USER MANUAL

HYDRAULIC MAGNET GENERATOR

rev 1.4
12/18

HMG/CMG PRO 3kW HMG/CMG PRO 12kW HMG/CMG PRO 30kW

HMG/CMG PRO 6kW HMG/CMG PRO 15kW HMG/CMG PRO 40kW
HMG/CMG PRO 10kW HMG/CMG PRO 20kW
Download PDF version from www.Dynaset.com/manuals Keycode: MYTQK8
 Congratulations!
You have just purchased DYNASET hydraulic equipment!

The equipment allows you to maximize the productivity and

efficiency of your mobile machine. Read this User Manual
before using your new equipment. It contains important
information that will help you to take the full advance of the
technical features avaible in your equipment.

Please contact us for any feedback you might have on our

products. Your feedback is important to us for improving our
products and customer service.

We are constantly developing and releasing new innovations.

Please visit on our website and social media channels for the
latest news and updates.

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 HYDRAULIC MAGNET GENERATORS
TABLE OF CONTENTS

1. GENERAL 9
1.1. PRODUCT INFORMATION 9
1.2. PRODUCT IDENTIFICATION KEY 9
1.3. TYPE PLATE  10
1.4. HMG/CMG PRO’S LINE-UP 10
1.5. MAIN COMPONENTS OF HMG/CMG PRO 12
1.6. IP (Ingress Protection) CLASSIFICATION 14
2. SAFETY 15
2.1. SAFETY PRECAUTIONS 15
2.2. SAFETY EQUIPMENT 16
2.3. OPERATING SAFETY 17
2.4. MAINTENANCE SAFETY 18
2.5. WARNING LABELS 18
3. OPERATING PRINCIPLES 21
3.1. OPERATING DESCRIPTION 21
3.2. PERFORMANCE OF AUTOMATIC RPM-CONTROL 22
3.3. PRESSURE POWER RATIO 22
3.4. MAGNETIZATION AND DEMAGNETIZATION 23
3.5. THE DISPLAY OF THE MAGNET GENERATOR 23
4. INSTALLATION 25
4.1. BEFORE INSTALLATION 25
4.1.1. HYDRAULIC SYSTEM OF A BASE MACHINE 25
4.1.2. DYNASET VALVES 32
4.2. INSTALLING DYNASET HYDRAULIC PRODUCT 33
4.2.1. PLACING DYNASET HYDRAULIC PRODUCT 33
4.2.2. INSTALLING DYNASET VALVES 33
4.2.3. CONNECTING HYDRAULIC HOSES 33
4.2.4. HYDRAULIC FLUIDS 35
4.3. INSTALLATION OF THE HMG/CMG PRO 35
4.3.1. PLACEMENT 35
4.3.2. ATTACHMENT PLATE FOR CMG PRO 36
4.3.3. GROUNDING 37
4.3.4. IP CODE REQUIREMENTS 38

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 HYDRAULIC MAGNET GENERATORS
TABLE OF CONTENTS

4.4. OUTPUT VOLTAGE INSPECTION AT START-UP 38

4.5. HGM/CMG PRO CONTROL CARD SETTINGS 40
4.5.1. SETTINGS FOR SINGLE/MASTER CONTROL CARD OPERATION 40
4.5.2. SETTINGS FOR MULTIPLE CONTROL CARD OPERATION 41
4.6. WIRE SIZES AND WIRING FOR THE HMG/CMG CABLES 43
4.7. OPTIONAL ELECTRIC ACCESSORIES 45
4.8. MAGNET COMPATIBILITY TABLE  46
4.8.1. MEASURING MAGNET’S RESISTANCE 46
5. OPERATION 49
5.1. OPERATING THE HMG/CMG PRO 49
5.2. POWER REDUCTION MODE 50
5.3. DISPLAY OF THE HMG/CMG PRO 51
5.4. HOW TO STOP THE HMG/CMG PRO 52
5.5. OVERHEAT AND OVERLOAD SITUATION 52
5.6. AMBIENT TEMPERATURE 53
6. MAINTENANCE 55
6.1. MAINTENANCE INTERVALS 55
6.2. HYDRAULIC FLUIDS 55
6.3. CLEANING THE HMG/CMG PRO 56
6.4. REPLACING CONTROL CARD 57
6.5. OUTPUT VOLTAGE ADJUSTING 59
6.6. TROUBLESHOOTING 63
7. MANUFACTURER’S LIMITED WARRANTY 67
8. PRODUCT DISPOSAL 69
9. DECLARATION OF CONFORMITY 71
10. TECHNICAL SPECIFICATIONS 73

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 HYDRAULIC MAGNET GENERATORS
TABLE OF PICTURES

Picture 1: HMG/CMG PRO Identification key. 9

Picture 2: Type plate 10
Picture 3: HMG PRO models line-up 11
Picture 4: CMG PRO model 11
Picture 5: Main components of HGM PRO 12
Picture 6: Main components of CMG PRO 13
Picture 7: HMG PRO 10 operating principle 21
Picture 8: Automatic RPM-control 22
Picture 9: Pressure/Power chart 22
Picture 10: Open centre hydraulic system with load sensing variable displacement pump 26
Picture 11: Connection figure for open centre hydraulic system with load sensing variable displacement pump 27
Picture 12: Closed centre hydraulic system with load sensing variable displacement pump 28
Picture 13: Connection figure for closed centre hydraulic system with load sensing variable displacement pump 29
Picture 14: Open centre hydraulic system with constant displacement pump 30
Picture 15: Connection figure for open centre hydraulic system with fixed displacement pump 31
Picture 16: LSV Load sensing valve 32
Picture 17: PV-SAE Priority valve 32
Picture 18: Placing dynaset product 33
Picture 19: Installing hydraulic hoses 33
Picture 20: Hydraulic flow at nominal 34
Picture 21: Base machine’s pumps 34
Picture 22: Return line (T) pressure must be under 5 bars. 34
Picture 23: Placement of the HMG/CMG PRO hydraulic magnet generator. 35
Picture 24: Attachment plate for CMG PRO 36
Picture 25: Grounding the HMG/CMG PRO hydraulic magnet generator 37
Picture 26: IP classification requirements 38
Picture 27: Starting HMG/CMG PRO 38
Picture 28: Adjusting voltage 39
Picture 29: Location of the DIP switches on the control card 40
Picture 30: Single/MASTER card DIP switches 40
Picture 31: MASTER and SLAVE card order 41
Picture 32: Multiple card DIP switches 42
Picture 33: Wiring for the cable from the generator to the magnet 43
Picture 34: Control wire plugs 44
Picture 35: HMG PRO Control wiring 44
Picture 36: Protected booms socket and 20m cable to the magnet generator 45
Picture 37: DYNASET MAG  46
Picture 38: Measuring resistance from the magnet 46
Picture 40: Hydraulic operation method 49
Picture 41: Operating the magnetization by controlling magnet generator’s magnetizing voltage 50
Picture 42: Operating in the reduction mode 51
Picture 43: Generator’s main steps and voltage sequence’s on the display 51
Picture 44: O.HEA on the Display 52
Picture 45: Power take off in higher temperatures 53
Picture 46: Cleaning the HMG/CMG PRO 56
Picture 47: Removing control card  58

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 HYDRAULIC MAGNET GENERATORS
TABLE OF PICTURES

Picture 48: Apply the thermal paste 58

Kuva 49: Installation of control box cover. 59

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 HYDRAULIC MAGNET GENERATORS
TABLE OF PICTURES

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 HYDRAULIC MAGNET GENERATORS
GENERAL

1. GENERAL

This manual contains general information about the assembly, installation,

operation and maintenance of the DYNASET HMG/CMG PRO hydraulic magnet
generators.

ATTENTION!
Read this operating manual before installation, use or maintenance of the
HMG/CMG PRO hydraulic magnet generator, to ensure proper, installation,
handling, operation and maintenance right from the beginning. Pay
attention to the warning and safety instructions. “2. SAFETY”.

1.1. PRODUCT INFORMATION

HMG/CMG PRO hydraulic magnet generators are compact and integrated all-
in-one units, designed especially for mobile installation. HMG/CMG PROs use
hydraulic power source to operate and produce high quality electricity for
magnetization.

