1 February 2014 JLe

HMG PRO HYDRAULIC MAGNET GENERATORS

HMG PRO
HYDRAULIC MAGNET GENERATORS

HMG PRO 6 KW
HMG PRO 10 KW
HMG PRO 15 KW
HMG PRO 20 KW

OPERATING INSTRUCTIONS
2 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

TABLE OF CONTENTS 2

1. SAFETY PRECAUTIONS AND WARNING STICKERS 3

2. PRODUCT DESCRIPTION 4

3. CONSTRUCTION 4
3.1 Automatic voltage control 4-5
3.2 Classification 5

4. INSTALLATION 5- 9
4.1 Open centre hydraulic system with variable displacement pump 6
4.2 Closed centre hydraulic system with variable displacement pump 6
4.3 Hydraulic system with constant displacement pump 7
4.4 DC voltage verification and adjustment at start-up 7
4.5 Control card settings 8-9

5. ELECTRIC INSTALLATION KITS TO HMG PRO MAGNET GENERATORS 10-11

5.1 Magnet cable kit 10
5.2 HMG PRO control wiring kit 11

6. OPERATION 12-1
6.1 Hydraulic control 12
6.2 External control 13
6.3 Additional features available under external control 13

7. MAINTENANCE 14-15

8. GROUNDING DYNASET EQUIPMENT 15

9. HYDRAULIC FLUIDS 16

10. PRODUCT DISPOSAL 16

11. TROUBLESHOOTING 17-19

12. AC-GENERATOR TROUBLESHOOTING 20-22

13. PARAMETERS 23

14. WARRANTY 24

15. DECLARATION OF CONFORMITY 25

16. NOTES 26
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HMG PRO HYDRAULIC MAGNET GENERATORS

SAFETY PRECATIONS

Operating voltage of HMG PRO-unit varies 110 - 415V depending on generator type.
The hydraulic system is usually pressurised up to 210 (420) bar.
In order to avoid damages and accidents operator and maintenance personal must act in compliance with the
laws, regulations and recommendations issued by local authorities in electricity and high pressure hydraulics.
Prior to detaching a magnet from a carrier, unplug it from a generator’s socket !
Control unit capacitors can develop discharge voltage over 200VDC even the equipment stands still. Wait at
least half an hour (0,5) since capacitors are properly discharged.
TECHNICAL CONDITION OF YOUR MACHINERY AND EQUIPMENT MUST BE SUBJECTED TO CONSTANT
SURVEILLANCE.
Hydraulic system of a carrier machine should be maintained according to the service program. All couplings,
valves and hoses should be maintained, tight and clean as well as kept under constant observation. Leaks in
the hydraulic system must be fixed immediately to avoid injuries caused by high pressure and oil blowouts.

Prior to maintenance, detaching from a carrier or disassembling a DYNASET-unit, the hydraulic system of a
carrier machine should be stopped and DYNASET unit hydraulic circuit depressurized.
Wearers of pacemakers must avoid being magnetic fields
in all possible means. The magnetic fields surrounding a
permanent magnet on all sides can affect and even destroy
sensitive electronic and mechanical measuring equipment.
Please observe sufficient distance (greater than 5 m) from
equipment of this type (including computers, screens, disks,
PACEMAKER MINIMUM BEWARE
SAFETY DISTANCE 5m credit cards, etc.). MAGNETIG FIELD
When operating or maintaining in the immediate vicinity of DYNASET hydraulic generator unit or accessories,
appropriate protective clothing, safety goggles, gloves, ear and eye protection should be worn. Do not touch
parts heated by hydraulic oil.

EXTERME CLEANLINESS MUST BE MAINTAINED WHEN CARRYING OUT ANY DISASSEMBLING OR

REPAIR OF DYNASET UNIT AND HYDRAULIC SYSTEM. THIS IS IMPORTANT TO ENSURE SAFE,
RELIABLE AND LONG-LIFE OPERATION OF YOUR EQUIPMENT.

All installation and service of both hydraulic and electric equipment must be performing experienced personnel
only.

NEVER GO UNDER THE LOAD!

AVOID STOPPING MAGNET GENERATOR WHILE LOAD IS ATTACHED TO THE LIFT MAGNET!

WARNING STICKERS
Dynaset dispatch department includes one (1) warning sticker bag per one (1) main product.
Product recipient is obligated to fix determinate warning sticker to Dynaset product.
Attach sticker to visible and appropriate place or close to Dynaset product where it is easily seen.
Before attaching sticker clean surface with solvent detergent.

READ OPERATING INSTRUCTIONS. GENERAL CAUTION. BEWARE OF HOT SURFACE. USE EAR PROTECTOR AND
BEWARE OF PRESSURE AIR. GLOGGLES
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HMG PRO HYDRAULIC MAGNET GENERATORS

GENERAL NOTES
DYNASET hydraulic magnet generator of HMG PRO-range, designed for an installation to material handling
machines (hydraulic excavators, heavy trucks with hydraulic cranes), is compact and complete power source for
ferrous metal handling magnet. The only power source is a hydraulic system to provide generator with required
hydraulic fluid flow at demanded pressure.
DYNASET hydraulic magnet generator transforms hydraulic power into high quality electricity, which is used
for energising metal handling magnet. HMG PRO generator is provided with a control unit which allows to use
either hydraulic (= HMG PRO-generator in CMG-mode) or alternatively external electric control (= HMG PRO-
generator in HMG-mode).
An automatic demagnetisation ensures fast disengagement of a picked and moved metal off from a magnet.
DYNASET HMG PRO-generators operate with all 220 VDC metal handling magnets upon condition that
magnet’s coil inductance is 0 ... 20 H.

