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 label affixed to the outside of the
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:

(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)

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)

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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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 FWG-1200 System

Installation:

The FWG-1200 system is designed to fit almost any standard industrial engine given the proper
space for all components. The three subassemblies shown above can be mounted to existing
engine components or modified to meet user requirements. The following instructions describe the
mounting procedures for each of the three subassemblies.

Rotor Assembly: The Rotor Assembly consists of (2) halves that are to be mounted to the engine
flywheel. The face plate halves of the rotor assembly are constructed of steel and need to be
drilled to allow for custom mounting using a minimum of (3) hex bolts on each half. Permanent red
Loctite should be used to secure the mounting bolts.

Power Coil: The power coil must be mounted on a bracket so that the core laminations of the
transformer face the outer circumference of the generator assembly, in line with the magnets. The
bracket must be sturdy enough to limit vibration and gap movement with the strong pull of the
magnets. The gap must be set to 0.070 +/- 0.010 inches. A gap of less than 0.070 will cause
excessive voltage into the Power Supply Module and could damage components. Once the air
gap has been established, the Power Coil can be attached to the bracket. The bracket can be
attached to the engine or supporting frame depending on space availability and user needs.

Power Supply Module: The Power Supply Module should be mounted where it will be protected
from weather, preferably within an existing panel or a suitable enclosure. It is also advisable to
keep away from heat sources such as the exhaust manifold. Shock mounts should be used if the
vibration is high where the Power Supply Module is going to be used.

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 Terminal Connections

Wiring:
Power Coil: The (4) wires on the power coil are color coded and must be connected to the 4-
terminal block (J1) of the Power Supply Module as indicated. The wiring between the Power Coil
and Power Supply Module must be run in conduit for protection.

Power Supply Module: The 12 VDC output from the Power Supply Module is available from (2)
outputs. The Main output provides up to 6 Amps output for powering the engine panel as well as
providing charging current to the battery. The Ignition output provides up to 2 Amps output for
powering the ignition system. All output connections are to be made on the 6-terminal block (J2)
as indicated. All wiring should be with AWG 16 minimum wire gage.

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 Important - Before Starting Engine:

The Main and Ignition outputs are separate outputs that must be kept isolated. The (2)
outputs must not be tied together.

The Ignition output must be used for ignition only.

The Main output must be connected to the battery (if applicable) and panel power.

If the existing alternator system is left in place, it must be disconnected from the electrical
system.

Verify that the magnets on the rotor assembly are free of material that they may have attracted
in the assembly process, i.e. washers, tools, etc.

Turn the engine over slowly to verify clearance between the rotor and power coil.

SEE PRECAUTIONS ON PAGE 2

Operation:
The
he Power Supply Module will begin to generate output voltage as soon as the engine starts to
crank and will regulate at nominal 12 VDC when sufficient voltage is available from the Power Coil.
The FWG1200 system is designed to first provide Ignition output power at engine cranking speed
to allow the engine to start. As the engine RPM increases, the Main output will then begin to
supply power to the panel. Please see the specifications on page 2 for the expected available
output current at various engine speeds.

There are (3) status indicators (LEDs) located on the Power Supply Module:

Vin: This LED will turn on (green) when sufficient power is being generated by the Power Coil.

Ignition: This LED should turn red initially when the engine is cranked and will turn green when 12
VDC regulated ignition voltage is available.

Main: This LED should turn red initially when the engine is cranked and will turn green when 12
VDC regulated main output voltage is available.

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Outline Drawing Power Supply Module