1.2. PRODUCT IDENTIFICATION KEY

HMG/CMG PROs are identified by identification key. The key can be found from
the products type plate which is attached on to HMG/CMG PRO side.

Picture 1: HMG/CMG PRO Identification key.

1. Product category HMG/CMG PRO Hydraulic magnet generators.

2. Generator’s theoretical power output in kW.

3. Generator’s output voltage for magnetizing is 220 VDC.

4. Nominal hydraulic flow.Theoretical hydraulic flow of the base machine needed

to operate the product.

5. Auxiliary power outputs are available for HMG PRO as an option by request.

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 HYDRAULIC MAGNET GENERATORS
GENERAL

1.3. TYPE PLATE

Picture 2: Type plate

1. Product identification key 5. Maximum hydraulic pressure
2. Product code 6. Production month / year
3. Serial number 7. Output power / voltage
4. Minimum hydraulic flow 8. Manufacturer’s contact
information

1.4. HMG/CMG PRO’S LINE-UP

DYNASET hydraulic magnet generator’s come in two main models HMG PRO and
CMG PRO.

HMG PRO models are operated through an external control typically from the
base machine’s cabin. There are two ways you can operate the HMG PRO.
1. Control the magnetization through the HMG PRO control box. In this mode
the hydraulic flow is on at all the time and the operator switches magnetization
on and off separately.
2. Control the hydraulic flow. In this mode the magnetization starts when the
operator turns hydraulic flow ON to the magnet generator. Demagnetation
begins when the hydraulic flow is stopped to the unit.

CMG PRO can only be operated by opening the hydraulic flow to the generator. As
the hydraulic flow is opened to the CMG PRO the magnetization begins.

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 HYDRAULIC MAGNET GENERATORS
GENERAL

STANDARD MODELS

DYNASET HMG/CMG PROs come in eight standard models. They variate by their
maximum generator power (3-40kW). The models can also be categorized through
their looks and appearance into five different categories as shown in the picture 3.

Picture 3: HMG PRO models line-up

1. HMG/CMG 3 kW 220 VDC 4. HMG/CMG 15 kW 220 VDC,

HMG/CMG 20 kW 220 VDC
2. HMG/CMG 6 kW 220 VDC,
HMG/CMG 10 kW 220 VDC 5. HMG/CMG 30 kW 220 VDC,
HMG/CMG 40 kW 220 VDC
3. HMG/CMG 12 kW 220 VDC

CMG models are similar to the HMG PRO models but have cable power outlet
instead of socket and no electrical control sockets as shown in the picture 4.

Picture 4: CMG PRO model

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 HYDRAULIC MAGNET GENERATORS
GENERAL

1.5. MAIN COMPONENTS OF HMG/CMG PRO

HMG PRO

Picture 5: Main components of HGM PRO

1. Type plate1 6. Electric sockets in HMG PRO/
Cable connection in CMG PRO
2. Serial number1
7. Solenoid valve plug
3. Hydraulic pressure line (P)
8. Control voltage plug
4. Hydraulic return line (T)
9. Digital display
5. Hydraulic motor
1
Place may vary between models

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 HYDRAULIC MAGNET GENERATORS
GENERAL

CMG PRO

Picture 6: Main components of CMG PRO

1. Type plate1 5. Hydraulic motor

2. Serial number1 6. Cable connection
3. Hydraulic pressure line (P) 7. Digital display
4. Hydraulic return line (T)
1
Place may vary between models

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 HYDRAULIC MAGNET GENERATORS
GENERAL

1.6. IP (Ingress Protection) CLASSIFICATION

HMG/CMG PRO hydraulic generators are IP classified according to the IEC standard
60529 for the degrees of protection of electrical equipment. The protection class
of standard HMG/CMG PRO hydraulic generators complies with the specifications
of the IP23.

From the IP classification guide you can check your IP class information.

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 HYDRAULIC MAGNET GENERATORS
SAFETY

2. SAFETY

2.1. SAFETY PRECAUTIONS

ATTENTION!
Operator and maintenance personnel must act in compliance with the laws,
regulations and recommendations issued by the local electricity and work
safety authorities.

ATTENTION!
All installations and maintenance must be performed according to this
manual. All electrical installations and maintenance that is not shown in
this manual should only be performed by a qualified electrician.

WARNING
RISK OF ELECTRIC SHOCK!
Risk of electric shock. Do not remove
any covers when operating. All the
repairs must be done by a qualified RISK OF ELECTRIC
electrician. SHOCK.

Operating voltage of the HMG/CMG PRO hydraulic magnet generators is 220 VDC

WARNING
HIGH PRESSURE OIL!
Can cause severe injuries.
Always wear appropriate clothing
and safety equipment.

The hydraulic system is pressurized up to 420 bar.

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 HYDRAULIC MAGNET GENERATORS
SAFETY

The pressure in hydraulic circuits of HMG/CMG PRO hydraulic magnet generator

is considerably high. Therefore the technical condition of your equipment should
be kept under constant observation.

All couplings, valves and hoses should be maintained tight and kept clean. Leaks
in the hydraulic system must be fixed immediately to avoid injuries caused by
high pressure and oil blowouts.

WARNING
MAGNETIC FIELD INTERFERENCE
Magnetic field may interfere and damage
electronics nearby. Do not use near
medical implants or electronics. Keep
safe distance according the magnet
manufacturer.

Magnet produces a strong magnetic field that interferes with electronic devices.
Do not use electronic devices near the magnet.

NOTE!
Technical condition of your machinery and equipment must be subjected
to constant surveillance.

2.2. SAFETY EQUIPMENT

When operating in the immediate vicinity of the HMG/CMG PRO hydraulic magnet
generator or its accessories, wear appropriate protective clothing, safety goggles,
gloves, ear and eye protection.

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 HYDRAULIC MAGNET GENERATORS
SAFETY

2.3. OPERATING SAFETY

WARNING
RISK OF BURNS!
The unit parts and oil can be hotter
than 80°C!

Wear personal safety equipment!

ATTENTION!
Maximum load must never be exceeded.

WARNING
RISK OF ELECTRIC SHOCK!
Do not unplug the magnet cable from the
generator when the magnet is powered on!
Unplugging the cable will cause an electric arc
that can cause a severe or fatal injury. Always
stop the generator and wait for the magnet to RISK OF ELECTRIC
discharge before unpluggin it from the generator. SHOCK.

Never get under the magnet when operating. The collected metals might drop
due to a failure in the base machine or in the HMG/CMG PRO system. Remember
to keep the safe distance and stay outside of the base machines reach.

Ensure also that the magnetic field does not interfere and damage other electrical
and electronic equipment and instrumentation. For the duration of using the
magnet, switch off and unplug all sensitive electric and electronic units. Such units
are e.g. AC-chargers, electronic sensors, control and measurement instruments.

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 HYDRAULIC MAGNET GENERATORS
SAFETY

2.4. MAINTENANCE SAFETY

NOTE!
When carrying out any maintenance to HMG/CMG PRO hydraulic magnet
generator keep the components of the system clean. This is to ensure safe,
reliable and longlife operation of your equipment.

Hydraulic system of the base machine should be maintained according to the

machine’s service program. READ CHAPTER “6.1. Maintenance Intervals” for more
information.

WARNING
RISK OF ELECTRIC SHOCK!
30min
Wait until the charge of the electric parts is
completely discharged before removing
any covers.
Stop and wait at least 30 minutes for a RISK OF ELECTRIC
proper discharge. SHOCK.

Prior to the maintenance, detaching from the base machine or disassembling

HMG/CMG PRO hydraulic magnet generator, the hydraulic system of the base
machine have to be stopped and the hydraulic circuit depressurized.

2.5. WARNING LABELS

Warning labels are included with each main product.

Product recipient is obligated to place warning labels on the DYNASET product.

Attach labels to visible and appropriate place on to or close to DYNASET product
where it’s easily seen. Clean surface with solvent detergent before attaching labels.

