1. Manuals
  2. Brands
  3. SmartPower Manuals
  4. Portable Generator
  5. ER-8
  6. Owner's manual

SmartPower ER-8 Owner's Manual

A.c. modular generator system
Hide thumbs Also See for ER-8:
Table of Contents

Advertisement

Quick Links

Download this manual
A.C. MODULAR
GENERATOR SYSTEM
OWNERS MANUAL
MODEL#: ER-6.2, ER-8, ER-10 and ER-110
For Compartment or Top Mounting

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the ER-8 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for SmartPower ER-8

Summary of Contents for SmartPower ER-8

  • Page 1 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: Table Of Contents

    Troubleshooting Guide ....................36   SPS Model Matrix ......................43   Component Part Number Lists ..................44   ER-6.2, ER-8, ER-10 AND ER-110 Assembly drawing ..........45   Pump Adjustment ......................47   Manufacturers Limited Warranty ................... 51   Doc. 9991031 Rev. H...
  • Page 3 ® 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.
  • Page 4 ® 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.
  • Page 5 ® 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.

  • Page 6: Disclaimer

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 5 of 52 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 publication, PROVIDES...

  • Page 7: Description Of Product

    ® 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 120/240 volt AC @ 60 Hz 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 52 BOOST BLOCK COOLER VENTURI BOOST RESERVOIR CHECK FILTER VALVE MOTOR PROPORTIONAL VALVE PUMP CASE DRAIN CASE DRAIN Hydraulic schematic for ER-6.2, ER-8, ER-10 and ER-110 generator system Figure 1...
  • Page 9 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 8 of 52 Electrical schematic for ER-6.2, ER-8, ER-10 and ER-110 generator systems...

  • Page 10: System Specifications

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 9 of 52 Figure 2 System Specifications MODEL ER-6.2 ER-8 ER-10 ER-110 GENERATOR Generator AC Inductive AC Inductive AC Inductive AC Inductive Type Speed 3600 RPM 3600 RPM 3600 RPM...
  • Page 11 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 10 of 52 Table 1 MODEL OF ER-6.2, ER-8 ER-10, ER-110 GENERATOR Oil Cooler Dimensions (Core) 2.25”D x 12.5” W x 10.3” H 2.25”D x 22.6” W x 11” H...

  • Page 12: Pre-Installation Guide

    The PTO speed must be between in the range specified in Table 1 for your model generator. Example: For an ER-8 System that is to operate at 600 RPM: PTO Ratio = 850 RPM ÷ 600 RPM = 1.42 or 142% WARNING: Never exceed the maximum pump shaft speed.
  • Page 13 ER-10; OR a SAE B-B 1” 15 tooth spline on the ER-110 model. Upon special order, a 1” keyed shaft is available on Models ER-6.2, ER-8 and ER- A 1 ¼” keyed shaft is available on the ER-110 Model.
  • Page 14 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. SPS models ER-6.2, ER-8, ER-10 and ER-110 can be mounted on top of a vehicle, in the open, without requiring any additional coverings. Reference Error! Reference source not found., Error! Reference source not found., Figure 3,...
  • Page 15 Page 14 of 52 12" MINIMUM OBSTRUCTION FREE CLEARANCE OIL FILTER ACCESS PANEL Front view of ER-6.2, ER-8, ER-10 and ER-110 tray assemblies showing minimum clearance for proper ventilation Figure 3 6" MINIMUM OBSTRUCTION FREE CLEARANCE 1" MAXIMUM SETBACK FROM FRONT OF COMPARTMENT Side view of ER-6.2, ER-8, ER-10 and ER-110 tray assemblies...
  • Page 16 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 15 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.

  • Page 17: Installation Guide

    Maintain minimum clearances as indicated in Error! Reference source not found., Error! Reference source not found., Figure 3, and Figure 4. OIL FILTER ACCESS PANEL 4 PL. 11.64 7.25 2.06 32.00 33.50 Hole pattern for mounting ER-6.2, ER-8, ER-10and ER-110 tray assemblies Figure 6...
  • Page 18 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 17 of 52 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 19: Hose Installation Guidelines

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 18 of 52 3.375 .208 CLEARANCE HOLE 1.688 FOR #10 SCREW 4 PL. 2.000 1.688 3.375 Hole pattern for Command & Control Center Figure 8 Flush the hoses with fresh hydraulic fluid (Dexron III). Install hoses and tighten hose ends, using the Hose Installation Guidelines.
  • Page 20 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 19 of 52 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.
  • Page 21 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 20 of 52 ALTERNATE CONFIGURATION: 120 VAC only: If the application requires 120 VAC only, the generator terminal strip should be configured as depicted below. This method ensures balanced loading of the generator, fully optimizing the system’s capabilities.
  • Page 22 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 21 of 52 ® 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.
  • Page 23 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 22 of 52 Note: The generator is shipped from the factory with the purge option enabled. 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 24 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 23 of 52 Enabling System Purge Option The purge option can also be set by performing the following steps: Step 5: Press On/Off Step 3: Hold Mode until y appears. until Amps Line 1 Blinks 88 .
  • Page 25 Systems 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.
  • Page 26 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 25 of 52 Step b: Hold Mode until Amps Line 1 Blinks 88 . Release switch so 0Pt and AStr appear. Step c: Press On/Off until the desired value appears Figure 12 Enabling Auto-Start Option a.

