USER MANUAL Installation & Operation
Contents
1. Watt Minimum speed for full load rom Introduction MANUAL CONTENT This manual covers Operating Instructions Installation Guidelines and Installation Instructions SYSTEM DESCRIPTION Generator and Control Unit The system consists of a high performance generator which is belt driven by the main engine and controlled by the control unit Whenever the engine is on a precisely controlled 230V power source with 50 Hz sine wave AC is available Once the system is installed the operation of the system is automatic including automatic shutdown if an overload or short circuit occurs Remote Control The remote control provides POWER and STANDBY OFF switch and has 4 LED status and fault indicators Power Transfer Switch A Power Transfer Switch is required for switching between an external power source 230V mains and the DYNAWATT Power System WARNING Voltage must never be connected to the control unit Return voltage will immediately result in the control unit being damaged NO WARRANTY OPERATION Figure 4 At full power the system delivers 4000 Watts AC and can deliver higher peak out put on a temporary basis However the system automatically shuts off in the event of a continuous overload This chapter explains how the user can avoid this situation arising It deals with four areas 1 Motor speed 2 Overload 3 Start phase 4 Remote control Engine2. 230V POWER SYSTEMS 4000 USER MANUAL Installation amp Operation L100 02E 02 08 gratulations on your purchase of a DYNAWATT 230V POWER SYSTEM 4000 You have now acquired a high quality precision manufactured power supply system for mobile use Please read these Operating Instructions through carefully before using the system for the first time In any event installation should only be carried out by a qualified technical workshop Manufacturer DYNAWATT AG Zinkereistrasse 35 8633 Wolfhausen Switzerland Tel 41 55 253 26 00 Fax 41 55 253 26 09 SYSTEM DATA DYNAWATT 230V Power System consists of three parts They are 1 Generator Figure 1 Page 16 2 Control unit Figure 2 Page 17 3 Remote control Figure 3 Page 18 option The basic system also comes with 2x installation brackets 6m of generator cable Please note the following information on your system Generator Series No Control unit Series No Safety Precautions e The DYNAWATT Power System 4000 generates an output voltage of 230V AC When operating the system please therefore observe the general safety regulations for using electrical equipment In other words e g do not allow any liquids to get into the housing do not use any sharp instruments in particular do not insert any metallic objects into the ventilation slot e he system is electrically insulated galvanic separatio
3. STANDBY ON add rom overload overheating short circuit bm standard 10m available on request See Figure 3 Additional components Power Transfer Switch A Power Transfer Switch must be installed for switching over from an external power source e g shore power 230V to on board power source DYNAWAT T Fig 7 ListofParts Supplied Generator is supplied with 6m cable Control unit 2 pc attachment brackets loose 4 pc M6 x 10mm attachment screws for brackets on the back of Control Unit EMI fitting for the generator cable on the front side of CU Fitting for the 230V cable on the front side of CU Remote control with 5 or 10 m cable available as an option User manual Parts Required Not Supplied 1 Three conductor power cable min 3x1 5mm2 2 Vehicle specific installation sets available on request 3 4 pc attachment screws for the Control Unit Generator Speed and Available Power Calculation Sheet Note Measure the belt pulley external diameter SWOO0TCDO NE Generator speed Belt pulley dia generator side mm Belt pulley dia motor side Risa mm Motor speed idling VUE Motor speed max NV os rpm Belt pulley transmission Bas 222442 Generator idling rpm NAigiing IR x nL rom Generator max rom Namax IR x nM rom Available output in watts Read from the Curve of Figure 21 Power at engine idle speed
4. 2 be fitted next to the engine This requires a special automatic belt tensioned which is available as an accessory 3 Whichever choice you make it is essential for the generator to be installed securely INFORMATION The generator cable should be laid in a separate protective conduit to safeguard it from mechanical effects Choice of Belt Pulley See Figure 4 System Performance curve The curve shows that no output is delivered by the system until the generator speed reaches approx 2900 rpm and the system generates a 50 output at a generator speed of approx 3700 rpm To achieve the best results the system should reach a minimum generator speed of 3500 rpm at engine idle Generator maximum speed 15 000 rpm continuous 18 000 rom maximum Choice of Belt The power which is transferred via the belts depends upon the belt width wrap around angle the number of belts and the belt tension The service life of a single belt system is considerably less than that of a twin belt system DIA pulley Belt size Type Qty Max output 12 5mm 12 5 ESC toothed 9 5mm 9 5 ESC toothed 2500 Watt 4000 Watt STANDARD 1 2 12 5 12 5 ESC toothed 2 gt 4000 Watt 1 Micro V Micro V 6 grooved 4000 Watt Belt Pulley Alignment Nothing is more important for the service life of a belt than the alignment of the generator pulley and engine pulley Both pulleys must be absolutely parallel and flush aligned If a pulley is positioned at an