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 HYDRAULIC MAGNET GENERATORS
SAFETY

READ OPERATING USE EAR PROTECTION WEAR GLOVES WEAR

INSTRUCTIONS AND SAFETY GOGGLES SAFETY BOOTS

RISK OF ELECTRIC BEWARE THE HOT BEWARE THE RISK OF MEDICAL HIGH PRESSURE
SHOCK SURFACE MAGNETIC FIELD EQUIPMENT FAILURE OIL

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 HYDRAULIC MAGNET GENERATORS
SAFETY

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 HYDRAULIC MAGNET GENERATORS
OPERATING PRINCIPLES

3. OPERATING PRINCIPLES

3.1. OPERATING DESCRIPTION

Picture 7: HMG PRO 10 operating principle

1. Starting the HMG/CMG PRO happens by opening the the hydraulic flow to the
RPM-valve block. The RPM-valve keeps the flow constant and controls the speed
of the hydraulic motor through the RPM-cartridge.
2. Hydraulic motor actuates the alternator’s rotor through a direct connection
to the rotor. When the rotor spins it produces a changing magnetic flux that
generates electricity.
3. From the stator windings the electricity is directed through the distribution
box on to the generators control box.
4. When the magnetizing button is pressed on the generator produces 220 VDC
to magnetize the magnet.

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 HYDRAULIC MAGNET GENERATORS
OPERATING PRINCIPLES

3.2. PERFORMANCE OF AUTOMATIC RPM-CONTROL

The RPM-cartridge maintains rotation speed of the hydraulic motor constant (±5
%). Even when incoming hydraulic flow (Q) can vary from minimal flow (Qmin) by
exceeding it up to 20-30%, depending on the HMG/CMG PRO ‘s size, the hydraulic
motors rpm is kept stable (±5 %).

Picture 8: Automatic RPM-control

3.3. PRESSURE POWER RATIO
Following chart in picture 9 describes the power to pressure ratio. The chart shows
output powers relation to the pressure, when the hydraulic flow Q is kept constant.
The best power to pressure ratio is achieved when the pressure is at nominal level,
little under the maximum value. READ CHAPTER “10. TECHNICAL SPECIFICATIONS”
for more information of each models nominal pressure.

Picture 9: Pressure/Power chart

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 HYDRAULIC MAGNET GENERATORS
OPERATING PRINCIPLES

3.4. MAGNETIZATION AND DEMAGNETIZATION

Magnetization and demagnetization are controlled electronicly by the HMG/CMG
PRO control unit. The electronic control enables the magnet to demagnetize in
0,8s.

3.5. THE DISPLAY OF THE MAGNET GENERATOR

The display shows the steps of the magnetization, magnetizing voltage and error
messages. Magnetization steps are described in READ CHAPTER “5.3. Display of
the HMG/CMG PRO” for more information. The error messages are described in
READ CHAPTER “6.6. Troubleshooting” for more information.

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 HYDRAULIC MAGNET GENERATORS
OPERATING PRINCIPLES

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 HYDRAULIC MAGNET GENERATORS
INSTALLATION

4. INSTALLATION

4.1. BEFORE INSTALLATION

ATTENTION!
Read these instructions before installation of the DYNASET product!

4.1.1. HYDRAULIC SYSTEM OF A BASE MACHINE

Base machines have different types of hydraulic systems. The most common
hydraulic systems in mobile machinery are:
• Open centre hydraulic system with a Load Sensing variable displacement pump
• Closed centre hydraulic system with a Load Sensing variable displacement pump
• Hydraulic system with a fixed displacement pump

Before installing the DYNASET product, find out the type of the hydraulic
system of your machine.

If you are unsure of the hydraulic system, please contact the manufacturer of your
base machine.

Next three paragraphs describe the hydraulic systems in more detail.

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 HYDRAULIC MAGNET GENERATORS
INSTALLATION

OPEN CENTRE HYDRAULIC SYSTEM WITH LOAD SENSING VARIABLE

DISPLACEMENT PUMP

Picture 10: Open centre hydraulic system with load sensing variable
displacement pump

In open centre hydraulic system the flow is returned to tank through the control
valves open centre; that is, when the control valve is centered. It provides an open
return path to tank and the fluid is not pumped into a high pressure. In variable-
displacement pump, the flow rate and output pressure adjusts automatically
based on the load of the hydraulic system.

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 HYDRAULIC MAGNET GENERATORS
INSTALLATION

Picture 11: Connection figure for open centre hydraulic system with load
sensing variable displacement pump

1. DYNASET hydraulic equipment control valves

2. DYNASET Priority valve PV-SAE 5. Oil cooler
2.1. DYNASET PC-SAE pressure 6. Oil filter
compensator
7. Oil tank
2.2. DYNASETLSVLoadSensingvalve
3. Base machine’s variable
displacement pump
4. Open centre directional

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 HYDRAULIC MAGNET GENERATORS
INSTALLATION

CLOSED CENTRE HYDRAULIC SYSTEM WITH LOAD SENSING VARIABLE

DISPLACEMENT PUMP

Picture 12: 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.

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 HYDRAULIC MAGNET GENERATORS
INSTALLATION

Picture 13: Connection figure for closed centre hydraulic system with load
sensing variable displacement pump

1. DYNASET hydraulic equipment 5. Closed centre directional

control valves
2. DYNASET LSV Load Sensing valve
6. Oil cooler
3. DYNASET Shuttle valve
7. Oil filter
4. Base machine’s variable
displacement pump 8. Oil tank

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 HYDRAULIC MAGNET GENERATORS
INSTALLATION

HYDRAULIC SYSTEM WITH FIXED DISPLACEMENT PUMP

Picture 14: Open centre 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.

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 HYDRAULIC MAGNET GENERATORS
INSTALLATION

Picture 15: Connection figure for open centre hydraulic system with fixed
displacement pump

1. DYNASET hydraulic equipment 4. Open centre directional

control valves
2. DYNASET Priority valve PV-SAE
5. Oil cooler
2.1. DYNASET PC-SAE pressure
compensator 6. Oil filter
2.2. DYNASETLSVLoadSensingvalve 7. Oil tank
3. Base machine’s fixed
displacement pump

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 HYDRAULIC MAGNET GENERATORS
INSTALLATION

4.1.2. DYNASET VALVES

DYNASET valves are designed to enable easy installation of your DYNASET
hydraulic product.

DYNASET LSV LOAD SENSING VALVE

Picture 16: 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 17: PV-SAE Priority valve

DYNASET PV- SAE priority valve enables the installations of the DYNASET products
into any hydraulic system.

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 HYDRAULIC MAGNET GENERATORS
INSTALLATION

4.2. INSTALLING DYNASET HYDRAULIC PRODUCT

4.2.1. PLACING DYNASET HYDRAULIC PRODUCT

Place the DYNASET hydraulic product where there is an easy access to the unit.
Ensure proper ventilation.

Picture 18: Placing dynaset product

NOTE!
When positioning the HMG/CMG PRO hydraulic magnet generator, ensure
that the air venting is sufficient. READ CHAPTER “4.3.1. Placement” 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 a hydraulic system are connected to the
DYNASET units corresponding hydraulic ports.

Picture 19: Installing hydraulic hoses

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 HYDRAULIC MAGNET GENERATORS
INSTALLATION

Ensure that the hydraulic flow of the base machine is sufficient to run the unit.
At least the minimal flow must be available. READ CHAPTER “10. TECHNICAL
SPECIFICATIONS” for more information.

Picture 20: Hydraulic flow at nominal

In case of the hydraulic flow being too high, it must be reduced. The flow can be
reduced either by lowering the rotation speed of base machine’s hydraulic pump
or using flow limiter valve. DYNASET priority valve is recommended.

Picture 21: Base machine’s pumps

Return line must be connected to a hydraulic oil tank directly in the shortest
possible line in order to keep the return hydraulic pressure under 5 bar in the tank
line. Generally DYNASET’s return line(T) is to be connected directly to the return
line of a hydraulic system.

Picture 22: Return line (T) pressure must be under 5 bars.

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 HYDRAULIC MAGNET GENERATORS
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ATTENTION!
Ensure that the filtering degree and cooling capacity of the hydraulic
system are sufficient. READ CHAPTER “10. TECHNICAL SPECIFICATIONS” for
more information.

4.2.4. HYDRAULIC FLUIDS

To use proper hydraulic fluid READ CHAPTER “6.2. Hydraulic fluids” for more
information.

4.3. INSTALLATION OF THE HMG/CMG PRO

4.3.1. PLACEMENT
DYNASET HMG/CMG PRO hydraulic magnet 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 the HMG/CMG PRO is ensured. The position
of the generator must be horizontal.

