A.C.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 1 of 54 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 54 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 54 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 oil filter periodic replacement, 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 54 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.
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Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 6 of 54 Description of Product Hydraulic Generator Applications: These heavy-duty electronically controlled generator systems have been designed to meet the most demanding mobile applications. The HR-15 provides 15000 watts @ 120/240 VAC @ 60 Hz. The HR-12 provides 12000 watts @ 115/230 VAC @ 50 Hz. How Our System Works: A generator driven by a hydraulic motor delivers the electrical power.
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Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 8 of 54 WARNING: 12 VOLTS DC MUST BE DIRECTLY APPLIED TO THE GENERATOR SYSTEM CONTROLLER WHENEVER THE HYDRAULIC PUMP IS ENGAGED. FAILURE TO DO SO MAY CAUSE EXCESSIVE FLUID TEMPERATURE, DAMAGING THE SYSTEM COMPONENTS AND WILL VOID THE WARRANTY FAN MOTOR + VEHICLE +12V SUPPLY RED VEHICLE GROUND - ORANGE NOT PROVIDED BLACK BROWN/WHITE BUZZER VEHICLE +12V SUPPLY GREY ORANGE YELLOW SPS DISPLAY WIRE HARNESS P/N 3722004 REMOTE ENB. SW.
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Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 10 of 54 System Specifications (cont.) Model of generator HR-15 HR-12 Fittings SAE SAE Dry Weight (without pump) Dimension of Tray Asm. 442 lbs. 442 lbs. 34.5” L x 19” W x 22” H 34.5” L x 19” W x 22” H (Including Reservoir) (including Reservoir) Ambient Operating 0°F to 120°F Temperature Range 0°F to 120°F Table 1 (cont.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 11 of 54 Pre-Installation Guide 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: K3VL80/B-10R A left hand rotating pump will have the letter “L” in its part number.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 12 of 54 4. Verify that the drive shaft selected will couple to both the PTO and the SPS supplied pump. Pumps supplied by Smart Power® Systems for this system have an SAE C, 1.25” keyed shaft. WARNING: The installer must provide guarding to prevent damage to the pump seals from road debris. Also, properly sized and installed vibration isolators must be used if the pump is mounted to the chassis. Failure to do either will void the system’s warranty.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 13 of 54 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 an abrasive surface or sharp edge or corner. Do not position hoses with tight bend radii. Consult the hose manufacturer’s installation guidelines. Tight bends may kink and cause serious damage to the system and will void the system’s warranty.
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Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 15 of 54 Left side view of HR-12/HR-15 tray assembly showing minimum clearance for proper ventilation Figure 5 WARNING: Do not mount the hydraulic pump, tray assembly or reservoir 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 16 of 54 a. Locate a position to mount the SPS Command & Control Center. The ideal location for the Command & Control Center will be in an area that is easily seen and accessed by the generator operator. When the generator system is in use, the Command & Control Center will continuously show the status of the generator, including faults (warnings) if they occur. The Command & Control Center can also be used to engage and disengage the generator.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 17 of 54 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 54 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 54 HR-12/HR-15 tray assembly 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 54 3.375 1.688 .208 CLEARANCE HOLE FOR #10 SCREW 4 PL. 2.000 1.688 3.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 21 of 54 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-12/HR-15 tray assembly Figure 11 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 22 of 54 Hose Installation Guidelines Never install a hose without first flushing it with clean hydraulic fluid to remove any debris. Never install a hose in a location where it will rub against an abrasive surface or sharp edge or corner. Do not position hoses with tight bend radii. Tight bends may kink and cause serious damage to the system. Consult the hose manufacturer’s guidelines when installing hoses.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 23 of 54 8. Connect the vehicle’s breaker panel to the generator output. The HR-15 generator is pre-wired to supply 120/240 VAC, the HR-12 generator is pre-wired to supply 115/230 VAC. The generator frame is bonded to ground. Route the generator output conduit/wiring to the breaker panel, and carefully cut the 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 24 of 54 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 25 of 54 WARNING: 12 volts DC must be directly applied to the generator system controller whenever the hydraulic pump is engaged. Failure to do so may cause excessive fluid temperature, damaging the system components and will void the warranty. Never come near a running fan with loose items such as long hair, clothing, jewelry, ties, items that can fall out of pockets, etc. Never operate the system with fan disabled or removed.