USER MANUAL Installation & Operation
Contents
1. 230V POWER SYSTEMS 5000 USER MANUAL Installation amp Operation 02 08 Congratulations on your purchase of a DYNAWATT 230V POWER SYSTEM 5000 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 41 55 253 26 00 Fax 41 55 253 26 09 www dynawatt SYSTEM DATA The DYNAWATT 230V Power System consists of three parts They are 1 Generator Figure 1 Page 19 2 Control unit Figure 2 Page 20 3 Remote control Figure 3 Page 21 option The basic system also comes with 2x installation brackets 6m of generator cable Please note the following information on your system Generator Series Control unit Series No SAFETY PRECAUTIONS e The DYNAWATT Power System 5000 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 The system is electrically insulated galvanic2. The system is guaranteed for material and production defects he warranty only covers the unit itself and not any consequential damage The warranty application form containing adequate information must be sent to the vendor 2 The warranty period extends for 12 months from the date of purchase by the first purchaser 3 The system must be used and installed in accordance with the details contained in these Operating Instructions 4 The warranty does not cover faults and repair costs caused as a result of improper use modifications or incorrect installation injuries and indirect damage to vehicles etc consequential costs and costs incurred due to loss of vehicle moving parts such as V belts 5 plastic components etc 5 The warranty application must be submitted within a reasonable period of time if possible within 14 days following the occurrence of the damage The applicant must provide appropriate evidence to show when and where the system was purchased 6 Despatch costs installation and dismantling costs are to be borne by the applicant unless expressly agreed otherwise 290 555 I AIR INAKE 165 Figure 1 Generator 08 280 DEP IF class 21 Figure 2 Control unit 19 30118 P 30115 P 30115 70 Adapter Remote control Cable RJ45 7 RJ45 SUB D9 RJ45 connector 2 5mm UB 03 08 98 Figure 3 Remote Control 20 0008 00
3. 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 rom at engine idle Generator maximum speed 13 000 rpm continuous 15 000 rpm maximum Choice of 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 output 12 5mm 12 5 ESC toothed 5000 Watt 12 5 12 5 ESC toothed Micro V Micro V 6 grooved gt 5000 Watt 5000 1 9 5mm 9 5 ESC toothed 2 5000 Watt STANDARD 2 1 Belt Pulley Alignment Nothing is more important for the service life of a belt than the alignment of the generator pulley and engine pulley Both pulleys must be absolutely parallel and flush aligned If a pulley is positioned at an angle to or slightly behind the other this can lead at least to a material related reduction in the useful life of the belt In addition the belt may slip out of the grooves INSTALLATION Generator Installation Figure 9 The generator is fitted as an additional alternator It must be securely and permanently installed since the drive takes two to three times more power than factory fitted standard alternator The ratio to be taken into account during installation 1 dependent upon the en
4. 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 Cable REMOTE CONTROL Switch Indicators Connection cable length Dimensions No Load 230 232 Load 235 237 V AC 1 phase 250V by the generator to 230V 50 Hz 0 5 sine wave 5000 VA intermittent 6000rpm generator 4800 VA continuous 25 C temp 70 Amp 5ms 96 9 kg IP 21 System automatically shuts of by overheating or short circuit double fault See Figure 1 max 5300 Watt 25 C temp 250V variable between 300 and 1500 Hz 15 000 rpm intermittent 13 000 rpm continuous 7 5 kg DIA 60mm 2 x 9 5mm belt 60 H 170 2 8 Ohm 0 3 from phase to phase 2 5 to 3 5 Ohm See Figure 2 5 X 2 5mm 10m max 20m on request STANDBY ON add rpm overload overheating short circuit 7 bm available max 20m 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 DYNAWATT Fig 7 List of Parts Supplied Generator is supplied with 10m 5 2 5mm cable Control unit 2 pc attachment brackets loose 4 pc M6 x 1
5. 0 335 V DC W ukpa ST REMOTE 1 i DYNAWATT System Block Diagramm GENERATOR
6. 02 0009 0006 0008 0005 0002 0001 wdi 220064 1012 19485 ZH 06 ADEZ 0006 LLYMYHAQ 0 0005 0002 000 000 0005 0009 Generator Performance Figure 4 21 preparing conneting cables 230 cable 3x1 5mm2 solder gen cable PG erai _ rii i lt remarks cable ends should be saldered 1 7 bmp How to assamble the EMI connector housing gen cable shield head nut 30mm rubber I spring Dynal Figure 5 Preparing cables 22 5 8 18UNF 2A N 1 2 9 I 21015 _ P30022C Figure 6 Connecting Terminals 23 5 8 18UNF 2A N 1 2 9 a 21015 _ P30022C Figure 7 Power Transfer Switch 24 1902 1101 N 155 5 JOU Aq g gt dr HUN 01U03 10 SMIIS 950 syed 1001 7 34 dn mo 14011500 ui pun 84 JUNO Control Installation Figure 8 25 Generator Installation with 2x9 5mm V Belts Generator with DIA 55mm air intake hose Cut any place at the rear cover for gen cable exit 26 OUTPUT 230V DYNAWATT 230V 50 Hz Figure 1
