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Smart Power

®

Systems

A. C. MODULAR GENERATOR SYSTEM

Page 7 of 53

CASE DRAIN

x

y

RESERVOIR

PUMP

PROPORTIONAL

VALVE

CASE DRAIN

MOTOR

COOLER

FILTER

BOOST BLOCK

VENTURI BOOST

CHECK

VALVE

IN

BP

REG

Hydraulic schematic for HR-15/HR-12 generator system

Figure 1

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Summary of Contents for HR-12

Page 1: ...A C MODULAR GENERATOR SYSTEM OWNERS MANUAL MODELS HR 15 60 Hz HR 12 50 Hz 9991041 Rev H ...

Page 2: ...mer 5 Description of Product 6 System Specifications 10 Pre Installation Guide 12 Installation Guide 18 Hose Installation Guidelines 23 Operation 31 Special Operating Instructions 37 Maintenance Instructions 38 Troubleshooting Guide 41 SPS Model Matrix 48 Pump Adjustment 49 Doc 9991041 Rev H ECO 16138 ...

Page 3: ...cted from the environment to prevent damage to the stator Smart Power stators go through a very important double dip coating process prior to generator assembly however exposure to direct water sprays can cause the stator to electrically short Generator damage and electrical shock can occur Caution should be taken during truck pressure washing since water damage to the generator can occur if direc...

Page 4: ...lems Operating the system while the hydraulic fluid is above 175 F will void the system s warranty Hydraulic fluid is combustible and toxic In the event of human contact with hydraulic fluid generously flush body part eyes skin etc with running water Avoid inhalation of any oil mist or vapor Do not ingest hydraulic fluid In case of fire use foam dry chemical or carbon dioxide to extinguish flame D...

Page 5: ...ing sound Do not allow anything to contact the hydraulic hoses that will cause a kink pinch or chaffing The A C modular hydraulic system generates hydraulic pressures approaching 4000 psi A ruptured hose may result from abrasion discharging hot high pressure hydraulic fluid which can cause serious personal injury fire and or damage to the system Never remove the guards on the generator to expose t...

Page 6: ...erein or the installation of the SPS unit This installation manual contains references to certain database and resources As SPS has no control over these database and resources you acknowledge and agree that SPS is not responsible or liable for any content advertising products information or other materials on or available from such database or resources You further acknowledge and agree that SPS ...

Page 7: ...proportional valve The proportional valve is directly driven by the system controller The piston pump delivers fluid to the proportional valve driven by an installer supplied PTO mounted to the vehicle s transmission Heat generated in the hydraulic fluid as it passes through the various components in the system is cooled by a heat exchanger and fan A filter removes impurities in the fluid A ventur...

Page 8: ...ODULAR GENERATOR SYSTEM Page 7 of 53 CASE DRAIN x y RESERVOIR PUMP PROPORTIONAL VALVE CASE DRAIN MOTOR COOLER FILTER BOOST BLOCK VENTURI BOOST CHECK VALVE IN BP REG Hydraulic schematic for HR 15 HR 12 generator system Figure 1 ...

Page 9: ...LOW PURPLE BLACK WHITE GREEN WHITE YELLOW BLACK YELLOW BLACK GREEN PINK BLUE PRESSURE SWITCH P N 8594019 YELLOW PURPLE YELLOW ASM OIL LEVEL SENSOR P N 3320106 SPS DISPLAY WIRE HARNESS P N 3722004 COMMAND CONTROL CENTER P N 1500047 FAN MOTOR CURRENT TRANS P N 1500035 WHITE RED WHITE BLUE PINK BLUE PURPLE WHITE RED WHITE BLUE WHITE ORANGE WHITE CIRCUIT BREAKER GENERATOR OUTPUT LOGIC HI L1 LOGIC LO L...

Page 10: ...Smart Power Systems A C MODULAR GENERATOR SYSTEM Page 9 of 53 Figure 2 ...

Page 11: ...d SAE C 2 bolt mount 80cc per revolution 4600 psi 320 bar 5075 psi 350 bar Engine right hand rotation opposite engine rotation available upon request Piston w pressure compensated control 800 3000 RPM SAE C 1 25 Keyed SAE C 2 bolt mount 80cc per revolution 4600 psi 320 bar 5075 psi 350 bar Engine right hand rotation opposite engine rotation available upon request Dry Weight of Hydraulic Pump 77 lb...

