A.C. MODULAR GENERATOR SYSTEM OWNERS MANUAL MODEL#: HR-6.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 1 of 53 Table of Contents Section Page Disclaimer .......................................................................................................................... 5 Description of Product...................................................................................................... 6 System Specifications ...................................................................................................... 9 Pre-Installation Guide .
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 2 of 53 WARNING: Do not install or operate the A.C. modular generator system without reading this entire manual. The A.C. modular generator system will generate enough voltage to produce a fatal electrical shock. Do not perform any wiring installations or modifications while the system is operating. Never touch any live connections while the system is operating. Never operate the system with the generator wiring enclosure open.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 3 of 53 Never operate the system with leaks of any type. Clean up any hydraulic fluid that is spilled or has leaked out of the system. Hydraulic fluid is combustible, and ignition may occur. With the exception of instructions within this manual, never modify or remove any of the components within the tray assembly. Never modify or remove any of the components within the pump or the controls mounted to the pump.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 4 of 53 Use only hoses that meet or exceed the minimum requirements specified in this manual. A ruptured hose can cause personal injury and/or damage to the generator system. Do not operate the system under electrical load with air in the hydraulic fluid (the system will make a growling sound). Do not allow anything to contact the hydraulic hoses that will cause a kink, pinch or chaffing. The A.C.
Smart Power® Systems A. C.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 6 of 53 Description of Product Hydraulic Generator Applications: This heavy-duty electronically controlled generator system has been designed to meet the most demanding mobile applications. It provides 120/240 volt AC @ 60 Hz from no-load to full load, handling electrical loads of 6200, 8000 and 10000 watts, depending on model. How our System works: A generator driven by a hydraulic motor delivers the electrical power.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 7 of 53 x y Hydraulic schematic for HR-6.
SYSTEM CONTROLLER P/N 8505035 (HR-6.2, HR-8, HR-10, HR-110) Electrical schematic for HR-6.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 9 of 53 System Specifications MODEL OF GENERATOR Generator Type HR-6.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 10 of 53 MODEL OF GENERATOR Oil Cooler Dimensions (Core) HR-6.2, HR-8 HR-10, HR-110 9.75”D x 22.6” W x 2.25” H 9.75”D x 22.6” W x 2.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 11 of 53 Pre-Installation Guide Pre-Installation Check List 1. Verify that the Power Take Off (PTO) and the pump rotations match. To identify the pump rotation, check the pump part number found on the metal tag attached to side of the pump. A right hand rotating pump (the standard pump offered by Smart Power® Systems), will have the letter “R” in its part number. Example: A10VO (45 or 60) DFR-1/52 R PUC.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 12 of 53 3. Verify the combined weight of the pump and hoses filled with hydraulic fluid do not exceed the PTO manufacturer’s weight restriction. If the pump weight does exceed this restriction, the installer has two options: A) a bracket to support the pump can be implemented, or B) the pump can be mounted to the vehicle chassis, connected to the PTO with a drive shaft. 4. Verify that the pump shaft will mount to the PTO.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 13 of 53 WARNING: Do not install hose ends until proper hose length has been determined. Never install a hose in a location where it will rub against another surface or abrasion member. Do not position hoses with tight bend radii. Consult the hose manufacturers installation guidelines. Tight bends may kink and cause serious damage to the system and will void the system’s warranty.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 14 of 53 1.00 MINIMUM CLEARANCE .50 MINIMUM CLEARANCE .50 MINIMUM CLEARANCE 15.00 AIR VENT OPTION B (IF AIR VENT OPTION A OR C IS USED .50 CLEARANCE REQUIRED ON THIS SURFACE) AIR VENT OPTION A (IF AIR VENT OPTION B OR C IS USED .50 CLEARANCE REQUIRED ON THIS SURFACE) AIR VENT OPTION C (IF AIR VENT OPTION A OR B IS USED .50 CLEARANCE REQUIRED ON THIS SURFACE) Bottom view of HR-6.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 15 of 53 Side view of HR-6.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 16 of 53 WARNING: Do not mount the hydraulic pump or tray assembly in any location that is not well ventilated. External heat sources elevating the hydraulic fluid and/or the generator temperature will result in premature wear and degraded system performance and void the system’s warranty. 