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 26 of 54 Main power breaker Figure 12 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 27 of 54 1. If the Command & Control Center is dark, press the Mode switch to put the display into Normal mode. 2. If the Display looks like Figure 13, The purge option is enabled. 3. Otherwise, press and hold the Mode switch until the Amps Line 1 field begins blinking 88 (more than 10 seconds). Release the switch so 0Pt appears. Reference Figure 13. 4. Press (and release) the Mode switch until PvrG appears. 5.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 28 of 54 11. Prior to applying full load, and after the oil temperature is above 100°F verify proper operation of the cooler fan by feeling for airflow being pushed out of the tray assembly. If the air is not being pushed through the cooler face contact Smart Power® Systems at (231) 832-5525 for more information. Also verify that the air passing through the cooler and the fan is not restricted.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 29 of 54 Step b: Hold Mode until Amps Line 1 Blinks 88. Release switch so 0Pt and AStr appear. Step c: Press On/Off until the desired value appears Figure 15 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 88 (more than 10 seconds). Release the switch so 0Pt and AStr appear.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 30 of 54 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 Figure 16). Example of Command & Control Center in Normal Mode Figure 16 2.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 31 of 54 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 32 of 54 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 33 of 54 The Er 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 34 of 54 e. bAd uoLts. 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. Bad tSnS. If the system detects a faulty temperature sensor, the generator will automatically shut down in 30 minutes unless the shutdown is overridden. g. OIL FILt.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 35 of 54 b. Note the y and n 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 36 of 54 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 37 of 54 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 38 of 54 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 39 of 54 4. The Command & Control Center will flash a fault when 250 hours have passed since the previous filter change. After replacing the filter, this fault can be removed from the Command & Control Center, and the filter run time can be reset by performing the following steps: Step a: Press Mode until InF, 0IL, and FILt appear. Step b: Hold Mode switch down and press On/Off three times in a row to clear the fault.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 40 of 54 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 41 of 54 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 42 of 54 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 4 Hydraulic Problems: 1.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 43 of 54 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 44 of 54 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 45 of 54 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 46 of 54 f. The generator drive motor is faulty. Observe the generator while the system is engaged. If it is not rotating, there may be a problem in the motor, or the motorto-generator linkage. g. The pump is faulty. If no faults are found in steps a. through g., the problem is likely to be a non-functional pump. Contact Smart Power® Systems at (231) 832-5525 for further instructions. 2.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 47 of 54 Table 5 MANUAL P/N 8510106 8510097 8510107 8510102 8510132 8510134 8510133 8510135 8510106 8510097 8510107 8510102 8510124 8510125 8510126 8510127 POWER OUTPUT KILOWATTS 8583052 8583052 8583052 8583052 8583055 8583055 8583055 8583055 8583055 8583055 8583055 8583055 8583055 8583055 8583055 8583055 MOTOR DISP.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 48 of 54 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 54 The Pump Set option can be accessed by performing the following steps: Step d: After selecting PSEt, Press On/Off until y appears. Step b: Hold Mode until Amps Line 1 Blinks 88. Release switch so 0Pt appears. Step c: Press mode twice to make PSEt 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 54 2. Adjust pump compensator: a. 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 4mm hex wrench. Adjust the flow control until the generator’s output frequency is 63 Hz for the HR-15 or 55 Hz for the HR-12. d. While keeping the setscrew from rotating, with the hex wrench, re-tighten the jam nut.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 51 of 54 Pump assembly Figure 30 3. Disable the generator Pump Set option.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 52 of 54 Step c: After selecting PSEt, Press On/Off until n appears. Step a: Hold Mode until Amps Line 1 Blinks 88. Release switch so 0Pt appears. Step b: Press mode twice to make PSEt appear. Disabling pump set option Figure 31 a. Press and hold the Mode switch until the Amps Line 1 field blinks with 88 (more than 10 seconds). Release the switch while the Amps Line 1 field is blinking to make 0Pt appear. Reference Figure 31. b.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 53 of 54 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 Page 54 of 54 4. 5. The premium costs for overtime labor requested by the owner. The cost of airfreight or other extraordinary expenses for shipment of parts over and above premium surface transportation.