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Smart power 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

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Summary of Contents for Smart power HR-6.2

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

  • Page 2: Table Of Contents

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 1 of 53 Table of Contents Section Page Disclaimer .......................... 5   Description of Product ...................... 6   System Specifications ...................... 9   Pre-Installation Guide ..................... 11   Installation Guide ......................17  ...
  • Page 3 Smart Power hydraulic generators, as well as all generators, must be sufficiently protected 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.
  • Page 4 Never make any adjustments to the pump other than for flow control. If it appears the ® pump needs to be adjusted, contact Smart Power Systems at (231) 832-5525 before proceeding. Damage to the generator from improper pump adjustment will void the system’s warranty.
  • Page 5 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 4 of 53 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 53 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...

  • Page 7: Description Of Product

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 6 of 53 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 53 Hydraulic schematic for HR-6.2, HR-8, HR-10 and HR-110 generator system Figure 1...
  • Page 9 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 8 of 53 Electrical schematic for HR-6.2, HR-8, HR-10 and HR-110 generator systems Figure 2...

  • Page 10: System Specifications

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 9 of 53 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 3600 psi, SAE 3600 psi, SAE All Others 1250 psi, SAE 1250 psi, SAE Fittings Dry Weight HR-6.2 165 lbs HR-10 220 lbs (without pump) HR-8 185 lbs HR-110 220 lbs Dimension of Tray Asm. 32” L x 13.5” W x 17” H 32”...

  • Page 12: Pre-Installation Guide

    To identify the pump rotation, check the pump part number found on the metal tag attached to side of the pump. A right hand rotating pump (the standard pump offered ® by Smart Power Systems), will have the letter “R” in its part number. Example: A10VO (45 or 60) DFR-1/52 R PUC.
  • Page 13 B) the pump can be mounted to the vehicle chassis, connected to the PTO with a drive shaft. ® Verify that the pump shaft will mount to the PTO. Pumps supplied by Smart Power Systems have an SAE B 2 bolt flange. The standard pumps supplied by Smart ®...
  • Page 14 (but not taut) between connections. Do not exceed hose lengths of 20 feet. 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, Figure 4 and Figure 5 for the minimum clearances around the perimeter of the generator tray assembly.
  • Page 15 (IF AIR VENT OPTION A OR B IS USED .50 CLEARANCE REQUIRED ON THIS SURFACE) Bottom view of HR-6.2, HR-8, HR-10 and HR-110 tray assemblies showing minimum clearance for proper ventilation and the three possible air vent options Figure 3 Front view of HR-6.2, HR-8, HR-10 and HR-110 tray assemblies showing tray...
  • Page 16 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 15 of 53 Side view of HR-6.2, HR-8, HR-10 and HR-110 tray assemblies showing tray dimensions and minimum clearance for proper ventilation Figure 5...
  • Page 17 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 16 of 53 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 18: Installation Guide

    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. Hole pattern for mounting HR-6.2, HR-8, HR-10 and HR-110 tray assemblies Figure 7...
  • Page 19 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.
  • Page 20 Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 19 of 53 HR-6.2, HR-8, HR-10 and HR-110 tray assemblies disassembled into base tray assembly (with diamond plate cover added), cooler/fan enclosure and reservoir Figure 9 Mount Command & Control Center: a.
  • Page 21 Figure 10 Flush the hoses with fresh hydraulic fluid (Dexron III). Install hoses and tighten hose ends, using the Hose Installation Guidelines. See Figure 11 for connection locations Hose connection locations for HR-6.2, HR-8, HR-10 and HR-110 tray assemblies Figure 11...