Picture 23: Placement of the HMG/CMG PRO hydraulic magnet generator.

A. Minimum 25 mm B. Minimum 50 mm

NOTE!
Sufficient venting is important. HMG/CMG PROs components heat up
during the use. Maintain the generator accordingly and keep the vents
open and clean.

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 HYDRAULIC MAGNET GENERATORS
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An additional oil cooler is required when HMG/CMG PRO unit is installed to a

truck with and hydraulic hoist. Ensure that the cooling capacity of your hydraulic
system is sufficient. READ CHAPTER “10. TECHNICAL SPECIFICATIONS” for more
information.

4.3.2. ATTACHMENT PLATE FOR CMG PRO

For CMG PRO 3-12 kW models there is a attachment available which helps to install
the CMG PPRO on magnets.

Picture 24: Attachment plate for CMG PRO

MODEL DIMENSIONS, mm (in)

a b c d e f g
370 196 230 159 10 100 19
CMG PRO 3kW-220VDC-21
(14.57) (7.72) (9.06) (6.26) (0.39) (3.94) (0.75)

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 HYDRAULIC MAGNET GENERATORS
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MODEL DIMENSIONS, mm (in)

a b c d e f g
163 170 545 130 60 40
CMG PRO 6kW-220VDC-34 -
(14.57) (7.72) (9.06) (6.26) (0.39) (3.94)
164 610 124
CMG PRO 10kW-220VDC-49 - - - -
(14.57) (7.72) (9.06)
665 305 260 180 40 100 32,5
CMG PRO 12kW-220VDC-59
(26.18) (12.01) (10.24) (7.09) (1.57) (3.94) (1.48)

4.3.3. GROUNDING

ATTENTION!
DYNASET HMG/CMG PRO must be grounded when the rubber cushions or
plastic pads are installed to the HMG/CMG PRO’s framework. Grounding is
also recommended when the generator is installed onto the base machine
without rubber cushions or plastic pads.

Do not ground the HMG/CMG PRO hydraulic magnet generator through hydraulic
connections. Make the grounding only to the base machines frame. Use external
galvanized wire to gain proper grounding as shown in the picture 25. The ground
wire size/gauge is to be selected according to the following table.

The ground wire is recommended to be according to the following table.

Generator size S (kW) Ground wire cross-section area (mm2)
S < 10 kW 2.5 mm2 (13AWG)
10 < S < 20 kW 4 mm2 (11AWG)
20 < S < 40 kW 6 mm2 (9AWG)
S ≥40 kW 10 mm2 (7AWG)

Ground the generator from the marked grounding spot in generators frame.
Grounding spot of the HMG PRO 10 is shown in the picture 25. The grounding
spot varies between different generator models.

Picture 25: Grounding the HMG/CMG PRO hydraulic magnet generator

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 HYDRAULIC MAGNET GENERATORS
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4.3.4. IP CODE REQUIREMENTS

Dynaset products with the IP class IP23 must be installed into a place where water
can’t enter the generator from below or from the sides according to the IP23
classification

Picture 26: IP classification requirements

4.4. OUTPUT VOLTAGE INSPECTION AT START-UP

HMG/CMG PROs are tested and adjusted at the factory but it is recommended to
check the DC voltage before taking the HMG/CMG PRO 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 the system.
2. Start the engine of your base machine. Adjust the engine speed to demanded
level if necessary.
3. Start the generator by opening the hydraulic flow to the generator.
4. Turn on the magnet:

Picture 27: Starting HMG/CMG PRO

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 HYDRAULIC MAGNET GENERATORS
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A. HMG PRO: Turn the magnet ON with ON/OFF switch.

B. CMG PRO: magnetization starts immediately when the the hydraulic flow is
opened to the generator.
5. Check the voltage from generator’s display. The voltage should be 220VDC±5%.

Picture 28: Adjusting voltage

6. Adjust the voltage if necessary. READ CHAPTER “6.5. Output voltage adjusting”
for more information.

NOTE!
DYNASET HMG/CMG PRO hydraulic magnet generators are tested and
adjusted at the factory! Do not adjust the voltage without real need.

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 HYDRAULIC MAGNET GENERATORS
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4.5. HGM/CMG PRO CONTROL CARD SETTINGS

Control mode settings for control cards are made with the following instructions
with DIP-switches SW1 and SW2, both located on a control card as shown in the
picture 29.

Picture 29: Location of the DIP switches on the control card

A. DIP switches SW1 and SW2

4.5.1. SETTINGS FOR SINGLE/MASTER CONTROL CARD OPERATION

Picture 30: Single/MASTER card DIP switches

DIP switch SW1:

• Switches 1 - 3 on MASTER position.
• Switch 4, select the operation mode:
• SW, when push button is used for external control in HMG PRO operation.
• GEN, when hydraulically controlled voltage level is used in CMG PRO operation.

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 HYDRAULIC MAGNET GENERATORS
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DIP switch SW2:

• Switch 1 at ON position, enables hard demagnetization.
• Switch 2-4 on OFF position

Switch 1 enables normal and hard demagnetization (giving 30% more efficient,
but is slower).
Switch 2 internal function.
Switch 3 enables the power reduction mode with HMG PRO. READ CHAPTER “4.5.
HGM/CMG PRO control card settings” for more information.
Switch 4 internal function.

4.5.2. SETTINGS FOR MULTIPLE CONTROL CARD OPERATION

Depending on the size of the HMG/CMG PRO generator, control units can be
equipped with more than one control card. The following instructions are for the
models where two or more control cards are used.

HMG PRO 12 - 20kW has two (2) cards. HMG PRO 30kW has three (3) and HMG PRO
40kW has four (4) cards.

NOTE!
The MASTER card is installed on the right side and SLAVE card to the left
side of the control unit as shown in the picture 31.

Picture 31: MASTER and SLAVE card order

1. MASTER card 2. SLAVE card

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 HYDRAULIC MAGNET GENERATORS
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FIRST (MASTER) CARD SWITCH SETTINGS:

The settings are the same for the MASTER control card as they are in single card
use. Use the settings on the chapter 4.5.1 for the MASTER card settings.

ATTENTION!
Dip switches on the SW2 should be set to the same position in all the control
cards.

SECOND (SLAVE) CARD AND ADDITIONAL (SLAVE) CARDS SWITCH

SETTINGS:

Picture 32: Multiple card DIP switches

DIP switch SW1:

• Switches 1 - 3 to the SLAVE position.
• Switch 4 selects the operation mode:
• SW, when the push button is used for the external control of the HMG PRO
operation.
• GEN, when the hydraulic controlled voltage level is used to control a CMG
PRO operation or HMG PRO in hydraulic mode.

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 HYDRAULIC MAGNET GENERATORS
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4.6. WIRE SIZES AND WIRING FOR THE HMG/CMG CABLES

MAGNET CABLE

Following table contains the recommended sizes for the output cables and sockets
when using the HMG/CMG PRO.

SOCKET
MODEL CABLE SIZE SIZE
HMG/CMG PRO 3 kW 5 x 2,5mm2 (3 x 6mm2) 13AWG5 (9AWG3) 5 x 16 A

HMG/CMG PRO 6 kW 5 x 2,5mm2 (3 x 6mm2) 13AWG5 (9AWG3) 5 x 16 A

HMG/CMG PRO 10 kW 5 x 6mm2 (3 x 10mm2) 9AWG5 (7AWG3) 5 x 16 A

HMG/CMG PRO 12 kW 5 x 6mm2 (3 x 10mm2) 9AWG5 (7AWG3) 5 x 32A

HMG/CMG PRO 15 kW 5 x 6mm2 (3 x 10mm2) 9AWG5 (7AWG3) 5 x 32A

HMG/CMG PRO 20 kW 5 x 10mm2 (3 x 16mm2) 7AWG5 (5AWG3) 5 x 63A

HMG/CMG PRO 30 kW 5 x 10mm2 (3 x 16mm2) 7AWG5 (5AWG3) 5 x 63A

HMG/CMG PRO 40 kW 5 x 10mm2 (3 x 16mm2) 7AWG5 (5AWG3) 5 x 63A

If you are using an another kind of cable, ensure the proper cable size.

