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Smart Power Systems

®

A. C. MODULAR GENERATOR SYSTEM

Page 43 of 56

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 31 for an example of an over-current fault.

The faults can also be accessed by repeatedly pressing the mode button.  After displaying
the oil temperature, oil filter time, and configuration, the next display will be the first active
fault.  Each time the Mode button is pressed; the next fault will be displayed.  When there
are no more faults to display, the Command & Control Center will return to Normal mode.

Figure

– 31 Line 1 High Current Display

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Summary of Contents for HR-10

Page 1: ...9991035 Rev N A C MODULAR GENERATOR SYSTEM OWNERS MANUAL MODEL HR 6 2 HR 8 HR 10 and HR 110 ...

Page 2: ...mer 5 Description of Product 6 System Specifications 9 Pre Installation Guide 13 Installation Guide 20 Hose Installation Guidelines 25 Operation 32 Special Operating Instructions 39 Maintenance Instructions 40 Troubleshooting Guide 43 Pump Adjustment 52 SPS Model Matrix 56 Doc 9991035 Rev N ECO 16417 ...

Page 3: ...rom 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 directly sp...

Page 4: ...mbustible 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 Do not exceed the wattage rating of the generator The generator may be permanently d amaged and the generator and hydraul...

Page 5: ...ng 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 ...

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: ...oportional valve The proportional 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...

Page 8: ...R GENERATOR SYSTEM Page 7 of 56 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 HR 6 2 HR 8 HR 10 and HR 110 ...

Page 9: ...Smart Power Systems A C MODULAR GENERATOR SYSTEM Page 8 of 56 Figure 2 Generator Electrical Schematic for HR 6 2 HR 8 HR 10 and HR 110 ...

Page 10: ...A 240 VAC 10 KW continuous 12 KW peak AC Inductive 3600 RPM 60 Hz 120 240 VAC or 120 VAC 84A 120 VAC or 42A 240 VAC 10 KW continuous 12 KW peak 50hz Generator Type Speed Frequency Voltage Amperage Power Output AC Inductive 3000 RPM 50Hz 230 VAC or 115 230 VAC 70A 115 VAC or 35A 230VAC 8 KW continuous 9 KW peak Hydraulic Motor Maximum Speed Motor Shaft Size Port Size Gear Type 8cc 4000 RPM 0 626 in...

Page 11: ... 7 8 13 Tooth Spline SAE 1 parallel with key SAE B B 1 15T Spline 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 compensated control 1100 3000 RPM continuous duty SAE B 7 8 13 Tooth Spline SAE 1 parallel with key SAE B B 1 15T Spline SAE B 2 bolt mount 45cc per revolution 3...

Page 12: ...ulic Oil recommended 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 3600 psi SAE 1250 psi SAE 3600 psi SAE 1250 psi SAE Hose Fittings JIC STD JIC STD Dry Weight without pump HR 6 2 255 lbs HR 8 255 lbs HR 10 280 lbs HR 110 280 lbs Dimension of Tray Asm 32 L x 13 5 W x 17 H Includ...

Page 13: ...Smart Power Systems A C MODULAR GENERATOR SYSTEM Page 12 of 56 Table 1 cont ...

Page 14: ... DRF 1 52 L PUC Depending on genset model a 45cc or 60cc pump is supplied To determine the PTO rotation check the PTO manufacturer s specification or 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 wh...

Page 15: ...HR 110 model Upon special order a 1 keyed shaft or 1 15 tooth spline is available on Models HR 6 HR 8 and HR 10 A 1 keyed shaft is available on the HR 110 Model Check the PTO manufacturer s specification to verify that the pump supplied with the system will mount to the PTO installed on the vehicle Note In some cases it may be necessary to mount the pump remote from the PTO and drive it with a dri...

Page 16: ...nlet hose 1 SAE 100R1AT 16 hose use Parker hose ends P N 10643 16 16 Note Maximum hose length is 20 b Pump outlet hose 1 2 SAE 100R9AT 8 rated to 4000 PSI use Parker hose ends part number 10643 8 8 Note Maximum hose length is 20 c Pump case drain hose 5 8 SAE 100R1AT 10 use Parker hose ends part number 10643 10 10 Note Maximum hose length is 20 ...

