATOR 35
4.3.3. COOLER 35
4.3.4. OIL TANK 36
4.3.5. ELECTRIC CENTRAL 36
4.4. HYDRAULIC AND ELECTRIC CONNECTIONS 37
4.5. ADJUSTING THE PUMP RPM 42
4.6. OUTPUT FREQUENCY CHECK AT START-UP 42
4.7. OUTPUT FREQUENCY ADJUSTING 43
5. OPERATION 47
5.1. STARTING AND STOPPING THE HGV SYSTEM. 47
5.2. AMBIENT TEMPERATURE 48
6. MAINTENANCE 49
6.1. MAINTENANCE INTERVALS 49
6.2. HYDRAULIC FLUIDS 50
6.3. CLEANING HGV GENERATOR 50
6.4. TEST SAFETY DEVICES 50
6.5. OIL LEVEL CHECK 51
6.6. OIL CHANGE 52
6.7. OIL FILTER CHANGE 53
6.8. TROUBLESHOOTING 54
7. MANUFACTURER’S LIMITED WARRANTY 57
8. PRODUCT DISPOSAL 59
9. DECLARATION OF CONFORMITY 61
10. TECHNICAL SPECIFICATIONS 63

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VARIABLE HYDRAULIC GENERATOR SYSTEM
TABLE OF PICTURES
Picture 1: HGV PowerBox identification key....................................................................................................................9
Picture 2: HGV Basic identification key ..........................................................................................................................10
Picture 3: HGV PowerBox type plate..............................................................................................................................11
Picture 4: HGV Power box system line-up......................................................................................................................12
Picture 5: HGV Basic system line-up..............................................................................................................................12
Picture 6: HGV PowerBox system’s main components ...................................................................................................13
Picture 7: HGV Basic system’s components....................................................................................................................14
Picture 8: HGV pump’s main components......................................................................................................................14
Picture 9: HGV generator’s main components ...............................................................................................................15
Picture 10: Oil cooler main components........................................................................................................................16
Picture 11: Oil tank main components ..........................................................................................................................16
Picture 12: HGV systems electric central’s components .................................................................................................17
Picture 13: Single phase voltage and frequency map....................................................................................................19
Picture 14: Three phase voltage and frequency world map ...........................................................................................19
Picture 15: Single phase sockets and plugs ...................................................................................................................21
Picture 16: Single phase plug and socket map ..............................................................................................................22
Picture 17: IEC60309 three phase sockets and plugs .....................................................................................................22
Picture 18: NEMA three phase sockets and plugs...........................................................................................................23
Picture 19: Operating principle......................................................................................................................................29
Picture 20: Positioning of the HGV system according the IP23 classification..................................................................32
Picture 21: Hydraulic pump installed to transmissions PTO ...........................................................................................32
Picture 22: Hydraulic pump installed to engines PTO ....................................................................................................33
Picture 23: Palcement of the HGV PowerBox system .....................................................................................................33
Picture 24: HGV Power Box installation measurements.................................................................................................34
Picture 25: 6,5 KVA HG hydraulic generator ..................................................................................................................35
Picture 26: DYNASET Oil cooler .....................................................................................................................................35
Picture 27: Oil Tank........................................................................................................................................................36
Picture 28: Electric central.............................................................................................................................................36
Picture 29: HGV Power Box S hydraulic connections......................................................................................................37
Picture 30: HGV Power Box S hydraulic connections......................................................................................................37
Picture 31: HGV Power box hydraulic schema................................................................................................................38
Picture 32: HGV Power Box electric connections............................................................................................................38
Picture 33: HGV Power box electric schema...................................................................................................................39
Picture 34: HGV basic systems hydraulic connections....................................................................................................40
Picture 35: HGV basic systems hydraulic schema...........................................................................................................41
Picture 36: HGV basic systems electric connections.......................................................................................................41
Picture 37: HGV systems frequency check 1...................................................................................................................43
Picture 38: HGV systems frequency check 2...................................................................................................................43
Picture 39: Adjusting HGV systems frequency 1 ............................................................................................................44
Picture 40: Adjusting HGV systems frequency 2 ............................................................................................................45
Picture 41: Adjusting HGV systems frequency 3 ............................................................................................................45
Picture 42: Starting HGV system 1.................................................................................................................................47
Picture 43: Starting HGV system 2.................................................................................................................................47
Picture 44: Starting HGV system 3.................................................................................................................................47
Picture 45: Power take off in higher temperatures ........................................................................................................48
Picture 46: Testing safety equipment ............................................................................................................................51

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VARIABLE HYDRAULIC GENERATOR SYSTEM
TABLE OF PICTURES
Picture 47: Oil tanks oil level gauge...............................................................................................................................51
Picture 48: Oil change ...................................................................................................................................................52
Picture 49: Oil filter change...........................................................................................................................................53