CONSTRUCTION
DYNASET hydraulic magnet generator is comprised of hydraulic synchronous generator and electric control
unit which includes a rectifier block and operation control automatics. The power-to-weight ratio of DYNASET
hydraulic magnet generator is excellent due to the modern construction. Depending on the type and size,
generator might be designed whether as a single bearing unit or as a bi-bearing machine.
The unit has an automatic rotation-speed control valve with ports for pressure and return lines.
Unit’s rotor, connected to the hydraulic motor’s shaft, is provided with excitation windings.
Electric power is taken from stator windings. Auxiliary winding of voltage control system is located in generator‘s
stator as well. Windings are isolated from unit’s body and their insulation class is H.

Protection class of DYNASET hydraulic magnet generator in standard execution complies with specifications
IP23, electric control unit meets requirements of IP44. Units with protection class IP 54 are available by request.
AC-auxiliary electricity is optional.
Automatic circuit breakers protect unit from overload.

DYNASET hydraulic generators are self-excited.

DYNASET hydraulic generator is assembled in lightweight aluminium alloy molded case with footing for fixing.

AUTOMATIC VOLTAGE CONTROL

Automatic voltage regulator adjusts rotor’s excitation power, maintaining constant output voltage at
discontinuous electric load.
Voltage control function depends on the rotor’s rotation speed, so that the nominal voltage value is being set at
the nominal frequency. Subject to unit size, several types of voltage regulator are applied.

HMG PRO-units are equipped with a compound voltage regulator:

Compound regulator is connected to the auxiliary winding and maintains the output voltage constant through the
entire load range with accuracy of ± 5%. Compound regulator sets the excitation current according to electric
load of each phase with its separate current windings individually. Each phase can be loaded up to maximum
current deliberately.
Performance speed of a compound voltage controls is less than 0,1 sec.
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HMG PRO HYDRAULIC MAGNET GENERATORS

AUTOMATIC VOLTAGE CONTROL

Automatic frequency control valve is to keep rotation

speed constant (± 5 %) when incoming hydraulic oil flow
(Q) can vary from minimal up to value exceeding Qmin
by 10 – 30 l/min depending on generator size.
Voltage regulator maintains the voltage constant at
constant rotor’s rotation speed.

Qmin = Qnom + 1...5 l/min

VOLTAGE, V
Qmin = minimal flow
Qnom = nominal flow

220 VDC CONTROL RANGE

Q, l/min
0 Qmin Qmax HYDRAULIC FLUID
FLOW

CLASSIFICATION
DYNASET hydraulic generators are manufactured in conformity with the 98/37, 73/23, 89/336 CEE directives
and their amendments. They are also manufactured in compliance with the following regulations: CEI 2-3, EN
60034-1, IEC 34-1, VDE 0530, BS4999-5000, CAN/CSA-C22.2, NF 51.100 and N° 14-95 - N° 100-95.
By request, DYNASET hydraulic generators can be equipped with a radio interference protection to meet
requirements of specifications MIL STD 461 A/B and VDE 0875 class N.

INSTALLATION
DYNASET hydraulic magnet generator works being integrated into an original hydraulic system of a material
handling machine.

Unit can be placed deliberately ensuring an easy access to the unit. Generator should be positioned
horizontally. Additionally, return line must be connected to a hydraulic oil tank in the shortest possible way in
order to keep return oil pressure under 5 bar.
Cooling capacity of hydraulic system, designed for continuous operation (an excavator), is generally sufficient
under proper installation of HMG PRO-generator. An additional oil cooler is required when HMG PRO-unit is
installed to a truck with and hydraulic hoist.
Ensure that the filtration capacity of a hydraulic system is sufficient.
P

T P

HMG PRO 6-10kW HMG PRO 15- 20kW T

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HMG PRO HYDRAULIC MAGNET GENERATORS

INSTALLATION
OPEN CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP
The demanded hydraulic flow is to be ensured and controlled with a DYNASET PRESSURE COMPENSATED
PRIORITY VALVE.
DYNASET PV SAE 3/4 - 1 1/4 -XX lpm
- 12/24 V priority valve includes following
components:
AUTIMATIC
1. Sandwich-mounted pressure
ROTATION SPEED compensator with SAE-flange
CONTROL VALVE
specification;
T P 2. Solenoid valve 12/24V;
S 3. Flow limiter;
M 4. Pressure relief valve.
PV SAE priority valve is designed for the
installation to main pressure line between
PV SAE valve
B G SAE-flanges of main hydraulic pump.
Pre-adjusted, independent from other
LS LS
CF HMG PRO functions and prioritised hydraulic flow for
P P DYNASET-unit comes from the solenoid
A valve. The rest of hydraulic pump’s
T capacity is available for all other functions.
Furthermore, pump’s control works
together with DYNASET PV SAE priority
valve.
ALSO AVAILABLE for open centre hydraulic systems with variable displacement pump: PRIORITY VALVE PV
SAE ¾ - 1 ¼ - 12/24 V.

DYNASET PRIORITY VALVES enable to operate your DYNASET-unit simultaneously with other hydraulic
executors.
CLOSED CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP
The demanded hydraulic flow is to be ensured and controlled with a DYNASET PRESSURE COMPENSATED
LOAD SENSING (LS) VALVE.

