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Smart Power Systems

®

A. C. MODULAR GENERATOR SYSTEM

Page 4 of 52

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.  modular hydraulic  system  generates  hydraulic
pressures approaching 3600 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 the rotating fan or motor coupling.
Personal injury will result if fingers, hair or loose clothing come in contact with rotating
components.

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Summary of Contents for ER-10

Page 1: ...9991031 Rev M A C MODULAR GENERATOR SYSTEM OWNERS MANUAL MODEL ER 6 2 ER 8 ER 10 and ER 110 For Compartment or Top Mounting ...

Page 2: ...mer 5 Description of Product 6 System Specifications 9 Pre Installation Guide 11 Installation Guide 16 Hose Installation Guidelines 20 Operation 28 Special Operating Instructions 35 Maintenance Instructions 36 Troubleshooting Guide 39 Pump Adjustment 48 SPS Model Matrix 52 Doc 9991031 Rev M ECO 16417 ...

Page 3: ...tected 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 dir...

Page 4: ...oblems Operating the system while the hydraulic fluid is above 195 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...

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 3600 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: ...tional valve is directly driven by the system controller The piston pump delivers fluid to the proportional valve through 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 venturi boost assembly monitors the volu...

Page 8: ...R GENERATOR SYSTEM Page 7 of 52 CASE DRAIN x y RESERVOIR PUMP PROPORTIONAL VALVE CASE DRAIN MOTOR COOLER FILTER BOOST BLOCK VENTURI BOOST CHECK VALVE IN BP REG Figure 1 Hydraulic Generator Schematic for ER 6 2 ER 8 ER 10 and ER 110 ...

Page 9: ...Smart Power Systems A C MODULAR GENERATOR SYSTEM Page 8 of 52 Figure 2 Generator Electrical Schematic for ER 6 2 ER 8 ER 10 and ER 110 ...

Page 10: ...nal Shaft Mounting Flange Displacement Continuous Pressure Max Peak Pressure Standard Rotation Dry Weight Piston w pressure compensated control 880 3000 RPM continuous duty SAE B 7 8 13 Tooth Spline SAE 1 parallel with key SAE B 2 bolt mount 45cc per revolution 3500 psi 250 bar 4600 psi 315 bar Engine right hand rotation opposite engine rotation available upon request 46 lbs Piston w pressure comp...

Page 11: ...ecommended alternate Op Temp range deg F ISO Approved Hydraulic Fluid Dexron III 13 F to 195 F ISO Approved Hydraulic Fluid Dexron III 13 F to 195 F Hoses Motor Inlet All Others JIC STD 3600 psi SAE 1250 psi SAE JIC STD 3600 psi SAE 1250 psi SAE Fittings SAE SAE Dry Weight without pump ER 6 2 235 lbs ER 8 235 lbs ER 10 255 lbs ER 110 255 lbs Dimension of Tray Asm 33 L x 15 W x 13 H Including Reser...

Page 12: ...r observe the PTO when it is engaged with the vehicle s engine running A right hand rotating pump requires a PTO that turns counter clockwise when looking at the free 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 V...

Page 13: ...he PTO and drive it with a drive shaft Contact the PTO manufacturer for information on the proper mounting configuration under these conditions WARNING The installer must provide guarding to prevent damage to the pump seals from road debris if the pump is remotely located Also properly sized and installed vibration isolators must be used if the pump is mounted to the chassis Failure to do either w...

Page 14: ... 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 Smart Power has fully tested and approved ISO fluids ISO 32 46 and 68 are approved for use in all Smart Power hydraulic generators Complete testing was performed using U S Oil Multi Vis R Hydraulic Fluid under controlled environments rang...

Page 15: ...ces around the perimeter of the generator s tray assemble Also do not position any obstructions directly in front of the system s oil cooler If the system cannot be installed without maintaining the minimum clearances as indicated or if you have any questions relative to the installation of these systems contact Smart Power Systems at 231 832 5525 Figure 3 Top View of ER 6 2 ER 8 ER 10 and ER 110 ...

Page 16: ...embly elevations above the pump Pump inlet hose length Minimum tray and reservoir elevation above pump 0 10 ft 12 inches 15 ft 18 inches 20 ft 24 inches 8 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 Cen...

Page 17: ...e 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 Error R eference source not found 5 Maintain minimum clearances as indicated in Error Reference source not found Figure 5 Mounting Hole Pattern for ER 6 2 ER 8 ER 10 and ER 110 Assembl...

Page 18: ...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 or tray assembly in any location that is not well ventilated External heat sour...

