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SmartPower HR-20 Owner's Manual

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A.C. MODULAR
GENERATOR SYSTEM
OWNER'S MANUAL
MODEL#: HR-20, HR-25, and HR-30
9991038 Rev. K

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Summary of Contents for SmartPower HR-20

  • Page 1 A.C. MODULAR GENERATOR SYSTEM OWNER’S MANUAL MODEL#: HR-20, HR-25, and HR-30 9991038 Rev. K...

  • Page 2: Table Of Contents

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 1 of 48 Table of Contents Section Page Disclaimer .......................... 5 Description of Product ...................... 6 System Specifications ...................... 9 Pre-Installation Guide ..................... 11 Installation Guide ......................16 Hose Installation Guidelines ..................19 Operation .........................
  • Page 3 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 2 of 48 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 48 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 48 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 48 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 48 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 20,000, 25,000, or 30,000 watts, depending on model.
  • Page 8 Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 7 of 48 BOOST BLOCK COOLER VENTURI BOOST RESERVOIR CHECK FILTER VALVE MOTOR PROPORTIONAL VALVE PUMP CASE DRAIN CASE DRAIN Hydraulic schematic for HR-20, HR-25, and HR-30 generator system Figure 1...
  • Page 9 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 8 of 48 Electrical Wiring Diagram for HR-20, HR-25, and HR-30 generator systems Figure 2...

  • Page 10: System Specifications

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 9 of 48 System Specifications MODEL OF HR-20 HR-25 HR-30 GENERATOR Generator AC Inductive AC Inductive AC Inductive Type Speed 1800 RPM 1800 RPM 1800 RPM Frequency 60 Hz 60 Hz...
  • Page 11 Temperature Range Table 1 (cont.) Note 1: The HR-20, HR-25 and HR-30 systems can provide 83 amps, 105 amps and 125 amps respectively on each of their two 120 volt circuits as long as the circuit-to-circuit imbalance does not exceed the maximum recommended value of 20% (See page 21 for more information and warnings).

  • Page 12: Pre-Installation Guide

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 11 of 48 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 13 Page 12 of 48 ® The pumps supplied by Smart Power Systems for Models HR-20, HR-25, and HR- 30 have either the standard 1-1/4” keyed shaft, or, the optional 1-1/4” shaft with a 14- tooth spline. 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-20, HR-25, and HR-30 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 Front view of HR-20, HR-25, and HR-30 tray assemblies showing tray dimensions and minimum clearance for proper ventilation Figure 4 Side view of HR-20, HR-25, and HR-30 tray assemblies showing tray dimensions and minimum clearance for proper ventilation Figure 5...
  • Page 16 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 15 of 48 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

    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-20, HR-25, and HR-30 tray assemblies Figure 7...
  • Page 18 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 17 of 48 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 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 18 of 48 HR-20, HR-25, and HR-30 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 20: Hose Installation Guidelines

    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-20, HR-25, and HR-30 tray assemblies Figure 11 WARNING: Never operate the system with the pump case drain plugged. Damage to the pump seals will result.
  • Page 21 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 20 of 48 Do not position hoses with tight 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.
  • Page 22 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 21 of 48 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 23 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 22 of 48 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. Bleed air from the hydraulic system: a.
  • Page 24 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 23 of 48 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 25 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 24 of 48 Engage the Power Take-Off (PTO). (Note: Pump may sound rough for a few minutes due to entrapped air.) Make sure the Command & Control Center displays the string “” as shown in Figure 14, press the On/Off switch to turn the generator off, if needed.
  • Page 26 A. C. MODULAR GENERATOR SYSTEM Page 25 of 48 WARNING: The SPS Model HR-20, HR-25, and HR-30 have been pre-set at the factory to provide correct frequency and voltage. No pump adjustment is required. If it appears the ® pump needs to be adjusted, contact Smart Power Systems at (231) 832-5525 before proceeding.

  • Page 27: Operation

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 26 of 48 c. Press the On/Off switch 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. Operation The Command &...
  • Page 28 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 27 of 48 The PTO driving the SPS hydraulic pump must be engaged for the system to generate electricity.  The Command & Control Center is equipped with two Smart Touch switches, labeled “Mode”...
  • Page 29 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 28 of 48 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”...
  • Page 30 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 29 of 48 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 Change in Hours.
  • Page 31 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 30 of 48 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 32 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 31 of 48 WARNING: Overriding an automatic system shutdown may result in permanent damage to the system and/or degrade the system’s performance. Overriding an automatic system shutdown may void warranty. The system’s electronic controller records whenever an override function is performed.
  • Page 33 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 32 of 48 c. If your answer was “yes” in the previous step, the confirmation screen shown in Figure 23 will be displayed. Again note the y and n labels below the Mode and On/Off switches.

  • Page 34: Special Operating Instructions

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 33 of 48 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 35: Maintenance Instructions

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 34 of 48 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 36 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 35 of 48 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 37 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 36 of 48 a. Press the Mode switch repeatedly until one of the screens shown in Figure appears. b. While holding the Mode switch down, press and release the On/Off switch three times in succession, then release the Mode switch.

  • Page 38: Troubleshooting Guide

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 37 of 48 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 39 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 38 of 48 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 40 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 39 of 48 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. Shutdown A condition causes the immediate shutdown of the generator.
  • Page 41 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 40 of 48 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 42 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 41 of 48 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 43 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 42 of 48 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).
  • Page 44 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 43 of 48 f. The generator drive motor is faulty. Observe the generator while the system is engaged. If it is not rotating, there may be a problem in the motor, or the motor- to-generator linkage.

  • Page 45: Sps Model Matrix

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 44 of 48 SPS Model Matrix Table 4...

  • Page 46: Pump Adjustment

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 45 of 48 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 47 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 46 of 48 The Pump Set option can be accessed by performing the following steps: a. If the Command & Control Center is dark, press the Mode switch to put the Command &...
  • Page 48 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 47 of 48 Adjust pump compensator: a. 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 4mm hex wrench.
  • Page 49 Press the On/Off switch until an  appears, indicating Pump Set option is inactive. d. Put system into Normal mode by pressing the Mode switch. NOTE: For a complete copy of Manufacturer’s Warranty please visit our website at: www.smartpower.com/warranty...

This manual is also suitable for:

Hr-25Hr-30

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