DYNASET LS-valve includes following

components:
1. Flow limiter;
2. Solenoid valve 12/24V;
AUTOMATIC
ROTATION SPEED
3. Pressure relief valve;
CONTROL VALVE 4. Shuttle valve (OPTIONAL).
T P DYNASET LOAD SENSING VALVES:
S LSV 40, LSV 60, LSV 95 and LSV 150
M
LS-connection, pressure relief, max.
hydraulic flow 40, 60, 95 ja 150 l/min
respectively.
G DYNASET FLOW LIMITERS to the
pressure line:
HMG PRO VR 40 PK - 1/2, max. 35 l/min, with
pressure compensation;
VR 95 PK - 3/4, max. 95 l/min, with
LS-valve pressure compensation.
VRD 180 PK - 1, max. 180 l/min, with
pressure compensation.

ALSO AVAILABLE for closed centre hydraulic systems with variable displacement pump:
DYNASET SOLENOID VALVE to the pressure line for remote starting.
SV 70 NC - 1/2 - 12 / 24 V max 70 l/min with LS -connection;
SV 150 NC - 1 - 12 / 24 V max 150 l/min with LS -connection.
7 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

INSTALLATION
HYDRAULIC SYSTEM WITH CONSTANT DISPLACEMENT PUMP

The demanded oil flow is to be ensured

with proper hydraulic pump choice. In
systems with redundant hydraulic flow
an installation with DYNASET PRIORITY
AUTIMATIC
ROTATION SPEED VALVE is recommended.
CONTROL VALVE

T P
Installation with a standard pressure
S compensated 3-way valve should be
avoided in order to close off potential
M
waving in hydraulic system.

G ALSO AVAILABLE for hydraulic systems

with constant displacement pump:
DYNASET FREE CIRCULATION VALVE
HMG PRO
with solenoid and pressure control, type
VKV 90—3/4.

DC VOLTAGE VERIFICATION AND ADJUSTMENT AT START-UP

Your DYNASET hydraulic magnet generator is tested and adjusted at factory, however is recommended to
check the DC voltage prior to taking the unit into operation.

1. Ensure that the generator is properly installed and connected to the hydraulic system of your carrier machine
and no hydraulic fluid leakages detect..
2. Start the engine of your carrier machine. Adjust the engine speed to the demanded level if necessary.
3. Start the generator with a ON/OFF switch and turn on the magnet.
4. Read generator’s voltmeter (digital display at control unit’s socket side). Verify the voltage value with an
multimeter from generator’s socket.
5. If voltage reading is out of limits:
5.1 Ensure whether the hydraulic fluid flow is on the demanded level.
5.2 Make setting by adjusting the RPM-cartridge:

1 Loosen the locknut (1), make an adjustment (2) with adjusting

screw according to the readings of an instrument and then tighten
the locknut

2 NOTE !
When making adjustment, the hydraulic fluid should be at normal
operation temperature !
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HMG PRO HYDRAULIC MAGNET GENERATORS

INSTALLATION
HMG PRO CONTROL CARD SETTINGS
Depending on size of a generator, Pro-control unit can be equipped with more than one control card.
Coil card is used for connection of multiple control cards.

HMG PRO 6 kW
HMG PRO 10 kW CONTROL CARD x 1

HMG PRO 12 kW
HMG PRO 15 kW CONTROL CARD x 2
HMG PRO 20 kW

power reduction
hard
1 4

nor.
nor.
nor.

gen. switch
master

slave

HMG PRO CONTROL CARD trig.

= DIP switch position

Settings related to the control mode are made with DIP-switches SW1 and SW2, both located on a control
card(s).

DIP switch SW1:

Switches 1 - 3 selects master or slave mode.
Switch 4 selects triggering source: button (external control - HMG) or voltage level (hydraulic control - CMG)
SINGLE CARD / FIRST OF MUTIPLE CARDS - switches 1 - 3 in MASTER-position.
OTHER CARDS - switches 1 - 3 in SLAVE-position.
DIP switch SW2:
Switch 1 enables normal and hard demagnetization (giving 30% more efficient, but is slower).
Switch 3 enables power reduction function
SWITCH SW2 SHOULD BE SET TO A SAME POSITION IN ALL CONTROL CARDS

ATTENTION !
When HYDRAULIC CONTROL (DIP Switch SW1, switch 4) has been chosen, both hard demagnezation and
power reduction functions are kept disabled.
 9

BRN
GRN
WHT
PI
GRY

BRN
GRN
WHT
PI
GRY
output active
display over display
over EM-224di4 temp
temp SNUB. EM-224di4 SNUB.
RES. RES.
12-18ohm 12-18ohm

- + -

gnd

+5V
snubber
+15V
gnd
isp reset
+5V
sck.
miso./reset
mosi
gnd

output active

on/off
shut down

c
temp sens. in
+

demag
magn.
snubber
shut down
+15V
gnd
isp reset
+5V
sck.
miso./reset
mosi
gnd

temp sens. in
demag.
magn.

gnd
27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10
9 8 9 8

sck
0V

+5V
sck
0V

+5V

miso
mosi
miso
mosi

snubber snubber

slave
SW1

master
slave

SW1
master

opto switch gen. opto switch gen.

2k2
MASTER

2k2
switch trig. switch trig.
MASTER
fault. fault.

nor,
nor.
nor.
nor,
nor.
nor.

opto coupler SW2 opto coupler SW2

mag.
mag.

4 3 2 1 4 3 2 1

power
power

demag
demag

hard
DC-TERMINAL
hard

DC-TERMINAL
3-ph SUPPLY MAGNET COIL 3-ph SUPPLY MAGNET COIL
(-) (+) (-) (+)

power save
power save

power reduction
power reduction

1 2 3 4 5 6 7 1 2 3 4 5 6 7

- + - +
(-) (+)
L1 L2 L3 MAGNET COIL 3-ph SUPPLY L1 L2 L3 DC-TERMINAL
+
-
+
2 x 2,5
3 x 2,5

3-ph SUPPLY

5 6
HMG PRO CONTROL CARD SETTINGS
INSTALLATION

- + MAGNET COIL
February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS
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HMG PRO HYDRAULIC MAGNET GENERATORS

ELECTRIC INSTALLATION KITS TO HMG PRO MAGNET GENERATORS

Having fitted generator to your carrier mechanically, accomplish an electric connection.