7. 0mm 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 7 5m cable available as an option User manual Parts Required Not Supplied 1 Three conductor Output power cable min 3x2 5mm2 2 Vehicle specific installation sets available on request 4 pc attachment screws for the Control Unit Generator Speed and Available Power Calculation Sheet Note Measure the belt pulley external diameter P G O O O Generator speed Belt pulley dia generator side mm Belt pulley dia motor side BTS as Motor speed idling Les rpm Motor speed max rom Belt pulley transmission Ras Generator idling NL rpm Generator max rpm Namax x NM rpm Available output in watts Read from the Curve of Figure 21 Power at engine idle speed NAidiing Watt Minimum speed for fullload __ 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 running
8. 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 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 Terminal No Voltage 1st Phase L 1 250V AC 2nd Phase L 2 250V AC Magnetizing current 4 red 12V DC 1 2 3 3rd Phase L 3 250V AC 4 5 Magnetizing current 5 blue 12V DC 230V Connection Prepare cable 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 3 x 2 5mm2 C
9. PTION 10 GENERATOR AND CONTROL UNIT 10 REMOTE CONTROL 10 POWER TRANSFER SWITCH 10 OPERATION 11 ENGINE SPEED 11 OVERLOAD 11 START PHASE 11 REMOTE CONTROL OPTION 12 OFF 12 ON 12 INCREASE SPEED 12 OVERLOAD 12 UNDERVOLTAGE 12 SHORT CIRCUIT 13 SYSTEM ON AND OFF 13 PERIODIC MAINTENANCE 13 GENERATOR DRIVE BELT 13 GENERATOR BEARINGS AND BRUSHES 13 Installation Guidelines and Safety Precautions GENERATOR INSTALLATIONS SITE CHOICE OF BELT PULLEY CHOICE OF BELT BELT PULLEY ALIGNMENT INSTALLATION GENERATOR INSTALLATION FITTING THE GENERATOR COVER GENERATOR MAGNETIZATION CONTROLLING RPM OF VEHICLES ENGINES CONTROL UNIT MOUNTING CONNECTION THE GENERATOR CABLE 230 V CONNECTION STARTING THE SYSTEM TROUBLESHOOTING TESTING THE GENERATOR WARRANTY TERMS LIST OF FIGURES 14 14 14 14 15 15 16 16 16 16 16 17 17 17 18 18 18 19 20 29 List of Figures All figures be found at the back of the manual listed in the order of the figure numbers Eigure Page Description 1 17 Generator 2 18 Control Unit 3 19 Remote Control 4 20 Generator Performance Curve 5 21 Preparing the Connection Cable 6 22 Generator and 230V Connection Terminals F 23 Power Transfer Switch 8 24 Control Unit Installation 9 25 Generator Installation 10 26 System Block Diagramm Technical Specification CONTROL UNIT Output voltage Phases Transformation Frequency Output wave Output power
10. a precisely controlled 230V power source with 50 Hz sine wave AC is available just turn the ON OFF switch to ON Remote Control The remote control provides a POWER ON and STANDBY OFF switch and has 4 LED status and fault indicators Power Transfer Switch A Power Transfer Switch is required for switching between an external power source 230V mains and the DYNAWATT Power System WARNING Voltage must never be connected to the control unit Return voltage will immediately result in the control unit being damaged NO WARRANTY OPERATION Figure 4 At full power the system delivers 5000 Watts AC and can deliver higher peak out put on a temporary basis However the system automatically limits the output power in case of overload Overload causes the output voltage to drop this can have a negative affect on the applied loads This chapter explains how the user can avoid this situation arising It deals with four areas 1 Motor speed 2 Overload 3 Start phase 4 Remote control Engine speed At idling speed the generator delivers a percentage of its potential output Generation of the maximum output requires a higher engine speed Figure 4 shows a performance curve for calculating the drive ratio the output available from the system on idling speed and the minimum engine speed required in order to achieve the system s maximum output Overload With most overload situations there are three adjustment options 1 Reduc
11. able 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 doesnt 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 slipping check tension and condition adjust tension Testing Generator With generator turning 250 AC must be measured on the terminal from phase to phase 1 2 3 Warning high voltage With generator stationary The resistance on the terminal from phase to phase 1 2 3 must be 2 8 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
12. e 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 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 can require a starting current of up to 50 amps The DYNAWATT 5000 delivers up to 70 amps starting current In some situations the user will have to follow the start up procedure as explaned below 1 Switch off all loads 2 Switch on the largest load first 3 switch on the remaining small loads If the starting current for a load is too high then a soft start can be connected between the DYNAWATT and the user The soft start reduces the starting current by up to 70 by electronically slowing down the start up speed of the load 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 on the Output and the STANDBY LED light comes on POWER ON Pressing the toggle switch to POWER activates the system The LED light comes on if the syste