Page 19: ...nter to vehicle using 10 stainless steel button head or cap screw fasteners Take care not to overtighten the fasteners as damage to the plastic Command Control Center housing may result c Connect Command Control Center to system controller unit Figure 8 using p n 3722004 harness Figure 7 Command Control Center Hole Pattern 208 CLEARANCE HOLE FOR 10 SCREW 4 PL 2 000 3 375 3 375 1 688 1 688 ...

Page 20: ...Systems A C MODULAR GENERATOR SYSTEM Page 19 of 52 6 Install hoses and tighten hose ends using the Hose Installation Guidelines See Figure 8 for connection locations Figure 8 ER 6 2 ER 8 ER 10 and ER 110 Interfaces ...

Page 21: ...ght bend radii Tight bends may kink and cause serious damage to the system Consult the hose manufacturer s guidelines when installing hoses Use caution when tightening the hose ends to prevent the hose from becoming twisted Never install a 90 fitting at the pump outlet or inlet Never use an inlet line fitting less than 1 Never install a hose tightly between connections Leave length for the hoses t...

Page 22: ...tal wattage add the individual wattage of each load together Exchange loads between the two groups until the total wattage of the two groups is as close as possible to being equal Wire the system with one group connected to Phase A BLACK and neutral with the other group connected to Phase B RED and neutral ALTERNATE CONFIGURATION 120 VAC only If the application requires 120 VAC only the generator ...

Page 23: ...es before wiring an 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 120 VAC and 240 VAC electrical connections between the generator and the distribution panel in condu...

Page 24: ...ry may result if clothing fingers or other body parts come in contact with rotating fan blades 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 9 Bleed air from the hyd...

Page 25: ...pe through the reservoir breather causing oil to spill over i Check for hydraulic fluid leaks all hose connections must be tight Continue monitoring the hydraulic fluid level adding fluid as needed to keep the level in the sight gauge Verify that the generator s output frequency is 59 62 Hz If the frequency is not within that range contact Smart Power Systems at 231 832 5525 for more information W...

Page 26: ... until the Amps Line 1 field begins blinking 88 more than 10 seconds Release the switch so 0Pt appears Reference Figure 11 4 Press and release the Mode switch until PvrG appears 5 Press the On Off switch until a y appears indicating Purge option is Active 6 Return to system purge display by pressing the Mode switch repeatedly until the screen shown in Error Reference source not found 12 is display...

Page 27: ...tems at 231 832 5525 for more information Also verify that the air passing through the cooler and the fan is not restricted WARNING The SPS Model ER 6 2 ER 8 ER 10 and ER 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 gene...

Page 28: ... 1 Blinks 88 Release switch so 0Pt and AStr appear Step c Press On Off until the desired value appears Figure 13 Auto start Selection Display 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 switc...

Page 29: ...ed 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 Command Control Center are used to indicate the status of the Mode and On Off switches respectively reference Error Reference source not found 5 Mo...

Page 30: ...ged 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 the hydraulic pressure is too low the following screen will be displayed Reference Error Reference source not found 6 Figure 16 Low Hydraulic Pressure Display If the generator...

Page 31: ...egrees Fahrenheit Figure 18 System Temperature Display b Inlet pressure to the generator will be displayed next in the hours field by pressing the Mode switch a second time as seen in Figure 19 Figure 19 System Inlet Pressure Display c DC supply voltage as measured by the generator system controller will be displayed next in the hours field by pressing the Mode switch a third time as seen in Figur...

Page 32: ...nfigured to run an enclosed generator and the number displayed corresponds to the maximum power output of the generator in kilowatts reference Error Reference source n ot found 22 The system controller is configured to operate a generator whose maximum output is this number in kW The Er indicates the system controller is configured to operate an ER series Generator Figure 22 Example Configuration ...

Page 33: ...Off button d If the system detects an insufficient level of hydraulic fluid in the reservoir it will begin displaying an alarm The generator will automatically be shut down in 30 minutes unless the shutdown is overridden or the fault is cleared by adding sufficient fluid e If the system measures a continuous current draw exceeding the generator s maximum output rating the generator will automatica...

Page 34: ... to start the generator with the condition present 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 Figure 24 Hot Oil Override Confirmation Display c If your answer was yes in the previous ...

Page 35: ... supply database information and screen layouts to their OEM customers Potential display screens and available information can be seen in Figures 22 and 23 below For independent development please contact Smart Power Systems at 231 832 5525 for J1939 message details Figure 25 J1939 Multiplex Monitoring Figure 26 J1939 Multiplex Control and Diagnostic Information 3 Generator systems equipped with t...

Page 36: ...ence source not found 7 Message advising the oil is cold less than 40 F Measured oil temperature in degrees fahrenheit Figure 27 Display When Operating with Cold Hydraulic Fluid Operating Modes when the system START button is activated or when the system is in auto start When the meter displays hydraulic oil temperatures below 20 F the hydraulic system will bypass the generator motor and the gener...

