DYNAWATT 4000 User manual

4000
User Manual
Installation
and
Operation
L100- 01E 05.99
230V POWER SYSTEMS

Congratulations
on your purchase of a DYNAWATT 230V POWER SYSTEM 4000. You have now
acquired a high quality, precision-manufactured power supply system for mobile use.
Please read these Operating Instructions through carefully before using the system
for the first time.
In any event, installation should only be carried out by a qualified technical workshop.
Manufacturer: DYNAWATT AG
Zinkereistrasse 35
8633 Wolfhausen
Switzerland
Tel: [phone]
Fax: [phone]
2

SYSTEM DATA
The DYNAWATT 230V Power System consists of three parts. They are:
1. Generator Figure 1 Page: 18
2. Control unit Figure 2 Page: 19
3. Remote control Figure 3 Page: 20 (option)
The basic system also comes with 2x installation brackets, 6m of generator cable.
Please note the following information on your system.
Generator: Series No. ........................
Control unit: Series No. .........................
Safety Precautions
• The DYNAWATT Power System 4000 generates an output voltage of 230V AC. When opera-
ting the system please therefore observe the general safety regulations for using electrical
equipment. In other words e.g. do not allow any liquids to get into the housing, do not use
any sharp instruments, in particular do not insert any metallic objects into the ventilation slot!
• The system is electrically insulated (galvanic separation between electronics and housing)
and is not earthed to the chassis. (IT mains installation with potential compensation)
• When the engine is running the circuits are live. In order to ensure optimum cooling the unit
must be installed vertically and the ventilation slots kept clear.
• All installation screws (installation kit) must be secured to prevent accidental loosening by
using Loctite.
IMPORTANT
Installation and maintenance of the system should only be carried out by trained
personnel. Any faults which are attributable to the use of components other than the
components supplied by DYNAWATT AG, or the failure to observe the safety
instructions as specified above, are not covered by the warranty.
A Power Transfer Switch must be installed if the vehicle (boat etc.) can also be connected
to other power sources e.g. 230V external power (shore power), generator, inverter etc.
Failure to comply with this instruction will cause damage to the control unit, this damage is
not covered by the guarantee. Power Transfer Switches are available from DYNAWATT as
an option.
3

Index of Contents
System Data 3
Safety Precautions 2
List of Figures 5
Technical Specification 6
Additional Components 7
List of Parts Supplied 7
Parts Required, but not Supplied 7
Generator Speed and Available Power 7
Introduction 8
Operation 9
Installation Guidelines and Safety Precautions 12
Installation Procedures 13
Warranty 16
Figures 17 – 26
4

List of Figures
All figures can be found at the back of the manual, listed in the order of the figure numbers.
Figure Page Description
1 17 Generator
2 18 Control Unit
3 19 Remote Control
4 20 Generator Performance Curve
5 21 Preparing the Connection Cable
6 22 Generator and 230V Connection Terminals
7 23 Power Transfer Switch
8 24 Control Unit Installation
9 25 Generator Installation
10 26 System Block Diagramm
5

Technical Specification
CONTROL UNIT
Output voltage: 230V .AC ± 5%
Phases: 1 phase
Transformation: 250V by the generator to 230V
Frequency: 50 Hz ± 0.5%
Output wave: sine wave
Output power: 4000 Watts intermittent @ 6000 rpm
generator: 3500 Watts continuous
Start-up current: 23 Amp (2ms)
Efficiency: 96%
Weight: 7.8 kg
Protection category: IP 21
System Protection: System automatically shuts of by: overload,
overheating or short circuit (double fault)
Dimensions: See Figure 1
GENERATOR
Power output: max. 4500 Watt
Output voltage: 3 x 250V AC
Output frequency: variable, between 300 and 1500 Hz
Generator speed: 18,000 rpm intermittent
15,000 rpm continuous
Weight: 7.2 kg
Belt pulley: DIA 57mm, 2 x 9,5mm belt
Efficiency: 70%
Insulation category: H (170º)
Phase resistance: 3.4 Ohm ± 0.3 (from phase to phase)
Resistance rotor: 2.5 to 3.5 Ohm
Dimensions: See Figure 2
REMOTE CONTROL
Switch: STANDBY / ON
Indicators add rpm, overload, overheating, short circuit
Connection cable length: 5m standard, 10m available on request.
Dimensions: See Figure 3
6

