HWG 180/6K-34
HWG 220/6K-49
HWG 300/10K-54
HWG 400/10K-79
06/18 re
v 1.3
HYDRAULIC WELDING GENERATORS
USER MANUAL
Download PDF version from www.Dynaset.com/manuals Keycode: CFJ3SA
Страница 1: ...HWG 180 6K 34 HWG 220 6K 49 HWG 300 10K 54 HWG 400 10K 79 06 18 rev 1 3 HYDRAULIC WELDING GENERATORS USER MANUAL Download PDF version from www Dynaset com manuals Keycode CFJ3SA ...
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Страница 3: ...ou to take the full advance of the technical features avaible in your equipment Please contact us for any feedback you might have on our products Your feedback is important to us for improving our products and customer service We are constantly developing and releasing new innovations Please visit on our website and social media channels for the latest news and updates www dynaset com info dynaset...
Страница 4: ...PRECAUTIONS 17 2 2 SAFETY EQUIPMENT 18 2 3 OPERATING SAFETY 18 2 4 MAINTENANCE SAFETY 20 2 5 WARNING LABELS 21 3 OPERATING PRINCIPLES 23 3 1 OPERATING DESCRIPTION 23 3 2 WELDING PERFORMANCE 23 3 3 AUXILIARY VOLTAGE CONTROL 24 3 4 PERFORMANCE OF AUTOMATIC FREQUENCY CONTROL 24 3 5 PRESSURE POWER RATIO 24 4 INSTALLATION 27 4 1 BEFORE INSTALLATION 27 4 1 1 HYDRAULIC SYSTEM OF A BASE MACHINE 27 4 1 2 D...
Страница 5: ... 6 WELDING WITH THE HWG 43 5 7 CONNECTING A LOAD TO GENERATOR 44 5 8 STOPPING THE HWG 45 5 9 BATTERY CHARGING AND JUMP STARTING PROCEDURE WITH HWG 300 45 5 10 REMOTE CONTROL 46 5 11 OVERHEATING AND OVERLOAD SITUATION 46 5 12 AMBIENT TEMPERATURE 47 6 MAINTENANCE 49 6 1 MAINTENANCE INTERVALS 49 6 2 HYDRAULIC FLUIDS 49 6 3 CLEANING HWG HYDRAULIC WELDING GENERATOR 50 6 4 TEST SAFETY DEVICES 51 6 5 ADJ...
Страница 6: ...pump 31 Picture 17 Hydraulic system with constant displacement pump 32 Picture 18 Connection figure for hydraulic system with fixed displacement pump 33 Picture 19 LSV Load sensing valve 34 Picture 20 PV SAE Priority valve 34 Picture 21 Placing DYNASET product 35 Picture 22 Installing hydraulic hoses 35 Picture 23 Hydraulic flow at least minimal 36 Picture 24 Base machine s pumps 36 Picture 25 Ret...
Страница 7: ...nerators 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 HW...
Страница 8: ...ion month year 7 Auxiliary output voltage current frequency IP classification 8 Max welding current 9 Manufacturer s contact information 1 4 HWG LINE UP DYNASET HWG come in eight standard models They vary by their welding current 180 400A 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 34 2 HWG 220...
Страница 9: ... 300 400 main components 1 Type plate1 2 Serial number1 3 Hydraulic return line T 4 Hydraulic pressure line P 5 Hydraulic motor 6 Electric sockets1 7 Residual current device 8 Voltage meter2 9 Fuses 10 Welding cable terminal 11 Welding current range selector1 12 Welding Generator switch1 1 Place may vary 2 Optional Welding controls of each model are described in chapter 5 ...
Страница 10: ...G GENERATORS GENERAL 1 6 IP Ingress Protection CLASSIFICATION HWG hydraulic generators are IP classified according to the IEC standard 60529 for the degrees of protection of electrical equipment The protection class of standard HWG 180 220 300 400 hydraulic generators complies with the specifications IP23 ...
Страница 11: ...nstant 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 ...
Страница 12: ...rs 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 ...