Page 37: ...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 hydraulic fluid Do not power wash the generator Doing so will void the system s warranty Do not allow liquid to enter the generator If the outside of the gen...

Page 38: ...ontroller 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 Error Reference source not found 8 Time Since last Oil Filter Change in Hours Press Mode until FLt and Xr are displayed Figure 28 Oil Filter Runtime Display ...

Page 39: ...gure 29 Oil Filter Service Warning Display a Press the Mode switch repeatedly until one of the screens shown in Error R eference source not found 9 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...

Page 40: ...trol Center interrupting the normal display Reference Error Reference source not found 30 for an e xample 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 ther...

Page 41: ...oir oil level low Add oil through filler cap to clear Check for oil leaks Oil xoT Temp Alarm Oil temperature is getting too high 185 F Measured Temperature in the Hours field Oil xoT Temp Override Oil Temperature is too high 195 F Oil xoT Temp Shutdown Oil Temperature dangerous 220 F bAd Ind Alarm Indicator Light Ground Fault The indicator light may not function properly bAd TSnS Override Temperat...

Page 42: ... 4 J1939 ECU Fault Conditions Notes 1 Times are representative 2 Where more than one proportional valve is used due to flow requirements 3 3 phase generators only 4 For external field excitation generators Power output will limit to alternator maximum KVA rating via limited field current 5 CCC displays bad data after 1 minute loss of communication with ECU ...

Page 43: ...pump inlet port Engage PTO Operate genset with no load for twenty minutes to purge air out of the system Observe the pressure reading The pressure should always be positive If the pressure is not positive system repair rework is required 2 Aeration Aeration results from air being drawn into the system through leak paths or a low fluid condition Aeration makes a growling sound and produces visible ...

Page 44: ...he 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 is greater than 7 psig the suction side plumbing will require evaluation Note the following pressure measurements Inlet pressures Should always be positive Outlet pressure Approximately 500 psig with no load on the generator Note If the gauge is fluctuating reco...

Page 45: ...ilation 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 Smart Power Systems at 231 832 5525 4 ...

Page 46: ...s 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 2 and 3 from the terminal strip located in the generator wiring enclosure Remove black and green jumper wires from terminal 3 of terminal strip Remove Breaker and wires 1 and 4 from the Line Side of the breaker Make resistance...

Page 47: ...h the system running Electrical shock may occur g The generator drive motor or coupling is faulty Observe the generator while the system is engaged If the coupling is not turning or if it is turning but the generator is not one or more of the coupling components may be damaged and must be replaced Also verify that the coupling halves are mating If the coupling halves are not mating remove the hydr...

Page 48: ... can be calculated by multiplying the engine RPM by the PTO ratio Adjust the engine speed or PTO ratio if necessary c The generator speed may be incorrect The generator output should be between 59 62 Hz If it is not contact Smart Power Systems at 231 832 5525 for further instructions d If the problem is not detected by performing steps a through c contact Smart Power Systems 3 Generator Noise Gene...

Page 49: ...rated output frequency is too low Verify output frequency when the vehicle is in fast idle and oil temperature is below 160 F If the frequency drops below 59Hz 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 Bef...

Page 50: ...ng Press On Off until appears Figure 31 Enabling Pump Set Option a If the Command Control Center is dark press the Mode button to put the Command Control Center into Normal mode b Press and hold the Mode button until the Amps Line 1 field blinks with more than 10 seconds Release the button while the Amps Line 1 field is blinking to make appear Reference Figure 31 c Press and release the Mode butto...

Page 51: ...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 65 Hz d While keeping the setscrew from rotating with the hex wrench re tighten the jam nut e Replace and tighten the flow control cap Figure 33 Pump Assembly ...

Page 52: ...g Press On Off until appears Figure 34 Disabling Pump Set Option a Press and hold the Mode button until the Amps Line 1 field blinks with more than 10 seconds Release the button while the Amps Line 1 field is blinking to make appear Reference Figure 34 b Press the Mode button until appears c Press the On Off button until an appears indicating Pump Set option is inactive d Put system into Normal mo...

Page 53: ...13 WR 45 K R 8 8 1710008 GENERATOR ER 8 45cc L SPL PUMP 8570008 8510004 WR 45 S L 8 8 1711008 GENERATOR ER 45cc L KEY PUMP 8570008 8510018 WR 45 K L 8 8 1700010 GERERATOR ER 10 45cc R SPL PUMP 8570010 8510001 Std 45 S R 11 10 1701010 GENERATOR ER 10 45cc R KEY PUMP 8570010 8510016 Std 45 K R 11 10 1710010 GENERATOR ER 10 45cc L SPL PUMP 8570010 8510002 Std 45 S L 11 10 1711010 GENERATOR ER 10 45cc...

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