5. must be measured on the terminal from phase to phase 1 2 3 Warning high voltage With generator stationary The resistance on the terminal from phase to phase 1 2 3 must be 3 4 ohms 0 3 If fault displayed Contact supplier Rotor resistance 2 5 to 3 5 ohms between cable no 4 and 5 If fault displayed Check generator carbon brushes Clean collector ring with fine sandpaper if necessary Warranty Terms Ae This warranty applies to new products and accessories sold by DYNAWATT AG The system is guaranteed for material and production defects The warranty only covers the unit itself and not any consequential damage 2 Coverage Duration 24 months beginning of the date of delivery to the first user 3 The product must be used and installed in accordance with the details contained in the DYNAWATT operating instruction manual 4 The warranty only covers the unit itself and not any consequential damage Not covered under warranty R amp R remove and reinstall cost and travel expenses are to be borne by the applicant unless expressly agreed otherwise faults and repair costs caused as a result of improper use modifications or incorrect installation injuries and indirect damage to vehicles etc consequential costs and costs incurred due to loss of vehicle moving parts such as V belts LED s plastic components etc LLI r rr SI yo yo Figure 1 Generator IP class 21 F
6. angle to or slightly behind the other this can lead at least to a material related reduction in the useful life of the belt In addition the belt may slip out of the grooves INSTALLATION Generator Installation Figure 9 The generator is fitted as an additional alternator It must be securely and permanently installed since the drive takes two to three times more power than factory fitted standard alternator The ratio to be taken into account during installation 15 dependent upon the engine idling soeed and the maximum speed NOTE All installation screws must therefore be secured using Loctite to prevent accidentally working loose Fitting the generator cover The generator cover must be positioned in such a way that the generator is able to take in dry cool air via the intake opening DIA 55 mm If this is not possible then a suction hose must be connected to the opening to provide dry cool air and must be fitted in an appropriate position in the vehicle The higher the air intake temperature the greater the heat related loss of generator performance See Figure 9 Generator Magnetization The generator must be magnetized before installing it otherwise the system may not operate at all Attach the 12 volt generator cable No 4 plus No 5 minus to a 12 volt battery for approx 30 seconds WARNING On no account must this be carried out whilst the engine is running and the Control Unit connected The Control Unit
7. d increase the system automatically shuts off and the OVERLOAD LED light comes on Remedy Reduce the load after approx 20 seconds the system automatically switches itself back on It can however also be switched off briefly and then back on again HIGH TEMPERATURE Overheating A continuously high load or an overload can cause the system to overheat If the system reaches a temperature of 62 C the HIGH TEMPERATURE LED light starts to flash At 65 C the system automatically shuts off The system only switches back on automatically once it has cooled down to 52 C The cause of the overheating can be either incorrect installation inadequate cooling or a defective fan Remedy Check that the Control unit is well ventilated Test the fan operation if a suction filter is used the filter may need to be cleaned SHORT CIRCUIT In the event of a short circuit or a very high load lt 70 amps the control unit automatically switches off and the SHORT CIRCUIT LED light comes on Remedy Switch off the unit and rectify the fault Then switch the unit back on again The system does not switch back on automatically after a short circuit System ON and OFF If the system has been turned off by engine shut down the ON OFF switch must be rest to off and on again otherwise the system will not start Periodic Maintenance V Belt The system does not need any periodic maintenance with the exception of checking the V belts w
8. er The soft start reduces the starting current by up to 70 by electronically slowing down the start up speed of the user This enables motors with considerably higher starting currents to be operated Remote control option STANDBY The system is switched to STANDBY by pressing the toggle switch In this state there is no voltage and the STANDBY LED light comes on 8 POWER ON Pressing the toggle switch to POWER activates the system The ON LED light comes on if the system is switched on NOTE The control unit mains switch must be set to ON if the remote control is used Otherwise it will not function INCREASE SPEED The control unit continuously measures the power output If the voltage falls by more than 5 under load or because the generator speed is too slow with the result that the power output is no longer sufficient for the current level of consumption then the control unit increases the magnetising voltage Once this reaches the maximum of 14V and the voltage generated is still below 218V then the ADD RPM LED light comes on Remedy Increase engine speed Check belt tension for slippage tighten or replace belt OVERLOAD Under a continuous heavy load the voltage falls to 180V and the current limiter limits the output current to 17 5 amps The system can however still continue to be operated without any problem although the OVERLOAD LED will come on If there is a sudden heavy loa