Page 17: ...wer hydraulic generators Complete testing was performed using U S Oil Multi Vis R Hydraulic Fluid under controlled environments ranging from below freezing to above NFPA s high temperature requirements The systems ran within our tight performance specifications using all three listed grades ISO 32 is recommended when ambient temperatures are generally between 2 and 56 F ISO 46 is recommended when ...

Page 18: ...A IF AIR VENT OPTION B OR C IS USED 50 CLEARANCE REQUIRED ON THIS SURFACE AIR VENT OPTION B IF AIR VENT OPTION A 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 Figure 3 HR 6 2 HR 8 HR 10 and HR 110 Bottom View Figure 4 HR 6 2 HR 8 HR 10 and HR 110 Front View ...

Page 19: ...Smart Power Systems A C MODULAR GENERATOR SYSTEM Page 18 of 56 Figure 5 HR 6 2 HR 8 HR 10 and HR 110 End View ...

Page 20: ...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 21: ... other 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 ...

Page 22: ...king compound or lock washer is preferred 1 2 13UNC Screw 1 2 Flat Washer Generator Tray Dunnage Area Floor 1 2 Flat Washer 1 2 Lock Washer 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 o...

Page 23: ... If desired reservoir and cooler fan assemblies can be remote mounted Contact Smart Power Systems at 231 832 5525 to review remote mounting applications and to order remote mounting kit PN 1500065 Figure 9 HR 6 2 HR 8 HR 10 and HR 110 Remote Mounting Sub Assemblies ...

Page 24: ...icle 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 using harness P N 3722004 Figure 10 Command Control Center Mounting Pattern 208 CLEARANCE HOLE FOR 10 SCREW 4 PL 2 000 3 375 3 375 1 688 1 688 ...

Page 25: ...ystems A C MODULAR GENERATOR SYSTEM Page 24 of 56 7 Install hoses and tighten hose ends using the Hose Installation Guidelines See Figure 11 for connection locations Figure 11 HR 6 2 HR 8 HR 10 and HR 110 Interfaces ...

Page 26: ...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 27: ...wattage of each 120 115 VAC load that will be connected to the generator Next create two groups of loads based on total 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 ...

Page 28: ...lled breaker will void the system s warranty Replacement breakers must be obtained from Smart Power Systems approved sources only 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 Connect 12 VDC vehicle battery ...

Page 29: ...the vehicle and engage the Power Take Off PTO Note Pump may cavitate briefly while air is purging making noise g The automatic purging function will cancel after the hydraulic pressure has stabilized and the Command Control Center will display all zeroes h Check for hydraulic fluid leaks all hose connections must be tight Continue monitoring the hydraulic fluid level adding fluid as needed to keep...

Page 30: ...therwise press and hold the Mode button until the Amps Line 1 field begins blinking more than 10 seconds Release the button so appears Reference Figure 13 4 Press and release the Mode button until appears 5 Press the On Off button until a appears indicating Purge option is Active 6 Return to system purge display by pressing the Mode button repeatedly until the screen shown in Figure 14 is displaye...

Page 31: ...p adjustment will void the system s warranty Improper ventilation will result in system overheating reduced performance and possible damage to the system and or cause personal injury If the system is installed such that improper ventilation exists the system s warranty will be voided 12 Set auto start option If the auto start option is enabled the generator will begin generating electricity whenev...

Page 32: ...ut the Command Control Center into Normal mode b Press and hold the Mode button until the Amps Line 1 field begins blinking more than 10 seconds Release the button so and appear Reference Figure 15 c Press the On Off button until the desired value appears A means Auto Start is enabled an means Auto Start is disabled d Return to Normal mode by pressing Mode ...

Page 33: ... system to generate electricity 3 The Command Control Center is equipped with two Smart Touch buttons labeled Mode and On Off respectively These buttons 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 b...

Page 34: ...l mode from Quiescent mode press the Mode button 6 Whenever 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 button on the Command Control Center If the PTO is not engaged or the hydraulic pressure is too low when the on off button is pressed the following screen will be ...

Page 35: ...egrees Fahrenheit Figure 19 Oil 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 20 Figure 10 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 Figure 2...

