USER MANUAL HYDRAULIC WELDING GENERATORS HWG 180/6K-34 HWG 220/6K-49 HWG 300/10K-54 HWG 400/10K-79. Download PDF version from

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1 rev 1.2 USER MANUAL HYDRAULIC WELDING GENERATORS HWG 180/6K-34 HWG 220/6K-49 HWG 300/10K-54 HWG 400/10K-79 Download PDF version from Keycode: CFJ3SA

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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 Subscribe to our newsletter. Follow the QR code! Dynaset Oy Menotie 3, FI Ylöjärvi, Finland tel: info@dynaset.com 3

4 TABLE OF CONTENTS 1. GENERAL PRODUCT INFORMATION PRODUCT IDENTIFICATION KEY TYPE PLATE HWG LINE-UP MAIN COMPONENTS OF HWG IP (Ingress Protection) CLASSIFICATION VOLTAGE AND FREQUENCY HYDRAULIC EQUIPMENT ELECTRIC EQUIPMENT SINGLE PHASE SOCKET PLUG TYPE THREE PHASE SOCKET PLUG TYPE SAFETY SAFETY PRECAUTIONS SAFETY EQUIPMENT OPERATING SAFETY MAINTENANCE SAFETY WARNING LABELS OPERATING PRINCIPLES OPERATING DESCRIPTION WELDING PERFORMANCE AUXILIARY VOLTAGE CONTROL PERFORMANCE OF AUTOMATIC FREQUENCY CONTROL PRESSURE POWER RATIO INSTALLATION BEFORE INSTALLATION HYDRAULIC SYSTEM OF A BASE MACHINE DYNASET VALVES INSTALLING DYNASET HYDRAULIC PRODUCT PLACING DYNASET HYDRAULIC PRODUCT INSTALLING DYNASET VALVES CONNECTING HYDRAULIC HOSES HYDRAULIC FLUIDS 37 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

5 TABLE OF CONTENTS 4.3. INSTALLING HWG HYDRAULIC WELDING GENERATOR GROUNDING IP CODE REQUIREMENTS OUTPUT FREQUENCY INSPECTION AT START-UP OPERATION HWG CONTROL PANEL STARTING HWG WELDING PREPARATION SELECTING WELDING CURRENT WITH HWG 180/220/ SELECTING WELDING CURRENT WITH HWG WELDING WITH THE HWG CONNECTING A LOAD TO GENERATOR STOPPING THE HWG BATTERY CHARGING AND JUMP STARTING PROCEDURE WITH HWG REMOTE CONTROL OVERHEATING AND OVERLOAD SITUATION AMBIENT TEMPERATURE MAINTENANCE MAINTENANCE INTERVALS HYDRAULIC FLUIDS CLEANING HWG HYDRAULIC WELDING GENERATOR TEST SAFETY DEVICES ADJUSTING OUTPUT FREQUENCY TROUBLESHOOTING MANUFACTURER S LIMITED WARRANTY PRODUCT DISPOSAL DECLARATION OF CONFORMITY TECHNICAL SPECIFICATIONS 65 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

6 TABLE OF PICTURES Picture 1: HWG Identification key... 7 Picture 2: HWG type plate... 8 Picture 3: HWG hydraulic welder generator line-up... 8 Picture 4: HWG 180/220/300/400 main components... 9 Picture 5: Single phase voltage and frequency world map Picture 6: Three phase voltage and frequency world map Picture 7: Single phase sockets and plugs Picture 8: Single phase plug and socket world map Picture 9: Three phase IP23 plug and socket Picture 10: HWG operating principlet Picture 11: Automatic frequency control Picture 12: Pressure/Power chart Picture 13: Open centre hydraulic system with load sensing variable displacement pump Picture 14: Connection figure for open centre hydraulic system with load sensing variable displacement pump Picture 15: Closed centre hydraulic system with load sensing variable displacement pump Picture 16: Connection figure for closed centre hydraulic system with load sensing variable displacement pump Picture 17: Hydraulic system with constant displacement pump Picture 18: Connection figure for hydraulic system with fixed displacement pump Picture 19: LSV Load sensing valve Picture 20: PV-SAE Priority valve Picture 21: Placing DYNASET product Picture 22: Installing hydraulic hoses Picture 23: Hydraulic flow at least minimal Picture 24: Base machine s pumps Picture 25: Return line (T) pressure must be under 5 bars Picture 26: Placement of the HWG hydraulic welding generator with sufficient room and ventilation Picture 27: Grounding the HWG hydraulic welding generator Picture 28: Starting the HWG with control valve Picture 29: Measuring frequency Picture 30: HWG models and their control panels Picture 31: Applying the welding cable pliers Picture 32: Welding Picture 33: HWG with connected load Picture 34: Stopping the HWG Picture 35: Power take off in higher temperatures Picture 36: Cleaning HWG Picture 37: Testing the residual current device Picture 38: Adjusting the frequency Picture 39: Cartridge tuning without installation valve Picture 40: Cartridge tuning without installation valve Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

7 GENERAL 1. GENERAL This manual contains general information about the assembly, installation, operation and maintenance of the DYNASET HWG hydraulic welding generators. ATTENTION! Read this user manual before installation, use or maintenance of the HWG hydraulic welding generator, to ensure proper handling, operation and maintenance right from the beginning. Pay attention to the warning and safety instructions. READ CHAPTER 2. SAFETY for more information PRODUCT INFORMATION HWG hydraulic welding generators are compact and integrated all-in-one units, designed especially for mobile installation. HWG hydraulic welding generators use hydraulic power source to operate and produce high quality electricity for welding and powering electric equipment 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: HWG Identification key 1. Product group HWG Hydraulic Welding Generators. 2. Maximum welding current. 3. Generator s theoretical power output in kva. 4. Nominal hydraulic flow.the theoretical hydraulic flow of the base machine needed to operate the product. 5. Hydraulic equipment attached to the HWG. READ CHAPTER 1.8. Hydraulic equipment for more information. 6. Electric output equipment attached to the HWG. READ CHAPTER 1.9. Electric equipment for more information. 7. Power output socket types are attached to the HWG. READ CHAPTER Single phase socket plug type for more information. Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 7