Along with a DYNASET HMG PRO generator following wiring kits can be purchased:

1. MAGNET CABLE KIT - suitable for all HMG PRO units.

2. HMG PRO CONTROL WIRING KIT - for units working under electric control.

1. MAGNET CABLE KIT

1.1
Magnet’s cable 5m with plug.
HMG PRO 3 kW 5 x 2,5 mm2
HMG PRO 6 kW 5 x 2,5 mm2
HMG PRO 10 kW 5 x 2,5 mm2
YELLOW-GREEN
HMG PRO 12 kW 5 x 6,0 mm2
HMG PRO 3 kW 5 x 16A HMG PRO 15 kW 5 x 6,0 mm2
HMG PRO 6 kW 5 x 16A HMG PRO 20 kW 5 x 10,0 mm2

BROWN
HMG PRO 10 kW 5 x 16A
BLACK

GREY

BLUE

HMG PRO 12 kW 5 x 32A

HMG PRO 15 kW 5 x 32A 5M
HMG PRO 20 kW 5 x 63A

1.3
Cable 20 m from beam’s socket to
a generator’s socket, with plug.

HMG PRO 3 kW 5 x 2,5 mm2

HMG PRO 6 kW 5 x 2,5 mm2
HMG PRO 10 kW 5 x 2,5 mm2
HMG PRO 12 kW 5 x 6,0 mm2
HMG PRO 15 kW 5 x 6,0 mm2
HMG PRO 20 kW 5 x 10,0 mm2

HMG PRO 3 kW 5 x 16A

HMG PRO 6 kW 5 x 16A
HMG PRO 10 kW 5 x 16A
HMG PRO 12 kW 5 x 32A
HMG PRO 15 kW 5 x 32A
HMG PRO 20 kW 5 x 63A

1.2
Socket with a protective cover,
to be fitted to a stub boom.
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HMG PRO HYDRAULIC MAGNET GENERATORS

WHEN USED AS HYDRAULICALLY CONTROLLED UNIT, DYNASET HMG PRO GENERATOR DOES NOT
REQUIRE ANY ELECTRICAL CONNECTIONS.

UNDER EXTERNAL (ELECTRIC) CONTROL, CONTROL VOLTAGE AND POWER SUPPLY FOR SOLENOID
ON/OFF VALVE SHOULD BE BROUGHT TO A GENERATOR’S CONTROL UNIT.

2. HMG PRO CONTROL WIRING KIT

SOLENOID VALVE

3
12

12
NO

+ 24V

yellow (blue)
red (white/brown) HMG PRO control wiring kit
includes magnet’s control switch,
generator starting switch, plugs for
red (black)
violet (blue) both generator and solenoid valve,
yellow (brown) magnetisation indicator light and
3
12

black (yellow/green)
cables (5m).
The kit is available by request.
1 23 456
Usually either pull-on switch
yellow (blue)
OR or rocker switch is applied for
red (white/brown) magnet generator’s starting.
Switch is to be placed on a
yellow (blue) dashboard or other suitable place.
red (white/brown)

yellow (blue)
red (white/brown) OR
red (white/brown)
yellow (blue)

AUXILIARY SOLENOID

Magnet’s control push-button switch should be placed,

if possible, on top of a boom’s control stick. If this is
not possible, machine’s horn switch is recommended
to connect to a magnet’s control. The horn connection
should be changed to a push-button switch, placed in
other user-friendly position.
Foot switch is an option in a number of installations.
CONTROL SOLENOID
VOLTAGE VALVE
If none of above options is available, any other
unconnected switches in machine’s cab can be applied
for the purpose.
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HMG PRO HYDRAULIC MAGNET GENERATORS

OPERATION
HYDRAULIC CONTROL
HMG PRO generator is controlled by opening and shutting off the hydraulic flow in the actuating circuit with the
assigned switch - either a push-button switch placed on top of a boom’s control stick (breaker circuit) or foot
switch (tilt bucket circuit).

After having ensured the proper mechanical and hydraulic installation of the HMG PRO unit, plug the magnet
into the generator’s socket with a suitable cable (Dynaset cable kit recommended).
Machine’s engine can be started and magnet moved to the working area. Start the HMG PRO with an assigned
switch. During of generator’s acceleration control card monitors increasing output voltage and engages the
magnet at preset recognition level - magnetization phase (1) begins.

Now the iron scrap can be sorted and picked. Having picked a sufficient amount of scrap, move it to a dump site
(for instance, scrap trailer). HMG’s control switch must be kept pressed down during this procedure.

To halt the HMG PRO, cut off the hydraulic flow by releasing the control switch when the unit stops. Control card
disengages magnet from power supply (i.e. generator) as generator’s output voltage drops to a recognition level
- magnetization phase (1) is over and process of dissipation of magnet’s residual power (2) with subsequent
demagnetization (3) begins.
High voltage capacitors of control unit are charged with a residual energy of magnet and discharged on a
control unit’s thermistor as many times as necessary to discharge the magnet. Having recognised the status of
magnet as discharged, control card changes the polarity of capacitor current executing the demagnetization.
Due to demagnetization, all material being kept by a magnet drops down.

