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SmartPower HR-6.2 Owner's Manual

A.c. modular generator system
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A.C. MODULAR
GENERATOR SYSTEM
OWNERS MANUAL
MODEL#: HR-6.2, HR-8, HR-10 and HR-110
9991035 Rev. N

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Summary of Contents for SmartPower HR-6.2

  • Page 1 A.C. MODULAR GENERATOR SYSTEM OWNERS MANUAL MODEL#: HR-6.2, HR-8, HR-10 and HR-110 9991035 Rev. N...

  • Page 2: Table Of Contents

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 1 of 56 Table of Contents Section Page Disclaimer .......................... 5 Description of Product ...................... 6 System Specifications ...................... 9 Pre-Installation Guide ..................... 13 Installation Guide ......................20 Hose Installation Guidelines ..................25 Operation .........................
  • Page 3 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 2 of 56 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.
  • Page 4 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 3 of 56 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.
  • Page 5 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 4 of 56 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.

  • Page 6: Disclaimer

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 5 of 56 Disclaimer Although SPS has taken all reasonable care to ensure that the information contained in this installation manual (including without limitation, references, databases, resources, specifications, illustrations and instructions) was accurate in all material respects at the time of publication, SPS PROVIDES NO ASSURANCE, REPRESENTATION, WARRANTY OR GUARANTEE, expressed or implied (including third party liability), with regard to this manual, including without limiting the generality of the foregoing, with regard to its accuracy,...

  • Page 7: Description Of Product

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 6 of 56 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 120/240 volt AC @ 60 Hz, or 115/230 volt AC @ 50hz from no-load to full load, handling electrical loads of 6200, 8000 and 10000 watts, depending on model.
  • Page 8 Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 7 of 56 BOOST BLOCK FILTER VENTURI BOOST RESERVOIR COOLER CHECK VALVE MOTOR PROPORTIONAL VALVE PUMP CASE DRAIN CASE DRAIN 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: System Specifications

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 9 of 56 System Specifications MODEL HR-6.2 HR-8 HR-10 HR-110 GENERATOR Generator AC Inductive AC Inductive AC Inductive AC Inductive Type Speed 3600 RPM 3600 RPM 3600 RPM 3600 RPM...
  • Page 11 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 10 of 56 Hydraulic Piston w/pressure Piston w/pressure Piston w/pressure Piston w/pressure Pump compensated control compensated control compensated control compensated control Operating 880-3000 RPM 880-3000 RPM 1100-3000 RPM 850-2700 RPM Speed continuous duty continuous duty...
  • Page 12 All Others 1250 psi, SAE 1250 psi, SAE JIC STD JIC STD Hose Fittings Dry Weight HR-6.2 255 lbs HR-10 280 lbs (without pump) HR-8 255 lbs HR-110 280 lbs 32” L x 13.5” W x 17” H 32” L x 13.5” W x 17” H Dimension of Tray Asm.
  • Page 13 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 12 of 56 Table 1 (cont.)

  • Page 14: Pre-Installation Guide

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 13 of 56 Pre-Installation Guide Pre-Installation Check List 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.
  • Page 15 ® Systems have an SAE B 2 bolt flange. The standard pumps supplied by Smart have either a SAE B 7/8” 13 tooth spline for Models HR-6.2, HR-8 ® Power Systems and HR-10; OR a SAE B-B 1” 15 tooth spline on the HR-110 model.
  • Page 16 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 15 of 56 Obtain the following hoses of the necessary length for the installation: a) Pump inlet 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”...
  • Page 17 For additional information on ISO fluids, contact U.S. Oils, or your local ISO grade fluid supplier. SPS models HR-6.2, HR-8, HR-10 and HR-110 can be mounted on top of a vehicle, in the open, without requiring any additional coverings. Reference Figure 3 and Figure 4 for the minimum clearances around the perimeter of the generator tray assembly.
  • Page 18 CLEARANCE 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 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 19 of 56 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.

  • Page 21: Installation Guide

    It is advisable to paint them before completing the installation. Locate and bore mounting holes for generator tray assembly as shown in Figure 7. Maintain minimum clearances as indicated in Figure 3, Figure 4 and Figure 5. Figure 7 – HR-6.2, HR-8, HR-10 and HR-110 Mounting Pattern...
  • Page 22 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 21 of 56 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.
  • 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 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 23 of 56 Mount Command & Control Center: a. Create hole pattern as shown in Figure 10. b. Mount Command & Control Center to vehicle using #10 stainless steel button head or cap screw fasteners.
  • Page 25 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 24 of 56 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: Hose Installation Guidelines

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 25 of 56 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. Hose Installation Guidelines Never install a hose without first properly cleaning it to remove debris and contaminants.
  • Page 27 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 26 of 56 Connect the vehicle’s breaker panel to the generator output. The generator is pre- wired to supply 120/240 VAC, with the generator frame 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.
  • Page 28 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 27 of 56 Figure 12 – Generator Output Wiring for 120VAC WARNING: Wiring of the A.C. modular generator system and electrical distribution throughout the vehicle must be done in accordance with applicable sections in the National Fire Protection Association’s document NFPA 1901, the National Electrical Code ®...
  • Page 29 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 28 of 56 Bleed air from the hydraulic system: The system controller has been designed to provide a purge option. With this option applied, the generator will turn at a reduced speed to minimize wear to the system’s hydraulic components while purging air from the system.
  • Page 30 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 29 of 56 Enabling System Purge Option The purge option can be set by performing the following steps: Step 5: Press On/Off Step 3: Hold Mode until  appears. until Amps Line 1 Blinks .
  • Page 31 (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 HR-6.2, HR-8, HR-10 and HR-110 have been pre-set at the factory to provide correct frequency and voltage. No pump adjustment is required. If it appears ®...
  • Page 32 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 31 of 56 Enabling Auto-Start 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 begins blinking  (more than 10 seconds).