8 GENERAL 1.3. TYPE PLATE Picture 2: HWG type plate 1. Product identification key 2. Product code 3. Serial number 4. Minimum hydraulic flow 5. Maximum hydraulic pressure 1.4. HWG LINE-UP 6. Production month / year 7. Auxiliary output voltage / current, frequency, IP classification. 8. Max. welding current. 9. Manufacturer s contact information DYNASET HWG come in eight standard models. They vary by their welding current ( A) and auxiliary power output (230V-400V). DYNASET HWG hydraulic welders are made for 50 Hz as standard. 60 Hz models are available by request. 1. HWG 180/6K HWG 220/6K - 49 Models are presented in picture HWG 300/10K HWG 400/10K - 79 Picture 3: HWG hydraulic welder generator line-up 8 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

9 GENERAL 1.5. MAIN COMPONENTS OF HWG Picture 4: HWG 180/220/300/400 main components 1. Type plate 1 8. Residual current device 2. Serial number 1 9. Voltage meter 2 3. Alternator 10. Fuses 4. Hydraulic return line (T) 11. Welding cable terminal 5. Hydraulic pressure line (P) 12. Welding current range selector 1 6. Hydraulic motor 13. Welding/Generator switch 1 7. Electric sockets 1 1 Place may vary 2 Optional Welding controls of each model are described in chapter 5. Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 9

10 GENERAL 1.6. IP (Ingress Protection) CLASSIFICATION HWG hydraulic generators are IP classified according to the IEC standard for the degrees of protection of electrical equipment. The protection class of standard HWG 180/220/300/400 hydraulic generators complies with the specifications IP Dynaset Oy Menotie 3, Ylöjärvi puh

11 GENERAL 1.7. VOLTAGE AND FREQUENCY HWG hydraulic welding generators are manufactured for an output of 21,5-73 VDC welding voltage. Striking voltage being up to 73 VDC and welding between 21,5-36 VDC, depending on the model. DYNASET HWG welding generators are made as a CC (Constant Current) welding machines. In this type of welding machine the current is kept constant while the welding voltage is allowed to change to maintain good welding result. HWG 180/220/300/400 also have 230V - 400Vac auxiliary outputs. Models are made for 50 Hz as standard. The picture 5 represents general single phase voltage and frequency areas in the world. The picture 6 represents general three phase voltage and frequency areas in the world. More information about different countries single and three-phase electric power usage can be found from the The pictures are based on information on the internet page: worldstandards.eu/electricity/plugs-and-sockets. Picture 5: Single phase voltage and frequency world map Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 11

12 GENERAL NOTE! Always check that the HWG hydraulic welding generators electric power output frequency, voltage and sockets are suitable for the use in your destination. Picture 6: Three phase voltage and frequency world map 1.8. HYDRAULIC EQUIPMENT The product identification key describes which options are include in the HWG hydraulic generator s structure. Drain line (L) An additional drain line can be installed if the pressure in tank line is too high. 12 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

13 GENERAL NOTE! The maximum continuous pressure in tank line is 5 bar. Pressure relief valve (P) An additional pressure relief valve can be installed on the generators RPM-block. Pressure release valve prevents oil pressure raising too high. Rubber cushions (R) Rubber cushions are attachments between HWG generator and its base machine. If HWG generator comes with rubber cushions, grounding of the generator have to be ensured. NOTE! READ CHAPTER 4.4. Grounding for more information about proper grounding for the HWG hydraulic welding generators. Silence-Motor (E) An additional hydraulic motor option. In this option noise level is reduced. Silencemotors are used when low noise level is required ELECTRIC EQUIPMENT The product identification key describes which electric equipment are included in HWG hydraulic welding generator s structure. Every DYNASET HWG hydraulic welding generator with an auxiliary power output include fuses, either a residual current device (V) or a residual current circuit breaker (Y). Other electric equipments are optional. Cable connection (K) Cable connection model has a cable auxiliary power output connection instead of a plain socket output. Cable connection models don t have any electrical safety devices such as fuses and residual current circuit breakers on them. Cable connection is available only by request only. 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) which functions are presented in the equipment (Y). Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 13

14 GENERAL Residual current circuit breaker device (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). 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 SINGLE PHASE SOCKET PLUG TYPE The product identification key describes which socket option includes to the HWG hydraulic generator s structure. In the picture 7 are presented all the single-phase electricity socket types and in the following chart their specification. All delivered sockets are with covers. The pictures are from: NOTE! Ungrounded plugs and sockets A,C and I are unavailable. Picture 7: Single phase sockets and plugs 14 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

15 GENERAL Type Grounding Current (A) Voltage (V) Socket compatibility with plug(s) A Not grounded A B Grounded A&B C Not grounded 2, C D Grounded C & D, (Unsafe with E & F) E Grounded C, E & F F Grounded C, E & F G Grounded G H Grounded C & H (Unsafe with E & F) I 2 pins: not grounded 3pins:grounded I J Grounded C & J K Grounded C & K (Unsafe with E & F) L Grounded A socket: C & L. 16 A socket: L M Grounded M N Grounded C & N O Grounded C & O (Unsafe with E & F) The single phase plugs are also presented in the following 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. Picture 8: Single phase plug and socket world map Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 15

16 GENERAL THREE PHASE SOCKET PLUG TYPE Three phase socket plugs are delivered according to the IEC60309 standard. Picture 9 shows typical IP23 plug and socket types. Delivered sockets or plugs might have different color or exterior than in the picture 9. Ask for suitable three phase plug and socket configuration when ordering a HWG hydraulic welding generator. Picture 9: Three phase IP23 plug and socket Nr. Voltage Rated current IP class Hz Number of poles Earthing sleeve position V 16 A p + n + e 6h V 16 A p + n + e 6h 16 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

17 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. Operating voltage of the HWG hydraulic welding generators vary from 21,5-73 VDC in welding mode to Vac in the generator mode. The hydraulic system can be pressurized up to 420 bar. HIGH PRESSURE OIL! WARNING Can cause severe injuries. Always wear appropriate clothing and safety equipment. Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 17

18 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. NOTE! Technical condition of your machinery and equipment must be subjected to constant surveillance. Base machine must be stopped and hydraulic circuit depressurized prior to maintenance, detaching or disassembling of the HWG hydraulic welding generator SAFETY EQUIPMENT Always wear appropriate clothing and safety equipment such as safety goggles, safety shoes, ear and eye protection when operating the HWG OPERATING SAFETY ATTENTION! Do not exceed the maximum load. RISK OF BURNS! WARNING The unit parts and oil can be hotter than 80 C! Wear personal safety equipment! 18 Dynaset Oy Menotie 3, Ylöjärvi puh

