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SmartPower HR-8 Owner's Manual

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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 SmartPower HR-8

  • 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 Systems A. C. MODULAR GENERATOR SYSTEM Page 2 of 53 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 53 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 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. Do not operate the system under electrical load with air in the hydraulic fluid (the system will make a growling sound).

  • 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 time publication, PROVIDES...

  • 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 BOOST BLOCK COOLER VENTURI BOOST RESERVOIR CHECK FILTER VALVE MOTOR PROPORTIONAL VALVE PUMP CASE DRAIN CASE DRAIN 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 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 10 of 53 MODEL OF GENERATOR HR-6.2, HR-8 HR-10, HR-110 Oil Cooler Dimensions (Core) 9.75”D x 22.6” W x 2.25” H 9.75”D x 22.6” W x 2.25” H 12 Inch Pusher...

  • Page 12: Pre-Installation Guide

    Table 1 for your model generator. Example: For an HR-8 System that is to operate at 650 RPM engine speed: PTO Ratio = 880 RPM ÷ 650 RPM = 1.35 or 135% (or higher) WARNING: Never exceed the maximum pump shaft speed.
  • Page 13 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 ¼” 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.
  • 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 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 18 of 53 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 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 schematic and wiring diagram): Phase A: Black wire (120 VAC)
  • Page 24 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 23 of 53 WARNING: To ensure proper voltage regulation, during the operation of generator system, the load difference between Phase A and Phase B must never exceed 20%. Damage to generator system caused by operating it with an unbalance load will void the system’s warranty.
  • 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. Never apply a load to the generator while there is air trapped in the hydraulic fluid.
  • Page 27 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 26 of 53 Indicates whether the generator is 0n or 0ff Example of display with purge option set Figure 14 f. Engage the Power Take-Off (PTO). (Note: Pump may sound rough for a few minutes due to entrapped air.) Make sure the Command &...
  • 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 88 Release the switch so 0Pt and AStr appear.

  • 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 switch twice will cause the amount of time since the oil filter was last changed to be displayed (reference Figure 20): Time Since last Oil Filter...
  • Page 33 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 32 of 53 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 21...
  • Page 34 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 33 of 53 e. bAd uoLts. 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 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”...

  • 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. b.
  • 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. The hours since the previous filter change can be accessed using the Command &...
  • Page 39 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 38 of 53 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 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 uLu CTrL 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. A condition causes the immediate shutdown of the generator.
  • 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 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 43 of 53 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 45 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 44 of 53 Electrical Problems 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 46 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 45 of 53 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 47 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 46 of 53 Output voltage exceeds 260 volts or falls below 220 volts AC on a 240 volt line: a. Verify that the hydraulic system is not overheating by viewing the temperature as displayed by the Command &...

  • Page 48: Sps Model Matrix

    2611006 GENERATOR, HR-6.2/45cc, L, 1” KEY PUMP 8583046 8510018 2602006 GENERATOR, HR-6.2/45cc, R, 15T SPL 8583046 8510099 2600008 GENERATOR, HR-8/45cc, R, 13T SPL PUMP 8583048 8510010 2601008 GENERATOR, HR-8/45cc, R, 1” KEY PUMP 8583048 8510013 2610008 GENERATOR, HR-8/45cc, L, 13T SPL PUMP 8583048 8510004 2611008 GENERATOR, HR-/45cc, L, 1”...

  • 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 PSEt, Press On/Off until Amps Line 1 Blinks 88. y appears.
  • 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 PSEt, Press On/Off until Amps Line 1 Blinks 88.

  • 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 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 54 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:

Hr-6.2Hr-10Hr-110

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