Picture 33: Wiring for the cable from the generator to the magnet

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 HYDRAULIC MAGNET GENERATORS
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HMG PRO CONTROL CABLES

HMG PRO has two control cables. Control voltage cable to opearate the
magnetizing and solenoid voltage cable to start the Hydraulic flow to the HMG
PRO generator.
A. Control voltage plug B. Solenoid voltage plug

Picture 34: Control wire plugs

Wire the control cables by the following wiring schema:

Picture 35: HMG PRO Control wiring

Solenoid cables “Potential free NO contact” can be used for e.g. excavators
hydraulic system to detect and inform the rest of the system that the generator
needs hydraulic flow.

Recommended cable size:

CABLE SIZE
0,75mm2 18AWG

DYNASET also offers an optional HMG PRO Control wiring kit for control cables.
More information about the Control wiring kit can be found from chapter “4.7
Optional electric accessories”.

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 HYDRAULIC MAGNET GENERATORS
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4.7. OPTIONAL ELECTRIC ACCESSORIES

Optional DYNASET magnet cable kit can be purchased for connecting DYNASET
HMG PRO to the magnet. Also optional HMG PRO control wiring kit is available to
enable the external control connections.

HMG PRO MAGNET CABLE KIT

Magnet’s wiring kits is suitable for all of the HMG PRO units the kit includes
1. Socket with a protective cover, to be fitted to a boom
2. 20 m cable from the booms socket to the generator’s socket, with a plug.

Picture 36: Protected booms socket and 20m cable to the magnet generator

HMG PRO CONTROL WIRING KIT

HMG PRO control wiring kit is available for all externally controlled HMG PRO
units. The kit includes:
• control switch for the magnet,
• generator’s starting switch,
• plugs for generator and solenoid valve,
• magnetization signal light and
• cables (5m)

Switches can be placed on a dashboard or to any other suitable place.

Wiring kit contains signal light to show the magnetizing phase.

• When the magnet is magnetized the indicator light will turn on
• When the demagnetization is on the indicator light will turn off

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 HYDRAULIC MAGNET GENERATORS
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4.8. MAGNET COMPATIBILITY TABLE

The following table shows an appropriate lifting magnet for different HMG/CMG
PRO models. Suitable DYNASET MAG lifting magnets are also listed. Coil resistance
values are measured at +20oC temperature.
MAGNET RECOMMENDED LIFT
GENERATOR RESISTANCE MAGNET TYPE
MODEL
Min Max General DYNASET
HMG/CMG PRO 3 kW 15 100 2,5 kW MAG 700
HMG/CMG PRO 6 kW 8,8 100 5,1 kW MAG 900
HMG/CMG PRO 10 kW 5,4 100 8,4 kW MAG 1200
HMG/CMG PRO 12 kW 4,5 50 10,1 kW MAG 1400
HMG/CMG PRO 15 kW 3,6 50 12,6 kW MAG 1500
HMG/CMG PRO 20 kW 2,6 50 16,8 kW MAG 1600
HMG/CMG PRO 30 kW 1,8 30 25,2 kW MAG 1800
HMG/CMG PRO 40 kW 1,3 20 33,6 kW MAG 2200

Picture 37: DYNASET MAG

4.8.1. MEASURING MAGNET’S RESISTANCE

Magnet’s resistance can usually be measured between the magnets + and - poles
as shown in the picture. Check the correct way to measure resistance from the
magnet’s manual or take contact to the magnet’s manufacturer.

Picture 38: Measuring resistance from the magnet

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 HYDRAULIC MAGNET GENERATORS
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 HYDRAULIC MAGNET GENERATORS
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 HYDRAULIC MAGNET GENERATORS
OPERATION

5. OPERATION

ATTENTION!
Check the HMG/CMG PRO hydraulic magnet generator and its hoses
condition before use to ensure there are no leaks or damages.

After having ensured the proper mechanical and hydraulic installation of the
HMG/CMG PRO unit, plug the magnet into the generator’s socket with a suitable
cable (Dynaset cable kit recommended).

5.1. OPERATING THE HMG/CMG PRO

WITH HYDRAULIC CONTROL

1. Start base machines engine and move the magnet to the working area.
2. Open the hydraulic flow and to the the HMG/CMG PRO begin the magnetization.

LS

ET
P
LS

AGN P

M
ET
AGN
M

Picture 40: Hydraulic operation method

NOTE!
The switch has to be pressed on all the time during the collecting and
moving metals to enable magnetization.

3. Release the control switch to demagnetize and drop the collected metals.

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 HYDRAULIC MAGNET GENERATORS
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WITH EXTERNAL CONTROL

1. Start machine’s engine and move the magnet to the working area.
2. Open the solenoid valve of the HMG PRO with the assigned switch.

HMG PRO generator is ready for the use when the hydraulic flow and the pressure
achieve the minimum level. Generator is running constantly in this installation
when the pressure line is open.
3. Activate the magnet by pressing the assigned switch once.
4. To drop the collected material, press the same switch again to demagnetize
the magnet.

3 2

ET
GN LS
MA OR
AT
N ER P
GE

Picture 41: Operating the magnetization by controlling magnet generator’s

magnetizing voltage

5.2. POWER REDUCTION MODE

In power reduction mode the collected metals can be sorted after being lifted.
Sorting means that the lowest collected metals can be separated from the rest
of the stack. Power reduction mode is only available with HMG PRO operated by
external conrol described in chapter 5.1.

For this mode the reduction mode must be enabled on the HMG PROs control
card. READ CHAPTER “4.5.1. Settings for single/MASTER control card operation” for
more information.

When the reduction mode is enabled the collected metals can be sorted in the
following way.
1. Lift the collected metals with the magnet
2. Push and hold the magnetizing/demagnetizing button. When the first metal
part drops release the button to continue magnetization.

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 HYDRAULIC MAGNET GENERATORS
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Picture 42: Operating in the reduction mode

If button is released too soon (less than 0,5 sec.) the reduction mode won’t activate
and the magnet will fully demagnetize.

5.3. DISPLAY OF THE HMG/CMG PRO

The display shows the main phases of the magnetization, magnetizing voltage
and error messages. READ CHAPTER “6.6. Troubleshooting” for more information.
about the error messages.
MAIN STEPS OF MAGNETIZATION
Magnetization is divided into three main steps.
1. Magnetization, when the magnet is magnetized with the HMG/CMG PRO
generator.
2. Magnet field dampen, when the HMG/CMG PRO generator is cut off and the
magnet starts to demagnetize.
3. Demagnetization, when the magnet is fully demagnetized.

When the magnetizing is started the magnetizing voltage is shown on the dispaly
between the steps 1 & 2.

Picture 43: Generator’s main steps and voltage sequence’s on the display

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 HYDRAULIC MAGNET GENERATORS
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5.4. HOW TO STOP THE HMG/CMG PRO

Stop the HMG PRO by switching off the hydraulic flow to the generator.

CMG PRO shuts off when the button enabling the hydraulic flow to the generator
is released.

5.5. OVERHEAT AND OVERLOAD SITUATION

HMG/CMG PRO’s alternator and control card are equipped with a temperature
temperature measuring circuit. In overheat situations the error message O.HEA
shown on the display.

In control unit’s overheating situations, control electronics prevent the HMG/CMG

PRO to magnetize the magnet until the temperature in control unit drops.

When alternator’s temperature switch trips, the magnetization should be switched

off in order to cool HMG/CMG PRO generator as fast as possible.

After few minutes, when the HGM/CMG PRO generator has cooled down, the unit
automatically switches the overheat alarm off and is operatable again.

NOTE!
Check and obey the magnet manufactures load duty value (ED). Exceeding
of the ED-value causes HMG/CMG PRO to overheat ! in need of more
information about the ED-value take contact to magnet’s manufacturer.

Picture 44: O.HEA on the Display

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 HYDRAULIC MAGNET GENERATORS
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5.6. AMBIENT TEMPERATURE

To avoid the power loss, it is not recommended to use the HMG/CMG PRO when
the ambient temperature exceeds +40 ºC. When the ambient temperature exceeds
+40 ºC power takeoff should be limited in accordance with the attached diagram
in picture 46, 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 achieves +40 ºC, the HMG/CMG PRO’s full output
power can be maintained by adding an additional air ventilation.