9. h clamp down Slide the right cable into the clamp and release make sure that the cables are clamped securly close the front cover 9 4 bho Figure 6 Connecting Terminals 21 Automatic power transfer switch for shore DYNAWATT power Connect the power transfer switch at any dry place in the vehicle or boat Connect as shown will have shore power as first priority power source 1 R RZ 230 50Hz output power sockets 230 Figure 7 Power Transfer Switch 22 J8A02 mo gt nei 9128 aen jou op Aq Hunjjoguo au NIE ay SAGS aen sued joo 7 o ay oj e m up dn sp jno uir yun ey Figure 8 Control Unit Installation 23 Generator Installation with 2 x 9 5 mm V Belts Generator with DIA 55 mm air intake hose Cut any place at the rear cover for gen cable exit Figure 9 Generator Installation 24 JLOWIY LLVMVNAG L i i i MOEZ 1nd1no ZH OS ADE LLVMVNAG Figure 10 System Block Diagramm 25
10. hich are used to drive the generator We strongly recommend purchasing replacement belts Where a twin belt system is used both belts must be replaced simultaneously Only high performance belts should be used such as e g GATES Type ESC or CONTI Industry NOTE A new V belt will expand during the first hours of operation and the tension must therefore be subsequently adjusted after the first 10 hours Generator Bearings and Brushes Depending upon the load and the extent to which the system is used the brushes and bearings should be replaced after approx 1000 hrs or 80 000 km Please contact your nearest DYNAWATT dealer for replacements Installation Guidelines and Safety Precautions IMPORTANT It is essential for the system to be installed professionally to ensure reliable operation over a long period of time The mechanical installation of the generator is of particular importance In the event of any problems occurring please contact your DYNAWATT dealer GENERATOR A number of factors must be taken into account to ensure the generator is correctly installed Particular attention must be paid to the correct selection criteria 1 Installation site and stability 2 Choice of belt pulley for the right speed range 3 Choice of belt for minimum system maintenance 4 Belt positioning alignment and tension Installation Site The generator can 1 be fitted to the engine block as an addition to the existing alternator
11. igure 2 Control Unit 17 P 30118 P 30115 P 30115 70 Adapter Remote control Cable RJ45 7m RJ45 SUB D9 RJ45 connector 2 5mm UB 03 08 98 Figure 3 Remote Control DOGE 0057 0002 jyezyaiq 991 0002 591 0061 SLL 000 99 Nd 10213489 ZH OG ADEZ ODF DeMmeuAg ann LEO PE 199 JOIN 0059 0009 0055 0005 DOGF Ont DOGE 000E 0065 005 0001 0061 0002 DOGE DODE DOGE DOT DOGF 0005 JO GEISHA HEM 15440 Figure 4 Generator Performance Curve 19 Preparing connecting cables 230V cable 3x1 5mm2 solder 10mm shield i generator cable Remarks the cable ends should be soldered 10mm cable 4 and 5 10mm longer How to assamble the EMI connector housing gen cable shield a Ki H a MAN P i 7 2 oe Ke mmm ee Gei Hu eem 2 E la SS A cone cone head nut 30mm nipple ribber spring ring insert Figure 5 Preparing cables 20 Right connection of the input and output cable filter housing input filter output filter L phase N neutral E earth Generator IN min recommended cable size 3x1 5mm2 mum 230V OUT C The No on the clamp have to correspond with the No on the cables How to connect the cables open front cover of the controllunit pull the cables into the housing use screwdriver to pus
12. n between electronics and housing and is not earthed to the chassis IT mains installation with potential compensation e When the engine is running the circuits are live In order to ensure optimum cooling the unit must be installed vertically and the ventilation slots kept clear e All installation screws installation kit must be secured to prevent accidental loosening by using Loctite IMPORTANT Installation and maintenance of the system should only be carried out by trained personnel Any faults which are attributable to the use of components other than the components supplied by DYNAWATT AG or the failure to observe the safety instructions as specified above are not covered by the warranty A Power Transfer Switch must be installed if the vehicle boat etc can also be connected to other power sources e g 230V external power shore power generator inverter etc Failure to comply with this instruction will cause damage to the control unit this damage is not covered by the guarantee Power Transfer Switches are available from DYNAWATT as an option Index of Contents System Data 2 Safety Precautions 2 List of Figures 4 Technical Specification 5 Additional Components 6 List of Parts Supplied 6 Parts Required but not Supplied 6 Generator Speed and Available Power 6 Introduction 7 Operation 8 Installation Guidelines and Safety Precautions 11 Installation Procedures 12 Warranty 15 Figures 16 25 List of Figure