19 SAFETY RISK OF ELECTRIC SHOCK! WARNING Electric shock from welding electrode can kill. Do not weld in rain or snow. Wear proper dry insulating safety equipment. RISK OF ELECTRIC SHOCK. WARNING RISK OF SEVERE EYE INJURY Arc rays can seriously harm your eyes and injure skin. Use welding helmet with correct shade of filter and wear proper protective gear. WARNING RISK INDUCED BY WELDING FUMES! Breathing welding fumes can be hazardous to your health. Use welding equipment in an open area. Use ventilating fan to remove fumes. RISK OF FIRE. WARNING Welding sparks can cause explosion or fire. Keep flammable material away from welding area. Do not weld in closed containers. Dynaset Oy Menotie 3, Ylöjärvi puh

20 SAFETY ELECTROMAGNETIC FIELD INTERFERENCE WARNING Welding current produces electromagnetic field. Do not use with medical implants. Never coil welding cables around your body. Ensure also that the electromagnetic field does not interfere or damage other electrical and electronic equipment and instrumentation. Switch off and unplug all sensitive electric and electronic units e.g. AC-chargers, electronic sensors, control and measurement instruments MAINTENANCE SAFETY NOTE! When carrying out any maintenance to the HWG hydraulic welding generator keep the components of the system clean. This is to ensure safe, reliable and longlife operation of your equipment. 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 10 minutes for proper discharge. 10min RISK OF ELECTRIC SHOCK. Hydraulic system of a base machine should be maintained according to the machine s service program. READ CHAPTER 6.1. Maintenance Intervals for more information. ATTENTION! Before beginning any maintenance or repair, ensure that the system is switched off. Make sure that the system can not start accidentally. 20 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

21 SAFETY 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 to or close to DYNASET product where it s easily seen. Clean surface with solvent detergent before attaching labels. READ OPERATING INSTRUCTIONS. USE EAR PROTECTION AND SAFETY GOGGLES. HIGH PRESSURE OIL RISK OF ELECTRIC SHOCK. BEWARE OF HOT SURFACE. Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 21

22 SAFETY 22 Dynaset Oy Menotie 3, Ylöjärvi puh

23 OPERATING PRINCIPLES 3. OPERATING PRINCIPLES 3.1. OPERATING DESCRIPTION Picture 10: HWG operating principlet 1. The hydraulic flow is directed through RPM-valve block to the hydraulic motor. The RPM-valve keeps the flow constant with a RMP-cartridge and controls the speed of the hydraulic motor. 2. Hydraulic motor actuates the alternator s rotor through a direct connection to the rotor. When the rotor spins it produces a changing magnetic flux that generates electricity. 3. Electricity is directed through the distribution box and on to the selected output, socket or welding WELDING PERFORMANCE DYNASET HWG welding performance is optimized by automatic excitation power regulator (EPR), which operates concurrently with the welding impedance and auxiliary windings of the unit. HWG hydraulic welding generators are equipped either with compound or electronic EPR. They ensure that striking voltage and control welding current are according to actual demand. In generator mode EPR works an automatic voltage regulator. Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 23

24 OPERATING PRINCIPLES DYNASET hydraulic welding generators have also an anti-stick function that activates when the electrode gets stuck during welding. Anti-stick function then cuts the welding current and keeps the electrode from being damaged AUXILIARY VOLTAGE CONTROL Auxiliary voltage regulator adjusts rotors excitation power, maintaining constant output voltage at a fluctuating electric load. HGW hydraulic welding generators are equipped either with compound or electronic voltage regulator. Compound regulator is connected to the auxiliary winding and it maintains the output voltage constant through the entire load range with accuracy of ± 5%. Compound regulator sets the excitation current according to the electric load of each phase individually with its separate current windings. Electronic voltage regulator is connected to the stators windings and achieves an accuracy of ± 3%. Electronic voltage regulator constantly compares output voltage to the pre-adjusted reference value and sets the excitation current according to the load. The response time of the voltage control is less than 1 second PERFORMANCE OF AUTOMATIC FREQUENCY CONTROL RPM-cartridge maintains rotation speed of the hydraulic motor so that the frequency is constant (±5 % ). The output power remains stable (±5 %) even when the hydraulic flow (Q) exceeds the nominal flow (Qnom) up to 20-30% l/min, depending on HG hydraulic generator size. Picture 11: Automatic frequency control 24 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

25 OPERATING PRINCIPLES 3.5. PRESSURE POWER RATIO The power to pressure ratio chart shows output power relation to the pressure, when the hydraulic flow Q is kept constant. The best power to pressure ratio is achieved when the pressure is at nominal level, little under the maximum value. READ CHAPTER 10. TECHNICAL SPECIFICATIONS for more information. Picture 12: Pressure/Power chart Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 25

26 OPERATING PRINCIPLES 26 Dynaset Oy Menotie 3, Ylöjärvi puh

27 INSTALLATION 4. INSTALLATION 4.1. BEFORE INSTALLATION ATTENTION! Read these instructions before installation of the DYNASET product! HYDRAULIC SYSTEM OF A BASE MACHINE Base machine s have different type of hydraulic systems. Most common hydraulic systems in mobile machinery are: Open centre hydraulic system with Load Sensing variable displacement pump Closed centre hydraulic system with Load Sensing variable displacement pump Hydraulic system with fixed displacement pump Before installing the DYNASET product, find out the type of the hydraulic system of your machine. If you are unsure of the hydraulic system, please contact the manufacturer of your base machine. Next three paragraphs describe the hydraulic systems in more detail. Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 27

28 INSTALLATION OPEN CENTRE HYDRAULIC SYSTEM WITH LOAD SENSING VARIABLE DISPLACEMENT PUMP Picture 13: Open centre hydraulic system with load sensing variable displacement pump In open centre hydraulic system the flow is returned to tank through the control valves open centre; that is, when the control valve is centered. It provides an open return path to tank and the fluid is not pumped into a high pressure. In variabledisplacement pump, the flow rate and output pressure adjusts automatically based on the load of the hydraulic system. 28 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

29 INSTALLATION Picture 14: Connection figure for open centre hydraulic system with load sensing variable displacement pump 1. DYNASET hydraulic equipment 2. DYNASET Priority valve PV-SAE 2.1. DYNASET PC-SAE pressure compensator 2.2. DYNASET LSV Load Sensing valve 3. Base machine s variable displacement pump 4. Open centre directional control valves 5. Oil cooler 6. Oil filter 7. Oil tank Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 29