After release of a material, magnet is returned to an iron picking point and the job continues in above sequence.

1 GENERATOR STOPPED
MAGNET ON

U 230 VDC

MAGNET MAGNET
ENGAGED CONTROL CARD’S DISENGAGED
RECOGNITION LEVEL

0
GENERATOR
STARTED

MAGNET
DISCHARGED

2 3
t

MAJOR PHASES DISPLAYED ON CONTROL UNIT’S DIGITAL DISPLAY:

1 2 3
1 MAGNETIZATION
2 DISSIPATION OF MAGNET’S RESIDUAL ENERGY
3 DEMAGNETIZATION
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HMG PRO HYDRAULIC MAGNET GENERATORS

OPERATION
EXTERNAL CONTROL
After ensuring the proper installation of the generator, plug magnet’s cable into generator’s socket.
Start machine’s engine.
Direct the hydraulic flow to a generator by opening a solenoid valve, when the control voltage 12/24V, brought
to the control unit, activates (ref. HMG PRO CONTROL WIRING KIT ). Magnet is ready for use when hydraulic
flow achieves a minimal demanded level. GENERATOR ROTATES CONSTANTLY THE PRESSURE LINE
BEING OPEN.

Magnet’s current is switched on by pressing magnet’s control push-button once for less than 0,5 sec, when
control card engages the magnet and material is to be picked and moved. Magnetization indicator light is ON.

Press the push-button sequently for less than 0,5 sec to cut-off magnet’s current (magnetization indicator light
is OFF) and to start dissipation of magnet’s residual power (2) with subsequental demagnetization (3). During
demagnetization an indication light flashes once.
Magnet’s residual power dissipation with demagnetization proceed as described on a previous page.

After release of a material, magnet is returned to an iron picking point and the job continues in above sequence.

MAGNET
ENGAGED 1
MAGNET ON

GENERATOR U 230 VDC MAGNET

STARTED DISENGAGED CONTROL CARD’S
RECOGNITION
FUNCTION DISABLED

24 VDC

BUTTON 1 BUTTON 2

MAGNET
DISCHARGED

2 3
t
14 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

OPERATION
Hydraulic pressure is being adjusted according to the
Pressure p, bar
magnet’s power demand, when the hydraulic fluid flow is pmax
being kept constant. pnom

DYNASET hydraulic magnet generator produces high quality

electric power within pressure range from idle run pressure
to the maximum allowed value. The nominal power output is
achieved at pressure value, which is noticeably less than the
Q (l/min) = const
maximum allowed operation pressure. pidle
Refer to the attached diagram and technical specifications. P ( kW )
Pmax kW
00 ,5 1,0
Attention:
HMG PRO’s alternator is equipped with a temperature switch (O.HEA),
as well a control card has a temperature measuring circuit, which
monitors temperature inside of control unit (max. allowed value 100 ºC).

When either of protector operates, control electronics allows to finish O.HEA

working cycle, but prevents to re-energize magnet until the temperature
in control unit drops under 90 ºC . O.HEA is indicated on
a digital display when
When alternator’s temperature switch trips, generator should be either of protection
immediately switched off in order to cool it as fast as possible. The operates.
unit being cooled enough, temperature switch closes when the control
electronics allows an operator to proceed with his job.

ATTENTION ! Magnet’s load duty is 60%. Exceeding of ED-value

causes magnet’s overheating !
MAINTENANCE
DYNASET hydraulic generators are low-maintenance units. Only normally wearing parts such as sealings in
hydraulics, brush collector and bearings should be replaced when necessary.
Refer also to the TROUBLESHOOTING section.

ATTENTION !
Capacitors in control unit keep the charge for a long time
after stopping a generator.
Prior to commence any service:
1. Stop both magnet generator and the carrier 1
2. Wait at least 10 minutes 2
3. Ensure with a gauge that capacitors have no charge.

Use air blow gun with a REASONABLE

DELIBERATION to dust your equipment.

ATTN. !
Remove side screens (1) and air diffuser (3) to
CLEANLINESS OF YOUR HMG PRO-UNIT MUST BE clean fan compartment as well as rotor and stator.
MAINTAINED ON A REGULAR BASIS. CHECK YOUR Remove cover (2) to dust alternator’s electric
EQUIPMENT AFTER EVERY WORKING SHIFT AND components. Having dusted/cleaned the generator,
DEPENDING ON AN OPERATIONAL ENVIRONMENT replace screens/covers and secure them with
CLEAN A GENERATOR AS FREQUENTLY AS appropriate screws.
NECESSARY TO KEEP IT IN PERFECT WORKING (Above picture for reference only - refer to the data
CONDITION. pages of specific HMG PRO-model).
15 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

MAINTENANCE
Remove all oil deposits. Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can
cause overheating and subsequent generator damage and may present a potential fire hazard. Do not leave in
the generator case or control box anything that does not belong to the assembly.

The tightness of lids and covers as well as of all screw joints must be inspected on a regular basis, for instance
at least once a week or more frequently, if a generator is exposed to a noticeable vibration.
Having carried maintenance or cleaning, NEVER LEAVE ALTERNATOR’S COVER AND/OR ELECTRIC BOX’
COVER UNREPLACED AND UNSECURED ! Condition of any seal / gasket must be inspected and defective
parts replaced.

GROUNDING DYNASET EQUIPMENT

Dynaset equipment has to ground in cases when rubber cushions or plastic pads are installed to the
framework. Grounding is also desirable in cases suspected insufficient grounding between working machine
and Dynaset equipment.

Cross section area (S / mm2) of outer CU grounding wire:

Phase wire cross section area (S / mm2). Ground wire cross section area (S / mm2).