Additional components
Power Transfer Switch
A Power Transfer Switch must be installed for switching over from an external power source
(e.g. shore power 230V) to on board power source, DYNAWATT. Fig. 7.
List of Parts Supplied
1. Generator is supplied with 6m cable
2. Control unit
a. 2 pc. attachment brackets (loose)
b. 4 pc. M6 x 10mm attachment screws for brackets (on the back of Control Unit)
c. EMI fitting for the generator cable (on the front side of CU)
d. Fitting for the 230V cable (on the front side of CU)
3. Remote control with 5 or 10 m cable (available as an option)
4. User manual
Parts Required, Not Supplied
1. Three-conductor power cable, min. 3x1.5mm2
2. Vehicle-specific installation sets available on request.
3. 4 pc. attachment screws for the Control Unit
Generator Speed and Available Power
Calculation Sheet
(Note: Measure the belt pulley external diameter)
Generator speed
Belt pulley dia. generator side: Ra = .......... mm
Belt pulley dia. motor side: Rm = ......... mm
Motor speed idling: nL = ........... rpm
Motor speed max.: nM = .......... rpm
Belt pulley transmission: iR = Rm : Ra= .............
Generator idling rpm: NAIdling = (iR) x (nL) = ........ rpm
Generator max. rpm: Namax = (iR) x (nM) = ........ rpm
Available output in watts
Read from the Curve of Figure 21
Power at engine idle speed (NAIdling) .................. Watt
Minimum speed for full load .................. rpm
7

Introduction
MANUAL CONTENT
This manual covers: Operating Instructions, Installation Guidelines and Installation Instructions.
SYSTEM DESCRIPTION
Generator and Control Unit
The system consists of a high performance generator which is belt-driven by the main engine
and controlled by the control unit. Whenever the engine is on, a precisely controlled 230V
power source with 50 Hz sine wave AC is available. Once the system is installed, the operation
of the system is automatic, including automatic shutdown if an overload or short circuit occurs.
Remote Control
The remote control provides a POWER ON and STANDBY OFF switch and has 4 LED status
and fault indicators.
Power Transfer Switch
A Power Transfer Switch is required for switching between an external power source (230V
mains) and the DYNAWATT Power System.
WARNING
Voltage must never be connected to the control unit! Return voltage
will immediately result in the control unit being damaged!!
NO WARRANTY
8

OPERATION
Figure 4. At full power the system delivers 4000 Watts AC and can deliver higher peak out put
on a temporary basis. However, the system automatically shuts off in the event of a continuous
overload. This chapter explains how the user can avoid this situation arising. It deals with four
areas.
1. Motor speed
2. Overload
3. Start phase
4. Remote control
Engine speed
At idling speed the generator delivers a percentage of its potential output. Generation of
the maximum output requires a higher engine speed. Figure 4 shows a performance curve
for calculating the drive ratio, the output available from the system on idling speed and the
minimum engine speed required in order to achieve the system’s maximum output.
Overload
With most overload situations there are three adjustment options.
1. Reduce the electrical load
2. Increase the motor speed slightly
3. Shut off the entire power consumption temporarily by switching off the control unit or
switching to STANDBY on the remote control. This option avoids the system automatically
shutting down. The load must then be reduced or the motor speed first increased.
Start phase
Electrical consumers (in particular electric motors) take up far more current when they are
switched on than when in operation. Electric motors are amongst the biggest ‘consumers of
electricity’, e.g. an air conditioning system which requires 6 - 7 amps when running operation
can require a starting current of up to 50 amps. The DYNAWATT 4000 delivers up to 23 amps
starting current. In some situations the user will have to follow the start-up procedure as
shown below:
1. Switch off all loads
2. Switch on the largest load first
3. Switch on the remaining small loads.
If the starting current for a load is too high then a soft start can be connected between
the DYNAWATT and the user. The soft start reduces the starting current by up to 70% by
electronically slowing down the start-up speed of the user. This enables motors with
considerably higher starting currents to be operated.
Remote control (option)
STANDBY
The system is switched to ‘STANDBY’ by pressing the toggle switch. In this state there is no
voltage and the ‘STANDBY’ LED light comes on.
9