Picture 45: Power take off in higher temperatures

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 HYDRAULIC MAGNET GENERATORS
MAINTENANCE

6. MAINTENANCE
DYNASET HMG/CMG PRO hydraulic magnet generators are low-maintenance
units. Only normally wearing parts such as sealings in hydraulics, brush collector
and bearings are needed to be replaced when necessary.

ATTENTION!
Before beginning any maintenance or repair, ensure that the system
is stopped and depressurized. Make sure that the system can not start
accidentally.

6.1. MAINTENANCE INTERVALS

All maintenance must be complied as they are scheduled in this manual. The
following table provides maintenance schedule for the HMG/CMG PRO.

NEW DEVICE AFTER AFTER DAILY

CHECK POINTS
INSTALLATION USE
Perform the needed actions after each HMG/CMG
PRO hydraulic magnet generator installation accord- x
ing to the chapter 4. Installation.
Check if the HMG/CMG PRO hydraulic magnet gen-
erator need cleaning and clean it according to the x
chapter 6.3.

6.2. HYDRAULIC FLUIDS

Wide range of standard hydraulic fluids can be used with the DYNASET hydraulic
equipment. Depending on the operating temperature, following mineral hydraulic
oils are recommended:

MINERAL HYDRAULIC OIL OPERATION TEMPERATURE UP TO

ISO VG 32S 60 °C
ISO VG 46S 70 °C
ISO VG 68S 80 °C

NOTE!
Recommended oil viscosity is between 10 to 35 cSt when operating at
normal operating temperature.

Synthetic and bio oils can also be used if their viscosity characteristics and
lubricating efficiency are corresponding to the mineral oils.

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 HYDRAULIC MAGNET GENERATORS
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Automatic transmission fluids and even engine oils can be used, provided that
they are allowed to be used in the hydraulic system of your base machine.

Hydraulic fluid change interval is according to the base machine’s maintenance

instructions. To use special hydraulic fluid with DYNASET equipment, please
contact nearest DYNASET presentative for an advice.

6.3. CLEANING THE HMG/CMG PRO

ATTENTION!
Maintain the generator accordingly and keep the vents open and clean.
Check your equipment after every work shift.

Picture 46: Cleaning the HMG/CMG PRO

Depending on the operational environment, clean the HMG/CMG PRO as

frequently as necessary to maintain it in perfect working condition.

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 HYDRAULIC MAGNET GENERATORS
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1. Remove the generator’s cover, side screens and the air diffuser.
2. Clean fan, rotor, stator compartments and alternator’s electric components
by using compressed air. Ensure that the electric enclosures drain holes are dirt
free.
3. After cleaning the generator, place the screens/covers back on and secure
them with appropriate screws.

NOTE!
Use compressed air to clean your equipment.

Remove all unnecessary grease and oil deposits from the HMG/CMG PRO.
Accumulated grease and oil can cause overheating and a potential fire hazard.

ATTENTION!
Do not leave anything inside the generator case or control box which does
not belong to the assembly.

Check the lids and the covers as well as the screw joints on regular basis, at least
once in a week, and tighten them if they are loose. When HMG/CMG PRO is exposed
to a noticeable vibration, checking should be done more frequently.

NOTE!
Ensure clean venting of the HMG/CMG PRO. Components wearing increases
in dusty conditions.

6.4. REPLACING CONTROL CARD

Replace the control card with the following instructions.

NOTE!
When replacing control card to multiple card control unit, all replaced
control cards must be the same alphabetical letter (e.g. EM-xxxf, e ...) type
version to ensure HMG/CMG PRO stable and correct function.

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 HYDRAULIC MAGNET GENERATORS
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1. Open the control box cover by unscrewing the screws.

2. Disconnect the wires and plugs from the faulty card. If needed mark the wires
and the plugs for the installation to secure them back on to their correct places
for the new card.
3. Unscrew all the control card’s screws (5) and remove the faulty card.

Picture 47: Removing control card

4. Apply the thermal paste provided with the card or quality termal paste to the
bottom of the new card

Picture 48: Apply the thermal paste

5. Install the new card to its place. Plug on all wires, plugs and screws(5). Tighten
the screws into the 4 Nm torque.

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 HYDRAULIC MAGNET GENERATORS
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NOTE!
Remember to check that the dip switches on the new control card are in
correct position. READ CHAPTER “4.5. HGM/CMG PRO control card settings”
for more information.

Kuva 49: Installation of control box cover.

6. Screw the control box cover back on

After installing the new card HMG/CMG PRO is operational.

6.5. OUTPUT VOLTAGE ADJUSTING

WHEN HMG/CMG PRO IS INSTALLED INTO THE HYDRAULIC SYSTEM WITH

A DYNASET INSTALLATION VALVE

ATTENTION!
The HMG/CMG PROs are tested and adjusted at the factory. Do not adjust
them without real need. Adjust first the base machine’s hydraulic flow to
demanded level.

ATTENTION!
When measuring the output frequency, act in compliance with the laws,
regulations and recommendations issued by the local electricity, work
safety authorities and universal multimeter manufacturer.

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 HYDRAULIC MAGNET GENERATORS
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ATTENTION!
Do not adjust the generator when a magnet is connected to it.

NOTE!
When doing adjustment, the hydraulic fluid should be at normal operation
temperature! READ CHAPTER “6.2. Hydraulic fluids” for more information.

Turn the generator on and ensure that the hydraulic flow is atleast at the minumum
level. When the hydraulic flow is at the proper level, set the voltage by adjusting
the RPM-cartridge with following instructions.
1. Loose the locknut A.
2. Adjust the adjusting screw B according of the voltage shown on the generator’s
display. Due to the response time make only a small adjustment at a time and
wait for the generator to level its speed before turning the screw B more. Do not
make more than quarter revolution turns at the time!
3. When the voltage has reached the required 220 VDC - tighten the locknut A
to 10 Nm.

During the adjustment U.CUR will blink on the display. This is normal. Do not
attach magnet on to the generator while measuring the voltage.

If voltage measurement option is not available, adjustments can be made by

measuring the output frequency (50Hz).

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 HYDRAULIC MAGNET GENERATORS
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WHEN HMG/CMG PRO IS INSTALLED TO THE HYDRAULIC SYSTEM

WITHOUT DYNASET INSTALLATION VALVE

ATTENTION!
Adjust only with the following instructions when the HMG/CMG PRO is
installed to the hydraulic system without a DYNASET installation valve.
Otherwise you may damage your HMG/CMG PRO doing the procedure.

Primarely adjust the base machine’s hydraulic flow to the required, atleast minimum
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 output voltage will achieve the value of 220
VDC. Follow the readings of generator’s display.

If the adjusting does not effect on the output voltage, there is a feed problem
in the base machines hydraulic system that has be fixed before continuing the
adjustments.

If the output voltage does change when the adjustments are made to the hydraulic
flow, continue with the following instructions.
2. Loose the locknut A.
3. Turn the adjusting screw B counter-clockwise until it starts to control the flow.
4. Then turn the screw B counter-clockwise for a another quarter of revolution.
5. Lock the setting with locknut A tightening it to 10 Nm.

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 HYDRAULIC MAGNET GENERATORS
MAINTENANCE

62 Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com
 HYDRAULIC MAGNET GENERATORS
MAINTENANCE

6.6. TROUBLESHOOTING
Performing these maintenance tasks requires a qualified hydraulic mechanic or/
and an electrician. Please, contact a DYNASET authorized workshop or a dealer in
case of a need for more information.

FAILURE REASON CORRECTIVE ACTION

The pressure line is

connected while the return
HMG/CMG PRO Check the connection and connect
line is disconnected and
GENERATOR IS OILY. the hoses to their correct places.
the pressure relief valve
leaks the oil.
Switch off the generator.
Magnet unplugged or
Check the plug to the magnet.
magnet cable is damaged.
Change the cable if it is damaged.
Check the coil’s resistance and
compare the result to the value
Magnet is damaged. indicated in the magnet’s manual.
Check also coil’s inductance if
MAGNET DOES NOT possible.
WORK
Turn off the generator.
Check whether there is a DC
voltage between the control card’s
terminals 6 and 7.