S ≤ 16 S
16 < S ≤ 35 16
S > 35 S/2

Use ground wire size at least phase wire cross section area.
Depending on operation, conditions Dynaset recommend use larger ground wire size than phase wire cross
section area.
Pay attention in Dynaset HG, HWG, HMG and CMG models used with rubber cushions or plastic pads enough
grounding does not achieve via hydraulic connections. Enough grounding achieves with external galvanic wire.
In fixed installation without rubber cushions or plastic pads we recommend grounding, but it’s not mandatory.
Grounding wire length 500mm ± 100mm, see picture below.
Pay attention in working machine, e.g. a floating electric circuit forms by Dynaset generator installation and
grounding to machine framework.
This circuit is not in galvanic connection to real earth potential instead they have their own potential in
machine’s framework.
16 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

HYDRAULIC FLUIDS
Wide range of standard hydraulic fluids can be used with the DYNASET hydraulic equipment.
Subject to the operating temperature, following mineral hydraulic oils are recommended:

ISO VG 32S for oil’s operation temperature up to 70 °C;

ISO VG 46S for oil’s operation temperature up to 80 °C;
ISO VG 68S for oil’s operation temperature up to 90 °C.

Synthetic and bio-oils can be used as well if their viscosity characteristics and lubricating efficiency are
corresponding to above mineral oils. Automatic transmission fluids and even engine oils can be used, if they are
allowed to be used in hydraulic system of your carrier machine.
Prior to use special hydraulic fluids a with DYNASET equipment, please be kindly requested to contact nearest
DYNASET representative for an advice.

PRODUCT DISPOSAL
Conform to waste legislation, regulations and recommendations in waste disposal and waste recycling
issued by local authorities.

1. Precondition:

• Product is permanently useless or beyond repair.

• Before transportation get off all used agent (oil, cooling liquid) and dirty filters.

Items requiring special handling can normally be done by authorized waste management facility,
if not:

• Separating the base materials, iron, copper, steel, electronics, removing paint, polyester resin,
and insulation tape and/or plastics residues from all components.
• This ‘waste material’ can now be recycled.

2. Deliver the recycling and waste material to waste management facility.

Note! Customer can send the DYNASET equipment for reuse or recycling to the Dynaset Oy or to
other location determinate by Dynaset representative.

• Customer pays shipping cost.

• Equipment must be adequately packed for shipment.
• Shipment documents must contain purchaser’s name, contact information, equipment type
and serial number.
17 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

1. AC-hydraulic generator 230V/50 Hz,

TROUBLESHOOTING
RPM-regulator;
2. Control unit, rectifier, PCI-card, contactors
3. Ferrous metal handling magnet 3

2
1

MAGNET’S RESISTANCE

Ω (Ohm)
min max

HMG PRO 6 kW 8,8 20

HMG PRO 10,0 kW 5,4 15
HMG PRO 12,0 kW 4,5 10
HMG PRO 15,0 kW 3,6 8
HMG PRO 20,0 kW 2,6 6
18 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

TROUBLESHOOTING
1. 1.1 1.1
MAGNET DOES NOT Magnet unplugged or magnet’s cable Replug the magnet; change the cable if damaged.
WORK damaged.

U.CUR is indicated on a digital display.

U.CUR
1.2 1.2
Magnet’s coil is damaged. Check coil’s resistance and compare the result to the
U.CUR readout is displayed value indicated in the table thereinafter. Check also
when magnet current is coil’s inductance if possible.
under 2A.
U.CUR blinks in turn with 1.3 1.3
voltage readout 225V. 230 VDC voltage does not come from Check whether there is a DC voltage on control
the control unit to magnet’s terminals. card’s terminals 6 and 7 (single card). If control unit is
provided with multiple control cards, gauge DC voltage
on both cards as well as on terminals 4 and 5 of coil
card. Defective card should be replaced.
Magnet’s cable damaged.

1.4 1.4
AC-voltage does not come from Check whether there is a 3-phase voltage 150 - 180
generator to the control unit. VAC on terminals 1 (L1), 2 (L2) and 3 (L3) of control
card (cards).
Potential malfunction in hydraulic system.
Potential failure in AC-generator’s windings, brush
gear, excitation rectifier or voltage regulator.
Ref. to the attached troubleshooting for AC-generator.

1.5 1.5
Damaged control wiring (external Check control wiring, especially magnet’s push-button
control). and generator’s starting switch.
Replace damaged parts.

2. 2.1 2.1
IRON DOES NOT Malfunction of control card. Defective card should be replaced.
GET RELEASED
FROM A MAGNET
(DEMAGNETISATION
DOES NOT WORK)
19 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

TROUBLESHOOTING

3. 3.1 3.1.1
MAGNET Magnet keeps working only a short time. Magnet’s power demand exceeds HMG PRO’s output.
MALFUNCTIONS. Generator gets overloaded and stopped..
Choose magnet according to HMG PRO’s power
output.
O.CUR is indicated on a digital display.
O.CUR O.CUR blinks in turn with time indication 3.1.2
countdown from 20 sec to 0 sec. Magnet cables short-circuit.

O.HEA is indicated on a digital display.

O.HEA 3.1.3
Control unit overheated due to overload or insufficient
cooling.

SNUB indicated on a digital display

SNUB 3.1.4
Failure on control unit’s thermoresistor or internal
wiring.

3.2
Low magnet’s power. 3.2
U.CUR Magnet’s voltage too low:
Does DC-voltage come to magnet’s terminals?
Does AC-voltage come to the control unit?