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VARIABLE HYDRAULIC GENERATOR SYSTEM
TABLE OF PICTURES

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VARIABLE HYDRAULIC GENERATOR SYSTEMS
GENERAL
1. GENERAL
This manual contains general information about assembly, installation, operation
and maintenance of the DYNASET HGV variable hydraulic generator systems.
ATTENTION!
Read this operating manual before the use of HGV variable hydraulic
generator system, to ensure proper handling, operation and maintenance
right from the beginning. Pay particular attention to all warning and safety
instructions.
1.1. PRODUCT INFORMATION
HGV variable hydraulic generator system is a compact and integrated all-in-one
generatorsystemdesignedformobileinstallation.HGVsystemsusebasemachine’s
power source to operate and produce high quality electricity for powering various
electric equipment.
HGV systems come in two forms, PowerBox and Basic. In HGV PowerBox main
components are fitted in to a compact casing. HGV Basic is a component kit that
includes same main components than the PowerBox system but whit out the
compact casing.
1.2. PRODUCT IDENTIFICATION
1.2.1. HGV POWERBOX
HGV PowerBox system has an identification key. The identification key of the
system informs the main specifications of the system. Identification key can be
found from the products type plate which are attached as shown in picture 6.
The HGV PowerBox’s product identification key includes following information.
Picture 1: HGV PowerBox identification key
1. Product Group HGV PowerBox Variable Hydraulic Generators.
2. Presents the box’size class.
3. Nominal power output in kVA
4. Main voltage of the generator.

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VARIABLE HYDRAULIC GENERATOR SYSTEMS
GENERAL
5. NominalHydraulicFlow.Thetheoreticalminimalhydraulicowneededtooperate
the HGV system.
6. Presents the voltage system on the base machine either 12V or 24V.
7. Oil cooler size in kW.
8. Oil tank size 18/36 in liters (4.75/9.5 gal).
1.2.2. HGV BASIC
HGV basic system has an identification key. The identification key of the system
informs the main specifications of the system.
The HGV Basic’s product identification key includes following information.
Picture 2: HGV Basic identification key
1. Product Group HGV Variable Hydraulic Generator System.
2. NominAl Power output. Presents the HG hydraulic generator’s nominal power
output in kVA.
3. Generator’s main voltage, 230 or 400 VAC.
4. Hydraulic nominal flow. Presents the theoretical minimal hydraulic flow needed
to operate the HGV system.
5. electric equipment. Presents the electric equipment on HG hydraulic generator.
READ CHAPTER ”1.12. Electric equipment”for more information..
6. The voltage system on the base machine truck (T) or van (V), either 12V or 24V.
7. Operating method. Presents the if the hydraulic pump is operatable (D) or not
operatable (C) when driving the base machine.
8. Pump size. Presents the the hydraulic pump’s size.
9. Pump rotation direction. Presents the rotation direction of the hydraulic pump.
10. Connection flange. Presents the hydraulic pump’s connection flange type to
the base machine’s engine.

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VARIABLE HYDRAULIC GENERATOR SYSTEMS
GENERAL
1.3. TYPE PLATES
HVG PowerBox systems have type plate to identify it. Also every component of the
system has its own type plate. HGV PowerBox’s type plate is presented in picture
3. The placement of the type plate is presented in picture 6.
HGV basic systems on the other hand have type plates only on the systems main
components.
On the HGV Power box’s type plate are the following information
Picture 3: HGV PowerBox type plate
1. Product identification key
2. Product code
3. Serial number
4. Minimal hydraulic flow
5. Maximum hydraulic pressure
6. Production month / year
7. Output power and main voltage
8. Manufacturer’s contact
information

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VARIABLE HYDRAULIC GENERATOR SYSTEMS
GENERAL
1.4. DYNASET HGV POWER BOX SYSTEMS LINEUP
DYNASET HGV Power box systems come in two standard box sizes S and M. Both
sizes come with hydraulic pump, generator, cooler and tank combination. Below
are listed the available standard systems.
Picture 4: HGV Power box system line-up
• HGV Power box 3,5 kVA S
• HGV Power box 6,5 kVA S
• HGV Power box 10 kVA S
• HGV Power box 15 kVA M
• HGV Power box 20 kVA M
1.5. DYNASET HGV BASIC SYSTEMS LINEUP
DYNASET HGV Basic systems consists of hydraulic pump, generator, cooler and
tank combination. Below are listed the standard systems.
1. HGV 3,5 kVA 230 V - R 45 LS
2. HGV 6,5 kVA 400 V - R 45 LS
3. HGV 10 kVA 400 V - R 45 LS
4. HGV 10 kVA 400 V - H90 LS
5. HGV 12 kVA 400 V - H90 LS
6. HGV 15 kVA 400 V - H90 LS
7. HGV 20 kVA 400 V - R140 LS
Picture 5: HGV Basic system line-up

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VARIABLE HYDRAULIC GENERATOR SYSTEMS
GENERAL
1.6. MAIN ASSEMBLY COMPONENTS OF HGV POWER BOX SYSTEM
Picture 6: HGV PowerBox system’s main components
1. Type plate
2. Variable hydraulic pump
3. Hydraulic generator
4. Cooler
5. Oil Tank
6. Hydraulic pressure line (P)
7. Hydraulic suction line (S)
8. Drain line (Dr)
9. LS - line (LS)
10. AC power outlet to central box
11. Control voltage 12/24 V
12. Cooler supply voltage 12/24V

