Dynalco DYNA-GEN User Manual

3690 N.W. 53rd Street

Fort Lauderdale, FL 33309

FWG-1200

Flywheel Generator

Installation and Operation

Manual

Rev. 1.10

P/N145F-12935

(c) Copyright 2010, Dynalco Controls

All Rights Reserved

Published: April 7, 2010

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CAUTION!! – SPECIAL HANDLING REQUIREMENTS
PLEASE READ THOROUGHLY BEFORE PROCEEDING

THIS PRODUCT CONTAINS RARE EARTH MAGNETS THAT CAN CAUSE SEVERE INJURY!
The rotor assembly consists of (2) rotor halves. Each rotor half has (18) rare earth magnets

which are embedded into the outer ring. These magnets have extremely high attraction
properties which can cause injury if not handled properly. Please use extreme caution when
handling, whether during initial unpacking, installation or during operation.

When Unpacking:

The (2) rotor halves are packaged together with a CAUTION
packing material. Please ensure that no ferrous (magnetic) material is within 12 inches of the
rotor assemblies when unpacking. It is best to keep the rotor assemblies in the packing material
until ready to install. These rotor halves will eventually need to be drilled to suit the engine
flywheel where they will be mounted.

When Installing:

Handle carefully during installation, being extremely aware of hand tools that could be attracted
to the magnets. It is advisable to wear gloves for additional protection. Precautions need to be
taken when locating and installing the rotor assembly to the engine flywheel, being aware of the
proximity to the engine and frame.

During Operation:

Always ensure that all metallic tools are kept clear of the flywheel area, especially prior to or
while running engine.

Note:
There is a potential data loss hazard to any magnetic media in close proximity, ie: credit cards, portable

memory, etc…

Needed For Installation:

Please verify the following parts / tools are available prior to installation:
Included in the Flywheel Generator System package:

Required For Installation:
Hand tools (wrenches, screwdrivers)
Power Drill, drill bits & taps (for drilling & mounting flywheel rotor)
Calipers (for ensuring proper centering of rotor halves on flywheel)
Multi-Meter (for verifying proper output voltage with engine running)

(2) Rotor Halves
(1) Power Coil
(1) Power Supply Module
(1) Shim (0.070” for setting power coil air gap)
(1) ETS202-20 cold junction compensation probe (included with FWG-1200B only)

label affixed to the outside of the

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System Overview

The FWG-1200 Flywheel Generator System is designed to provide power to medium and high
speed industrial engines. There are no wearing parts because there are no bearings, shafts, or
couplings. The FWG-1200 can simultaneously power other products including engine shutdown
panel, air/fuel ratio controls, and other auxiliary components. The FWG-1200 is CSA approved for
Class I, Division 2, Groups A, B, C & D hazardous locations.

The FWG-1200 is made up of three subassemblies: the Rotor Assembly, Power Coil and Power
Supply Module. The FWG-1200 obtains power from the changing magnetic field created by
magnets (mounted in the rotor assembly) passing by the power coil. The output of the Power Coil
is wired to the Power Supply Module which provides a nominal 12 VDC output. The FWG-1200
flywheel generator system provides up to 8.0 Amps total depending on engine RPM. There are (2)
outputs which combine to provide the 8 Amp output current. The “Ignition” output is rated at up to

2.0 A which is used to provide power to the ignition system only. The “Main” output provides up to

6.0 A for providing current to the engine panel, including AFR controller, shutdown devices,
scanner / annunciator as well as supplying battery charging requirements.

Specifications

Operating Speed:
Nominal Run Speed Range: 1200 – 2400 RPM

Maximum Speed (Absolute): 2400 RPM

Electrical:

Output Voltage: Nominal 12VDC (Regulated @ 13.8 +/- 0.5 VDC)
Output Current: 8 Amps Total from (2) Outputs as follows:
Ignition Power 1.0 Amp available at 300 RPM

1.4 Amps available at 500 RPM

2.0 Amps available at 1000 – 2400 RPM
Main Power 3.5 Amps available at 1000 RPM

5.0 Amps available at 1500 RPM

6.0 Amps available at 1800 RPM

Mechanical:

Rotor Assembly outside diameter: 14.25 inches
Rotor inside diameter: 6.00 inches (for drive shaft clearance)

Environmental:
Operating Temperature Range: -40 to +70 C

NEMA 4 enclosure available
CSA Class I, Division 2, Groups A, B, C & D approved

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