7. The tray assembly must be mounted in a position that is higher than the pump.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 17 of 53 Installation Guide 1. Mount the pump securely to the Power Take-Off (PTO). This may require attaching a mounting bracket to the PTO housing prior to mounting the pump. WARNING: Always mount the hydraulic pump in a position with the pump controls up.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 18 of 53 3. Mount the tray assembly as high as possible within the structure of the vehicle. The ideal location for the generator is at the top of the truck in the dunnage area. The manufacturer must also take sufficient precautions to ensure that the generator is not mounted in the path of the deck gun/water cannon. 4. Mount the hydraulic generator tray securely to vehicle.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 19 of 53 HR-6.2, HR-8, HR-10 and HR-110 tray assemblies disassembled into base tray assembly (with diamond plate cover added), cooler/fan enclosure and reservoir Figure 9 6. Mount Command & Control Center: a. Create hole pattern as shown in Figure 10. b. Mount Command & Control Center to vehicle using #10 stainless steel fasteners. c. Connect Command & Control Center to system controller unit using p/n 3722004 harness.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 20 of 53 3.375 1.688 .208 CLEARANCE HOLE FOR #10 SCREW 4 PL. 2.000 1.688 3.375 Hole pattern for Command & Control Center Figure 10 7. Flush the hoses with fresh hydraulic fluid (Dexron III). Install hoses and tighten hose ends, using the Hose Installation Guidelines. See Figure 11 for connection locations Hose connection locations for HR-6.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 21 of 53 WARNING: Never operate the system with the pump case drain plugged. Damage to the pump seals will result. To do so will void the system’s warranty. Lubricate hose fitting o-rings with clean hydraulic fluid (Dexron III) before installation to prevent damage to them. Hose Installation Guidelines Never install a hose without first flushing it with clean hydraulic fluid to remove any debris.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 22 of 53 conduit to length without cutting the wire insulation. A conduit connector has been provided to connect the conduit to the breaker panel.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 23 of 53 WARNING: To ensure proper voltage regulation, during the operation of generator system, the load difference between Phase A and Phase B must never exceed 20%. Damage to generator system caused by operating it with an unbalance load will void the system’s warranty. Wiring of the A.C.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 24 of 53 Never operate the system with fan disabled or removed. System over-heating will result and this will void the system’s warranty. Improper wiring of the generator system to the vehicle may discharge the vehicle battery, cause a fire, or cause improper operation of the generator system. 10. Bleed air from the hydraulic system: a. Turn off the generator’s main power breaker. See Figure 12. b.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 25 of 53 WARNING: Never operate the system without the filler/breather plug installed. Contaminants may enter the hydraulic fluid through the filler opening, causing premature wear on the hydraulic components and void the system’s warranty. Never apply a load to the generator while there is air trapped in the hydraulic fluid. Damage to the system’s hydraulic components, as well as ruptured hoses, may result and void the system’s warranty.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 26 of 53 Indicates whether the generator is or Example of display with purge option set Figure 14 f. Engage the Power Take-Off (PTO). (Note: Pump may sound rough for a few minutes due to entrapped air.) Make sure the Command & Control Center displays the string “” as shown in Figure 14, press the On/Off switch to turn the generator off, if needed. g. Check for hydraulic fluid leaks, all hose connections must be tight.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 27 of 53 WARNING: The SPS Model HR-6.2, HR-8, HR-10 and HR-110 have been pre-set at the factory to provide correct frequency and voltage. No pump adjustment is required. If it appears the pump needs to be adjusted, contact Smart Power® Systems at (231) 832-5525 before proceeding. Damage to generator from improper pump adjustment will void the system’s warranty.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 28 of 53 Enabling Auto-Start Option a. If the Command & Control Center is dark, press the Mode switch to put the Command & Control Center into Normal mode. b. Press and hold the Mode switch until the Amps Line 1 field begins blinking (more than 10 seconds). Release the switch so and appear. Reference Figure 15. c. Press the On/Off switch until the desired value appears. A means Auto-Start is enabled, an means Auto-Start is disabled. d.