  • Page 27: Operation

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 26 of 52 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 the Normal mode. To access Normal mode, press the Mode switch repeatedly until the correct information is displayed (reference Figure 13).
  • Page 28 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 27 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.
  • Page 29 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 28 of 52 Displayed Oil Temperature in degrees Fahrenheit Example of oil temperature display Figure 16 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 17): Time Since last Oil Filter...
  • Page 30 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 29 of 52 The Er indicates the system The system controller is configured to operate a generator controller is configured to whose maximum output is this operate an ER-series number (in kW). Generator Example of configuration display Figure 18...
  • Page 31 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 30 of 52 a. From the Normal mode display, press Mode, as if you wanted to display the oil temperature. The screen shown in Figure 19 will be displayed instead, asking if you want to “Run hot.”...
  • Page 32 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 31 of 52 Step a: Press Mode to cause rvn and the y and n labels to appear. Step b: Press On/Off to answer “yes” and make the next screen appear. Example of Command &...

  • Page 33: Special Operating Instructions

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 32 of 52 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 34: Maintenance Instructions

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 33 of 52 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 35 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 34 of 52 Lubricate the oil filter gasket with Dexron III before installation to permit proper sealing of the filter. WARNING: Do not by-pass the filter or alter filtration plumbing in any way. Doing so will void the system’s warranty.
  • Page 36 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 35 of 52 Step a: Press Mode until InF, 0IL, and FILt appear. Step b: Hold Mode switch down and press On/Off three times in a row to clear the fault.

  • Page 37: Troubleshooting Guide

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 36 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 &...
  • Page 38 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 37 of 52 Diagnostic Faults: The following is a list of the diagnostic faults, with a brief explanation of each. String Class Meaning uLu CTrL Alarm The control valve feedback is invalid, indicating the system is not under control.
  • Page 39 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 38 of 52 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 40 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 39 of 52 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. This occurs due to the excessive lower pressure created on the fill (down) stroke of the piston.
  • Page 41 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 40 of 52 a. Check the oil cooler fins for debris or damage. Clean and/or replace cooler. b. Verify that the generator load is not excessive. c. Verify that there is proper ventilation. d.
  • Page 42 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 41 of 52 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.
  • Page 43 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 42 of 52 h. 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.

  • Page 44: Sps Model Matrix

    8510013 1710006 GENERATOR, ER-6.2/45cc, L, SPL PUMP 8570006 8510004 1711006 GENERATOR, ER-6.2/45cc, L, KEY PUMP 8570006 8510018 1700008 GENERATOR, ER-8/45cc, R, SPL PUMP 8570008 8510010 1701008 GENERATOR, ER-8/45cc, R, KEY PUMP 8570008 8510013 1710008 GENERATOR, ER-8/45cc, L, SPL PUMP 8570008...

  • Page 45: Component Part Number Lists

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 44 of 52 Component Part Number Lists (Reference Figure 27 and Figure 28) ITEM NO. PR. SW., GAUGE, ELEC. PROP. GENER- ASM, ASM, FILTER HOUSING HYD. BREATHER ASM, PARENT TRAY FLUID OIL RES.

  • Page 46: Er-6.2, Er-8, Er-10 And Er-110 Assembly Drawing

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 45 of 52 ER-6.2, ER-8, ER-10 AND ER-110 Assembly drawing Figure 27...
  • Page 47 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 46 of 52 THIS VIEW SHOWN WITH LID REMOVED LID LATCH (2 EA) ER-8, ER-10 and ER-110 Assembly drawing Figure 28...

  • Page 48: Pump Adjustment

    ® 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.
  • Page 49 ® 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 Step b: Hold Mode until PSEt , Press On/Off Amps Line 1 Blinks 88 . until y appears.
  • Page 50 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 49 of 52 Adjust pump compensator: a. Loosen and remove flow control cap. Reference Figure 31. 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 51 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 50 of 52 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 Step a: Hold Mode until PSEt , Press On/Off Amps Line 1 Blinks 88 .

  • Page 52: Manufacturers Limited Warranty

    ® 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.
  • Page 53 Contact your SPS distributor for questions regarding your warranty rights and responsibilities at (231) 832- www.smartpower.com 5525; or visit our website at...

This manual is also suitable for:

Er-6.2Er-10Er-110

Table of Contents