30 INSTALLATION CLOSED CENTRE HYDRAULIC SYSTEM WITH LOAD SENSING VARIABLE DISPLACEMENT PUMP Picture 15: Closed centre hydraulic system with load sensing variable displacement pump In a closed centre hydraulic system the oil flow is stopped from the pump when control valve is centered. The pump can rest when the oil is not required to operate a function. In variable-displacement pump, the flow rate and output pressure adjusts automatically based on the load of the hydraulic system. 30 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

31 INSTALLATION Picture 16: Connection figure for closed centre hydraulic system with load sensing variable displacement pump 1. DYNASET hydraulic equipment 2. DYNASET LSV Load Sensing valve 3. DYNASET Shuttle valve 4. Base machine s variable displacement pump 5. Closed centre directional control valves 6. Oil cooler 7. Oil filter 8. Oil tank Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 31

32 INSTALLATION HYDRAULIC SYSTEM WITH FIXED DISPLACEMENT PUMP Picture 17: Hydraulic system with constant displacement pump In hydraulic system which has the fixed displacement pump, the oil flow from the pump is fixed. Every stroke of the hydraulic motor moves the same amount of oil. The output flow is function of the motor s rpm and pump s displacement. 32 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

33 INSTALLATION Picture 18: Connection figure for hydraulic system with fixed displacement pump 1. DYNASET hydraulic equipment 2. DYNASET Priority valve PV-SAE 2.1. DYNASET PC-SAE pressure compensator 2.2. DYNASET LSV Load Sensing valve 3. Base machine s fixed displacement pump 4. Open centre directional control valves 5. Oil cooler 6. Oil filter 7. Oil tank Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 33

34 INSTALLATION DYNASET VALVES DYNASET valves are designed to enable easy installation of your DYNASET hydraulic product. DYNASET LSV LOAD SENSING VALVE Picture 19: LSV Load sensing valve DYNASET LSV load sensing valves are made for installations in a closed centre hydraulic systems. DYNASET PV-SAE PRIORITY VALVE Picture 20: PV-SAE Priority valve DYNASET PV- SAE priority valve enables the installations of the DYNASET products into any hydraulic system. 34 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

35 INSTALLATION 4.2. INSTALLING DYNASET HYDRAULIC PRODUCT PLACING DYNASET HYDRAULIC PRODUCT Place DYNASET hydraulic product where there is an easy access to the unit. Ensure proper ventilation. Picture 21: Placing DYNASET product NOTE! When positioning the HWG hydraulic welding generator, ensure that the air venting is sufficient. READ CHAPTER 4.3. Installing HWG hydraulic welding generator for more information INSTALLING DYNASET VALVES Installation instructions can be found in the DYNASET LSV or DYNASET PV SAE Installation manual CONNECTING HYDRAULIC HOSES Pressure (P) and return (T) lines of a hydraulic system are connected to the DYNASET units corresponding hydraulic ports. Picture 22: Installing hydraulic hoses Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 35

36 INSTALLATION 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 23: Hydraulic flow at least minimal In case of the hydraulic flow being too high, it must be reduced. The flow can be reduced either by lowering the rotation speed of base machine s hydraulic pump or using flow limiter valve. DYNASET priority valve is recommended. Picture 24: Base machine s pumps Return line must be connected to a hydraulic oil tank in the shortest possible line in order to keep the return hydraulic pressure under 5 bar in the tank line. Generally DYNASET s return line(t) is to be connected directly to the return line of a hydraulic system. Picture 25: Return line (T) pressure must be under 5 bars. 36 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

37 INSTALLATION ATTENTION! Ensure that the filtering degree and cooling capacity of the hydraulic system are sufficient. READ CHAPTER 10. TECHNICAL SPECIFICATIONS for more information HYDRAULIC FLUIDS To use proper hydraulic fluid READ CHAPTER 6.2. Hydraulic fluids for more information INSTALLING HWG HYDRAULIC WELDING GENERATOR DYNASET HWG hydraulic welder generator can be installed into the original hydraulic system of any base machine. It can be installed to a place where sufficient venting and easy access to HWG hydraulic welder generator is ensured. The position of the generator must be horizontal. Picture 26: Placement of the HWG hydraulic welding generator with sufficient room and ventilation A. Minimum 25 mm B. Minimum 50 mm NOTE! Sufficient venting is important. HWGs components heat up during the use. Maintain the generator accordingly and keep the vents open and clean. Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 37

38 INSTALLATION 4.4. GROUNDING ATTENTION! DYNASET HWG hydraulic welding generator must be grounded when rubber cushions or plastic pads are installed to the generator s framework. Grounding is also recommended when the generator is installed onto base machine without rubber cushions or plastic pads. Do not ground HWG hydraulic welding generator through hydraulic connections. Make the grounding only to the base machines frame. Use external galvanized wire to gain proper grounding as shown picture 27. The ground wire size/gauge is to be selected according to the following table. The ground wire is recommended to be according to following the table. Generator size S (kva) Ground wire cross-section area (mm 2 ) S < 10 kva 2.5 mm 2 (13AWG) 10 < S < 20 kva 4 mm 2 (11AWG) 20 < S < 40 kva 6 mm 2 (9AWG) S >40 kva 10 mm 2 (7AWG) Ground the HWG hydraulic welding generator from the marked grounding spot in generators frame. The grounding spot varies between different generator models. Picture 27: Grounding the HWG hydraulic welding generator 38 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

39 INSTALLATION 4.5. IP CODE REQUIREMENTS IP23 HWG hydraulic welder generator must be installed in a location and position where water can not enter the generator from below or from the sides according to the IP23 classification OUTPUT FREQUENCY INSPECTION AT START-UP HWG hydraulic welding generators are tested and adjusted at factory but it is recommended to check the output frequency prior to taking HWG hydraulic welding generator into operation. 1. Ensure that the generator is properly connected to the hydraulic system of your base machine and there are no oil leakages in system. 2. Start the engine of your base machine. Adjust the engine speed to the demanded level. 3. Start the generator with a control valve and ensure that the hydraulic flow is at demanded level. Picture 28: Starting the HWG with control valve 4. Check the output frequency. For this purpose use a universal True RMS-multimeter. When the generator is running without load, switch the metering device to the Hz-position and check the frequency between a phase and ground. Frequency value should be 50 Hz ± 5%. Picture 29: Measuring frequency Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 39