POWER ON
Pressing the toggle switch to ‘POWER ON’ activates the system. The ‘ON’ LED light comes on
if the system is switched on.
NOTE
The control unit mains switch must be set to ON if the remote control is used.
Otherwise it will not function.
INCREASE SPEED
The control unit continuously measures the power output. If the voltage falls by more than 5%
under load or because the generator speed is too slow, with the result that the power output is
no longer sufficient for the current level of consumption, then the control unit increases the
magnetising voltage. Once this reaches the maximum of 14V and the voltage generated is still
below 218V then the ‘ADD RPM’ LED light comes on.
Remedy: – Increase engine speed
– Check belt tension for slippage, tighten or replace belt
OVERLOAD
Under a continuous heavy load the voltage falls to 180V and the current limiter limits the
output current to 17.5 amps. The system can however still continue to be operated without
any problem although the ‘OVERLOAD’ LED will come on.
If there is a sudden heavy load increase the system automatically shuts off and the
‘OVERLOAD’ LED light comes on.
Remedy: Reduce the load, after approx. 20 seconds the system automatically switches itself
back on. It can however also be switched off briefly and then back on again.
HIGH TEMPERATURE Overheating
A continuously high load or an overload can cause the system to overheat. If the system
reaches a temperature of 62 °C the ‘HIGH TEMPERATURE’ LED light starts to flash. At 65 °C
the system automatically shuts off. The system only switches back on automatically once
it has cooled down to 52 °C.
The cause of the overheating can be either incorrect installation, inadequate cooling or a
defective fan.
Remedy: Check that the Control unit is well ventilated. Test the fan operation, if a
suction filter is used the filter may need to be cleaned.
10

SHORT CIRCUIT
In the event of a short circuit or a very high load (<70 amps) the control unit automatically
switches off and the ‘SHORT CIRCUIT’ LED light comes on.
Remedy: Switch off the unit and rectify the fault. Then switch the unit back on again.
The system does not switch back on automatically after a short circuit.
System ON and OFF
If the system has been turned off by engine shut down the ON / OFF switch must be rest
to off and on again otherwise the system will not start.
Periodic Maintenance
V-Belt
The system does not need any periodic maintenance with the exception of checking the
V-belts which are used to drive the generator. We strongly recommend purchasing replacement
belts. Where a twin belt system is used both belts must be replaced simultaneously. Only high
performance belts should be used, such as e.g. GATES Type ESC or CONTI Industry.
NOTE
A new V-belt will expand during the first hours of operation and the tension must
therefore be subsequently adjusted after the first 10 hours.
Generator Bearings and Brushes
Depending upon the load and the extent to which the system is used the brushes and
bearings should be replaced after approx. 1000 hrs or 80,000 km. Please contact your
nearest DYNAWATT dealer for replacements.
11

Installation Guidelines and Safety Precautions
IMPORTANT
It is essential for the system to be installed professionally to ensure reliable
operation over a long period of time. The mechanical installation of the generator is
of particular importance. In the event of any problems occurring please contact
your DYNAWATT dealer.
GENERATOR
A number of factors must be taken into account to ensure the generator is correctly installed.
Particular attention must be paid to the correct selection criteria.
1. Installation site and stability
2. Choice of belt pulley for the right speed range
3. Choice of belt for minimum system maintenance
4. Belt positioning, alignment and tension.
Installation Site
The generator can:
1. be fitted to the engine block as an addition to the existing alternator
2. be fitted next to the engine. This requires a special, automatic belt tensioner which
is available as an accessory.
3. Whichever choice you make it is essential for the generator to be installed securely.
INFORMATION
The generator cable should be laid in a separate protective conduit to
safeguard it from mechanical effects.
Choice of Belt Pulley
See Figure 4; System Performance curve. The curve shows that no output is delivered by the
system until the generator speed reaches approx. 2900 rpm. and the system generates a 50%
output at a generator speed of approx. 3700 rpm.
To achieve the best results the system should reach a minimum generator speed of 3500 rpm
at engine idle
Generator maximum speed: 15,000 rpm continuous
18,000 rpm maximum
12

Choice of Belt
The power which is transferred via the belts depends upon the belt width, wrap-around angle,
the number of belts and the belt tension. The service life of a single belt system is considerably
less than that of a twin belt system.
DIA pulley Belt size Type Qty Max. output
65 mm 12.5mm 12.5 ESC toothed 1 2500 Watt
57 mm 9.5mm 9.5 ESC toothed 2 4000 Watt STANDARD
65 mm 12.5 12.5 ESC toothed 2 > 4000 Watt
50 mm Micro-V Micro-V 6 grooved 1 4000 Watt
Belt Pulley Alignment
Nothing is more important for the service life of a belt than the alignment of the generator
pulley and engine pulley. Both pulleys must be absolutely parallel and flush aligned. If a pulley
is positioned at an angle to or slightly behind the other this can lead at least to a material
related reduction in the useful life of the belt. In addition the belt may slip out of the grooves.
INSTALLATION
Generator Installation
Figure 9. The generator is fitted as an additional alternator. It must be securely and
permanently installed since the drive takes two to three times more power than factory-fitted
standard alternator. The ratio to be taken into account during installation is dependent upon
the engine idling speed and the maximum speed.
NOTE
All installation screws must therefore be secured using Loctite to prevent
accidentally working loose.
Fitting the generator cover
The generator cover must be positioned in such a way that the generator is able to take in dry,
cool air via the intake opening (DIA. 55 mm). If this is not possible then a suction hose must
be connected to the opening to provide dry, cool air and must be fitted in an appropriate
position in the vehicle. The higher the air intake temperature the greater the heat related loss of
generator performance. See Figure 9.
13