Страница 13: ...ion 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 inst...
Страница 14: ...eakage 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 1 9 1 SINGLE PHASE SOCKET PLUG TYPE The product identification key describes which socket op...
Страница 15: ...unded 13 220 240 G H Grounded 16 220 240 C H Unsafe with E F I 2 pins not grounded 3pins grounded 10 220 240 I J Grounded 10 220 240 C J K Grounded 16 220 240 C K Unsafe with E F L Grounded 10 16 220 240 10 A socket C L 16 A socket L M Grounded 15 220 240 M N Grounded 10 20 220 240 C N O Grounded 16 220 240 C O Unsafe with E F The single phase plugs are also presented in the following picture 8 by...
Страница 16: ...d 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 1 380 415 V 16 A 44 50 3p n e 6...
Страница 17: ...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 230 400Vac in the generator mode The hydraulic system can be pressurized...
Страница 18: ... 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 detachingordisassemblingoftheHWGhydraulicweldinggenerator 2 2 SAFETY EQUIPMENT Always wear appropriate clothing and safety equipment such as safety goggles safety shoes ear...
Страница 19: ...RIC 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 WARNING RISK OF FIRE Welding sparks can cause explosio...
Страница 20: ...ment instruments 2 4 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 prop...
Страница 21: ...ain 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 USE EAR PROTECTION AND SAFETY GOGGLES READ OPERATING INSTRUCTIONS BEWARE OF HOT SURFACE RISK OF ELECTRIC SHOCK HIGH PRESSURE OIL ...
Страница 22: ...22 Dynaset Oy Menotie 3 33470 Ylöjärvi puh 03 3488 200 info dynaset com www dynaset com HYDRAULIC WELDING GENERATORS SAFETY ...
Страница 23: ...ectricity 3 Electricity is directed through the distribution box and on to the selected output socket or welding 3 2 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...
Страница 24: ...ed to the stators windings and achieves an accuracyof 3 Electronicvoltageregulatorconstantlycomparesoutputvoltage 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 3 4 PERFORMANCE OF AUTOMATIC FREQUENCY CONTROL RPM cartridge maintains rotation speed of the hydraulic motor so that the frequency is...
Страница 25: ...25 Dynaset Oy Menotie 3 33470 Ylöjärvi puh 03 3488 200 info dynaset com www dynaset com HYDRAULIC WELDING GENERATORS OPERATING PRINCIPLES Picture 12 Pressure Power chart ...
Страница 26: ...26 Dynaset Oy Menotie 3 33470 Ylöjärvi puh 03 3488 200 info dynaset com www dynaset com HYDRAULIC WELDING GENERATORS OPERATING PRINCIPLES ...
Страница 27: ...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 s...
Страница 28: ...tre 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 variable displacement pump the flow rate and output pressure adjusts automatically based on the loa...
Страница 29: ...tion 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 ...
Страница 30: ...MENT 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 ...
Страница 31: ...ATION 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 ...
Страница 32: ...DRAULIC 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 ...
Страница 33: ...icture 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 ...
Страница 34: ...able 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 ...
Страница 35: ...1 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 4 2 2 INSTALLING DYNASET VALVES Installation instructions can be found in the DYNASET LSV or DYNASET PV SAE Installation manual 4 2 3 CONNECTING HYDRAULIC HOSES Pressure P and return T lines of...
Страница 36: ...e 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...
Страница 37: ...ormation 4 3 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 su...
Страница 38: ...hrough 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 mm2 S 10 kVA 2 5 mm2 13AWG 10 S 20 kVA 4 mm2 1...
Страница 39: ...y 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 Starttheengineofyourbasemachine Adjusttheenginespeedtothedemanded level 3 Start the generator with a control valve and ensure that the hydraulic flow is at demanded level Picture 28 Starting the HWG...
Страница 40: ...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 ...
Страница 41: ... 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 onl...
Страница 42: ...ing 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...
Страница 43: ...ENT WITH HWG 300 1 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 5 6 WELDING WITH THE HWG After following previous steps start welding simply by scratching the surface you want to weld on with the welding electrod...