40 INSTALLATION 5. Tune frequency if necessary. READ CHAPTER 6.5. Adjusting output frequency for more information. Generator can also be tested by measuring the output voltage. The output voltage can be inspected from the voltmeter with distribution box equipment models. NOTE! DYNASET HWG hydraulic welding generators are tested and adjusted at factory! Do not adjust frequency without real need. 40 Dynaset Oy Menotie 3, Ylöjärvi puh

41 OPERATION 5. OPERATION ATTENTION! Always check the HWG hydraulic generator and its hoses that they don t leak before using the generator HWG CONTROL PANEL The control panels are described in picture 30. The panels consist of the following components and functions. Picture 30: HWG models and their control panels A. Welding terminals. B. Welding current range/ mode selector. C. Welding current selector (Potentiometer in HWG 300). D. Arc force potentiometer (only in HWG 300) E. Voltage ON - indicator light F. Welding overload warning (only in HWG 300) G. Generator protection reset switch (only in HWG 400) H. Operating time counter (only in HWG 400) I. Remote control socket (only in HWG 300)) Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 41

42 OPERATION 5.2. STARTING HWG After ensuring the proper operation of DYNASET HWG hydraulic welding generator, as shown in chapter 4.6, it is ready for use. To start the HWG hydraulic welding generator follow same procedures than in the chapter 4.6 phases 1-3. ATTENTION! Exceeding the maximum hydraulic flow causes generator to overspeed and may damage it. READ CHAPTER 10. TECHNICAL SPECIFICATIONS for more information WELDING PREPARATION 1. Connect the welding cables to the HWG hydraulic welders terminals A. The ground cable (with the pliers head) to the minus(-) terminal and the electrode cable to the positive(+) terminal. 2. Connect the ground(-) cable s pliers to the piece you want to weld on. Picture 31: Applying the welding cable pliers 3. Choose welding electrodes that suit your job. Check the specification from the electrode package. 4. Set the welding electrode to the electrode welding cable. Run the cables along side each other. Check the condition of the cables and don t use cables which insulation is spoiled or worn out. NOTE! Both electrode-positive and electrode negative welding methods are possible with DYNASET HWG welding generators. To enable electronegative welding connect the welding cables invertly to the terminals A. 42 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

43 OPERATION 5.4. SELECTING WELDING CURRENT WITH HWG 180/220/ Select welding current area with welding current range selector B 2. Select welding current with the welding current selector switch C 5.5. SELECTING WELDING CURRENT WITH HWG Select Welding from mode selector B 2. Adjust welding current with the welding current potentiometer C. NOTE! When using a cellulose based electrodes, the ARC FORCE potentiometer D has to be adjusted for maintaining good welding quality WELDING WITH THE HWG After following previous steps, start welding simply by scratching the surface you want to weld on with the welding electrode. Picture 32: Welding ATTENTION! Always remember to use proper safety equipment such as a welding mask, dry insulating gloves and suitable outfit. Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 43

44 OPERATION 5.7. CONNECTING A LOAD TO GENERATOR After ensuring the proper operation of the DYNASET HWG hydraulic welding generator, the load can be connected. Load can be any electrical device e.g. work lamp, grinder etc. ATTENTION! Do not weld and use the generator at the same time. Disconnect all other devices from the sockets before welding. Avoid starting the HG generator with load connected to it. 1. Models HWG 180, 220 and 400: Select GEN option with the welding current switch C to use the generator mode. Models HWG 300: The generator mode is always on. Make sure you turn the potentiometer C to 100% with HWG 300 when using generator mode. 2. Connect your load to the generator s socket(s). Picture 33: HWG with connected load NOTE! It is recommended to use UPS(uninterruptable power source) with electrical equipment such as computers to protect them from power surges and spikes. 44 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

45 OPERATION 5.8. STOPPING THE HWG 1. Stop the HWG hydraulic welding generator by closing the hydraulic control valve. Picture 34: Stopping the HWG 5.9. BATTERY CHARGING AND JUMP STARTING PROCEDURE WITH HWG 300 HWG 300 hydraulic welding generator can be used to charge batteries and jumpstart vehicles. To use this function you need a DYNASET jump-start cable set, which can be ordered separately by request. JUMP-STARTING PROCEDURE The jump starting will not work unless a battery is attached in to the circuit of the vehicle. 1. Set the selector switch B to the 0 position. 2. Connect the DYNASET jump-start cables to the terminals A of the HWG 300 hydraulic welding generator. 3. Connect the positive and the negative to the respective terminals on the battery. 4. Set the current potentiometer C to 50 %. 5. Set the selector switch B to the same voltage than the battery. Always make sure you have the voltage selector switch in the correct battery voltage position. 6. After 2 minutes set the current potentiometer C to 100 % and wait another 2 min. 7. Start vehicle s engine. Depending on the batterys age and condition you may have to repeat the above several times. After engine starts disconnect cables from battery immediately. Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 45

46 OPERATION BATTERY CHARGING CHARGING A HEALTHY BATTERY 1. Set the selector switch B to the 0 position. 2. Connect the DYNASET jump-start cables to the terminals A of the HWG Connect the positive and the negative DYNASET cables to the respective terminals on the battery. 4. Set the selector switch B to the same voltage than the battery. Always make sure you have the voltage selector switch in the correct battery voltage position. 5. Set the current potentiometer C to battery charge area, 10 to 30 %. Never exceed the 30% for more than 5 min. You can damage the battery when charging too fast. A new battery should come to full charge within 1 hour. An old or a battery in poor condition will take sometimes 3 to 4 hours. CHARGING WHEN THE BATTERY IS COMPLETELY EMPTY 1. Set the selector switch B to the 0 position. 2. Connect the negative DYNASET cable to the respective terminal on the battery. 3. Set the selector switch B to the same voltage than the battery. Always make sure you have the voltage selector switch in the correct battery voltage position. 4. With the HWG running at the proper speed, tap the positive terminal of the battery with the positive DYNASET cables clamp several short times. You should see the spark slowly getting stronger. Now the battery is ready to be charged. 5. Connect the leads to the battery, observe polarity REMOTE CONTROL The HWG 300 have a remote control option. With the remote control, user can adjust the welding current. Remote control is an optional equipment and can only be included with the HWG 300 by request OVERHEATING AND OVERLOAD SITUATION If the HWG hydraulic welding generator overheats or overloads, it shuts off automatically. The unit will switch itself back on operational after a few minutes. 46 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