13. nal No Voltage 1st Phase L 1 250V AC 2nd Phase L 2 250V AC Magnetizing current 4 red 12V DC 1 2 3 L 3 250 4 5 Magnetizing current 5 blue 12V DC 230V Connection Prepare cable as shown in Figure 5 and pull it through the plastic screw connection into the Control Unit Attach cable to the output filter terminal clamp Ensure secure fit Minimum recommended cable size 3x1 5mm2 Cable up to 4mm2 possible 230V connection Terminal No Function Cable colour terminal function L Phase Brown N Neutral Blue E Earth Yellow Green Starting the System The following must be checked before starting the system that the generator cable has been correctly installed that the V belt tension has been correctly set that all installation screws have been tightened that the cables have been connected to the correct terminals and are securely clamped when unit is switched ON check if fan is operating Troubleshooting The system doesn t work Check the condition and tension of the V belts Check the cable and terminal connections LEDs on the remote control faint Check to see whether cable 4 and 5 but no power have been connected the wrong way around or whether generator must be magnetized again See Page 14 Increase Speed Light comes on V belt slipping check tension and condition adjust tension Testing the Generator With generator turning 250V AC
14. s All figures be found at the back of the manual listed in the order of the figure numbers Figure Page Description 1 16 Generator 2 17 Control Unit 3 18 Remote Control 4 19 Generator Performance Curve 5 20 Preparing the Connection Cable 6 21 Generator and 230V Connection Terminals 7 22 Power Transfer Switch 8 23 Control Unit Installation 9 24 Generator Installation 10 25 System Block Diagramm Technical Specification CONTROL UNIT Output voltage Phases Transformation Frequency Output wave Output power Start up current Efficiency Weight Protection category System Protection Dimensions GENERATOR Power output Output voltage Output frequency Generator speed Weight Belt pulley Efficiency Insulation category Phase resistance Resistance rotor Dimensions REMOTE CONTROL Switch Indicators Connection cable length Dimensions 230V AC 5 1 phase 250V by the generator to 230V 50 Hz 0 5 sine wave 400 Watt intermittent 6000 rpm generator 3500 Watt continuous 25 C temp 23 Amp 2ms 96 7 8 kg 21 System automatically shuts of by overload overheating or short circuit double fault See Figure 1 max 4500 Watt 3 x 250V AC variable between 300 and 1500 Hz 18 000 rpm intermittent 15 000 rpm continuous 7 2 kg DIA 57mm 2 x 9 5mm belt 70 H 170 3 4 Ohm 0 3 from phase to phase 2 5 to 3 5 Ohm See Figure 2
15. speed At idling speed the generator delivers a percentage of its potential output Generation of the maximum output requires a higher engine speed Figure 4 shows a performance curve for calculating the drive ratio the output available from the system on idling speed and the minimum engine speed required in order to achieve the system s maximum output Overload With most overload situations there are three adjustment options 1 Reduce the electrical load 2 Increase the motor speed slightly 3 Shut off the entire power consumption temporarily by switching off the control unit or switching to STANDBY on the remote control This option avoids the system automatically shutting down The load must then be reduced or the motor speed first increased Start phase Electrical consumers in particular electric motors take up far more current when they are switched on than when in operation Electric motors are amongst the biggest consumers of electricity e g an air conditioning system which requires 6 7 amps when running operation can require a starting current of up to 50 amps The DYNAWATT 4000 delivers up to 23 amps starting current In some situations the user will have to follow the start up procedure as shown below 1 Switch off all loads 2 Switch on the largest load first 3 Switch on the remaining small loads If the starting current for a load is too high then a soft start can be connected between the DYNAWATT and the us
16. will be immediately damaged by high voltage NO WARRANTY Engine rpm control To enable the idling speed to be increased we recommend fitting a hand throttle or an automatic engine speed accelerator Available as an option Control Unit mounting The control unit is to be installed in a well ventilated dry place with average temperature levels See Figure 8 The ideal position is against a wall cable connections at the bottom For this the two brackets supplied separately are screw connected to the rear of the control unit The control unit must not be installed horizontally it is important to ensure that the air outlet slots on the reverse are not blocked WARNING The brackets must only be fitted to the rear of the Control Unit by using the supplied M6 screws with a maximum length of 10 mm Connection the generator cable The five conductor generator cable has to be prepared as shown in Figure 5 Open the front cover of the control unit undo 3 screws and insert the cable into the housing through the metal fitting Lead the numbered cables 1 5 to the correct terminal number and attach To attach the cable press the terminal clamp down by using a small screwdriver Ensure the cables are securely clamped The cable shield mash is fitted as shown in Figure 5 Then gently tighten the screw connection using an SW 30 mm spanner Make sure that the gen cable is not turning around while tightening Cable function Function Termi
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