A.C.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 1 of 52 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 52 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 52 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 52 Operating the A.C. modular generator system in the presence of flammable vapors may result in an explosion. 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).
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Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 6 of 52 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 138/240 volt AC @ 60 Hz from no-load to full load, handling electrical loads of 30,000 watts. How our System works: A generator driven by a hydraulic motor delivers the electrical power.
Smart Power® Systems A. C.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 8 of 52 WARNING: 12 VOLTS DC MUST BE DIRECTLY APPLIED TO THE GENERATOR SYSTEM CONTROLLER WHENEVER THE HYDRAULIC PUMP IS ENGAGED. FAILURE TO DOSO MAYCAUSEEXCESSIVEFLUIDTEMPERATURE,DAMAGINGTHESYSTEM COMPONENTS AND WILL VOID THE WARRANTY FAN MOTOR + VEHICLE +12V SUPPLY RED VEHICLE GROUND - ORANGE BLACK NOT PROVIDED BROWN/WHITE BUZZER VEHICLE +12v SUPPLY GREY ORANGE YELLOW SPS DISPLAY WIRE HARNESS P/N 3722004 VEHICLE +12v SUPPLY REMOTE ENB.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 9 of 52 System Specifications MODEL OF GENERATOR HR-30 Generator Type AC Inductive (3-Phase) Speed Frequency Voltage 1800 RPM 60 Hz 138/240 VAC Amperage 76A @ 240 VAC or per phase Output Power 30 KW continuous Hydraulic Motor Piston type, 40cc Max. Speed 4000 RPM Hydraulic Pump Piston w/pressure compensated control Operating Speed (For full output) 1200-3000 RPM continuous duty Standard Shaft SAE ‘C’ Flange 1-1/4”-keyed (1.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 10 of 52 MODEL OF GENERATOR HR-30 Oil Cooler Dimensions (Core) 2”D x 15” W x 30”L Fan 16 Inch Pusher Voltage 12 Volts DC Amperage 22 Amps Filter 10 Micron Hydraulic Oil (recommended) (alternate) Dexron III ISO Approved Hydraulic Fluid Maximum Viscosity 4600 SUS (1000mm2/S) 60 SUS (10mm2/S) Op. Temp. range (deg. F.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 11 of 52 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 12 of 52 4. Verify that the pump shaft will mount to the PTO. Pumps supplied by Smart Power® Systems have a SAE ‘C’ 2 bolt flange. The pumps supplied by Smart Power® Systems for the Model HR-30 have either the standard 1-1/4” keyed shaft, or, the optional 1-1/4” shaft with a 14-tooth spline. Check the PTO manufacturer’s specification to verify that the pump supplied with the system will mount to the PTO installed on the vehicle.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 13 of 52 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 manufacturers 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 16 of 52 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 52 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 52 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 52 HR-30 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 52 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 21 of 52 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 52 8. Connecting the generator to the Vehicle’s breaker panel: a. The generator does not include the main 80A 3 phase circuit breaker. A main breaker must be installed in a separate panel or in the vehicle breaker panel. b. If a separate main breaker panel is installed, connect the 3 phases (black wires) to the input terminals of the 80A 3 phase breaker. Neutral (white wire) should pass through this box, isolated from ground.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 23 of 52 138V circuits, 3 240V 2 phase circuits (phase A-B, B-C, C-A), and one 3 phase circuit, all active concurrently. To completely utilize the generator’s output capabilities, the loads must be equally divided between the generator’s three main windings and neutral. Before wiring the vehicle, calculate the total wattage of the load that will be connected to the generator. Next, create three groups of loads based on total wattage.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 24 of 52 breaker will void the system’s warranty. The main breakers must UL/CSA approved and meet applicable standards for the application. Do not perform any wiring installations or modifications while the system is operating. The A.C. modular generator system will generate enough voltage to produce a fatal shock. Never touch any live connections while the system is operating. 9.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 25 of 52 enabled, the purge option will remain set until automatically reset by the system controller. The system controller will reset the option once the following two conditions are met: 1. The hydraulic system has been purged for a total of at least 30 minutes. 2. Of those 30 minutes, at least 20 occurred with the generator on. WARNING: Never operate the system without the filler/breather plug installed.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 26 of 52 Figure 13 6. Return to system purge display by pressing the Mode switch repeatedly until the screen shown in Figure 13 is displayed. Purge will still be active. Indicates whether the generator is 0n or 0ff 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 27 of 52 Verify that the generator’s output frequency is 59-63 Hz. If the frequency is not within that range, contact Smart Power Systems at (231) 832-5525 for more information. 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 28 of 52 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. Reference Figure 15. c. Press the On/Off switch until the desired value appears. A y means Auto-Start is enabled, an n means Auto-Start is disabled. d.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 29 of 52 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 52 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 52 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 52 The Hr indicates the system controller is configured to operate an HR-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 52 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 34 of 52 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 35 of 52 Measured oil temperature in degrees fahrenheit Message advising the oil is cold (less than 40°F) Example of Command & Control Center when operating with cold hydraulic fluid Figure 24 Operating Modes when the system START button is activated (or when the system is in “autostart”): • When the meter displays hydraulic oil temperatures below 20°F, the hydraulic system will bypass the generator motor and the generator will not produce power.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 36 of 52 g. If the hydraulic fluid appears dirty or black in the reservoir sight gage, replace the fluid and filter immediately. Also, if the hydraulic fluid sustains a temperature over 175° F, replace the fluid immediately. Oxidation can occur naturally over time and can be accelerated with over temperature operation, affecting generator output. Always change the filter when the hydraulic fluid is changed.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 37 of 52 Press Mode until FLt and Xr are displayed Time Since last Oil Filter Change in Hours. Example of oil filter run time display Figure 25 4. The Command & Control Center will flash a fault when 250 hours have passed since the previous filter change.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 38 of 52 will be removed and replaced by another screen. The fault has been cleared and the timer reset. c. When the fault has been cleared, the system automatically enters purge mode to purge any entrapped air from the hydraulic lines (see Figure 13). The system must be purged for 30 minutes, 20 of which must be with the generator ON. Turn off the main power breaker during purge. While purging, the system will not produce usable electrical power.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 39 of 52 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 52 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 52 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 52 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 52 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 52 Electrical Problems 1. No Output Voltage: a. No output voltage may be caused by excessive current draw opening the circuit breakers. Remove all electrical loads from the generator and reset breaker(s). Re-engage electrical load in increments. If possible, monitor current draw with the Command & Control Center to determine which portion of the load is causing the breaker to open. b. The PTO is faulty.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 45 of 52 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. 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 46 of 52 SPS Model Matrix PARENT P/N 2600330 2601330 2610330 2611330 DESCRIPTION Generator, HR-30/80cc, R, SPL PUMP Generator, HR-30/80cc, R, KEY PUMP Generator, HR-30/80cc, L, SPL PUMP Generator, HR-30/80cc, L, KEY PUMP TRAY ASM P/N Command& ControlCenter P/N RANGE WR= WIDE RANGE. Std= Standard 8583071 8583071 8583071 8583071 1500047C 1500047C 1500047C 1500047C Std. Std. Std. Std. Table 4 PUMP DISP.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 47 of 52 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 48 of 52 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 49 of 52 2. 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. 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 50 of 52 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 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 51 of 52 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 52 of 52 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.