47 OPERATION AMBIENT TEMPERATURE To avoid the power loss, it is not recommended to use HWG hydraulic welding generator when the ambient temperature exceeds +40 ºC. When the ambient temperature exceeds +40 ºC power takeoff should be limited in accordance with the attached diagram, e.g. for instance, at the ambient temperature of +50 ºC the power takeoff should not be more that 80 % of the maximum. If the ambient temperature reaches +40 ºC, HWG hydraulic welding generator s full output power can be maintained by adding additional air ventilation. Picture 35: Power take off in higher temperatures Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 47

48 OPERATION 48 Dynaset Oy Menotie 3, Ylöjärvi puh

49 MAINTENANCE 6. MAINTENANCE DYNASET HWG hydraulic welding generators are low-maintenance units. Only normally wearing parts and materials should be replaced either when necessary or in accordance with a service program. ATTENTION! Before beginning any maintenance or repair, ensure that the system is stopped and depressurized. Make sure that the system can not start accidentally MAINTENANCE INTERVALS All maintenance must be complied as they are scheduled in this manual. The following table provides maintenance schedule for DYNASET HWG hydraulic welding generator. CHECK POINTS NEW DEVICE AF- TER INSTALLATION AFTER DAI- LY USE MONTHLY Perform the needed actions after HWG s installation according to the chapter 4. Installation. x Clean if the HWG hydraulic welding generator needs cleaning and clean it according to the chapter 6.3. x Test safety devices. x 6.2. HYDRAULIC FLUIDS Wide range of standard hydraulic fluids can be used with DYNASET hydraulic equipment. Depending on the operating temperature, following mineral hydraulic oils are recommended: MINERAL HYDRAULIC OIL OPERATION TEMPERATURE UP TO ISO VG 32S 60 C ISO VG 46S 70 C ISO VG 68S 80 C NOTE! Recommended oil viscosity is between 10 to 35 cst when operating at normal operating temperature. Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 49

50 MAINTENANCE Synthetic and bio-oils can also be used if their viscosity characteristics and lubricating efficiency are similar to the 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 base machine. For the hydraulic fluid change interval follow the base machine s maintenance instructions. To use special hydraulic fluids with DYNASET equipment, please contact the nearest DYNASET representative for more information CLEANING HWG HYDRAULIC WELDING GENERATOR ATTENTION! Maintain the generator accordingly and keep the vents open and clean. Check your equipment after every work shift. Depending on the operational environment, clean the HG hydraulic generator as frequently as necessary to keep it in perfect working condition. Picture 36: Cleaning HWG 50 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

51 MAINTENANCE 1. Remove cover, side screens and air diffuser. 2. Clean fan, rotor, stator compartments and alternator s electric components by using compressed air. Ensure that electric enclosures drain holes are dirt free. 3. After cleaning the generator, place screens/covers back on and secure them with appropriate screws. NOTE! Use compressed air to clean your equipment. Remove all grease and oil deposits from the HWG hydraulic welding generator. Accumulated grease and oil can cause overheating creating subsequent generator damage and may present a potential fire hazard. ATTENTION! Do not leave anything in the generators case or control box which does not belong to the assembly. Check the lids and covers as well as screw joints on regular basis, at least once in a week, and tighten them if they are loose. if HWG hydraulic welding generator is exposed to a noticeable vibration, checking is be done more frequently. Condition of all oil seals/gaskets must be inspected and defective parts be replaced. After maintenance or cleaning, remember to install and tighten all covers! NOTE! Ensure clean venting of the HWG hydraulic welding generator. Dusty conditions increase the wear of the components TEST SAFETY DEVICES HWG hydraulic welding generator s residual current device (RCD) or Residual current circuit breaker device (RCCBD) test button has to be pressed monthly to test the condition of the safety device. NOTE! Safety devices can only be tested when the HWG welding generator is on. When the test button is pressed the switch must release immediately. Use of the HWG hydraulic welding generator with faulty safety equipment is forbidden until they are replaced. Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 51

52 MAINTENANCE If a fault condition trips the safety device, the fault has to be cleared before the switch can be set back up. Bypassing or removing the safety devices to clear the problem is strictly forbidden. 1. Push the RCD/RCCBD test button to check the functionality of the device. If everything is in order, the switch releases. 2. Switch the RCD/RCCBD reset switch back up to put the HWG hydraulic welding generator back on operational condition. Picture 37: Testing the residual current device A. Fuses 6.5. ADJUSTING OUTPUT FREQUENCY ATTENTION! HWG hydraulic welding generators are tested and adjusted at the factory. Do not adjust them without real need. Adjust first the base machines hydraulic flow to demanded level. ATTENTION! When measuring output frequency, act in compliance with the laws, regulations and recommendations issued by local electricity, work safety authorities and universal multimeter manufacturer. 52 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

53 MAINTENANCE ATTENTION! Do not adjust generator when load is connected to it. NOTE! When doing adjustment, the hydraulic fluid should be at normal operation temperature! NOTE! Only use a True RMS multimeter for making adjustments. WHEN HWG HYDRAULIC WELDING GENERATOR IS INSTALLED TO HYDRAULIC SYSTEM WITH DYNASET INSTALLATION VALVE Turn the generator on and ensure that the hydraulic flow is at least at nominal level. When the hydraulic flow level is on the proper level, set the frequency by adjusting the RPM-cartridge with following instructions. Picture 38: Adjusting the frequency 1. Loose the locknut A. 2. Make the adjustment by adjusting screw B according to the readings of frequency meter. Due to the response time make only small adjustments at a time and wait for the generator to level its speed before turning the screw B more. Do not make more than quarter revolution turns at the time! Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 53

54 MAINTENANCE 3. When the frequency has reached the required level, tighten the locknut A to a moment of 10 Nm. If a frequency measurement option is not available, adjustments can be made by measuring the output voltage. WHEN HWG HYDRAULIC WELDING GENERATOR IS INSTALLED TO THE HYDRAULIC SYSTEM WITHOUT A DYNASET INSTALLATION VALVE ATTENTION! Only adjust with these instructions when HWG hydraulic welding generator is installed to hydraulic system without a DYNASET installation valve. Otherwise you may damage your HWG hydraulic welding generator doing the following procedure. Primarely adjust the base machine s hydraulic flow to the required, nominal level before making any adjustment to the RPM-cartridge. If the voltage is still out of the range, adjust the RPM-cartridge with the following instructions. 1. Adjust the hydraulic flow until the frequency achieves the value of 50 Hz(60Hz). Follow the readings on the True RMS multimerter. Picture 39: Cartridge tuning without installation valve 1 If the adjusting does not effect on the frequency, there is a feed problem in the base machine s hydraulic system that has be fixed before continuing the adjustments. If thefrequency does change when the adjustments are made to the hydraulic flow, continue with the following instructions. 2. Loose the locknut A. 3. Turn the adjusting screw B counter-clockwise until it starts to control the flow. 4. Then turn the screw B counter-clockwise for a another quarter of revolution. 5. Lock the setting with the locknut A tightening it to 10 Nm. 54 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