If control unit is provided with

Readout is displayed multiple control cards check the
when magnet current connection between different cards.
is under 2A. Check the connection between
Generator won’t produce
different card terminals 6 and 7
220 VDC.
e.g check if there is a connection
between card 1 terminal 6 and card
2 terminal 6 etc. If connection is lost
it has to be set back up to clear the
problem.

If the connection is in order the

control card is broken. Defective
card(s) should be replaced.

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com 63
 HYDRAULIC MAGNET GENERATORS
MAINTENANCE

FAILURE REASON CORRECTIVE ACTION

MAGNET MAL- Magnet shuts

FUNCTIONS down by itself after
magnetization is
In single card use: Choose magnet according to
started.
HMG PRO’s power output.
Magnet’s power
With multiple cards: Check first the connection
demand exceeds
between terminals 6 and 7 between different
HMG PROs output.
cards. e.g check if there is a connection
Generator gets
between card 1 terminal 6 and card 2 terminal
overloaded and
6 etc. if connection is lost it has to be repaired.
stopped.
If the connection is in order the control card is
Generator’s
broken. Defective card(s) should be replaced.
output voltage is
too high causing
O.CUR blinks in turn
overloading.
with time indication
countdown from 30 To test the cable shut down the generator,
sec to 0 sec. unplug the cable and turn on the generator.
Magnet’s cable
!WARNING! If the generator’s display shows O.CUR, problem
shortcircuits.
O.CUR stops is in the control unit’s connections.
the magnet Connections in
immediately from If the generator’s display blinks U.CUR/220,
control card short
magnetization. the problem is outside the control unit. Then
circuit.
Watch out the check the frequency (50Hz±5%). Frequency
dropping collected can be measured between terminal 1 and 3 in
Problem outside the
metals. the control box. If the frequency is ok, then the
generator.
generator’s hydraulics are in order.

After this measure the AC voltage between all the

phases from terminals 1-2,2-3,1-3. If the Voltage
is under 170 VAC the problem is in the voltage
regulator system and it needs a repair.
Ensure proper ventilation and clean the
generator. READ CHAPTER “6.3. Cleaning the
HMG/CMG PRO” for more information.. Check if
The generator is
the fans are working in the multiple card use.
overheating
The generator will turn back on automatically
O.HEA indicated on after it has cooled enough.
a digital display. Measure resistance between control card
terminal 8 and 9.

If it is 12 Ohms, the problem is in the control card

Failure on the
and it needs to be replaced.
control unit or in the
internal wirings.
If it is not 12 Ohms the problem is in the resistors.
SNUB indicated on a If it is 24 Ohms, one resistor is broken. If it is
digital display. something else both resistors are broken and
need replacing.

64 Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com
 HYDRAULIC MAGNET GENERATORS
MAINTENANCE

FAILURE REASON CORRECTIVE ACTION

Check VDC-voltage on the display. If ok, check
magnet’s resistance.

If VDC is not ok check the frequency and AC

voltage (170VAC) between all phases to the
Low magnet control unit between terminals 1-3. If the
MAGNET MALFUNC-
power. frequency is out of range, the problem is in
TIONS
hydraulic system. If the frequency is ok and the
AC voltage is not, the prolem is in the generator
(not in the control box).

If the frequency is ok, the problem is in the

control card.
Control cable
DEMAGNETIZATION Lay magnet down, switch off generator. Check
or push button
DOES NOT WORK control cable and push button.
malfunction.

FAILURE REASON CORRECTIVE ACTION

Check all internal contacts and wirings of the

LOW OUTPUT VOLT- Poor contact in
generator. Check and clean brushes and slip
AGE AT NO LOAD electric system.
ring.
Excitation rectifiers Trace the failure and replace the rectifier (with
failure. compound or Capasitor voltage regulator).

Replace the capacitor.

OUTPUT VOLTAGE < Voltage regulators Check and adjust the air gap of the compound
20Vac failure. regulator. Replace if broken.
Check and adjust or replace the electronic
regulator (HMG/CMG PRO with AVR).

Insufficient residual Use external 12 V DC battery for 1 - 2 sec. to

magnetizm. magnetize the rotor.

LOW OUTPUT VOLT-

The generator is Reduce the load and check the current I (A) to
AGE AND FREQUENCY
being overloaded. ensure that the proper load is being applied.
AT LOAD

If frequency is out of range, hydraulic system

failure is concerned.

Check whether the hydraulic flow and pressure

LOW FREQUENCY AT Too low rotation
are sufficient. Adjust RPM-cartridge if neces-
NO LOAD speed
sary.

Check the hydraulic motor for possible leakage.

Replace motor if necessary.

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com 65
 HYDRAULIC MAGNET GENERATORS
MAINTENANCE

FAILURE REASON CORRECTIVE ACTION

If frequency is out of range, hydraulic system

failure is concerned.
HIGH FREQUENCY AT Too high rotation
LOAD speed Check whether the hydraulic flow and pressure
are sufficient. Adjust RPM-cartridge if neces-
sary.

Check generator’s hydraulics, including auto-

matic frequency control valve. Make an adjust-
ment if necessary.

OUTPUT VOLTAGE Instable rotation Check that the hydraulic oil Flow is constant.
INSTABILITY speed of generator Check whether the hydraulic fluid flow and
pressure are not excessive. Adjust when neces-
sary.
Check the hydraulic motor for possible leakage.
Replace motor if necessary.
LOW OUTPUT VOLT- The generator is Reduce the load and check the current I (A) to
AGE AT LOAD being overloaded. ensure that the proper load is being applied.

Failure of axial seal-

ing in generator’s
Axial sealing of hydraulic motor broken by
hydraulic motor.
reason of excessive pressure in return line (T).
GENERATOR CON- Rebuild the return line (T). Maximum allowed
SUMES ABNORMAL External indication:
pressure in return line is 5 bar. Replace axial
AMOUNT OF HYDRAU- hydraulic oil out-
sealing of generator’s motor.
LIC FLUID flow from ventila-
tion grids.

Oil leakage from Hydraulic motor worn out and should be

hydraulic motor. replaced.

GENERATOR CON-
SUMES ABNORMAL One ore more stator winding is in short circuit.
Winding failure.
HYDRAULIC PRESSURE Replace generator.
AT NO LOAD

A MILD ELECTRIC Ensure proper grounding cable installation.

Poor hydraulic gen-
SHOCK FROM HY- READ CAPTER “4.3.2 Grounding” for more
erator grounding.
DRAULIC GENERATOR information.

Bearing failure. Replace broken/worn bearing.

ABNORMAL NOISE
FROM GENERATOR
Broken fan. Replace broken/worn fan.

66 Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com
 HYDRAULIC MAGNET GENERATORS
WARRANTY

7. MANUFACTURER’S LIMITED WARRANTY

1. Warranty coverage
All hydraulic accessories manufactured by DYNASET OY are subject to the terms
and conditions of this limited warranty. Products are warranted to the original
purchaser to be free from defects in materials or workmanship. Exclusions from
warranty are explained in item Exclusions from warranty.
2. Beginning of warranty period
Warranty period begins from the delivery date of the product. Delivery is
considered to be done on the date when installation has been accomplished or
purchaser has taken the product in use. Product is considered as taken in use at the
date when DYNASET OY has delivered the product to purchaser, unless separately
agreed otherwise by written agreement.
3. Warranty period
Warranty period is twenty four (24) months based on maximum of 2000 hours
usage during this time period. In cases where the system is provided complete with
certain special components (e.g. drive unit), those components are considered as
a subject to their manufacturer’s warranty.
4. Warranty procedures
Immediately upon identifying a problem which purchaser believes to be a failure
subject to the product’s limited warranty, purchaser must contact primary to the
seller of the product. Contact must be made as soon as possible, latest thirty (30)
days after the problem was identified. Seller and/or manufacturer technical staff
determines the nature of the problem primarily by phone or 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
procedures.
5. Warranty repairs
If the product is found to be defective during the warranty period, DYNASET
OY will, at its option, either repair the product, author it to be repaired at its
authorized workshop or exchange the defective product. If the product must be
repaired elsewhere than premises of DYNASET OY or authorized workshop, all
costs excluded from this warranty (traveling and waiting hours, daily allowance,
traveling expenses and uninstallation/reinstallation costs) will be charged from
the purchaser.
If the problem is not covered by this limited warranty, DYNASET OY has the right
to charge purchaser of troubleshooting and repairing.
6. Delivery terms of warranty repair
If the product is found possible to be defective under this limited warranty and it
needs to be repaired, DYNASET OY gives Warranty Return Number (WRN). Items
being returned must be shipped, at the purchaser’s cost, adequately packed for
shipment, to the DYNASET OY or to other location authored by DYNASET OY.
Shipment documents must contain:
• Purchaser’s name and contact information
• Receipt of original purchase
• WRN code
• Problem description