13. gine idling speed and the maximum speed NOTE All installation screws must therefore be secured using Loctite to prevent accidentally working loose Fitting the generator cover The generator cover must be positioned in such a way that the generator is able to take in dry cool air via the intake opening DIA 55 mm If this is not possible then a suction hose must be connected to the opening to provide dry cool air and must be fitted in an appropriate position in the vehicle The higher the air intake temperature the greater the heat related loss of generator performance See Figure 9 Generator Magnetization The generator must be magnetized before installing it otherwise the system may not operate at all Attach the generator cable No 4 to plus and No 5 to minus to a 12 volt battery for approx 5 seconds Note Some generator cables has Yellow Green as No 5 WARNING account must this be carried out whilst the engine is running and the Control Unit connected The Control Unit will be immediately damaged by high voltage NO WARRANTY Engine rpm control To enable the idling speed to be increased we recommend fitting a hand throttle or an automatic engine speed accelerator Available as an option Control Unit mounting The control unit is to be installed in a well ventilated dry place with average temperature levels See Figure 8 The ideal position is against a wall cable connections at the bottom
14. itches 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 gt 70 amps the control unit automatically switches off and the SHORT CIRCUIT LED light comes on Remedy Switch off the unit reduce load or correct 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 lf 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 Generator Drive Belt The system does not need any periodic maintenance with the exception of checking the belts which are used to drive the generator We strongly recommend purchasing replacement belts Where a twin belt system is used both belts must be replaced simultaneously Only high performance belts should be used such as e g GATES Type ESC or CONTI Industry NOTE A new V belt will expand during the first hours of operation and the tension must therefore be subsequently adjusted after the first 10 hours Generator Bearings and Brushes Depending upon the load and the extent to which the
15. m 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 220V then the ADD RPM LED light comes Remedy Increase engine speed Check belt tension for slippage tighten or replace belt OVERLOAD Under a overload the current limiter limits the output current to 22 5 amps the OVERLOAD LED will come on Output Voltage will drop depending on the overload The system can however still be operated without any problem CAUSON have to be taken in order not to affect loads applied Some appliances may be damaged by undervoltage If there is a sudden heavy load increase the system automatically shuts off and the SHORT CIRCUIT LED light comes on Remedy Reduce the load switch the system ON HIGH TEMPERATURE Overheating A continuously high load or an overload can cause the system to overheat If the system reaches a temperature of 65 C the HIGH TEMPERATURE LED light starts to flash At 68 C the system automatically shuts off The system only sw
16. separation between electronics and housing and is not earthed to the chassis IT mains installation with potential compensation e When the engine 1 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 SAEFTY PRECAUTIONS 3 INDEX OF CONTENTS 2 TECHNICAL SPECIFICATION 7 CONTROL UNIT 7 GENERATOR 7 ADDITIONAL COMPONENTS 8 REMOTE CONTROL 8 POWER TRANFER SWITCH 8 LIST OF PARTS SUPPLIED 8 PARTS REQUIRED NOT SUPPLIED 8 GENERATOR SPEED AND AVAILABLE POWER 9 GENERATOR SPEED 9 AVAILABLE OUTPUT IN WATTS 9 INTRODUCTION 10 MANUAL CONTENT 10 SYSTEM DESCRI
17. 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 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 Installation site and stability Choice of belt pulley for the right soeed range Choice of belt for minimum system maintenance Belt positioning alignment and tension JD Installation Site The generator can 1 be fitted to the engine block as an addition to the existing alternator 2 be fitted next to the engine This requires a special automatic belt tensioner which is available as an accessory 3 Whichever choice you make it is essential for the generator to be installed securely INFORMATION The generator cable should be laid in a separate protective conduit to safeguard it from mechanical effects Choice of Belt Pulley See Figure 4 System Performance curve The curve shows that no output 1 delivered by the system until the generator speed reaches approx
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