55 MAINTENANCE Picture 40: Cartridge tuning without installation valve 2-5 Dynaset Oy Menotie 3, Ylöjärvi puh

56 MAINTENANCE 6.6. TROUBLESHOOTING Performing the maintenance tasks requires a qualified hydraulic mechanic or/ and electrician. Please, contact DYNASET authorized workshop or dealer for more maintenance information. FAILURE REASON CORRECTIVE ACTION LOW OUTPUT VOLTAGE AT LOAD HYDRAULIC WELDING GENERATOR CONSUMES HYDRAULIC FLUID HYDRAULIC PRESSURE IS ABNORMALLY HIGH AT NO LOAD A MILD ELECTRIC SHOCK FROM HYDRAULIC WEL- DING GENERATOR The generator is being overloaded. Failure of axial sealing of generator s hydraulic motor. External indication - hydraulic oil outflow from ventilation grids. Oil leakage from the hydraulic motor. Winding failure. Poor hydraulic generator grounding. Reduce the load and check the current I (A) to ensure that the proper load is being applied. Axial sealing of hydraulic motor broken by reason of excessive pressure in return line (T). Rebuild the return line (T). Maximum allowed pressure in return line is 5 bar. Replace axial sealing of generator s motor. Hydraulic motor worn out and should be replaced. One or more stator winding is in short circuit. TAke contact to nearest DYNASET dealer. Ensure proper grounding cable installation. ABNORMAL NOISE FROM HYDRAULIC WEL- DING GENERATOR Bearing failure. Broken fan. Replace broken/worn bearing. Replace broken/worn fan. FAILURE REASON CORRECTIVE ACTION AN WELDING ARC CAN NOT BE STRUCK OR IS DIFFICULT Too low rotation speed of the HWGs generator. Winding failure. Ref. on tables sections about LOW OUTPUT VOLTAGE. Verify the winding resistance with parameters shown in technical specification and replace stator/rotor if damaged. 56 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

57 MAINTENANCE FAILURE REASON CORRECTIVE ACTION LOW WELDING CUR- RENT Welding current setting does not meet the required level. Too low rotation speed of generator. Excitation rectifiers failure. Winding failure. Check the welding requirements (ref. Electrode package) and turn the selectors in appropriate position. Check whether the hydraulic flow and the pressure are sufficient. Adjust when necessary. Trace the failure and replace the rectifier. Verify the winding resistance with parameters shown in technical specification and replace if damaged. FAILURE REASON CORRECTIVE ACTION AC-ELECTRICITY IS NOT AVAILABLE, WHILE HWG WORKS PROPERLY AND AC INDICATOR IS ON. AC-voltage sockets automatic circuit breaker has been tripped due to a current overload. Reset an automatic circuit breaker with its push button on front panel. FAILURE REASON CORRECTIVE ACTION EXCESSIVE WELDING CURRENT Welding current setting does not meet the required level. Too high rotation speed of generator. Check welding requirements (ref. Electrode package) and turn selectors in appropriate position. Failure at the automatic rotation speed control valve due to an excessive hydraulic flow. Replace the automatic rotation speed control valve. FAILURE REASON CORRECTIVE ACTION LOW OUTPUT VOLTAGE AT NO LOAD Poor contact in electric system. Check all internal contacts and wirings of the generator. Check and clean brushes and slip ring. Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 57

58 MAINTENANCE FAILURE REASON CORRECTIVE ACTION Excitation rectifiers failure. Trace the failure and replace the rectifier (with compound voltage regulator). Replace the capacitor. OUTPUT VOLTAGE < 20Vac LOW OUTPUT VOLTAGE AND FREQUENCY AT LOAD LOW FREQUENCY AT NO LOAD HIGH FREQUENCY AT LOAD OUTPUT VOLTAGE INSTABILITY Voltage regulators failure. Insufficient residual magnetism. The generator is being overloaded. Too low rotation speed. Too high rotation speed. Instable rotation speed of generator. Check and adjust the air gap of the compound regulator. Replace if broken (HWG180, 220, 400). Check and adjust or replace the electronic regulator (HWG 300). Use external 12 V DC battery for 1-2 sec. To magnetise the rotor. Reduce the load and check the current I (A) to ensure that the proper load is being applied. If frequency is out of range, hydraulic system failure is concerned. Check whether the hydraulic flow and pressure are sufficient. Adjust RPM-cartridge if necessary. Check the hydraulic motor for possible leakage. Replace the motor if necessary. If frequency is out of range, hydraulic system failure is concerned. Check whether the hydraulic flow and pressure are sufficient. Adjust RPM-cartridge if necessary. Check generator s hydraulics, including automatic frequency control valve. Make an adjustment if necessary. Check that the hydraulic oil flow is constant. Check whether the hydraulic fluid flow and pressure are not excessive. Adjust when necessary. Check the hydraulic motor for possible leakage. Replace the motor if necessary. 58 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

59 WARRANTY 7. MANUFACTURER S LIMITED WARRANTY 1. 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 Exclusions from warranty. 2. 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 twenty four (24) months based on maximum of 2000 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 . 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 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 59

60 WARRANTY the end of original warranty period. 8. Exclusions from warranty This warranty shall not apply to: 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. Cost of maintenance, adjustments, installation or startup. Coating, hydraulic oil, quick couplings and interconnection hoses (internal or external to system assemblies). Products altered or modified in a manner not authorized by DYNASET OY in writing. Products which have been repaired during warranty period by others than DYNASET OY or its authorized workshop. 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. Telephone or other communications expense. Product that is used in exceptional conditions, considered to cause excessive wear and tear. Faults caused by nature phenomenon s like flood, thunder, etc. DYNASET OY, all rights reserved 60 Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com