Page 12: ...x 22 H Including Reservoir 34 5 L x 19 W x 22 H including Reservoir Ambient Operating Temperature Range 0 F to 120 F 0 F to 120 F Table 1 cont System Requirements Power Take Off Attachment Pump must be remote mounted and driven by the PTO via a drive shaft Power Take Off Rotation Engine rotation systems for opposite engine rotation available upon request Power Take Off Speed extended range 800 to ...

Page 13: ... end of the PTO shaft A left hand rotating pump requires a PTO that turns clockwise when looking at the free end of the PTO shaft WARNING Operating the pump with reverse rotation will damage the pump and void the system s warranty 2 Verify that the PTO ratio is properly sized to provide adequate speed to the hydraulic pump during normal operation of the generator system The PTO output speed must b...

Page 14: ...rranty Never use an unbalanced drive shaft to drive a remotely located pump An unbalanced drive shaft will cause premature wear of the pump and will void the system s warranty Do not approach a running A C modular generator when wearing long loose items such as hair jewelry ties clothing etc Direct contact with a rotating drive shaft can cause serious personal injury and or damage to the system 5 ...

Page 15: ...d the use of flow restricting fittings Do not form loops in the hose that may collect air or kink Run hoses as straight as possible but not taut between connections Do not exceed hose lengths of 20 feet 6 Mounting considerations The SPS models HR 12 and HR 15 have been specifically designed to be mounted on top of a vehicle in the open without requiring any additional coverings Reference Figure 3 ...

Page 16: ... MODULAR GENERATOR SYSTEM Page 15 of 53 Bottom view of HR12 HR 15 tray assembly showing minimum clearance for proper ventilation Figure 3 End view of HR 12 HR 15 tray assembly showing minimum clearance for proper ventilation ...

Page 17: ...egraded system performance and void the system s warranty 7 The tray assembly must be mounted in a position that is higher than the pump If the pump inlet hose is 10 in length or less the tray and reservoir assemblies must be a minimum of 12 higher than the pump If the pump inlet hose is longer than 10 elevate the tray and reservoir assemblies an additional 12 for every additional 10 of pump inlet...

Page 18: ...nuously 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 The Command Control Center is water sealed and operates on low voltages so pump house mounting is permissible A 15 ft water sealed harness is provided to connect the Command Control Center to the system controller mounted within the gene...

Page 19: ...her orientation will not allow hydraulic fluid in the pump to reach the correct level before starting causing premature wear of the pump thus voiding the system s warranty The pump and undercarriage components will corrode if they are left unprotected It is advisable to paint them before completing the installation 2 Locate and bore mounting holes for generator tray assembly as shown in Figure 7 M...

Page 20: ...1 2 13UNC Nut Figure 8 WARNING Never mount the Generator on its side or upside down Always mount the generator upright with its base horizontal Improper mounting will lead to poor performance and damage to the system and will void the system s warranty Never operate an AC modular generator system that is not secured in place damage will result Do not mount the hydraulic pump cooler fan assembly or...

Page 21: ...ssembly 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 ...

Page 22: ...Smart Power Systems A C MODULAR GENERATOR SYSTEM Page 21 of 53 208 CLEARANCE HOLE FOR 10 SCREW 4 PL 2 000 3 375 3 375 1 688 1 688 Hole pattern for Command Control Center Figure 10 ...

Page 23: ...tion 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 Lubricate hose fitting o rings with clean hydraulic fluid Dexron III before installation to prevent damage to them ...

Page 24: ...et Never use an inlet line fitting less than 1 Never install a hose tightly between connections Leave length for the hoses to expand Do not form loops in the hose that may collect air or cause kinking Run hose as straight as possible but not taut between connections To keep debris out of hoses while being positioned cover the ends Do not bundle installed hoses tightly together with banding Hoses m...

Page 25: ...wiring diagram HR 15 HR 12 Phase A Black wire 120 VAC Phase A Black wire 115 VAC Phase B Red wire 120 VAC Phase B Red wire 115 VAC Neutral White wire Neutral White wire Ground Green wire Ground Green Wire To completely utilize the generator s output capabilities the 115 120 VAC loads must be equally divided between the generator s two main windings Before wiring the vehicle calculate the wattage o...