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 29 of 53 Operation 1. The Command & Control Center will show the generator’s output voltage, frequency, current, and system run time whenever the Command & Control Center is in the Normal mode. To access Normal mode, press the Mode switch repeatedly until the correct information is displayed (reference Figure16). Example of Command & Control Center in normal mode Figure 16 2.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 30 of 53 Normally, the status lights will be off. When a switch is pressed, the corresponding light will be illuminated. When a status light is flashing, the corresponding switch is calibrating, and the switch should not be pressed. The system controller will ignore the switch while it is calibrating. 4.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 31 of 53 Displayed Oil Temperature in degrees Fahrenheit Example of oil temperature display Figure 19 b. When the Command & Control Center is in Normal mode, pressing the Mode switch twice will cause the amount of time since the oil filter was last changed to be displayed (reference Figure 20): Time Since last Oil Filter Change in Hours. Example of oil filter run time display Figure 20 c.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 32 of 53 The indicates the system controller is configured to operate an ER-series Generator The system controller is configured to operate a generator whose maximum output is this number (in kW). Example of configuration display Figure 21 d. If there are no active faults, pressing the Mode switch once more will return the Command & Control Center to its normal mode.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 33 of 53 e. . If the system measures an output voltage that is too low or too high the generator will automatically shut down in 30 minutes unless the shutdown is overridden. f. . If the system detects a faulty temperature sensor, the generator will automatically shut down in 30 minutes unless the shutdown is overridden. g. .
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 34 of 53 b. Note the and labels below the Mode and On/Off switches. Press the On/Off switch to answer “yes” and proceed to the next screen, or press Mode to answer “no” and proceed to the oil temperature display. Step c: Press On/Off to answer “yes” and override the shutdown. Example of Command & Control Center in hot oil fault override confirmation Figure 23 c.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 35 of 53 Special Operating Instructions Cold Weather Procedure: It is strongly recommended that the generator PTO be engaged prior to leaving a heated garage or fire station in cold weather. The system will generate enough heat to keep its hydraulic fluid viscosity low enough for proper operation, in all but the most extremes of low ambient air temperatures.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 36 of 53 Maintenance Instructions WARNING: Do not perform maintenance while system is running. 1. Perform regular, periodic checks to verify: a. The cooler, the cooler fan and generator vents are not plugged by debris. b. There are no fluid leaks within the framework of the generator, along the hoses, or at the pump. c. The hoses are not cut, chaffed, bulged or kinked. d. That no electrical connections are loose. e.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 37 of 53 WARNING: Do not by-pass the filter or alter filtration plumbing in any way. Doing so will void the system’s warranty. 3. The system controller automatically records the time from the previous filter change.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 38 of 53 Step a: Press Mode until , , and appear. Step b: Hold Mode switch down and press On/Off three times in a row to clear the fault. Procedure will also work in the Oil Filter Hours Information display Example of oil filter service warning display Figure 26 a. Press the Mode switch repeatedly until one of the screens shown in Figure 26 appears. b.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 39 of 53 Troubleshooting Guide Diagnostic: The Command & Control Center will display certain faults that can assist a service technician in trouble shooting a problem with the generator system. When these faults occur, the fault message will periodically flash on the Command & Control Center, interrupting the normal display. Reference Figure 27 for an example of an over-current fault.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 40 of 53 Diagnostic Faults: The following is a list of the diagnostic faults, with a brief explanation of each.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 41 of 53 Note: The fault “Classes” are defined in the table below: Class Service Warning Alarm Shutdown Override Meaning Normal maintenance needs to take place. A condition requires the immediate attention of the operator. A condition causes the immediate shutdown of the generator. A condition that will cause the generator to be shut down in 30 minutes unless explicitly overridden by the operator. Table 3 Hydraulic Problems: 1.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 42 of 53 After correcting any problems, again operate the generator twenty minutes to purge air out of the hydraulic fluid. Note that any bubbles seen in the reservoir indicate leakage in the pump inlet line. 3. Differential Pressure: Differential pressure between the inlet pressure and the case pressure over 7 psig causes the piston shoes to lift off the swash plate.