Check AC-generator according the attached

instructions;
Check actuating hydraulics.
3.3
Magnet’s power consumption excessive, 3.3
control card stops the generator. Generator output voltage is too high causing
overloading.
Check AC-generator according the attached
instructions;
Check actuating hydraulics.
Adjust the output voltage to proper level.

ATTN ! High voltage is hazardous to a generator.

Remedy a malfunction immediately.
20 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

AC-GENERATOR TROUBLESHOOTING

1. 1.1 1.1.1
LOW OUTPUT VOLTAGE Too low rotation speed of generator. Check first the output frequency. If the frequency is
AT NO LOAD out of range, hydraulic system failure is concerned.
1.1.2
Check whether the hydraulic fluid flow and pressure
are sufficient. Adjust when necessary.
1.1.3
Check the hydraulic motor for possible leakage.
Replace motor if necessary.

1.2 1.2
Excitation rectifier‘s failure. Trace the failure and replace the rectifier.

1.3 1.3
Poor contact in electric system. Check all internal contacts and wiring of the generator.
Check and clean brushes and slip ring
(HMG PRO 6 - 20 kW).

1.4 1.4.1
Voltage regulator’s failure. Check the compound regulator. Replace if broken
(HMG PR0 6 - 20 kW).

1.5 1.5
Winding failure. Check the condition of winding; verify winding’s
resistance with parameters shown in technical
specification and replace if damaged.

ATTENTION !
To avoid damaging the control unit, set the
overload protection switch to OFF-position prior
to measuring winding’s insulation resistance.

2. 2.1 2.1
LOW OUTPUT VOLTAGE The generator is being overloaded. Reduce the load and check the current I (A) to ensure
AT LOAD, WHILE that the proper load is being applied.
NO-LOAD VOLTAGE IS
CORRECT 2.2 2.2.1
Too low rotation speed of generator. Hydraulic pressure insufficient.
2.2.2
Hydraulic system failure to be traced and cleared.
2.2.3
Hydraulic motor worn out. Replace hydraulic motor.

2.3 2.3.1
Voltage regulator’s failure. Check and adjust or replace the compound regulator.
(HMG PRO 6 - 20 kW).

2.3.2
Check resistors of rotor’s current circuit (2 pcs).
21 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

AC-GENERATOR TROUBLESHOOTING

3. 3.1 3.1
EXCITATION FAILURE Rectifier‘s failure. Trace the failure and replace the rectifier.

3.2 3.2.1
Voltage regulator’s failure. Check and adjust or replace the compound regulator
(HMG PRO 6 - 20 kW).

3.3 3.3
Winding failure. Verify the winding resistance with parameters shown in
technical specification and replace if damaged.

3.4 3.4
Poor contact in electric system. Check all internal contacts and wiring of the generator.
Check and clean brushes and slip ring
(HMG PRO 6 - 20 kW).

3.5 3.5
Insufficient residual magnetism. Use external battery of 12 V for 1 - 2 sec to magnetise
the rotor.

4. 4.1 4.1.1
OUTPUT VOLTAGE Instable rotation speed of generator. Check generator’s hydraulics, including automatic
INSTABILITY frequency control valve. Make an adjustment; replace
RPM-cartridge if necessary.
4.1.2
Check whether the hydraulic fluid flow and pressure
are excessive. Adjust when necessary.
4.1.3
Check the hydraulic motor for possible leakage.
Replace motor if necessary.

4.2 4.2
Electronic voltage regulator’s failure Adjust stability of the regulator.
(HMG PRO30 kW). Replace if broken.

4.3 4.3
Poor contact in electric system. Check all internal contacts and wiring of the generator.
Check and clean brushes and slip ring (HMG PRO
6 - 20 kW).

5. 5.1 5.1
ABNORMAL NOISE Bearing failure. Replace broken bearing.
LEVEL
5.2 5.2
Generator is being overloaded. Reduce the load to proper level.

5.3 5.3
Short circuit in powered unit. Check powered unit. Rectify a defect.

5.4 5.4
Foreign items in generator’s casing. Stop generator and hydraulic system. Remove foreign
item from unit.

5.5 5.5
Extremely fluctuating load. Can it be fixed?
22 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

AC-GENERATOR TROUBLESHOOTING

6. 6.1 6.1
OIL LEAKAGES Failure of axial sealing of generator’s Axial sealing of hydraulic motor broken
hydraulic motor. External indication - by reason of EXCESSIVE PRESSURE IN RETURN
hydraulic oil outflow from ventilation LINE.
grids. Rebuild the return line. Maximum allowed pressure in
return line is 5 bar.
Replace axial sealing of generator’s motor.

6.2 6.2
Oil leakage from hydraulic motor. Hydraulic motor worn out and should be replaced.
23 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

TECHNICAL SPECIFICATIONS

PARAMETERS HMG PRO - MODELS

PRO 6 kW PRO10 kW PRO12 kW PRO 15 kW PRO20 kW

220 VDC-33 220 VDC-48 220VDC-57 220 VDC-65 220 VDC-86

POWER CHARACTERISTICS
Generator power, max. kW 6,0 10,0 12,0 15,0 20,0
Magnet coil power, max. kW 5,5 9,5 11 14,5 19,5
Operation voltage V±% 225±%5 225±%5 225±%5 225±%5 225±%5
AC-voltage regulator, automatic COMPOUND-REGULATOR

AUXILIARY ELECTRICITY OPTIONAL

1~/230 VAC kVA (3,5) (3,5) (3,5) (3,5) (3,5)
3~/400 VAC kVA (5,0) (9,0) (9,0) (9,0) (9,0)