Page 36: ...tes the controller is configured to run an enclosed generator and the number displayed corresponds to the maximum power output of the generator in kilowatts reference Figure 23 The system controller is configured to operate a generator whose maximum output is this number in kW The indicates the system controller is configured to operate an ER series Generator Figure 23 Configuration Display f If t...

Page 37: ...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 38: ... the generator with the condition present b Note the and labels below the Mode and On Off buttons Press the On Off button 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 25 Hot Oil Fault Override Confirmation c If your answer was yes in the previous step the confirm...

Page 39: ...ply database information and screen layouts to their OEM customers Potential display screens and available information can be seen in Figures 26 and 27 below For independent development please contact Smart Power Systems at 231 832 5525 for J1939 message details Figure 26 J1939 Multiplex Monitoring Figure 27 J1939 Multiplex Control and Diagnostic Information 3 Generator systems equipped with the J...

Page 40: ...and Control Center reference Figure 28 Message advising the oil is cold less than 40 F Measured oil temperature in degrees Fahrenheit Figure 28 Cold Oil Operating Modes when the system START button is activated or when 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 This mode wa...

Page 41: ...on 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 ...

Page 42: ...y 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 button until the following screen appears reference Figure 29 Time Since last Oil Filter Change in Hours Press Mode until and are displayed Figure 29 Oil Filter Hours Display ...

Page 43: ...er Hours Information display Figure 30 Filter Service Reset a Press the Mode button repeatedly until one of the screens shown in Figure 30 appears b While holding the Mode button down press and release the On Off button three times in succession then release the Mode button The Oil Filter Fault display will be removed and replaced by another screen The fault has been cleared and the timer reset c ...

Page 44: ...n the Command Control Center interrupting the normal display Reference Figure 31 for an example of an over current fault The faults can also be accessed by repeatedly pressing the mode button After displaying the oil temperature oil filter time and configuration the next display will be the first active fault Each time the Mode button is pressed the next fault will be displayed When there are no m...

Page 45: ...eservoir 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 Tem...

Page 46: ... 4 below Table 4 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 47: ...ystem 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 bubbles in the fluid stream and or reservoir Conditions frequently associated with aeration are the following a Air leaks in the pump inlet flow path b Low fluid level allowing air to be drawn into the syst...

Page 48: ...ll 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 record limits Case drain pressure to inlet pressure differential The difference between pump inlet pressure and case drain pressure should not exceed 7 psig Pump inlet pressure minus case drain...

Page 49: ... 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 5 Low Hydra...

Page 50: ...s not available check the vehicle for a blown fuse or a loose open electrical connection d The stator field may be shorted or open With a flashlight check the generator windings visible through the ventilation slots If the windings appear burnt in any area the generator must be replaced If the windings are not burnt disconnect wires 1 2 3 and 4 from the terminal strip located in the generator wiri...

Page 51: ...ling 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 hydraulic motor from the generator to inspect coupling and the rubber insert between the coupling halves Replace components as necessary reposition and tighten coupling setscrew so both halves of the coupling are mating correctly h The pump is faulty ...

Page 52: ... 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 Generator noise can be caused by defective generator bearings or a faulty generator hydraulic motor coupling a Contact Smart Power Systems if bearings need replacement b Check the generator hydraulic motor ...

Page 53: ...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 54: ...ng Press On Off until appears Figure 32 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 32 c Press and release the Mode butto...

Page 55: ...hile 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 for 60 Hz application or 54 55 Hz for 50 Hz application 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 34 Pump Assembly ...

Page 56: ...g Press On Off until appears Figure 35 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 35 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 57: ...3048 8510004 WR 45 S L 8 8 2611008 GENERATOR HR 45cc L 1 KEY PUMP 8583048 8510018 WR 45 K L 8 8 2602008 GENERATOR HR 8 45cc R 15T SPL PUMP 8583048 8510099 WR 45 S R 8 8 2600010 GENERATOR HR 10 45cc R 13 SPL PUMP 8583040 8510001 Std 45 S R 11 10 2601010 GENERATOR HR 10 45cc R 1 KEY PUMP 8583040 8510016 Std 45 K R 11 10 2610010 GENERATOR HR 10 45cc L 13 SPL PUMP 8583040 8510002 Std 45 S L 11 10 2611...

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