Page 26: ... SPS A C modular generator system Never wire any loads to the generator s output without a circuit breaker in series with the load Damage to the generator to the components within that circuit electrical shock or fire may result if a short occurs in an unprotected circuit Run all 115 120 VAC and 230 240 VAC electrical connections between the generator and the distribution panel in conduit Bypassin...

Page 27: ...y removing the plug See Figure 30 c Fill the Gen set reservoir with fresh Dexron III hydraulic fluid until the sight gauge is full As hydraulic fluid begins to fill the hoses maintain the level of fluid in the reservoir until hydraulic fluid begins to flow from the case drain hole on the pump Replace the case drain hole plug d Start the vehicle and allow the engine to idle e Ensure the generator p...

Page 28: ...the hydraulic fluid Damage to the system s hydraulic components as well as ruptured hoses may result and void the system s warranty Always run the purge cycle after installation after replacing the hydraulic fluid and the filter or after making any other repairs that may allow air into the hydraulic system Failure to do so will void the system s warranty Enabling System Purge Option The purge opti...

Page 29: ...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 Monitor the hydr...

Page 30: ... HR 15 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 Improper ventilation will result in system overheating reduced performance and possible damage to th...

Page 31: ...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 Return to Norm...

Page 32: ...ode Figure 16 2 The PTO driving the SPS hydraulic pump must be engaged for the system to generate electricity 3 The Command Control Center is equipped with two Smart Touch switches labeled Mode and On Off respectively These switches do not require pressure to be activated but instead sense the presence or absence of your fingertip The decimal points in the Amps Line 1 and Amps Line 2 fields of the...

Page 33: ...enever the PTO is engaged and the system controller is in Normal or Quiescent mode the generator can be switched from an off state to an on state and vise versa by pressing the on off switch on the Command Control Center If the PTO is not engaged or the hydraulic pressure is too low when the on off switch is pressed the following screen will be displayed reference Figure 18 Example of low hydrauli...

Page 34: ...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 When the Command Control Center is in Normal mode pressing the Mode switch three times will cause the configuration of the generator system controller to be displayed The indicates the controller is configured to run an enclosed generator and the number dis...

Page 35: ...e that exceeds 175 F 79 C the system will begin displaying an alarm If the system measures a hydraulic oil temperature that exceeds 180 F 82 C the generator will automatically shut down in 30 minutes unless the shutdown is overridden If the temperature of the hydraulic oil reaches 220 F 104 C the system will immediately shut down above 220 F 104 C the shutdown cannot be overridden b If the system ...

Page 36: ...system and or degrade the system s performance Overriding an automatic system shutdown may void warranty The system s electronic controller records whenever an override function is performed Always avoid overriding a shutdown if possible 9 The following is an example of how an automatic shutdown can be overridden This example describes how to override an OIL HOT shutdown but the override procedure...

Page 37: ...and Control Center in hot oil fault override confirmation Figure 23 c If your answer was yes in the previous step the confirmation screen shown in Figure 23 will be displayed Again note the y and n labels below the Mode and On Off switches Press the On Off switch to answer yes and override the shutdown Press Mode to answer no and proceed to the oil temperature display Note If you override the syst...

Page 38: ...essage advising the oil is cold less than 40 F Measured oil temperature in degrees fahrenheit 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 gener...

Page 39: ... 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 WARNING When adding or replacing hydraulic fluid always use clean new Dexron III fluid Do not power wash the generator Doing so will...

Page 40: ...any way Doing so will void the system s warranty 3 The system controller automatically records the time from the previous filter change The hours since the previous filter change can be accessed using the Command Control Center by pressing the Mode switch until the following screen appears reference Figure 25 Time Since last Oil Filter Change in Hours Press Mode until and are displayed Example of ...

Page 41: ...il filter service warning display Figure 26 a Press the Mode switch repeatedly until one of the screens shown in Figure 26 appears b While holding the Mode switch down press and release the On Off switch three times in succession then release the Mode switch The Oil Filter Fault display will be removed and replaced by another screen The fault has been cleared and the timer reset c When the fault h...