CONTROL VOLTAGE VDC 24 V 24 V 24 V 24 V 24 V

DEMAGNETISATION AUTOMATIC HMG PRO/CMG HYBRID CONTROL (HYDR / 24 V DC)

HYDRAULIC CONNECTIONS
Pressure line P BSP 1/2” BSP 1/2” BSP 3/4” BSP 3/4 ” BSP 3/4”
Return line T BSP 1/2” BSP 1/2” BSP 1” BSP 1” BSP 1”
Serial connection S BSP 3/8” BSP 3/8” BSP 3/8” NO NO

HYDRAULIC REQUIREMENTS
Minimum flow l/min 36 51 61 69 91
Nominal flow l/min 33 48 57 65 86
Maximum flow l/min 62 70 74 95 110
Pressure at nominal power bar 190 190 190 190 190
Maximum pressure bar 210 210 210 210 210
Idle run pressure bar 50 50 40 40 30

HYDRAULIC FLUID REQUIREMENTS

Viscosity cSt 10 - 200 / optimum 25 - 35
Temperature ºC max. 70 **
Filter ratio, recommendation um min. 25

OUTLINE DIMENSIONS
Length mm 500 560 560 790 910
Width mm 320 320 460 430 525
Height mm 380 380 370 450 440

WEIGHT kg 52 66 100 150 163

24 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

MANUFACTURER’S LIMITED WARRANTY

1. Warranty coverage 6. Delivery terms of warranty repair

All hydraulic accessories manufactured by If the product is found possible to be defective
DYNASET OY are subject to the terms and under this limited warranty and it needs to be
conditions of this limited warranty. Products are repaired, DYNASET OY gives Warranty Return
warranted to the original purchaser to be free from Number (WRN). Items being returned must be
defects in materials or workmanship. Exclusions shipped, at the purchaser’s cost, adequately
from warranty are explained in item 8. packed for shipment, to the DYNASET OY or to
other location authored by DYNASET OY.
2. Beginning of warranty period Shipment documents must contain:
Warranty period begins from the delivery date of - Purchaser’s name and contact information
the product. Delivery is considered to be done on - Receipt of original purchase
the date when installation has been accomplished - WRN code
or purchaser has taken the product in use. - Problem description
Product is considered as taken in use at the date
when DYNASET OY has delivered the product to 7. Warranty of repaired product
purchaser, unless separately agreed otherwise by Warranty period of the product repaired under this
written agreement. limited warranty continues to the end of original
warranty period.
3. Warranty period
Warranty period is twenty four (24) months based 8. Exclusions from warranty
on maximum of 2000 hours usage during this time This warranty shall not apply to:
period. In cases where the system is provided
complete with certain special components (e.g. a. Failures due to normal wear and tear,
drive unit), those components are considered as a improper installation, misuse, abuse, negligence,
subject to their manufacturer’s warranty. purchaser selection of improper product to intended
use, accident, improper filtration of hydraulic oil or
4. Warranty procedures intake water or lack of maintenance
Immediately upon identifying a problem which
purchaser believes to be a failure subject to the b. Cost of maintenance, adjustments, installation
product’s limited warranty, purchaser must contact or startup
primary to the seller of the product. Contact must
be made as soon as possible, latest thirty (30) c. Coating, hydraulic oil, quick couplings and
days after the problem was identified. Seller interconnection hoses (internal or external to system
and/or manufacturer technical staff determines the assemblies)
nature of the problem primarily by phone or
e-mail. Purchaser commits to give necessary
information and to perform routine diagnostic d. Products altered or modified in a manner not
procedures in order to determine the nature of the authorized by DYNASET OY in writing
problem and necessary procedures.
e. Products which have been repaired during
5. Warranty repairs warranty period by others than DYNASET OY or its
If the product is found to be defective during the authorized workshop
warranty period, DYNASET OY will, at its option,
either repair the product, author it to be repaired at f. Costs of any other damage or loss, whether
its authorized workshop or exchange the defective direct, indirect, incidental, special or consequential,
product. If the product must be repaired elsewhere arising out of the use of, or the inability to use, the
than premises of DYNASET OY or authorized product
workshop, all costs excluded from this warranty
(traveling and waiting hours, daily allowance, g. Telephone or other communications expense
traveling expenses and uninstallation/reinstallation
costs) will be charged from the purchaser. h. Product that is used in exceptional conditions,
considered to cause excessive wear and tear
If the problem is not covered by this limited
warranty, DYNASET OY has the right to charge i. Faults caused by nature phenomenon’s like
purchaser of troubleshooting and repairing. flood, thunder, etc.

© DYNASET OY, all rights reserved

25 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

EC DECLARATION OF CONFORMITY

We hereby declare that the below-reference product design and manufacturing are in
conformity with the provisions in the Council Directive on mutual approximation
of laws of the Member States on the safety of machines.

- Machine directive 2006/42/EC

- LVD directive 2006/95/EC
- EMC directive 2004/108/EC.

Applied harmonized standards:

- EN60204-1 Safety of machinery – Electrical equipment of machines.

- EN ISO 4413: EN ISO 4413:2010 Hydraulic fluid power - General rules and safety
requirements for systems and their components.

If device has changed by someone other than at the hands of manufacturer or his
permission, this declaration is not valid.

PRODUCT: DYNASET HYDRAULIC MAGNET GENERATOR

ALL TYPE NUMBERS: HMGxxxxxx-xxxxxx-xxx-xxxx-xxxx

YLÖJÄRVI 31.08.2012
DYNASET Oy

Timo Nieminen
R&D Manager
26 February 2014 JLe
HMG PRO HYDRAULIC MAGNET GENERATORS

NOTES