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VARIABLE HYDRAULIC GENERATOR SYSTEMS
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1.7. MAIN ASSEMBLY COMPONENTS OF HGV BASIC SYSTEMS
1 2 3 4
Picture 7: HGV Basic system’s components
1. DYNASET Hydraulic pump
2. DYNASET HG Hydraulic
generator
3. DYNASET Oil cooler
4. DYNASET Oil tank
1.7.1. MAIN ASSEMBLY COMPONENTS OF HGV PUMP
Picture 8: HGV pump’s main components
A. 28, 45, 60, 71 and 100
high speed models B. 60 and 90 models

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VARIABLE HYDRAULIC GENERATOR SYSTEMS
GENERAL
1. Type plate
2. Hydraulic pressure line (P)
3. Hydraulic suction line (S)
4. Hydraulic drain Line (Dr)
5. LS-pressure valve (LS)
6. Pressure release valve
The placement of hydraulic lines and LS-pressure valve varies between pump
models.
1.7.2. MAIN ASSEMBLY COMPONENTS OF HGV GENERATOR
1 5 2 4 3 6
Picture 9: HGV generator’s main components
1. Type plate
2. Serial number
3. Hydraulic pressure line (P)
4. Hydraulic return line (T)
5. Electric sockets
6. Residual current device (RCD)
More detailed information about the generator is found in the HG hydraulic
generatorusermanual.NotethatcontrarytotheHGmanualHGhydraulicgenerator
can’t be adjusted in HGV system because it doesen’t have RPM-cartridge to control
oil flow. The oil flow adjustments are made through HGV systems hydraulic pump.

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VARIABLE HYDRAULIC GENERATOR SYSTEMS
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1.7.3. MAIN ASSEMBLY COMPONENTS OF HGV COOLER
Picture 10: Oil cooler main components
1. Input line (IN)
2. Output line (OUT)
3. 12/24/230V DC Power inlet
1.7.4. MAIN ASSEMBLY COMPONENTS OF HGV TANK
Picture 11: Oil tank main components
1. Return line (T)
2. Hydraulic suction line (S)
3. Hydraulic case drain line (Dr)
4. Filling hole
5. Emptying valve
6. Oil surface sensor outlet
7. Optical oil surface sight

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VARIABLE HYDRAULIC GENERATOR SYSTEMS
GENERAL
1.8. MAIN ASSEBLY OF THE ELECTRIC CENTRAL
The HGV systems can be ordered with or without a electric central.The appearance
of the central box may vary from the example below but the main parts are the
same regardless of the model used.
Picture 12: HGV systems electric central’s components
1. Electric cable from
the generator
2. Electric sockets
3. Safety devices
4. Voltage meter
1.9. IPIngress Protection) CLASSIFICATION
HGV systems are IP classified according to IEC standard 60529 for the degrees of
protection of electrical equipment. The protection class of standard HGV system
comply with specifications IP23. IP54 classification HGV systems are available by
request.
From the IP classification chart you can check your IP class information.

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VARIABLE HYDRAULIC GENERATOR SYSTEMS
GENERAL
1
2
3
4
5
6
1
2
3
5
6
7
8
2
3
4
SOLIDS WATER
30 min
0,15 - 1 m
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. Limited ingress
permitted.
Protected against direct
sprays of water with
up to 15 degrees from
vertical. Limited ingress
permitted.
Protected against
direct sprays of water
up to 60 degrees from
vertical. Limited ingress
permitted.
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.
1.10. VOLTAGE AND FREQUENCY
HGV variable hydraulic generator systems are manufactured to output up to
350kVA with the range of 110V-690V voltage for 50 or 60 Hz frequecies.
Picture 13 represents different single phase and picture 14 represents different
three phase voltage and frequency areas in the world.

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VARIABLE HYDRAULIC GENERATOR SYSTEMS
GENERAL
NOTE!
Always check that the HG hydraulic generators output frequency, voltage
and socket are suitable for your work location.
Picture 13: Single phase voltage and frequency map
Picture 14: Three phase voltage and frequency world map

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VARIABLE HYDRAULIC GENERATOR SYSTEMS
GENERAL
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.
1.11. HYDRAULIC EQUIPMENT
The HGV variable hydraulic generator system has optional hydraulic equipment.
High speed hydraulic pump
Optional hydraulic high speed pump is available for the HGV systems. High speed
pump tolerates high RPM (up to 5000 RPM) and can be used while driving the
base machine.
Silence motor (E)
An additional silenced hydraulic motor is an option to the HGV generator. Silence-
motor’s noise level is reduced and they are used when low noise level is required.
1.12. ELECTRIC EQUIPMENT
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” for
more information.
The RCD (V) includes a residual current circuit breaker device (RCCBD).
Residual current device circuit breaker (Y)
The Residual current device circuit breaker (RCCBD) is installed in the distribution
box. Each socket in central 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).
Other Electric Equipment
If you have a need for other electrical equipment for your generator please contact
DYNASET for more information about the possibilities for upgrading your product.