  • Page 22: Hose Installation Guidelines

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 21 of 53 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 23 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 22 of 53 conduit to length without cutting the wire insulation. A conduit connector has been provided to connect the conduit to the breaker panel. Connect the (4) four generator output wires to the breaker panel as follows (see Figure 2 for electrical...
  • Page 24 Bypassing the SPS factory installed 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.
  • Page 25 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 24 of 53 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.
  • Page 26 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 25 of 53 WARNING: Never operate the system without the filler/breather plug installed. Contaminants may enter the hydraulic fluid through the filler opening, causing premature wear on the hydraulic components and void the system’s warranty.
  • Page 27 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. Prior to applying full load, and after the oil temperature is above 100°F verify proper operation of the cooler fan by feeling for airflow being pushed out of the tray assembly.
  • Page 28 Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 27 of 53 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 ®...
  • Page 29 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 28 of 53 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 ...

  • Page 30: Operation

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 29 of 53 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 Figure16).
  • Page 31 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 30 of 53 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 32 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 31 of 53 Displayed Oil Temperature in degrees Fahrenheit Example of oil temperature display Figure 19 b. When the Command & Control Center is in Normal mode, pressing the Mode...
  • Page 33 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 32 of 53 The  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).
  • Page 34 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 33 of 53 e. . If the system measures an output voltage that is too low or too high the generator will automatically shut down in 30 minutes unless the shutdown is overridden.
  • Page 35 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 34 of 53 b. Note the  and  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”...

  • Page 36: Special Operating Instructions

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 35 of 53 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 37: Maintenance Instructions

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 36 of 53 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.
  • Page 38 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 37 of 53 WARNING: Do not by-pass 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.
  • Page 39 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 38 of 53 Step a: Press Mode until , , and  appear. Step b: Hold Mode switch down and press On/Off three times in a row to clear the fault.

  • Page 40: Troubleshooting Guide

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 39 of 53 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 41 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 40 of 53 Diagnostic Faults: The following is a list of the diagnostic faults, with a brief explanation of each. String Class Meaning  Alarm The control valve feedback is invalid, indicating the system is not under control.
  • Page 42 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 41 of 53 Note: The fault “Classes” are defined in the table below: Class Meaning Service Warning Normal maintenance needs to take place. Alarm A condition requires the immediate attention of the operator.
  • Page 43 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 42 of 53 After correcting any problems, again operate the generator twenty minutes to purge air out of the hydraulic fluid. Note that any bubbles seen in the reservoir indicate leakage in the pump inlet line.
  • Page 44 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. Low Hydraulic Fluid Level In Reservoir: Low hydraulic fluid level in reservoir can be caused by leaking fittings, hoses or pipes.
  • Page 45 Measure the resistance of the exciter field using an ohmmeter. The resistance of the exciter field should be between ® .27 and .29 ohms. Contact Smart Power Systems at (231) 832-5525 if the resistance is outside this range.
  • Page 46 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 47 The generator speed may be incorrect. The generator output should be ® between 59-61 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 ®...

  • Page 48: Sps Model Matrix

    2600006 GENERATOR, HR-6.2/45cc, R, 13T SPL 8583046 8510010 2601006 GENERATOR, HR-6.2/45cc, R, 1” KEY PUMP 8583046 8510013 2610006 GENERATOR, HR-6.2/45cc, L, 13T SPL PUMP 8583046 8510004 2611006 GENERATOR, HR-6.2/45cc, L, 1” KEY PUMP 8583046 8510018 2602006 GENERATOR, HR-6.2/45cc, R, 15T SPL...

  • Page 49: Pump Adjustment

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 48 of 53 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 50 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 49 of 53 The Pump Set option can be accessed by performing the following steps: Step d: After selecting Step b: Hold Mode until , Press On/Off until Amps Line 1 Blinks .
  • Page 51 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 50 of 53 Adjust pump compensator: a. Loosen and remove flow control cap. Reference Figure 30. 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 52 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 51 of 53 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 , Press On/Off until...

  • Page 53: Manufacturers Limited Warranty

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 52 of 53 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...
  • Page 54 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 53 of 53 The cost of airfreight or other extraordinary expenses for shipment of parts over and above premium surface transportation. Limitation SPS is not responsible for the repair of generators that is required because of normal...

This manual is also suitable for:

Hr-8Hr-10Hr-110

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