Страница 44: ... 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 so...
Страница 45: ...ing 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 Connectthepositiveandthenegativetotherespectiveterminalsonthebattery 4 Set the current potentiometer C to 50 5 Set the selector switch B to the same voltage than the batt...
Страница 46: ...urs 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 termin...
Страница 47: ...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 40 30 20 10 0 10 20 30 40 50 60 70 75 100...
Страница 48: ...48 Dynaset Oy Menotie 3 33470 Ylöjärvi puh 03 3488 200 info dynaset com www dynaset com HYDRAULIC WELDING GENERATORS OPERATION ...
Страница 49: ...s 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 HYDR...
Страница 50: ...ic 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 6 3 CLEANING HWG HYDRAULIC WELDING GENERATOR ATTENTION Maintain the generator accordingly and keep the vents open and clean Check your equipment after e...
Страница 51: ...y 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 E...
Страница 52: ...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 ...
Страница 53: ...IC 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 met...
Страница 54: ... 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 Ifthe...
Страница 55: ...55 Dynaset Oy Menotie 3 33470 Ylöjärvi puh 03 3488 200 info dynaset com www dynaset com HYDRAULIC WELDING GENERATORS MAINTENANCE Picture 40 Cartridge tuning without installation valve 2 5 ...
Страница 56: ...e 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 Oil leakage from the hyd raulic motor Hydraulic motor worn out and should be replaced HYDRAULIC PRESSURE IS ABNORMALLY HIGH AT NO LOAD Winding failure One or more stator winding is in short circuit TAke contact to nearest DYNASET dealer A MILD ELECTRIC S...
Страница 57: ...aged FAILURE REASON CORRECTIVE ACTION AC ELECTRICITY IS NOT AVAILABLE WHILE HWG WORKS PROPERLY AND AC INDICATOR IS ON AC voltage sockets automa tic 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 Check ...
Страница 58: ... the proper load is being applied LOW FREQUENCY AT NO LOAD Too low rotation speed 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 pos sible leakage Replace the motor if necessary HIGH FREQUENCY AT LOAD Too high rotation speed If frequency is out of range h...
Страница 59: ...mary 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 e mail Purchaser commits to give necessary information and to perform routine diagnostic procedures in order to determine the nature of the problem and necessary proced...
Страница 60: ...f 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...
Страница 61: ...ponsible 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 recycli...
Страница 62: ...62 Dynaset Oy Menotie 3 33470 Ylöjärvi puh 03 3488 200 info dynaset com www dynaset com HYDRAULIC WELDING GENERATORS PRODUCT DISPOSAL ...
Страница 63: ...C LVD directive 2014 35 EU EMC directive 2014 30 EU RoHS directive 2011 65 EU Applied conformity standards CEN EN ISO 4413 EN ISO 4413 2010 Hydraulic fluid power General rules and safety requirements for systems and their components EN60204 1 Safety of machinery Electrical equipment of machines Manufacturer DYNASET Oy Menotie 3 FI 33470 Ylöjärvi Finland Product group HYDRAULIC WELDING GENERATORS P...
Страница 64: ...Dynaset Oy Menotie 3 33470 Ylöjärvi puh 03 3488 200 info dynaset com www dynaset com 64 HYDRAULIC WELDING GENERATORS DECLARATION OF CONFORMITY ...
Страница 65: ...A 400 VAC 6 0 kVA 400 VAC 8 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 IP class 23 23 23 23 HYDRAULIC CONNECTION 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 l min gpm 36 5 5 51 13 5 56 14 8 81 21 4 Flow max l min gpm 53 14 0 68 17 9 88 23 2 101 26 7 Pressure...
Страница 66: ...66 Dynaset Oy Menotie 3 33470 Ylöjärvi puh 03 3488 200 info dynaset com www dynaset com HYDRAULIC WELDING GENERATORS TECHNICAL SPECIFICATIONS ...
Страница 67: ... DYNASET OY med enerett ...
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