Generator Magnetization
The generator must be magnetized before installing it otherwise the system may not
operate at all.
Attach the 12 volt generator cable, No. 4 (+) plus, No.5 (-) minus to a 12 volt battery
for approx. 30 seconds.
WARNING
On no account must this be carried out whilst the engine is running and
the Control Unit connected. The Control Unit will be immediately damaged by
high voltage. NO WARRANTY
Engine rpm control
To enable the idling speed to be increased we recommend fitting a hand throttle or an
automatic engine speed accelerator. Available as an option.
Control Unit mounting
The control unit is to be installed in a well ventilated, dry place with average temperature levels.
See Figure 8. The ideal position is against a wall, cable connections at the bottom. For this
the two brackets, supplied separately, are screw connected to the rear of the control unit.
The control unit must not be installed horizontally, it is important to ensure that the air outlet
slots on the reverse are not blocked.
WARNING
The brackets must only be fitted to the rear of the Control Unit by using the
supplied M6 screws, with a maximum length of 10 mm.
Connection the generator cable
The five conductor generator cable has to be prepared as shown in Figure 5. Open the front
cover of the control unit (undo 3 screws) and insert the cable into the housing through the
metal fitting. Lead the numbered cables (1-5) to the correct terminal number and attach. To
attach the cable press the terminal clamp down by using a small screwdriver. Ensure the
cables are securely clamped. The cable shield mash is fitted as shown in Figure 5. Then gently
tighten the screw connection using an SW 30 mm spanner. Make sure that the gen.cable is not
turning around while tightening.
Cable function: No. Function Terminal No. Voltage
1 1st Phase L (1) 250V AC
2 2nd Phase L (2) 250V AC
3 3rd Phase L (3) 250V AC
4 (+) Magnetizing current + (4) red +12V DC
5 (-) Magnetizing current - (5) blue - 12V DC
14

230V Connection
Prepare cable as shown in Figure 5 and pull it through the plastic screw connection
into the Control Unit. Attach cable to the output filter terminal clamp. Ensure secure fit.
Minimum recommended cable size: 3x1.5mm2. (Cable up to 4mm2 possible)
230V connection terminal function: Terminal No. Function Cable colour
L Phase Brown
N Neutral Blue
E Earth Yellow/Green
Starting the System
The following must be checked before starting the system:
- that the generator cable has been correctly installed
- that the V-belt tension has been correctly set
- that all installation screws have been tightened
- that the cables have been connected to the correct terminals and are securely clamped.
- when unit is switched ON, check if fan is operating
Troubleshooting
The system doesn’t work Check the condition and tension of the V-belts.
Check the cable and terminal connections.
LEDs on the remote control faint Check to see whether cable 4 (+) and 5 (-)
but no power have been connected the wrong way
around or whether generator must be
magnetized again. See Page 14.
Increase Speed Light comes on V-belt slipping, check tension and condition,
adjust tension.
15

Testing the Generator
With generator turning: 250V AC must be measured on the terminal from phase to
phase (1-2-3). (Warning, high voltage)
With generator stationary: The resistance on the terminal from phase to phase (1-2-3)
must be 3.4 ohms +/- 0.3.
If fault displayed: Contact supplier
Rotor resistance: 2.5 to 3.5 ohms between cable no. 4 (+) and 5 (-)
If fault displayed: – Check generator carbon brushes
– Clean collector ring with fine sandpaper if necessary
Warranty Terms
1. The system is guaranteed for material and production defects. The warranty only
covers the unit itself and not any consequential damage. The warranty application
form, containing adequate information, must be sent to the vendor.
2. The warranty period extends for 12 months from the date of purchase by the first
purchaser.
3. The system must be used and installed in accordance with the details contained
in these Operating Instructions.
4. The warranty does not cover:
– faults and repair costs caused as a result of improper use, modifications or
incorrect installation
– injuries and indirect damage to vehicles etc.
– consequential costs and costs incurred due to loss of vehicle
– moving parts such as V-belts, LED’s, plastic components etc.
5. The warranty application must be submitted within a reasonable period of time, if
possible within 14 days following the occurrence of the damage. The applicant must
provide appropriate evidence to show when and where the system was purchased.
6. Despatch costs, installation and dismantling costs are to be borne by the applicant
unless expressly agreed otherwise.
16

17
Figure: 1 Generator

18
Figure: 2 Controllunit

19
Figure: 3 Remote Control

20
Figure: 4 Generator Performance Curve