  • Page 33: Operation

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 32 of 56 Operation The Command & Control Center will show the generator’s output voltage, frequency, current, and system run time whenever the Command & Control Center is in Normal mode.
  • Page 34 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 33 of 56 corresponding button is calibrating, and should not be pressed. The Command & Control Center will ignore the input while it is calibrating. If the Command & Control Center is powered on, but the generator is not running and no buttons are pressed for 5 minutes, the system will enter Quiescent mode (sleep.) In Quiescent mode all displays are blank to conserve power.
  • Page 35 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 34 of 56 Additional Information provided by the Command & Control Center: a. When the Command & Control Center is in Normal mode, pressing the Mode button once will display the oil temperature (reference Figure 19.) Displayed Oil Temperature in degrees Fahrenheit...
  • Page 36 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 35 of 56 d. Pressing the Mode switch a fourth time will cause the amount of time since the oil filter was last changed to be displayed in the hours field as seen in Figure 22. Time Since last Oil Filter Change in Hours.
  • Page 37 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 36 of 56 Alarms, Shutdowns and Overrides provided by the Command and Control Center The following is a list of diagnostic faults displayed by the Command and Control Center that will cause an automatic shutdown of the system (see the Diagnostic Faults section of this manual for a complete list of diagnostic faults.): a.
  • Page 38 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 37 of 56 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 is the same for all the above listed diagnostic faults: Step a: Press Mode to cause ...
  • Page 39 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 38 of 56 Optional J1939 Interface 1. The integrated J1939 interface makes it possible to connect the generator’s ECU to a vehicle multiplexing system for monitoring, control and real time diagnostic information.

  • Page 40: Special Operating Instructions

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 39 of 56 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.

  • Page 41: Maintenance Instructions

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 40 of 56 Maintenance Instructions WARNING: Do not perform maintenance while system is running. Perform regular, periodic checks to verify: a. The cooler, the cooler fan and generator vents are not plugged by debris. b.
  • Page 42 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 41 of 56 WARNING: Do not bypass the filter or alter filtration plumbing in any way. Doing so will void the system’s warranty. 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 &...
  • Page 43 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 42 of 56 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 &...

  • Page 44: Troubleshooting Guide

    ® 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 &...
  • Page 45 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 44 of 56 Diagnostic Faults: The following is a list of the diagnostic faults as displayed on the Command & Control Center, with a brief explanation of each. CCC Display Class Description The control valve feedback is invalid, indicating the system is not under...
  • Page 46 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 45 of 56 The complete list of faults, including conditions and times may be found in Table 4, below. Table 4 Notes: Times are representative. Where more than one proportional valve is used due to flow requirements. 3 phase generators only.
  • Page 47 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 46 of 56 Hydraulic Problems: Cavitation: Cavitation is caused by trying to pump more fluid than is available at the pump inlet due to system restrictions. Pump cavitation sounds like “marbles” passing through the pump.
  • Page 48 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 47 of 56 NOTE: This is NOT NORMAL. The piston shoes should always remain in contact with the swash plate. The causes of and correction for this problem are the same as for cavitation above.
  • Page 49 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 48 of 56 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.
  • Page 50 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 49 of 56 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).
  • Page 51 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 50 of 56 WARNING: Do not attempt to measure the exciter field resistance while the system is operating. Electrical shock may occur. f. Exciter field capacitor may be faulty. Disconnect the exciter field from the field capacitor.
  • Page 52 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 51 of 56 b. Table 1). Pump speed 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 for 60 Hz application or 49-52 Hz for 50 Hz application.

  • Page 53: Pump Adjustment

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 52 of 56 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.
  • Page 54 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 53 of 56 Pump adjustment procedure: Enable the generator Pump Set option. The system controller has been designed to provide a Pump Set option. With this option applied, the generator will turn at the maximum speed allowed by the hydraulic pump to allow proper adjustment of the pump’s flow.
  • Page 55 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 54 of 56 Adjust pump compensator: a. Loosen and remove flow control cap. Reference Figure 34. 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 3mm hex wrench.
  • Page 56 Press the On/Off button until an  appears, indicating Pump Set option is inactive. d. Put system into Normal mode by pressing the Mode button. NOTE: For a complete copy of Manufacturer’s Warranty please see our website at: www.smartpower.com/warranty...

  • Page 57: Sps Model Matrix

    PUMP 8583046 8510013 WR PUMP 2610006 GENERATOR, HR-6.2/45cc, L, 13T SPL 8583046 8510004 WR 2611006 GENERATOR, HR-6.2/45cc, L, 1” KEY PUMP 8583046 8510018 WR PUMP 2602006 GENERATOR, HR-6.2/45cc, R, 15T SPL 8583046 8510099 WR PUMP 2600008 GENERATOR, HR-8/45cc, R, 13T SPL 8583048 8510010 WR 2601008 GENERATOR, HR-8/45cc, R, 1”...

This manual is also suitable for:

Hr-8Hr-10Hr-110

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