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com 67
 HYDRAULIC MAGNET GENERATORS
WARRANTY

7. Warranty of repaired product

Warranty period of the product repaired under this limited warranty continues to
the end of original warranty period.
8. Exclusions from warranty
This warranty shall not apply to:
• Failures due to normal wear and tear, improper installation, misuse, abuse,
negligence, purchaser selection of improper product to intended use, accident,
improper filtration of hydraulic oil or intake water or lack of maintenance.
• Cost of maintenance, adjustments, installation or startup.
• Coating, hydraulic oil, quick couplings and interconnection hoses (internal or
external to system assemblies).
• Products altered or modified in a manner not authorized by DYNASET OY in
writing.
• Products which have been repaired during warranty period by others than
DYNASET OY or its authorized workshop.
• Costs of any other damage or loss, whether direct, indirect, incidental, special
or consequential, arising out of the use of, or the inability to use, the product.
• Telephone or other communications expense.
• Product that is used in exceptional conditions, considered to cause excessive
wear and tear.
• Faults caused by nature phenomenon’s like flood, thunder, etc.

© DYNASET OY, all rights reserved

68 Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com
 HYDRAULIC MAGNET GENERATORS
PRODUCT DISPOSAL

8. PRODUCT DISPOSAL
Dispose and recycle all DYNASET products and their packaging environmentally
responsible way.

Do not dispose used oils, electrical components, batteries or any other hazardous
waste with normal waste. They are harmful to the environment and can be recycled
for re-use.

Contact your local waste recycling facility for more information about recycling
hazardous waste.

NOTE!
Always act according to the waste legislation, regulations and
recommendations in waste disposal and waste recycling issued by your
local authorities.

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com 69
 HYDRAULIC MAGNET GENERATORS
PRODUCT DISPOSAL

70 Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com
 HYDRAULIC MAGNET GENERATORS
DECLARATION OF CONFORMITY

9. DECLARATION OF CONFORMITY

We hereby declare that the design and manufacture of the product stated below
are in conformity with the provisions of the European Parliament and Councils on
the harmonization of the laws of Member States on the safety of machines.

Machine directive 2006/42/EC

LVD directive 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 MAGNET GENERATORS

Product: HMG PRO hydraulic magnet generator

CMG PRO hydraulic magnet generator

If the device has been modified by someone other than the manufacturer or
without the manufacturer’s permission, this declaration is not valid.

Timo Nieminen
R&D Manager
Ylöjärvi, Finland 20.04.2016

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com 71
 HYDRAULIC MAGNET GENERATORS
DECLARATION OF CONFORMITY

72 Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com
 HYDRAULIC MAGNET GENERATORS
TECHNICAL SPECIFICATIONS

10. TECHNICAL SPECIFICATIONS

HMG/CMG HMG/CMG HMG/CMG HMG/CMG
PRO PRO PRO PRO
STANDARD MODELS
3kW 6kW 10kW 12kW
21 34 49 59
OUTPUT CHARACTERISTICS
Generator power max. kW 3 6 10 12
Magnet coil power max. KW 0,5 - 3 0,5 - 5,5 1,0 - 9,1 1,0 - 11
Operating voltage VDC 220±5%
Auxiliary electricity Optional
Operating control voltage* VDC 6 - 32
HYDRAULIC CONNECTION
Pressure line P P BSP 1/2” BSP 3/4”
Return line T T BSP 1/2” BSP 1”
Drain line D D 06L - (M12x1,5 Male) BSP 1/4”
HYDRAULIC POWER REQUIREMENTS
l / min
Flow min. 23 (6.1) 37 (9.8) 53 (14.0) 63 (16.6)
(gpm)
l / min
Flow max. 37 (9.77) 53 (13.99) 68 (17.95) 77 (20.33)
(gpm)
bar
Pressure at nominal power output 210 (3000) 160 (2300) 200 (2900) 200 (2900)
(psi)
bar
Pressure max. 210 (3000) 210 (3000) 210 (3000) 210 (3000)
(psi)
bar
Pressure when unloaded 50 (725) 50 (725) 50 (725) 40 (580)
(psi)
HYDRAULIC FLUID REQUIREMENTS
Viscosity cSt 10-200 / optimum 25-35
Temperature ° C(°F) max. 70 (158)**
Filter ratio um 25 or better
Cooling capacity requirements *** kW 1,4 2,4 3,1 3,5
OVERALL DIMENSIONS
mm
Length 431 (17.0) 526 (20.7) 582 (23.0) 580 (22.8)
(in)
mm
Width 337 (13.3) 326 (12.9) 325 (12.8) 460 (18.1)
(in)
mm
Height 317 (12.5) 351 (13.8) 355 (14.0) 375 (14.8)
(in)
kg
Weight 34 (75) 58 (128) 60 (132) 100 (220)
(lb)
Gallons are U.S. liquid gallons.

* Only with HMG PRO

** Ref. to hydraulic fluids in chapter 6.2
*** Minimum cooling capacity for the HMG/CMG PRO on the base machine.

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com 73
 HYDRAULIC MAGNET GENERATORS
TECHNICAL SPECIFICATIONS

HMG/CMG HMG/CMG HMG/CMG HMG/CMG

PRO PRO PRO PRO
STANDARD MODELS
15kW 20kW 30kW 40kW
65 92 120 165
OUTPUT CHARACTERISTICS
Generator power max. kW 15 20 30 40
Magnet coil power max. KW 14,5 19,5 29,5 39,5
Operating voltage VDC 220±5%
Auxiliary electricity Optional
Operating control voltage* VDC 6 - 32
HYDRAULIC CONNECTION
Pressure line P P BSP 3/4” BSP 3/4” BSP 3/4” BSP 3/4”
Return line T T BSP 1” BSP 1” BSP 3/4” BSP 3/4”
Drain line D D BSP 1/4" BSP 1/4" M22x1,5 M22x1,5
HYDRAULIC POWER REQUIREMENTS
l / min
Flow min. 68 (18.0) 94 (24.9) 122 (32.2) 167 (44.1)
(gpm)
l / min
Flow max. 95 (25.08) 110 (29.04) 140 (36.96) 185 (48.84)
(gpm)
bar
Pressure at nominal power output 190 (2750) 190 (2750) 190 (2750) 190 (2750)
(psi)
bar
Pressure max. 210 (3000) 210 (3000) 210 (3000) 210 (3000)
(psi)
bar
Pressure when unloaded 40 (580) 30 (440) 40 (580) 30 (440)
(psi)
HYDRAULIC FLUID REQUIREMENTS
Viscosity cSt 10-200 / optimum 25-35
Temperature °C (°F) max. 70 (158) **
Filter ratio um 25 or better
Cooling capacity requirements *** kW 3,9 4,5 7,8 8,5
OVERALL DIMENSIONS
mm
Length 828 (32.6) 878 (34.6) 993 (36.7) 1003(39.5)
(in)
mm
Width 501 (19.7) 511 (20.1) 515 (20.3) 600 (23.6)
(in)
mm
Height 416 (16.4) 416 (16.4) 450 (17.7) 600 (23.6)
(in)
kg
Weight 145 (320) 163 (359) 175 (386) 198 (437)
(lb)
Gallons are U.S. liquid gallons.

* Only with HMG PRO

** Ref. to hydraulic fluids in chapter 6.2
*** Minimum cooling capacity for the HMG/CMG PRO on the base machine.

74 Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: +358 3 3488 200 | [email protected] | www.dynaset.com
© DYNASET OY, all rights reserved
 Menotie 3
FI-33470 Ylöjärvi, Finland
tel: +358 3 3488 200
[email protected]

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www.DYNASET.com