Page 42: ...and Control Center interrupting the normal display Reference Figure 27 for an example of an over current fault The faults can also be accessed by repeatedly pressing the mode switch After displaying the oil temperature oil filter time and configuration the next display will be the first active fault Each time the Mode switch is pressed the next fault will be displayed When there are no more faults...

Page 43: ...oltage Sensor Fault The indicated voltage may be incorrect Alarm Oil temperature is getting too high 175 F Measured Temperature in the Hours field Override Oil Temperature is too high 180 F Measured Temperature in the Hours field Override Oil level in reservoir is low Add oil to clear the error Shutdown Oil Temperature dangerous 220 F Measured Temperature in the Hours field Alarm Indicator Light G...

Page 44: ...Tight bends or kinks in pump inlet hose and or tubing c Insufficient tray height above the pump resulting in low head pressures d Under sized pump inlet hose minimum pump inlet hose size is 1 e Excessively long inlet hose may be corrected by using larger hose f Cold hydraulic fluid Finding the cause and correcting it should stop cavitation Install a 0 25 psig gauge in line between inlet hose fitti...

Page 45: ...r this problem are the same as for cavitation above With the pressure gauge still installed in the suction line at the pump inlet port install a second gauge 0 50 psig pressure gauge in the case drain line at the pump case port Next engage the PTO and operate the genset with no load for twenty minutes to purge air out of the fluid Note both gauge readings If the differential pressure at the case i...

Page 46: ...e c Verify that there is proper ventilation d Verify that the DC fan motor is operating properly e Verify that warm air from the fan outlet is not being re circulated through the cooler f Check the hydraulic fluid to see if it is black or darkened This indicates overheating or aging Drain and flush the system g Fill with new clean hydraulic fluid h Adjust pump if necessary only after contacting Sm...

Page 47: ... s system controller has lost power reference Figure 2 The Command Control Center would stay dark even after the mode and or on off switch is pressed Verify that the vehicle 12V supply has both 12 volts and ground If 12 volts is not available check the vehicle for a blown fuse or a loose open electrical connection d The stator field may be shorted or open Disconnect wires 1 2 3 and 4 from the term...

Page 48: ...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 Verify that the hydraulic pump speed is in the required range see Table Pump speed can be calculated by m...

Page 49: ... HR 15 60cc R KEY PUMP 1500047C 8583055 8510134 STD 60 K R 30 15 9991041 2610215 GENERATOR HR 15 60CC L SPL PUMP 1500047C 8583055 8510133 STD 60 S L 30 15 9991041 2611215 GENERATOR HR 15 60CC L KEY PUMP 1500047C 8583055 8510135 STD 60 K L 30 15 9991041 2600015 GENERATOR HR 15 80cc R SPL PUMP 1500047C 8583055 8510106 WR 80 S R 30 15 9991041 2601015 GENERATOR HR 15 80cc R KEY PUMP 1500047C 8583055 8...

Page 50: ...the HR 15 or 49 Hz for the HR 12 the pump output flow may need to be increased 2 The hydraulic system is running excessively hot If the system s oil temperature is running above 160 F with an ambient air temperature of 80 F the pump output flow may need to be decreased Before making any adjustment verify the system is getting adequate ventilation that the fans are both operating the oil cooler air...

Page 51: ...ter into Normal mode b Press and hold the Mode switch until the Amps Line 1 field blinks with more than 10 seconds Release the switch while the Amps Line 1 field is blinking to make appear Reference Figure 28 c Press and release the Mode switch until appears d Press the On Off switch until a appears indicating Pump Set option is Active e Return to Normal mode by pressing the Mode switch until the ...

Page 52: ...ontrol 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 ...

Page 53: ...stems A C MODULAR GENERATOR SYSTEM Page 52 of 53 Pump assembly Figure 30 3 Disable the generator Pump Set option After the pump has been properly adjusted disable the Pump Set option by performing the following steps ...

Page 54: ...and hold the Mode switch until the Amps Line 1 field blinks with more than 10 seconds Release the switch while the Amps Line 1 field is blinking to make appear Reference Figure 31 b Press the Mode switch until appears c Press the On Off switch until an appears indicating Pump Set option is inactive d Put system into Normal mode by pressing the Mode switch NOTE For a complete copy of Manufacturer s...

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