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 43 of 53 4. System Overheating: System overheating may be caused by re-circulation of hot air through oil cooler, dirty or obstructed oil cooler fins, restricted hydraulic fluid flow, excessive generator load, restricted airflow, previously overheated (old) fluid, non-functional fan, or improperly adjusted pump. a. b. c. d. e. Check the oil cooler fins for debris or damage. Clean and/or replace cooler.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 44 of 53 Electrical Problems 1. No Output Voltage: a. No output voltage may be caused by excessive current draw opening the circuit breakers. (The circuit breakers can be found mounted on the generator wiring enclosure.) Remove all electrical loads from the generator and reset breaker(s). Re-engage electrical load in increments.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 45 of 53 WARNING: Do not attempt to measure the exciter field resistance while the system is operating. Electrical shock may occur. f. Exciter field capacitor may be faulty. Disconnect the exciter field from the field capacitor. Using a screwdriver, short leads of capacitor together to discharge capacitor. Measure capacitance using a capacitance meter. Capacitor should have capacitance between 47 and 53 microfarads.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 46 of 53 2. Output voltage exceeds 260 volts or falls below 220 volts AC on a 240 volt line: a. Verify that the hydraulic system is not overheating by viewing the temperature as displayed by the Command & Control Center. The temperature should not exceed 175° F. If the temperature is greater than 175° F, follow instructions for system overheating (see hydraulic problems). b. The hydraulic pump speed may be too low.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 47 of 53 PARENT P/N DESCRIPTION TRAY ASM P/N PUMPASM P/N RANGE WR=WIDE RANGE PUMP DISP. CC SHAFT K=KEYED S=SPLINE D(STD) SHAFT ROTATION R=CW (STD), L=CCW MOTOR DISP. CC POWER OUTPUT KILOWATT S5 SPS Model Matrix 2600006 2601006 2610006 2611006 2602006 2600008 2601008 2610008 2611008 2602008 2600010 2601010 2610010 2611010 2602010 2600110 2601110 2610110 2611110 8583046 8583048 8583040 GENERATOR, HR-6.2/45cc, R, 13T SPL GENERATOR, HR-6.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 48 of 53 Pump Adjustment WARNING: The SPS Electronic Controlled Generators have been pre-set at the factory to provide correct frequency and voltage, no pump adjustments are required. If it appears the pump need to be adjusted, contact SPS at (231) 832-5525 before proceeding. Damage to the generator from improper pump adjustments will void the system’s warranty.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 49 of 53 The Pump Set option can be accessed by performing the following steps: Step d: After selecting , Press On/Off until appears. Step b: Hold Mode until Amps Line 1 Blinks . Release switch so appears. Step c: Press mode twice to make appear. Enabling pump set option Figure 28 a. If the Command & Control Center is dark, press the Mode switch to put the Command & Control Center into Normal mode. b.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 50 of 53 2. Adjust pump compensator: a. Loosen and remove flow control cap. Reference Figure 30. b. Loosen the flow control pressure jam nut. c. While monitoring the generator’s output voltage, slowly rotate the flow control set screw with a 3mm hex wrench. Adjust the flow control until the generator’s output frequency is 64 Hz. d. While keeping the setscrew from rotating, with the hex wrench, re-tighten the jam nut. e.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 51 of 53 3. Disable the generator Pump Set option. After the pump has been properly adjusted, disable the Pump Set option by performing the following steps: Step c: After selecting , Press On/Off until appears. Step a: Hold Mode until Amps Line 1 Blinks . Release switch so appears. Step b: Press mode twice to make appear. Disabling pump set option Figure 31 a.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 52 of 53 Manufacturers Limited Warranty Smart Power® Systems Hydraulic Generator Coverage period Provided such goods are operated and maintained in accordance with SPS’s written instructions, SPS warrants the hydraulic generators manufactured or supplied by it will be free from defects in material and workmanship for a period of five (5) years or one thousand (1,000) hours, whichever comes first, from the date of delivery to the first purchaser.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM 5. Page 53 of 53 The cost of airfreight or other extraordinary expenses for shipment of parts over and above premium surface transportation. Limitation SPS is not responsible for the repair of generators that is required because of normal wear, accident, misuse, abuse, improper installation, corrosion, lack of maintenance, unauthorized modifications, the use of add-on or modified parts, improper storage or negligence.