61 PRODUCT DISPOSAL 8. PRODUCT DISPOSAL Dispose and recycle all DYNASET products and their packaging environmentally responsible way. Do not dispose used oils, electrical components, batteries or any other hazardous waste with normal waste. They are harmful for the environment and can be recycled for re-use. Contact your local waste recycling facility for more information about recycling hazardous waste. NOTE! Always act according to the waste legislation, regulations and recommendations in waste disposal and waste recycling issued by your local authorities. Dynaset Oy Menotie 3, Ylöjärvi puh

62 PRODUCT DISPOSAL 62 Dynaset Oy Menotie 3, Ylöjärvi puh

63 DECLARATION OF CONFORMITY 9. DECLARATION OF CONFORMITY We hereby declare that the design and manufacture of the product stated below are in conformity with the provisions of the European Parliament and Councils on the harmonization of the laws of Member States on the safety of machines. Machine directive 2006/42/EC LVD directive 2006/95/EC EMC directive 2004/108/EC Applied conformity standards: CEN EN ISO 4413: EN ISO 4413:2010 Hydraulic fluid power - General rules and safety requirements for systems and their components. EN Safety of machinery Electrical equipment of machines. Manufacturer: Product group: Product: DYNASET Oy Menotie 3, FI Ylöjärvi, Finland HYDRAULIC WELDING GENERATORS HWG Hydraulic welding generator If the device has been modified by someone other than the manufacturer or without the manufacturer s permission, this declaration is not valid. Timo Nieminen R&D Manager Ylöjärvi, Suomi, Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 63

64 DECLARATION OF CONFORMITY 64 Dynaset Oy Menotie 3, Ylöjärvi puh

65 TECHNICAL SPECIFICATIONS 10. TECHNICAL SPECIFICATIONS STANDARD MODELS OUTPUT CHARACRETISTICS HWG 180/6K 34 HWG 220/6K 49 HWG 300/10K 54 HWG 400/10K 79 Welding current ADC ADC ADC ADC ADV Welding electrode Ø 4 mm Ø 5 mm Ø 6 mm Ø 7 mm Welding current adjustment Load duty ED Selector switch Continuous regulator Selector switch 2 x 7 positions 3 x 7 positions 3x 12 positions % 50%/180 A 35%/220 A 35%/300 A 35%/400 A 100%/110A 60%/170 A 60%/ 250 A - Arc striking voltage VDC 73 VDC 73 VDC 70 VDC 70 VDC Welding voltage VDC 21,5-28,8 21,5-28,8 21, Welding cables mm 2 /m 35 mm 2 / 5m AUXILIARY ELECTRICITY 1-phase* 3-phase 230 VAC/ 3,0 kva 400 VAC/ 6,0 kva 230 VAC/ 3,5 kva 400 VAC/ 6,5 kva 230 VAC/ 4,0 kva 400 VAC/ 8,0 kva 230 VAC/ 4,0 kva 400 VAC/ 10,0 kva Socket 2P+PE 16A 1 pc 1 pc 1 pc 1 pc Socket 3P+N+PE 16A 1 pc 1 pc 1 pc 1 pc HYDRAULIC CONNECTION IP class Pressure line P BSP 1/2 BSP 1/2 BSP 3/4 BSP 3/4 Return line T BSP 1/2 BSP 1/2 BSP 3/4 BSP 1 HYDRAULIC POWER REQUIREMENTS Flow min. Flow max. Pressure max. l / min (gpm) l / min (gpm) bar (psi) HYDRAULIC FLUID REQUIREMENTS 36 (5.5) 51 (13.5) 56 (14.8) 81 (21.4) 53 (14.0) 68 (17.9) 88 (23.2) 101 (26.7) 210 (3000) 210 (3000) 210 (3000) 210 (3000) Viscosity cst / optimum Temperature C ( F) max. 70 (158)** Filter ratio μm 25 or better Cooling capacity requirements*** OVERALL DIMENSIONS kw 1,5 1,5 2,5 3,0 Length mm (in) 563 (21.10) 567 (22.35) 613 (24.15) 801 (31.55) Width mm (in) 212 (8.35) 212 (8.35) 285 (11.15) 318 (12.55) Heigth mm (in) 365 (14.40) 365 (14.40) 434 (17.10) 544 (21.45) Weight kg (lb) 51 (112) 52 (114) 92 (203) 132 (291) Gallons are U.S. liquid gallons. * Nominall current (1~phase / 3~phase) /phase must not exceed maximum load. ** Ref. to hydraulic fluids in chapter 6.2 *** Minimum cooling capacity for HG hydraulic generator on the base machine. Dynaset Oy Menotie 3, Ylöjärvi puh info@dynaset.com 65

66 TECHNICAL SPECIFICATIONS 66 Dynaset Oy Menotie 3, Ylöjärvi puh

67 DYNASET OY, all rights reserved

68 Menotie 3 FI Ylöjärvi, Finland tel: info@dynaset.com ELECTRICITY HG Hydraulic Generator HGV POWER BOX Variable Hydraulic Generator System HGV Variable Hydraulic Generator System HWG Hydraulic Welding Generator HGG Hydraulic Ground Power Generator MAGNET POWER HMG PRO Hydraulic Magnet Generator MAG Lift Magnet HMAG PRO Hydraulic Magnet HIGH PRESSURE WATER HPW Hydraulic High Pressure Water Pump HPW Hydraulic Power Washer KPL High Pressure Street Washing Unit HPW-DUST High Pressure Dust Suppression System PPL High Pressure Pipe Cleaning Unit HPW-FIRE High Pressure Firefighting System FP Fire Fighting Piercing Kit HDF Hydraulic Drilling Fluid Pump JPL High Pressure Bin Washing System HSP Hydraulic Submersible Pump VIBRATION HVB Hydraulic Vibra HVD Hydraulic Directional Vibra HVC Hydraulic Vibration Compactor HRC Hydraulic Reversal Cylinder POWER BOOSTING HPI Hydraulic Pressure Intensifier HPI-C Hydraulic Pressure Intensifier for Cylinder COMPRESSED AIR HK Hydraulic Piston Compressor HKL Hydraulic Rotary Vane Compressor HKR Hydraulic Screw Compressor KNOW-HOW Hydraulic Power Take-off (PTO) Hydraulic Power Unit Technology HEU Hydraulic Expansion Unit HRU Hydraulic Rescue Unis De-Icing Technology Installation Valves HHK Hydraulic Grinder HV/HVY Hydraulic Winch / Winch Unit